LZX200GY-2(EC)Maintenance Manual L k Ze staz Foreward a Since its establishment, Zongshen Industry Group, which has obtained the IS09001:2000 Certification, has developed numerous well-received motorcycles with the emission reached Euro I standard, Z1P STAR brand has been authorized as Chinese Famous Brand. This manual isto help our service personnal and customers know more about the service of this motorcycle. LZX2006Y-2 motorcycle is anewly developed motorcycle with outstanding style and easily operation. The engine installed on this model is Z2S167FML which is an air cooling, one cylinder and 4-stroke one with advantages of strong power and good acceleration performance. The spoke wheel installed, front brake is dise and rear is drum respectively.with a feature of strong, reliability. This book lays stress on the disassembly/assembly, removal installation, inspection, trouble- shooting and service methods of L2X200Y-2 motoreyele, It also introduces the general knowl edge of service tools. With both the descriptions and pictures, you may have a comprehensive understanding of the configuration as well as the service and repair skill. When reading this book, the users are suggested to make reference to User’s Manual and Parts Breakdown & Catalogue of LZX200GY-2 motoreycle for better understanding, This book is based on this model only. To ensure the book is always consistent with the ever updating products, Zongshen Industry Group reserves the ri ht to make changes to the specifications of its vehicles without notification. This book is prepared by Zuo Zongshen(editor-in- ief),Wu Jian,Lei Ting,Li Heping (subeditor), Hu Zhiping, Wang Chong (executive editor), Liu Fubo, Zhongsueliang, Zhang Qiaoli (editor ). All people involved in the preparation of this book are employees of Zongshen group who have long been devoted to the development and management of the generator. Due to our limited knowledge and urgent time, it is very possible to have errors in this book.And we wel- come your comments. Editor Dec. 2005LZX200GY-2(EC)Maintenance Manual L28TAR CONTENT Chapter 1 General ... 1.1Vehicle introduction ... 1.2 Specification .. Chapter 2 Maintenance Knowledge ... 2.1 Maintenance and adjustment data... 2.2 Maintenance Tool ... Chapter 3. Maintenance of Engine... 3.1 Maintenance of Body 9 3.2 Maintenance of Crankshaft Connecting Rod .. 3.3 Maintenance of Valve Mechanism... 3.4 Maintenance of Fuel System ..... 3.5 Maintenance of Intake and Exhaust System ... 3.5.1 Dismantle, Mount and Maintain Intake System .. 3.5.2 Dismantle, Mount and Maintain Exhaust system ... 3.5.3 Dismantle, Mount and Maintain Environmental Protection Device .. 3.6 Maintenance of Lubricant System .... 3.7 Maintenance of Cooling System 51 Chapter 4 Maintenance of Transmission 4.1 Maintenance of Starter ... 4.2 Maintenance of Clutch .....LZX200GY-2(E E ance Manual LP STAR 4.3 Maintenance of Transmission .... 4.4 Maintenance of Rear Drive system .. Chapter 5 Maintenance of Riding System... 5.1 Maintenance of Frame and Accessories... 5.2 Maintenance of Suspention system 7 5.3 Maintenance of Wheel .... Chapter 6 Maintenance of Controls and Brakes System.. 6.1 Maintenance of Controls System ..... 6.2 Maintenance of Brakes System .. Chapter 7 Maintenance of Electrical Parts and Meter System... 7.1 Maintenance of Charging System... 7.2 Maintenance of Ignition System ... 7.3 Maintenance of Signal System ... 7.4 Maintenance of Illuminating System ..... 7.5 Maintenance of Electrical Starter control system . 7.6 Maintenance of Meter .. 114 Chapter 8 Analyze of Motorcycle Troubles . 8.1 Analyze of Engine Trouble... 8.2 Analyze of Electric System Trouble .. 124 Circuit Diagram...LZX200GY-2(EC)Maintenance Manual L28TAR Chapterl General Vehicle introduction LZX200GY-2 motoreycle is a newly developed product with outstanding style and easily operation. The engine installed on this model is ZS167FML, which is 4-stroke, air-cooling engine with advantages of strong power and good acceleration performance. Pig. 1 left view of LZX200G¥-2 | front shock absorber 2 fmot brakes 3 stozring bar 4 gearshiftlever 5 carburetor 6side stand 7 rear wheel 8 taillamp 2 Fig. 1-2 right view of LZX200G¥-2 Imufiler 2rear brakes 3starting lever 4-rear brakes lever $-fuel tank 6-headlamp 7- front wheel 8-front fenderLZX200GY-2(EC)M aintenance Manual Specification Description Specification Length X width * height 2180mm X 810mm X 1200mm Wheelbase 1375 Sze and net weight fis ground dearance 250mm Netweight 15K aloud 50 Enginemodel ‘ZS167FML Engine ope single, tok, ar cooling ore X stoke mx 57m Total capacity 196 Om compression ratio 951 Be ‘craburetor type ‘vacuum fim airdeaner foam combined with plastic Tubrication way pressure and splash starting type electric starter / kick starter ‘max power/comesponding rer T0.5KW? (7500 = 500) rimin max powerlcomesponding rr TLORW? (7500 = 500) rnin max torque/comesponding rev 14,5N *m/ (6500 + 500) r/min idle speed (1400 + 140) r/min THoat shock absorber Thydrauio spring Riding system [rear shook absorber hydra spring angle of tering handlebar =a" fyrestandard’ | ffont wheel | 100/ 90-18 > 225kPa pressure rearwheel | 130/90-15/ > 250kPa Riting system | sive ws bin rin tuming diameter 200mm Clutch rmulipleswetand-mannal “Transmission, mesh with Sspeed ‘Transmission way return spring with left control Primary decelerate ratio 3.318 Final decelerate ratio 3286 ‘Transmission apes ess. 2speed | 1.789 Gear speedratio | 3.sye0d | 1318 d-speed | 1.040 Speed | 0.821 modal | 428H driven chain ce Se control and brake Eee csc beakes earbrake drum brakesLZX200GY-2(EC)Maintenance Manual Description Specification ignition way CDI igniiton tining 20° before top dead center (1200s/min) Spark plug: DBEA Clearance of spark plug O.6mm-0.mm Capncity of battery 1V7Ah electrical system | Fuse 10a, headlamp RVaSWASW Tail Light/Brake Light 12VSW/21W Tumsianal Tight BVIOW x4 Turn signal indicator 1RVLTW x2 Meter Light 1RVLTW x2. Neutral indicating Viaht avi posi ticnlight nvaw fel brand > 90 {GB 17930-1999) Capacity(ineluding spare) 7 8.0L Fuel fel tank ina iL fuel brand SF_1SW/40_ (GB 11121-1995) ensineot | capacity Lb ‘and QUO damping of1 [capacity 200 = mL Chapter 2 Maintenance Knowledge Maintenance and adjustment data Engine System ot 041 pump Description Standard ( imitation Ga) ap of pump top 020 radial gap between outer rotor and pump 0.25 zap hetween outer rotor and iner rotor 025LZX200GY-2(EC)M aintenance Manual 22 Cylinder, piston crankshaft and connecting rod Description Standard (om) ration (mm) Jolearance of piston and cylinder 002 0.06 foylinder internal diameter 7 67,045 piston diameter 66955 66.825 loylinder head ond surface ie deformed 0.05. leylinder end surface is bend 0.05 Jond clearance ofpiston ring 035 0.10 side clearance of piston ring (005 0.10 [elearance of piston pin and pin hole 002 008 jintemal diameter of piston pin 16 + 0.013 16.05 Jextemal diameter of piston pin 16,00 — 0,009. 15.855, note diameter of connecting rod small end 16.00 + 0,015 16,045 jradial clearance of connecting rod small end 002 0.05 jadial clearance of connecting rod bigend 001 0.05 [axial clearance ofconnecting rod big end 040 0.00 [axial jumpimg of erankshatt 002 0.05 2 etaeienta Deassption ee eo) 3 make 3586 0.05 36580 ei —i oe — valve spring length i a Sou ter 383 3650 valve gap, 0.06-0.08 0.09-0.10 Saiyan a a outernal diameter of valve intake 6.00-5.985 5.955 ude exit Sosa SHS aie intake coneon 304s eee al dare — = Re racecar =e — — oe exhaust 0.03-0.057 0.06LZX200GY-2(EC)Maintenance Manual Transmission 4 clutch, starting gear, gearbox Description Standard (an) [intention (m) friction discheight 300-310 2.60 clutch [deformation of friction dise 2.800-2.825 020 free length clutch spring 3730 36.50 internal dieneter of gear hole 16 x 136 axial diaeterof shifting fork eet [as 8°15 comal diameter of shifting fork ie 18.985 Tight of shi ine Fork claw 75 7485 fouter diameter of dram |outer dianeter of pricipal shaft 15.02 lod > ‘ 25.021 24.96 vearbox outer dimeter of comtershatt es Cl 19.50 19.45 wz a internal diameter of ey 1338 a 20.021 1936 M4 20.02 19.95 cs 25.021 298 ad wheel and shock absorber Description Standard (en) Limitation Gm) deepth of tire surface 40 2.0 stroke of front absorber shock 108 five length of front absorber shock spring 185.9 180.00 stroke of rear absorber shock 70 free length of rear absorber shock spring 125.00 120,00 ‘aia =e 200 Somping of rin =a = xo Bg frat Same, 200 Jumping of axle = a a Controls Systsem 2-6 Controls system Description Standard (am) Limitation (x) free stroke of front brake lever 10~20 20~30 free stroke of rear brake pedal 20~30 30~40 iecteweer aioe 39-40 20LZX200GY-2(EC)Maintenance Manual Assembly requirement and tools 21 Tighten torque Description Standard value Torave valve(N.m) \Grlinder head bolt Mo 82 \Cinnecting bolt of cylinder head Mo 10-12 \Grlinder head nst Mg. 20-30 Bolt of left crankease cover Mo 82 [bolt of generator rotor M10 50-60 bolt of starting motor Mo 812 Bolt of timing gear Mo 812 Engine Iright crankease cover bolt Me 812 lock nut of cluteh and drive gear pa 40-50 oil pump gear bolt a 69 eluteh cover boad bolt Bis) 812 fixing bolt of gear change drum can M6 812 crankcase bolt Ea B12 Locking nut of vertical tube M6 842 |fixingbolt of handlebar M24 {fixing bolt of upper connecting block TS [fixing bolt of lover connecting block ace NNutof frontaxle Me) Vehicle (Mtofzear axle Mid [Engine suspension bolt MIs {fixing nut of rear shock absorber M10 [Sprocket retainer mt Mi? Isteering stem bolt M8 [Nut of rear rocker arm ae Md Assenble location a. The top mark | ” should be toward intake position when fitting piston. b. The mark “A” on the first and second ring should be upside, and be 120 degree each other, c. The dense end of the valve spring should be downside. d.The T line of magneto, timing gear mark 0 and crankshaft gear mark 0 should be aimed, e Onark of balance shaft drive gear should aim to 0 mark of balance shaft pinion,LZX200GY-2(EC)Maintenance Manual Maintenance Tool 28 Special Tools and Gauge Motorized gun: special power tool for manling/dismanting and clutch nut wrench: special tool used with socket fe 3 ‘A, B bolt socket for mantling dismantling A, B bolt and exhaust smutiler bolt; Adaptor. electric special tool for eross, hexagon gun tip; Valve adjusting socket: for valve clearance adjustment Socket: for mantling/dismantling nuts, bolts, A A | KA TTTT (Cutting pier, nipper pier, expansion plier for mantlingy dismantling flexible retainer ye 71 totor puller for dismantling magneto rotor Rubber hammer, iton hammer, eopperhammerLZX200GY-2(EC)Maintenance Manual Feeler gauge: to measure the clearanes of pston, cylinder, Micrometer: to measure the dimensions ofpiston, valve, ete piston pin, ct, Dial gauge: to measure the wheel bouncing, cylinder aren ee (Cylinder barometer: to measure the eylinder pressuredf qq LZX200GY-2(EC)Maintenance Manual L28TAR Chapter 3 Maintenance of Engine 3.1 Maintenance of engine body Dismantle, mount and maintain cylinder head figuration of engine is shown in fig. Check engine surface and rinse sand or dirt on engine sur- face if necessary Cnfiguration of engine is shown in fig. Check leakage from engine and repair engine if necessary. remove cylinder head cover. remove C.D.I cap. check seal ring of C.D.I. cap and replace seal ring if necessary. -10-LZX200GY-2(EC)Maintenance Manual LP STAR unscrew cylinder head nut, remove oylinder head nut washer. unscrwe bolt of intake and exhaust valve cover. check intake and exhaust valve, change seal ring, of valve if necessary tool “1 valve coverLZX200GY-2(EC)Maintenance Manual unscrew bolt of chain tensioner. remove tensioner and check wear of tensioner, change if necessary. tensioner unserew connecting bolt of cylinder head crankcase. unscrewlock bolt of sprocket 12-LZX200GY-2(EC)Maintenance Manual LP STAR remove driven sprocket and check wear of sprocket, change sprocket if necessary. remove oylinder head. check end surface and change cylinder head if necessary, the limitation of deformation shuold be 0. 05mm, check carbon deposit in combustion chamber and remove carbon deposit. ‘combustion chamber -13-df qq L28TAR LZX200GY-2(EC)Maintenance Manual remove camshaft, rocker shaft and rocker to check wear. change camshaft, rocker shaft and rocker if necessary, fill petrol into intake and exhaust pipe of eylinder head and check. grind valve if necessary, Check valve seat and grind valve seat if necessary. width of valve seat should be 1,6mm-2,0mm measure guide pipe inside diameter of valve and change guide pipe if necessary. the limitation of guide pipe should be 6,045mm. check carbon deposit and remove carbon deposit and clean spark plug if necessary.adjust spark plug, clearance, it should be 0.6mm-0.8mm. “ue guide pipe ‘micremeter spark plug toolX200GY- 2(EC)Maintenance Manual 3-1 Maintenance of Cylinder Head Component “Trouble spmpton “Trouble eymplom description | __Pamast form ‘of component of motoreycle Repair method |Too much oil ditt or sand | Poor heat radiation of the fins a oe Remove the oil ditt or sand onthe radiating fins. [on cylinder head net NaS om the radiating fin. aR) ‘The engine overheats Remove the carbon deposit combustion charnber i "The engine is difficult or impos-| Repair the threaded hole or Failure of sparking plug| Ait leakage between the sparking] "© ene! et ace ent ey ie wba eter all sible to sare replace the cylinder hea thyeaded hole Ss eatin Fn le ace ee Cae inder head end suc G.| gi jahagebetwcen the eylinder| SDH 10 start. Istficient engine] heay ne deformations beyond | ea and eylinder output; Engine speed changes| thelimito 005mm). ugar Cylinder | Tee are is, bitin or pock| ai teakage between the valve and| Meet flea o posse to head [mas anges n te Wo |yaiye seat dve to impreper| Sa" Mle engine ouput E-| Repair the valve seat ingsurficeof valve seat | tightness Meg eee ies "The ier hoe of valve guide is over wor (le the mer |The fing clearance betneon | Thick ble and white IME POM) ne wae gi ameter ofthe waveguide is | pe valve andthe valve guide |the exhaust maMer pipe Soe beyond the limit-of 6.) Me Vee oF 43mm, iad ee ‘The engine is difficult or impos-| Replace the cylinder head Phe extn gasket is] eg wen heli yt an erie La at output Engine speed ckanges dr ing idle rn, PR a Me aeons sible to stat. Insufficient engine roperly tightened. _| Air leakage between the cylinder ee ieee ‘output; Engine changes speed] T° stew up the retainer mit ving ile ru oil wage between the eyinder and [Improper clearance bs-| Weak or no sparking from the| yjeare ier Adjust by slightly pulling] pees eeceies eeepliecer ne the side electrode tll the clearance is 0.6-0.7rmm, he spark hig electrodes sparing rom the spark pug] eshe invite et | ston depo are jointed by carbon | ecard e lectrodes. betwen the electrodes deposit ‘Spark phog_ | EXtessive carbon deposit ‘The enue is diticult or impossible to| Remove the carbon deposit oroil din the sparkplug, |" er no sparking from the] a innuscietenine ope agin | or oil dt spark plug electrodes chges speed ig ier re eine etic or inponsne to] Replace with a new spark ‘The spark plug insulatis| Weak or no sparking from the| "ww ut eoae supe eaue| tin ott ie pig of the same type Su spark plug electrodes chaste meet i [The spark plug is not properly tightened. Air leakage between the spark plug and cylinder head. "The gine i cl To ta. rain] changes sped daring erm. Tighten the spark plug, “15.df qq LZX200GY-2(EC)Maintenance Manual L28TAR Dismantle, mount and maintain cylinder configuration of cylinder is shown in fig and remove dowel pin to check deformation and change dowel pin, remove cylinder gasket to check gasket, change gasket if necessery. remove tension strip to check wear and change if necessary unscrew connecting bolt and remove cylinder to check wear, change cylinder if necessary. -16-LZX200GY-2(EC)Maintenance Manual LP STAR remove balile ring of piston pinto check baffle ring. ‘Never fall baflle ring into erankease remove piston pin to check wear, the use limi- tation of piston pin external diameter should be 15. 855mm, ‘Never fall bafile ring into crankcase remove piston to check wear. the maximum limitation of extemal diameter should be 66.825mm and the minimum limitation of piston pin hole inter- nal diameter shoule be 16,05mm. check wear of connecting rod small end and the maximum limitation should be 16.045mm. piston “17LZX200GY-2(EC)Maintenance Manual remove residual gasket on cylinder surface and check deformation of cylinder, change if necessary. residual gasket > Or remove cylinder and check wear of eylinder, change if necessary. inside check deformation of cylinder end face and the deformation limitation is 0,05mm. end face measure internal diameter of eylinder from upper, mid and lower, the max. limitation is 67 045mm. upper mid lower -18- micrometerLZX200GY-2(EC)Maintenance Manual 32 Maintenance of Cylinder body Component Faeere Trouble symptom of : : aia ae ‘Trouble symptom of motoreycie | Repair method Remove the oil dirt or ‘The engine overhents, sand on the radiating ins Poor heat radiation ofthe fins ‘on eylinder head ‘Serious defor ler end surface (larger) Air leakage between the cyl than limitation of 0.0 "The engine i dificult or impossible| crind the cylinder head| to start Insuificient engine output;|end surface or replace! Engine changes speed during idle run. |tbe cylinder head. inder head and eylinder Cylinder ‘The engine is dificult or impossible! "The eylinder is worn (larger to star. Insufficient engine output: Repair with boring Pan 67-045) Engine changes speed during ile|ene oy epace te run Thick bive and white fume fom er he exhaust er pipe. arse eine ot eage between he extn nd Replace the cylinder erankcase. zasket Dismantle, mount and maintain crankease Unscrew engine oil plug and check oil to check oil and oil level remove clutch rod and stell ball, check wear of rod. change clutch rod and stell ball if necessary. -19-L28TAR LZX200GY-2(EC)Maintenance Manual ‘View of right crankcase is shown in fig, and check ‘wear of balance shaft bearing, crankshaft beating, prin- cipal and countershaft view of right crankcase is shown in fig, and check wear of balance shaft bearing, crankshaft bearing, principal and countershaft, change if necessary, view of left crankcase is shown in fig and check wear of countershaft oil seal, gear change lever oil seal. change if necessary. view of left crankease is shown in fig and check ‘wear of balance shaft bearing, principal shaft bearing and countershaft bearing. change if necessary. -20- countershaftbearing principal shaft bearing \ belaneestiaft principal shaft balaheeshaft bearing bearing bearingLZX200GY-2(EC)Maintenance Manual engine number is stamped on right crankcase and remove oil plug and check oil quality. check lubricant level and add if below lower line. unscrew filter net cap bolt of right crankease cover and remove filter cap. remove filter net cap to check rubber ring and re- move filter net to clean. filter net Oring fitet net capLZX200GY-2(EC)Maintenance Manual L28TAR remove right crankcase cover and check oil line, clean tight crankcase cover oil line remove fuel inspection cap and check seal ring of fuel inspection cap. change seal ring if necessary unscrew bolt of left crankcase cover and re- move crankcase cover to check. change gasket check bolt of stator and trigger coil, check wear of roller needle beating of electrical starter. change stator if necessary1D. OLU I ena ‘Take off the residual bolt in crankcase as shown in fig, and remove broken bolt. Triangle taper of wedge 2 Residual bolt 3.Crankease 33 Maintenance of crankcase TomPOTEN | Damage “Trouble smprom oF Trouble symptom aR aan deseription component of motoreyele Crackin the crankease Oilleakage from the erankease,| Repair of replace threaded hole of cil drain] plug screw is ineffective, threaded hoks of eylider boltar inelsctive Crankease (cylinder head fasten nut isi: [possible to sorew fiemly so thal levlinder head fasten nuts im bolt of the cylinder is |possible to screw firmly so that] broken lsirleskage between head andl lylinder lair leakage between head anc leylinder Oil leakage from the joint of Teft and right crankcase. engine is difficult or impossible to start, Insufficient power, un- sable idle spoed engine is difficult or impossible tostart, Insufficient power; un- stable idle speed replacecrankease Repair the threaded hole or replace the erankease Replace the eylinder bolt ‘Oil seal is damaged or ol] \sealedgeis damaged il leakage from the oil seal Replace the oil seal ‘rankcase covers wom or Cilleakage from the case cover Replaez or repair theease| broken, Rightcrankease| cracked cover Sei Tesi ont! a is UelWEET GSE COVET) Replace the gasket TCE VETS WORT OF 3 Replace ar repair cas Lefterankease | cracked, Oil Ieakage fom the ease cover rat cover | gasket of fe erankease i il Tekage between the casa Ee [eee ee Replace the gasket [cover and the case -23-LZX200GY-2(EC)Maintenance Manual L28TAR Maintenace of crankshaft connecting rod Dismantle, mount and maintain crankshaft connecting rod Unscrew fixing bolt of crankcase remove left crankcase never fall principal shaft, coutnershaft and starting shaft washer into crankcase. Jeftcrankease right erankease remove crankshaft connecting rod and check wear of bearing, change if necessary —_s connectingrodLZX200GY-2(EC)Maintenance Manual remove balance shaft and check wear of bal- ance shaft neck. change balance shaft if necessary. balan shaft neck check clearance of connecting rod big end and change connecting rod if necessary bigend ‘measure extemal diameter of piston and check wear of piston, the minimum limitation should be 15.95mm, piston pin measure side gap between piston ring and pis- ton groove, the maximum limitation is 0.08mm. groove feelergaugeTk L28TAR check baffle ring of piston pin and change baffle ring if necessary ‘measure piston skirt diameter to check and the use limitation should be 66.825mm.change piston if necessary, measure diameter by moved 15mm upwards from. piston bottom. change piston ring if necessary and the fixing pro- cess is shown in fig, -26- LZX200GY-2(EC)Maintenance Manual piston pin rilcrometer piston L Istring 22nd ring 3 oil ring Ascraper Soilring 6 markLZX200GY-2(EC)Maintenance Manual LIP STAR Measure radial jumping of crankshaft and check both ends of crankshaft, the limitation is 0.05mm. Im dial gouge crankshat Measure axial jumping of connecting rod and check needle bearing, the limitation is 0.0Smm. ‘Measure connecting rod big end gap and check gap. the limitation is 0.60mm. change connecting rod if necessary. bigend felergavge {- radial check axial jumping of crankshaft and the limi- tation is 0.05mm.LZX200GY-2(EC)Maintenance Manual 4 Maintenance of Crankshaft Connecting Rod descrip Damage fi Semen ‘Trouble symptom of viel z hod description mage fom ny rouble symptom of vebile ntenance metho Fetes ‘The engine overheats remove carbon deposit The engine is dificult or impossible t Carbon deposit inthe ring | The piston rings seized it lsu, insuticent engine output; thi ae rove fing sroave lolue and white fume from the exhausy TEmOYE carbon deposit Inufe pipe the engine is dificult or impossible t Scuing ot scratches on} scuting or scratches onthe [tart Insufficient engine output; thie te surface of piston skirt surface of piston ski. flue and white fume ftom the extaus Replace the piston Aas Imufe pipe lexcessive wear of pis engin is dificult o impossibie to start ton (diamter is less ee a Insuicient engine ouput: thick BIE AMF se the piston. than Linitation of 66 |" 10, cinder tite fume from the exhaust mute pipe] SSPI6® IHS P s25mm) ; fitting clearance between Ie82| hick ble and white fume fom the excessive wear |pitonsing an gove mover] Uo Nn Replace the pists of groove large lexcessive wear of pis~ ton pin hole inter di-|fiting clearance between the | seiking sound of the piston pin and of lameter is more than|Piston ring and the Hole se cylinder, Replace the piston Limitat fonof 1604S) |°°e" ee mee crank pin | excessive wom, | Radial and axes gap is 100 suiking sound of the bis-end bearing | NEPl#CE erankshalt ie connecting rod needle bearing iS eV nadiat and axes gap is too Stiking sound ofthe bigend bearing | Replace crankshaft worn ee connecting rod. Bearing de qu enie Abnormal Sound during the crankshaft | Replace cranks! over wom ce damage ao ae ithe engine is dificlt or impossible & start Insufficient engine output; tic piston ring is fractarea, | PitON Hingis meted. Ea nite ume from the extausy Replace piston set Piston Inufe pipe ring st piston ring is over wom, [The engin is difficult or star, Insufficient engine output; tic lolue and white fume from the exhaust Me pipe. possible t end or side gap is over large, Replace piston setX200GY- 2(EC)M intenance Manual Maintenance of Crankshaft Connecting Rod LP STAR Trouble symptom oF fiescription | Damage fon : Trouble symptom of vehicle buitenance meld component He engine sifu or impossib osficen elasticity or] mae of piston ete 2m ho startin egine ODMH] Replace piston st Piston [piston ring, ae thick blue and white fume from th teeta estaust mule pipe ston ring gap is not stag Improper fixing ge SP "hue and white fume from mate pipe Refitting excessive wear (extemal Siting clearance beween pe Piston pin | dlameteristess than nie |e ee ole is over lege | Siking sound of piston pin Replace piston pin tation of 15 095mm) ‘exoesie wearofmallend hole (ner diamteris morefitting clearance between Replace crankshaft than limitation of 16. l-cnd and piston ‘Striking sound of piston pin conn rod. dsm) lover are. Comest- ingrod | connecting rod is bend | connecting rod is bend Ssrking sound of eylinger | RePlace crankshaft connecting rod big holes over wom. [Raia and aes gap isto | Striking sound ofthe igen beu-| Replace crankshaft ce Pi connecting ro Tiny , Replace timing damaged, sprocket -29-df qq LZX200GY-2(EC)Maintenance Manual L28TAR Maintenace of valve mechanism Dismantle, mount and maintain crankshaft connecting rod remove cylinder head assembly and remove valve clip and spring, valve by tool to check wear, change if necessary, unscrew bolt of cylinder head cam shaft remove cam shaft baffle to check and change if necessary, remove valve rocker shaft, rocker and camshaft to check wear, change if necessary. -30-LZX200GY-2( Hl ance Manual remove rocker, rocker shaft and timing cam to check wear, change if necessary. rocket rocker shaft camshaft measure valve spring length and check wear of valve spring, the minimum limitation of inner spring is 36.00mm, the minimum limitation of outer spring, is 36.50mm, Caution: the end with dense spring should be downwards when fitting, valve spring caliper measure minimum limitation of outer diameter is 5.95Smm ancl check carbon deposit on valve stem. measure valve interface width and the limita- tion is 2.20mm. change valve if necessary. -31- calliper valveLZX200GY-2(EC)Maintenance Manual Check deformation of valve stem and measure the limitation of roundness is 0.05mm, change valve stem if necessary check cam lif and the minimum limitation of cam lift is 36.50mm. change camshaft if necessary check wear of camshaft neck and gap between camshaft and bush change camshaft or bush if necessary, check wear of rocker interface and gap between. rocker shaft and rocker. change rocker shaft or rocker if necessary -32- iP [ dia gauge cod i rocker ‘ valvestem fdthole camshaft neck Ne rocker shaftLZX200GY-2(EC)Maintenance Manual Measure extemal diameter of rocker by mi- crometer and the minimum limitation is 11,93mm, check wear of drive sprocket and change drive sprocket if necessary. check wear of timing chain, tension strip and chain guide and change if necessary check wear of tension strip and change tensioner if necessary. roetler shaft chain tensioner thicrometer chain guide -33-L28TAR LZX200GY-2(EC)Maintenance Manual remove valve cover firstly when adjusting engine timing position remove fuel inspection cap and rotate magneto to make piston locate at top dead center and make T aim to mark of left crankcase cover. Lineal mark of timing sprocket should be aimed to lineal mark of cylinder head plane when T mark aimed to mark on left crankease fuel inspection cap. adjust sprocket location if necessary adjust valve gap. intake gap should be 0.05-0.08mm exhaust gap should be 0.08-0.10mm. -34- valve cover wrench adjustmentnutX200GY-2(E ¢C)Maintenance MW ETIE | 35 Maintenance of Valve Mechanism Description Damage form ‘Trouble symptom of compfnent Trouble symptem of vehicle Maintenance method Valve iT edge of valve oll seal is worn, aged Jick ue and white fume fro seal ed he exaust muftle pipe. _ | Replace valve oll sel excessive wear (Lifting is less Micent engine output. | Replace the eamsha then min, Limitation 36, 50am) dene |e < & ™ | cessive wear of interface of | @§isl or radial clearance of the| shaft | shaft and bearing or daw [Destine istoo wide, Ineffective] Abnormal sound heard dari camshaft and bearing OF So" suing swiveling orabnonmallcamshaf transmission. | Replace cama Ee vlduring swivsing rors SaaTESTE Sa ails pam" RES cessive war of rocker am hall pig gap between rocker arm Rocker [hole (inner dimetar ie more thd ang rocker ann shat Valve striking sound. | Replace rocker arm. am |imitation-12 tm lsxceasive wear of Toker eat mg gap benweon Tooker am and Kextrnal dlancter i los than lini-| eye ar shan ‘Valve striking sound, | Replace rocker shat engine is dificult oF impos: Carbon deposit on surfieo. is impossible to At valve and) ye tg sat, insuficienten-| Remove carbon deposit atie acs Lely sine output; unsteady idle working surface is over wom oF |p i impossible to fit valve and | SME's difficult or impos has pits, pock mars, ablation oF | ey sible to star. nsutficient en-| Replace valve damage. " gine output; uasteady idle ave |(Conteral canter of intake ston isf€@P between valve steal sound from valve hick blue less than limitation-#5.955mmand guide tube is over| and white fume from mume | Replace valve. exhaust dimter is ess than Li-} ge ms tation-5 955mm) Pips valve stem is deformed valvean not close completely. | engine can not start. Replace valve rap between valve Stem 5 5 thick blue and white fume| excessive wear of valve sten Jand guide tube is over| Replace valve ice fiom mule pipe. valve stem is deformed. valweannot case completely) engine can not star. Replace valve. E isimpossibleto ftthe valve| $2 is dificult or impos- valve iffistntelastittyorgpring] ts pone 10 ME VANVE| a.com elae val eine spring | is broken and the valve scat tightly. sing output; uasteady tle Tinie 7 excessive wear of sprocket ene diving | oth replace sprocket 3 sprocket excessive wear or elongated abnormal sound from replace chain ining bain chain | isproperfittingof FESER TAL engine can not stat. refit excessive wear of tension | insufficient tension force [abnormal sound fron] replace tension strip chain | stripand guide roller of chain chain and guide strip tensiones| {insufficient tensionforeeof [abnormal sound from tensionerfailure replace tensioner -35-LZX200GY-2(EC)Maintenance Manual L28TAR Maintenance of fuel system Dismantle, mount and maintain fuel system shut off fuel shut-off and remove fuzel line, drain off fuel in fuel tank. Caution: keep away from fire to avoid accident while drain fuel shut off fuel tank key and check gasket ficl tank key unscrew bolt of fuel tank protective cover and. remove cover. protective cover unscrew bolt of seat and remove seat and then unscrew bolt of fuel tank. —36-LZX200GY-2(EC)M aintenance Manual remove fuel tank and check inside of fuel tank. unscrew bolt of fuel shut-off and check inside of fuel tank, clean inside with petrol if necessary remove fuel filter to check and clean filter net if fuel tank eover necessary fuel iter ‘Table 3-6 Maintenance of Fuel Tank Component ‘Trouble symprom TraubTe SympTOR detente of component of motorcycle Se Repair or replace the fuel Sarat Oil leakage ftom the tank ener Fuel tank ‘The venting holes of fuel S Iimpeded fuel supply ‘The engin i impossible to tart, Clean the venting holes. tank cap are clogged Bea is ‘The engine is dificult or impos- ‘The fuel filtering tube is | impeded tuel suppl sible to start, Insufficient engine impeded fuel supply. ‘Clean the ful swith fouled or choked a eS output; ‘The engine changes Fuel switch speed during ile mun assembly The switch is clogged or damaged. lmpeded fuel supply. The engine is impossibi 1 start. Replace the fuel switch “37df qq LZX200GY-2(EC)Maintenance Manual L28TAR Dismantle, mount and maintain carburetor unserew intake pipe clip screw and air filter joint clip serew. shut off fuel shut-off and remove fuel pipe remove carburetor assembly unscrew throttle cap screw of carburetor. -38- | ‘throttle capLZX200GY-2(EC)Maintenance Manual remove throttle cap and check throttle ring and spring remove throttle and check wear of throttle and oil needle. fj throttle check oil needle clip and clip should be at the third layer clean caburetor surface and unscrew flaot chamber screw. -39- ‘aot chamber coverLZX200GY-2(EC)Maintenance Manual L28TAR open float chamber cover and check inside of float chamber, clean float chamber, faot chamber cover dismantle main jet to check and clean jet if necessary. Dismantle idle jet and check is jet is smooth idle jet check flaot cylinder or float needle if fuel leak- age from carburetor. ~49- float eylinderLZX200GY-2(EC)Maintenance Manual LP STAR clean carburetor by petrol and blow all line then fit carburetor. unscrew bolt of mixture jet and clean jet. tighten mixture screw and screw 2 cirlces back- wards while fit mixture jet ‘measure float cylinder height and adjsut height if out of the range of 1Smm-1 6mm. check abrasion of oil needle valve surface and if wear, fuel leakage from carburetor. needle valve surface needle valve “41LZX200GY-2(EC)Maintenance Manual chee! fitting of carburetor oil neddlle and adjust oil needle if necessary, clip should be at third layer. third layer olip 37 Maintenance of Carburetor Campanent Trouble symprom ‘Trouble Symptom description ee ‘of component of motoreyele Repair method Insufficient engine output, The engine lle speed sir ace com aa ae Improper adjustment 68 speed during idle run, Exces- adjusting serew sive fuel consumption ‘The clip is improperly Jet needle set Insufficient engine ouput: Excessive |Readjust the clip posi adjusted vel consumption, tion in the jet nee. ‘The float level is too engine is difficult or impossible to| high (i.e, the float level | The oil level in float cham |Stat. gine overheats, Insufficient] Repiace the float set. engine output; engine changes speed) is over 16mm), ber of carburetor is 100 lew uring idle mn. Excessive fuel ‘The Hoat level t00 Tow Float set |e, the float level is be- | i spilled out of the carbure- tor The engine i eifficult oF impossible| repair or replace the to start, Insufficient engine output:| goat set. Excessive fuel consumption, low 15mm) ‘The engine is difficult or impossible Oil spilled out of the carbure- aes eee es to Start. Insufficient engine output tor Replace the float set deformed. Excessive fuel consumption Nec vate of [Te cme TTS TUTE [cdot ofthe cat | Tene is CUO IMOSTHE] eosiace he needle tate of | eis mag wor | Ot is eae eet cee ee Eas i trace spe scene fel emnptin Nin jet |The jet diameter on sce fe anno —. Reps em jet ed o i "The engine is difficult or impossible to stat. The engine changes speed during| Replace the slow jet. ile run, idle speedjet | The slow jet is clogeed, "The jet diameter is too fa Excessive fuel consumption, | Replace the slow jet (rhe engine is dificult or impossible to Air jet ‘start, Insufficient engine output; the ‘The sr jet is clogged [opine changer spect aarkys ia ne, |cteen ore -49-LZX200GY-2(EC)Maintenance Manual Maintenance of intake system and exhaust system Dismantle, mount and maintain intake system unserew bolt of left cover and then remove left unscrew bolt of air cleaner cover. remove air filter cover to check broken and change cover if necessary. remove foam element of air filter to check and clean element if necessary. -43- foam SlementLZX200GY-2(EC)Maintenance Manual remove air cleaner element bracket to check air cleaner and remove dust in air cleaner. Clean foam element as follows: - put foam element into detergent to wash - then squeeze foem element - drop proper lubricant on foam element ~ extrude excessive lubricant from foam element and then fit foam element. clean process 38 Maintenance of Air filter ‘Component aid seiien| ‘Trouble: symptom “Trouble sympian sleseription of component ‘of motorcycle “The ei ict os. ns cet engine pupa; Poor performance —__|teavine dining ste rum exewoive Air cleaner | the filtering element ud consumption, The est utter | 8 elemen Pipe fmes strona (ac). ‘Too much dust deposit on Clean the filter- The filtering element is Engine air suction noise is too Replace the fil- fractured or chape’ oud = fractured or chaped, tering elementLZX200GY-2(EC)Maintenance Manual Dismantle, mount and maintain exhaust system unscrew connecting nut of muffler. unscrew connecting bolt of exhaust pipe to check washer. change washer if necessary unscrew suspention bolt to check suspention bracket and change muffler if bracket broken, remove muffler and check break of exhaust pipe, change exhaust pipe if necessary 45.remove muffler and check break of washer, LZX200GY-2(EC)Maintenance Manual change washer if necessary pump and exhaust pipe if pullotion can not be check carbon deposit in exhaust pipe and re- move carbon deposit, change ait pump filter, air reached requirement, check rear section of muffler and change mufiler if rear section broken. exhaust pipe rearsection 2 Neittenanee of Exhnst Muffler 5 Trouble symptom “Tous S7o meee eh pate of componet of motorcycle Exhaust pipe reas ea cg re PIPE] gsktis broken. | a Tekage ram ext ppe. | B= ete rian gasket —46~ muller smumMer case is broken, muller case is broken Engine exhaust noise is 0 loud change mufMer. protection de— environment pro~ tection device fail environment protection de~ vice damage or posion emission pollution exceeds standard change exhaust pine, air pump andairfilterLZX200GY-2(EC)Maintenance Manual Dismantle, mount and maintain environmental protection device check nut of environmental protection device and tighten nut if necessary. check connecting clip of air pump when pulltion exceed standard and tighten or change clip. ‘unscrew fixing bolt of sir pump when pollution exceeds standard and check air pump, change if dismantle hose of air pump to check and tighten or change hose if necessary -47-LZX200GY-2(EC)Maintenance Manual dismantle secondary intake air filter to check and change air filter if necessary remove connecting hose of air pump to check loose or aging, tighten or change hose if necessary. disassembly ensure seal of environmental protection device connection, environmental protection device 3-10 Maintenance of Enviromental Protection Device rouble sympion ‘Trouble symptom Deseription Dasage form on oe Repair method of component i caission pollution ex air pump | jamed or danaged | outof action change air pump Ss aa ceeds standard i 4 ‘emission pollution ex aititte | janed or damaged | outof acticb ‘ change air filter coeds standard noise from environment pro- | emission pollution ex-| change connecting joonnectil ie f acer pease ieee ait pump |ioiee fron eocndary Jair leakeae fron eoadaiy|enisefon ollstTon | “change quaker feares Pilla nee ae aaa sence ~48— carbon deposit on ex emission pollution ex-| 7 fautFlew exhaust|°aPOn deposit eee ere cebustite! ply Irenove carbon deposit havet ceeds standardLZX200GY-2(EC)Maintenance Manual Maintenance of Lurbricant System Dismantle, mount and maintain lubricating system remove valve cap to inspect inside of cylinder head and if no lubricant.check oil line of cylinder head and clean oil line if necessary. Ibricant valve eap then dismantle fuel filter to check filter element and clean element if necessary. check oil line and remove impurity if neces- sary to keep smooth, -49-LZX200GY-2(EC)Maintenance Manual L28TAR unscrew drain bolt and drain oil to check fuel line and fuel. remove right crankease and clutch, unscrew oil pump screw and remove oil pump. check break of oil pump gasket and check smooth of fuel line. clean fuel line and change gasket if necessary, check inlet and outlet of oil pump to keep oil line smooth,LZX200GY-2(EC)Maintenance Manual check wear of fuel pump gear when fitting fuel upmp. check cylinder head oil line, oil line of main shaft and countershaft and outlet to keep smooth check oil line of cylinder head, crankshaft and outlet to keep smooth check wear of inner rotor, outer rotoe and gear, change if necessary the useage limitation of external diameter of rotor gap should be 0.25mm, outlS line cylina cylindef oil line head oll ine outlet cilpufp case oil pmp cover cil pump gear outer rotor inn3 rotor “51fit oil pump and keep seal and oil line smooth. LZX200GY-2(EC)Maintenance Manual cil pump component 311 Maintenance of Lubrication System ‘Component rouble symptom Trouble sympiom scription Sane ee of component of motoreycte Repair method cit pump _ | THe ier and outer rtatr [No or insuficeat oil is dlivered|nsucient engine eutput Pum Jottne pump is over worn by the oil pun. The engine overheats. Replace the oil pump Inpeded oll sppiy easing so Sane is The strainer is clogged. ficient or no oil delivery from| msuiTicient engine output. | ciner il strainer ine i The engine overheats. Clean the inside of Oil filter |The inside of rotor is foul ‘The engine overheats. = Labricaion| Insufficient engine output. | system | Oil chamel is clogged. Insufficient of oil supply. paisa ante’ (Clean the oil channel Maintenance of Cooling System Dismantle, assenble and maintain cool ing system Check if there are dirt on cylinder head, eylin- der and erankease surface, clean radiating blade and crankcase, | eylindorhead cylinderLZX200GY-2(EC)Maintenance Manual LP STAR Chapter 4 Maintenance of Drive System Maintenance of Kick Starter Disassemble, assemble and maintain kick starter remove clutch and remove starting shaft. remove starting shaft gear to check wear of gear and change gear if necessary remove starting shaft and check wear of starting shaft and change wole set starting shaft if necessary 53: starting shaftLZX200GY-2(EC)Maintenance Manual remove starting shaft spring to check spring and change spring if necessary remove starting rachet and check wear of rachet, change rachet if necessary check wear of starting shaft surface and change starting shaft if necessary. check wear of starting assembly and change if starting rachet starting shaft starting shaft assemblyX200GY-2(EC)Maintenance Manual 4 Maintenance of Kick Starter Ta Troxble Spon Tronble sym Damage form epuit metho description i of component of motorcycle en es j Ispine connected with oe startinglever startingleversliy start skiddi e . |starting lever slipping facta iy car ver eS wear of rachet_ start skidding start skidding: re Ay starting gear see te ieatsenaticd lange arene orar r' bi ae difficuiltostart : tecth wear of rachet start skidding start skidding Serene chet startinerechet rashet spring broke ) change rachet ea start skiddi : start skidding wy: spring ea ee change starting ing leer ond starting shatt| start skiddin ens pon ; tart skidding tart skidding ees startingshaft |" RA og Ge eos a EN Disassemble, assemble and maintain electric starter unscrew motor bolt and remove motor. check wear of motor gear and change motor as- sembly if necessary ‘motorgeatLZX200GY-2(EC)Maintenance Manual unscrew left crankcase cover bolt and check left crankcase cover. remove left crankcase cover to check gasket and change gasket if necessary. unscrew stator bolt and trigger coil bolt check wear of trigare coil, ignition loop and illu- minating loop. change stator if necessary. ignition loop illuminating loop ‘tigger eoilLZX200GY-2(EC)Maintenance Manual unscrew fixing bolt of magneto rotor. pull rotor by special tool to check wear of ro- tor and change rotor if necessary. remove reduction gear and check wear of re- duction gear and change gear if necessary. remove overrun clutch gear and check wear of overrun clutch gear and change if necessary xk LP STAR ostLZX200GY-2(EC)Maintenance Manual remove overrun clutch holder and roller to check wear and change clutch holder and roller if necessary, starting clutch spring collar Maintenance of Starting Clutch Pei ae Trouble sympiom Trouble symptom excessive wear of eam bon brush (length is less | | moter rim without J os ine potor carbon brush spring is Starter motor run without pring is _| Startermot thou} change carbon brush “Armature commutator sur Starter motor run without] Clean the commutator surface Men Polish tesurce against the com i utator with fine abrasive paper, tha ee Oatrn Make the cut on the mica plate face is spotted, bumt or] ———————_| _Starermotorrunwith- [between each commutator pizce with broken saw bit 0.5-0. 81am ldcoper than the commutator surface. Remove the chip and bur [Armature commutator sur Starter motor run without —— Replace startor motor Broken circuit or short ci-| Starter motor failure | Replace starter motor contact surface of starter cutch s sipping or stata wea terclutch is slipping o| start sipping or has abnor clutch gear and rlleris over Replace starter clutch gear starting | eomtt surfce of tater] Jtuteh andl roller is damage] Starter clutch is slipping oy start sipping or has abnor} Replace starter clutch lor worn out into concave roller is over worn or| Starter cutch is sipping of start sipping orhas abnor] -58- arias Replace starter eluteLZX200GY-2(EC)Maintenance Manual L k LP STAR Maintenance of Clutch Disassemble, assemble and maintain clutch ‘unscrew right crankcase cover bolt. remove right crankcase cover remove gasket of right crankcase cover and change gasket if necessary pasket unscrew adjustment nut of clutch and check ‘wear of connecting rod jet. -59- adjustment nutLZX200GY-2(EC)Maintenance Manual L28TAR unscrew clucth cover plate bolt and remove clutch spring to check wear of spring, change spring if necessary remove clutch cover plate and check wear of clutch cover plate, change cover if necessary. unscrew lock nut of clutch and remove driving disc remove driving piece and driven piece to check wear. change if necessary ~60- T driven piece davingpieceLZX200GY-2(EC)Maintenance Manual remove driving disc and check wear of driving disc, change driving dise if necessary remove clutch spline washer and check wear of spline washer change spline if necessary check wear of clutch driven disc and change driven disc if necessary. check wear of driven hub spline slot and check ‘wear of groove of clutch friction disc, change driven dise if necessary. ‘groove spline slot -61-LZX200GY-2(EC)Maintenance Manual unserew nut of drive gear and check wear of drive gear change drive gear if necessary ‘unscrew pinion nut and check wear of balance shaft pinion. change pinion if necessary. tool ut ‘measure thickness of clutch driving friction plate and the minimum limitation is 2.60mm, fiiefion plate calliper 4 * Crea ae acre Metin ae ort of Reta resting regulator ‘The batery # damaged. | No power output. ‘The starter motor is not running | Replace battery ergs ie | Te mio power z fining toute, egal] CABIN nig etery_ [oe dtc vas ton low, | RS Hey. te spl sy) Commons ce -99.df qq LZX200GY-2(EC)Maintenance Manual L28TAR Maintenance of Ignition System Disassemble, assemble and maintain ignition system ‘Tum on ignition switch to check operation of vehicle and check charge system if vehicle can not be started. Start motoreycle by kick lever or press electric starter and nun engine. check sparking of high tension ignition coil and check ignition system if abnormal the output voltage should be above 10,000 volt, spark should be in blue. sparking experiment Remove spark plug and check cylinder pressure dismantle engine to check if insufficient pressure. -100- spark plugLZX200GY-2(EC)Maintenance Manual check short circuit of spark plug cap electrode if normal and change spark plug cap if necessary. check if there are carbon deposit on spark plug or spark plug clearance is over large, adjust clearance to 0.6mm-0.7eam spark plug remove connector of ignition coil and trigger coil, check ignition loop and trigger coil by multimeter remove C.D.I. connector and check resistance between Black and Red wire of ignition switch. change if abnormal -101 cbi ‘connector-102- dismantle C.D.Loutlet and check high tension LZX200GY-2(EC)Maintenance Manual loop. change high tension loop if necessary dismantle left crankease cover to change igni- tion loop and trigger loop if abnormal, Maintenance of ignition system 2 A “Trouble Spon oF OTT scription] Damage fora | Trouble symptom of component ea Maintenance method a Veak or no sparkover of the | dificult to start or can't start. ignition | stortaireutt vice parkover of he | cient engine power anq| change ignition power| power spark plug electrodes ine : stable ile speed loop ee io sparkover of the spark plu; broken eireuit(e)|™ an T the spark PIE |The engine does not start. Jchange ignition power loop Weak ornowputoverottespue |Aiukioaatoremtaet sina] cent engine power and unstable Ice tiger coi Trigger | Shor circuit plugeleetrodes Ry Li place trues coil Erk cit GoM] as patoveraftie paige | Theat doen wat | Replse tigger el Sot rent No spatove ofthespark plug lectroie | The engine does ot tart Replace ignition switch Ianition swish faker cit ia ‘The engine does top. Replace ignition switch DI tga : cr mae Nosparkover othe sparkplug lero | The eine doesnot sat, | Replace CDI ignition un atic tos rc, re Short ciruit Weak oro sparkover of thespark ne | cen engine power and unstable pe dlotrodee ie peed Broken cieui reisane ee [No sparkover ofthe sparkplug electrode. | The engine doesnot start. Replace ignition coilLZX200GY-2(EC)Maintenance Manual Maintenance of signal system tum on ignition switch to check indicator and check signale system as follows. dismantle battery and measure voltage, remove battery to charge if below 12V battery dismantle charging loop socket and check short circuit of charging loop. change magneto charge loop. check rectifier by multimeter. -103LZX200GY-2(EC)Maintenance Manual L28TAR dismantle fuse to check and change same type fuse if necessary dismantle signale system falsher socket and check short circuit of falsher, change falsher if necessary. dismantle left controls switch and check rast or contact of turn indicator switchm repair or change left controls switch if necessary. signale indicator switeh, check turn light bulb and change bulb if, necessary. -104-LZX200GY-2(EC)Maintenance Manual LP STAR check contact of brake light socket and tail light socket, tighten socket if necessary check operation of brake light and adjust or change brake light switch if necessary. rear Drake light check tail light bulb and brake light bulb, change bulb if necessary. check rust or contact of horn switch and repair or change left controls holder if necessary 105 hom switehLZX200GY-2(EC)Maintenance Manual adjust horn sound or change same type horn if necessary. hom socket check contact of neutral indicator socket, neutral indicator socket 3 Maintenance of Signal System Compe ae atic peo ‘serpton | ___ Page prema pee Rest mad SR | be ete winter a |Winker switch] Poo" connection of inner cOn- | Poor connection of winker switch ss Poersene kes ou ot wok Fee eae coe Seas ey Flasher nner partis burt out | Winker is out of work or not lasing, [Replace fasher Brake Hight | ine contact isnt toretrst© | ter contac isnot to tum tothel Braking light is on all the ime or switch | the position or damaged Sra ca arise ut of work Replace braking ight site Rear light? | The iat laments of rear tt brake light | and braking light are turn out | [E84 Blament fra liek an braking light are burt out ‘Rea lihubeaking iaisout of work [Replace ex lishing Poor connection of inner con Hom button Poor comestion of hombutton in| Elestre hom is out of work or has | Repair orreplacehom button tae or dazed er coact o dag atmormal sound Bectric horn | ime ablation or damaged | Electric hom ier partis bum out Eesti hom is out of work OF B95 Ie oisce tre hom ie sbnormal sound eutal sitch| Poorconection ofswitch | The neutral indicator switch hs! he natal indiatr is ut of work. [Replace nana switch oor comestion -106- Neural | he lame is bur out, | Theneura intr filmer stu rye neural indiewtor is ou of work. [Replace neutral inictor indicator ut or daagedLZX200GY-2(EC)Maintenance Manual Maintenance of Illuminating System Disassemble, assemble and maintain illuminating system tum on ignition switch to check headlight, Check battery electrolyte and add electrolyte then charge if below lower line. measure output voltage of reotifier and change rectifier if below 13.0V. the output voltage should be 13.0V-14.5V. remove charge loop socket and measure short cit- cuit of charge loop, change charge loop. -107LZX200GY-2(EC)Maintenance Manual L28TAR dismantle battery and measure voltage, remove battery to charge if below 12V. remove fuse to check and change same type fuse, dismantle left controls switch and check rust or contact of headlamp, change left controls switch if necessary, unscrew fixing bolt of headlamp mask and re- move headlamp, -108- headlamp masicLZX200GY-2(EC)Maintenance Manual remove headlamp switch socket to check socket, sotket remove headlamp socket to check contact of socket. socket remove high beam socket, low beam socket and passign light socket to check, remove headlamp socket to check contact be- tween headlamp socket and headlamp bulb. -109 socket-110- LZX200GY-2(EC)Maintenance Manual remove headlamp bulb to check burn and change same type bulb of 12V3SW/35W fit headlamp bulb and socket then check opera- tion of headlamp bulb cheek bulb fa Maintenance of Tluminating System Component “Trouble symptom “route symprom description of component of motoreyele Repair method Insufficient output voltage of anc [Coldcut nation. | ATC HOSTER tae iin gneve | Rep il iuminating veil | Cail crit is broken, ‘No output of illuminating cot | Head tight i ia defective evel. | Replace coil Light bundle is not properly | The head light bundle is too Adjust the head Tih bundle tiead tight | adhsted near oF tof. i i assembly | The filament of head light is| The filament of head light is ha = "| Head tights ia defective evel. | Replace head ight bulb [Rear lighv/brake] The filament of rear light and] The filament of rear light and| The filament of rear light and fight [brake tight is bumt out brake light is bumt out, brake light is bumt out, a ee ittuminating tight Poor connection of inner €on-| Poor connection of inner con- | Itiumianting light is abnormal | Repair or replace illuminat- fad ner wit |*2Ct OF it is damaged. tact or it is damaged, ‘of out of work ing/high-low light switchLZX200GY-2(EC)Maintenance Manual Maintenance of electric start control system Diasssemble, assemble and maintain electric start control system turn on ignition switch and check electric statt igmition switch remove fuse to check and change same type fuse. dismantle battery and measure voltage, remove bat- tery to charge if below 12V check electrode plate and change battery or add electrolyte unscrew fixing bolt of electrical start button to check short circuit of electrical start switch, change electrical start if necessary. Z -111 electrical start buttondf qq LZX200GY-2(EC)Maintenance Manual L28TAR check connector of battery anode and cathode, tighten connector immediately if necessary. battery ‘measure output voltage of rectifier and change rectifier if below 13.0V. the output voltage should be 13.0V-14.5Y, remove charge loop socket and measure short circuit of charge loop, change loop if necessary remove relay and measure short circuit of relay, change same type relay if necessary. -112-LZX200GY-2(EC)Maintenance Manual check connector of relay wire and tighten connector. check operation of motor and dismantle motor to repair or change if necessary turn on flameout switch and press electrical start button change flameout switch if vehicle can not be started by electrical start button. \ electrical start button check short citcuit of clutch electrical statr con- trol switch and change if necessary. -113 \ electrical start contiol switeh,LZX200GY-2(EC)Maintenance Manual remove side stand switch and measure short circuit, change if necessary. start Switch 1s Maintenance of Electric Starting Control System Pee Damage form Trouble symptom “Trouble smpom of mtorgele Repair method Inet coil ret is shor oe Juaernetorisout of work torte isinposble to startup | Replace stating relay Starter relay [EE a Inner contact is ablation Starter motor rotation is ineffec- IMfotoreyle is impossible to Mart Replace starting relay ive i Starting | Poor comestion of ner €0- |e. water gonofwek [eoraeleisinponte to mertop | Replace baton Pushbutton |raet oF damaged [No output or insufficient oUt: [starter motor is out of work oF Battery ¥ | put rottionsinetTetive [Motorcycle is impossible to art up | Inspect battery -114-LZX200GY-2(EC)Maintenance Manual Maintenance of meter Dismantle, fit and maintain meter turn on ignition switch to check neutral indica tor and operation. ignition switeh remove fuse to check and change same type fuse. dismantle battery and measure voltage, remove battery to charge if below 12V. check electrode plate and change battery or add electrolyte. dismantle odometer cable stly then unscrew fixing bolt of meter and remove meter. oN -115 odometer cableLZX200GY-2(EC)Maintenance Manual dismantle meter cover to check indicator bulb and change bulb if necessary. check operation of odometer,tachmeter and fuel gauge, and check if indicator bulb is bumed, change bulb if necessary remove meter core to check odometer core, tachmeter core broken, change meter assembly if) necessary, 7-6 Maintenance of meter err ‘Damagetform ‘Troublesymptom of component | Trouble symptom ofmotoreycle | Maintenance method description pikes indicator IAN inger indicator filament is bunt out | Winker indicator scat of work. is unt out Replace winkerindietor meter ional eer thuminator tment is bu ut uminatr i tof Work Repl ty_|is burt om tal speedon ris damaged. | specter is damage Speedometer it of work | Replacespeedometer =116- ‘Tachometer is damaged. |Tachometer is damaged “Techomter ist of work ReplaetachometerLZX200GY-2(EC)Maintenance Manual Chapter 8 Analyze of MotorcycleTroubles 8.1 Analyze of Engine Trouble 8.1.1 Analyze of engine idle speed failure Engine idle speed failure T [ERT ETT TTI a Tl [Engine has no idle speed Iiesiile pose iatioo lng [Engine idle speed is we Os ras 7 T cl pgiadar a Pull the eabureiorvalve tochedk| [Check whether the engin pressure, cov whether it is completely closed ignition is on timing, Lereseure oe vce Oy f 1 1 1 LS = ee o Insufficient of the Ses ee ia Normal of the | [Check | [Check the whether] [Check eee evlinesr comPress) | eylinder com- | | tether the| |the iron line of the | | whether tate of the CDI pressure ; ress pressure ||itejetis ||gun control cables} |the spark| —lipntion system over large | | is flexible in the plug gap Dh _ 1. Check whether th piemar c ak |2. Inspect the Tay gine: cable sleeve or the| |is narrow! ot engine outside connect- ee Imagneto fly throttle spring is vt ing parts have leaks; ua oe = a 8 Ee ‘ ‘wheel and trigger| 2. Check whether the | |5P°* Fs = \coil for tightness air inlet and exhaust is oan serge ey Engine now has] [Engine without | 3. Check whether the | | idle speed idle speed r aT aan valve clearance is | limproper adjust-] [Check whether the Adjust the electrode ea Iment of the car-| | carburetor idle jet, 4. Check whether the | [PUtor air adjust-| | idle oil channel and ing screw or the| | airchannel is sirprootofthe valve and | liroite adjusting| {jammed valve seat is in good | |screw aN Yes condition; f 1 5. Check whether the Check whether the Stee carburetor float over high or the insufficient pyre me rere PS aN spring; [Adjust the float height to the . Check whether the insulator of 6. Check the condition |_| standard data or replace the float the carburetor is cracked: of the piston ring and 2. Inspect the carburetor fitting cylinder nut for tightness “117LZX200GY-2(EC)Maintenance Manual 8.1.2 Analyze of engine power insufficient Engine power is insufficient 1 Hold the main stand to make the wheel away] from the ground,rotate the wheel by hand F 1 ‘The wheel rotate freely ‘The wheel rotate hardly 1 Chains Genus of thd wheal T. Check whether the brake is delay; - 2. Check whether the wheel shalt is over en wom or damaged; TDresuie Ww the law ee ea 3. Cheek whether the hub is short T 7 (Check whether there is air leakage | {Remove the spark plug.plug up the Iiom the tire valve element or the | |thread hole,then press the starting [button or step on the starting pole i [The finger can feel the strong The finger can not feel outward gas and the sound the strong outward gas tire is broken, he eylinder press ability 1. Check whether the engine Start the eres the ar side oe mace gradually to check the engine rotate changes| See en ate an ant (tt el exhaust is on timing, ‘The engine rotate speed increased | |The engine rotate speed 3. Check whether the valve with the enlarge of the gun not increased with the sthacaiies 6 Soariole. enlarge of the gun 4. Check whether the airproof of 1 ‘Check whether the engine ignition is on timing es a ea SS . condition, We SS 5, Check whether the piston ring 1. Check whether the fuse supply system is |]. Check the state of CDI || is damaged or the spring elasticity through; ignition system; is insufficient; 2. Check whether the carburetor.air 2, Inspect the magneto |] 6, Check the condition of the icleaner,muffer exhaust is jammed, flywheel and trigger coil. | piston ring and eylinder |3. Check whether the carburetor float for tightness, height is properly -118-LZX200GY-2(EC)Maintenance Manual 8.1.3 Analyze of engine starts hard or fails to start Engine starts hard or fails to start r (Check the ignition system [Remove the spark plug.check whether the electrode is carbon connected ee Do the spark experiment of the spark plug | [Remove the carbon deposit | r No spark or dim spark from the electrode ] T Dismantle the spark plug cap to do| ‘Check whether the engine ignition is the high voltage spark experiment on timing by the ignition timing light Bree ENO a eS [Strong blue or purple spark from the electrode] 7 [Check the state of CDI ignition | {Loosen the earburetor (cERERTAEca| isystem, ‘drain oil screw.check 2)Inspect the magneto flywheel | | whether there is oil out spark plug spark plug} (Dimsparieor] land trigger coil for tightness from the carburetor cap with trouble race ‘ overflow pipe £ I T 1 Yes, [Check the supply [Check whether] {Check whether the [Check whether] = {condition of the ||the ignition coil Ithe CDI ignition col ignition system Lytinder ignition power |is tumoff or || inside is tumoff or| ignition system pressure supply Ishort circuit _ | |short circuit is with trouble % a ¥ ? T i 1 WESC eyinden presse Insufficient of chee arb etentie) Wt Tea Peace eae Meeerrieees cylinder press ability] Plowhole is jamed:2) Jin ee T theck whether the oil the ee T)Check whether the engine outer connection part liter and switch is eat 1-Check whether thas leaks;2) Sheck whether the air inlet and ‘exhaust is on timing:3)Check whether the valve ‘clearance is narrow;4)Check whether the seal of Ihe valve and valve seat is in good condition;5) (Check whether the piston ring is broken or |clamped in the groove ;6)Check the condition of [piston and cylinder jammed;3)Check whether the ignition power the fuel switch is in good supply is broken ondition;4)Check ihether the carburetor oil inlet hole is jammed5) Check whether the float lor short circuit; 2. Check whether the trigger coil is, broken or short is too high cirouit i 1 ‘Wet spark plug electrode [Dry spark plug electrode T 7 [Check whether the oil is overflow in the carburetor| Drop a little oil into the cylinder and try to start 7 1 esi No r fc 1 1. Cheek the seal condition of the carburetor float] {Check needle valve and seat; [Running time is short| [Can work continuous whether 2 = 2. Check whether the surface of the needle valve| |ine air [Trouble with the carbure- is worn, eee tor starting system a 3, Check whether the carburetor float is damaged;| | "7" eater a incase 4. Check whether the carburetor float is too low aLZX200GY-2(EC)Maintenance Manual 8.1.4 Analyze of engine overheat [Engine is overheat T T Check whether the control way is correct Mee 1, Check whether the oil is lower than the| [brand or storage time is too long; 2. Check whether the engine is in the high speed condition or overload Check whether the engine ignition is on timing Check the cooling system i Cool the engine by wind T [Check whether there is sand or ofl dirt on the radiating fins i Yes Clean’ Yes T, Check the condition of CDI 2. Inspect the magneto wheel and trigger coil for tightness. The clutch is slid (Check whether the clutch is skid ignition system; ro [Remove the spark plug and judge the mixing ratio of the mixing gas according to the colar lat the bottom of the insulator and other ‘abnormal symptom 7 i 1 The bottom of the spark plug is black, black fuse or fire a gun during the engine in the The bottom of the spark plug insulator is brown ‘The bottom of the spark plug is white,intermission middle or low speed,acclerate performance is insufficient, speed is instable during idle run, ‘Normal mixing ratio of the mixing buy gas during acclerate,carbure- tor is backfire, insuffeient normal in high speed running, r power of the engine E 1 I [Thick of the mixing bury gas_| |Check whether T the vent of the 1, Check the air cleaner, cylinder and 2. Check whether the carburetor muffler is starting system(iethe starting | | aimed thickness system) is in good condition: 3. Check whether the carburetor float is too low -120- [Check the lubrication system | [Thinner of the 1, Check whether the oil is insufficient in the crankcase:| 2. Check whether the oil is lburny mixing gas 1. Check whether the {fuel switch is in good lcondition; lover dirt or viscosity is low; 3. Check whether the oil | |2 filter is jammed; 4. Check whether the oil pump is in good condition: 5. Cheok whether the lubri- cation channel is jammed Check whether the lcarburetor float is too high; |3. Check whether there is jam on the carbure- ‘tor jet and channelsLZX200GY-2(EC)M aintenance Manual 8.1.5 Analyze of engine oil over consumption Engine oil over consumption H Check whether the contral and use ways is correct Yes No iota the main stand and rotate the wheel| { [The wheel rotate unfieely T a 1. Check whether the brake is | Check the pressure of the wheel delay, T 2. Check whether the wheel f shaft is worn or damaged: || PTes8ure 18 too low | | Pressure is normal 3. Check whether the hub is i T i Charge accord- ‘Check whether the oil tank,oil switch, ote ing to the rule 1. Check whether the motorcycle is over- load when driving, 2. Check whether the oil brand is correct The wheel rotate freely 1 oil channel.carburetor have leaks Remove based on the practical Check the mixing ratio of the bumy gas T | Thick of the burny mixing gas ] Nommal ofthe missing ratio “Thinner of the burny mixing gas 7 T T Check whether the engine 1. Check whether the air 1. Check whether the carburetor idle speed is over high cleaner is jammed; is jammed; 2. Check whether the carbure- tor float is high wa No 2. Check whether the carbure: (Check whether (Check and adjust the carburetor _| |the engine ignition is nomal tor float is lower, 3. Check whether the carbure- tor main jet is over large Chee the ignition system -121LZX200GY-2(EC)Maintenance Manual L28TAR 8.6 Analyze process of clutch skid (Clutch is skid Oe peers ‘The handle control wet multiplate clutch is skid 20mm arrange Yes (Check whether the iron line of the clutch control cables is freely in the cables sleeve| ee ae cee RS DS PRS Clean, lubrication or replace Check whether the oil is less in the crankease| ee a Se Full in the oil Check whether the oil of the erank- case is dirt or lower in stickness T jie pate ae OE on BE S| Replace the oil Cheek whether the press bolt of the clutch is flexible, 1 2. Check whether the clutch friction dise is ablation or wom; 3. Check whether the clutch spring is insufficient; 4 Check whether the clutch driven hub,clutch press plate and| the clutch friction surface is over worn; 5. Check whether the clutch drive hub and driven hub gear [groove is worn to the sawtooth 8.7 Analyze process of blue white thick fuse of the exhaust muffler Blue white thick fuse of the four stroke engine exhaust mufiler Check whether the oil position in the crankcase is over the upper marked line ef ae anette oleae meena [Too much of the oil in the Start the engine, dismantle the oil ruler to check] lcrankcase,drain the excessive whether there is fuse in the oil put in hole oil to make the oil position | No, z Yes 1 match the upper maked line _|/(Check whether the valve and valve| [1, Check whether the oylinder, guide pipe clearence is over large Nes Check whether the valve and valve (Oil seal of the valve guide pipe is over worn is damaged pistion pistion ring is over damaged; 2. Check whether the pistion rin spring is insufficient or clamped in the ring groove, ~122- 3. Check whether the pistion ring| split position is seperate 120.LZX200GY-2(EC)Maintenance Manual 8.8 Analyze process of clutch disengage imcompletly (Clutch separate micompletly 7 Check whether the free stroke of the clutch is within10mm-20mm. Np ee is (Check whether the screw of the clutch pull rod is properly SSS ae ‘Check whether the clutch drive and driven Replace the set of the hub gear groove is worn in saw shape clutch spring completly (= ay Repair or replace |__| 1. Check whether the driven clutch plate is hold up; 2. Check whether the clutch control mechanism (i.e separate cam,separate pull rod ete. is over worn 8.9 Analyze process of difficult to gear change ‘Transmission is difficult to gear change r [Start engine,check whether the idle speed is too high Check whether the control of the gearshift s correct jee i Check whether the clutch spearate not entirely Improve the control method Ninn aa eel Check whether the gear shaft is de- 1. Check whether the clutch handle free stroke formed or the gear arm is over worn is within 10mm-20mm; Ya 2. Check whether the clutch spring ability is equality: 3. Check the clutch drive and driven hub gear ‘groove is wom in saw shape; 4. Check whether the friction dise is hold up; 5, Check whether the component of the clutch. control mechanism is over worn 1)Check whether the gear cam groove is over wom or damaged: 2)Check whether the fork is over wom; 3)Check whether the fork is deformed; 4)Check whether the fork shaft is deformed or over worn =df qq LZX200GY-2(EC)Maintenance Manual L28TAR 8.10 Analyze process of transmission shift ‘Transmission shift Check whether the dowel spring is broken or insufficient Yes No a oe Replace Dismantle the crankease,check whether each gear approach depth is accordance with the standard r Enough of the approach depth Insufficient of the approch depth 7 r Check whether the approch end of the eam surface | _ [Check whether the fork is over worn or damaged] is wom to taper or circularity,and the corresponding peers ence ear surface groove is worn to evase type T oe ean Replace the gear 1, Check whether the fork hole and fork shaft is over worn; 2. Check whether the fix of the Check whether the main spline and sub spline gear and the spline groove of the sliding gear is over wom transmission is correct -124-LZX200GY-2(EC)Maintenance Manual LP STAR 8.2 Analyze of Electric System Trouble 8.11 Analyze process of battery discharge Battery dischage [Dismantle the package between the magnetic motor ead an vehicle cables.then check if there is any broken between the illuminating output coil and ground by ohmmeter Ne Oo ee Ol) (Get through the package between the magnetic motor [Resistance is infinity lead and vehicle cables,cut off the package between the T rectifying regulator and vehicle cables Yes poe 2 No Broken of charging coil (Check whether there is any broken between the or output lead illuminating output coils by ohmmeter T [No display of voltage] Voltage is in gear| i 7 Cireuit broken between the | [Check whether there is any troubles in the package to the battery lead rectifying regulator by ohmmeter 8.12 Analyze process of battery insufficient charge insufficient charge of battery | Check the brake light Yes No i the multimeter into the OV-20V DC gear to mesure the | __[Insufficient connecting or short circuit from the| voltage from the musering package to the red thread magnetic motor to rectifying regulator circuitr battery. And connect negative of current pole, positive to positive pole to check current leakage | [Cheek short circuit of magneto cahrge coil | ‘Adjust or replace the brake light switch) [Put ignition switch to “OFF " dismantel negtive pole from meter to the negative Leakage current is less then standard value| ‘Leakage current is more then standard valuc T (more than ImA normally) l short circuit or broken circuit in rectifying regu: if S No lator or between the battery to the ignition switct Replace T. Check electrolyte of battery: illuminationcoil | _|2. Check specific gravity of electrolyte 3, Check short circuit of pole plate -125-126- LZX200GY-2(EC)Maintenance Manual 8.13 Analyze process of starting motor without rotate Starting motor without rotate ‘Turn on the ignition switch,press the hom button or tum on the winker switch a [There is no or weak sound of electric horn loud sound from electric hom, bright light of| the winker Insufficient charge off [battery.or lead lose conatet There is no sound of the starter relay| | There is sound of the starter relay when press the starting button ree eee l Use the scraper or lead to short circuit by con- nect the battery coil to the starting motor coil [Dismantel relay package from vehicle cables,then con- Inect battery positive and negative pole to relay coils by two leads : 1 motor ean rotate motor can not rotate starting motor is stil not | [Fhe starting motor is rotating | 1 T [contact of start-| [Disassemble starting moto: rotating,and no sound Check the inner ofeuit oF | ing relay is abla-| |and check as follows: electric starting control system | rion or damaged | |1- Check wear af carbon rust Short circuit or broken of t 2. Check brush spring 1. Check inner contacto of clutch Se ee 2. Check contact of starting button ae 3. Check broken ci it or short circuit of from starting relay starting relay 4. Check broken circuit o1 eclectrie starting control system hort Gitnit af arctan ae 8.14 Analyze process of motor rotate with disability ‘motor rotate with disability ‘Turn on the ignition switch,press the horn or tum on the winker switch no sound or weak sound from eleotichom]) [low sound ffom electric hom bright light of winker | TRaRICIEAT chenge oC battery. lem Check lead contactor between relay and motor joint lose contact No Yes Dismanile connecting lead of motor and battery, press button, {Check and remove When sound from relay, mesure resistance between motor connecting pole and battery connecting pole by ohmmetor Yes contactor of relay is ablation or damaged [Mesure resistance by ohmmetorLZX200GY-2(EC)Maintenance Manual 8.15 Analyze process of illuminating lights all out of work Illuminating lights all out of work ODE TS Aiea ae AC supply illuminating system DC supply illuminating system T Dismantle the packages between the mag- Press the hom button or turn on the winker light netic leads and the vehicle cables.use try the eee Lound sound of the electric | [The electric hom and the magnetic illuminating leads hom,winker is working Iwinker is out of work T r 4 2 Battery supply in gear | [Scull the anode and cathode The light is out of work | [The light is working z : by a lead to see the spark of] T ‘The magenetic lliminating_||Star the motor dismantle the mesure by multimeter il or output Teads is broken || package between the rectify a or short circuit Peeve esti ‘No spark when scull| [Spark and voltage pases brane or no voltage is in gear i t light to check whether there is output from aca Allsenis tina aki No power of] [Check whether the fuse pt wore ua the battery_| is fusion: Short circuit in the Check whether there is rectify regulator Dismantel the head light component,check broken or short circuit Whether the head light bulb is burnout between the battery and Se the switeh; Replace the head illuminating | [Try the light to check whether there is] |Check whether there is light bulb and check whether | output of power from the illuminating switch | | broken or short cirouit other bulbs are bumout | Yas; 7 No |i ignition switch Short circuit the power supply lead and the Broken or shotr circuit of the joutput lead of the illuminating switch by lead | | magneto or illuminating switch Tr ae! illuminating light Mluminating light is is working out of work 7 r Insufficient contact of the illuninating] | Broken or shotr circuit from the illuminating, switch inner contactor switch to the illuminating light -127LZX200GY-2(EC)Maintenance Manual 8.16 Analyze process of illuminating lights easy to burnout bulb is easy to bumout Switch ignition switch press hom button or switch winker a eer ge asa oR creer ea ee eros ‘Loud sound from electric hom, bright light of the winker work. weak light of winker : [Disconneat part of rectify regulator and vehicle T 1. Check contact of battery lead ‘cables, mesure broken circuit from magneto illu- 2, Check electrolyte in battery, ‘minating coil to regulator by ohmmeter T 3. Check specific gravity of battery electrolyte a re 4. Check short circuit or sulfuration of pole plate Put the multimeter to the OV- engage 20V DC gear,mesure the voltage between the package and battery red ground lead T Saag Set [No symptom of voltage Symptom of voltage T 1 [Broken circuit from oart to battery [Check regulator 8.17 Analyze process of illuminating lights dim light weak light of winker T cha a a ay Be AC supply illuminating system DC supply luminating system i [Disconnect part between magnete leads and vehicle cables,] [Press the horn button or turn on the winker light heck resistance between illuminating coil output leads r Loud sound from electric hom bright light of winker Raucity of the electric hhorn,dim light of the swinker light Start engine and limit rotate speed. discon, nect part of regulator and vehicle cable,check| illuminating light i Replace the luminating coil el [ iluminating light is in operating] flight of the luminating Hight is stil weak 1 r froitane of regulator is too low | [Check short circuit oF charg coil of magneto and charging system we 1_No_ Repair and remove Dismantel head light component, check head light Bulb ——— ee insufficient charge of battery, oi ‘ontact between battery an: ition switch lose contact heck bulb poweer of the illuminating system [Replace the head ight bulb Yes : No. 1. Check contactor of luminating switch and Replace the illuminating light bulb -128- high/low beam switeh 2. Cheek contactor of partLZX200GY-2(EC)Maintenance Manual Winker out of work All winkers of one side out of work T Press the hom button to Part winkers of one side out of work x T Dismantle the winker Dismantle the winker llens,check whether the llens,check whether the check the electric hora bulb is burnout bulb is burnout No sound or Ser ar pra ag RNS Xs No raucity of the [Replace ] [Mesure the voltage between ||Replace | [Dismantle the pack- electric horn ithe bulb | |the light seat and the ground ||the bulb | /age of the winker , r 7 ‘check whether it is | [Supply of [The battery| fos oeee eyed Voltage is in gear ‘No voltage ‘through in the winker| |the battery lack of L c ‘swith by ohmmeter | |is in gear power Insufficient of the | [Broken of the : = Yes 5 {No ; ——————— > Abnonmal Broken or short circuit re [The igni nn switch] [Cut the ignitioner output tie-in is damaged ito mesure the voltage r Have voltage [—____No voltage ? ‘The magneto wheel is severity lose of magnetism of the charging coil and. trigger coil r i ‘The ignition coil is ‘The electric ignition Full inthe Repair or replace broken or short circuit is damaged magnetism r 7 -131 or replace Replace ReplaceLZX200GY-2(EC)Maintenance Manual CIRCUIT DIAGRAM -132-LZX200GY-2(EC)Maintenance Manual k LP STAR Copyright reserved by Zongshen Group rmat 210mm X 285mm Edition Istedition Dec.2005 Print Istprint Dec.2005 -133