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1. 4 ELECTRICAL DIFF pin DIFF CUNTRUL amp STARTER IN GEAR UNIT CIRCUIT 2 S W ASSY R DCU HARNI FDSW 9 S W ASSY R DCU HARNI P1 02 P N 0 DIOD1 CU HARNI P1 03 DAD 05 5 Mixes DCU HARNI P1 04 0 cavs SPEEDMETER 19 DCU HARNI P1 05 CAVS SWITCH BREAK FOOT DCU HARNI P1 06 B Jeavs irr 2107 s anon ul v DCU HARNI DCU HARNI DCU HARNI P1 10 SPEEDMETER PIN 3 DCU HARNI 11 SPEEDMETER DCU HARNI 1 12 E G RELAY DCU HARNI EE m s olo eje oj ojojo inum on on on cavs oe ron DIFF LORK MOTORY cut 1 n AVX GNDC DCU 11 13 Fh 12 01 DIFF LOCK DCU Pe 028 DCU 03 DCU 05 DCU HARN2 DCU 2 06 DCU DCU ud E T DIFF LOOK MITOR 3 FUSE FUSE7 LL mx FIN19 DCU HARNI 3 0 BATE 3 FUSE1 10 P2 16 V 5 ELECTRICAL Other pi
2. ASSY L ALX FUSES FLSHER SW FLASHER AEX E z 61012 AEX FLSHE amp SW DI FLS2 eee FUSE2 S W ASSY LF GND36 AEX FLSHER VOL GNIX DLGI CAVS ASS Y LF LAMP 557 FR LAMP ASSY 2 1 FR S W ASSY LF ASS LAMP ASSY DLG CAVS S W ASSY LF LAMP t rM DIRECTION INDICATOR i v pex een en mo es swmwar E G RELAY 151 E FREAK LAMP LAMP BREA X HANDCR BLG2 CAVS SUI TCH BREAK HANK BREAK LAMP Lue a ens nr RELAY BLG3 CAVS SWITCH BREAK HANIKL oe LAMP BREAK HAND L EE CAWS SUITCH SREAK ZHANTE L e BREAK LAMP pee Ens me mae 3 Tax LLGI Y CAVS DTHER LIGHT RELAY FLG HEADLIGHT RELAYCHID LAMP TOWAGE ALL KIND OF LAMP TOWAGE amp o 0 G8 L CAVS SV I TCH BREAK HANIK LAMP IO SWITCH BREAK FOOT LAMP TOWAGE mi rw SiS SSF CS me pws wi Hz L 5 js wassviw DIOE
3. NC NC NC NG 18 19 _ __21__ 22 28 _ 34 28 EE 8 28 28 _ BHI BLO ECU Type MC21 1030 a A ee Part Introduction ECU MC21 1030 Assembly BOLT M X 1 0 mm X 1220 mm LOCATION FOR LABEL CLAMP 7 0 mm MAP TUBE ID23 18 0 25 mm OD Min 8 33 mm 9 53 mm OPERATE CONNECTOR DUWWN LOCK 2 143 285 5 Electrical Characteristic Operation Voltage Range 9 16V Storage Temperature Range 40 70 Operation Current lt 500 1 12 Identification Code 28140652 MUT ECUPin28 Part Introduction Identification Code 28140652 Injector Holes 4ea Circuit Diagram Main Power Relay MPH Pin 28 Measurement Resistance 12 0 0 60 Throttle Body ASM Idle Air Control Valve lt IACV gt Step Motor a Oy n dme Throttle Position Sensor Throttle Body TPS 1 14 Throttle Body TPS gt Step Motor d Step Motor GND ECU Pine 5V m A B 5 Part Introduction TPS Circuit Diagram THROTILE POSITION SENSOR otep Motor Circuit Diagram gt ecu G TAES BLO Measurement TPS Resistance 1 20 ECU Pin21 GND
4. 1 15 Rollover Fuel Cut Sensor Left View Top View Part Introduction sensor Voltage 12V sensor Pitch Angle 65 10 Sensor Roll Angle 20 20 Sensor Temperature 10 60 C Circuit Diagram Vcc 12V Assembly Bolt M4 Bolt x 2 Tighten Torque 1 5 2 5Nm Measurement Resistance 3 90 Vcc Output 16 Fuel Connector Sensor Meter Pin24 Fuel Filter Fuel Level Sensor Part Introduction Pump Characteristic Voltage 12V Feed Fuel Pressure 250 10Kpa Feed Fuel Rate 30 6 L hr min Circuit Diagram meter Sensor GND Y 12V Pump Pint Pin1 Measurement Resistance 4 100 Full Stop 93 1000 Empty Stop Ignition Coil E Black v E _ e 5 E 4 E E gt to Spark Side PBT Green Part Introduction Sensor Characteristic Voltage 12V Sensor Temperature 10 60 C Circuit Diagram Spark Side PBT Black Secondary 4 PBI Black Assembly Bolt M4 Bolt x 2 Tightening Torque 10 2 Nm Measurement Primary 2 9 Q 10 oecondary 15 1096 I 18 Alternator Crank Sensor RTV y Connector Rectifier Connector CNKN GND CNKP I 19 Alternator Part Introduction Electric Characteristic Voltage
5. SNS R Y R_ cavs _ jg SNSR CF ECM HARN PINIO PEXCS SO CRANK SNSR ECM HARN PINSI CRANK SENSOR B 5 501 CRANK SNSR ECM HARN PINS2 B W CAVS IAT SNSR ECM HARN PINO cur susr ECM harn ms Y AX tes raev ECM IACV_BL 0 AEX IACV ECM HARN PIN34 iav PINES 021 0 2 O2RA CNKP CNKN 5051 SENSOR FRI a en zn c eet ult an a na u Olloa 6n ci va T RLYP 125 RW AX r P RELY Fuses FUP 0 8 CAVS F P RELAY S W ASSY R FUEL PM D cavs F P RELAY HARN PINCI FUEL PUMP amp F P RFLAY PUMB 64025 UNF P GND17 HI 10 Joo pincnasic ecv rae Proa 1 1 G R AEX DIAGNOSTIC E G RELAY DiAGNUSIIC B CAVS DIAGNOSTIC GNIX 5 GND B 1 25 L pracnostic HARN PINOS DIA 0 5 KLI 0 5 v piacnostic HARN PINO RYE E G RELAY rus BAT 1 25 R B cavs FUSES ECM PINOS a MIL PINI4 MALFUNCTION INDICATO
6. CHASSIS ANTLE Dismantle the screws under the front cover from the two sides of the cover Pull out the front cover Z Warning Dismantle the connector of power supply The front cover 2 CHASSIS FRONT COVER DISMANTLE Dismantle the front cover then turn it over Turn counterclockwise to dismantle the power supply The power supply 9 CHASSIS LHS COVER DISMANTLE Dismantle the rivets amp screw then pull out the panel The mudguard panel LH Dismantle the bolt amp rivet then pull out the left side cover The side panel LH 10 CHASSIS LHS COVER DISMANTLE Dismantle the screws H Release the tenon of left cover Then pull out the cover side cover LH CHASSIS LHS COVER DISMANTLE Dismantle the bolts then remove the cover The engine cover LH 12 CHASSIS RHS COVER DISMANTLE Dismantle the rivet Release the tenon then pull out the cover CHASSIS RHS COVER DISMANTLE Dismantle the rivets and screw then remove the panel The mudguard panel RH Dismantle the rivets then remove the cover upper engine cover 14 CHASSIS RHS COVER DISMANTLE Dismantle the bolt and rivet then remove the panel um 4 The panel Dismantle the screws Push the revolve lever from the
7. zc Glue diameter about 2mm 57 ENGINE Assembly Install oil sump then tighten the bolts Torque 10Nm Install the CVT drive pulley then tighten the bolt Torque 120Nm Install the driven pulley then tighten the bolt X Torque 45Nm Tighten the Belt Removal Tool to end to open the driven pulley then install the belt ENGINE Assembly Then rotate driven pulley check the belt on position lt The driven pulley can be free rotate Install the CVT cover then tighten the bolts Torque 10Nm Install the rewind starter Then tighten the bolts Torque 10Nm al On Road Type The engine assembly complete CHASSIS SEAT DISMANTILE P1 AIR CLEANER COVER DISMANTLE P2 FRONT DECK DISMANTLE P4 METER DISMANTLE P5 FRONT COVER DISMANTLE P7 LHS COVER DISMANTLE RHS COVER DISMANTLE HEAD LAMP DISMANTLE UPPER MUDFLAP DISMANTLE P21 PROTECTOR DISMANTLE P23 FOOT REST PEDAL DISMANTLE P28 FRONT FENDER DISMANTLE P30 INNER MUDFLAP DISMANTLE P32 REAR LAMP DISMANTLE P36 REAR COVER DISMANTLE P40 TAIL LAMP ASSEMBLY DISMANTLE P47 ELECTRICAL HOUSING DISMANTLE P50 THROTTLE BODY DISMANTLE P52 MUFFLER DISMANTLE P56 FUEL
8. Dismantle the bolts of air cleaner X Torque 10 Nm Dismantle the connector of Sensor Release the screw of clamp Release the screw of clip then remove the hose and pull out the air clenaer 52 CHASSIS THROTTLE BODY DISMANTLE m 2 Pull out the air cleaner The air cleaner 53 CHASSIS THROTTLE BODY DISMANTLE Dismantle the connector of IACV and TPS Dismantle the bolts of throttle cable cover Warning Be careful about the O ring of the throttle cable cover throttle cable cover ri 54 CHASSIS THROTTLE BODY DISMANTLE Zo a Release the nuts to loosen the throttle cable then remove throttle cable Release the screw then remove the throttle A Warning Avoid any dirt Cover the intake pipe The throttle 55 CHASSIS MUFFLER DISMANTLE Release the bolt of clip Torque 15 Nm Torque 25 Nm Then remove the muffler The muffler 56 CHASSIS MUFFLER DISMANTLE Check the gasket of muffler The gasket Dismantle the connector of O2 sensor Dismantle the nuts of exhaust pipe Torque 20 Nm 57 CHASSIS MUFFLER DISMANTLE Then remove the exhaust pipe he exhaust pipe 58 CHASSIS FUEL PUMP DISMANTLE Use Spanner Fuel Retainer to dismantle the retainer
9. LEL KINGCOBRA ESTOC SERVICE MANUAL v1 3 TOPIC POWER TRAIN I POWER TRAIN Engine Specification Engine Lubrication System Engine Breather System CVT Systemu r AFIRM n o Start System Injection System Emission Control System Cylinder Head Block qi pa 5255 27 Lc ED Engine Specification Type 4 Stroke Single Cylinder SOHC 4 Valves Displacement 497cc Bore x Stroke 090 x 78mm Compression Ratio 10 0 Max rev 7500rpm Transmission CVT V belt Emission 2002 51 EC Weight 67kg I 1 Engine Lubrication System Left Side Right Side E Gan 4 x Pressure SW en oe Lubrication Wet Sump Oil Inlet Oil Pump Rotor Type Oil Return Oil Filter Paper Oil 10w 40 Oil Volume 3 0L 3 5L Replace Filter Pressure Release 4 5 kg cme Pressure S W 0 2 kg cm 1 2 Engine Breather System Intake Side Exhaust Side Breather Hose Blow by Gas cm s Engine Oil Crankshaft Li CVT System E Drive Wheel CVT Belt Type DAYCO 5324 Drive Wheel Tightening Torque 40 45Nm Driven Wheel Tightening Tor
10. E 4 zd 3 gt a 4 p pesar ga _ A 4 cr 4 tn SS DSA 2 aa Sees NE um Fin TOL gt 4 Je 2 1 ee 1 RG CAT LAN A 7 Caw 7 FUEL PUMP RECTIFIER Ground Wire Position Maintenance Step 1 Dismantle the wire 2 Use the sand paper to clean the position 3 Use the sand paper to clean the ground wire 4 Lay the grease on the position and wire N 1 727 D l SS NA Tu M Lal E 1 em C Mea e av A ___ Av gt 7 zd gt A m d gt _ gt PA j 2 2780 N fi lt P 7 N E 2 2 a 1 2 1 A ws 5 i v A kx 77 do pere 1 ce 7 lt 22 AES d AY NN TN SZAL AOU er 722 7 Li MAINTENANCE Regular Maintenance Table P1 Engine Oil Type P2 Differential Oil Type P4 Coolant P6 Engine Torque Table P8 Chassis Torque check P9 Spark Plug
11. 12V Output 16V 1500rpm 7 Circuit Diagram Rectifier RECTIFIER Vehicle CRANK SNSR FLY WHEEL I 20 DISMANTLE CVT Cover Dismantle P1 CVT Belt Dismantle P2 CVT Driven Pulley Dismantle P2 CVT Driving Pulley Dismantle P3 Rewind Starter Dismantle P4 Timing Check P4 Accessory Cover Dismantle P6 Discompressor Dismantle P7 Alternator Rotor Dismantle P8 Cam Shaft Dismantle P9 Chain Dismantle P11 Cylinder Head Dismantle P12 Balancer Dismantle P13 The Oil Pump Dismantle P14 The Driveshaft Dismantle P15 The Main Circuit Dismantle P17 The Cylinder Block Dismantle P18 The Transmission Gear Dismantle P20 The Oil Release Valve Dismantle P22 The Crankshaft Dismantle P23 The Piston Dismantle P24 ASSEMBLY The Piston And Connection Rod htc M P25 The Balancer Assembly P27 The Main Shaft Assembly P29 The Lay Shaft Assembly P30 The Rear Driveshaft Assembly P32 The Cylinder Head Assembly P33 The Water Pump Assembly P36 The Shift
12. 41010004 NUT M30 install long side into gear side shortside long side figure 28 40110024 1 Install key 2 into crankshaft 1 keep the key parallel with crankshaft taper 2 Install gear 3 into crankshaft 1 gear groove must be alignment key of crankshaft 3 Install cam chain sprocket 4 into crankshaft 1 shall be install long side into gear side of crankshaft reference to figure A 4 Screw nut 5 to crankshaft 1 tighten torque 250Nm ri ENGINE Assembly THE MAIN SHAFT ASSEMBLY PARI NAME PART NO MAIN SHFAT 46030001 BEARING 46030034 SPACER 46010003 LIP SEAL 40016004 RETAIN C RING RCS025 WASHER 46030010 NEEDLE BEARING CAGE TYPE 46030030 HIGH SPEED DRIVE GEAR 27T 46030003 LOW SPEED DRIVE GEAR 18T 46030004 NEEDLE BEARING OPEN TYPE 46030028 Z O Before install gear and bearing please lubricate with 10W 40 oil 1 Install bearing 2 into main shaft 1 the bearing of ring side shall be install to main shaft of gear side 2 Install spacer 3 into main shaft then install seal 4 into spacer 3 3 Install a C ring 5 into main shaft of groove then put a washer 6 into main shaft 4 Install needle bearing 7 and high gear 8 into main shaft shall be install high gear of raised side into main shaft of gear side 5 Install a washer 6 into main shaft then install C ring 5 int
13. Use the Rewind Starter Stopper clockwise rotate crankshaft then check chain timing ALT rotor mark meet the accessory cover mark When ALT mark correct then check cylinder head sprocket have six pieces counter from cylinder head ENGINE Dismantle ACCESSORY COVER DISMANTLE Loosen the accessory cover bolts Raise the accessory cover by screwdriver from the prominence of case When remove the accessory cover be care the spin nose antithrust spring and washer 6 ENGINE Dismantle Loosen the discompressor mechanism bolt by open wrench DISCOMPRESSOR DISMANTLE Fi Pull out the discompressor mechanism The discompressor mechanism and notice the spring 7 ENGINE Dismantle A Loosen the ALT rotor nut by air wrench lt The socket deep 85mm Tighten Crankshaft Protector to end on crankshaft Tighten the ALT Puller to end on ALT rotor Tighten the CVT Puller on ALT Puller by air wrench then remove the ALT rotor ENGINE Dismantle CAM SHAFT DISMANTLE Loosen the tensioner cover and notice the spring and O ring Loosen the tensioner bolts then remove the tensioner Loosen the cam sprocket bolts then remove the cam sprocket Loosen the cam antithrust plate Bolt then remove the plate ENGINE Dismantle Pull out intake and exhaust rock arm shaft by magnet Pull out the
14. rear lamp CHASSIS REAR LAMP DISMANTLE amp Dismantle the screw Dismantle the bottom bolts of the bracket Z Warning Dismantle the connectors The rear lamp housing LH 38 CHASSIS REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the screws then remove the cover The rear lamp cover LH The rear lamp LH 39 CHASSIS REAR COVER DISMANTLE Dismantle the bolts then remove the hooks X Torque 10 Nm hook carrier The hook alignment Dismantle the bottom screws from two sides of rear cover CHASSIS REAR COVER DISMANTLE Dismantle the upper bolts Torque 10 Nm Screw out the fuel cap Warning Avoid any dirt Cover the fuel tank The fuel cap III 41 CHASSIS REAR COVER DISMANTLE Pull up the rear cover Z Warning Avoid any dirt reinstall the fuel cap The rear cover 42 CHASSIS REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Push the tenon then remove the cover The rear cover RH 43 CHASSIS REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Push the tenon then remove the cover The rear cover LH CHASSIS REAR COVER DISMANTLE i Dismantle the rear cover The mesh Turn over the rear cover th
15. Tensioner 10Nm Discompressor 54 5Nm 10Nm 12Nm 200Nm Accessary Cover 56 10Nm 20Nm Balancer Cover 10Nm 10Nm 45Nm CO VI Chassis Torque Check ip EM 3 5 LHS Engine Bolts x 2 6 LHS Footrest Bolts x 4 7 Propeller Shaft Bolts x 8 12 Muffler Bolts x 2 20 N m Chassis Torque Check I 1 T A LI 22 b us UM a s UA 3 7 iHHRSuspensonBotsx2 70Nm _ 72 Caliper Boltsx2 25Nm 3 RHR Wheel Rim Nutsx4 60Nm ARHSFooestBots x4 40Nm 5 RHS Engine Bolts 2 45 N m 6 Front Propeller Shaft Bolts x 8 7 RHF Wheel Rim Nuts x 4 8 Caliper Bolts x 2 9 Suspension Bolts x 2 10 Front Muffler Bolts x 2 20 N m u 10 MAINTENANCE Spark Plug SPARK PLUG EXCHANGE 4 Dismantle the screws and bolt of LHS upper mudflap Then remove the LHS upper mudflap Pull out the spark plug hat Clean up around the spark plug then dismantle the spark plug ri MAINTENANCE Spark Plug SPARK PLUG EXCHANGE The spark plug lt Champion PRG7C Gap 0 6 0 7mm Assemble The spark plug 12N m VI 12 MAINTENANCE Oil Filter OIL FILTER EXCHANGE From the LHS of vehicle after dismantle the LHS engine cover Or from the RHS of vehicle Clean up around the oil filter cover to avoi
16. BLOCK ASSEMBLY NO PART NAME PART NO 1 CYLINDER BLOCK 40018014 gt MAIN BEARING BLACK 888 4001 613 3 MAIN BEARING NO COLOR 888 4001 614 4 MAIN BEARING GREEN 888 4001 615 5 CONROD ASSY 40098013 6 BEARING BLACK 40096025 7 BEARING YELLOW 40096024 BEARING BLUE 40096023 II 43 ELTEK ENGINE Assembly The connecting rod mark position gt a Aili Re VA f CRANKCASE Y Yellow BL Blue Black Choose bearing color and install to connecting rod EX connecting rod mark is A crankcase mark is A2B 50 we choose the bearing color is blue A amp 2 A 2 and low bearing install the same color II 44 ENGINE Assembly Lubricate all bearing THE BEARING AN CRANKSHAFT ASSEMBLY Install crankshaft Lubricate all rotation position Before tighten the two bolts be lubricate connecting rod bolts X Torque 20Nm 90 90 tighten the two bolts equally ENGINE Assembly Lay the Case Assembly Glue on cylinder block according figure A and glue diameter about 1mm M B Glue Path Main Gallery II 46 ENGINE Assembly Lubricate the bolt and washer then tighten it lt Torque 35Nm 90 tighten the bolts equally Install the cylinder block bolts The tighten torque 2
17. Drum And Fork Assembly P37 The Transmission Gear Assembly P38 The Gear Idle Gear Assembly P40 The Crankcase And Cylinder Block Assembly X X lo a6 41 The Bearing And Crankshaft P45 ENGINE Dismantle CAUTION Only trained and certificated technician can disassembly the CECTEK 500 EFI ENGINE Improper disassembly may damage the engine CECTEK can not provide the warranty to the engine which has not been properly disassembled and assembled by trained and certificated technician Remove the CVT cover The CVT cover ri ENGINE Dismantle CVT BELT DISMANTLE Tighten the Belt Removal Tool to end to open the driven pulley then removal the belt The belt X Reinstall the installer must can read the printed word on the belt Loosen the driven pulley bolt then remove the driven pulley The Driven pulley 2 ENGINE Dismantle CVT fadt anzi DISMANTLE Loosen the driving pulley bolt L mA Tighten the Puller by air wrench to remove the drive pulley The drive pulley 3 ENGINE Dismantle REWIND STARTER DISMANTLE The rewind starter TIMING CHECK before dismantle engine must be check the chain timing Loosen the cam cover bolts then remove the cam cover ENGINE Dismantle Loosen the taper plug for check the timing
18. FN Plug d Mano _ Iryectes inn 6 AL YNI m co zum I mn pe poH MP 4 r SREP A 271 E 3 ZAN VR s REF LO lu lt MFR PR oa Sere Oi ps a 6 7 TAH L gt E mamik P4 acm 7 FOSITIOH SEISSOR p ps fag Rolie Switch F romans IHR _ Cooki te Ground e LED 219 Heutral Feth 1 9 EMS System CONNECTOR ON BOARD CONNECTOR 4 143 290 0 PIN 34 PEN FIN connector viewed irom hemes side Pin Assignment Pin Operation Voltage Operation Current A at Voltage V Number Pin def E pases Mas gt PUMP CAMHi asl Tachometer O M a a asa meets e s E IAT i TPS o NC 5 51 5 5 69 O2Signal NC 16 6 54 2 LO 132 146 250 46
19. LHR amp RHR WHEEL DISMANTLE Dismantle the bolts of wheel then remove the wheel Torque 60Nm The wheel Off Road Hemove the wheel cap On Road Push the cap from the back of wheel The wheel cap ON ROAD OFF ROAD SUSPENSION TRANSMISSION LHR amp RHR CALIPER Dismantle the upper bolt of caliper Torque 25 Dismantle the lower bolt of caliper then remove the caliper Torque 25Nm Avoid any knock suspend the Caliper with cloth Avoid any knock suspend the caliper with cloth SUSPENSION TRANSMISSION LHR amp RHR HUB n Dismantle the pin of nut Dismantle the nut of hub by 1 Reinstall the caliper then use brake to hold the hub Torque 100Nm Dismantle the nut of hub by 2 Reinstall the nuts of wheel then use big screw driver to hold the hub Torque 100Nm The pin gt nut and washer SUSPENSION TRANSMISSION LHR amp RHR HUB DISMANTLE Z Warning The flange of washer is lower when install the washer must in the right direction Z Warning The flange of washer is lower when install the washer must in the right direction Pull out the hub The hub SUSPENSION TRANSMISSION LHR amp RHR DISK amp KNUCKLE DISMANTLE Turn the hub over and dismantle the bolts of disk then remove the disk Torque 20Nm The disk Dismantle the nuts and bolts of knuckle then
20. PHOTO TOOL NUMBER amp NAME 991000005 REMOVER ALTERNATOR ROTOR ASSY Include 991000006 991000007 991000008 991000006 CRANKSHAFT PROTECTOR 991000007 HOLDER ALTERNATOR REMOVER 991000008 PULLER CVT 8 ALTERNATOR M12 1 5 SPECIAL TOOLS TOOL PHOTO TOOL NUMBER amp NAME 992000001 SPANNER FUEL RETAINER 992000002 REWIND STARTER STOPPER 888 4002 653 B1 CASE ASSEMBLY GLUE 1207F Brand ThreeBond Type 1207F Liquid Gasket Black Silicone Type Volume 333ml 888 4002 670 B BOLT GLUE T272 Brand Loctie Type 272 Volume 250ml VI 3 htto www cectekpowersports com
21. The Vehicle On The Flatland Make Sure The Oil Level Between Max and Min Level Of Dipstick While Engine Is Cold Differential Front and Rear Differential Gear Original Oil Type PENNZOIL 80w 90 lt The approved oil PENNZOIL 4096 80w 90 SAE GRADE 80W 90 API SERVICE GRAVITY API VISCOSITY 40 C cSt VISCOSITY 100 C cSt VISCOSITY INDEX POUR POINT FLASH POINT C COLOR Use a SAE 80w 90 hypoid oil on classification GL 5 to fill the differential Total Differential Oil Capacity 325 20cc gt Li Differential Differential Oil Drain Bolt e Ditferential Oil Fill Plug lt The Differential Oil Drain Bolt Torque 40 Nm Coolant THE RADIATOR N PARI NAME PART NO RADIATOR ASSY 60046001 BOLT BFH060200884 CAP ASSY 60046002 BOLT BFH060120882 HOSE RADIATOR OUTLET 60040005 CLIP CC02003209 HOSE RADIATOR INLET 60040004 CLIP CC02504009 Connect to Thermostat Cover Connect to Water Pump Cover Coolant The Coolant type 50 50 50 water 50 antifreeze Reservoir Tank Engine Torque Table hain Sprocke 250Nm JNM 10Nm OQ 1 4 20Nm 90 90 Engine Block M8 20Nm 10Nm 10Nm 20Nm Balancer Plate 20Nm 10Nm Water Pump Gear 1 50 10Nm 10Nm
22. screw driver to lock the shaft Torque 25Nm Dismantle the bolts of shaft 2 By shift the gear position to engage reverse gear Then pull out the shaft The propeller shaft IV 26 SUSPENSION TRANSMISSION REAR GEAR BOX DISMANTLE EI Dismantle the upper bolt of gear box Torque 25Nm Dismantle the lower nuts and bolts of gear box Lift the gear box Turn the contraclockwise side SUSPENSION TRANSMISSION REAR GEAR BOX DISMANTLE Then remove the gear box The gear box ELECTRICAL CONNECTOR ours piti Ha o eo GA P1 WIRE CIRCUIT P2 ee eee Eee P3 EENMUIN 40 P4 5 PIN e P6 ADJUSTMENT FOR TIRE CIRCUMFERENCE P7 INJECTION PARTS POSITION P9 ELECTRIC PARTS POSITION GROUND WIRE POSITION Li T x lt Q Q LLI LAMP REAR te E Ele LAHP LICEMCE fe PLATE LAMP ASSY 071 Ke LAMP ASSY Pri m s Pr nt 1 B T TCH BHE AX SHAME LY DETAIL 22 LAMP ASST FL POINT PEINT XENZDR SZ
23. the piston 4 5 is matching the category of liner 2 category piston only can be installed on A category liner 3 B category piston only can be installed on B category liner 4 Make sure the liner size mark on the cylinder block ENGINE Assembly 5 The piston size mark on top Aor B 6 Confirm when you face the piston the piston 4 5 exhaust mark is in the down side 7 Confirm the connecting rod 1 right side mark is same side of piston 8 Install one clip 3 into the piston clip groove firmly 9 Install pin 2 into pin groove 10 Install the clip 3 into the other side groove to stop the pin 2 11 Then sequentially install parts 8 7 6 the crevice position of each ring as figure A shows first ring crecice ij 1 2 opening of ring 8 of spacer shall be upward as figure B shows pistion pin up oil ring crecice low oil ring crecice Scrape crevice be tor scrape ring crecice second ring crecice figure 26 ENGINE Assembly 1 Install pin 2 into balancer shaft 1 2 Install gear oil pump driver 3 into balancer reference to figure A 3 Clip the E ring 4 check the retain E ring install into the groove of balancer shaft ri 27 ENGINE Assembly THE BALANCER ASSEMBLY PART NAME PART NO CRANKSHAFT 40110023 KEY 40110108 GEAR 36T 40120018 CAM CHAIN SPROCKET
24. 0Nm Install shift drum anti thrust plate Torque 10Nm ENGINE Assembly Lay the Case Assembly Glue on shift drum cover zc Glue diameter about 1mm Install the shift drum cover X Torque 10Nm Heverse the engine then tighten the cylinder bolt xX Torque 20Nm Install the main circuit Torque 20Nm l SCREW LINE ENGINE Assembly Lubricate the balancer Install balancer gear then check crankshaft gear mark to balancer of gear position Lay the Bolt Glue on the bolt then install the balancer plate Torque 20Nm 227 SCREW LINE Lubricate the oil pump and rotor ENGINE Assembly X The bolts torque 10Nm Install the oil pump gear then clip the E clip Install the water pump idle gear then tighten the bolt Torque 10Nm Install the chain guide Torque 10Nm ENGINE Assembly Install the chain guide into cylinder block and notice the lock position Install the cylinder head gasket and lock pins Install the cylinder head Lubricate the cylinder head bolts and washer ENGINE Assembly Torque 35Nm 90 90 tighten the four bolts equally Install the cam shaft into cylinder head Lubricate the rock arms and shafts then install into cylinder head ENGINE Assembly Check the crankshaft gear mark and balancer mark X crankcase mark line have POR five gears 2 T five gears Between balancer mark to crankshaft sprocke
25. 2 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts Then remove the cover X Torque 10 Nm The protector cover RHF Dismantle the bolts then remove the cover The protector cover LHF 23 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts Torque 10 Nm Dismantle the bottom bolt then remove the cover Torque 10 Nm The protector cover RHR 24 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts X Torque 10 Nm Dismantle the bottom bolt then remove the cover Torque 10 Nm The protector cover LHR 25 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts Then remove the cover X Torque 10 Nm The front protector cover Dismantle the bolts then remove the cover X Torque 10 Nm engine protector cover 26 CHASSIS PROTECTOR DISMANTLE Dismantle the rear bolts X Torque 10 Nm Dismantle the bolts from two sides of the cover Torque 10 Nm The rear protector cover 27 CHASSIS FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the front Dismantle the rivets and screw of the rear Dismantle the bottom bolts Then remove the right foot rest Torque 10 Nm The right foot rest 28 CHASSIS FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the front Dismantle the rivets and screw of the rear Dismantle the b
26. DAR 1 POSITIONE Pana es RECTIFIER ASST Dh in N E um IH JAE AK ZHAMIE RI ie m n e ii JH 1 e i Gi E m n m 8 p e E nuum Ferree i E NEUE E S T At br n n n rer Pre He P P Pe Pe PUINT 2 i i SPEED SENSOR i i do Su TH eo n i EJ BEAR FF LUT LAMP a DA d fie ee i RESDLAHP 557 4 NJ 25 Y AR Ti Ay FLORES STARTER RELAY gr ay W Lu LI n FEE V 1 ELECTRICAL Wire circuit LOCK wOTORIRI pire DIFF LOG bOTORIT T FLASHDA PATER EA LIGHT RELAY 1101 HAZARD Sw ELECTRICAL ECU pin Lew exp meo B evo GNC SB ORCAS CL E G RELAY SC 05 8 3 5 Cu ECM HARN PINI 640 CAVS SENSOR FUEL CUT GNIX 3 0 5 W IGN COIL SNSR FCM HARN GND IGN 1 25 GR CAVS gt HARN SENSDR FUEL CUT INJECTOR DRIVER IGNITION COIL SENSOR T if PIN26 P CAVS De SNSR CAVS _SNSR FR R_ cavs
27. Exchange P11 Oil Filter Exchange P13 Air Filter Exchange P15 Li Regular Maintenance table ENGINE R R Engine Oil Fiter R R H R _ Valve Adjustment fJ CoolantWater J Il R CVT Drive Belt 18 FUEL AirFilter R R Throttle Body 21 77 ELECTRICAL Spakpug Battery ool Control Switches 1 1 1 m Meer acs II DRIVE Front Propeller 1 L I t t Rear Propeller 1 L I L I LA Il 1907 72 BENT Steerinc Be Differential Oi R 1 l R Wheel Nut BRAKE Brake System J i Brake I J i J Ii i BODY Aso Inspect Clean L Lubricate R Replace e Engine The Engine Original Oil 10w 40 The viscosity of oil should follow the temperature range of your area according to below chart X Recommended engine oil classification service SJ type or higher 10 30 50 70 90 110 F SAE 10W 30 SAE 10W 40 SAE 20W 40 SAE20W 50 10 0 10 20 30 40 F Total Engine Oil Capacity with filter 3500cc v 2 Engine Oil Engine Oil Drain Bolt lt The Engine Oil Drain Bolt Torque 20 Nm Put
28. MANTLE P20 REAR ABSORBER amp UPPER ARM DISMANTLE P21 REAR LOWER ARM DISMANTLE P22 REAR STABILIZER BAR DISMANTLE P23 REAR GEAR BOX DISMANTLE P24 SUSPENSION TRANSMISSION LHF amp RHF WHEEL DISMANTLE Dismantle the nuts of wheel then remove the wheel Torque 60Nm The wheel Off Road Hemove the wheel cap On Road Push the cap from the back of wheel The wheel cap ON ROAD OFF ROAD SUSPENSION TRANSMISSION amp RHF CALIPER DISMANTLE E Dismantle the upper bolt of caliper T 4 2 i E 1 5 Torque 25 a Dismantle the lower bolt of caliper then remove the Caliper Avoid any knock suspend the Caliper with cloth Avoid any knock suspend the caliper with cloth SUSPENSION TRANSMISSION LHF amp RHF HUB DISMANTLE Dismantle the pin of nut Dismantle the nut of hub by 1 Reinstall the caliper then use brake to hold the hub Torque 100Nm Dismantle the nut of hub by 2 Reinstall the nuts of wheel then use big screw driver to hold the hub Torque 100Nm The pin gt nut and washer v 3 SUSPENSION TRANSMISSION LHF amp RHF HUB DISMANTLE Z Warning The flange of washer is lower when install the washer must in the right direction Z Warning The flange of washer is lower when install the washer must in the right direc
29. PUMP DISMANTLE P59 FUEL PUMP ASSEMBLY P61 CHASSIS SEAT DISMANTLE Use the key to open the seat lock Remove the seat The seat The tool bag under the seat 1 CHASSIS Dismantle the rivets and pull out the air cleaner cover AIR CLEANER COVER DISMANTLE Z Warning Dismantle the connector of main switch Air cleaner cover assembly CHASSIS AIR CLEANER COVER DISMANTLE Dismantle the cover then turn it over Press the flange then remove the main switch The main switch 3 CHASSIS FRONT DECK DISMANTLE v Dismantle the rivets of front deck Pull out the front deck The front deck The front box 4 CHASSIS METER DISMANTLE Ms Dismantle the bolts of bracket N Torque 10 Nm Push the pin to dismantle the connector Z Warning Be careful about the orange O ring of the wire harness connector The meter 5 CHASSIS METER DISMANTLE Dismantle the meter then turn it over Dismantle the screws then remove the cover meter cover CHASSIS FRONT COVER DISMANTLE Release the tenon from the brake oil reservoir Pull out the brake oil reservoir Dismantle the bolt Torque 10 Nm Dismantle the screws from two sides of the cover RONT COVER DISM
30. R LAMP IGNK 0 5 G S W ASSY R ECM HARN PINOS IGN_KEY 01 0 5 5 _ sa 05 B yas joxxp so O5 B crank SNSR ECM ARN O5 SPEEDMETER PIN26 ECM HARN PINIS INS S W D VERRIDE E SENSUR GEAR DVERRIDE SWITCH Rx im se B cavs GNXO LIGHT RELAY Y L vex omer im eer FUSES 0 05 B jrNE GNXO CT O 503 5 B 5 PDINT F GNIX 503 5 B 5 IGN COIL SNS amp ECM HARN V 3 T C C DLR GND33 ELECTRICAL Lamp pin L Al CIRCUIT APPL I NU HDSW R W AVS S W ASSY LM IGN S W HEAD LIGHT SWITCH EEE S W ASSY LM prm Wer s 125 65 POSITION eue E o E CAVS OTHER LIGHT RELAY wi Mast TAIL LAMP AEX OTHER LIGHT RELAY LAYE LICENCE amp LAMP LICENCE PLATE PLATE GND10 B S HEADLAMP ASSY L GNIDX FD GND HEAD LAMP eo mex uu GND34 Hec Ss 172208 o J HEADLIGHT HI 3 mE 0 AEX PTS HEADLIGHT RELAYCHI gt HEAD LIGHT HI HLG4 1 25 CAVS HEADLIGHT
31. SSION LHF amp RHF LOWER ARM DISMANTLE lt d E b d m E d PS Dismantle the nuts and bolts of arm then remove the arm Torque 70 The lower arm w 10 SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE ei Dismantle the bolt of differential to drain the gear oil The bolt and washer Change new washer A Warning By check the gear oil to know the stative of differential Then reinstall the bolt SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Pull out the CV Joint horizontally Or use the screw driver to open the CV Joint The CV Joint Z Warning Avoid any dirty cover the differential SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Dismantle the bolts of shaft 1 By use the screw driver to lock the shaft Torque 25Nm Dismantle the bolts of shaft 2 By shift the gear position to engage reverse gear and 4 wheel driver Then pull out the shaft The propeller shaft w 13 _ SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Z Warning Dismantle the connector of differential Dismantle the nuts and bolts of differential Lift the differential Turn the counterclockwise side v 14 ecTeK SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE aj the differential The differential A CeCTBKk SUSPENSION TRANSMISSION
32. Then turn counterclockwise Pull out the fuel pump half way Then turn counterclockwise 59 CHASSIS FUEL PUMP DISMANTLE Pull out the fuel pump Z Warning Turn counterclockwise then take out the fuel gauge carefully A Warning Be careful about the O ring of the fuel pump The fuel pump 60 CHASSIS FUEL PUMP ASSEMBLY Install the O ring then use oil to lubricate Put in the fuel gage first Then turn counterclockwise Put in the fuel pump half way 61 CHASSIS FUEL PUMP ASSEMBLY Turn counterclockwise And pull out the fuel pump half way Then put in the fuel pump to end Turn clockwise Li 62 CHASSIS FUEL PUMP ASSEMBLY Then install the retainer Z Warning Make sure the mark of fuel tank match the output pipe of fuel pump Use the special tool to tighten the retainer r Torque 25 Nm ri 63 DISMANTLE FRONT WHEEL DISMANTLE P1 FRONT CALIPER DISMANTLE P2 FRONT HUB DISMANTLE P3 FRONT DISK amp COVER DISMANTLE P5 FRONT KNUCKLE DISMANTLE P6 FRONT ABSORBER amp UPPER ARM DISMANTLE P9 FRONT LOWER ARM DISMANTLE P10 FRONT DIFFERENTIAL DISMANTLE P11 REAR WHEEL DISMANTLE P16 REAR CALIPER DISMANTLE P17 REAR DISMANTLE P18 REAR DISK amp KNUCKLE DIS
33. arts and lubricate with 10W 40 1 Knock the 2 balls 3 into cylinder head 1 2 Paste the screw 4 with LT272 tighten to cylinder head with 5Nm 3 Install the washer 5 on the valve spring seat 4 Knock valve stem seal 6 into valve guide keep distance between the bottom of seal and the top of cylinder head within 12 750 5 mm 33 ENGINE Assembly THE CYLINDER HEAD ASSEMBLY PART NAME PART NO VALVE INTAKE 40050133 VALVE EXHAUST 40050134 SPRING 40050135 SPRING CAP 40050136 COTTER 40056003 Please clean up correlative parts and lubricate with 10W 40 1 Install valve spring 3 x4 on the valve spring washer 2 Install cotter 5 x2 on the spring cap 4 4pcs 3 Install assembled spring cap 4 on the spring with Jig press it into the valve stem seals until a clear click sound was heard 4 check the cap is firmly installed on the stem with jig 34 ENGINE Assembly THE CYLINDER HEAD ASSEMBLY NO PART NAME PART NO 1 CAM SHAFT 40070068 2 ROCKER ARM ASSY INTAKE 40078016 3 ROCKER ARM ASSY EXHAUST 40078017 4 SHAFT 40070063 5 PLATE 40070065 6 FLAT HEAD SCREW _ SCF060160883 Please clean up correlative parts and 1 Install cam 1 through cam bore 2 Install intake rocker 2 on the cam shaft the rocker face toward intake side 3 Install exhaust rocker 3 on the cam shaft the rocker face
34. ase valve bolt then remove the oil release valve by magnet 22 ENGINE Dismantle The oil release valve Loosen the connecting rod bolts Remove the connecting rod cap then remove the crankshaft The cylinder block X When reinstall must clean the surface of the crankcase ENGINE Dismantle THE PISTON DISMANTLE Pull out the piston Must clean the carbon on piston Piston ring inspection The second ring top side wc ESL 23 ao 4 gt 4 a i 53 z ey at 4 48 93 s EVE 4 M3 Mes 1 ie 1 Loosen the speed sensor bolt then remove the speed sensor 24 ENGINE Assembly CAUTION Only trained and certificated technician can disassembly the CECTEK 500 EFI ENGINE Improper disassembly may damage the engine CECTEK can not provide the warranty to the engine which has not been properly disassembled and assembled by trained and certificated technician THE PISTON AND CONNECTION ROD ASSEMBLY PART NAME PART NO CONROD ASSY 40098013 PISTON PIN 40090024 CLIP 40090027 PISTON A 4009601 1 PISTON B 40096012 PISTON RING TOP 40096013 PISTON RING SECOND 40096014 NO 2 3 4 5 6 7 8 PISTON RING OIL CONTROL 25 40096015 1 Before assembly must confirm if
35. cam shaft The rock arms and cam thrust plate The cam shaft ENGINE Dismantle Loosen the chain guide bolt then remove the chain CHAIN DISMANTLE Notice the boss The chain 11 ENGINE Dismantle CYLINDER HEAD DISMANTLE Loosen the cylinder head bolts Remove the cylinder head and notice the lock pins Remove the gasket and chain guide The cylinder head gasket and chain guide 12 ENGINE Dismantle Raise the balancer cover by screwdriver from the prominence of case Loosen the water pump idle pulley bolt and unclip the oil pump gear clip 223 oil pump gear The water pump idle gear ENGINE Dismantle Loosen the balancer bolt by use screwdriver stop the balancer The balancer THE OIL PUMP DISMANTLE Loosen the oil pump bolts and unclip the oil pump gear clip The oil pump and back plate 14 ENGINE Dismantle Remove the spin nose and washer Loosen the front driveshaft yoke bolts then remove the yoke THE DRIVESHAFT DISMANTLE Loosen the front driveshaft seal cover bolts then remove the cover The yoke The seal cover 15 ENGINE Dismantle Pull the front driveshaft and remove the 4WD gear The 4WD gear Remove the rear driveshaft yoke and seal cover same procedure of front driveshaft Loosen the starter bolts then remove the starter ENGINE D
36. cover inside CHASSIS RHS COVER DISMANTLE ur y 55 Dismantle the center bolt from the revolve lever X Torque 10 Nm Revolve lever alignment Opposite side of revolve lever The revolve lever and button 16 CHASSIS RHS COVER DISMANTLE Screw contraclockwise the shift bar 2 4WD of the rod The shift bar 2 4WD Release the tenon then pull out the cover The side cover RH 17 CHASSIS HEAD LAMP DISMANTLE v T Dismantle the bolts X Torque 10 Nm Dismantle the screws from the two sides of the cover Dismantle the screws from the two side of the cover Z Warning Dismantle the head lamp connector CHASSIS LAMP DISMANTLE The front nose Press the tenon then remove the grille The grille 19 CHASSIS HEAD LAMP DISMANTLE Dismantle the screws from the back of the lamp Dismantle the screw from the front of the lamp The head lamp assy The head lamp angle adjustment bolt lt Upper clockwise Lower counterclockwise 20 CHASSIS UPPER MUDFLAP DISMANTLE lt lt 2 Dismantle the bolt EN Torque 10 Nm Pull out the tenon then remove the The upper mudflap 21 CHASSIS UPPER MUDFLAP DISMANTLE Dismantle the bolt X Torque 10 Nm Pull out the tenon then remove the mudflap Upper mudflap L 2
37. d any dirt then dismantle the cover Pull out the oil filter then clean the old oil inside MAINTENANCE Oil Filter Assemble the new oil filter use some oil lubricate the front rubber of filter OIL FILTER EXCHANGE Push the oil filter to end then add some oil to the filter Before assembly the cover lubricate the O ring Tighten the cover to end MAINTENANCE Air Filter AIR FILTER EXCHANGE o Dismantle 1 The air cleaner cover 2 he front deck 3 The front cover UU d Push the revolve lever from the cover inside Dismantle the center bolt from the revolve lever Screw counterclockwise the shift bar 2 4WD of the rod T MAINTENANCE Air Filter AIR FILTER EXCHANGE w Release the RHS tenon Release the LHS tenon Dismantle the LHS bolt of seat holder Dismantle the RHS bolts of seat holder Li MAINTENANCE Air Filter AIR FILTER EXCHANGE seat holder Release the clips of cover then remove the air cleaner COVer Pull out to open the clip Change the air filter SPECIAL TOOLS TOOL PHOTO TOOL NUMBER amp NAME A t 2 x 991000001 EMS DIAGNOSTIC KIT ASSY Include 991000002 991000003 991000004 991000002 EMS DIAGNOSTIC SOFTWARE 991000003 EMS DIAGNOSTIC CABLE 991000004 EMS DIAGNOSTIC USB ADAPTOR SPECIAL TOOLS TOOL
38. en push the tenon The meshes RHS amp LHS 45 CHASSIS REAR COVER DISMANTLE Dismantle the rear cover The slipproof on the rear cover Turn over the rear cover then push the tenon to remove the slipproof The slipproof pad 46 CHASSIS TAIL LAMP ASSEMBLY DISMANTLE j Pull out the wire then remove the seat wire oh Dismantle the bottom bolt from two sides of bracket Z Warning Dismantle the connector then remove the tail lamp The tail lamp assy 47 LELTEK CHASSIS TAIL LAMP ASSEMBLY DISMANTLE _ Turn over the tail lamp Pull out the plate of lock Z Warning When reinstall the wire make sure the wire into the position lock 48 CHASSIS TAIL LAMP ASSEMBLY DISMANTLE Turn over the lamp Dismantle the nuts Torque 10 Nm The tail lamp 49 CHASSIS ELECTRICAL HOUSING DISMANTLE Z Warning Dismantle the negative wire to protect the electrical parts Torque 10 Nm Dismantle the connector After dismantle all connector Dismantle the nuts then remove the wire of start relay Torque 10 Nm CHASSIS ELECTRICAL HOUSING DISMANTLE Dismantle the screws of fuse Remove the small wire harness Lift the rear of electrical housing to remove other wire harness The electrical housing Li 51 CHASSIS THROTTLE BODY DISMANTLE
39. he same time Adjustment Tire Circumference ADJUSTMENT FOR TIRE CIRCUMFERENCE M Install the connector of speedometer Release the two button at the same time while install the connector of speedometer then show the three figure number The Tire Circumference shift the flashing position of number increase the flashing number On Road 556 Off Road 646 Press and release the two Buttons at the same time then the speedometer will auto restart to normal function V 8 Injection Parts Position 1 THROTTLE BODY INJECTOR _ lt 7 S INS NT DAN 3 k gt AY X SN x RE TEC 2 y 1 res 7 SOS d ANUA p 2 ean 2 _ Injection Parts Position 2 ENT ENN y Jas aw gt WPS VE em 2 TA TH 2 o gt y gt V 4 17 r 7 1 j IF o gt E T INA A 2 F m LEJ JE lt AS iOS STAT a L Pu CUT SENSOR WATER TEMP SENSOR Electric Parts Position 1 PS AVES NN CAT FEN LIS Vf v 7 P AN i W SHEP a aa a m xp x 4 33 X iia E
40. ismantle Loosen the shift drum cover bolts Loosen the shift drum antithrust plate THE OIL MAIN CIRCUIT DISMANTLE 775 ac Loosen the oil filiter cover Remove the oil filter 749 Il 17 ENGINE Dismantle Loosen the main circuit bolt then remove the main circuit The main circuit the rear driveshaft yoke and seal cover Turn the engine over and loosen the oil sump bolts 18 ENGINE Dismantle Use scraper and hammer to open the oil sump The oil sump z When reinstall must clean the surface of the oil sump Loosen the crankcase bolts Raise the crankcase by screwdriver from the prominence of case lI 19 ENGINE Dismantle The crankcase zc When reinstall must clean the surface of the crankcase Tr TN 5 E NH I pee Ls i m Hemove the lay shaft the rear shaft ENGINE Dismantle The cylinder block zc When reinstall must clean the surface of the crankcase Loosen the shift fork bolt then pull out the shift fork shaft and remove the fork The shift fork Loosen the shift position rotor bolt then remove the parking shaft plate ENGINE Dismantle The parking shaft Pull out the shift drum from the cylinder block The shift drum Loosen the oil rele
41. n STARTER amp CHARGE SYSTEM and LII HER IGN S W IVB2 AEX FUSE4 IGN S W 2 CAVS FUSES SPEEDMETER 2 STATER RELAY GND3 HEN EEG _ GNDX RECTIFIER ASSY 155 77 3 FUS EX FUSES E G RELAY EGSW GE S W ASSY R IGNITION FUSE SPB PEXCS 502 SPEED SENSOR SPEEDMETER PINI8 T SPS TMI CAVS FAN IT E G RELAY RLYF FUSEG FAN RELAY HON1 CAVS S W ASSY LF FUSES GNDS I pes oem 1 GND lt F SIGP Y CAVS SPEEDMETER PINO4 SIGR DUE position m SPEEDMETER PINOS SIGN Y G CAVS SPEEDMETER PINOG SENSOR GEAR POSITION SIGL va SPEEDMETER PINOB 74 GNDe3 GND lt B VBS Tee SPEEDMETER 2 se tv jews speepwerer PINO DLSP 1 8 CAVS FLSHER SW D I SPEEDMETER PINO2 SPEEDMETER HDSP L G CAVS S W ASSY LM SPEEDMETER PINOI CAVS DIL P S W SPEEDMETER 1 4WD CAVS SPEEDMETER PIN12 GNDe4 GNXP se 55 55 pns nre 0 5 SIP1 CAVS DIODE1 POSITION AR WIN R W CAVS F G RELAY WINCH V 6 Adjustment Tire Circumference ADJUSTMENT FOR TIRE CIRCUMFERENCE E Turn off the main switch FA Dismantle the connector of speedometer Turn on the main switch Press the two buttons at t
42. ng 8 into lay shaft 6 Install reversal gear 9 into lay shaft then put a washer 7 into lay shaft shall be install reversal gear 9 of groove side into bevel gear side 7 Install retain C ring 10 into lay shaft of groove 8 Measure and calculate gear back clearance then choose and install adjusting washer 11 9 Install bearing 12 into lay shaft 10 Install washer 13 and screw flat head screw 14 into lay shaft tighten torque 9Nm 1 37 _ ENGINE Assembly THE REAR DRIVESHAFT ASSEMBLY PART NAME PART NO DRIVE SHAFT ASSY 46058001 BEARING DGB6205 GEAR 46050023 WASHER 46050007 BOLT BFH080251094 WASHER 46050009 19 BEARING DGB6305 46050025 Z 1 2 3 4 5 6 7 8 Before install gear and bearing please lubricate with 10W 40 oil 1 Press the bearing 2 into the shaft 1 thoroughly 2 Install the gear 3 into shaft 1 3 l ighten the 5 with washer 4 on the shaft 1 the tighten torque 20Nm 4 Install the washer 6 which thickness shall be measured in advance into shaft 1 then press the bearing 7 into shaft 1 finally install the O ring 8 ri lI 32 ENGINE Assembly THE CYLINDER HEAD ASSEMBLY PART NAME PART NO CYLINDER HEAD ASSY 4005801 1 VALVE STEM SEAL 40056002 SEALING BALL 40070031 HEXAGON SOCKET SCREW 26050121291 VALVE SPRING WASHER 40050140 Please clean up correlative p
43. o main shaft of outside groove 6 Install low gear 9 into main shaft then install needle bearing 10 into main shaft low gear of forl groove shall be in the outside 29 ENGINE Assembly THE LAY SHAFT ASSEMBLY NO PART NAME PART NO 1 LAY SHFAT 46030002 2 CYLINDRICAL ROLLER BEARING CRBNU 1007NR 3 NEEDLE BEARING HALF CAGE TYPE 46030031 4 LOW SPEED DRIVEN GEAR 45T 46030007 5 RETAIN C RING RCS030 6 HIGH SPEED DRIVEN GEAR 36T 46030005 T WASHER 46030010 8 HNEEDLE BEARING CAGE TYPE 46030030 3 REVERSE DRIVEN GEAR 34T 46030008 10 RETAIN C RING 5025 11 ADJUSTING WASHER 46030016 26 12 BEARING DOUBLE ROW ANGULAR 46030029 13 WASHER 46030012 14 WASHER SCF060200883 Before install gear and bearing please lubricate with 10W 40 oll 1 Install bearing 2 into lay shaft 1 be shall install bearing of long side into bevel gear side 2 Install needle bearing 3 into lay shaft then install low gear 4 into lay shaft be shall install low gear 4 of plane into bevel gear side 3 Install retain C ring 5 into lay shaft of groove 4 Install high gear 6 into lay shaft be shall install high gear 6 of fork groove side into another bevel gear side 30 ENGINE Assembly Before install gear and bearing please lubricate with 10W 40 oil 5 Install washer 7 into lay shaft then install needle beari
44. ottom bolts then remove the left foot rest X Torque 10 Nm The left foot rest 29 CHASSIS FRONT FENDER DISMANTLE Pull out the tenon Dismantle the upper bolt then remove the fender Torque 10 Nm The front fender RH 30 CHASSIS FRONT FENDER DISMANTLE Pull out the tenon Dismantle the upper bolt then remove the fender Torque 10 Nm The front fender LH III 31 CHASSIS INNER MUDFLAP DISMANTLE Dismantle the bolt X Torque 10 Nm Pull out the tenon then remove the mudflap The inner mudflap RH Li 32 CHASSIS INNER MUDFLAP DISMANTLE mudilap RH Dismantle the screws then remove the ventilator The ventilator RH ri 33 CHASSIS INNER MUDFLAP DISMANTLE Dismantle the bolt X Torque 10 Nm Pull out the tenon then remove the mudflap The inner mudflap LH Li 34 CHASSIS NNER MUDFLAP DISMANTLE The inner mudflap LH Dismantle the screws then remove the ventilator ventilator LH 35 CHASSIS REAR LAMP DISMANTLE Dismantie the rivet Dismantle the bottom bolts of the bracket Z Warning Dismantle the connectors The rear lamp housing RH 36 CHASSIS REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the bolts then remove the cover The rear lamp cover RH
45. que 120Nm Ratio 0 316 min 1 581 max Engine Speed Limit 7500 I 4 Start System Rewind Starter Handler Starter Output 0 7KW Operation Voltage 12V Temperature Range 10 120 otarter Circuit Diagram Verom ren GND EET Battery GND I 5 Injection System Cylinder Head Idle Air Control Valve Intake Valve CH M X ZACS 7 EX 4 M SRM WA K QV ACC LAS Intake Port Intake Air Throttle Body ASM Fuel Injection Air Flow Temperature IACV or TPS Air Temp MAP Coolant Temp Gtc ri Emission Control System Injector Throttle Body ASM O2 Sensor Ignition Coil ASM Catalyst Emission Helational Part ECU Throttle Body ASM Spark Plug Ignition ASM O2 Sensor Catalyst Catalyst 100 cells in2 Catalyst Volume 116cc Emission Updated 2002 51 EC Cylinder Head Block amp T UE Intake Valve im p QU p u A Cylinder Head ASM Aluminum Alloy lt AC4B T6 gt SOHC Chain Drive 4 Valves Spark Plug Type Champion PRG7C Cylinder Block ASM Liner Material lt FC250 gt Aluminum Alloy lt ADC12 gt EMS System Block Diagram 12 Pras Pf 8 CUT Gr juli hi 1 p SWITCH 5
46. remove the knuckle Torque 70Nm knuckle SUSPENSION TRANSMISSION amp RHR ABSORBER amp UPPER ARM DISMANTLE Dismantle the nuts and bolts of absorber then remove the absorber 70Nm The absorber Dismantle the nut and bolt of arm then remove the arm Torque 70Nm The upper arm 1 Cec SUSPENSION TRANSMISSION LHR amp RHR LOWER ARM DISMANTLE D Dismantle the nuts and bolts of arm then remove the arm Use the open wrench to lock the ball joint then dismantle the nut The lower arm SUSPENSION TRANSMISSION REAR STABILIZER BAR DISMANTLE Dismantle the bolts of bar from two sides Torque 30Nm The stabilizer bar Dismantle the nut of ball joint Torque 70Nm The ball Joint SUSPENSION TRANSMISSION REAR GEAR BOX DISMANTLE Dismantle the bolt of gear box lt to drain the gear oil The bolt and washer Change new washer A Warning By check the gear oil to know the stative of gear box Then reinstall the bolt SUSPENSION TRANSMISSION REAR GEAR BOX DISMANTLE Pull out the CV Joint horizontally Or use the screw driver to open the CV Joint The CV Joint Z Warning Avoid any dirty cover the differential SUSPENSION TRANSMISSION REAR GEAR BOX DISMANTLE Dismantle the bolts of shaft 1 By use the
47. t mark Crank sprocket mark must correct to blue mark of chain When crank sprocket mark correct then check cylinder head sprocket have six pieces counter from cylinder head SIX pleces ENGINE Assembly 2008 05 15 Install the tensioner and tighten the bolts then put the spring and screw the he bolts torque 10Nm The cover torque 10Nm Install discompressor Lay Bolt Glue LT272 on discompressor bolt then screw it e 1 rr Torque 5Nm d SCREW LINE Install the thermostat Torque 10Nm ENGINE Assembly Install the cylinder head cover then tighten the bolts Torque 10Nm Install the spark plug Torque 10 12 Lubricate the spin nose then install into cylinder block Install the fly wheel assy and ALT rotor then tighten the nut Torque 200Nm ENGINE Assembly Check 4WD gear groove correct to low crankcase groove Lay the Case Assembly Glue On accessary cover zc Glue diameter about 1mm Install accessary cover then tighten the bolts Torque 10Nm Install the drive shaft seal cover then tighten the bolts Torque 10Nm 56 ENGINE Assembly Lay the Bolt Glue on drive yoke bolt then install drive yoke Torque 20Nm Lay the Case Assembly Glue on balancer cover zc Glue diameter about tmm Install balancer cover then tighten the bolts Torque 10Nm Lay the Case Assembly Glue on oil sump cover
48. tion Pull out the hub The hub IV 4 SUSPENSION TRANSMISSION LHF amp RHF DISK amp COVER DISMANTLE Turn the hub over dismantle the bolts of disk then remove the disk The disk Torque 20Nm Dismantle the bolts of cover then remove the cover The cover Torque 10Nm lt SUSPENSION TRANSMISSION LHF amp RHF KNUCKLE DISMANTLE Turn the knuckle Then dismantle the pin and nut of knuckle Torque 25Nm The pin washer and nut Use the tool to dismantle the ball joint of tie rod IV 6 C SUSPENSION TRANSMISSION LHF amp RHF KNUCKLE DISMANTLE UP 775 Dismantle the lower pin and a nut of knuckle Torque 50Nm The pin and nut Use the tool to dismantle the ball joint of lower arm then remove the knuckle SUSPENSION TRANSMISSION LHF amp RHF KNUCKLE DISMANTLE Dismantle the upper pin and nut of knuckle Torque 30Nm The pin gt washer and nut Use the tool to dismantle the ball joint of upper arm knuckle IV 8 SUSPENSION TRANSMISSION val LHF amp RHF ABSORBER amp UPPER ARM DISMANTLE Dismantle the nuts and bolts of absorber then remove the absorber a s X Torque 70Nm iL The absorber 3 Dismantle the nut and bolt of arm then remove the arm Torque 70 The upper arm lt SUSPENSION TRANSMI
49. to cylinder Then push it to position ENGINE Assembly Install rear drive shaft to cylinder block then push it to position Install main shaft and push the needle bearing to position Lubricate oil release valve and install valve spring guide into cylinder block Then tighten the bolt Torque 10Nm ENGINE Assembly THE REAR IDLE GEAR ASSEMBLY NO PART NAME PART NO 1 SHAFT 46030009 2 O RING 46030027 3 NEEDLE BEARING 46030032 4 REVERSE GEAR 27 46030006 5 WASHER 4603001 1 6 lI 40 ENGINE Assembly THE CRANKCASE AND CYLINDER BLOCK ASSEMBLY NO PARI NAME PART 1 CRANKCASE 40018014 2 MAIN BEARING BLACK 888 4001 607 3 MAIN BEARING NO COLOR 888 4001 608 4 MAIN BEARING GREEN 888 4001 609 The crankshaft mark position have 3 marks EX A2B II 41 ENGINE Assembly CVT The cylinder block mark position have 3 number 1 1 A AS a EE N No color G Green B Black Choose bearing color and install to crankcase cylinder block markis 1 crankcase markis 2 50 we choose ALT side bearing color is No color 1 amp A 2 side bearing color is Green 1 amp B 1 1 2 and low bearing install the same color II 42 ENGINE Assembly THE CRANKCASE AND CYLINDER
50. toward exhaust side 4 Install shaft rocker assy 4 x2 through intake rocker 2 and exhaust rocker 3 5 Install the screw 6 through plate 5 and tighten to 9Nm attention for the bottom of plate shall be clipped onto the groove of cam shaft 6 Adjust the intake exhaust valve gap to 0 3 mm 35 ENGINE Assembly THE WATER PUMP ASSEMBLY NO PARI NAME PART NO 1 ACCESSORY COVER 40010053 2 MECHANICLA SEAL 4013601 1 3 SHAFT 40130075 4 PROPELLER 40130071 5 WASHER 40130077 6 PIN 40130083 7 GEAR 35 40130063 8 CAP 40070064 9 RETAIN C RING RCS012 Please clean up correlative parts and keep dry 1 After install mechanical seal 2 on water pump shaft 3 and check the shaft have 12 1mm between mechanical seal and water pump shaft ENGINE Assembly THE SHIFT DRUM AND FORK ASSEMBLY NO PARI NAME PART 1 SHIFT DRUM ASSY 46078002 2 SHAFT SHIFT FORK 46070013 3 SHIFI FORK MAIN SHAFT 46070001 4 SHIFT FORK LAY SHIFT 46070002 5 PARKING BREAK SHAFT 46070005 6 THRUST PLATE 46070022 7 BOLT BFH060120884 8 SHIFT LOCATING SPRING 46070015 9 SPRING BLADE 46070014 10 RETAIN C RING RCS010 ENGINE Assembly Shift locating rotor install position Install fork shift by plastic hammer and all parts lubricate Install lay shaft

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