Preface

Thanks for purchasing VOGE LX300 GY-G ( DS2)

This user manual introduces the main specification, basic structure, adjustment method and
maintenance skill of this motorcycle. This user manual will make you know well about the basic
operation, and how to eliminate common malfunctions, so to make the motorcycle play its best
performance, decrease malfunctions, and prolong its service life.
Please ware the helmet when driving the motorcycle for ensuring safety, also the passenger.

Warning/Caution
Read this book and keep firmly in mind the essentials. We use words such as “Warning” or
“Caution” for differentiating the importance of issues need be paid attention to, please carefully
comprehend their exact definition.
Warning — This word indicates the issues involved personal safety of the driver, and neglect of this
issue may lead to injury.
Caution — This word indicates issues need to be paid attention to, which are relative to motorcycle
operation and its maintenance.
 List of content
Matters need pay attention to. . . . . . . . . . . . . . . . . . . . . 1 Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1. Safe driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Checking and adjustment of valves clearance . . . 24
2. Main parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Clutch lever adjustment . . . . . . . . . . . . . . . . . . . . . . 25
3. Structure of motorcycle. . . . . . . . . . . . . . . . . . . . . . . . 7 Adjustment of brake pedal . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parking stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Meter indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Repair and maintenance of Fr.&Rr. Disc brake . . . 26
Fuel evaporation control system . . . . . . . . . . . . . . . 11 Driving chain adjustment . . . . . . . . . . . . . . . . . . . . . 28
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake switch adjustment . . . . . . . . . . . . . . . . . . . . . 28
Power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel filling-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back-view mirror adjustment . . . . . . . . . . . . . . . . . . 12 Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Handle bar adjustment . . . . . . . . . . . . . . . . . . . . . . . 12 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Air pressure in tires . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Right switch assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Table of fastening parts' specific torque . . . . . . . . . 32
Left switch assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Periodic Maintenance Plan . . . . . . . . . . . . . . . . . . . 32
Gear shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 7.Motorcycle washing . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5. Matters need pay attention to during driving . . . . . 17 8.Maintenance for long-term storage . . . . . . . . . . . . . 35
6. Checking, adjustment and maintenance . . . . . . . . 19 Storage and maintenance . . . . . . . . . . . . . . . . . . . . 35
Oil checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Recovery of using . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 9. Electrical starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 10.Electrical schematic diagram . . . . . . . . . . . . . . . . . 37
Coolant replacement. . . . . . . . . . . . . . . . . . . . . . . . . 20 11. EFI System schematic Diagram . . . . . . . . . . . . . . 38
Spark plug checking . . . . . . . . . . . . . . . . . . . . . . . . . 21 12.Operation and maintenance of the EFI System . . 39
Checking and replacement of air filter . . . . . . . . . . 22 13. Battery charging reminder . . . . . . . . . . . . . . . . . . . 39
Adjustment of throttle cable . . . . . . . . . . . . . . . . . . . 23 14. ABS special reminder . . . . . . . . . . . . . . . . . . . . . . . 40
Matters need pay attention to

Matters need pay attention to for smooth driving within long term:

(1) Use and drive as this user manual says to ensure safe driving.

(2) No refit at will is allowed for accessories and circuits.

(3) Do the routine maintenance as this manual book shows.

(4) Check before every driving to ensure the bolt fastening, tire pressure, oil and coolant are normal.

(5) Maintain the motorcycle as this user manual says during parking to ensure the use after it.

1
 1.Safe Driving
Regulation of Safe Driving
1.Check motorcycle before starting engine to avoid damaged parts and possible accidents.
2.Motorcycle driver mustn't drive before passing the examination and getting driver's license of Traffic
Management Department, and lending motorcycle to a user without driver's license is not allowed.
3.For avoiding injury, give your whole attention on operation when in driving. Please pay attention to:
Please do not get too close to other motor vehicle;
Please do not compete for road;
4.Strictly adhere to local traffic regulations.
Over-speed driving caused many accidents, so speed exceeding permission scope is not allowed.
Turn on the turning signal lamp when changing lanes to inform other drivers.
5.Pay a special attention to driving when at crossroad, driveway, or the doorway of parking lot.
6.Firmly grasp on the grips with both of your hands, and step on footrests when it is in running.
7.The storage rack is designed to store light-weight goods. To avoid unexpected movements that cause
danger, please firmly fix the goods to the rack.
8.It is forbidden to shift gears from neutral to a low level (gear 1) in high speed running.

Protective devices
1.For ensuring your personal safety, please wear protection equipment such as safety helmet, face
shield, dust spectacles, and gloves during driving.
2.The muffler is very hot in driving, so for avoiding scald, it is strongly recommended to wear boots or
other wearing that can cover the driver's leg.
3.It is not allowed to wear loose wearing in driving, or it may grasp the operation arm, starting pedal,
2 footrests or wheels and endanger the driver
 ★Motorcycle refit
Caution:
Motorcycle refit and original devices replacement are illegal, for those measures can 't guarantee the
safety in driving. Our company will take no responsibility of those unauthorized refit motorcycles.

Warning:
It is not allowed to add or change the wiring system (or the alarm component) without authorization.
When fuse is cut off, it is not allowed to replace it with copper wire or the fuse with different capacity.
The motorcycle close to fire is not allowed to avoid be burned.
The motorcycle is burned or damaged due to reasons above, our company take no responsibility.

Checks before driving

Carefully check the motorcycle before driving according to the table below.
Checking items Contents
Handle bar Flexible in turning, no clearance and looseness
Brake Brake lever and brake pedal should have correct clearance, and brake lamp should light on when it is at braking.
Fuel storage Enough for the traveling plan
Gear box Check oil level, and supply if needed
The throttle handle and the throttle cable should have suitable clearance.
Throttle The throttle should perform smoothly in acceleration and firmly in choking.
Clutch Cables with suitable clearance and no stagnation
Tyres Correct air pressure, no crack on the surface
Transmission chain Suitable tightness and with proper lubrication oil
Lights and horn Check the performance of lights and horn
Check the oil gauge of engine and confirm the correct oil position Check the
Oil Coolant overflow pot to confirm its normal level, and fill up when it is necessary 3
Essentials of driving

Warning:

1.In case this is your initial driving of this model, it is suggested that you find a road of
nonpublic use for practice until you know well about the control and operation of this model.
2.Driving with single hand is dangerous, please firmly hold the motorcycle with both hands,
and make sure your feet step on the pedals. In any case, it is not allowed that driving without
a single hand.
3.Before turning, please decrease speed to safe level. Please don't shift gear or decelerate in
turning.
4.Tires are weak in frictional force when driving on a wet and smooth road, and that may
weaken the braking and turning ability of the motorcycle. In this case, please decelerate in
advance.
5.Crosswind usually occurs at the exit of tunnel, in valley or when an oversize vehicle is
overtaking. You must be careful and stay calm in these cases, and, please decelerate.
6.Follow the traffic regulation and limit your speed.

4
2.Main technological parameter
Name Parameters Name Parameters
Length 2150mm Braking deceleration GB20073
Width 875mm Max grade-ability 17°(≥30% )
Height 1405mm Bore × Stroke 78×61.2
Wheelbase 1430mm Compression ratio 11:1
Curb weight ≤158kg Max net power/Rotational speed 21kw/9000r/min
Loading 190kg (including driver) Max torque/Rotational speed 25N.m/6500r/min
Max. allowed weight 348kg Rotational speed under low idling status (1500±150)r/min
Front axle loading 78.5kg Engine type Water-cooling, single cylinder, 4-stroke
Rear axle loading 79.5kg Working volume of cylinder 292ml
Front tire size 3.00-21 Spark plug B8RC
Rear tire size 5.10-18 Spark plug gap (0.7~0.8)mm
Max. speed ≥125km/h Inlet: (0.10~0.19)mm
Valve clearance
Min. ground clearance ≥310mm Exhaust:(0.15~0.24)mm
5
Main technological parameter(Additional)

Name Parameters Name Parameters

Fuel consumption 3.4L/100km according to GB15744-2008 Piece fuse 25A、15A、10A
Lubricant capacity 1.5L Headlight 12V-35W/35W

Fuel tank capacity 11L Brake light 12V-1.2W(LED)

Transmission box ratio Front turning signal light 12V-1.8W(LED)×2

1 st gear 3.000 Front position light 12V-0.84W(LED)×2

2 nd gear 2.000 Rear turning signal light 12V-1.8W(LED)×2

rd
3 gear 1.500 Rear position light(With registration light) 12V-0.5W(LED)
th
4 gear 1.250 Battery 12V7Ah
th
5 gear 1.050 Ignition method ECU control
th
6 gear 0.905 Meters Liquid screen

Terminal transmission ratio 3.428

Primary transmission ratio 2.8

6
 3.The motorcycle structure
Parts name (The head parts)

(1) Clutch handle (1) (2) (3) (4) (5) (6)

(2) Left back-view mirror
(3) Instrument
(4) Power switch
(5) Right rear-view mirror
(6) Front brake handle
(7) Handle glue
(8) Left hand handle switch
(9) ank lock
(10) Handle tube fastening bolt
(11) Throttle handle

(7) (8 ) (9) (10) (11)

7
Parts name (Body parts 1 st)
(1) (2) (3 ) (4 )
(1) Headlamp
(2) Fuel tank
(3) Seat cushion lock
(4) Rear turn signal lamp
(5) Rear wheel
(6) Chain
(7) Rear shock absorber
(8) Engine model and factory
number
(9) Side support
(10) Shift pedal
(11) Electric horn
(12) Front shock absorber
(13) Front disc brake
(14) Front wheel
(15) Motorcycle product label
location
(frame nameplate, upper left
tube of frame)

8 (15) (14) (13) (12) (11) (10) (9 ) (8 ) (7 ) (6 ) (5 )

 Parts name (Body parts 2 nd)

(1) Rear disc brake (8 ) (7 )

(2) Silencer
(3) Seat cushion
(4) Rear brake pedal
(5) Vehicle identification
number (VIN)
Engraving position (right
side of riser)
(6) Side light sheet
(7) Front turn signal lamp
(8) Auxiliary pedal

(1) (2) (3) (4) (5 ) (6 ) 9

 Instrument indicator light

Ref.No. Part name Note (8 ) (9)(7)(6) (3) (10) (5)

(1) Speed meter It displays speed by km/h

(2) Odometer It displays the motor's vehicle's mileage
This light on means fuel supplement is
(3) Fuel meter needed; Fuel overloading is not allowed
for avoiding leakage during driving
(4) Gear indicator It displays the current gear position
(5) Right turning signal It flashes when turning right
(6) High beam indicator It turns on when high beam is on
(7) Neutral gear indicator It is on when at the neutral gear (11) (2 ) (4 ) (1 ) (13) (12)
(8) Left turning signal It flashes when turning left Instruction for pressing button
① Long press the button MODE > 5s, the
(9) OBD malfunction indicator It flashes when occurs OBD malfunction Metric and Imperial shift begins; Short press
It is on when the engine is starting, and turns < 1s, the ODO and TRIP start their display
(10) ABS malfunction off after the speed is over 5km/h; And if ABS shift (The Total mileage could be displayed)
indicator malfunction occurs it will be constantly on ② Under the mode TRIP, press button
(11) USB interface It is power chargeable RESET > 3s, the single mileage clears to
zero;
(12) Button MODE Shift the display of instrument
Warning:
(13) Button RESET Clear the single mileage to 0
It is important to form a habit of turning on
signal before lane shifting or turning, and
10 turn off the signal after that.
 Fuel evaporation set Gasoline vapor absorbed into carbon tank
Gasoline vapor rejected from carbon tank Fuel tank
Air
The fuel evaporation control system works as below:
1.When the gasoline in the fuel tank is heated, the gasoline vapor Pouring valv e
evaporates and gets to the TANK end through the dumping valve of TANK
carbon canister, and then absorbed by the port.
2.In case the motorcycle tilts over 60 degrees, the dumping valve will Check valve
be closed to seal gasoline from the carbon canister. CANIS TER
PURGE
3.Fresh air comes through the A end of the carbon tank to its PURGE
port, carrying the gasoline vapor into throttle body. And then the mixed
gas gets into the engine through the gas inlet for combustion.
Engine AIR INLET TUBE Throttle valve End A
(to atmosphere)
4.Operation Fuel evaporation control system

Power switch Fuel filling-up

For the fuel tank capacity, please refer to the main
Position Usage Note parameter. When filling-up, support the cycle by its side
stand first, and then open the fuel tank cap. After injected,
OFF For parking (All power off) Key can be removed tightly press the fuel tank cap, remove the key after it
returned back.
For starting or driving
ON (Main power on)
Key can't be removed Caution:
1. Please use lead-free or low-lead gasoline above 90#.
LOCK For locking steering stem Key can be removed 2. The filling fuel mixed with water or other impurities in are
not allowed.
ON
OFF
Warning:
When steering lock is locked, pushing motorcycle is
LOCK not allowed, or it may lead to imbalance. 11
 Adjustment for back-view mirror
1. Adjust the mirror surface parallel to the handle bar;
2. Loosen the nut by wrench(14), leave gap between locking nut and screw rod of back-view mirror.
3. Sit on the motorcycle, because this motorcycle has side stand only, so in case there is no assistance from
others, make the motorcycle upright rely on the wall, then begin the
adjustment, under common situation, one of the back-view mirrors
can let you watch the situation behind you, another side makes 3/4
area behind you in sight. (The suitable positions may be different
among every driver).
4.After finished, fasten the locking nut of back-view mirror again.

Adjustment for handle bar

The comfortable angle for every driver may be different.
Handle bar fastening bolt
1. Loosen the 4 pcs of bolts on handle bar by 90~180º, too
flexible the bolts are difficult for adjusting, so to the position
which the handle bar removeable by hands is enough;
2. Sit on the motorcycle, move forward or backward, then turn
left and right the handle bar for a trial to find out the suitable
angle for driving, then screw up the loosened bolts.
Caution: When screwing up the bolts, the two in front first,
then the rear two.

12
 Engine starting
★Engine turning off
1. Put the ignition key on the position of “ ” .
2. Put the emergency choke switch on the position of “ ”. 1. Release the greaser grip, and slow down the engine.
3. Confirm the neutral gear indicator is on. 2. Put on neutral position.
4. Confirm fuel amount. 3. Put the ignition switch at the position OFF.
★Engine's cold starting
1. Press the electrical starting button.
2. Slightly turn the fuel grip to speed up engine for Engine's running-in
pre-heating when engine started.
The first 1000km is the running-in period for
motorcycles. In running-in period,
please pay attention to issues below:
1. In the first 500km please don't drive faster than
40km/h, and in the second 500km it is
recommended to keep the max speed lower than
55km/h.
2. Don't carry any heavy load or climb a steep
Electrical starting button slope. Carry out acceleration in slow way, and do
★Caution: not drive continuously more than 50 km.
3. Pre-heating for 3～5 minutes before start is
Do not start before neutral gear confirmed, or it may
lead to accident. Idle running is unnecessary and bad necessary for sufficient lubrication of the working
for engine (especially in high speed). parts.

Warning:
It is forbidden to start the engine in a room with poor ventilation due to the exhausted CO gas is
poisonous! And do not leave alone a cycle with its engine in running! 13
Right switch assembly
1. Electrical starting button
The electrical starting button is under emergency switch. When the emergency
switch is put to “ ” and the engine is under neutral gear, press this button to
start.
2. Emergency switch (1) Electrical starting button
When engine in running, the emergency switch is put to “ ” . Under
( 2) Emergency switch
emergency situation，put the switch to “ ” to directly cut down the power and
the engine goes off.
(1 ) (2 )

Warning:
Under continuous starting of engine, each starting should not last for more than 5 seconds, because
large scale of discharges may make the wire system and starting motor abnormally hot. In case
failed starting for several times, please check the fuel supplying and the starting circuit.

(4) (5)
Left switch assembly
1.Dimmer switch 3.Horn switch
Headlight is working at High beam; Press this button to ring the horn;
Headlight is working at Low beam; 4.Overtaking switch
2.Turning signal light switch Turn it on while overtaking. (1) (2) (3)
(1) Dimmer switch
Left turning signal is on; Caution: (2) Horn switch
Right turning signal is on; (3) Turn signal lamp switch
Take care when you are overtaking. (4)Overtaking switch
14 (5) ABS switch
5. The ABS switch
(1) Turn off the ABS system: When the motorcycle is parking, press the ABS switch for 3-5 seconds
and then release, then the ABS system goes off, meanwhile, the warning alarm of ABS flashes in
frequency of 1.2 seconds/each.
(2) Turn on the ABS system: When the motorcycle is parking, press the ABS switch for 3-5 seconds
and then release, then the ABS system goes on. At this moment, the ABS warning alarm is
permanently on. In case there is no malfunction when driving started, the ABS warning alarm goes
off.
(3) Other situations: Press the ABS switch less than 3 seconds or more than 5, the operation goes
failed; In case long press over 30 seconds, the ABS switch is regarded as malfunction, which falls
short of turning off any more, turn on by key again, the ABS function is going on.

Warning:
It is important to form a habit of turning on signal before lane shifting or turning, and turn off the
signal after that.
The ABS is a device for safety, take cautiously when shifting mode or turning off.

15
Gear shifting
Pre-heat the engine for normal working.
(1)When the engine is in idling running, please detach the clutch (tightly grasp the clutch lever),
and step on the gear-shift pedal to make the speed transmission enter the low speed（the 1st）
gear；
(2)Gradually accelerate the engine and slowly release the clutch lever coordinately for ensuring
natural starting.
(3)When got balance driving，decelerate the engine and detach the clutch，draw up the gearshift
pedal to enter the 2nd gear,
and this method could be applied for other gear's shifting. The gear returning could follow the
sequence above, the only difference is stepping the pedal down.
(4)The different gear positions have influence not only on speed but also fuel consumption, the
higher gear uses less fuel, which is important to select gears under different road conditions.

Figure for International 6 gears

6
5
4
3
2
N
16 1 Forward gear
 5.Matters need to pay attention during driving
1)Please avoid idling running especially in high speed, or the engine may be seriously damaged.
2)Clutch working in semi-separation status may wear-out the friction plates.
3)Please shift to low speed gear if the motorcycle performs insufficient power during climbing, pay
attention to safety when climbing, in case bad road was met, choose other roads, the forced
climbing is not allowed.
4)Using front brake only or coasting in neutral is not allowed when running during declining or in
high speed.
5)Watch the back-view mirrors, take care other vehicles in front or behind, slowly take your
motorcycle to opening place right side, then throttle down and meanwhile detach the clutch before
braking.

Warning:
Climbing with passenger or heavy loading is not allowed
1.High speed corresponds to long braking distance. Please correctly estimate the distance for
braking.
2.Singly use the rear brake makes the faster wearing of brake system and the longer of braking
distance.
3.Singly operate the front or rear brake is dangerous, which leads to motorcycle skidding or out
of control. On wet, smooth road or at turning place, please carefully and slightly use the brake
system. Sudden braking on smooth or rough road may make the motorcycle out of control.

17
 Safe driving
1. Before driving
(1). After took medicine or with inattention, the driving is not allowed.
(2). Check the motorcycle carefully without driving the one with malfunctions.
(3). Before driving, wear the helmet, in tight cloths with light color and other protective device for body.
(4). Don't drive when you are feeling bad.
(5). Drunk driving or without license are not allowed.
2. During driving
(1). Keep smooth mood, fine mentality, and pay your whole attention to when you are driving.
(2). Keep even speed if possible and drive on the right.
(3). Please pay a special attention to driving when at the crossroads, get through after confirmed safe.
(4). Turn on the turning signal light before overtaking or shifting lane, moving on after confirmed safe and pay
attention to distance among vehicles and pedestrians.
(5). Drive slowly at night due to short visual range, open the headlight to attract attention from vehicles and
pedestrians.
(6). Frequent sudden braking or lane shifting during driving is not a llowed.
(7). Sudden braking or acceleration shall be avoided for avoiding accident.
(8). Decelerate before turning to avoid side skidding (The front brake under this situation is forb idden to avoid
bringing motorcycle out of control).
(9). The wet road or rainy days the braking distance goes longer due to weak resistance, drive slow ly and brake softly
to avoid locking-up or accident.
(10). In case feel abnormally during driving, stop the motorcycle and check.
3. In packing
(1). Turn off the power supply and lock up the motorcycle.
(2). Stably park by side stand.
(3). Lift the rear wheel by holding rack to reduce tire loading and increase its working life.
(4). Check the fuel, oil, and water leakage for engine.
(5). Keep far away from fire, smoking near to motorcycle is not allowed.

18
 6.Checking, adjusting and maintenance
Oil checking 20W.50

15W.50
It is necessary to check oil before driving. Keep the motorcycle upright
Oil 10W.40 10W.50
on a flat ground and pick up side stand, check through the oil-view
10W.30
window, the level of oil should be between the upper and lower scale line
at this moment. 5W.40

In case the engine is running, turn it off and wait for minutes to let the oil ℃ -30 -20 -10 0 10 20 30 40
-22 -4 14 32 50 68 86 104
reach the bottom of crankcase. Put the engine vertical to the ground and
check through oil-view window 3, whose level should be between the
upper and lower scale line. 1 Overline
1
In case the level is higher than scale line 1, outlet the extra oil. 2 Underline
In case the level is lower than scale line 2, the filling-up is necessary. 2 3 Oil-view window
3
Oil replacement
The complete synthetic oil for motorcycle only above APISNMA2 must be
adopted.
Oil is important for engine, so, periodic checking is necessary. After the first
500km , please replace the specialized engine oil，the second maintenance shall
be at the 5000km mileage, then replace oil each 7500km; 2000km；(Check oil
each 1000km and suitably fill); The oil specification:5W/40-SJ.
Pre-heat the engine and then turn off when oil replacing is needed, the Oil drainage plug screw
replacement shall be done when the engine is warm without completely cooled
down, screw off the oil drainage plug at the bottom of engine to swiftly and totally
drain off the oil in crankcase. 19
Coolant checking
It is necessary to check coolant before driving. Keep the
motorcycle upright on a flat ground and pick up side
stand, check through the water pot on heat radiator, the
level of coolant should be between the upper and lower
scale line at this moment.
In case the level is higher than scale line 1, outlet the
extra coolant.
In case the level is lower than scale line 2, the filling-up is
necessary. Heat radiator water pot

Coolant replacement
The coolant with specification of G40 for engine must be
adopted.
Coolant is important for engine, so, periodic checking is
necessary.
When replacing, remove the cap of heat radiator first, then the
water drainage plug at the bottom of engine to make sure
swiftly and totally drain off the coolant in engine.
Water drainage plug
Caution:
The checking could not be done when the coolant Heat radiator water cap
20 is hot, whose cap could not be removed also.
Replace the secondary oil filter: Replace the secondary oil filter when
replacing oil. Remove the cap of the secondary filter, then take out the filter
A. Assemble the new oil filter and then the cap.
Wash the filtering screen of oil filter, after that, assemble, the fill-up the new
oil by 1.4L and start engine to idly run for 2~3 minutes.
Stop the engine for 1~2 minutes then check and confirm the oil level is
between the upper and lower scale marks, in addition, at this moment the
motorcycle must be upright.
The oil falls short of meeting the requirement or unqualified is not allowed to
avoid malfunction.
Spark plug checking
1.Open the cap of spark plug and screw off spark plug by the spanner.
2.Wash surroundings of the spark plug. If it is corroded or with too much
0.7～0.8mm
sediment, please replace a new one.
3.Adjust the clearance of spark plug to 0.7～0.8mm.
4.Please adopt specified spark plug with specification of B8RC.

Caution:
1.Do not screw up the spark plug too tight or in wrong threaded connection ,
otherwise it may damage the threads on cylinder cover. Do not let impurity get into
the engine through the spark plug hole when disassembling it.
2.The spark plug for this model of motorcycle is carefully selected, which fits most
of the working circumstance. Please discuss with Loncin's distributor first if you
hope to adopt another type of spark plug with different thermal resistance,
because unsuitable spark plug may seriously damage the engine. 21
Checking and replacement of air filter
Draw out the element of air filter to check if it is dirty.
(Disassemble) Remove the right side cover of air filter, draw out the
screw, then remove the element.
(Replace) The air filter element must be replaced if it is found dust
or greasy dirt.
Steps:
1. Remove the seat and right side cover.
2. Remove the right side cover of air filter.
3. Remove the element and replace for the one with same
specification.
4. Do oppositely to assemble on the motorcycle.
Caution:
Please properly assemble the element of the air filter, otherwise
dust or dirt may get into the engine to shorten its service life. Please
don't let water get in the air filter when washing.

Caution:
1.Driving in a dusty circumstance, it is necessary to replace the filter element
frequently, and merely relying on the periodic maintenance is not enough.
2.Check if there are any cracks on the filter element, and in case that any
cracks are found, replace it immediately.
3.The waste gas nozzle is for storing the water and oil from air filter failed
22 return to engine, so the periodic drainage and exhausting is necessary.
Throttle cable adjustment
1.Confirm if the throttle cable's adjustment nut works normally.
2.Check if the free travel of throttle turning grip is within the normal range.
3.The specified free travel is 2~6mm, please adjust it through the Locking nut Adjusting nut
adjustment nut if not matched.

Warning:
Check the turning performance of the throttle turning grip after the adjustment of the
throttle cable. And make sure the engine's idling speed is not higher than before due
to the adjustment. The grip should return to 'off' automatically.

Throttle valve body

1. The throttle valve;

2. The EFI system implements the
auto-adjustment function on idling
speed control, that locks the idling
Idling control valve position. So it is not allowed to do
Idling control any manual adjustment on the
screw idling screw.

Sensor
23
 Checking and adjustment of throttle valve clearance
Wide valve clearance may produce noise. Narrow valve clearance or no valve clearance may obstruct the
valve's choke so lead to valve ablation and low power efficiency, in this case, periodic checking for valve
clearance is necessary. The engine which meets the State-IV standard has a precisely polished throttle valve,
and that ensures a suitable valve clearance.
Checking and adjustment of valve clearance should be under the status of cold engine. Please follow the
measures below:
1.Remove the seat, left & right side cover, then the fuel tank.
2.Remove the center hole cap and top cap (Ignition observation hole) on the left engine case cover;
3.Remove the valve cap or cylinder cover on the cylinder head （Only when the fuel tank is removed）.
4.Insert T typed spanner into the center hole and seize-up it on the nut of fly-wheel, turn the fly-wheel
clockwise, until the “T” on the fly wheel aligns with scale line on the top of the case. Slightly shake the swing
arm, if it is flexible (with clearance), that indicates the piston is at the upper stopping point of the compression
stroke; or if the swing arm is tight, that means the piston is at the lower stopping point of
the exhaust stroke, in this case, continue to turn T spanner for 360 degrees clockwise Cylinder cover
until it aligns with the scale line. And then the valve is adjustable. Insert the feeler gauge
between the valve end and its adjustment nut to check the clearance of valve.
As for the standard valve clearance: Inlet: (0.10~0.190mm Exhaust: (0.15~0.24)mm
5.In case adjustment is needed，loosen the valve fastening nut, adjust the screw until
the feeler gauge meets slight resistance when it is inserted in.
6.Waste gas from the crankcase enter the air filter through the waste gas circulation
without directly entering the atmosphere.
7.Motorcycle with negative pressure tube, whose oil returning cuts off air supplying to
prevent the reverse flow of air.
After adjustment, screw up the fastening nut to avoid looseness. Check again the valve
clearance, and install the valve cap (or cylinder cover) and the 2 holes' cap on the left
engine case.

24
Clutch lever adjustment
Clutch lever adjustment should take place after the engine has stopped. 10～20mm
The free travel of the clutch lever's end is within 10～20mm. In case adjustment
is needed,loosen the locking nut on the clutch operation cable, and adjust the
free travel to the stipulated range.
If the adjustment scope needs to be extended, adjust the clutch adjustment
stud on the right engine case cover.
After the engine started confirm the normal work of clutch in case the
clutch goes skidding or difficult in gear changing, adjust again is needed.

Brake pedal adjustment

Well uphold the motorcycle by side stand when checking the disc
brake.
1.The free travel of the rear brake pedal should be within
15~25mm. Clutch adjusting stud Locking nut
2.Please fasten the adjusting nut after adjusted.
Caution: After adjustment, it is expected that the brake light will on Parking stand
while testing brake.
This model is equipped side stand only.

(1)Side stand
(1)Pedal limit pin shaft
(2)Side bracket
(2)Adjusting nut
flameout switch
(3)Rear brake pedal
(3)Rear rack (Rear armrest)

(1) (2) (3) (1) (2) (3) 25

 Front & rear disc brake maintenance
1.Brake oil (brake liquid)
Observe if the oil level is lower than scale line “LOWER” (2) through the oil level view window (1). If lower,
please add some brake oil in. It is best to add the brake oil until its surface higher than the LOWER mark by
3~5mm. When oil level falls down and close to the scale line (2), please check the wear situation of the brake
lining (friction pad). And if the wear situation is within acceptable limit, check the leakage of brake system, and
then please consult local service stations of our company.
2.Brake oil replacement
Drain off the oil brake oil first as the measures below:
Horizontally lay the master cylinder(no need to remove from the handle
bar) , and then open the oil pool cap and its gasket; (1)Oil level view window
Remove the brake caliper and put the deflating valve to the lowest position; (2)LOWER scale line
Screw off deflating valve and make fluid freely flow out;
When the brake liquid is unable to flow out any more, add new brake liquid
by 30～50ml，and let it drain off;
Screw up the deflating valve, wipe up the liquid on caliper, and then install the
(1) (2)
caliper on the motorcycle.
And then add again the new specialized brake liquid into the oil cylinder as the
measures below:
Put a transparent tube onto the deflating valve (tightly matched)，screw off the valve by 90 degree；
Add new brake liquid into master cylinder and outlet liquid from the deflating valve (without turning the lever)
until no bubbles come out with the flowing out liquid, and then screw up the valve；
Turn the lever, and repeat the step until the lever performs sound hand-feel in turning.
Finally, properly install the oil pool cap and its gasket, and screw up its screw.

1.Please use D0T4 specialized brake oil for replacement. 2. Don't mix up different
Caution: types of brake oil.3. Don't use the contaminated brake oil.
26
 Accidental drinking of brake liquid or splashing it in eyes or on skin is harmful. It is strongly
Warning: recommended to seek doctor for help. If you have drunk it, please spit it out immediately. And in
the case of splashing into eyes or onto skin, please wash it with pure water.

3. Brake lining (Friction pad)

Wear situation could be observed by eyes directly during the stipulated
maintenance period. When checking ，follow the direction of double
arrow（3）.In the case that the wear situation of any lining reaches scale
line（4）,replace the pads of both sides. Leakage of brake liquid is not
allowed, check if there is any crack or distortion on the connective parts
and the brake liquid tube.

Caution: 1. Only our company original packed products from service stations are allowed when replacement is
needed. As for any repair or maintenance of the brake system, please contact our local service stat ion.
2. Don't drive immediately right after the brake lining replacement. First, grasp and loosen the br ake
level and step the rear brake pedal for several times, to make complete plying-up of braking pads and
recover the holding force to normal, and to build a stable circulation of the brake liquid.
3. Make grinding-in after new brake pads replaced, accelerate to 50km/h, then slightly brake till the
speed slow down to 5-10km/h. The accelerate to initial speed again and keep, then slightly brake
again. During the repeated slight braking, the brake device shall not be hot while braking temperature
should not be higher than 100℃.

4. Deflating for the brake system

(1)Master cylinder deflating: It needs to turn the front wheel to left in the case of the master cy linder installed on right
side (on left turn oppositely), open the oil cup cap and the oil pool gasket, repeatedly operate the front brake lever
and observe until no more bubble appears. If the hand-feel is still powerless, try deflating by bra ke caliper.
(2) Caliper deflating：Put a transparent tube onto the deflating valve (tightly matches the valve), tight ly hold the front
brake lever, and screw off the valve by 90 degrees. Flow the liquid out for 1~2 seconds. Screw up t he deflating valve,
and release the front brake lever，repeat steps above until good hand-feel set.

27
Caution: Add some brake liquid into master cylinder while doing caliper deflating to keep the liquid level
height. The tiny hole of the master cylinder of 0.5 size (supplement hole) is not allowed to be exposed
in the air.
Disc brake system is with high pressure braking. To ensure safety, timely
Warning: replacement of oil tube and brake oil is necessary.

Driving chain adjustment

Check the chain's wear, tightness and lubrication situation.
1.Uphold the motorcycle, and pull the chain up and down to check whether its
flexibility is within 30~40mm;
2.When adjustment is needed, screw off rear axle nut and locking nut on chain Swing travel
adjustor, make the chain's tightness meet the requirement of stipulation.
3.Add some lubrication oil on the chain.
After adjustment, the left and right marks on the chain adjustor should be at (2) (1)
the same position with scale mark on the rear fork.
(1)Rear wheel axle
Warning: (2)Chain adjusto

Excessive flexibility of chain may lead to chain's detachment and accident

and also damage the engine. Immediate replacement is necessary in case Brake switch
that chain is corroded by electrolyte or other corrosive liquid.

Brake switch adjustment Caution:

After the rear wheel braked, check the braking light. If Before adjusting the brake
it is off, adjust the nut. light switch, check if the
Turn on the brake light switch. If the bulb is off, check free travel of the brake is
28 braking light, circuit, and switch,replace it if needed. within the defined limits.
Battery checking
1.Open the seat and remove the left side cover. Negative terminal Positive terminal
2.Clean up dust and corrosive impurity on the surface of battery.
3.Check the joint of conductive wire, please replace it if corroded.
Caution:
(1) When disassembling or re-assembling the battery, turn off the ignition
switch first, then the seat and left side cover, remove the （-）pole first, and
then the（+）pole; When installing，install the（+）pole first，and then
the（-）pole; And during the installing, keep the（+）pole off the other
motorcycle parts. The opposite connection is not allowed.
(2) The battery need to be charged separately when its power exhausted.
(3) It is not allowed that any impurity gets into the battery when in installation
or disassembling.
The fuse tube/piece replacement
(1) Replacement for electrical box: Put the ignition switch to the position “OFF”, loosen the
connective bolt (Figure 1) between frame and electrical box bracket, then remove the electrical box
with its bracket (Figure 2), then loosen the self-tapping screw by cross-head screwdriver, open the
electrical box cover and replace the fuse chip, with specified specification of: 25A, 15A, 10A.
(2) Replacement for ABS fuse: Open the seat, remove the left side cover, then open the fuse box
cover of ABS ( Figure 4), take out the fuse chip and replace (Figure 5).
(3) Immediate burnout after replacement indicates faults existing in other electrical equipment. 29
 F1 general fuse: For
EFI, oil pump, fan, and
power supply fuse (Blue
Connecting bolt fuse chip of 15A)
of electrical box
bracket F2 fuel pump fuse:
(Red fuse chip of 10A)

Figure 1 Figure 2 F3 fan fuse: (Blue fuse

chip of 15A)
Spare fuse: (Red fuse
chip of 10Ax1, Blue
fuse chip of 15Ax3)

Figure 3

ABS fuse box cover ABS motor fuse:(White fuse chip of 25A)
ABS ECU fuse: (Red fuse chip of 10A)
Spare fuse: (White fuse chip of 25A , Red fuse
chip of 10Ax1)
Figure 4 Figure 5

Warning:
Don't wash the battery with water! It is not allowed to adopt fuse with different specification, otherwise
it may make the engine lose power, or seriously damage the electrical system even burn the
30 motorcycle down. Extremely dangerous!
 Bulb replacement
Power rating of each bulb shows as the table blow. The power Headlight 12V 35W
rating of replacement bulb must be the same with the replaced
one. If the new bulb with different power rating is adopted, that Front position light 12V 5W
may lead overloading of the electrical system and damage the
new bulb.
Muffler
The muffler contains catalytic device. It is not allowed that any foreign
matter such as lubricating oil, gasoline, acid, alkali or salt get into the
muffler, because they may make the catalytic become invalid.
Caution: The muffler is with high temperature during running, at this
moment, touch the surface of muffler is not allowed to avoid scald.
Scale mark for tire wear-out
Tires Air pressure of tyres

It is necessary to check Insufficient pressure in tyre may not only accelerate its abrasion
the air pressure and the but also seriously affect stable driving and make it hard in
depth of the tyre tread in turning. But high air pressure decreases tyre's grounding area
periodic maintenance. which leads to skidding and makes motorcycle out of control. So
For ensuring safety and it is necessary to keep the tyre pressure within the defined limits.
the longest service life, Front tyre pressure: 225kPa; Rear tyre pressure: 225kPa.
usual checking is highly In case the serious abrasion is met, please contact our service
needed besides the station.
periodic maintenance. 31
Specification table of fastening parts' torque

Ref No. Position Torque(N*m) Ref No. Position Torque(N*m)

Hanging and fastening of M8×1.25: (18±2.7) Connecting and fastening of the

1 6 M8×1.25: (18±2.7)
the engine M10×1.25: (45±4.5) handle bar and steering stem
Front shock absorber M8×1.25: (18±2.7) Upper fastening of the rear
2 7 M12×1.25: (60±6)
fastening M14×1.5: (75±7.5) shock absorber
Front disc brake plate Lower fastening of the rear
3 M8×1.25: (35±3.5) 8 M12×1.25: (60±6)
fastening shock absorber

4 Rear wheel axle fastening M16× 1.5: ( 75±7.5 ) 9 Rear braking disc fastening M8×1.25: (35±3.5)

M22×1: (50±5)
5 Steering stem fastening 10 Rear fork fastening M14×1.25: (75±7.5)
M25× 1: (60±6)

Caution: The fastening bolts or nuts are specially marked when made out, in case these marks show
miss-threaded or flexible, please fasten timely.

Periodic maintenance plan

The maintenance shall be done according to the Matenance Table
below (As below shows)
Note：
1. Driving in dusty region, usual washing is needed.
2. When the mileage data surpass the highest limit, repeat
maintenance according to the table below.

32
 Periodic m aintenance table
Ite m s Inte r v a l km ×1000
1 5 10 15 20 25 30
Lubrica nt The first m a in tenan ce is at 500km , the second is 5000km , then 7500km each
Lubrica tion elem ent Replace a t sa m e tim e w ith oil m aintena nce
Check lubrica nt lev el I I I I I I I
Check sea l perform ance for fuel tub e I I I I I I I
Check the fuel pum p elem ent \ \ I \ I \ I
Fuel filter \ R R R R R R
Throttle v alve bod y/Ca rburetor \ \ \ C \ \ C
Check co ola nt level I I I I I I I
Coolant 2 y ea rs \ \ \ \ \ \ R
Check sea l perform ance o f air inlet system I I I I I I I
V alve cleara nce I I I I I I I
Spa rk plug cleara nce \ I I R I I R
Air filter elem ent I C R C R C R
Throttle operation sy stem A A A A A A R
Clu tch opera tion system A A A A A R A
Check lubrica tion and tightness fo r steering bea ring I \ L I L I L
Check lubrica tion fo r Fr. & Rr. W heel and sp rocket b ase b ea ring \ L L L L L L
Check lubrica tion fo r tun ing sha ft of m a in and pillion steps \ L L L L L L
Check lubrica tion fo r sid e sta nd sha ft \ L L L L L L
Check lubrica nt for brake an d clutch lever sha ft \ L L L L L L
Check lubrica tion fo r bea ring on rocker ra ck o f rear shock a bsorber \ L L L L L L
Check lubrica tion fo r bea ring of rea r fork shaft \ L L L L L L
Check lubrica tion fo r driving chain A A A R A A R
Battery v oltag e \ I I I I I I
Seal perform a nce for brake oil tube I I I I I I I
Brake liquid 2 y ea rs I I I I I I I
Brake liquid level I I I I I I I
Fr.& Rr. Bra ke pads I I I R I I R
Fr.& Rr. Bra ke sw itch I I I I I I I
Check fuel ev apo ra tion sy stem I I I I I I I
Check tightness of fa stening pars on b ody I I I I I I I
Check lea kage for Fr. & Rr. shock ab sorbers I I I I I I I
Alum iniu m a lloy w heel/Spoke w heel I I I I I I I
Meaning o f sy m bols：I：Inspectio n C：Clean R：Repla cem ent A：Adjustm ent L：Lub rication

33
 7.Motorcycle washing

Periodic washing can prevent color fading, and also is convenient for checking vehicle damage or
oil leakage.
Caution：Water flow with strong pressure may damage some parts. So do not spray the high
pressure water directly on the parts below:
— Wheel hub;
— Exhausting pipe;
— Fuel tank and lower part of seat;
— Head lock and ignition switch;
— Odometer;
(1) Motorcycle should be washed with pure water after scrubbing to clean up remaining dirt and
prevent from rust. Plastic parts should be wiped up by cloth or sponge with neutral cleaning fluid
and then wash by pure water.
(2) Dry the motorcycle in the air, and lubricate the chain, and then turn it run for even spread
(3) Check brake system before driving to prevent braking performance fall.

Caution: Wash the motorcycle when engine in hot is not allowed, do the work when it cooled down.

34
8.Maintenance for long-term storage
Maintenance and storage
In the case of long-term storage, pay attention to damp-proof, sun-block, and rain-proof to avoid
damage. Make special inspection on important parts before storage.
1. Replace lubrication oil.
2. Lubricate the chain.
3. Drain off the fuel in fuel injector's pipe and fuel tank, and then fill up anti-rust liquid in fuel tank
and cover up the fuel cap.
4. For motorcycles parking more than 2 months, it is necessary to drain off the fuel from the fuel
injector's pipe. For keeping the motorcycle normally work, start the motorcycle per month, make
idling for 10 minutes (With the rotation speed within 2000r/min) and run out the residual fuel in its
tank.
Caution:
Fuel is combustible, so turn off engine before adding or draining off the fuel. Smoking is not allowed
in the place adding or storing fuel.
5. Remove the spark plug and add 15~20mL of pure lubrication oil into the cylinder, and then install
the spark plug.
6. Remove battery and put it in a cool and ventilated place, charge per month as suggestion.
7. Scrub motorcycle and spray dye-fixing agent on those colored parts, and spread anti-rust oil on
the parts may rust.
8. Cover the motorcycle.

35
Recovery of using
1.Remove the covering cloth, and wipe up the motorcycle.
2.Charge the battery and then install it on the motorcycle.
3.Drain off the anti-rust liquid in fuel tank and then fully add fuel in it.
4.Checking before driving is necessary, and it is recommended to do some low-speed test driving at
some safe place.
Caution:
1.After long term parking, heat the tire before driving without high speed.
2.Heavy collision shall be avoided during driving.
3.The air pressure in tires are both around 225ka, too high or low are both bad.

9.Electrical starting
This model is for electrical starting only with battery specification of “12V7Ah”. Clutch lever
switch for starting is installed on the left switch assembly，and the engine could be started only
when clutch is separated. Electrical starting button is equipped on the right switch assembly for
starting the engine. When starting, put the key of master switch on position “ON”, tightly hold the
clutch grip, and then press down the electrical starting button. In case that starting failed in 5
seconds, release the switch, and re-start it after a few seconds.
For your convenience of using and maintenance, please read the schematic diagram for
electrical starting in the next page:
36
10.Electrical schematic diagram

37
11.EFI System schematic Diagram

1.Battery
2.Meter
3.ECU
4.Fuel pump relay
5.Fuel pressure regulator
6.Electronic fuel pump
7.Fuel filter
8.Fuel injector
9. lgnition coil
10.Spark plug
11.Sensor
12.ldling speed controller
13.Carbon tank
14.Throttle valve assy.
15.Speed phase sensor
16.Coolant temperature sensor
17.Oxygen sensor
18.Muffler (with catalytic agent)
19. Diagnostor interface
20.Fuel tank
21.Air filter

38
 12.Operation and maintenance of the EFI System
* For the first drive of a new motorcycle, add the fuel more than 5L, it is recommended to
continuously turn the key on and off with a 5-second interval for 3 times before ignition. This
measure is about to exhaust the remaining gas in the fuel supply system and build sufficient fuel
pressure.
** In the normal service after its first drive, it is recommended to ignite after the fuel pump has
finished its work (or 5 seconds after turning on the key). This measure is about to build sufficient
fuel pressure for starting.

13.Special reminder for battery charging

1.Check the voltage on both terminals of battery, whose voltage above 5V is chargeable;
2.Charge by adjustable charger, which directly change the charging voltage to 16V-17V, activate
the battery under high voltage by 40 minutes;
3.In case there is still no charging current after 40 minutes activation, which indicates this battery
failed, in case there is current found (Without using high voltage), adjust the voltage to 14V-14.5
constant current for charging;
4.When the charging current rises up around 2A, keep it constant: Use 14V-14.5V, with constant
current: 2A, till it decrease to 0.2A, stop the charging and the battery is full power.
5.Lay the battery by 1 hour, check the voltage on both terminals, in case whose voltage above
12V, indicates normal, otherwise the battery goes failed.
39
 14.Special reminder for ABS
1.Braking or deceleration under normal situations, release the throttle first, then brake. When the
motorcycle slowed down, grasp the clutch and engage into low gear for avoiding engine off.
2.Deceleration in advance is needed before turning. When passing the turning, try to keep even
speed, and light braking is allowed when it is necessary, while sudden braking is forbidden.
3.When met the ice, snow or wet road, decelerate in advance and be careful.
4.Pre-judge the road condition if possible to avoid sudden braking.
5.When the emergency is met, release the throttle swiftly, tightly hold the steering bar and
powerfully brake.
Caution:
When fully braked the motorcycle with ABS, there is active bounce on brake lever and pedal,Which
is normal, no hurry, firmly hold the steering bar.
Danger:
Singly use front or rear brake under high speed or during deceleration, which may lead to skidding
or bring motorcycle out of control.
Warning:
1.When parking after long time driving, the engine is hot, please keep far way from kids to
avoid touching and scald.
2.Parking on soft ground is not allowed to avoid overturning. In case parking on the gentle
slope, engage to low gear and let vehicle head forward uphill to avoid the side stand turning
and motorcycle falling.
3.Parking on combustibles such as dried grass is not allowed due to the three-way catalyst in
40 muffler works under high temperature which easily catch fire.