Service Manual for

LX900-A
LXMT-WX-001

Loncin Motor. Co. ltd., Chongqing Jan. 2024

Foreword
The motorcycles on market are increasing with each passing day,
while new structure and technology are adopting. For easy maintenance,
adjustment and repair to Loncin users and service workers of model
LX900-A, we made this Service Manual, which provides you
convenience and guidance of technology for repair and maintenance.
All the content such as form list, diagram, data, and performance in
this book are the latest until it released. The Loncin motor reserves the
right for revision of this book at any time without notice in advance. Any
part of this book is the copyright reserved by Loncin only, reprint of other
person or company is forbidden unless got writing authorization from
Loncin.

Service Manual for LX900-A

Content list
1. Disassembly, re-assembly and maintenance for engine 1
Engine kit and its parts 1
Disassembly and re-assembly for engine 2
Filling-up for oil of engine 4
Replace oil filter 5
2. Disassembly, re-assembly and maintenance for handle bar 5
Handle bar kit and its parts 5
Disassembly and re-assembly for handle bar 6
Disassembly and re-assembly for left lever kit 8
Disassembly and re-assembly for clutch cable 9
3. Disassembly, re-assembly and maintenance for air filter 9
Air filter kit and its parts 9
Disassembly and re-assembly for air filter element 10
Disassembly and re-assembly for air filter kit 11
Disassembly and re-assembly for throttle kit 11
Disassembly and re-assembly for oil rail 12
4. Disassembly, re-assembly and maintenance for air exhaust kit 13
Air exhaust kit and its parts 13
Disassembly and re-assembly for muffler kit 14
5. Disassembly, re-assembly and maintenance for fuel tank kit 15
Fuel tank kit and its parts 15
Removal for fuel tank kit 16
Removal for fuel tank lock 17
Removal for fuel pump 17
6. Disassembly, re-assembly and maintenance for fuel evaporation controller
kit 18
Fuel evaporation controller kit and its parts 18
Removal for fuel evaporation controller kit 18
Figure of connection for fuel evaporation controller 19
Working principle for fuel evaporation controller system： 19
7. Disassembly, re-assembly and maintenance for heat radiator system 20
Heat radiator system and its parts 20
Inspection for coolant 21
Replacement for coolant 21
Filling-up for coolant 21
8. Disassembly, re-assembly and maintenance for front wheel 22
Front wheel kit and its parts 22
Removal for front wheel 23
Removal for brake plate 24
Removal for tires 24
Removal for front wheel bearing and oil seal 25
9. Disassembly, re-assembly and maintenance for front fork kit 26
Front fork kit and its parts 26
Disassembly and –re-assembly for steering stem 27
Disassembly and re-assembly for steering bearing 30
Judgement for clearance of steering bearing 31
10. Disassembly, re-assembly and maintenance for rear wheel kit 32
Rear wheel kit and its parts 32
Removal for rear wheel 33
Removal for damper kit 34
Removal for brake plate 34
Removal for rear tire 35
Removal for rear wheel bearing and oil seal 35
11. Disassembly, re-assembly and maintenance for rear suspensionkit 36
Rear suspension kit and its parts 36
Disassembly and re-assembly for rear shock absorber 37
Disassembly and re-assembly for rear fork and chain 38
Disassembly and re-assembly for rear fork bearing 39
Disassembly and re-assembly for chain slider 39
Disassembly and re-assembly for driving sprocket wheel 40
Disassembly and re-assembly for damper kit 41
Disassembly and re-assembly for damping pieces of rear wheel 42
Conditions for chain replacement 43
Condition for sprocket wheel replacement 43
12. Disassembly, re-assembly and maintenance for brake system 44
Brake system and its parts 44
Replacement for front brake pads 45
Replacement for rear brake pads 46
Inspection for disc brake pad 47
Inspection for liquid level in front and rear brake system 47
Replacement for brake liquid in front disc brake 47
Replacement for brake liquid in rear disc brake 48
Replace parts for ABS and in pipeline of front and rear brake 49
Removal for speed sensor of front wheel 50
Removal for speed sensor of rear wheel 51
13. Disassembly, re-assembly and maintenance for lights set on motorcycle 51
Headlight kit and its parts 51
Removal for headlight kit 52
Tail light and its parts 53
Removal for tail light kit 53
Removal for rear turning signal and rear registration plate light 54
14. Disassembly, re-assembly and maintenance for main footrestand step
pillion 55
Main footrest, step pillion and their parts 55
Removal for left and right main footrest and step pillions 56
Removal for left and right main footrest 57
Removal for left and right step pillion 57
15. Disassembly, re-assembly andmaitenance for side stand, main stand,
gearshift and rear
brake pedal 58
Side stand, main stand, gearshift pedal, rear brake pedalandtheir parts 58
Disassembly and re-assembly for side and main stand 59
Disassembly and re-assembly for gearshift pedal 60
Disassembly and re-assembly for rear brake pedal 61
Service Manual for LX900-A

1. Disassembly, re-assembly and maintenance for engine

Engine kit and its parts

1 Engine kit SET 1

2 Ignition coil PCS 1
3 Socket spline head bolt PCS 2
4 Lower lug for heat radiator PCS 1
5 Connective piece for side strip PCS 1
6 Horn bracket PCS 1
7 Socket hex. spline flange bolt PCS 1
8 Hex. flange bolt PCS 1
9 Spline base set PCS 1
10 Flat washer PCS 1
11 Damping cushion PCS 1
12 Gearshift trending sensor PCS 1
13 Collar PCS 1
14 Pin shaft PCS 1
15 Socket spline head bolt PCS 3
16 Engine shield cover PCS 1
17 Damping rubber PCS 4
18 Socket hex. spline head flange bolt PCS 1
19 Middle connective holder for muffler PCS 1
20 Socket hex. spline head flange bolt PCS 3
21 Socket spline head bolt PCS 1
22 Tube clamp PCS 1
23 Collar PCS 1
24 Tube joint PCS 1

Disassembly and re-assembly for engine

Lift up tail part of frame by hanging device.
Remove bumper bar 2.
Remove engine shield 4.
Remove fuel tank kit 1 by referring is steps for disassembly and re-assembly.
Remove muffler kit 3 by referring its steps for disassembly and re-assembly.
Remove main footrest 5 and rear fork 6 by referring disassembly and re-assembly for main footrest.
Removing hanging plate 8 for chain adjustor.
Loosen the chain 7 by referring its steps for disassembly and –re-assembly.

Loosen connective rubber tube between air

filter and engine, then remove air filter kit 9.
Remove all wire joint connect to engine.。
Remove the ignition coil connects to engine.
Drain off coolant in cooling system by
referring replacement for coolant.
Cut off all pipeline of cooling system 11 who
connect to engine.
Cut off clutch cable.
Remove bolts connect engine and frame in
turn.
Remove throttle valve kit 10.
Remove the other related accessories and to
achieve the disassembly for engine.
The re-assembly is precisely opposite to
disassembly.
Caution:
Use the tools for removing engine only when
disassembling to avoid injury due to the
heavy engine.
Important:
Please dispose the drained coolant in environment friendly way.
Please refer to corresponding chapter for coolant filling-up when re-assembling.。
Recover the wire’s binding-up to the status before disassembly, which fully take water
proof, interference and harmful heat into consideration.
When re-assembling gearshift trend sensor, to ensure part performance, please
Replace the damping cushion in list (11) above.
Parameters:
Fastening bolt for rear fork Nm M20 70
Left front fastening bolt for engine Nm M12 75
Right front fastening bolt for engine Nm M12 75
Left rear fastening bolt for engine Nm M12 75
Right rear fastening bolt for engine Nm M12 75
Fastening bolt for left main footrest Nm M10 40
Fastening bolt for right main footrest Nm M10 40
Left front fastening bolt for bumper bar Nm M8 22
Left rear fastening bolt for bumper bar Nm M8 22
Fastening bolt for appearance plastic parts Nm M5 3
Nm M6 4．5
Fastening bolt for engine shield Nm M6 9
Nm M8 22
Fastening nut for clutch cable Nm M8 9
Fastening bolt for lug of heat radiator Nm M6 9

Oil filling-up for engine

Remove oil gauge at left rear side of engine.
Fill up oil.
Keep motorcycle upright by parking rack.
Re-assemble oil gauge in place.
Start engine , let it idly run until cooling fan works, then keep idling for a minute.。
Stop engine and wait for one minute to wait oil flowing back.
Turn and take out oil gauge and wipe it up then insert once again by turning one
Round to check if the oil level is between upper and lower scale line.
In case the oil level is out of range, please repeat the steps above to add or reduce oil until oil level is
within two scale lines.

上刻度线：Upper scale line 下刻度线：

Lower scale line
Caution:
In case the oil level is above upper scale line, please extract surplus oil by tools
for it only from filling-up port.
Important:
When oil filled up, start engine and idly run for 30 seconds, then check the oil level
once again.
When checking oil level, please keep motorcycle upright, otherwise the oil level could
not be confirmed.
Parameters:
Oil capacity in engine （Without L 2.7
replacing element）
Oil capacity in engine（Replacing L 3.0
element）
Oil capacity（Break up engine） L 3.2
Oil specification Specification for suggested oil shall be ：Grade 5W/40 SL or
above

Replacement for oil filter

Put the oil collection case under oil filter at right rear side of
engine.
Remove oil filter by tool for it only (Picture below shows),
remove the oil filter and drain off oil.
Assemble the new oil filter.
Assemble the o-ring onto cover of oil filter.
The re-assembly is precisely opposite to disassembly.
Caution:
When the work above
finished, please clean
up greasy dirt on
surface of engine and
muffler by cleanser,
then dry them up by
compressed air.
Important:
Please dispose the used
oil and its filter by
environment friendly
way.
Check oil filter and o-ring, replace if it is necessary.
Parameters:
External oil drainage bolt for engine N.m 25
Internal oil drainage bolt for engine N.m 8
Oil filter N.m 11
帽式机油滤清器扳⼿：Cap-shaped wrench for secondary oil filter.

2. Disassembly, re-assembly and maintenance for handle bar kit

Handle bar kit and its parts

1 Socket hex. spline flange bolt PCS 2

2 Flat washer PCS 2
3 Left grip shield PCS 1
4 Flanging washer PCS 2
5 Decorative weight PCS 2
6 Balancing weight for handle bar PCS 2
7 Grip (Under heating) PCS 1
7 Grip (Without hearing) PCS 1
8 Cross head pan-shaped screw PCS 2
9 Left switch assembly SET 1
10 Handle bar PCS 1
11 Clutch cable PCS 1
12 Clamping band PCS 1
13 Cross head self-tapping screw PCS 2
14 Right switch assembly SET 1
15 Accelerator PCS 1
15 Accelerator PCS 1
16 Right grip shield PCS 1
17 Left lever kit SET 1
18 Clutch cable jacket PCS 1
19 Grip shield bracket PCS 1
20 Clipping nut PCS 2
21 Socket spline head bolt PCS 2
22 Left back-view mirror PCS 1
Left back-view mirror (With lane
22 PCS 1
shift reminder）
23 Grip shield bracket PCS 1
24 Right back-view mirror PCS 1
Right back-view mirror (With lane
24 PCS 1
shift reminder）

Disassembly and re-assembly for handle bar kit

Keep motorcycle upright by parking rack.
Cut off all connectors on handle bar kit for electrical parts
Remove left and right back-view mirror 1.
Loosen bolt 2 for grip shield, remove left and right grip shield 5, flat washer 3, collar 6 and decorative
weight 4 for handle bar.
Remove balancing weight 7.
Remove left lever kit 8.
Remove upper pump 9 for front brake.
Remove left switch assembly 10 and right switch assembly 11.
Remove accelerator 12.
Remove grip rubber 13.
Remove steering clip 14 and remove handle bar.
The re-assembly is precisely opposite to disassembly.

Caution:
When re-assembling left and right switch assembly, please align the positioning pin on
handle bar to its corresponding hole on handle bar, then fasten the bolt on switch
assembly.
Important:
The re-assembly finished, please confirm the turning free play for clutch lever and
accelerator.
When handle bar was re-assembled, please confirm if its angle is correct, turn the handle bar to the left
and right limit to check if there is interference among handle bar, cable, fuel tank and surroundings,
please adjust if it is necessary, otherwise there will be risk for safety.
When back-view mirror was re-assembled, adjust the angle of the mirror once again and confirm its
viewing range is correct or safe.
Make sure the free play of ball joint on clutch lever is within 10-15mm, otherwise the clutch may not
totally separate which leads to engine damage.
Parameters:
Fastening torque for steering clip Nm M8 18
Fastening torque for left lever kit Nm M6 9
Fastening torque for decorative weight of handle bar Nm M6 9
Fastening torque for balancing weight of handle bar Nm M16 25

Fastening torque for back-view mirror Nm M10 25

Fastening torque for right switch assembly and accelerator Nm ST2.5 0.3
Fastening torque for accelerator and grip rubber Nm M4 1
Fastening torque for left switch assembly Nm M4 1

Disassembly and re-assembly for left lever kit

1 Lever adjusting screw PCS 1

2 Lever adjusting nut PCS 1
3 Left lever base PCS 1
4 Adjusting base for left lever PCS 1
5 Pin shaft PCS 1
6 Circlip with opening PCS 1
7 Lever adjusting nut PCS 1
8 Left lever rod PCS 1
9 Clutch switch PCS 1
10 Hex. locking nut of inserted non-metallic piece PCS 1
11 Connective bolt PCS 1
12 Left lever clip PCS 1
13 Socket hex. cheese head bolt PCS 2

Remove circlip 6 by tools.

Pull out pin shaft 5.
Remove left lever rod 8.
Important:
Coat every turning set of left lever with lithium lubricant when re-assembling.
When re-assembled clutch switch, repeatedly confirm if it was assembled in place, while
confirming on and off for clutch switch on motorcycle.

Disassembly and re-

assembly for clutch
cable
Remove left side cover 1.
Remove clamping band 2 for
fixing from frame.
Loosen clamping band 3 for
fixing wires.
Remove cable end 4 on
engine.。
Remove cable end 5 on left
lever.
Finally pull out the cable.
Replace clutch cable for a new
one with same specification.
The re-assembly is precisely
opposite to disassembly.
Caution:
Coat turning joint of lever end
with lithium lubricant,
otherwise the working life of
cable may get shorter.
When re-assembling clutch cable, please pay attention to its wiring, which shall be the same to that
before disassembling, otherwise there will be problem for its returning.
When re-assembled, hold and release the clutch lever to confirm its correct assembly, which shall not
be with jamming or returning failure.

3.
Di
sa
ss
e
m
bl
y,
re-
9
as
sembly and maintenance for air filter kit
10
Air filter kit and its parts
 11

12

1 Air filter PCS1

2 Air intake tube of air filter PCS1
3 Air intake tube for air filter PCS1
4 Frame of filter element PCS1
5 Air filter element kit PCS1
6 Air filter case kit PCS1
7 Damping rubber jacket PCS2
8 Installation piece for filter element PCS1
9 Socket spline head bolt PCS1
10 Flat washer PCS1
11 I-ring PCS1
12 Flanging washer PCS1
13 Throttle valve kit PCS1
14 Pressure sensor for air intake temperaturePCS2
15 Clamp kit PCS4
16 Tube clamp PCS1
17 Breathing tube PCS1
18 Tube clamp PCS1
19 Fuel tube kit PCS1

Disassembly and re-assembly for element of air filter

Keep motorcycle upright by parking rack.
Remove decorative piece, left and right decorative cover kit of fuel tank by referring steps for
disassembling and re-assembling fuel tank kit.
Powerfully press installation piece 1 for element in place by finger along the direction of arrow points
at, meanwhile pulling frame kit of element of air filter upwards.
Remove element of air filter and replace it for a new one.
The re-assembly is precisely opposite to disassembly.
Important:
Please repeatedly confirm if the re-assembled filter element is installed in place, otherwise it may lead
to poor sealing for element, get dust into engine and let engine life shorter.
In case there is damage on filter element, please replace.
In case there is greasy dirt on filter element, please replace.
In case filter element is wet, please replace.
Dispose the replaced filter element in environment friendly way.
Parameters:

Installation bolt for

M6 N.m 4.5
appearance parts
M5 N.m 3

Disassembly and re-assembly for air filter kit

Keep motorcycle upright by parking rack.
Remove fuel tank and its related covering parts by
referring their disassembly.
Pull out air intake tube of air filter diagonally below.
Remove bolt 1 connecting frame and air filter.
Loosen clamp 2 connecting throttle valve kit and
connective tube of air filter.
Slowly lift up air filter, remove clamp 3 for waste gas
tube of crankcase, then cut off connection between the
waste gas tube to air filter, finally remove the air filter
kit.
The re-assembly is precisely opposite to disassembly.

Disassembly and re-assembly for

throttle valve body
Remove connectors on throttle valve body, then pull off
fuel and breathing tube kit.
Remove clamp 1 for throttle valve kit by tool.
Powerfully pull out throttle valve kit.
The re-assembly is precisely opposite to disassembly.
Important:
When throttle valve kit assembled, please repeatedly
confirm the sealing pieces to air filter case are installed
in place, otherwise the poor sealing may let dust get into
engine and make engine damage.
Wash up by cleanser for the air intake tube and throttle valve
kit only and dry them up before re-assembling to ensure engine performance.
Parameters:
Fastening torque for installation bolt between air filter and frame M6 Nm 9
Installation torque for clamp between throttle valve kit and connective tube
M4 Nm 2
of air filter
Installation torque for clamp of throttle valve kit M4 Nm 2

Disassembly and re-assembly for oil rail

Remove bolt 1 for connecting throttle valve kit and oil rail by tool.
Powerfully pull the oil rail kit and finally remove it.
The re-assembly is precisely opposite to disassembly.
Important:
Check if there is damage, distortion or wrong assembly for o-ring 1 on fuel injector when re-
assembling the oil rail, please make correction or replacement in case it is necessary, otherwise it may
lead to poor sealing even abnormal combustion.
Make sure the locating clip 2 between fuel injector and oil rail is in same condition with that before
disassembly when re-assembling fuel injector and oil rail.
Wash fuel injector up by cleanser for it only before re-assembling and dry it up to ensure engine
performance.
Parameters:
Fastening torque for bolt between oil
M6 Nm 6
rail and throttle valve kit
4. Disassembly, re-assembly and maintenance for air exhaust kit

Air exhaust kit and its parts

1 Front part of muffler and air exhaust pipe PCS1

2 Welding kit for air exhaust pie PCS1
3 Clipping nut PCS3
4 Flat washer PCS5
5 Elastic washer PCS4
6 Socket hex. spline flange bolt PCS2
7 Hot proof shield PCS1
8 Middle part of muffler and air exhaust pipePCS1
9 Connective jacket PCS2
10 Graphite ring PCS2
11 Hot proof shield PCS1
12 I-ring PCS2
13 Rear part of muffler PCS1
14 Muffler body PCS1
15 Socket hex. spline flange bolt PCS2
16 I-ring PCS2
17 Flanging washer PCS2
18 Muffler shield PCS1
19 I-ring PCS1
20 Hanging plate for muffler PCS1
21 Socket spline head bolt PCS2
22 Hex. nut PCS2
23 Socket hex. spline flange bolt PCS1
24 Reinforcing washer for hanging plate PCS1
25 Flanging washer PCS1
Flat washer
26 PCS1

27 Metallic hex. flange nut PCS1

28 Gasket for air exhaust port PCS2
29 Hex. flange nut PCS4
30 Oxygen sensor PCS2

Disassembly and re-assembly for muffler

Keep motorcycle upright by parking stand.
Remove bolt 1 and bolt 2 of connective jacket for muffler, then remove rear part 3 of muffler.
Remove bolt 4 of connective jacket for middle part of muffler by tool, then remove the middle part 5 of
muffler.
Remove the joint between oxygen sensor and wire harness.
Remove nut on air exhaust port by tool, then remove front part 6 of muffler.
Remove gasket for air exhaust port for muffler.
Remove oxygen sensor 7 by tool.
The re-assembly is precisely opposite to disassembly.

Caution:
Please don’t remove graphite ring for sealing at connecting place between front and rear part of muffler
under normal conditions, otherwise it may damage.
Important:
Check if there is damage on graphite ring before re-assembling, the damage may get graphite ring in
poor sealing, which needs be replaced.
Before re-assembling the front part of muffler, please replace the gasket of air exhaust port for a new
one, otherwise the used gasket is with poor sealing and makes air leakage.
Remove muffler when the muffler is cooled down to avoid scald.
There is steel wire in graphite ring, please avoid injury to hands when replacing.
When re-assembled, please start the engine to check if there is air leakage at sealing position.
Please dispose the replaced graphite ring in environment friendly way.
The inserting position of oxygen sensor to wire harness shall be the same to that before disassembling,
otherwise the wrong connection makes malfunction for engine even motorcycle.
Parameters:
Connective bolt for rear part of muffler M8 Nm 22

Bolt on connective sleeve for rear part of muffler M10 Nm 30

Bolt on connective sleeve for middle part of muffler M10 Nm 30

Nut on air exhaust port for front part of muffler M7 Nm 15

Fastening for oxygen sensor / Nm 40

5. Disassembly, re-assembly and maintenance for fuel tank kit

Fuel tank kit and its parts

2 1
4
3

5
 1 Water tube PCS 1
2 Water tube PCS 1
3 Clamping band PCS 1
4 Support rubber jacket for fuel tank PCS 2
5 Fuel tank welding kit PCS 1
6 Clipping nut PCS 4
7 Fast change joint PCS 2
8 Socket spline head bolt PCS 7
9 Electric fuel pump PCS 1
10 T-ring PCS 4
11 Collar PCS 2
12 Flat washer PCS 2
13 Socket spline head bolt PCS 4
14 Rear holder of fuel tank PCS 1
15 Socket hex. spline flange bolt PCS 2
16 Bracket for protective plate of fuel tank PCS 1
17 Fuel tank lock PCS 1
18 Socket hex. screw PCS 5

Removal for fuel tank kit

Keep motorcycle upright by parking stand.
Remove seat 1 by key (Remove connectors to wire harness in case the seat is with heating function).
Loosen bolt, remove left and right bumper bar 2.
Loosen bolt 3, remove decorative cover 3 for fuel tank.
Loosen bolt, remove left and right fairing cover 4.
Loosen bolt, remove left and right side cover 5.
Remove decorative cover 6 for left and right windshield plate by hand.
Loosen bolt, remove left and right decorative cover kit 7 for fuel tank.

Cut off water leakage tube 8.

Remove left and right installation bolt 9 on the rear part of fuel
tank.
Suitably lift up fuel tank apart from ground, then remove rubber
tube for fuel evaporation at bottom of fuel tank, then remove
wire joint for fuel pump, fast change joint for fuel tube and
finally remove the fuel tank kit 10.
The re-assembly is precisely opposite to disassembly.
Caution:
Because there are so many connectors at lower side of fuel tank,
please install every part in place to avoid pipeline excessively
getting bent or pressed.

Parameters:
Installation bolt for appearance part M6 N.m 4.5
M5 N.m 3
 installation bolt for fuel tank kit M8 N.m 22
Installation bolt for bumper bar M8 N.m 22
Installation bolt for bumper bar M10 N.m 40

Removal for fuel tank lock

Remove the 5 pieces of bolt for installing fuel tank lock.
Remove fuel tank lock.
The re-assembly is completely opposite to disassembly.
Caution:
Repeatedly confirm if the sealing rubber piece between fuel tank lock and port is installed in place
when re-assembling fuel tank lock, otherwise the fuel may leak.
Parameter:
Fastening bolt for fuel
M5 N.m 6
tank lock

Removal for fuel pump

Drain off residual fuel in fuel tank first.
Get the removed fuel tank upside down.
Remove the 7 pieces of bolt for installing fuel pump.
Remove fuel pump.
The re-assembly is completely opposite to disassembly.
Caution:
Confirm if the fuel filtering screen is clean when removing the fuel pump, please wash if it is
necessary, the washing shall be done in clean fuel and repeatedly wash it.
Important:
Please replace gasket for fuel pump for a new one when re-assembling fuel pump, otherwise it may
leak.
When fuel pump re-assembled, please check its sealing performance, which needs pressure measuring
device for it only.
Dispose the replaced gasket for fuel pump in environment friendly way.
Parameters:
1
Installation torque for bolt
M5 N.m 6
of fuel pump
Static pressure for fuel
/ kp 130
tank

6. Disassembly, re-assembly and maintenance for fuel evaporation

2
controller kit

Fuel evaporation controller kit and its parts

1 Fuel evaporation controller kit SET1

2 Breathing tube kit SET1
3 Clamp kit PCS1
4 Socket spline head bolt PCS1
5 Solenoid valve for carbon canisterPCS1
6 Hex. flange nut PCS1
Disassembly for fuel evaporation
controller kit
Remove fuel tank kit by referring its corresponding
content.
Remove bolt 1, then the fuel evaporation controller
kit.
The re-assembly is completely opposite to
disassembly.
Caution:
Because the layout space for fuel evaporation
controller kit is narrow while pipeline is many, so
please take wiring and layout for pipeline into record
before disassembling for a correct re-assembly.
Important:
Please pay attention to the layout of dumping valve when re-assembling fuel evaporation controller kit, make sure
this part is horizontal to ground when re-assembled, otherwise the dumping function doesn’t work.
Fastening torque for bolt
M6 Nm 4.5
of appearance parts
M5 Nm 3
Fastening torque for
M6 Nm 6
bracket of carbon canister

Figure of connection for fuel evaporation controller

炭罐吸附和脱附油蒸汽示意图：Showing figure for absorption or desorption for fuel

vapor of carbon canister⼤⽓：Air炭罐：Carbon canister 通⼤⽓：Connect to air
单向阀：One-way valve 燃油蒸汽:Fuel vapor 电磁阀：Solenoid valve 三通接头：
Three-way joint倾倒阀：Dumping valve 发动机：Engine 油箱：Fuel tank 油箱盖：Fuel
tank cap燃油泵：Fuel pump 转换接头：Changing joint 进油：Fuel intake 回油：Fuel
return 油轨：Oil rail 喷油器：Fuel injector 节⽓⻔体总成：Throttle valve body kit
空滤器:Air filter

Working principle for fuel evaporation controller system:

（1） When gasoline in fuel tank got heat, the fuel vapor runs out, reach end TANK of carbon canister
through dumping valve, then absorbed by it.
（2） When the inclining for motorcycle is over 60°, the dumping valve closed, the gasoline is unable
flow to carbon canister through dumping valve.
（3）The fresh air get to end PURGE through end connects to air of carbon canister then brings fuel
vapor to throttle valve, finally gets into engine and joins combustion.
（4）When fuel level in fuel tank fell down (The internal of fuel tank produced negative pressure),
make up for air to fuel tank through one-way valve to keep normal air pressure on fuel level.

7. Disassembly, re-assembly and maintenance for heat radiation

system

Heat radiation system and its parts

 Ref.
Ref. No. Parts name Unit Qty. Parts name Unit Qty.
No.
Socket hex. spline
1 Heat radiator kit PCS 1 16 PCS 2
flange bolt
2 Heat radiator body PCS 1 17 Water supplement pot PCS 1
3 Tank cover PCS 1 18 Water filling-up cap PCS 1
4 I-ring PCS 2 19 Water tube PCS 1
5 Hex. flange bolt PCS 1 20 Tube clamp PCS 2
6 Flat washer PCS 1 21 Tube clamp PCS 3
7 Elastic washer PCS 1 22 Water tube PCS 1
8 Socket hex. screw PCS 1 23 Tube clamp PCS 1
9 Electric fan kit PCS 1 24 Tube clamp PCS 1
10 I-ring PCS 2 25 Water tube PCS 1
Socket hex. spline flange
11 PCS 2 26 Water tube PCS 1
bolt
12 Flanging washer PCS 2 27 Tube clamp PCS 2
13 I-ring PCS 2 28 Water tube PCS 1
14 Clipping nut PCS 4 29 I-ring PCS 2
15 Flanging washer PCS 2

Inspection for coolant

Keep motorcycle upright by parking rack.
Check water supplement pot 1 on the right front of engine, the coolant level shall be within upper and
lower scale line, in case it is below the lower scale line, please make up for coolant, but shall not be
over the upper scale line.

Replacement for coolant

Keep the motorcycle upright by parking rack.

Remove air intake tube 2 on the right of air filter.

Remove water filling-up cap 3 on the right side of heat radiator.
Remove bumper bar 4 on the right side.
Remove decorative cover 5 for muffler.
Remove decorative cover 6 for right windshield plate.
Lay the liquid collection tray under coolant drainage bolt on the left front of engine
Remove coolant drainage bolt 7 by tool, drain off coolant in water passage of engine
until it finished.
Important:
Collect drained coolant by suitable container and dispose it in environment friendly way.
Replace gasket of coolant drainage bolt for a new one when re-assembling.
Clean up installation surface for gasket of coolant drainage bolt to avoid impurity on it. When coolant
drainage bolt assembled, wipe up residual coolant on parts such as muffler or engine.
When replaced, please start engine and suitably run it in high speed to check if the coolant pipeline
leaks.
Parameters:
Coolant drainage bolt M5 N.m 4.5
Coolant capacity L 2

Coolant with ethanol without

Coolant specification G40
silicate

Filling-up for coolant

Fill up with coolant from filling port of heat radiator by tools such as funnel until it got full to the
filling port.
Start engine to get it idly run, check filling port of heat radiator, at this moment the coolant level on
port may fall, then continue filling up until the coolant level without falling.
Assemble filling-up cap.
Fill up with coolant into filling port of water supplement pot by tools such as funnel, confirm if the
coolant level is within upper and lower scale line.
Re-assemble rubber cap 8 of water supplement pot.
The coolant filling-up achieved.
Re-assemble air intake tube of air filter, decorative cover of right windshield plate, bumper bar and
decorative cover for muffler.
Important:
When replacement finished, start engine and suitably run it in high speed to check if the coolant
pipeline leaks.
Caution:
When the work above finished, please wash up the greasy dirt on engine surface by cleanser, then dry it
up by compressed air.

8. Disassembly, re-assembly and maintenance for front wheel

Front wheel and its parts

1 Socket hex. screw PCS 1

2 Collar PCS 1
3 Front disc brake plate PCS 2
4 Fastening bolt for disc brake platePCS12
5 Speed sensor shim PCS 1
6 Socket spline head bolt PCS 5
7 Flat washer PCS 5
8 Tire PCS 1
9 Front wheel PCS 1
10 Bolt of plug PCS40
11 Spoke nut for front wheel PCS40
12 Inner spoke of front wheel PCS40
13 Front wheel hub SET 1
14 Oil seal PCS 2
15 Bearing PCS 2
16 Seal ring PCS 1
17 Front wheel hub body PCS 1
18 Collar PCS 1
19 Rubber jacket PCS 1
20 Front wheel rim PCS 1
21 Tire pressure sensor PCS 1
22 Axle PCS 1

Removal for front wheel

Keep motorcycle upright by parking stand.
Remove caliper 1 of front disc brake by tool.
Loosen fastening bolt 2 on left and right bottom case of front shock absorber.
Remove front wheel axle and bolt 3.
Remove front wheel kit 4.
The re-assembly is completely opposite to disassembly.

Caution:
When caliper of front disc brake was removed, please don’t operate the front lever to avoid piston
moving of the front caliper which makes re-assembly difficult.
Important:
There shouldn’t be any dirt on working surface between brake pad and disc brake plate.
Repeatedly hold and release front brake lever to confirm its normal work when replaced.
Confirm dynamic balance for front wheel when tire re-assembled.
Coat collar and oil seal with lithium lubricant when re-assembling front wheel.
Parameters
Aluminum rim of
Front wheel / 2.15×21
spoke wheel
Radial ply tire of
Front tire / 90/90-21
tubeless
Run-out for end surface of front
/ mm 1
wheel shall not bigger than
Radial run-out of front wheel shall not
/ mm 1
be bigger than
Fastening bolt for upper axle of front
M8 Nm 22
wheel
Fastening torque for front wheel axle M20 Nm 70
Fastening torque for caliper of front
M10 Nm 40
disc brake
Fastening torque for disc brake plate M8 Nm 35
Loctite Loctite 262 ml 10
Lubricant / g 10
Allowed maximum imbalance of front
/ g 5
wheel
Air pressure in tire Kp 2.2

Removal for disc brake plate

When front wheel removed, put it on working bench.
Remove fastening bolt of disc brake plate, then remove
front disc brake plate and gear ring 5.
The re-assembly is completely opposite to disassembly.
Caution:
There is Locatie on thread of screw for front brake plate,
please adopt suitable tools for disassembly, otherwise it
would be a difficult work.
Important:
There shouldn’t be any dirt on working surface between
brake pad and plate when re-assembling.
When re-assembling brake plate, whose fastening bolt
shall be coated with Loctite on its thread.
When brake plate re-assembled, please confirm run-out on
end surface of brake plate as picture shows:
Put the front wheel on balancing rack by balancing shaft
①.
Measure run-out for end surface of brake plate by
measuring device ②.

Run-out for end surface shall not

mm 0.3
be bigger than

Removal for front wheel

Remove front wheel first, then put it onto working bench.
Eject air valve core of tire pressure sensor inward by tool to discharge the air in tire.
Remove front tire 6 by tools for it only.
Remove tire pressure sensor.
The re-assembly is completely opposite to disassembly.
Caution:
The re-assembly for tire needs the equipment for it only, forcedly assemble by external power may
permanently damage the tire.
Important:
When re-assembling tire, align the light point of tire to air valve core on wheel hub, this get following
work easier
1
Removal for front wheel bearing and oil seal
Put front wheel onto working bench when it is removed.
Remove brake plate and tire.
Remove oil seal, bearing, collar and rubber jacket for front wheel by tools in turn.
Replace bearing and oil seal for a new one with same specification.
The re-assembly is completely opposite to disassembly.
Important:
The oil seal on front wheel gets damaged when it is removed, so please replace it for a new one,
otherwise its poor water-proof accelerates bearing wear-out.
The removal for front wheel bearing needs pulling tools for it only.
For easy re-assembly, heat the hole of front wheel bearing to 100℃, then press-fit the bearing.

9. Disassembly, re-assembly and maintenance for front fork

Front fork kit and its parts

1 Left front shock absorber PCS 1
2 Socket hex. spline flange bolt PCS 4
3 Right front shock absorber PCS 1
4 Oil seal PCS 2
5 Front fender PCS 1
6 Socket spline head bolt PCS 6
7 Steering stem body PCS 1
8 Socket spline head bolt PCS 2
9 Front upper fender PCS 1
10 Socket hex. spline flange bolt PCS 1
11 Socket hex. spline flange bolt PCS 1
12 Turning damper PCS 1
13 Damping cushion PCS 2
14 Collar PCS 1
15 Collar PCS 1
16 Socket hex. flange spline bolt PCS 10
17 Turning seal PCS 1
18 Bearing circlip PCS 2
19 Steel ball kit SET 2
20 Bearing base ring PCS 2
21 Dust proof cap for steering stem PCS 1
22 Washer for steering stem PCS 1
23 Locking nut for steering stem PCS 2
24 Rubber flat washer PCS 1
25 Locking washer PCS 1
26 Socket spline head bolt PCS 4
27 Wire clip PCS 1
28 Wire clip PCS 1
29 Locking bolt for steering stem PCS 1
30 Upper connective plate PCS 1
31 Handle bar clip PCS 2
32 Socket spline head bolt PCS 2
33 Tube clamp PCS 2
34 Hex. flange nut PCS 2
35 Side reflector PCS 2

Disassembly and re-assembly for steering stem

Keep motorcycle upright by parking stand.
Remove handle bar kit 1.
Remove front fender 2.
Remove lower caliper 3 for front brake.
Remove front wheel kit 4.

Remove upper connective plate 5.

Remove front shock absorber 6.

Remove locking nut 7.

Remove steering stem 8.

The re-assembly is completely opposite to disassembly.

Caution:
Please bind up the wire package for wire harness when re-assembling, its condition shall be the same to
that before disassembling, otherwise the water-proof performance may get bad.
When re-assembling front fender, please bind up the oil tube and wires of ABS to the same with that
before disassembling, otherwise there will be interference between oil tube and front fender which
makes noise.
When re-assembling front shock absorber, please pre-fasten front wheel axle, then fasten locking bolt
on upper connective plate and steering stem.
Important:
When re-assembling steering bearing, coat it with lithium lubricant to ensure its normal lubrication.
When re-assembling, please ensure correct clearance between detector of sensor ABS and gear ring of
front wheel.
The re-assembly for 2 adjusting and locking nuts for steering stem shall strictly follow their
requirements for installation, whose parameter refers to corresponding form list, otherwise their turning
may be bad.

Parameters:
Torque for bolt of handle bar clip M8 N.m 22
Fastening torque for bolt on upper connective plate M22 N.m 100
Fastening torque for bolt on steering stem and upper
M8 N.m 22
connective plate
50±5 Return by
Torque for locking nut (lower) of steering stem
M26 N.m 45°Rear 35
Torque for locking nut (upper) of steering stem
2
Clearance between detector and sensitive gear ring of front
/ mm 0.5-1.5
wheel

Disassembly and re-assembly for steering bearing

Remove basing ring 1 for bearing in standing tube of frame by tools for it only.

Remove bearing circlip 2 on steering stem by pulling tools (As picture shows)
Replace steering bearing for a new one with same specification.
Remove oil seal under oil seal.
The re-assembly is completely opposite to disassembly.
Caution:
When removing the steering bearing, the irregular operation should not be adopted, please use the tools
for it only, otherwise the steering stem body may permanently damage.
When re-assembling steering bearing, please pay attention to installation sequence of bearing, oil seal
and flat washer.
Important:
When press-fitting steering bearing, please suitably heat the bearing to 100 ℃ , which is easier for
bearing press-fitting.

Judge for clearance of steering bearing

When driving under low speed, please repeatedly and fast operate front brake lever to feel if there is
flexibility of steering bearing.
Keep motorcycle upright by parking stand.
Follow the direction in figure below, repeatedly pull the front wheel to feel if there is flexibility on
steering bearing.
10. Disassembly, re-assembly and maintenance for rear wheel kit

Rear wheel kit and its parts

1 Metallic hex. locking nut PCS 1

2 Flat washer PCS 1
3 Collar PCS 1
4 Oil seal PCS 1
5 Bearing PCS 1
6 Metallic hex. flange locking nut PCS 5
7 Sprocket wheel SET 1
8 Bolt for sprocket wheel PCS 5
9 Base for sprocket wheel PCS 1
10 Collar PCS 1
11 Damper piece for rear wheel PCS 1
12 Socket hex. spline flange bolt PCS 5
13 Connective plate of rear wheel PCS 1
14 Collar PCS 1
15 Rear wheel PCS 1
16 Outer spoke for rear wheel PCS40
17 Bolt for plug PCS40
18 Nut for rear wheel spoke PCS40
19 Rear wheel hub PCS 1
20 Bearing PCS 2
21 Rubber jacket PCS 2
22 Rear wheel hub body PCS 1
23 Collar PCS 1
24 Elastic circlip PCS 1
25 Oil seal PCS 1
26 Rear wheel rim PCS 1
27 Tire pressure sensor PCS 1
28 Tire PCS 1
29 Fastening bolt for disc brake platePCS 5
30 Rear disc brake plate PCS 1
31 Speed sensor shim PCS 1
32 Socket spline head bolt PCS 5
33 Flat washer PCS 5
34 Collar PCS 1
35 Axle PCS 1

Removal for rear wheel

 Keep motorcycle
upright by parking
stand.
Loosen nut 1 for
chain adjustor.
Remove rear
wheel axle and nut
2.
Get chain
dropping off.
Remove rear
wheel kit.
Remove collar of
rear wheel.
Remove damper
kit.
Remove damping
rubber piece.
Re-assembly is completely opposite to disassembly.
Caution:
Please don’t operate rear brake pedal when caliper of rear brake was removed to avoid piston moving which makes
installation of caliper difficult.
Important:
There should not be any dirt on working surface between brake pad and brake plate.
When replaced, please repeatedly step down the rear brake pedal to confirm its normal work.
When the tire replaced, please confirm dynamic balance on equipment once again.
When re-assembling collar or oil seal for rear wheel, please coat them with lithium lubricant.
Parameters:
Aluminum rim of spoke
Rear wheel 4.25x17
wheel
Radial ply tire of
Rear tire 150/70-R17
tubeless
Run-out for end surface of rear wheel
mm 1
shall not be bigger than
Radial run-out of rear wheel shall not be
mm 1
bigger than
Torque for nut on chain adjustor M8 9

Fastening torque for rear wheel axle M20 100

Fastening torque for brake plate M8 35

Loctite Loctite 262 ml 10
Lubricant g 5
Allowed maximum imbalance for rear
g 5
wheel
Air pressure in tire bar 2.5

Removal for damper kit

Remove nut connects sprocket wheel first,
then the sprocket wheel.
Remove oil seal, bearing and collar in
damper kit in turn by tools.
The re-assembly is completely opposite to
disassembly.
Important:
When re-assembling collar or oil seal for
damper kit, please coat them with lithium
lubricant.
The oil seal of damper gets damaged when it removed, please replace immediately.
The removal for bearing of damper needs the pulling tool for it only.
For easy re-assembly, please heat the hole of bearing for damper to 100 ℃ first, then press-fit the
bearing.
Parameters:
5
4 Lubricant / g 5

Removal for brake plate

6
Remove rear wheel kit and put it onto working
bench.
Remove fastening bolt for disc brake plate, then
remove rear disc brake plate and ring gear.
The re-assembly is completely opposite to

8
disassembly.
Caution:
The screw of rear brake plate is coated with Loctite,
please adopt tools meet demands when removing,
otherwise it will be a difficult work.
Important:
7
There shouldn’t be any dirt on working surface
between brake pad and brake plate when re-
assembling.
Please coat fastening bolt of brake plate with Loctite
when re-assembling brake plate.
Confirm run-out of end surface for brake plate when
it was assembled, whose method is show as figure:
Put rear wheel on balancing rack by balancing shaft
(1).
Measure run-out of end surface by measuring gauge
(2).
Run-out for end surface shall not
mm 0.3
be bigger than

Removal for rear tire

Remove rear wheel kit and put it on working bench.
Remove air valve core to discharge the air in tire.
Remove rear tire by tools for it only.
Remove air valve core.
The re-assembly is completely opposite to disassembly.
Caution:
The re-assembly for tire please adopt equipment for it only, forcedly assemble by external power may
get tire permanently damage.
Important:
When re-assembling tire, please align the light point of tire to air valve core on wheel hub, which
makes following works easier.

Removal for bearing and oil seal on rear wheel

Remove rear wheel and put it on working bench.
Remove brake plate and tire.
Remove oil seal, elastic circlip, bearing and inner liner of wheel hub by tools such as circlip pliers.
Replace parts for new ones with same specification.
The re-assembly is completely opposite to disassembly.
Important:
The oil seal on of rear wheel gets damaged when it removed, please replace.
The removal for rear wheel bearing needs pulling tools for it only.
For easy re-assembly, heat the hole of bearing to 100℃, then press-fit the bearing.
One side of bearing is with locating circlip, missing assembly is forbidden.
When press-fitting the bearing, it needs the press-fitting equipment for it only, press-fit the side with
elastic circlip (Right side) to the bottom, then the other side of bearing.

11. Disassembly, re-assembly and maintenance for rear suspension

kit

Rear suspension kit and its parts

1

1 Elastic circlip PCS1

2 Rear fork kit PCS1
3 Dust-proof cap for rear fork PCS2
4 Collar PCS2
5 Bearing PCS4
6 Rear fork body PCS1
7 Socket hex. screw PCS2
8 Collar PCS1
9 Metallic hex. flange locking nut PCS1
10 Rear shock absorber PCS1
11 Plug PCS2
12 Chain adjustor 2 PCS1
13 Bolt or screw and flat washer kitPCS2
14 Chain adjustor body 2 PCS1
15 Chain adjustor PCS1
16 Chain adjustor body PCS1
1
17 Chain slider PCS1
18 Flanging washer PCS2
19 Socket spline head bolt PCS3
20 Axle PCS1
21 Chain case PCS1
22 Collar PCS1
23 Socket spline head bolt PCS2
24 Socket hex. screw PCS1
25 Chain PCS1
26 Chain slider PCS1
27 Collar PCS1
28 Hex. flange bolt PCS1

Disassembly and re-assembly for rear

shock absorber
Keep the motorcycle upright by parking stand.
Remove fuel tank by referring to corresponding
content for its disassembly.
Remove blocking piece 1 for main footrest.
Remove chain case 2.
Remove installation bolt and nut 3 on rear shock
absorber by tool.
Remove lower installation bolt 4 on rear shock
absorber by tool and finally remove the rear shock
absorber.
The re-assembly is completely opposite to
disassembly.

Parameters:
Upper and lower installation bolt for rear
M12 Nm 60
shock absorber
Installation bolt for chain case M6 Nm 6
Installation bolt for blocking piece of
M5 Nm 3
main footrest

Disassembly and re-assembly for rear fork and chain

Hang up the motorcycle by lifting device.
Remove the rear shock absorber first.
Loosen bolt 1 of chain adjustors on both sides.
Loosen nut 2 on rear wheel axle, powerfully push rear wheel forward for a short distance, then remove
the rear wheel axle.
Remove rear wheel 3.
Remove tube clamp on oil tube of ABS for rear brake and installation bolt for rear fork.
Loosen nut for rear fork shaft, remove left main footrest 4, then loosen installation bolt for right main
footrest.
Remove elastic circlip of rear fork shaft, then remove the shaft 5.
Remove rear fork.
Remove chain.
Replace the chain for a new one with same specification.
The re-assembly is completely opposite to disassembly.

Caution:
Adjust the left and right chain adjustor first when re-assembling, then fasten the nut of rear wheel axle,
then fasten the left and right chain adjustor.
Important:
Confirm if the left and right chain adjustors are on the same scale line when re-assembling.
Inspection for tensioning force of chain must be under 0 loading of motorcycle.
Parameters:
Torque for nut on chain adjustor M8 N.m 9
Torque for nut on rear wheel axle M20 N.m 100
Torque for left and right cover of engine M6 N.m 9
Fastening torque for left main footrest M8 N.m 22
M10 N.m 40
M20 N.m 70
Deflection for chain N.m 35-45

Disassembly and re-assembly for bearing of rear fork

Put the removed rear fork on working bench.
Remove collar, dust proof cap and bearing at rear fork shaft’s tube in turn by tool.
The re-assembly is completely opposite to disassembly.
Caution:
The removal for bearing needs tools for it only, forcedly remove may damage the parts.
Caution:
Coat the collar and bearing with lithium lubricant when re-assembling.

Disassembly and re-assembly for chain slider

Keep motorcycle upright by parking stand.
Remove blocking piece 1 for main
footrest.
Remove chain case 2.
Remove chain slider 3 from rear
fork.
Replace chain slider for a new one
with same specification.
Remove left main footrest 4.
Remove chain slider 5 from engine.
Replace chain slider for a new one
with same specification.
The re-assembly is completely
opposite to disassembly.
Caution:
When re-assembling chain slider 3, please clip the limit pillar 3 into limit hole on rear fork.
Parameters:
Installation bolt for blocking piece of main footrest M5 N.m 3
Torque for bolt between chain slider and engine M6 N.m 9
Torque for bolt between chain slider and rear fork M6 N.m 4.5
Fastening torque for left main footrest M8 N.m 22
M10 N.m 40
M20 N.m 70
Installation bolt for chain case M6 Nm 6

Disassembly and re-assembly for

driving sprocket wheel
Keep motorcycle upright by parking stand
Remove chain slider by referring its corresponding
content.
Remove installation bolt, collar and butterfly-
shaped washer 1, then remove driving sprocket
wheel 2.
Replace the driving sprocket wheel for a new one
with same specification.
The re-assembly is completely opposite to
disassembly.
Caution:
Adjust left and right chain adjustor when re-
assembling, then fasten nut on rear wheel axle, then fasten the left and right chain adjustor.
Important:

Check and confirm if the left and right

chain adjustors are on the same scale line.
Inspection and adjustment for tensioning force of chain must be under 0 loading of motorcycle.
When re-assembling the driving sprocket wheel, please coat thread of bolt with Loctite, the inner ring
of butterfly-shaped washer is a protrusion outwards, insert the flanging side of collar into inner hole of
elastic butterfly-shaped washer.
Parameters:
Installation bolt for blocking piece of main footrest M5 N.m 3

Torque for bolt between chain slider and engine M6 N.m 9

Torque for bolt between chain slider and rear fork M6 N.m 4.5

Fastening torque for left main footrest M8 N.m 22

M10 N.m 40
M20 N.m 70
Installation bolt for chain case M6 N.m 6
Installation torque for driving sprocket wheel M10 N.m 50
Evenly spread
Loctite / /
on thread

Disassembly and re-assembly for damper kit

1 Oil seal PCS 1

2 Bearing PCS 1
3 Metallic hex. flange locking nut PCS 5
4 Bolt for sprocket wheel PCS 5
5 Sprocket wheel PCS 1
6 Sprocket wheel base PCS 1
7 Collar PCS 1
Keep motorcycle upright by parking stand.
Loosen the nut on chain adjustor.
When nut on rear wheel axle loosened, powerfully push rear wheel forward to remove the rear wheel
axle.
Remove damper kit.
Replace damper and its damping rubber for new ones with same specification.
The re-assembly is completely opposite to disassembly.
Caution:
Adjust left and right chain adjustor when re-assembling, then fasten nut on rear wheel axle, then fasten
the left and right chain adjustor.
Important:
Check and confirm if the left and right chain adjustor are on the scale line when re-assembling.
The inspection and adjustment for tensioning force of chain must be under 0 loading of motorcycle.
When replacing the damper kit please coat the position of oil seal with lithium lubricant.
Parameters:
Torque for nut on chain adjustor M8 N.m 9
Torque for nut on rear wheel axle M20 N.m 100
Chain deflection mm 35-45

Disassembly and re-assembly for damper piece of rear wheel

Keep motorcycle upright by parking stand.

Remove rubber damping piece by referring to content of removal for damper kit.
Check if there is wear-out or crack on damper piece, in case it is, please replace.
In addition, it could be judged on motorcycle, when it is parking, lift up the rear wheel, lay stress on
sprocket wheel along the direction of figure showing, in case obvious radial run-out could be felt,
which indicates the rubber damper piece was worn out, it needs be replaced.

Caution:
Excessive acceleration or deceleration makes continuous impact on damper rubber, which produce
heat, while the damper rubber is sealed in its chamber with poor heat radiation, it accelerates the wear-
out of damper rubber piece.

Conditions for replacement for chain

There are several places of dead-lock on chain.
There is crack on roller of chain.
There are missing on seal ring of chain.
The distance between links got to be 2 times of new one.
In case adjust to limit but still fail to meet conditions below, whose data are bigger than it.

Conditions for replacement of sprocket wheel

There is buckling on surface of sprocket wheel.

Teeth of sprocket wheel break off or damaged.
In figure below, in which 1 is qualified, 2 and 3 need be replaced.

12. Disassembly, re-assembly and maintenance for brake system

Brake system and its parts

1 Lower pump of rear disc brake PCS 1

2 Brake pad of rear disc brake PCS 1
3 Flat washer PCS11
4 Bolt for disc brake hose PCS 2
5 Cap for air exhaust screw PCS 2
6 Connective oil tube for ABS PCS 1
7 Wire clip PCS 9
8 Socket hex. spline flange bolt PCS 2
9 Connective oil tube for ABS PCS 1
10 Clamping band PCS 3
11 Connective oil tube for ABS PCS 1
12 Upper pump of front disc brakePCS 1
13 Right lever PCS 1
14 Bolt for disc brake hose PCS 2
15 Socket spline head bolt PCS 2
16 Connective oil tube of ABS PCS 1
17 Socket spline head bolt PCS 2
18 Clamp PCS 1
Lower pump of front disc
19 PCS 1
brake
20 Front disc brake pads kit PCS 2
21 Socket hex. spline flange bolt PCS 2
22 Speed sensor bracket PCS 1
23 Socket spline head bolt PCS 4
24 Speed sensor PCS 2
Lower pump 2 for front disc
25 PCS 1
brake
26 Bolt for disc brake hose PCS 1
27 Front disc brake hose PCS 1
28 Front disc brake switch PCS 1
29 Bolt for disc brake hose PCS 3
30 ABS kit PCS 1
31 Collar PCS 2
32 I-ring PCS 2
33 Installation bracket for ABS PCS 1
34 Socket spline head bolt PCS 3
35 Hex. flange bolt PCS 1
36 Upper pump of rear disc brake PCS 1
37 Rear brake switch PCS 1
38 Socket hex. spline flange bolt PCS 2
39 Rear disc brake bracket PCS 1
40 Flat washer PCS 8

Replacement for front disc brake

Keep motorcycle upright by parking stand.
Remove installation bolt 1 for lower caliper.
Remove split pin 2.
Press out connective pin 3 of brake pads by pin shaft of 4mm.
Finally remove brake pad 4.
Replace front brake pads for new ones. (The removal for left and right lower pump of front disc brake
is symmetrical in same way).
The re-assembly is completely opposite to disassembly.
Important:
When re-assembling, missing assembly for shim between end surface of brake pad and limit groove of
front caliper is not allowed, please assemble it in place.
Please don’t operate front brake lever when brake pads are removed to avoid piston moving and make
difficult re-assembly for brake pad.
Replace the outer and inner brake pad as a kit when replacing them.
There should not be dirt on working surface between brake pad and brake plate.
When replaced, repeatedly and tightly hold brake lever to confirm its normal work.
Dispose the replaced front brake pads in environment friendly way.

Replacement for rear disc brake pad

Keep motorcycle upright by parking stand.

Remove split pin 1.
Press out connective pin 2 of brake pads by pin shaft of 4mm.
Finally remove brake pad 3.
Replace rear brake pads for new ones.
The re-assembly is completely opposite to disassembly.

Important:
When re-assembling, missing assembly for shim between end surface of brake pad and limit groove of
rear caliper is not allowed, please assemble it in place.
Please don’t operate rear brake pedal when brake pads are removed to avoid piston moving and make
difficult re-assembly for brake pad.
Replace the outer and inner brake pad as a kit when replacing them.
There should not be dirt on working surface between brake pad and brake plate.
When replaced, repeatedly step down brake pedal to confirm its normal work.
Dispose the replaced rear brake pads in environment friendly way.

Inspection for brake pad

The abrasion mark on brake pad must clearly be seen as figure below shows, whose minimum
thickness is 1mm.

Inspection for liquid level in front and rear brake system

Keep motorcycle upright by parking stand.
Turn the grip to get oil pump of front brake horizontal.
The liquid level in front and rear brake system must be between scale mark UPPER and LOWER on
upper pump of front and rear disc brake.
Caution:
During the consumption from brand new to limit, the (Min./Max.) capacity for brake liquid both meet
demands, usually needn’t fill up due to consumption of brake pads.
In case the brake liquid level is lower than the minimum limit, which indicates there may have other
malfunctions.

Replacement for brake liquid in front disc brake

Keep motorcycle upright by parking stand.

Turn the grip to get oil cup cap 1 horizontal.
Remove oil cup cap with its rubber cover by tool.
Connect the extraction device for brake liquid to air exhaust screw 2 on brake caliper.
Open air exhaust screw by turning half round by tools.
Start brake liquid extraction device to drain off the brake liquid.
Fill up with fresh brake liquid from oil cup, meanwhile starting extraction device until the liquid fulfill
the brake pipeline.
Fasten air exhaust screw.
Check if the liquid level is between scale mark UPPER and LOWER.
Connect diagnosis device of ABS into its controller to check if there is malfunction code, in case there
is please make troubleshooting.
The re-assembly is completely opposite to disassembly.
Caution:
When brake liquid filled up, please clean up greasy dirt around oil cup and air exhaust screw of lower
caliper.
Important:
Please don’t let brake liquid touch any painting part of motorcycle, because the brake liquid is
corrosive.
When extracting brake liquid, please don’t get the liquid level under scale mark LOWER, otherwise
the air bubble may get into brake system, under this case, the extraction needs be done once again.
When filled up, lay stress on brake lever and keep for a while to check if there is liquid leakage on
brake pipeline.
In case there is problem on disc brake hose kit or connection of threaded part, please replace
immediately.
Mixture of brake liquid of two brands or specification even above is not allowed.
Parameters:
Torque for oil cup cap M6 N.m 2~3
Torque for air exhaust screw M8 N.m 4~7
Capacity for liquid of front
mL 150
brake system
Specification for brake liquid Great wall DOT4

Replacement for rear brake liquid

Keep motorcycle upright by parking stand.

Remove the fixing bolt 1 on oil cup of disc brake by socket hex. tool of T25.
Remove oil cup cap 2 with its rubber cover.
Connect the extraction device for brake liquid to air exhaust screw 3 on brake caliper.
Open air exhaust screw by turning half round by tools
Start brake liquid extraction device to drain off the brake liquid.
Fill up with fresh brake liquid from oil cup, meanwhile starting extraction device until the liquid fulfill
the brake pipeline.
Fasten air exhaust screw.
Check if the liquid level is between scale mark UPPER and LOWER.
Connect diagnosis device of ABS into its controller to check if there is malfunction code, in case there
is please make troubleshooting.
The re-assembly is completely opposite to disassembly
Caution:
When brake liquid filled up, please clean up greasy dirt around oil cup and air exhaust screw of rear
caliper.
Important:
Please don’t let brake liquid touch any painting part of motorcycle, because the brake liquid is
corrosive.
When extracting brake liquid, please don’t get the liquid level under scale mark LOWER, otherwise
the air bubble may get into brake system, under this case, the extraction needs be done once again.
When filled up, lay stress on brake pedal and keep for a while to check if there is liquid leakage on
brake pipeline.
In case there is problem on disc brake hose kit or connection of threaded part, please replace
immediately.
Mixture of brake liquid of two brands or specification even above is not allowed.

Parameters:
Torque for air exhaust screw M8 N.m 4~7
Capacity for liquid of rear
mL 150
brake system
Specification for brake liquid Great wall DOT4

Replacement for ABS and parts in front and rear brake pipeline
Remove seat, covering plastic parts, fuel tank and air filter.
Loosen air exhaust screw 1, then connect the air exhaust screw to vacuum device, drain off liquid in
pipeline. Replace the brake liquid according to procedure above.

Remove punching bolt 2 on installation oil tube of upper pump of front disc brake, punching bolt 3 of
lower pump of left front disc brake, double punching bolt 4 for lower pump of right front disc brake,
hydraulic switch 3 of rear upper pump and its related sealing washer.

Remove punching bolt 6 connects oil tube of brake and controller for ABS and sealing washer, then
remove controller of ABS and two screws 7 connect installation bracket.
When works above finished, remove controller of ABS and oil tube of brake.
The re-assembly is completely opposite to disassembly.
Finally fill up with brake liquid according to procedure for its replacement above, then check.
Important:
The brake liquid is corrosive, please don’t touch it to skin or cloths when draining off or filling up.
The gasket at place of punching bolt needs be replaced for a new one when re-assembling, otherwise
the oil may leak.
Every adjacent sealing surface needs install a gasket.
Parameters:
Torque for ABS and punching bolt M8 N.m 24
Torque for front and rear disc
M8 N.m 32
brake pump and punching hole
Torque for air exhaust screw M8 N.m 4~7

Removal for speed sensor on front wheel

Keep motorcycle upright by parking stand.
Remove bolt 1 and speed sensor on front wheel.
The re-assembly is completely opposite to disassembly.
 Important:
When speed sensor of front wheel re-assembled, let front wheel suspend, check clearance change
between speed sensor and gear ring of ABS,
Parameters:
Torque for fastening bolt of sensor M6 Nm 9
Clearance between sensor and gear
mm 0.8~1.5
ring

Removal for speed sensor of rear wheel

Keep motorcycle upright by parking stand.
Remove bolt 1, then remove speed sensor of rear wheel.
The re-assembly is completely opposite to disassembly.

Important:
When speed sensor of rear wheel re-assembled, let rear wheel suspend, check clearance change
between speed sensor and gear ring of ABS.
Parameters:
Torque for fastening bolt of sensor M6 Nm 9
Clearance between sensor and gear 1
mm 0.8~1.5
ring

13. Disassembly, re-assembly and maintenance for lights set on

motorcycle

Headlight kit and its parts

4
1 Meter kit SET1
3
2 I-ring PCS9 Removal
2 3 Collar PCS9 direc
4 Socket spline head bolt PCS9
5 Meter bracket PCS1
6 Socket hex. spline flange bolt PCS4
7 Collar PCS4
8 Clipping nut PCS6
9 Clipping nut PCS9
10 Headlight PCS1
11 Socket spline head bolt PCS6
12 Cross self-tapping screw PCS6
13 Headlight lens PCS1
14 Installation bracket for cameraPCS1
 15 Fairing cover PCS1

Removal for headlight kit

Keep motorcycle upright by parking stand.
Loosen bolt and remove windshield glass 3.
Loosen bolt and remove adjustive device 2 of windshield glass.
Loosen bolt and remove decorative cover 1 for meter.
Remove covering parts kit 7 on left and right side by referring removal of fuel tank.
Loosen bolt and remove front fairing cover 5.
1 Remove bolt 6 and headlight kit. Removal
Loosen bolt and remove protective shield 4 of headlight.
direction
Finally remove headlight kit.
2 The re-assembly is completely opposite to disassembly.

Tail light kit and its parts

1 Rear registration plate light PCS 1

2 Hex. flange nut PCS 2
3 Rear reflector PCS 1
4 Hex. flange nut PCS 6
6 Clipping nut PCS 8
6 Right turning signal light PCS 1
7 Socket hex. spline flange bolt PCS 3
Abrasion
8 Rear registration plate bracket PCS 1
mark
9 Damper rubber nail PCS 2
10 Rear fender PCS 1
11 Connective piece for tail cover PCS 1
12 Taillight PCS 1
13 I-ring PCS 3
14 Collar PCS 3
15 Socket spline head bolt PCS 3
16 Left turning signal light PCS 1
17 Hex. flange bolt PCS 2
18 Socket hex. spline flange bolt PCS 2
 19 Linner plate for rear fender PCS 1
20 Socket spline head bolt PCS 4
21 Carpet PCS 2

Removal for taillight kit

Keep motorcycle upright by parking stand. 1
Remove the seat.
Loosen bolt and remove rear luggage rack 1.
2 tail cover kit 2.
Loosen bolt and remove left and right tail cover and
Loosen bolt and remove rear fender kit 3.
Loosen bolt 4 and remove taillight.
The re-assembly is completely opposite to disassembly.

Caution:
Before removing taillight, please cut off wires for taillight and connectors for wire harness.

Removal for rear turning signal light and rear registration plate light
Keep motorcycle upright by parking stand.
The removal way is the same with taillight, then
remove rear fender kit.
Loosen bolt and remove liner plate 1 of rear fender.
Remove rear registration plate light and turning
signal light.
The re-assembly is completely opposite to
disassembly.

3
Caution:
When re-assembling rear turning signal light and rear registration light, please straighten up wires
between inner and outer plate of rear fender to avoid pressed.
Parameters:
Torque for self-tapping screw for
ST4.2 Nm 1
appearance parts
 Hex. flange nut M5 Nm 4.5
Socket spline head bolt for
M5 Nm 3
appearance part
M6 Nm 4.5
Bolt for headlight and taillight M6 Nm 6
Bolt for turning signal light M6 Nm 4.5

14. Disassembly, re-assembly and maintenance for main footrest and

pillion step

Main footrest kit, pillion step and their parts

1 Right main footrest SET1

2 Bracket for right main footrest PCS1 1
1 3 Main footrest PCS1
4 Circlip with opening PCS2
5 Seal ring PCS2
6 Pin shaft PCS2
7 Twist spring PCS2
8 Main footrest body PCS1
9 Socket hex. spline flange bolt PCS2
10 Socket hex. spline flange bolt PCS1
11 Socket spline head bolt PCS4
12 Stopping piece for main footrestPCS1
13 Right pillion step kit SET1
14 Bracket for right pillion step PCS1
6 15 Right pillion step body PCS1
16 Circlip with opening PCS2
17 Seal ring PCS2
18 Steel ball PCS2
19 Pressure spring PCS2
220 Limit piece for footrest
3 4 5 3
PCS2
21 Limit piece for footrest PCS2
22 Pin shaft PCS2
23 Right pillion step PCS1
24 Socket hex. spline flange bolt PCS4
25 Left footrest kit SET1
26 Bracket for left pillion step PCS1 7
27 Left pillion step body PCS1
28 Left pillion step PCS1
29 Stopping piece for main footrestPCS1
30 Socket hex. spline flange bolt PCS2
31 Socket hex. spline flange bolt PCS1
32 Socket hex. spline flange bolt PCS2
33 Left main footrest kit SET1
34 Left main footrest bracket PCS1
35 Main footrest body PCS1
36 Main footrest body PCS1

Removal for left and right footrest and pillion step

Keep motorcycle upright by parking stand.
Remove bolt 1 by tool and finally remove left and right pillions step.
The re-assembly is completely opposite to disassembly.

1
Remove the left main footrest in same way with that for gearshift pedal.
Remove the right main footrest in same way with that for gearshift pedal.
Parameters:
Installation torque for
M8 N.m 30
pillion step

Removal for left and right main footrest

Break down left and right footrest according to picture below.

Caution:
When re-assembling the footrest, please coat the turning place
with lithium lubricant.
参数：

Lithium lubricant g 10

Removal for left and right pillion step

Break down right pillion step according to figure below.

Caution:
When re-assembling pillion step, please coat turning place
with lithium lubricant.
When re-assembling limit piece, spring and steel ball for
pillion step, coat the surface
1 of limit piece and spring place
with lithium lubricant.

Lithium lubricant g 10

15. Disassembly, re-assembly and maintenance for main, side stand,

gearshift pedal and brake pedal

Main, side stand, gearshift pedal and rear brake pedal

1 Tension spring PCS1
2 Tension spring PCS1
3 Metallic hex. flange locking nutPCS1
4 Side stand PCS1
5 Hex. shoulder bolt PCS1
6 Kill switch for side stand PCS1
7 Socket spline head bolt PCS1
8 Gearshift pedal PCS1
9 Shaft PCS2
10 Seal ring PCS4
11 Flat washer PCS4
12 Socket hex. spline flange bolt PCS2
13 Socket spline head bolt PCS1
14 Spring hanging plate PCS2
15 Tension spring PCS2
16 Installation base for main stand PCS1
17 Socket hex. flange bolt PCS2
18 Socket hex. flange bolt PCS2
19 Main stand PCS1
20 Hex. nut PCS1
21 Damping cushion PCS1
22 Installation base for main stand PCS1
23 Socket hex. spline flange bolt PCS2
24 Rear brake pedal PCS1
25 Tension spring PCS1
26 Installing body for side stand PCS1

Disassembly and re-assembly for main and side stand

Keep motorcycle upright by parking stand.
Removing tension spring 1 for side stand by tool.
Remove kill switch 2 of side stand when bolt removed.
Remove side stand 3.
The re-assembly is completely opposite to disassembly.
Keep motorcycle upright by parking stand.
Remove tension spring 1 for
main stand by tool.
Loosen nut and remove collar 2.
Remove main stand 3.
The re-assembly is completely
opposite to disassembly.
Important:
When re-assembling main and
side stand, coat its turning place
with lithium lubricant.
The re-assembly for tension spring of main and side stand needs tools for it only for avoid damage
when re-assembling.
Parameter:
Fastening torque for hex.
M10 Nm 20
shoulder bolt of side stand
Fastening torque for nut
M10 Nm 40
of side stand
Fastening torque for kill
M6 Nm 6
switch of side stand
Fastening torque for nut
M10 Nm 40
of main stand shaft
Lithium lubricant g 5

Disassembly and re-assembly for gearshift pedal

Keep motorcycle upright by parking stand.
Remove bolt 1 by tool and separate gearshift pedal and spline base
Remove bolt 2 by tool and remove bolt 3. Then remove left main footrest and gearshift pedal.
Remove bolt 4 by tool and then remove gearshift pedal.
The re-assembly is completely opposite to disassembly.

Caution:
Adjust the length of connective bar of gearshift through loosening nut 5, when adjusted to suitable
position, then fasten nut 5.
Important:
Coat fixing place 1, 4 with Loctite when re-assembling gearshift pedal.
Coat turning place 3 with lithium lubricant when re-assembling gearshift pedal.
Parameters:
Fastening torque for ball
M6 Nm 9
joint of gearshift pedal
Fastening torque for left
M8 Nm 22
main footrest
M10 Nm 40
M20 Nm 70
Fastening torque for
M8 Nm 18
gearshift pedal
Lithium lubricant / g 10
Evenly coat onto threaded
Loctite / /
part
Disassembly and re-assembly for rear brake pedal
Lift up the motorcycle by hanging device.
Remove main stand by referring its description above.
Remove connective bolt 1 for installation base of main
stand.
Remove bolt 2 for right main footrest.
Remove elastic circlip 3 on rear fork shaft.
Remove bolt 4 for rear fork shaft, move right main
footrest and rear brake pedal kit backwards and get out
of operational range.
Remove bolt 5 for stopping piece of main footrest.
Remove bolt 6 connects upper pump of rear disc brake.
Remove split pin connects rear brake pedal and main oil
cylinder of rear brake, then remove washer and pin shaft
7.
Remove bolt 8 of rear brake pedal and tension spring, finally remove rear brake pedal.
The re-assembly is completely opposite to disassembly.
Caution:
The height of rear brake pedal is adjustable by
loosening nut 1.
Important:
When re-assembling rear brake pedal, please coat
turning position with lithium lubricant, when it re-
assembled, coat the fixing position 8 for rear brake
pedal with Loctite.
When the height of rear brake pedal was adjusted,
please fasten its nut, otherwise it may get brake
failure even accident.
When re-assembling the split pin connects rear brake
pedal and main oil cylinder, please replace the split
pin for a new one, the used split pin may crack and
lead to accident.
Parameters:
Fastening torque for installation base of main stand M10 Nm 40
Fastening torque for right main footrest M10 Nm 40
M12 Nm 95
Fastening torque for rear fork shaft M20 Nm 70
Fastening torque for stopping piece of main footrest M5 Nm 3
Fastening torque for upper pump of rear disc brake M6 Nm 9
Fastening torque for rear brake pedal M8 Nm 18
Lithium lubricant / g 10

68 / 61