Lifan Lf 150-10b User manual

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IMPORTANTNOTICES

Operator and Passenger

LF150-10B motorcycle is designed to carry the operator and one passenger. Never exxceed the maximum weight capacity as following:

Maximum load: 150kg including 5kg for rear carrier.

On-road

LF125T-19 motorcycle is designed for on-road use.

Pay special attention to statements preceded by the following words:

WARNING: Indicates a strong possibility of severe personal injury or death if instructions are not followed.

CAUTION: Indicates a possibility of equipment damage if instructions are not followed.

NOTE: Gives helpful information.

Environmental Protection (EP) : Indicates special precautions that must be taken to meet environment protection laws and regulations. Improper use of a motorcycle

may cause environment pollution.

If the operator fails to follow safe operating and maintenance practices, Lifan Co. will not take any responsibility to any injury or damage occured.

This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.

Thank you for choosing LIFAN motorcycle. May you enjoy riding all time.

The manual contains the necessary instructions and guidance with respect to the operation and maintenance of the motorcycle, and BE SURE TO READ IT CAREFULLY

BEFORE YOU RIDE THE MOTORCYCLE. Proper operation and maintenance can guarantee a safe riding to minimize troubles of the motorcycle and keep it in a sound condition,

which can extend the engine service life.

PREFACE

LF150-10B motorcycle is subject to the standard Q/LF20257.

The quality system of Lifan Industry (Group) Co., Ltd. is certificated to ISO9001.

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CONTENTS

MOTORCYCLE SAFE RIDING

Safe Riding Rules .............................................................................. 1

Protective Cloths .............................................................................. 1

Refitting .............................................................................................. 1

Loading .............................................................................................. 1

Accessories ........................................................................................ 1

GENERAL INFORMATION

Parts Location ................................................................................... 2

VIN Record ......................................................................................... 3

Fuel and Engine Oil (EP) ................................................................. 3

CONTROLLING PARTS

Meter and Indicators ......................................................................... 4

Ignition Switch and Steering Lock ................................................. 4

Right Handlebar Controls ................................................................ 4

Left Handlebar Controls ................................................................... 5

Choke Lever ....................................................................................... 5

Refueling and Cap ............................................................................. 5

Fuel Cock............................................................................................ 5

Gearshift Pedal .................................................................................. 6

Rear Brake Pedal ................................................................................ 6

Rear Shock Absorber ........................................................................ 6

Stands ................................................................................................. 6

Principle of Fuel Evaporating Systerm (EP) .................................. 7

OPERATION GUIDE

Pre-ride Inspection............................................................................ 7

Starting the Engine ........................................................................... 7

Breaking-in ........................................................................................ 8

Riding ................................................................................................. 8

Braking and Parking ......................................................................... 8

MAINTENANCE

Tool Kit ............................................................................................... 9

Maintenance Schedule ...................................................................... 9

Engine Oil (EP) ................................................................................... 10

Coolant ............................................................................................... 10

Servicing of Cooling System ............................................................ 11

Clear away Carbon Deposit (EP) ....................................................... 11

Spark Plug (EP)................................................................................. 11

Air Cleaner (EP) ................................................................................ 11

Valve Clearance .................................................................................. 12

Exhaust Muffler .................................................................................. 12

3-Way Catalytic Converter (EP) ........................................................ 12

Fuel Filter ........................................................................................... 13

Operation of Throttle ........................................................................ 13

Idle Speed of Carburetor (EP) ......................................................... 13

Check Leaks along Air Supply (EP)............................................... 13

Clutch ................................................................................................. 13

Drive Chain ........................................................................................ 13

Front Brake ......................................................................................... 14

Rear Brake ........................................................................................... 15

How to Check and Replace Brake Pad ............................................ 15

Front/Rear Shock Absorber and Suspension ................................. 15

Tyre ...................................................................................................... 15

Front Wheel ....................................................................................... 16

Rear Wheel ......................................................................................... 16

Fuse ..................................................................................................... 16

Battery (EP) ....................................................................................... 16

TROUBLESHOOTING AND STORAGE

Troubleshooting................................................................................ 17

Cleaning and Storage ........................................................................ 17

Removal from Storage ........................................................................ 17

Anti-fall-over Device (Optional) .................................................... 17

Motorcycle Alarm (Optional) .......................................................... 18

ELECTRIC DIAGRAM ......................................................................... 19

SPECIFICATIONS .................................................................................. 20

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SAFE RIDING RULES

WARNING Motorcycle riding requires special efforts on your part to ensure

safety. Know these requirements before you ride.

Always make a pre-ride inspection before you start the engine. You may prevent

accident or equipment damage.

Most countries require a special motorcycle riding test or license. Make sure you are

qualified before you ride. NEVER lend your motorcycle to an inexperienced rider.

Make yourself conspicuous to help avoid the accident that wasn’t your fault:

Wear bright or reflective clothing.

Don’t ride in another motorist’s “blind spot”.

Don’t speedily cross another’s way.

Obey all national and local laws and regulations.

Obey the speed limits, and NEVER travel faster than conditions warrant.

Signal before you make a turn or lane change to draw other motorists’ attention.

Use extra caution at intersections, parking lot entrances and exits.

Always remember to ride with both hands and keep both feet on the rider footrest while

the passenger grasps the handrail with both feet on the rear footrest.

PROTECTIVECLOTHS

For the safety sake, always wear a helmet, a face shield, dust glasses and protective

clothing. Your passenger needs the same protection.

The exhaust system becomes hot during operation, and it remains hot for a while after

stopping the engine. Take care not to touch the exhaust system while it is hot. Wear

clothing that fully covers your legs.

Do not wear loose clothing that could catch on the control levers, wheels, etc.

REFITTING

WARNING Arbitrarily refitting the motorcycle or removing the original parts

MOTORCYCLE SAFE RIDING

may make riding unsafe, and is illegal also. The user must obey all national and local

laws and regulations in relation to vehicle and traffic. If you have a good proposal

concerning refitting of the motorcycle, please write us. The refitment can be done with

permission of the Co. Otherwise, the user will take the consequences.

WARNING Addition of accessories and cargo may reduce the motorcycle’s

stability, performance and safe operating speed.

Keep cargo and accessory weight lower and close to the center of the motorcycle. Load

weight equally on both sides to minimize imbalance. As weight is located further from

the motorcycle’s center of gravity, handling is proportionally affected.

Adjust tyre pressure and rear suspension to suit load weight and riding conditions.

Make sure that cargo is fastened on the vehicle.

Do not attach items to the handlebars, fork or fender. Otherwise, unstable handling or

slow steering response may occur.

The maximum load weight of the motorcycle is 150kg. Please do not overload.

ACCESSORIES

Genuine accessories of LF Motors have been specifically designed and tested on the

motorcycle. Beacuse the factory cannot test all other accessories, you are personally re-

sponsible for selection, installation and use of accessories not produced by the Co. Al-

ways follow Safe Riding Rules and these below:

Carefully inspect the accessory to make sure that it does not obscure any lights, reduce

ground clearance or banking angle, or limit suspension travel, steering travel or con-

trol operation.

Do not add electrical equipment that will exceed the motorcycle’s electrical system

capacity.

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PARTS LOCATION (Fig. 1-3) Fig. 1 (Left-view) Fig. 2 (Right-view)

Exhaust muffler Main step Radiator Front wheel Front shock absorber

Front winker Headlight Meter Rear shock absorber Front brake Gearshift pedal Center stand Side stand Rear wheel Rear winker

Pillion rail Seat Fuel tank Front fender Rearview mirror

GENERALINFORMATION

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VIN RECORD (Fig. 4-6)

VIN:

Engine Code:

Engine Model

Fig. 7

VIN Engine Code Nameplate

Fig. 3

Rearview mirror

Tachometer

Fuel gauge

Odometer

Throttle grip

Left grip

Handlebar controls, RH

Handlebar controls, LH

Fuel tank lock

Ignition switch

Please fill the VIN and engine code of your motorcycle in the blank below. They will help

order spare parts and find out the vehicle when stolen.

The VIN is stamped on the right of the steering stem (Fig. 4).

The engine code is stamped on the bottom-left of the crankcase (Fig. 5).

The vehicle nameplate is fixed on the mid of the steering stem (Fig. 6).

Fig. 4 Fig. 5 Fig. 6

FUELAND ENGINE OIL(EP)

Fuel Selection

Fuel is a key factor in deciding the exhaust emissions

from the engine, so selection of fuel must follow the

rules below. Selected fuel must be unleaded gasoline with

octane No. RQ-93 or higher. Using improper fuel could

reduce performance, shorten the engine’s service life.

Engine Oil Selection (Fig. 7)

The quality of the engine oil plays a vital role in deciding

the engine performance and service. Engine oil must be

selected in accordance with rules below and other oils, such as ordinary engine oil, gear

oil and vegetable oil, are forbidden to be used.

The vehicle has been filled with engine oil SAE15W/30-SE before being delivered. The

lubricant is only suitable at a temperature range within 20 35 . If other motor oil

is to be used instead, the alternative must be technically equivalent in every respect.

Viscosity varies with regions and temperatures, so the lubricant has to be selected accord-

ing to our recommendation.

If there is no gasoline engine oil SAE15W/40-SE, the engine oil No. HQB-10 (or HQB-

6 in regions where the temperature is lower than 10 ) can be used instead.

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RIGHT HANDLEBAR CONTROLS (Fig. 10)

Starter Button

Depress the button to start up the engine.

Headlight Switch

The 3-position switch functions as follows:

The headlight, taillight and meter lights are

bright.The parking light, tailight and meter lights are

bright.

(OFF) The headlight, taillight, parking light and

meter lights are off.

METER AND INDICATORS (Fig. 8)

Left turn signal indicator Odometer

Neutral indicator

Fuel gauge shows fuel amount remained in the

tank. With the pointer facing F, fuel amount is 13L.

When the pointer is near red zone, the remainder is

only 2.8L, in this case, add fuel as soon as possible.

Tachometer

Red zone ( of tachometer) means that the engine runs

at a top limit speed, in this case, service life of the

engine will be shortened. Fig. 8

Fig. 10

Starter button

Headlight sw.

Emergency sw.

Throttle grip

Front brake lever

Fig. 9

Ignition sw.

Steering lock

CONTROLLING PARTS

IGNITION SWITCH AND STEERING LOCK

(Fig. 9)

Ignition Switch

The ignition switch is equipped with 2 keys inclucing a spare

one. OFF Engine and lights cannot be operated and the

key can be removed.

ON: Engine and lights can be operated, neutral light

“N” is lit and the key cannot be removed.

Steering Lock

To lock the steering head, turn left or right the steering bar as far as it will go, insert the

key into the ignition switch slot, turn to (OFF) position, then depress and turn

counterclockwise to LOCK position, at last remove the key. To unlock the steering

head, turn the key clockwise.

EmergencySwitch

In an emergency, setting the switch to will stall the engine at onec.

In normal riding cases, always set it at .

Throttle Grip

The grip is used to control the engine power. Turning toward in the grip will increase fuel

supply, while turning toward out it will decrease fuel supply.

Grasping in the lever will apply the front brake.

CAUTION Do not let the pointer face to the red zone with the engine running.

High beam indicator

Water temperature alert

Right turn signal indicator

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LEFT HANDLEBAR CONTROLS (Fig. 11)

Headlight Dimmer Switch

Push the switch to to select high beam.

Push the switch to to select low beam.

Turn Signal Switch

Move the switch to to signal a left turn; and to to signal a right turn.

Horn Button

Press the button to sound the horn.

ClutchLever

Cap lock

Fuel filler cap

Fig. 12 Choke lever

Fig. 13

Fig. 14

Fig. 11

Clutch lever

High beam dimmer sw.

Turn signal switch

Horn button Do not overfill the tank (there should be no fuel in the filler neck). After refueling,

make sure the fuel filler cap is closed securely.

Gasoline is extremely flammable and is explosive under certain conditions. Refuel

in a well-ventilated area with the engine stopped. Do not smoke or allow flames or

sparks in the area where the fuel tank is refueled.

Before refueling, make sure to filter fuel first. Spilled fuel vapor may ignite. If any

fuel is spilled, make sure the area is dry before starting the engine.

KEEP OUT OF REACH OF CHILDREN.

FUEL COCK (Fig. 14)

The 3-way fuel cock is on the bottom-left side of the fuel tank. With the fuel cock in the

position, fuel cannot flow from the tank to the carburetor. Turn it OFF whenever

the motorcycle is not kept in use.

With the fuel cock in the position, fuel will flow from the main fuel supply to

the carburetor.With the fuel cock in the position, fuel flow the reserve fuel

supply to the carburetor. Use 2.8 L of reserve fuel only when the main sypply is gone.

CHOCK LEVER (Fig. 12)

The choke lever is located in the left-front of the handlebar.

The choke set in position A is fully open, in position B

half-open and in position C fully closed.

REFUELING AND FUELFILLER CAP

Opening of Cap (Fig. 13)

The fuel filler cap is located on the front of fuel tank. Insert

the ignition key.

Turn the key clockwise by 90 .

Remove the cap.

To reinstall the cap, depress it onto the tank inlet in

position, then turn and remove the key. The fuel tank

capacity is 13L including the reserves supply of 2.8 L.

WARNING

OFF RES

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Gearshift pedal

Fig. 15

5-speed non-cyclical pattern Fig. 16

It is forbidden to

gearshift up or

down when the

throttle is still not

decreased and

clutch is in.

Fig. 17

Rear brake

pedal

Fig. 18

Fig. 20

Fig. 19

REAR BRAKE PEDAL (Fig. 17)

The rear brake will function and the rear stop

light will glow when applying the pedal.

REAR SHOCK ABSORBER (Fig. 18)

The shock absorber has 5 adjustment positions

for different loads and riding conditions.

STANDS

Side Stand (Fig. 19)

When parking the vehicle, turn the side stand clockwise along the frome to position.

Before driving the vehicle, turn the stand to the initial position

CAUTION Be sure to set the stand to position B before driving the motorcycle.

Otherwise, it may fall over.

Center Stand (Fig. 20)

When parking the vehicle, step on the center stand at the left of body while rising the rear

portion of body with right hand so as to support the motorcycle. Before driving the

vehicle, move the steering head forward to let the center stand return automatically.

Refuel at the earliest opportunity.

CAUTION After refueling, return the fuel cock to ON

position. Otherwise, you mayrun out of fuel with no reserve.

Learn how to operate the fuel cock when riding the

motorcycle.

GEARSHIFT PEDAL (Fig. 15 & 16)

The motorcycle is equipped with a 5-speed mesh

transmission. The gear indicator shows the gear position at

present.

The shifting patterns are as shown in the Fig.16

Position I is for light loads and smooth road conditions. Position II to V increase spring

preload for a stiffer rear suspension, and can be used when the motorcycle is heavily

loaded or ridden in rugged roads.

NOTE Be certain to adjust shock absorbers both left and right to the same position.

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OPERATIONGUIDE

PRE-RIDE INSPECTION

Inspect your motorcycle every time before you ride it. The items listed here will only take

a few minutes to inspect, and in the long run they can save time, expense, and possibly

your life.

1. Engine oil level - add engine oil if required. Check for leaks.

2. Fuel level - fill fuel tank when necessary. Check for leaks.

3. Coolant level - fill the reverse when necessary. Check for leaks.

4. Front and rear brakes - check operation and adjust free play if necessary.

5. Tyres - check condition and pressure.

6. Battery eletrolyte - check that the electrolyte is suitable.

7. Throttle - check for smooth opening and full closing in all steering position.

8. Lights and horn - check that headlight, tail/brake light, winkers, parking light, indi-

cators and horn function properly.

9. Drive chain - check condition and slack. Adjust and lubricate if necessary.

10. Steering system - check for its smoothness and reliability.

11. Fastener - check that all nuts, screws and bolts are mounted securely.

Correct any discrepancy before you ride. Contact your dealer for assistance if you cannot

correct the problem.

STARTING THE ENGINE

WARNING Do not start the engine in a narrow area to prevent accidents. The

exhaust contains poisonous carbon monoxide (CO) gas that cause loss of conscious-

ness and lead to death.

PRINCIPLE OF FUEL EVAPORATING SYSTEM (EP)

Fuel Evaporating System (See attachment below)

System working priniple: mainly consists of an adsorption and a desorption process.

When the fuel evaporation comes out from the fuel tank, the evaporation is absorbed and

storaged by active carbon in the canister via pipe to make sure no it let off into the

atmosphere. After starting the engine, inhale a certain amount of fresh air from the can by

negative pressure via intak pipe, make the fuel moleucles of active carbon surface are

sucked into the engine for burning, relying on these fresh air dirve between the flow of

activie carbon.

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RIDING

Start the engine and warm up it.

While the engine idling, pull in the clutch lever and push down the gearshift pedal to

shift into low (1st) gear.

Slowly release the clutch lever and at the same time gradually increase engine speed by

opening the throttle.

When the motorcycle attains a steady speed, close the throttle, pull in the clutch lever

and shift to 2nd gear by treading the gearshift pedal.

This sequence is repeated to progressively shift to higher gears.

Coordinate the throttle with brakes for smooth deceleration.

Both front and rear brakes should be used at the same time and should not be applied

strongly enough to lock the wheel, or braking effectiveness will be reduced and control

of the motorcycle be difficult.

CAUTION

It is forbidden to gearshift up or down when the throttle is still not decreased and the

clutch is in. Otherwise, damage to the engine, chain and other parts may occur. Make

sure the gearshift pedal is operated gently and exactly. Riding with your foot resting

onthebrakepedalmaysuddenlychangeaspeedand/ordamagethedrivingmechanism.

BRAKING AND PARKING

To stop the motorcycle, close the throttle and disengage the clutch by pulling in the

clutch lever, then smoothly operate the front and rear brakes until stopping the motorcycle.

Shift the transmission into neutral, turn the emergency switch to position. Then

set the fuel cock to position, support the motorcycle with the center or side

stand. After parking, turn the ignition switch to position and lock the

steeringlock, followed by removing the key.

Attempting to start the engine with the transmission in gear may result in damage to

equipment.

Make sure the fuel in the tank is enough. Set fuel cock to position.

Insert the ignition switch and turn it to position.

Move the gearshift pedal into NEUTRAL to light up the indicator “N” (green).

slightly turn the throttl grip, then operate the starter button to start the

engine.

By lightly turning the throttle grip, increase the engine’s rotational speed to warm up

the engine at 1500r/min approximitly until it works normally, the push the chock lever

to the fully open position.

CAUTION Do not use the electric starter for more than 5 seconds at a time. Release

the starter button for approxmately 10 seconds before pressing it again. Don’t run

the throttle grip fast and make sure that the vehicle is under the user’s guarding when

the engine is being warmed up.

NOTE Startingup the engineinregions with especiallylowairtemperature, treadthe

kick-starter pedal several timex first to run the crankshaft while the ingition key

should be at “ ” (OFF).

BREAKING-IN

Help assure your motorcycle’s future reliability and performance by paying extra attention

to how you rid during the first 1000km.

During this period, avoid full-throttle riding and loading the engine heavily, besure to

drive at speeds not more then 60% of each gear and to keep changing speed.

NOTE After the first 1000km’s, be sure to conduct maintenance so as to make in

compensation for slightly wear. The service life will be extended obviously through

such maintenance.

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MAINTENANCE

TOOL KIT (Fig. 21)

Some roadside repairs, minor adjustments and parts replacement can be performaced with

the tools available in the kit.

Screw driver grip

Double-end screw driver

Spark plug wrench

Open-ended spanner, 8 10mm

Open-ended spanner, 13 15mm

Tool bag

Socket wrench, 8

MAINTENANCE SCHEDULE

Maintenance work should be performed in light of Maintenance Schedule. Letters in the

table indicate as follows:

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY

C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE

The item should be serviced by your dealer, unless the owner has the proper tools and

is mechanically qualified. Refer to the manual.

In the interest of safety, we recommend these items should be serviecd only by your

dealer.

NOTES: Clean more frequently when riding in unusual wet or dusty areas.

At higher odometer readings, still follow the frequency intervals established in

this manual.

MAINTENANCE SCHEDULE

Fig. 21

REGULAR

SERVICE

I T E M

ODOMETER READING, km (Note )

First

1,000km 4,000km 8,000km 10,000km Remarks

Fuel line system I I I

Fuel filter C C C C

Throttle operation I I I I

Carburetor choke I I I

Air cleaner element Note C C C

Spark plug I I I I

Valve clearance I I I I

Engine oil Yearly R Every 2,000km-R

Engine oil strainer Yearly-R C

Cam chain slack A A A A

Engine idle speed I I I I

Drive chain I, L I, L I, L I, L

Battery Monthly I I I I

Brake shoes/pad wear I I I

Brake system I I I I

Brake light switch I I I I

Headlight adjustment I I I I

Clutch I I I I

Side stand I I I

Suspension I I I I

Nuts, bolts, fasteners I I I I

Wheels/spokes I I I I

Steering bearings I I

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COOLANT (Fig. 24 & 25)

1. Function

The special coolant is designed for cooling, anti-depositing and promoting the boil

point. In addition, it prevents the engine from overheating when the engine runs at idle

or lower speed, and the inside of the radiator from depositing furring. Its ice point is -40

, and boilling point 108 (under an atomspheric pressure).

ENGINE OIL (EP)

Check of Engine Oil (Fig. 22)

Check the engine oil level every use.

The dipstick is located onto the rear portion of the

right crankcase cover. The level must be maintained be-

tween upper mark and lower mark .

Place the motorcycle on a level ground with the center

stand. Remove the dipstick, wipe it clean. Reinsert and

screw in the dipstick, then remove it for checking.

Add engine oil SAE15W/40-SE to upper level mark.

Do not overfill.

Insert the dipstick. Check for leaks.

Fig. 22

Dipstick Upper mark

Lower mark

Fig.23

Engine model &

code

Drain plug

Fig. 24 Radiator cap

Reserve tank cap

Lower Mark High Mark

Fig. 25

CAUTION Running the engine with insufficient oil can cause serious damage to the

engine.

Change of Engine Oil (Fig. 23)

It is better to drain when the engine is still warmed.

Place an empty container under the engine, unscrew

the drain plug.

Shift the transmission into neutral, operate the starter

button several times so as to help empty the oil thoroughly.

Reinstall the drain plug, and tighten it up.

Pour approx. 1L of SAE15W/40-SE into the engine. Re-

start the engine, keep it idle for a few minutes, and then stall

it. Recheck the oil level, and add oil if necessary.

CAUTION When running in very dusty conditions, oil

changesshouldbeperformed more frequently than specifed

in the maintenance schedule.

NOTES

(1) The density of the prepared coolant is 55%, which can be poured

directly into cooling system. If it is no enough, do not apply

water instead.

(2) Do not mix it with other coolant.

(3) Never drink the coolant because it is poisonous.

2. Adding of Coolant

(1) Place the motorcycle on the level ground with center. Open

the radiator cap (Fig. 24) and add more coolant.

(2) Start the engine and run it at idle and high speed aternatively for

2-3 times. Add more coolant if necessary. Cover the cap securely.

(3) The reserve tank is located under the seat.

(4) Add coolant to between “L” mark and “H” mark of reserve

tank. Then put the cap.

3. Change of Coolant

Set the motorcycle on the level ground with the center stand.

Place an empty tray under the radiator, then open the radiator and

remove the hose from the radiator. After discharging out, fit the hose to initial position,

add the coolant.

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Inspect the electrodes and center porcelain for deposits, and

clean with a wire brush. If the spark plug is damaged, replace

it.

Check the spark plug gap which should be 0.90 0.05mm,

and adjust by bending the side electrode if necessary.

CAUTION The spark plug must be securely tightened.

Improperly tightened plug can become very hot and possibly

damage the engine.

AIR CLEANER (EP) (Fig. 27)

The air cleaner must be cleaned and then soaked in clean oil

at least once every 4000km’s drive. Riding in very dusty area,

the job should be done more often. See your dealer for further

information.

4. NOTES

Do not open the radiator cap just after stopping the engine. Otherwise, burn you by

aqueous vapour or boiling liquid.

Take care to discharge the coolant from the cooling system so as to prevent the crankcase

from getting liquid before maintaining the engin.

SERVICE OF COOLING SYSTEM

1. The cooling system should be checked for tightness at least once every 3000km’s

drive. Check the hoses by pressing the surfaces with finger for damage such as ageing,

cracks. If any, send it to your dealer for help.

2. Check the coolant once every 3000km’s drive as following:

(1) Check the cooland level in the radiator. The coolant may be ablated a little as the

engine runs. For adding coolant, select the same density and the same type of coolant. Do

not use water instead.

(2) Check that the coolant is clear. If it becomes cloudy or its service limit arrives, replace

it in good time.

CLEAR AWAY CARBON DEPOSIT (EP)

Clear away carbon deposit around the spark plug and piston ring, on the piston top, in

the piston ring slot and combustion chamber regularly.

SPARK PLUG (EP) (Fig. 26)

Spark Plug Type CPR8EA

Check and Replace

Disconnect the spark plug cap from the spark plug. Clean any dirt from around the

spark plug base. Remove the spark plug by the special wrench.

Side

electrode

Fig. 26

Seat lock Screw Air cleaner cover Element Fig. 27

Insert the ingition key into seat lock , turn it clociwise and remove the side cover.

Drive out screw , remove the air cleaner cover .

Take the element out of the housing.

Replace the element with a new one.

Reinstall all the removed parts well in the reverse order of removal.

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Index mark

Mark T

Fig. 28

Adjusting

screw

Locknut

VALVE CLEARANCE (Fig. 28 )

Check valve clearance when the engine is cold at the specified intervals.

Take the top view hole (for ignition timing) cap and magneto cap out of the left cylinder

head cover.

Rotate the flywheel counterclockwise until mark T on the flywheel aligns with the

index mark on the view hole. Check it is in TDC of the compression stroke by moving

the rocker arms. If they are free, it means check can be done. Otherwise, rotate the fly-

wheel through 360 .

Clearance should be 0.08mm for the intake valve and 0.12mm for exhaust valves.

If it is necessary to make an adjustment, loosen the valve lock nut and turn the adjust-

ing screw so there is a slight resistance when the feeler gauge is inserted. Then tighten

up the lock nut, and recheck the clearance.

EXHAUST MUFFLER (EP)

Clear away regularly carbon deposit in the exhaust pipe; check the exhaust pipe inside

for crack and washer for damage, and repair or replace if necessary.

WARNING Replace the gasket whenever a muffler is disassembled. The muffler

becomes very hot during operation and remains hot for a while after stopping the

engine. Be careful not to touch the muffler after stopping the engine.

3-WAY CATALYTIC CONVERTER(EP) (Fig. 29)

3-way catalytic converter is mounted on the exhaust system of motorcycle. It is designed

to decrease contaminations such as CO, HC, NOx, etc. by redox reaction to catalyst when

the exhaust gases flow through the device.

Applying the catalyst controls the pollutant emissions from the motorcycle, i.e. a chemi-

cal reaction sets in when exhaust gases pass through the converter that contains a catalyst.

The noble metal catalyst is characterised by good adhesiveness, and accelerates a chemi-

cal reaction without itself being affected. Its basic principle is as follow: pollutants in

the exhaust gases, such as CO, CH, NOx, etc, spread into micro-holes in the catalyst when

gases pass through the device, an adsorption reaction happens on the surfaces of catalyst,

as a result, converting them into harmless compounds (CO2, H2O, N2, etc.) and entering

the air. The purging efficiency of catalyst varies with temperature of, density of and speed

of gases.

Attention should be drawn to the following points during service:

1. Handle 3-way catalyst with care, don’t knock or press it, and keep away oil and dirt.

It should be stored in dry and well-ventilated place.

2. Never let acid liquid or electrolyte infiltrate into the exhaust muffler, otherwise, make

the catalyst unefficient.

3. Unleaded gasoline should be used.

Fig. 29

ＬＦ　１５０－１０Ｂ（ＥＮＧＬＩＳＨ）Ａ．ｐ６５ 2012-4-23, 9:3315

Fig. 30

Strainer Cup Fuel filter

FUEL FILTER(EP) (Fig. 30)

The fuel filter is a fuel cock strainer. Remove the plug by turning it in B direction, take out

the strainer and clean it in gasoline. Reinstall the parts in the reverse order.

Throttle stop

screw

Fig. 32

Throttle grip Locknut

Adjuster Fig. 31

Plug

OPERATION OF THROTTLE (Fig. 31)

Check for smooth rotation of the throttle grip

from the fully open to the fully closed position at

both full steering position.

Measure the throttle grip free play at the throttle

grip flange. The standard free play should be

approx. 2-6mm.To adjust the free play, loosen the

locknut,turn the adjuster. Adjustment over, fas-

ten the locknut.

IDLE SPEED OF CARBURETOR (EP)

(Fig. 32)

The carburetor is installed between the engine

and air cleaner.

NOTE The carburetor has been set accurately in

factory. The user only needs to adjust idle speed

after the engine is warmed up.

Adjust idle speed with the throttle stop screw

to set idle speed at about 1500r/min. Turn the

screw in direction A will increase idle speed, in

direction B decrease idle speed.

When the engine has no idle speed or runs at a decreased speed, set the throttle stop

screw in the middle between the two limit positions to help mix air and fuel.

Run the engine again. Readjust the throttle stop screw, if necessary.

CAUTION Since the carburetor is a precision apparatus, don’t disassemble it without

the professional knowledge.

CHECK LEAKS ALONG AIR SUPPLY LINE (EP)

Check regularly air supply line, specially such as the joint between the muffler and engine,

the joint between the air cleaner, carburetor and inlet pipe, etc. for leakage, and repair or

replace damaged parts once there are some troubles to assure a normal air supply, and avoid

polluting the environment.

ADJUSTMENT OF CLUTCH (Fig. 33)

Measure the clutch lever free play at the clutch lever flange. The free play should be 10

20mm. Adjustment of the clutch should be done with the engine stalled.

Turn loose the locknut at the clutch cable holder located on the crankcase, and then

make adjustment by screwing in or out the corresponding adjusting nut. After adjustment,

tighten up the locknut.

DRIVE CHAIN (Fig. 34)

Check

Check the drive chain for wear and slack. Lubricate the chain if it seems to be dry.

Slack should be 10-20mm. Support the motorcycle with the center stand, check slack in

the lower chain run midway between the sprockets.

Fig. 33

Locknut

Clutch cable holder

Boot

ＬＦ　１５０－１０Ｂ（ＥＮＧＬＩＳＨ）Ａ．ｐ６５ 2012-4-23, 9:3316

Fig. 34

Chain clip Adjusting bolt Locknut

Index mark Rear axle locknut Chain

Max. 10-20mm

Adjustment

Loosen the rear axle nut and locknut, turn both adjusting bolts until the chain slack

meets the standard, and make sure left and right adjusters align with the same index marks.

After checking, tighten up the rear axle nut with a torque of 50 60N.m.

NOTE Turning the adjusting nut in direction A will increase the chain slack, and in

direction B decrease the slack.

Check the chain for slack

If slack of chain is changed, it is necessary to relocate the rear wheel, for adjustment

will affect the rear brake pedal free play.

Lubrication

Pull out the chain clip with pliers, remove the joint and chain. Wash the chain in cleansing

solution and dry it in the air. Check the chain including link plates, bushings, and rollers

for damage, cracks, wear-out. Replace if necessary. Lubricate the chain, then reinstall and

adjust it.

CAUTION The chain clip should be so installed as to make sure that its closed end faces

the direction of wheel rotation.

FRONT BRAKE

Front Disk Brake (Fig. 35)

Fr. brake lever Brake main cylinder Sight glass Screw Cover Brake calliper

The front brake lever is located at the right handlebar. The distance the front brake lever

moves before the brake starts to engage is called free play, which should be 10-20mm (Fig.

35).

Place the motorcycle on the level ground. Check the brake fluid level through the sight

glass. If the fluid level is below the LOWER, loosen the cylinder cover screws, remove

the cover, add brake fluid up to the UPPER level mark.

Air Bleeding

If the brake lever free play becomes excessive and the brake pads are not worn beyond its

minimum depth, there is probably air in the brake system and bleed it as follows:

Pump the front brake lever, then gently loosen the bleed valve while holding the lever.

Take care to tighten up the bleed valve as soon as flowing fluid. Repeat above the proce-

dure until the system is completely bled.

Apply the breke several times and check for free wheel rotation after the brake lever is

released.

WARNING Apply only specified brake fluid, or braking effectiveness and riding

safety will be affected adversely. Do not allow contaminants such as dirt or water to

enter the brake fluid tank. Brake fluid may cause irritation.Avoid contact with skin

or eyes. In case of contact, flush thoroughly with water.

Wear limit

Fig. 35

ＬＦ　１５０－１０Ｂ（ＥＮＧＬＩＳＨ）Ａ．ｐ６５ 2012-4-23, 9:3317

REAR BRAKE (Fig. 36)

Support the vehicle on its center stand. Measure the distance the rear brake pedal moves

before the brake starts to engage. The free play should be 20 30mm.

Apply the brake several times and check for free wheel rotation after the brake pedal is

released.

NOTE There are no adjustments to be made to the brake. For any doubt, see your dealer

for help.

HOW TO USE BRAEK WEAR INDICATOR (Fig. 37 & 38)

If any pad is worn to its limit depth, replace both pads as a set at the first opportunity.

Rear brake pedal ~Fig. 36

Fr. brake disk

Fr. brake caliper Rr. brake disk

Rr. brake caliper

Wear limit

Fig. 37 Fig. 38

Tyre Pressure

Rider Front tyre: Rear tyre:

Rider & passenger Front tyre: Rear tyre:

Tyre size Front tyre: Rear tyre:

Tread Depth Limits

Front tyre Rear tyre

FRONT/REAR SHOCK ABSORBER AND SUSPENSION

Support the motorcycle on the center stand, pull in the front brake lever to lock the front

wheel, pump the front/rear shock absorber up and down several times to see that it func-

tions well without noise or leakage.

Check the rear fork bushing for proper play by pressing the side of the rear wheel. Make

sure that all of the fasteners are tightened securely.

NOTE If the shock absorber is damaged, repair or replace it.

TYRE

Proper air pressure will provide maximum stability, riding comfort and porlong tyre life.

WARNING Operation with excessively worn tyres is hazardous and will adversely

affect traction and handling.

NOTE Tyre pressure should be checked before you ride while the tyres are “cold”. Check

the tyres for cuts, embedded nails, or other sharp objects. Check the rims for dents or

deformation. See your deler for change or damaged tyres or punctured inner tubes.

CAUTION Improper tyre inflation will cause abnormal tread wear and create a

safety hazard. The tyre pressure less than the rated value may result in slipping wheel

on the ground or coming off from the rim.

When the tread depth in the middle section of tyres reached limits below, please replace

them.

ＬＦ　１５０－１０Ｂ（ＥＮＧＬＩＳＨ）Ａ．ｐ６５ 2012-4-23, 9:3318

Installation shall be done in the reverse order of

removal.

NOTES

Tightening torque of rear axle nut: 50 60N.m

For adjustment of the rear brake and chain, refer to

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