XY Powersports XY500UTV Service Manual

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jim

March 2, 2025

where is the latch or catch for the dump bed on the 2011 xy500c 4 seater located

Terence Booth

March 2, 2025

what makes the UTV over heats if the **** and sensor both work?

1 comments:

Mr. Anderson

March 2, 2025

If the thermostat and sensor are functioning, the XY Powersports XY500UTV may overheat due to other factors such as low coolant levels, clogged or damaged radiator, faulty water pump, blocked cooling passages, or improper airflow to the radiator. Checking these components can help identify and resolve the overheating issue.

This answer is automatically generated

Charles Rochon

March 21, 2025

I Have a Chironex Spartan 600 XY efi 2013 looking parts and service or shop Manuel

1 comments:

Mr. Anderson

March 21, 2025

You can find the service manual for the XY Powersports XY500UTV at eManualOnline. To replace parts, it is recommended to use genuine XinYang parts with the correct part number or an equivalent part. The service manual provides information on inspection, maintenance, overhaul, disassembly, assembly, removal, installation, troubleshooting, and service data.

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Neil

April 10, 2025

Hi my auto gear shift is very stiff and clunks when you change gear ?

1 comments:

Mr. Anderson

April 10, 2025

A stiff and clunking auto gear shift in an XY Powersports XY500UTV could be caused by:

1. Gear wear or damage, especially if abnormal sounds occur during acceleration or deceleration.
2. Incorrect gear clearance due to improper assembly.
3. Gear block, particularly if noise is heard at low speed but not at high speed.
4. Lack of lubrication or lubricant leakage.
5. Foreign matter in the front or rear gear.
6. Drive shaft issues or a blocked gear.

These issues require inspection and correction to avoid further damage or accidents.

This answer is automatically generated

Veselin Dimitrov

April 16, 2025

Hello, my 4x4 is not included. What could be the reason?

Tom

April 20, 2025

How to remove front engine cover

Julie LB

April 27, 2025

Courroie de variateur

1 comments:

Julie Menguy

April 27, 2025

Connaissez vous la référence de la courroie de variateur ? Merci d'avance de vos réponses

Summary of Contents for XY Powersports XY500UTV

Page 2 Service Manual XY500UTV/XY500LUTV XY500UE/XY500UEL 4×4 ZHEJIANG XINYANG INDUSTRY CO.,LTD.
Page 3: Table Of Contents
FOREWORD This service manual is designed primarily for use by certified XINYANG Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Page 4: Service Information
1. SERVICE INFORMATION A few Words About Safety ……………1-1 Tightening Torque………………………1-9 Lubricating oil, and brake liquid ……1-12 VIN Number Engine Number…………1-3 Cables Pipes, Cable Routing ……………1-13 Main Data Table………………………1-4 Overhaul Datasheet……………………1-6 A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Page 5 1. SERVICE INFORMATION ● Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. ●...
Page 6 1. SERVICE INFORMATION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen. Vehicle Identification Number (500UTV): LCXRSTS1~ Vehicle Identification Number (500LUTV): LCXLSTS1~ Vehicle Identification Number (500UE): LCXRSTS3~ Vehicle Identification Number (500UEL): LCXLSTS3~...
Page 7 1. SERVICE INFORMATION Main Data Table Item Parameter Model 500UTV/500UE 500LUTV/500UEL Length 2600mm 3200mm Width 1280mm 1300 mm Height 1960mm 1880mm Wheel base 1760mm 2440mm Engine type 500UTV/500LUTV:CF188 500UE/500UEL:CF188-B Displacement 493ml Fuel type Unleaded gasoline 93octane or above Mass of whole equipments (Not include 580kg 720 kg driver)
Page 8 1. SERVICE INFORMATION Parameter Item Fuel type Higher class than RQ-93 Transmission V-belt with teeth on, auto stepless gear change, plus gear change cam with change gear transmission Gear change type Gear lever with hand Clutch type Wet, hoof centrifugal type Primary speed change...
Page 9 1. SERVICE INFORMATION Item Parameter Engine Output Mode Front/Rear Shaft Gearing Direction of Output Rotation Clockwise on forward shift Steering Steering Right 35° device angle Left 35° Brake type Front Hydraulic Disc Rear Hydraulic Disc Bumper Suspension Swing Arm Device Frame type Welded steel tube and plate Overhaul Datasheet...
Page 10 1. SERVICE INFORMATION Air Inlet System Standard Item Fuel Tank Capacity Full capacity Valve CF188-B-173000 Inlet Pressure Sensor CF188-B-175000 Inlet Temperature Sensor CF188-B-177000 Air Bypass Valve CF188-B-172000 Injector CF188-B-171000 Idle Speed 1400±100rRPM Cooling Device Item Standard Full Capacity 2620ml Coolant capacity Reservoir tank capacity 300 ml Standard Density...
Page 11 1. SERVICE INFORMATION Brake System Item Standard Service Limit Front brake Brake disc thickness 17mm 16mm Brake Pedal Play Rear brake Brake disc thickness 17mm 16mm Battery、Charging System Item Standard Permanent magnet AC type AC magneto Model Motor 3- phase AC Output Charging coil Resistance (20℃) 0.2-0.3Ω...
Page 12 1. SERVICE INFORMATION Screwing moment of important bolts Engine： Sequence Item Quantity Thread diameter Torque Remark number （N·m） Sensor reverse M10×1.25 gear Spark plug M12×1.25 Sensor water Rc1/8 Spread thread temperature glue Adjust nuts of air valve gap Nut of driving disk M20×1.5 Nut of driven disk M20×1.5...
Page 13 1. SERVICE INFORMATION Bolts pressure limiting valve Bolts principal prick gear cover Bolts on driven prick gear cover Gear positioning bolt M14×1.5 Bolt on hand start M10×1.25 disk Bolts on crankcase Bolt Gear changing sector gear Bolt on oil filter M20×1.5 Bolts on start motor Bolts...
Page 14 1. SERVICE INFORMATION FRONT, REAR SUSPENSION： Thread diameter Torque Remark s.q. Item Qty. （N·m） Bolts on front steering joint M12×60 45~50 and absorber Bolts on front and rear brake M10×30 45~50 disk Bolts on front brake Caliper M10×30 45~50 Bolts on rear brake Caliper M12×30 55~60 Bolts on support frame of...
Page 15 1. SERVICE INFORMATION Drain bolt on front axle M10×1.25 23~25 Bolts on rear axle box M10×1.25×25 35~40 Bolts on rear axle box M8×25 23~25 Nut on rear axle input shaft M12×1.25 58~62 Bolts on base of rear axle M8×30 20~25 input shaft Bolt on rear axle positioning M65×1.5×10...
Page 16 1. SERVICE INFORMATION Cables, Pipes, Cable Routing 1-13...
Page 17 1. SERVICE INFORMATION 1-14...
Page 18 1. SERVICE INFORMATION Carburetor Condition: 1-15...
Page 19 1. SERVICE INFORMATION Carburetor Condition: EFI Condition: 1-16...
Page 20 1. SERVICE INFORMATION Carburetor Condition: 1-17...
Page 21 1. SERVICE INFORMATION 1-18...
Page 22 2. VEHICLE BODY，MUFFLER Overhaul info……………………………2-1 Side door(R&L)......2-11 Troubleshooting…………………………2-1 Bumper& ………………………2-12 Fuel tank Center cover, steering wheel ……………2-2 Headrest, driver & Backrest, passenger …2-13 Holder, meter& Engine cover……………2-3 Safety belt…………………………………2-14 Front side support (L&R) ………………2-5 Roll-over bar……………………………2-15 Seat, driver&...
Page 23: Steering Wheel
2. VEHICLE BODY，MUFFLER Center cover, steering wheel Remove Remove six bolts 1 Exert upward to separate center cover, steering wheel; Installation Reverse the removal procedure for Installation Steering wheel Remove Exert upward to separate center cover, steering wheel Remove steering wheel Installation Note Align the front wheel first, and then ad...
Page 24 2. VEHICLE BODY，MUFFLER Holder, meter Remove Remove eight bolts 1 Loosen all electronic component and plugs in holder, meter. Remove holder, meter. Engine cover Remove Remove four bolts 1 Remove two bolt 3 Loose cables on the engine cover.
Page 25 2. VEHICLE BODY，MUFFLER Remove two bolts 4 Remove two nuts 4 Remove panel, engine cover (L) Remove two bolts 4 Remove two nuts 4 Remove panel, engine cover (R) Remove engine cover Installation Reverse the removal procedure for installation...
Page 26 2. VEHICLE BODY，MUFFLER Front side support(LH) Remove Remove mount bolts 2; Remove front side support (LH); Installation Reverse the removal procedure for Installation Front side support (RH) Remove Remove mount bolts 3; Remove front side support (RH); Installation Reverse the removal procedure for Installation Front vent cover Remove...
Page 27 2. VEHICLE BODY，MUFFLER Seat, driver Remove Use the latch puller to unlock the seat lock Remove eight bolts 1 Remove seat, driver Installation Reverse the removal procedure for installation Seat, passenger Remove Use the to unlock the seat lock; latch puller Remove eight bolts 2 Remove seat, passenger Installation...
Page 28 2. VEHICLE BODY，MUFFLER Gearshift knob Remove Remove bolt 1 Remove gearshift knob Installation Reverse the removal procedure for Installation. Note Check the return flexibility of gear limit, and the flexibility of gear shifting. Decorate cover，gearshift Remove Remove bolt 2 Remove decorate cover，gearshift. Installation Reverse the removal procedure for Installation.
Page 29 2. VEHICLE BODY，MUFFLER Handle, parking brake Remove Remove nut 1 Loosen cable, parking brake Remove bolt 5 Remove handle, parking brake. Skid plate (L) Remove Remove fuel tank cap. Remove bolt 1 Remove bolt 2 Remove skid plate (L) Installation Reverse the removal procedure for installation Skid plate (R)
Page 30 2. VEHICLE BODY，MUFFLER Rear fender (L) Remove Remove screw 1 Remove rear fender (L) Installation Reverse the removal procedure for installation Rear fender(R) Remove Remove screw 2 Remove rear fender (R) Installation Reverse the removal procedure for Installation Fender, cargo box（L） Remove Remove screw 3 Remove fender, cargo box (L)
Page 31 2. VEHICLE BODY，MUFFLER Fender, cargo box（R） Remove Remove screw 1 Remove fender, cargo box (R) Installation Reverse the removal procedure for Installation Cargo box Remove Remove nut 1 Remove bolt 2 Remove cargo box Installation Reverse the removal procedure for Installation 2-10...
Page 32 2. VEHICLE BODY，MUFFLER Side door (LH) Remove Remove bolt 1 Remove side door (LH) Installation Reverse the removal procedure for installation Side door (RH) Remove Remove bolt 2 Remove side door (RH) Installation Reverse the removal procedure for Installation 2-11...
Page 33: Fuel Tank
2. VEHICLE BODY，MUFFLER Bumper Remove Remove bolt 1 Remove bumper Installation Reverse the removal procedure for installation Fuel tank Remove Remove skid plate (L) (→2-8) Loosen fuel pipe Loosen fuel sensor connector Remove bolt 2 Remove fuel tank Installation Reverse the removal procedure for installation 2-12...
Page 34 2. VEHICLE BODY，MUFFLER Headrest, driver Remove Remove nut 1 Remove headrest, driver Installation Reverse the removal procedure for Installation Headrest, passenger Remove Remove nut 2 Remove headrest, passenger Installation Reverse the removal procedure for Installation Backrest, passenger (500L/500UEL) Remove Remove bolt 1 Remove backrest, passenger Installation Reverse the removal procedure for...
Page 35 2. VEHICLE BODY，MUFFLER Safety belt, driver Remove Remove bolt 1 Remove bolt 2 Remove safety belt, driver Installation Reverse the removal procedure for Installation Safety belt, passenger Remove Remove bolt 3 Remove bolt 4 Remove safety belt, passenger Installation Reverse the removal procedure for Installation Safety belt fastener Remove...
Page 36 2. VEHICLE BODY，MUFFLER Roll-over bar(500UTV/500UE) Remove Remove bolt 1， Remove bolt 2 Loosen nut 11 Remove bolt 5 Remove roll-over bar Installation Reverse the removal procedure for Installation Rear mirror(LH) Remove Remove rear mirror (L)48 Rear mirror (RH) Remove Remove rear mirror (R)49 2-15...
Page 37 2. VEHICLE BODY，MUFFLER Roll-over bar(500LUTV/500UEL) Remove Remove bolt 1， Remove bolt 2 Remove bolt 3 Remove roll-over bar Installation Reverse the removal procedure for Installation Rear mirror(LH) Remove Remove rear mirror (L)48 Rear mirror (RH) Remove Remove rear mirror (R)49 2-16...
Page 38 2. VEHICLE BODY，MUFFLER Bumper protector Remove Remove nut 14 Remove bumper protector 1 Installation Reverse the removal procedure for Installation Winch cable and motor Remove Remove nut 5 and bolt 4 Remove bolt 2 and nut 5 Remove winch cable and motor 13 Installation Reverse the removal procedure for installation...
Page 39 2. VEHICLE BODY，MUFFLER Cargo box Rear side support (LH) Remove Remove nut 3 Installation Remove side support (L)1 Reverse the removal procedure for installation Installation Reverse the removal procedure for Protector (R), cargo box Installation Remove Remove bolt 3 and bolt 4 Rear side support (R) Remove protector (R), cargo box 7 Remove...
Page 40 2. VEHICLE BODY，MUFFLER Muffler Caution: Perform disassembly only after the muffler is cooled down. Remove Remove connect nut 1 on muffler pipe elbow Remove bolt 1 Remove exhaust pipe protector(F) Caution: Perform disassembly only after the muffler is cooled down. Remove bolt 2 Remove muffler Note:...
Page 41 2. VEHICLE BODY，MUFFLER Description of visible parts 2-20...
Page 42: Inspection & Adjustment
3. INSPECTION & ADJUSTMENT Overhaul Info…………………………3-1 Valve Clearance………………………3-13 Maintenance Table…………………3-2 Engine Idle & Spark plug………………3-14 Inspection & Maintenance…………3-3 Air Filter…………………………………3-15 Steering Stem………………………3-6 Carburetor hose & Driving Belt…………3-16 Wheels………………………………3-8 Lubrication system………………………3-18 Suspension System………………3-10 Cooling system……………………………3-20 Gear Shifting, Fuel Device………3-11 Testing cylinder pressure…………………3-21 Throttle Pedal check………………3-12 Clutch check 、lock-up speed check……3-23 Overhaul Info...
Page 43 3. INSPECTION & ADJUSTMENT Regular Maintenance Table The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and hours, whichever occurs first. Note: More frequent maintenance may be required on vehicles that are used in severe conditions.
Page 45 3. INSPECTION & ADJUSTMENT Check Item Intervals Standard Part Item Daily 1/2 year Annual Drive Train Final shaft Looseness of ○ ○ ○ (Drive joint parts shaft) Sway of ○ Spline Electrical Ignition Spark plug ○ ○ System Device Ignition ○...
Page 46 3. INSPECTION & ADJUSTMENT Check Item Intervals Standard Part Item Daily 1/2 year Annual Lighting device Function ○ ○ ○ and turning indicators Alarm and lock Function ○ device Instruments Function ○ Exhaust pipe Looseness or damage caused ○ and muffler by improper installation Function of muffler ○...
Page 47 3. INSPECTION & ADJUSTMENT Steering Stem Park the vehicle on level place, hold steering wheel, and shake in the direction as illustrated on the right and see if there is any sway In case of any sway, check if it is the problem of the steering stem or other parts and then do the maintenance accordingly.
Page 48: Master Cylinder
3. INSPECTION & ADJUSTMENT Master Cylinder Fluid level Check the brake fluid level When the brake fluid level is near to the lower limit line, check master cylinder, brake hoses and joints for leakage. Remove fluid reservoir cap. add DOT3 or DOT4 brake liquid till the upper limit line.
Page 49 3. INSPECTION & ADJUSTMENT Wheels Lift front wheel on level place, and make sure there is no loading on the wheels. Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways. Not tighten enough ? Tighten it sway: Replace the rocker arm Front Toe-in size...
Page 50 3. INSPECTION & ADJUSTMENT Tire pressure Check the pressure of the tires with a pressure gauge. Note Check the tire pressure after tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires.
Page 51 3. INSPECTION & ADJUSTMENT Wheel Nut and Wheel Axle Check front and rear wheel axle nuts for looseness Loosened axle nuts Tighten Tightening Torque: Front wheel axle nut: 180-200N.m (18.3kgf.m-20.3kgf.m) Rear wheel axle nut: 180-200N.m (18.3kgf.m-20.3kgf.m) Sway of Wheel Bearing Lift the front wheel Make sure there is loading on the vehicle shake the wheel in axial direction for any sway In case...
Page 52 3. INSPECTION & ADJUSTMENT Adjusting the Absorber Use special tools to adjust the length of absorber according to loading requirement Turn clockwise to adjust from high to low. Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the lock nut to adjust the length of gearshift Carburetor: Fuel Device...
Page 53 3. INSPECTION & ADJUSTMENT Throttle Pedal Check Check the free play of throttle pedal Free play: 1.5-3mm If out of range, then adjust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle pedal After adjusting, tighten locknuts and install throttle cable sleeve.
Page 54 3. INSPECTION & ADJUSTMENT This section describes the maintenance procedures for each item mentioned in the Periodic Maintenance Chart. VALVE CLEARANCE Inspect initially at 20-hour break-in and every 40 hours or every 1000km thereafter. Inspect the clearance after removing cylinder head. Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power.
Page 55 3. INSPECTION & ADJUSTMENT Take out the feeler gauge, measure the clearance. If the clearance is incorrect, repeat the above steps until the proper clearance is obtained.Locknut: 10 N.m Caution: Securely tighten the locknut after completing adjustment Install: 2 valve adjusting cover; Inspection cap;...
Page 56 3. INSPECTION & ADJUSTMENT has a broken insulator, damaged thread, etc, replace the spark plug with a new one. SPARK PLUG GAP Measure the spark plug gap with a feeler gauge. Out of specification: → Adjust Spark plug gap: 0.8-0.9mm Caution: Check the thread size and reach when replacing the spark plug.
Page 57 3. INSPECTION & ADJUSTMENT A--Non-flammable cleaning solvent B—Engine oil SAE#30 or SAE10W/40. Warning: Never use with gasoline or low flash point solvents to clean the filter element Inspect the filter element for tears. torn element must be replaced. Note: If driving under dusty conditions, clean the air filter element more frequently.
Page 58 3. INSPECTION & ADJUSTMENT Inspection: Inspect drive belt for wear and damage. If any cracks or damages are found, replace drive belt with a new one. Inspect drive belt for width, if width is out of service limit, replace drive belt with a new one. Service Limit: 33.5mm Tool: Vernier Caliper Installation...
Page 59 3. INSPECTION & ADJUSTMENT Inspection of Lubrication System Replace engine oil and oil filter initially at 20 hours or 200km and every 80 hours or 2000km thereafter. Check Engine Oil Level ● Keep the engine in a plan position. ● Remove the fixture A, fixture B, then remove the left side cover 1.
Page 60 3. INSPECTION & ADJUSTMENT Caution: The engine oil should be changed when the engine is warm. If the oil filter should be replaced, replace engine oil at the same time. Replacing Oil Filter ● Remove relative parts ( see Replacing Engine Oil) ●...
Page 61 3. INSPECTION & ADJUSTMENT Inspection of Cooling System Check initially at 40 hours or 1000km, replace coolant every 2 years. Check radiator, reservoir tank and water hoses. Leakage or Damage: → Replace Check coolant level by observing the upper and the lower limit on the reservoir tank.
Page 62 3. INSPECTION & ADJUSTMENT Install reservoir tank cap. Warning: Never mix with other brand. Inspection of Radiator Hose Perform inspection every 40 hours or Check radiator hose and clamp. Leakage or Damage: →Replace Inspection of cylinder pressure Check cylinder pressure is necessary. Cylinder Pressure: 1000kpa A lower cylinder pressure may be caused by: ●...
Page 63 3. INSPECTION & ADJUSTMENT Inspection of Oil Pressure Oil Pressure: 130～170kpa at 3000r/min Lower or higher oil pressure may be caused by: Ⅰ Oil pressure is too low ● Clogged oil filter; ● Leakage from oil passage; ● Damaged O-ring; ●...
Page 64 3. INSPECTION & ADJUSTMENT Inspection of Clutch Engagement and Lock-up CF engine is equipped with a centrifugal type automatic clutch. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train. I Initial Engagement Inspection ●...
Page 65 4. COOLING AND LUBRICATIING SYSTEM Cooling System Illustration…………………………………………4-2 Engine Coolant………………………………………………………4-3 Inspection of Cooling Circuit……………………….………………4-3 Inspection and Cleaning of Radiator and Water Hoses……………4-4 Inspection of Fan Motor……………………………………….……4-5 Inspection of Water Temperature Sensor……………………………4-6 Inspection of Thermostat……………………………………………4-6 Water Pump……………………………………………………….…4-7 Water Pump Removal and Disassembly………………………4-7 Inspection………………………………………………………4-9 Water Pump Assembly and Installation………..……………4-10 Lubrication System Illustration………………………………..……4-14...
Page 66 4. COOLING AND LUBRICATIING SYSTEM Cooling System Illustration...
Page 67: Engine Coolant
4. COOLING AND LUBRICATIING SYSTEM Engine Coolant The coolant used in cooling system is a mixture of 50% distilled water and 50% ethylene glycol antifreeze. This 50:50 mixture provides the optimized corrosion resistance and fine heat protection. The coolant will protect the cooling system from freezing at temperature above –35℃.
Page 68 4. COOLING AND LUBRICATIING SYSTEM Inspection and Cleaning of Radiator and Water Hoses Radiator Cap ● Remove radiator cap① ● Install radiator cap to cap tester② ● Slowly increase pressure to 108 kPa and check if the cap can hold the pressure for at least 10 seconds.
Page 69 4. COOLING AND LUBRICATIING SYSTEM Inspection of Fan Motor ● Remove fan motor from radiator ● Turn the vanes and check if they can turn smoothly; ● Check fan motor: Make sure that the battery applies 12 volts to the motor and the motor will run at full speed while the ammeter shall indicate the ampere not more than 5A.
Page 70 4. COOLING AND LUBRICATIING SYSTEM nspection of Water Temperature Sensor ● Place a rag under water temperature sensor① and remove it from cylinder head. ● Check the resistance of water temperature sensor as illustrated on the right. Connect the temperature sensor②...
Page 71 4. COOLING AND LUBRICATIING SYSTEM ● Check thermostat pellet for cracks ● Test the thermostat in the following steps: ● Pass a string between thermostat flange as illustrated on the right; ● Immerse the thermostat in a beaker with water. Make sure that the thermostat is in the suspended position without contact to the vessel.
Page 72 4. COOLING AND LUBRICATIING SYSTEM ● Remove clamps and water hoses ● Release bolts and remove water pump ● Remove O-ring Note: Do not reuse the O-ring. ● Remove the overflow tube ● Release water pump cover screws, water pump cover and gasket ●...
Page 73 4. COOLING AND LUBRICATIING SYSTEM ● Remove mechanical seal with special tool Note: The mechanical seal does not need to be removed if there is no abnormal condition. Note: Do not reuse a removed mechanical seal. ● Put a rag on the water pump body ●...
Page 74 4. COOLING AND LUBRICATIING SYSTEM Oil Seal ● Check oil seal for damage. Pay special attention to the oil seal lip; ● In case of damage or leakage, replace the oil seal; Water Pump Body ● Check the mating mace of water pump body with bearing and mechanical seal.
Page 75 4. COOLING AND LUBRICATIING SYSTEM ● Install mechanical seal with a suitable socket wrench Note: Apply sealant to side “A” of mechanical seal. ● Install bearing with special tool Tool: Bearing Installer Note: The stamped mark on the bearing faces outside. ●...
Page 76 4. COOLING AND LUBRICATIING SYSTEM ● Install E-ring to water pump shaft; ● Install new gasket to water pump body; ● Install water pump cover and tighten the bolts and bleed bolt. Water Pump Cover Bolts Tightening Torque: 6N.m ● Check impeller for smooth turning. ●...
Page 77 4. COOLING AND LUBRICATIING SYSTEM ● Install water pump and tighten the bolts to the specified torque; Water pump bolts tightening torque: 10N.m Note: Set the water pump shaft slot end “B” to oil pump shaft flat side “A”. ● Connect water hoses ●...
Page 78 4. COOLING AND LUBRICATIING SYSTEM Inspection of Lubrication System (→3-18) Inspection of Oil Pump and Relief Valve(→6-41) 4-14...
Page 79 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Inspection Information……………5-1 Removal and Installation of Front and Rear Engine Removal and Installation…5-2 axle……………………………………5-5 Removal and Installation of Gearshift…5-7 Inspection Information Note: ● When removal Engine, please use jack to support the bodywork. Don’t damnify the frame, body of Engine, bolt and cable etc.
Page 80 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Disassembly Engine Remove plastic parts（→Chapter 2） Remove air filter Remove carburetor Remove hoop Remove water inlet hose of engine Remove inlet and outlet oil hose of engine Remove bolt Remove shift of gearshift Remove hoop Remove water outlet hose of engine Remove magneto connector、speed...
Page 81 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove spark plug Separate jacket of starter relay, remove nut, remove anode cable of starter relay. Remove bolt and cathode cable of starter rely Remove fixing bolt of engine...
Page 82 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove hoop of air inlet and outlet duct for Remove carburetor Remove air filter Remove muffler（→2-18） Remove gearshift（→2-7）...
Page 83 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Installation of engine Put engine on the bodywork. first, install two bolt and nut, then, install upper bracke and rear bracket. Tighten moment£ŗ upper bracke of engine:35～45N·m Removal and Installation of Front and Adown fixing bolt of engine:50～60N·m Rear axle Install water inlet and out let hose in the en-...
Page 84 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove bolt and nut fixed in the frame of front axle. Remove bolt and nut fixed in the frame of Rear axle...
Page 85 5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT Remove joint bolt in drive shaft, Front and Rear axle Remove Front and Rear axle, Drive shaft and Rear brake disc Installation Installation as contradictorily process of remove Bolt torque of Front axle：45-50N·m Bolt torque of Rear axle: 45-50N·m Bolt torque of Front and Rear drive shaft: 40-45N·...
Page 86 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Δ Engine Removal/Installation Orders and the Relative Page Numbers Item Description Disassembly Inspection / Assembly Remarks Maintenance Engine Water Hose/Pipe 3-24 6-69 Periphery Left Side Cover — 6-69 Recoil Starter 6-49 6-68 Engine Spark Plug 3-17 6-68 Front...
Page 87 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Engine Removal ΔPreparation before engine removal ● Prepare a proper tray used for load of components ● Prepare necessary removal and assembly tools ● Drain up engine oil（→3-18） ● Drain up coolant（→ 3-20） △ Engine Periphery Water Hose/Pipe ●...
Page 88 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Cylinder Head Cover ● Remove valve adjusting cover ● Remove12 bolts of cylinder head cover ● Remove cylinder head cover Timing Chain Tensioner ● Remove screw plug , insert a flat screwdriver into slot of timing chain tensioner adjuster , turn it clockwise to lock tensioner spring;...
Page 89 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Remove C-ring① ● Remove timing sprocket from camshaft, remove camshaft Note: Take care not to drop spacer, bolt, bolt lock and C-ring into crankcase. ● Remove tensioner plate Cylinder Head ● Remove cylinder head bolt ●...
Page 90 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Remove cylinder bolt ● Remove cylinder Note：Take care not to drop dowel pin into crankcase ● Remove dowel pin and cylinder gasket Note：When performing above removal process, be sure to hook up timing chain to prevent it from falling into crankcase Piston ●...
Page 91 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Oil Filter ● Remove oil filter with special tools Tool: Oil filter Remover Sector Gear ● Remove bolt 1 of gearshift rocker arm ● Remove gasket 2 and gearshift rocker arm 3 ● Remove bolt of sector gear housing cover ●...
Page 92 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Water Pump ● Screw out bolt of water pump ● Remove water pump Sheave Drum ● Remove the sheave drum by using a suitable bar; ● Remove washer and sheave drum Left Crankcase Cover ●...
Page 93 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Starting Motor Gear ● Remove driven gear 1 and needle bearing ● Remove spacer 2 ● Remove dual gear and shaft 3 ● Remove idle gear and shaft 4 Oil Pump Sprocket and Chain ●...
Page 94 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Δ Engine Right Side CVT Cover ● Remove bolt of CVT cover ● Remove CVT cover ● Remove gasket and dowel pin CVT(Continuously Variable Transmission) ● Remove primary sheave nut with special tool ● Remove primary sliding sheave ●...
Page 95 6. ENGINE REMOVAL; INSPECTION & INSTALLATION CVT Case ● Remove bolt 1 of CVT case ● Remove nut 2 of CVT case ● Remove outer clutch face and CVT case ● Remove dowel pin, front and rear gasket Clutch ● Remove one-way clutch ●...
Page 96 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Engine Center Gear position bolt ● Remove gear position bolt 1 ● Remove spring and steel ball ● Right Crankcase ● Remove left crankcase bolts ● Remove right crankcase bolts ● Separate right crankcase with special tool Caution ●...
Page 97 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Remove Oil seal①, Bearing limit nut① ● Remove Front Output Shaft ④ Shift Cam, Fork/Shaft ● Remove Shift Cam⑤, Fork /Shaft⑥ Drive Bevel Gear ● Remove left crankcase from driven bevel gear Drive Shaft, Drive Shaft ●...
Page 98 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Crankshaft ● Separate crankshaft from left crankcase with Special tool Tool: Crankshaft Separator Oil bump, Relief Valve ● Remove oil bump and relief valve 6-13...
Page 99 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Engine Components Inspection Cylinder Head Cover Disassembly Caution: Each removed part should be identified to its location, and the pars should be laid out in groups designated as “Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
Page 100 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Rocker Arm ● When checking the rocker arm, check the inner diameter of the valve rocker arm and wear of the camshaft contact surface. ● Rocker Arm I.D. : .000~12.018mm Tool: Dial Calipers Assembly Note: Intake rocker arm shaft A has oil holes.
Page 101 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Remove thermostat ● Compress the valve spring and remove valve cotter with tweezers. Tools: Valve Spring Compressor Tweezers ● Remove valve spring upper seat and valve spring ● Remove valve from the other side. ●...
Page 102 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Cylinder Head Distortion Clean off carbon deposit from combustion chamber; Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge. Take clearance readings from several places. If any clearance reading is out of the service limit, replace with a new cylinder head.
Page 103 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Valve Stem O.D ● Measure valve stem O.D with a micrometer Service Limit IN: 4.975-4.990mm EX: 4.955-4.970mm Tool: Micrometer (0-25mm) Valve Stem Run-out ● Support valve stem with V block as illustrated on the right.
Page 104 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Valve Spring ● Valve Spring keeps valve and valve seat tight. Weakened spring results in reduced engine power output and chattering noise from valve mechanism. ● Measure the spring free length. Spring free length out of range: →Replace Service Limit: 38.8mm Tool: Vernier Caliper.
Page 105 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install valve spring with small-pitch end “b” facing cylinder head. Big-pitch end “a” is marked. ● Put on the valve spring retainer. Use the valve spring compressor to press down the spring. Fit the two cotter halves to the stem end and release compressor to allow the cotter ①...
Page 106 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install thermostat ● Install thermostat cover ● Install water temperature sensor, apply thread locker to the thread part, tighten it to the specified torque. Water temperature sensor Tightening torque: 10 N·m ● Install intake pipe, apply lubricant to 0-ring. Camshaft Check camshaft for wear and run-out of cams and journals if the engines produces abnormal noise or...
Page 107 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Automatic Decompression ● Move the automatic decompression weight with hand and check if it is operating smoothly. If it is not working smoothly, replace with a new camshaft/automatic decompression assembly. Cam Wear Worn cams can often cause mistimed valve operation resulting in reduced power output.
Page 108 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Camshaft Journal O.D. ● Measure camshaft journal O.D. with a micrometer. If the O.D. is out of range, replace camshaft with a new one. Camshaft journal O.D. service limit: Sprocket end: 22.959 mm—21.980mm Other end: 17.466mm—17.484mm Tool: micrometer (0-25mm) Camshaft Run-out...
Page 109 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Chain Tensioner Inspection ● Check tensioner for any damage or poor function. Damage, poor function: →Replace ● Insert screw driver into the slotted end of adjusting screw, turn it clockwise to loosen the tension and release the screwdriver.
Page 110 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Piston Piston Diameter ● Use a micrometer to measure the diameter at the point 10mm above the piston end, as illustrated on the right. If the measurement is less that the limit, replace the piston Standard: 87.460-87.480mm Limit: 87.380mm Tool: Micrometer (75-100mm)
Page 111 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Piston Ring Free End Gap and End Gap ● Before installing piston rings, use vernier caliper to measure the free end gap of each ring, and then fit ring into the cylinder. ● Use thickness gauge to measure each ring end gap, if any ring has an excess end gap, replace the piston ring.
Page 112 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Connecting Rod/Crankshaft Connecting rod small end I.D. ● Use a dial gauge to measure the I.D. of connecting rod small end. If the measurement exceeds the limit, replace the connecting rod. Connecting rod small end I.D. : 23.040mm Tool: Dial Gauge (18-35mm) Connecting Rod Deflection ●...
Page 113 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Clutch Clutch Shoes ● Check clutch for chipping, scrape, uneven wear or heat discoloration. At the same time check depth of the grooves of clutch shoes. If any of the clutch shoes has no groove, replace the clutch. Note: clutch should be replaced as a set.
Page 114 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Primary and Secondary Sheave 6-29...
Page 115 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Primary Sliding Sheave Disassembly ● Remove spacer ● Remove Cam ①and Roller② Roller ● Check each roller and sliding face for wear and damage. → Wear and damage: Replace Note: rollers should be replaced as a set. Oil Seal ●...
Page 116 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Primary Sliding Sheave and Fixed Sheave ● Check the drive face for any abnormal conditions such as damage or stepped wearing. Damage or wearing: → Replace ● Install oil seal with special tool. Tool: Bearing install set Assembly Reverse the removal procedure of primary sliding and fixed sheave for installation.
Page 117 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Install spacer Secondary Sheave Disassembly ● Use special tool and holder to hold the secondary sheave. Remove secondary sheave nut with special tool. Caution: Do not remove the ring nut before attaching the clutch spring compressor. Tool: Nut Wrench Sheave Holder ●...
Page 118 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Remove spring ① ● Remove spring seat ②. ● Remove guide pin and spacer. ● Remove secondary sliding sheave③ O-ring and Oil Seal Check the O-ring and oil seal for wear and damage. →...
Page 119 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install oil seal with special tool. Tool: Bearing install set Secondary Sheave Spring ● Use vernier caliper to check the spring free length. If xthe length is shorter than the service limit, replace with a new one.
Page 120 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install guide pin and spacer ① Note: To avoid damage to the oil seal lip during assembly, slide the lip with a 0.1mm steel sheet as guide. ● Install spring seat. Align hole A with hole B. ●...
Page 121 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Tighten the ring nut with special tool to the specified torque. Ring Nut Tightening Torque: 100N·m Tool: Ring nut wrench Sheave Holder Drive belt ● Check belt for any greasy substance. ● Check contact surface of belt for any cracks and damage.
Page 122 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Transmission No. Description No. Description MAIN SHAFT. GEARSHIFT DRIVEN GEAR, HIGH RANGE SHIFT CAM DRIVEN GEAR, LOW RANGE RIGHT CRANKCASE SPRING, SHIFT FORK LEFT CRANKCASE RIGHT SHIFT FORK DRIVEN SECTOR GEAR GUIDE BAR SPROCKET, REVERSE GEAR DRIVEN SHAFT CHAIN, REVERSE GEAR SPRING, SHIFT FORK...
Page 123 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Inspection ● Check main shaft gear and sprocket surface for any damage or over wear. Damage or over wear: → Replace ● Check reverse gear chain for any damage or over wear. Damage or over wear: → Replace ●...
Page 124 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Check the shift fork clearance with a thickness gauge in the groove of its gear. Clearance exceeds the limit: → Replace Shift fork to Groove clearance Standard clearance :0.10-0.30mm Service Limit :0. 50mm ●...
Page 125 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Put the guide bar on a flat plate and roll it. In case of any bend, replace with a new one. NOTE:DON NOT attempt to correct a bent guide bar. ● Check shift fork spring for breakage, damage Broken or damaged: →...
Page 126 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● When assembling the guide bar, take care not to assemble the two shift forks and springs in the opposite direction. 1. Guide bar 2. Retainer 3. Left shift fork 4. Shift fork Spring (small) 5.
Page 127 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Oil strainer ● Check oil strainer ① and O-ring ② for damage Damaged oil strainer: → Replace ● Clean the surface of oil strainer with engine oil Relief Valve ● Check the valve body ①、valve ② and spring ③O –ring ④for damage or wear.
Page 128 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Front Output Shaft ● Check bearing 7 for smooth turning and abnormal wear. Check oil seal 5 for damage. Wear or damage: → Replace ● Apply lubrication oil to bearing 7 and oil seal 5 lip before assembly.
Page 129 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Bevel Gear Note: Proper bevel gear engagement depends on that the gear backlash and tooth contact are within the proper range. Bevel Gear Backlash ● Install drive and driven gears to the crankcase. Wrap a (--) screwdriver ③with a rag ②...
Page 130 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Tooth Contact ● After adjusting the backlash, check the tooth contact according to the following procedures: ● Remove drive and driven bevel gear shafts from crankcase; ● Clean and degrease every tooh of drive and driven bevel gear;...
Page 131 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Balancer Shaft ● Remove the parts as illustrated on the right. Check each part for abnormal wear or damage. Wear or damage: → Replace ① Balancer shaft gear ② Woodruff key ③ Balancer shaft ④...
Page 132 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Check starter clutch roller and holder for abnormal wear or damage. Wear or damage: → Replace ● Install the starter clutch in the correct direction. Note: When install the starter clutch to the magneto rotor, make sure side “A”...
Page 133 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Electric Starter Gear ● Check the gear surface for scrap or damage. Scrape or Damage: → Replace LEFT CRANKCASE COVER ● Check magneto stator coil 2, pickup coil 3 for damage, ● burn or short circuit, if any , replace with new one; ●...
Page 134 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Recoil Starter ● If the recoil starter works normally, it’s not necessary to disassemble it. DISASSEMBLY ● Remove nut 10, ● Remove the parts from the starter housing. WARNING ! The coil spring may quickly unwind and cause injury when the sheave drum is opened.
Page 135 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Assembly ● Reverse the removal procedure for installation and pay attention to the following: ● Install sheave drum①, rope②, coil spring③, damper④ ● Wind the rope clockwise around the sheave drum three times and hook the rope at “a” of sheave drum.
Page 136 6. ENGINE REMOVAL; INSPECTION & INSTALLATION CVT Cover ● Remove screw 5, oil seal limitator 4. Remove oil seal 3 with special tool; ● Check bearing 2 for free turning. In case of any abnormal, remove with special tool and replace with a new bearing;...
Page 137 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Crankcase 1. Right Crankcase 10. O-ring 19. Bearing 2. Bearing 11. Gear Sensor 20. Bearing 3. Oil Seal 12. Left Crankcase 21. Bearing 4. Bearing 13. Screw 22. Oil Dip Rod 5. Bearing 14. Oil Pipe 23.
Page 138 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install new O-ring and apply grease; ● Install gear sensor; ● Install reverse gear sensor 9 and tighten to the specified torque. ● Reverse gear sensor tightening torque: 20N.m ● Install speed sensor 24 ●...
Page 139 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Connecting Rod ● Install connecting rod to left crankcase with special tool; Note: ● Do not hammer the conrod into crankcase with plastic mallet; ● Use special tool to avoid affect of conrod precision Tool: Conrod Installer Balancer Shaft ●...
Page 140 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Shift Cam, Shift For ● Install shift can① and shift fork② ● Check each part for smooth turning ● Install low range driven gear to counter shaft③ ● Spray adequate engine oil to each part. Drive Bevel Gear ●...
Page 141 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Apply sealant ①to the mating face of right crankcase. Note: Apply sealant evenly in an uninterrupted thin line. ● Install 2 dowel pins② ● Assemble crankcase and tap slightly with a rubber hammer so that the crankcase is properly fitted. ●...
Page 142 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install new o-ring in spacer⑧ ● Install spacer onto the clutch housing shaft, then install into CVT case Note: align oil nick on spacer with oil hole on the shaft. CVT Case ● Install dowel pin ④, gasket ② and gasket ⑤ to the right crankcase.
Page 143 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install secondary sheave; ● Install primary sliding sheave ● Tighten primary sheave nut with special tool to the specified torque; Primary sheave nut tightening torque: 115 N·m Tool: Rotor Holder ● Tighten secondary sheave nut with special tool to the specified torque;...
Page 144 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install CVT case cover bolts and tighten diagonally in several steps. Engine Left Oil Pump Sprocket and Chain ● Install oil pump drive sprocket; ● Install oil pump driven sprocket; ● Install oil pump drive chain; ●...
Page 145 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install starting driven gear; Magneto Rotor ● Install woodruff key into crankshaft groove; ● Install magneto rotor 1; Note: Degrease the tapered part of rotor and crankshaft. Use nonflammable solvent to clean off the oily or greasy matter and fully dry the surfaces.
Page 146 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Water Pump ● Install water pump; ● Install water pump fixing bolts; Note: Before tightening the bolts, be sure to insert oil pump shaft into groove of water pump shaft. Sector Gear ● Install the parts as illustrated on the right. 1- sector gear cover and gasket 2-dowel pin 3-drive sector gear...
Page 147 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Oil Filter ● Install oil filter bolt and tighten to the specified torque; Oil filter bolt tightening torque: 63 N·m ● Apply engine oil to O-ring; ● Install oil filter, turn it by hand until the filter gasket contacts the mating surface.
Page 148 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● 1st and 2nd rings have letter “R” marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. ● Position the gaps of the three rings as illustrated on the right.
Page 149 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Cylinder ● Apply engine oil to piston skirt and cylinder wall; ● Hold each piston ring with proper position, insert piston into the cylinder; ● Tighten the cylinder base bolts temporarily; Note: When installing the cylinder and cylinder head, pull the cam chain upward, or the chain will be caught between sprocket and crankcase.
Page 150 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install chain tensioner; Camshaft ● Align mark “A” on magneto rotor with mark “B” on crankcase; Note:while rotating crankshaft, pull the cam chain upward, or the chain will be caught between sprocket and crankcase. ●...
Page 151 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install crankshaft C-ring ① ● Install lock washer so that it covers the locating pin; ● Apply thread locker to the bolts before installing, and tighten them to the specified torque; Sprocket bolt tightening torque: 15 N·m ●...
Page 152 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Gasket Sealant Applying Place Chain Tensioner ● Insert (--) screwdriver into slotted end of chain tension adjuster, turn it clockwise to lock the tensioner spring; ● Install the chain tensioner and the new washer 1; ●...
Page 153 6. ENGINE REMOVAL; INSPECTION & INSTALLATION ● Install the new gasket 3; ● Install chain tensioner screw, tighten it to the Specified Torque Chain tensioner screw tightening torque: 8 N·m Valve Adjuster Cover ● Refer to 11-3 for valve clearance; ●...
Page 154 6. ENGINE REMOVAL; INSPECTION & INSTALLATION Left Plastic Cover ● Install left plastic cover 6 Water Pipe and Hose ● Install water hose 5 ● Install bolt 4 ● Install water hose 3 ● Install clamp 1 and 2 6-69...
Page 155: Carburetor、Fuel System, Air Intake System
7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM …………………………………………………………………7-2 Overhaul Info Carburetor Removal…………………………………………………………7-3 Inspection………………………………………………………………………7-4 Measurement and Adjustment………………………………………………7-5 Carburetor Assembly………………………………………………………7-6 Carburetor Installation………………………………………………………7-7 Carburetor Parameters………………………………………………………7-7 High Pressure Fuel Line Disassembly/ Installation…………………………7-8 Throttle Body Disassembly/Installation………………………………………7-8 Fuel Injector Assy Disassembly/Installation…………………………………7-9 Fuel injector Assy Removal/Assembly………………………………………7-9 Idle Air control valve Disassembly/Installation………………………………7-9...
Page 156 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM Overhaul Info CAUTION NOTE Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-ventilated place.
Page 157: Carburetor Removal
7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM 1. Carburetor Removal Disassemble the carburetor in the following serial number: Serial No Description Serial No Description Idle Adjust Shaft Drain Screw Vacuum Chamber Cover Float Chamber Spring Float Jet Needle Holder Needle Valve Set Spring Main Jet (MJ) Jet Needle Set...
Page 158 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM 2. Inspection ● Check carburetor body for cracks or damage. Cracks or damage:→ Replace ● Check carburetor float chamber, fuel passage for dirt or clog. Clean these parts. ● Check float①, float tang ② for damage. Damage: →...
Page 159 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM ● Check the diaphragm ① for tears; Tears: → Replace ● Check the spring ②,cover ③ for damage and tears; Damage or tears: → Replace ● Check the jet needle , mail jet , needle jet , pilot ③ air jet , pilot jet , starter jet and starter plunger for wear and bends;...
Page 160 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM ● If float height is not within the specification, check the valve seat and needle valve; ● If either of valve seat or needle valve is worn, replace both; ● If both are fine, adjust float height by bending the float tang ①on the float;...
Page 161 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM Carburetor Installation ①-vacuum breather hose ②-starter cable ③-carburetor joint (engine intake manifold)) ④-throttle valve cover ⑤-throttle cable ⑥-Carburetor joint (air filter) ⑧-drain hose ⑨-fuel inlet hose ⑦-carburetor Note: Align the installation mark of carburetor and carburetor joint. 6.
Page 162 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM High Pressure Fuel Line Disassembly Loosen the special fuel line clamp on fuel injector cap. loosen the special fuel line clamp on fuel tank. Disassemble High pressure fuel line. NOTE:Use container to keep the remaining fuel from high pressure fuel line, when loosening the special fuel line clamp.
Page 163 7. CARBURETOR、FUEL SYSTEM, AIR INTAKE SYSTEM Fuel Injector Assy Removal Use thumbs of both hands to push two sides of fuel injector cap snap spring, and then remove it. Seperate fuel injector cap and fuel injector. Fuel Injector Assy Assembly Install fuel injector cap on the fuel injector, Align the groove of fuel injector cap snap spring to the edge of fuel injector cap;and press the snap spring...
Page 164 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Overhaul Info……………………..…8-1 Brake System…………………………8-4 Troubleshooting………………….…8-2 Suspension……………………………8-7 Front Wheel………………………...8-3 Steering………………………………8-12 Overhaul Information Operating cautions Notes ● Securely support the vehicle when overhauling the front wheel and suspension system. ● Refer to chapter10 for overhaul and inspection of lighting, instruments and switches. ●...
Page 165 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Troubleshooting Heavy Steering Wheel Cannot Turn Freely ● Steering bearing is damaged or worn ● Faulty wheel bearing ● Inner & outer bearing races are damaged, ● Front wheel axle is bended worn or stepped ●...
Page 166 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Front wheel Removal Securely support the front wheels Remove: --Wheel cap --4 bolts from wheel hub --Front wheel Inspection Rim Damage, warpage or serious scrapes: →Replace Replace with a new one, if any. Slowly turn the wheel, measure the rim vibra-tion with a dial gauge.
Page 167 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Brake System Front brake caliper Removal Remove: --Front wheel（→8-3） --2 bolts from arm --Front caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage. Replace if any. Installation Reverse the removal procedure for installation.
Page 168 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Brake Disc Removal Remove: --Front wheel（→8-3） --Brake caliper（→8-4） --Front brake disc and wheel hub --4 bolts from brake disc --Brake disc Inspection： Brake disc thickness: <16mm →Replace Installation Install brake disc Tightening Torque Fixing bolt, brake disc：45-50N·m Front Brake Master Cylinder Disassembly Remove:...
Page 169 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Brake Pedal Removal Remove: --Bolt 1 and Nut 1 -- Bolt 2 and Nut 2 -- Spring1 -- Brake Pedal Seperate Brake Pedal from vehicle Disassembly of front brake master cylinder （→ 8-5） Installation Reverse the removal procedure for installation. NOTE Do not put the master cylinder upside down to avoid possible entrance of air into brake system.
Page 170 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Front Left Suspension NOTE: DO NOT Remove both left and right suspension at the same time to avoid fall down of the vehicle. Park the vehicle on a level ground and securely support front part of the vehicle.
Page 171 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING 1. BOLT ，(M10×1.25×30) 2. WHEEL HUB L.FR.LOWER SWING ARM 19. R.FR.LOWER 3. GRIP BRAKE 4.HOOP 5. BEARING SWING ARM 6. TRIFURCATE SHAFT (LEFT) 7. TRIFUR- 20. FR.ROCKER BUTTONHEAD CATE SHAFT (RIGHT) 8. BOLT(M12×60) 21.CALIPER,BRAKE(L) 22. CALIPER,BRAKE(R) 9.
Page 172 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Installation Reverse the removal procedure for installation. Refer to Front Right Shock Absorber for removal, installation and inspection of Front Left Shock Absorber. Rocket Arm Note: This vehicle has 6 rocket arms. The removal, disassembly, inspection and installation of the 6 rocket arms are the same.
Page 173 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Inspection Ball Pin Check if Lower Ball Pin (20) and Front Right Arm(Lower) (19) can turn freely in all directions. Check clearance of lower ball pins. Clearance out of range or no free turning:→Replace Ball pin Right Steering Knuckle Inspection: Damaged steering knuckle: →...
Page 174 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Constant Velocity Drive Shaft NOTE： The removal, inspection and installation of Left and Right Constant Velocity Drive Shafts of the Front/Rear Axles are the same. The following will give instruction only on the removal, inspection and inspection of Left Constant Velocity Drive Shaft of Front Axle.
Page 175 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Steering System Front Cover, Steering Stem Removal Remove cover, steering stem （→ 2-2） Combination Switch Removal Remove combination switch（→ 2-3） 8-12...
Page 176 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Rear View Mirror Removal Remove left and right rear view mirrors（→ 2-15） Note: Left rear view mirror is right-threaded. Turn counter clockwise for removal. Note: Right rear view mirror is left-threaded. Turn clockwise for removal. 8-13...
Page 177 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Steering Stem Removal Remove: --Steering wheel（→ 2-2） -- cover, steering stem（→ 2-2） --Combination switch（→ 2-3） --Bolt --Shaft assy., steering joint --Steering stem 8-14...
Page 178 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Installation of Combination Switch Install combination switch（→ 2-3） Insert main cable with connector of combination switch. 8-15...
Page 179 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Installation of Steering Wheel Install steering wheel（→ 2-2） Installation of Rear View Mirror Install rear view mirror（→ 2-15） 8-16...
Page 180 8 FRONT WHEEL, FRONT BRAKE，SUSPENSION，STEERING Steering System 1. STEERING WHEEL 2. STEERING COLUMN 3. DECORATE COVER,STEERING COLUMN 4. SCREW（M6×12） 5. LOCKING NUT(M8) 6. HOLDER,STEERING COLUMN 7. BOLT，FLANGE(M8×35) 8. RUBBER CUSHION,COLUMN 9.BOLT(M8×25) 10. SPRING WASHER 11. STEERING JOINT 12. BOLT(M10×30) 13. SPRING WASHER(Ф10) 14. GASKET(Ф10) 15. HOOP， STEERING COLUMN （IRON） 16.
Page 181 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Overhaul Info………………………………9-1 Rear brake………………………………9-4 Troubleshooting……………………………9-2 Rear suspension…………………………9-5 Rear wheel…………………………………9-3 Overhaul info: Note: ● Securely support the vehicle when overhauling the rim and suspension system. ● Use genuine parts of bolts and nuts for rear rim and suspension. ●...
Page 182 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Troubleshooting Rear wheel wobbles ● Rim warpage ● Faulty tire. ● Tire pressure too low ● Improper wheel balance ● Improper tightening of wheel axle nut ● Loosened wheel nut Rear shock absorber is too soft ●...
Page 183 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear wheel removal: Refer to front wheel remove.（→8-3） Inspection Rim: Damage, warpage, serious scrapes, etc. Replace if necessary. Slowly turn the wheel, measure the rim vibration with a dial gauge. Service limit：Axial: 2.0mm Radial: 2.0mm Installation: Refer to front wheel installation.（→8-3）...
Page 184 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear Brake Rear Brake Caliper ● Remove: ● Rear left wheel（→9-3） ● 2 bolts from arm ● Brake caliper Inspection: Brake Caliper: Cracks, Oil leakage: → Replace Installation Reverse the removal procedure for installation. Note：...
Page 185 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Rear Suspension System Rear Right Suspension NOTE DO NOT remove both left and right suspension at the same time to avoid fall down of the vehicle. UPPER 1.BOLT ，(M10×1.25×30) 2. WHEEL HUB 3. REAR BRAKE DISC 4. BUSH（THICK） 5. SWING ARM （L）...
Page 186 9. REAR WHEEL 、REAR BRAKE 、SUSPENSION Disassembly Stabilizer Bar Remove: Bolt (24), Spring Washer (23), Nut (22), Nut (20), Washer (19) Rubber Gasket(26) Remove Stabilizer Bar . Installation: Reverse the removal procedure for installation Right rear absorber Removal: Note: Securely support the vehicle when removing rear left and right absorbers. Maintenance of rear absorbers only does not require removal of rear suspension.
Page 187 10. FRONT/REAR AXLE Front/Rear Axle Overhaul Information Standard Lubricating Period Replaced Item Capacity Initially Afterwards SAE15W/40 SF Front Axle I:0.33L/R: 0.28L 350km 5000Km Rear Axle I:0.30L/R:0.25L SAE80W/90 GL-4 I= Initial, R=Replaced Tightening Torque Table Item Type Torque(N.m) Remark Fornt axle bolt M8×28 Screw M8×20...
Page 188: Front And Rear Axle
10. FRONT/REAR AXLE Inspection & Overhaul Inspection and overhaul if any of problems below happens to front and rear axle. Descriptions Causes 1. Unstable moving during accelerating, A. Bearing broken; decelerating or constant speed. B. Gear clearance over/under size; C. Gear severely worn; 2.
Page 189 10. FRONT/REAR AXLE Disassembly of front axle Ref.No Description Ref.No Description Bolt M8×28 Needle bearing 1512 Front dif gear casecover Drive pinion gear O-Ring 141×2.4 Bearing 6007 Bearing 16007 Oil seal 18×65×9 Circlip Coupler Drive clutch cover O seal 14×6.8 Drive clutch 1～2 Nut washer...
Page 190 10. FRONT/REAR AXLE Inspection after front axle disassembly Check if there is damage or crack on the front differential gear case cover and bearing assembling hole is ok. Replace case cover if necessary; Check if front axle bearing clearance ok or turning stable, and roll way, steel ball, needle and plate are ok.
Page 191 10. FRONT/REAR AXLE Front axle assembly and adjustment Front axle case cover assembly Item“31”tightening torque80Nm Item“24”tightening torque62Nm Note：Use engine oil for oil seal, bearing and drive clutch assembly; “ 24” Use screw thread fastening glue; Front differential gear case cover assembly;...
Page 192 10. FRONT/REAR AXLE Front axle assembly and adjustment Illustration： Tightening torque Item“ 1” 25Nm Item“25” 13Nm Item“30” 13Nm Bolt 25Nm Bolt 25Nm Use fastening glue for item“30” assembly. a. Use proper washer 8 and 10 thick ness to adjust gear side clearance between drive pinion gear and differential gear.
Page 193 10. FRONT/REAR AXLE c. Use special equipment or vehicle control circuit into two stroke position before gear motor assembly; d. Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle. 10–7...
Page 194 10. FRONT/REAR AXLE Disassembly of rear axle Ref.No Description Ref.No Description Bolt M10× 1.25× 25 Bevel gear bearing hous. Bolt M8× 25 O-ring 64.5× 3 Rear gear case cover(R) Bearing 6305 O-Ring 151× 3 Bearing retainer Bearing 16017/C2 Drive bevel gear Adjust washer（2）...
Page 195 10. FRONT/REAR AXLE Needle bearing removal a. Disassemble needle bearing 55BTM6720 as illustration if necessary. b. Disassemble needle bearing NA5903 as illustration after heating upto ℃ Rear axle inspection after disassembly Check if there is crack or damage in rear gear case, see mounting hole is ok . Replace gear case or right cover if necessary;...
Page 196 10. FRONT/REAR AXLE Rear axle assembly and adjustment Illustration Tightening torque Item“ 1” 40Nm Item“ 2” 25Nm Item“ 12” 70Nm Item“ 15” 25Nm Item“ 20” 70Nm Item“ 31” 16Nm Bolt 25Nm Bolt 25Nm Use glue for Item“29”assembly Assembly clearance and adjustment of drive bevel gear assembly rear axle.
Page 197 10. FRONT/REAR AXLE f. Adjust item 29 as illustrated, and make sure its end and back clearance of drive gear is 0.3～0.6. Tighten item 31. 10–11...
Page 198: Electric System
11. ELECTRIC SYSTEM CHARGING SYSTEM…………………………………………………………………………………11-1 ELECTRIC STARTING SYSTEM……………………………………………………………………11-3 ELECTRICITY-SPRAYING SYSTEM………………………………………………………………11-8 1. ELECTRICITY-SPRAYING SYSTEM STRUCTURE……………………………………………11-8 2. ELECTRICITY-SPRAYING SYSTEM DIAGRAM………………………………………………11-9 3. ELECTRICITY-SPRAYING SYSTEM MAINTENANCE NOTICE……………………………11-9 4. MAINTENANCE TOOL……………………………………………………………………………11-10 5. ELECTRICITY-SPRAYING SYSTEM COMPONENTSCOMPOSITION&FUNCTION……11-12 ECU………………………………………………………………………………………………………11-12 THROTTLE ASSEMBLY………………………………………………………………………………11-13 INLET PRESSURE SENSOR…………………………………………………………………………11-14 INTAKE AIR TEMPERATUR SENSOR……………………………………………………………11-15 WATER TEMPERATURE SENSOR…………………………………………………………………11-16 OXYGEN SENSOR……………………………………………………………………………………11-17 TRIGGER………………………………………………………………………………………………11-18...
Page 199 11. ELECTRIC SYSTEM △ CHARGING SYSTEM CHARGING CIRCUIT DIAGRAM MAGNETO COIL RESISTANCE ● MEASURE TRIPHASE MAGNETOR STATOR COIL RESISTANCE ● IF THE RESISTANCE VALUE OUT OF PRE- SCRIBED VALUE, REPLACE THE STATOR COIL. ● INSPECT IF THE STATOR COIL AND STATOR CORE INSULATION.
Page 200 11. ELECTRIC SYSTEM ● USE MULTIMETER MEASURE THE ● AFTER ENGINE RUNNING, BATTERY RESISTANCE BE TWEEN THE FULL POWER,IF VOLTAGE BETWEEN TERMINALS, AS BELOW FORM SHOWS, RED LINE, GREEN LINE EXCEED 15V IF THERE IS ONE DATA OUT OF THE OR UNDER 12V, REPLACE WITH A SETTING VALUE, REPLACE WITH A NEW ONE.
Page 201 11. ELECTRIC SYSTEM △ STARTING SYSTEM TRIGGER CIRCUIT DIAGRAM STARTING MOTOR 1. End Cover 2. Brusher Holder 3. Brush Spring 4. O-ring 5. Brush Terminal 6. Stating Motor Cylinder 7. Washer 1.Eed Cover 8. Armature 2.Brush Holder 9. Washer 10. Inner Cover 11.
Page 202 11. ELECTRIC SYSTEM ELECTRIC BRUSH ● CHECK IF THE ELECTRIC BRUSH PERMANENT SEAT ABNORMAL, CRACK, UNSMOOTH. ● IF THERE IS ANY BROKEN, CHANGE THE WHOLE ELECTRIC BRUSH ASSEMBLY COMMUTATOR ● CHECK IF THE COMMUTATOR CHANGE COLOR, ABNORMAL DAMAGE OR OVER WEAR.
Page 203 11. ELECTRIC SYSTEM INITIATING RELAY ● PUT 12V TO THE SMALL TERMINALS;THERE IS CONTINUITY BETWEEN THE LARGE TERMINALS. ● IF THE START RELAY CONTACTS,SHOULD MAKE A CLICKING SOUND. ● WHEN POWER IS TAKEN AWAY FROM THE SMALL TERMINALS,THERE SHOULD BE NO CONTINUITY BETWEEN LARGE TERMINALS.
Page 204 11. ELECTRIC SYSTEM STARTING ENGINE NOTICE ● JOINT LINES ACCORDING TO TRIGGER CIRCUIT ● BEFORE STARTING, CHECK IF ALL THE PARTS ARE CORRECT JOINTED.ELECTRICITY SPRAYING JOINT SEE BELOW: ● CHECK IF GAS CIRCUIT NORMAL. ● CHECK IF OIL CHANNEL AT FAULT. IF BLOCKED,CLEAR BLOCKED PART, SECURE FUEL CHANNEL SMOOTH.
Page 205 11. ELECTRIC SYSTEM △ELECTRONIC FUEL INJECTION SYSTEM ● OXYGEN SENSOR(EXCESS AIR COEFFICIENT ENGINE ELECTRONIC FUEL INJECTION SYSTEM ABOVE 1 OR LOWER THAN 1 INCLUDING THREE PARTS: ● FOUR WHEEL DEAD LOCK (4WD DEAD LOCK (1)SENSOR: INFORMATION). TRANSFORM THE ENGINE NON-ELECTRICITY ●...
Page 206 11. ELECTRIC SYSTEM ELECTRONIC FUEL INJECTION SYSTEM DIAGRAM ELECTRONIC FUEL INJECTION SYSTEM FUEL PIPE’S DISMANTLE AND FUEL FILTER’S MAINTENANCE NOTICE REPLACEMENT SHOULD BE CARRY ON BY PROFESSIONAL ● USE QUALITY COMPONENTS FOR SERVICE, OR ELSE IT PERSON IN WELLVENTILATED PLACE. CANNOT GUARANTEE THE ELECTRONIC FUEL INJECTION ●...
Page 207 11. ELECTRIC SYSTEM SERVICE TOOLS TOOL NAME:DIAGNOSTIC EQUIPMENT FUNCTION: READ CLEAR ELECTRONIC FUEL INJECTION SYSTEM TROUBLE CODE,OBSERVE DATA STREAM, COMPONENETS MOTION TESTS. TOOL NAME: DIGITAL MULTIMETER FUNCTION: INSPECT ELECTRONIC FUEL INJECTION SYSTEM VOLTAGE, CURRENT, RESISTANCE ETC. TOOL NAME: VACUUM METER FUNCTION: INSPECT INLET PIPE PRESSURE STATE.
Page 208 11. ELECTRIC SYSTEM TOOL NAME: ELECTRONIC IGNITION TIMING FUNCTION: INSPECT ENGINE ELECTRONIC SPARK TIMING. TOOL NAME: CYLINDER PRESSURE GAUGE FUNCTION: CHECK CYLINDER COMPRESSION. TOOL NAME: FUEL PRESSURE GAUGE FUNCTION: INSPECT FUEL SYSTEM PRESSURE STATE,JUDGE THE FUEL SYSTEM FUEL PUMP AND FUEL PRESSURE REGULATING VALVE WORK STATE.
Page 209 11. ELECTRIC SYSTEM ELECTRONIC FUEL INJECTION PARTS STRUCTURE AND FUNCTION (1) ECU: ECU,IT IS THE BRAIN OF THE ENTIRE ELECTRONIC FUEL INJECTION SYSTEM. IT ANALYZE AND PROCESS THE INFORMATIONS PROVIDED BY THE SENSOR, REACH A CONCLUSION, THEN TRANSMIT THE CONCLUSION TO THE ACTUATOR AS INSTRUCTION,SO AS TO MAKE THE ENGINE OPERATION IN OPTIMAL STATE.
Page 210 11. ELECTRIC SYSTEM (2)THROTTLE VALVE ASSY: JOIN THE AIR CLEANER AND ENGINE, CONTROL THROTTLE VALVE OFF AND ON ANGLE THROUGH THROTTLE CABLE. AIR DAMPER POSITION SNESORTRANSMIT ANGLE SIGNAL TO ECU. EACH PIN FUNTION: 1. CONNECT 5V POWER 2. GROUNDING 3. OUTPUT VOLTAGE SIGNAL THE RIGHT DRAWING IS THE WIRING DIAGRAM WITH ECU IDLE SPEED LIMIT SCREW NOT...
Page 211 11. ELECTRIC SYSTEM (3)MAP Sensor: MONITOR AIR PRESSURE IN MANIFOLD,PROVIDE ENGINE LOAD INFORMATION TO ECU. EACH STITCH FUNCTION: 1.CONNECT 5V POWER 2.GROUNDING 3.OUTPUT VOLTAGE SIGNAL THE RIGHT DRAWING IS THE CONNECTION DRAWING FOR SENSOR&ECU. THE RIGHT DRAWING IS THE PERMIT FITTING LIMIT, IN THIS WAY CAN ENSURE THERE IS NO CONDENSED WATER INSIDE THE SENSOR,THE...
Page 212 11. ELECTRIC SYSTEM (4)INTAKE AIR TEMPERATURE SENSOR(IAT Sensor): THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT (NTC) THERMISTANCE, IT’S RESISTANCE VALUE DECREASE WHEN THE COOLANT TEMPERATURE INCREASE, BUT IT IS NOT LINEAR RELATION.THE SENSOR HAVE 2 PINS, AND THEY CAN BE EXCHANGED USING. THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR SNESOR&ECU.
Page 213 11. ELECTRIC SYSTEM (5)WATER TEMPERATURE SENSOR: THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT (NTC) THERMISTANCE,IT’S RESISTANCE VALUE DECREASE WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT LINEAR RELATION.ONE GROUP PROVIDE TO ECU,MONITOR ENGINE HEAT CONDITION.THE OTHER GROUP PROVIDE TO THE METER,MONITOR WATER TEMPERATURE. A AND C IN ONE GROUP, THEY PROVIDE WATER TEMPERATURE TO ECU.
Page 214 11. ELECTRIC SYSTEM (6)OXYGEN SENSOR: THIS SENSOR USED IN ELECTRONIC CONTROL FUEL INJECTION EQUIPMENT FEEDBACK SYSTEM,TO REALIZE CLOSED-LOOP CONTROL,RAISE ECU CONTROL THE AIR-FUEL DELIVERY RATIO. IT INSTALLED IN THE EXHAUSTPIPE,MEASURING WASTE GAS OXYGEN CONTENT,DEFINITE IF THE GAS AND AIR COMPLETE BURNT,SO AS TO ENSURE UNIT TRIPLET CATALYTIC CONVERTER HAVE MAXIMUM CONVERSION EFFICIENCY TO EXHAUST HC,CO AND NOX.
Page 215 11. ELECTRIC SYSTEM (7)TRIGGER: PROVIDE ENGINE ROTATE SPEED INFORMATION TO ECU,ECU DETERMINE IGNITION ANGLE,FUEL INJECTION ANGLE ACCORDING TO THIS INFORMATION. THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR TRIGGER AND ECU. TESTING THE THRIGGER RESISTANCE VALUE. ● ADJUST MULTIMETER TO 1x100Ω TRIGGER WINDING RESISTANCE:100-130Ω(20℃) ●...
Page 216 11. ELECTRIC SYSTEM (8)ODOMETER SENSOR: PROVIDE ENGINE OUTPUT SHAFT SPEED TO ECU, ECU JUDGE VEHICLE SPEED ACCORDING TO THIS INFORMATION.IT IS A KIND OF HALL SWITCH COMPONENTS,IT OUTPUT SQUARE WAVE VIA INDUCTION FIELD. PINS FUNTION: 1.GROUNDING 2.OUTPUT SQUARE WAVE VOLTAGE SIGNAL( ＞IN PUT POWER VOLTAGE 80%).
Page 217 11. ELECTRIC SYSTEM (9)GEAR SENSOR CLUSTER: PROVIDE GEAR INFORMATION TO THE METER,SOAS TO AT THE SAME TIME,COORDINATE WITH CABLE AS STARTING PROTECTION. FUNCTIONS OF THE FOOTS: YELLOW/BLUE-L (UNDERDRIVE) ORANGE/BLUE-H (HIGH POSITION) YELLOW/BLACK-P (PARK POSITION) WHITE/YELLOW-N (NEUTRAL POSITION) ● WHEN EACH OF THE FOUR GEAR IN A CERTAIN POSITION,GEAR CORRESPONDING FOOT CON DUCT TO THE ENGINE COVER, OR ELSE IT NONCONDUCTION WITH THE ENGINE...
Page 218 11. ELECTRIC SYSTEM (11)FUEL PUMP ASSY: THE OIL FUEL PUMP ASSY COMBINED OF FUEL PUMP,PLASTIC BRACKET PREFILTRATION PRES SURE REGULATING VALVE. IT DELIVER THE FUEL TO THE ENGINE WITH A CERTAIN OIL PRESSURE AND FLOW. FUNCTIONS OF THE FOOT: 1. BLUE (GROUNDING) 2.
Page 219 11. ELECTRIC SYSTEM (12)FUEL INJECTOR: FUEL INJECTOR ONE END INSTALLED IN SEAT, THE OTHER END CONNECT WITH THE FUEL PIPE VIA FUEL INJECTOR CAP.ACCORDING TO THE ECU INSTRUCTION, IT SPRAY FUEL IN FIXED TIME.SO AS TO SUPPLY OIL TO THE ENGINE AND ATOMIZING.
Page 220 11. ELECTRIC SYSTEM (13)IDLE SPEED CONTROL VALVE (CARBON TANK CONTROL VALVE): CONTROL PASS-BY AIR FLOW. ECU CONTROL THE IDLE SPEED VALVE ACCORDING TO THE INFORMATION OF ENGINE LOAD,THE ELECTRICAL PULSE DURATION,ANDFREQUENCY:(DUTYRATIO)THE IDLE SPEED VALVE HAS DIFFERENT AIR FLOW UNDER DIFFERENT PRESSURE ,SO IT MUST BE CONNECTED ACCORDING TO PRESCRIPTIVE METHOD,OR ELSE WILL CAUSE INCORRECT IDLE SPEED,WHEN WITHOUT ELECTRICAL...
Page 221 11. ELECTRIC SYSTEM (14)IGNITION COIL: IGNITION COIL CHANGE THE PRIMARY WIND ING LOW VOLTAGE INTO SECONDARY WINDING HIGH VOLTAGE,THROUGH SPARK PLUG DISCHARGE TO CREAT SPARK,FIRING THE FUEL AND GAS MIXTURE. FUNCTION OF PINS: 1. GROUNDING. 2. CONNECT POWER+. 3. CONNECT ECU 1 POINT; THE RIGHT IS THE CONNECTION CIRCUIT DIAGRAM OF IGNITION COIL AND ECU.
Page 222 11. ELECTRIC SYSTEM ELECTRONIC FUEL INJECTION SYSTEM FAULT SELF-DIAGNOSIS ECU CONTINUOUSLY MONITOR THE SENSOR,ACTUATOR,RELEVENTCIRCUIT ,TROUBLE LAMP,BATTERY VOLTAGE ETC,EVEN THE ECU ITSELF.ALSO THE SENSOR OUTPUT,ACTUATOR DRIVING SIGNAL,INTERNAL SIGNAL(SUCH AS CLOSED-LOOP CONTROL COOLANT TEMPERATURE,IDLING SPEED CONTROL,BATTERY VOLTAGE CONTROL ETC),DO THE RELIABILITY MEASUREMENT. ONCE DISCOVER SOME WHERE BREAK DOWN,OR SOME SIGNAL VALVE UNTRUSTED,THE ECU WILL IMMEDIATELY SET UP FAULT RECORD INFORMATION IN RAM TROUBLE MEMORY.THE FAULT INFORMATION STORE AS TROUBLE CODE,AND DISPLAY THE FAULT IN IT’S EMERGENCE SEQUENCE.
Page 223 11. ELECTRIC SYSTEM TROUBLE CODE LIST: TROUBLE CODE INSTRUCTION P0030 OXYGEN SENSOR HEA TING CONTROL CIRCUITOPEN CIRCUIT P0031 OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT TO GOUND OXYGEN SENSOR HEA TING CONTROL CIRCUITSHORT CIRCUIT TO P0032 POWER OXYGEN SENSOR TING INTERNAL RESISTANCE P0053 UNREASONABLE P0105...
Page 224 11. ELECTRIC SYSTEM TROUBLE CODE INSTRUCTION P0560 SYSTEM BATTERY VOLTAGE SIGNA L UNREASONABLE P0562 SYSTEM BATTERY VOLTAGE TOO LOW P0563 SYSTEM BATTERY VOLTAGE TOO HIGH P0602 ECU CODING TROUBLE P0627 OIL PUMP RELAY CONTROL CIRCUIT OPENING P0628 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO GROUND P0629 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO POWER P0650...
Page 226: Lighting & Switches
12. LIGHTING AND SWITCHES Overhaul Info……………………12-1 Horn…………………………………… 12-8 Troubleshooting…………………12-2 Fuel Sensor…………………………… 12-9 Replacing bulbs…………………12-3 Water Temperature Transducer………12-10 headlight…………………………12-5 Ignition Switch…………………..12-6 Handlebar Switch………………..12-7 Brake Light Switch……………….12-8 Overhaul Information Warning ● Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down.
Page 227: Troubleshooting
12. LIGHTING AND SWITCHES TROUBLESHOOTING Head Light Cannot Turn On ● Broken fuse ● Open circuit with main cable ● Burnt Bulb ● Faulty Switch 12-2...
Page 228 12. LIGHTING AND SWITCHES Replacing Bulb Headlight Bulb Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down. Remove headlight(→13-5） Disconnect headlight.
Page 229 12. LIGHTING AND SWITCHES Brake Light/Tail Light Bulb Remove 2 tapping screws, Remove tail light cover. Turn brake light/tail light bulb counter clockwise And remove it. Replace brake light/tail light bulb Bulb Specification: 12V 21/5W Reverse the removal procedure for installation Front Turning Indicator Bulbs Remove headlight (→13-5) Remove cover of front turning light...
Page 230 12. LIGHTING AND SWITCHES Dashboard Lighter Bulb Remove dashboard (→13-9) Remove bulb socket and replace with a new bulb. Bulb specification: 12V-1.7W Note: Main cable and wires should be routed properly (→chapter 1) Reverse the removal procedure for installation. Dashboard Indicator Bulb Remove dashboard (→13-9) Remove dashboard indicator socket.
Page 231 12. LIGHTING AND SWITCHES Disconnect headlight connector. Reverse the removal procedure for installation. Note: Be careful not to damage main cable when assembling. After replacing, adjust the headlight beam. (→chapter 3) Note Main cables and wires should be routed properly.( →chapter 1) Ignition Switch Inspection Remove front &...
Page 232 12. LIGHTING AND SWITCHES Check according to the following table if the connector terminals are in continuity. Remove: Remove holder, meter (→2-3) Disconnect 4P connector of ignition switch Reverse the removal procedure for installation Combined Switch Remove front &rear cover of steering rack (→2-2) Remove combined switch（→2-3）...
Page 233 12. LIGHTING AND SWITCHES Horn Button 2WD、4WD、4WD Diff-Lock Switch No continuity: Change the switch. Brake Light Switch Disconnect brake light switch connector and check terminators for continuity. Hold the brake lever——Continuity Release the brake lever—No continuity No continuity: Replace brake light switch Horn Inspection: Remove engine cover (→2-3)
Page 234 12. LIGHTING AND SWITCHES Fuel Sensor (Carbureter) Remove: —Fuel tank top cover with key —5 fixing bolts —Fuel sensor Disconnect 2P connector Inspection Remove fuel sensor (refer to above steps) Connect 2P connector Turn ignition switch to ON Shake fuel sensor float with hand, locate the float po- Sition and check if it conforms to the fuel gauge reading.
Page 235 12. LIGHTING AND SWITCHES Inspection of Fuel Gauge Switch on power supply and check if fuel level gauge functions normally. If fuel gauge works normally, Reverse the removal procedure for installation of plastic parts and seat. Water Temperature Transducer Warning: Be careful not to get scalded and do not place flammables nearby.
Page 236 13. TROUBLESHOOTING 1. Engine troubleshooting..................13-2 2. Diagnosis troubles according to EFI system Trouble Code........13-5 3. Diagnosis troubles according to engine fault phenomena........13-14 13-1...
Page 237 13. TROUBLESHOOTING 1.Engine troubleshooting Complaint Symptom and Possible Causes Remedy Compression is Too Low 1.Worn cylinder Replace 2.Worn piston ring Replace 3.Leakage with cylinder gasket Replace 4.Wear valve guide or improper valve Repair or Replace seating 5.Loose spark plug Tighten 6.Slow cranking of starting motor Check electrical part Engine will not start...
Page 238 13. TROUBLESHOOTING Complaint Symptom and Possible Causes Remedy 1. Weak valve spring Replace 2. Worn camshaft Replace 3. Fouled spark plug Clean or replace Poor engine 4. Insufficient spark plug gap Adjust or replace running in 5. Improper valve timing Replace high-speed 6.
Page 239 13. TROUBLESHOOTING Complaint Symptom and Possible Causes Remedy Valve Chatter 1. Excessive valve clearance Adjust 2. Worn or broken valve spring Replace 3. Worn rocker arm or camshaft Replace Noise from Piston 1. Worn piston Replace 2. Worn cylinder Replace 3.
Page 240 13. TROUBLESHOOTING 2 Diagnosis troubles according to EFI system Trouble Code NOTE: 1. Only start inspection and fixation when trouble is steady-state; otherwise diagnosis would probably be wrong. 2. The “multimeter” mentioned below are numerical mutimeter; it is forbidden to use pointer type multimeter to make EFI system inspecting.
Page 241 13. TROUBLESHOOTING Trouble Code: P0030 Oxygen Sensor Heating Control Circuit Broken Note Note Possible Troubles are as below Inspect as below 1）Circuit broken between ECU Pin and Oxygen 1）Check if resistance between ECU Connector Sensor Pin 2. Pin and Oxygen Sensor Pin 2 is normal or not. 2）Circuit broken between Oxygen Sensor Pin 1 2）Check if resistance between Oxygen Sensor and Main Relay.
Page 242 13. TROUBLESHOOTING Trouble Code：P0106 Air Inlet Pressure Sensor Signal irrationally failure Note Possible Troubles are as below 1）Air leakage of Air Inlet Pressure Sensor. 2）Air Inlet Pressure Sensor broken. 3）Air leakage from assemble point. 4 ） Air Inlet Pressure Sensor characteristically defluxion.
Page 243 13. TROUBLESHOOTING Trouble Code：P0117 Engine Water Temperature Sensor Circuit Voltage low. Note Note Possible Troubles are as below Inspect as below 1）Circuit between ECU Pin and ground short. 1) Check resistance between ECU Pin and Ground. Trouble Code：P0118 Engine Water Temperature Sensor Circuit Voltage high. Note Note Possible Troubles are as below...
Page 244 13. TROUBLESHOOTING Trouble Code：P0132 Oxygen Sensor Circuit Voltage High Explanation： When engine starts, ECU check the Oxygen Sensor Circuit Voltage; When voltage is continuously higher than 1.5 Volt, system decides Oxygen Sensor Circuit Voltage is short to power. Note Note Possible Troubles are as below Inspect as below 1）Short Circuit between Signal Circuit connect to...
Page 245 13. TROUBLESHOOTING Errors coding: P0261 Control circuit of single cylinder injector short to ground Maintenance Tips： Maintenance Tips： The possible faults may exists as follow: Check the item as follow: 1）All drivers ECU pin connected short to 1）Measure ECU pin connected resistance ground to ground Errors coding: P0262 Control circuit of single cylinder injector short circuit...
Page 246 13. TROUBLESHOOTING Errors coding: P0458 Control circuit voltage of idle air control valve too low Maintenance Tips： Maintenance Tips：Check the item as follow: The possible faults may exists as follow: 1 ） Measure connected to the ECU 1）Circuit ECU connected is short circuit pin-to-ground resistance whether proper or not Errors coding: P0459 Control circuit voltage of idle air control valve too high...
Page 247 13. TROUBLESHOOTING Errors coding: P0507 Rotate speed of idle speed control valve faster than target idle speed Introduction of theory and fault reason: Engine rotate speed of idle speed works by closed-loop control. And it indicates fault if ECU performs idle speed controlling after a certain time, but the actual engine speed faster than target idle speed.
Page 248 13. TROUBLESHOOTING Errors coding: P2177 Self-learning value of air-fuel ratio, closed-loop control exceeds upper limit Errors coding: P2178 Self-learning value of air-fuel ratio, closed-loop control exceeds lower limit Introduction of theory and fault reason: In order to make catalytic converters for HC, CO and NOx to maximize conversion efficiency, the air-fuel ratio of mixture should be 14.7:1.
Page 249 13. TROUBLESHOOTING 3.Diagnosis troubles according to engine fault phenomena Before start to diagnosis fault, please take the primary inspection first: 1.Engine failure indicator light works regularly. 2.Affirm that no errors Code have been found by Diagnosis Analyze. 3.Affirm the fault that user complaint is exist, and affirm the condition of fault happened. Then, take external inspection: （1）...
Page 250 13. TROUBLESHOOTING （1）Starting Failure/Hard Starting Possible defective part ： 1.Battery； 2.Starter motor； 3. Wiring harness or ignition switch;4.engine mechanism part. Overhaul: Ref No. Operation Test result Next Steps Check the voltage between the two poles of battery next by multimeter, the voltage whether around 8-12V or Replace battery not when engine starting.
Page 251 13. TROUBLESHOOTING Check compression of cylinder and observe the pressure Eliminate engine if is discrepantly. mechanism fault next Contact EFI commutator, open ignition switch, check Diagnosis help ECU5#、10#、13# stitch, the power whether supply Examine and repair normally or not, check 2#、21# stitch whether Put up iron relevant wiring or not.
Page 252 13. TROUBLESHOOTING Ref no Operation Test Next Steps result Contact fuel pressure meter(contact front point of oil input next pipe of injector), starting engine, check the fuel pressure examine and repair whether is around 300kPa or not oil support system Pull out ignition coil, and contact with spark plug, keep next pole of spark plug 5mm away of body of engine, starting...
Page 253 13. TROUBLESHOOTING Contact fuel pressure meter (contact front point of oil next input examine and repair pipe of injector), starting engine, check the fuel pressure oil support system whether is around 300kPa or not Pull out ignition coil, and contact with spark plug, keep next pole of spark plug 5mm away with body o f engine, examine and repair...
Page 254 13. TROUBLESHOOTING Check idle speed valve whether clogged or not. Clean or replace next Check spark plug, look its type and gap if accords next with standard. Adjust or replace Check throttle valve body and idle speed side air Clean duct whether have carbide accumulated or not.
Page 255 13. TROUBLESHOOTING next Check fuel and observe the fault if caused after Replace fuel fueling next Check compression of cylinder and observe the Eliminate engine pressure. mechanism fault next Contact EFI commutator, open ignition switch, Diagnosis help check ECU5#、10#、23# stitch, the power Examine and repair whether supply normal or not, check 2#、21# relevant wiring...
Page 256 13. TROUBLESHOOTING Possible defective part：1、idle speed valve；2、injector Overhaul : Ref no Operation Test Next Steps result Disassembly idle speed valve and check the throttle Clean related parts valve body, idle speed valve and idle speed side air next duct whether have carbide accumulated or not. Observe output power whether is increasing or not Turn step no.4 when begin loading work, namely observe the...
Page 257 13. TROUBLESHOOTING Contact with EFI commutator, open ignition switch, Diagnosis help check ECU5#、10#、23# stitch, the power whether supply normal or not, check 2#、 21# stitch whether is Examine and repair putting up iron or not. relevant wiring （ 11）Rotate speed can not increase or engine power off when in acceleration. Possible defective part：1、fuel containing water；...
Page 258 13. TROUBLESHOOTING （12）Reaction slowly when in acceleration. Possible defective part：1、fuel containing water；2、air intake pressure sensor and throttle position sensor；3、spark plug；4、throttle valve body and idle speed side air duct；5、input air duct；6、idle speed valve；7、fuel injector；8、ignition timing；9、muffler Overhaul： Ref no Operation Test result Next Steps Check air cleaner if is clogged.
Page 259 13. TROUBLESHOOTING Overhaul： Ref no Operation Test Next Steps result Check the faults if exist clutch skid, low tyre repair pressure, lagged brake, improper tyre size etc. next Check air cleaner if is clogged. Examine and repair air input system next Contact fuel pres sure meter(contact front point of oil next...

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