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1. 02 44 aS e 3 SIF 213 we 2 a 8 2 1 8 BE 4 3 088 E i rr 85 LA e r 315 5118 icm E T T 5 Fuel Se 14 wa as 5 ME z 5 Fuel Injector 2 XS as 5 g E 2 e Ds Speed Ve Sox Tub P oss SEI Sensor ele E s po sens a A MBs BS Mmi vA t5 10 Reverse ipa sersor T Throttle postin sensor sa lo er 33 B m Lys
2. 4 11 15 WATER TEMPERATURE 5 nnn 11 16 OXYGEN 5 1 0 senes 11 17 FOR NE nase scones 11 18 ODOMETER eset sese sess etna 11 19 SHIFT LEVER POSITION 11 20 FULE OIL PUMP 8 1 ese 11 21 OIL 6 01100 eese 11 22 IDLE AIR 2 11 23 IGNITION 1 1 senes senes enses ness nne 11 24 6 ELECTRICITY SPRAYING SYSTEM 8 11 25 DIAGNOSTIC 1 1 6 este sese 11 25 i U2618 3 E X07 rr 11 26 7 VEHICLE SCHEMATIC CIRCUIT 20 1 0 2 11 28 11 E
3. Contact fuel pressure meter contact front point of oil yes next 2 input 2 examine and repair pipe of injector starting engine check the fuel pressure whether is around 300kPa not Pull out ignition coil and contact with spark plug keep yes next 3 pole of spark plug 5mm away with body o f engine starting engine and check it whether has blue white high no examine and repair pressure fire or not ignition system Check spark plug look its type and gap if accords with yes next 4 standard no Adjust or replace Pull out connector of engine water temperature sensor yes Examine and repair star ting engine observe engine whether succeed starting wiring or replace or not a t this moment sensor no next Draw accelerograph gently observe it whether starting yes Clean throttle valve 6 engine easily o r not body and idle speed air duct no next Disassembly injector and check the injector by special yes replace 7 washing analysis instrument if exists the phenomena of SUR leaks or clogs Check fuel and observe the fault i f caused after fueling yes Replace fuel 8 no next Check compression o f cylinder and observe the pressure yes Eliminate engine 9 if is discrepantly mechanism fault no next Check engine ignition timing if accords with standard yes next 10 no examine and repair ignition timing Contact EFI commutator open ignition switch check yes Diagnosis help
4. Check Item Intervals Standard Part Item Daily 1 2 year Annual Lighting device Function O turning indicators Alarm and lock Function O device Instruments Function O Exhaust pipe Looseness or damage caused O and muffler by improper installation Function of muffler O Frame Looseness and or damage O Others Lubrication amp grease of frame O parts Abnormal parts Make sure if there is any determined when driving abnormal with relative parts 3 5 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 In case of sway of the steering stem tighten the locknut or disassemble the steering stem for further check Park the vehicle on level place slowly turn the steering wheel left and right to see if it can turn freely In case there is any hindrance check if there is any interference If no check the steering tie rod end and check if the steering stem bearing is damaged Note Make sure the steering can be operated freely 3 INSPECTION amp ADJUSTMENT An accident may occur if the steering wheel is out of control 3 6 Master Cylinder Fluid level Check the brake fluid level When t
5. XY500UTV XY500LUTV XY500UE XY500UEL 4x4 XY POWERSPORTS LLC 2630 Glendale Milford Rd Ste 100 Evendale Ohio 45241 1 888 926 8997 2 9 20 7 XY500UTV XY500LUTV XY500UE XY500UEL 4x4 ZHEJIANG XINYANG INDUSTRY CO LTD 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 Some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service procedures before starting the work Certain procedures require the use of special tools Use only the proper tools as specified This manual contains an introductory description of procedures for inspection maintenance overhaul disassembly amp assembly removal and installation of components and parts troubleshooting and service data together with illustrations of our UTV Model XY500 and 5001 The manufacturer reserves right to make improvements modifications to products without prior notice Overhaul and maintenance should be done according to the actual state and condition of the UTV
6. Ref No Description QTY Ref No Description QTY 1 Bolt 8 28 6 17 Needle bearing 1512 1 2 Front dif gear casecover 1 18 Drive pinion gear 1 3 O Ring 141 2 4 1 19 Bearing 6007 1 4 Bearing 16007 1 20 Oil seal 18x65x9 1 5 Circlip 62 1 21 6 1 22 seal 14 6 8 1 7 Drive clutch 1552 23 Nut washer 1 8 Washer 83 71 1 24 Nut washer M14x1 5 1 9 Dif gear assembly 1 25 Bolt M8x20 4 10 Washer 61 48 2 4 26 Gear motor 1 11 Bolt M10x1 25 1 27 O seal 81 2x1 9 1 12 Washer 10 1 28 1 13 Washer 14 1 29 Pin roll 1 14 Bolt M14x1 25 1 30 Screw 8 10 1 15 Oil seal 24x38x8 2 31 Bearing M64x1 5x7 1 1 16 Dif Gear case 1 1 10 3 10 Inspection after front axle disassembly 10 Check if there is damage or crack 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 Replace bearing if necessary Using special tools Check if oil seal lips and O ring shape are ok Replace if necessary Check cylndrical surface of front axle and oil seal lips Replace broken parts if necessary Check drive pinion gear and differential gear inspect worn surface Replace broken if necessary Check driven gears surface gear center differential
7. Remove rear wheel 9 3 Remove axle nut Remove wheel hub Installation Reverse the removal procedure for installation Tightening torque Rim Axle Nut 180 200N m Brake Caliper Wheel Hub Brake Disc 9 3 9 REAR WHEEL REAR BRAKE SUSPENSION Rear Brake Rear Brake Caliper Remove e Rear left wheel 9 3 e 2 bolts from arm e Brake caliper Inspection Brake Caliper Cracks Oil leakage Replace Installation Reverse the removal procedure for installation Note Refer to Chapter 1 for brake hose routing Rear Brake Disc Remove e Rear left wheel 9 3 e Remove axel nut e Remove wheel hub e Rear brake caliper 9 4 e Rear brake disc 8 3 Inspection Brake Disc Thickness lt 16mm Replace Installation Reverse the steps of removal for installation Note Refer to Chapter 1 for brake hose routing Parking caliper Remove rear wheel 9 3 Rear drive shaft Remove two nuts Remove parking caliper Remove parking disc Nut Rim Axle Brake Caliper Wheel Hub Brake Disc Rear Drive Shaft Split Washer a 1 9 4 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 1 2 3 4 56 7 8 4 9 10 1 MH 1 10 1 25 30 2
8. Main Data Table Item Parameter Model 5000 5000 S00LUTV 500UEL Length 2600mm 3200mm Width 1280mm 1300 mm Height 1960mm 1880mm Wheel base 1760mm 2440mm Engine type 500UTV S00LUTV CF188 500UE 500UEL CF188 B Displacement 493ml Fuel type Unleaded gasoline 93octane or above Mass of whole equipments Not include 580kg 720 kg driver Number of Passengers 2 for 500UTV 500UE 4 500L UTV SOOUEL including driver Max Load 300Kg Tire Front 25x8 12 Rear 25x10 12 Minimum turning radius 4200mm 4900mm Starting Electrical starting Form Single cylinder four stroke liquid cooling 4 valves OHC Combustion Chamber Type Triangle Valve Driving SOHC ChainDrive Bore x stroke 87 5x82 0 mm 3 4x3 2 in Compression ratio 10 2 1 Lubrication Type Pressure and splash lubricating type Lowest fuel consuming rate lt 3400 h Engine g Kw h Idling speed r min S500UTV SOOLUTV 13004100 SOOUE SOOUEL 1400 100 Starting system Electrical starting Spark Plug type DPR7EA 9 NGK Lubricating oil category SAE 15W 40 SF Engine oil pump type ROTOR Oil filter type Whole way paper filter element 1 4 1 SERVICE INFORMATION Item Parameter 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
9. ro Tee 12 8 Troubleshooting 12 2 SEnSOP egeat 12 9 Replacing 12 3 Water Temperature Transducer 12 10 12 5 Ignition Switch 12 6 Handlebar Switch 12 7 Brake Light Switch 12 8 Overhaul Information Warning e 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 Inspection of water temperature alarm may use fire source and liquid of high temperature Do not put flammable matters nearby and take care not to get burnt The temperature of headlight is quite high when turned on Replacing with bare hand or stained glove will cause oil stains on the glass face which may form hot spot and cause deformation of glass face and damage to bulb Pay attention to the following when replacing the bulb not replace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil stains on the glass surface If the Inspection has to be done with battery check if the battery is normal Inspection of switch continuity can be done without re
10. 5 10 13 stitch power whether supply normal ls relevant wiring not check 27 21 stitch whether Put up iron r not 6 Eng in e works regularly but unsteady idle speed at any time Possible defective part 1 fuel containing water 2 injector 3 spark plug 4 throttle valve body and idle speed side air duct 5 inputair duct 6 idle speed valve 7 ignition timing 8 engine mechanism part Overhaul Ref no Operation Test result Next Steps Check air cleaner and input air duct yes Examine and repair 1 whether are clogged r not air input system no next 13 18 13 TROUBLESHOOTING 2 Check idle speed valve whether clogged or not Yes Clean or replace no next 3 Check spark plug look its type and gap if accords Yes next with standard no Adjust or replace 4 Check throttle valve body and idle speed side air Yes Clean duct whether have carbide accumulated or not no next Disassembly injector and check the injector by Yes Fault replacement 5 special washing analysis instrument if exists the ext phenomena of leaks clogs or flux discrepantly Check fuel and observe the fault if caused after Yes Replace fuel 6 fueling Check compression of cylinder and observe Yes Eliminate engine 7 pressure if is discrepantly mechanism fault no next Check engine ignition timing if accords with Yes
11. 11 Rotate speed not increase or engine power off 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 fuelinjector 8 ignition timing 9 muffler Overhaul Ref no Operation Test result Next Steps Check air cleaner if is clogged yes Examine and repair 1 air input system no next Contact fuel pressure meter contact front point of oil yes next 2 input pipe of injector starting engine check the fuel iio examine and repair pressure whether is around 300kPa or not oil support system Check spark plug look its type and gap if accords with yes next t 3 standard no Adjust or replace Disassembly idle speed valve and check the throttle yes Clean related parts 4 valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next Check air intake pressure sensor throttle position yes next 5 sensor and their wiring whether works regularly or not m examine and repair wiring or replace sensor Disassembly injector and check the injector by special yes Fault replacement 6 washing analysis instrument if exists the phenomena of leaks clogs or flux discrepantly no next Check fuel and observe the fault if caused after fueling yes Replace fuel 7 no ne
12. 000000900500 chain 6 8 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION A Engine Right Side CVT Cover e Remove bolt of CVT cover 7 i e Remove CVT cover r e Remove gasket and dowel pin X CVT Continuously Variable Transmission Remove primary sheave nut with special tool Remove primary sliding sheave e Remove secondary sheave nut with special tools e Remove secondary sheave e Remove drive belt Tool Sheave Holder e Remove primary fixed sheave Remove bolt for air guide plate Remove air guide plate 6 9 6 ENGINE REMOVAL INSPECTION amp INSTALLATION CVT Case e Remove bolt 1 of CVT case e Remove nut 2 of CVT case e Remove outer clutch face and CVT case Remove dowel pin front and rear gasket Clutch Remove one way clutch Remove clutch shoe fixing nut with special tool e Remove clutch shoe Note The clutch shoe nut has left hand threads Tool Timing Chain Remove timing chain 6 10 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Engine Center 6 Gear position bolt Remove gear position bolt Remove spring and steel ball Right Crankcase Remove left crankcase bolts Remove right crankcase bolts Separate right crankcase with special tool Caution The Crankcase separator plate should be parallel with the end face of crankcase Crankshaft should remain in the left crankcase half Tool Crankcase separator Driv
13. Brake fluid should be above brake and brake fluid level LOWER limit brake disc Brake disc Replace when the thickness of damage and wear front brake disc is less than 16 5mm rear brake less than 16 5mm Driving wheel Tire pressure Front tire 145 System 21 1 51 Rear tire 193kPa 28 1PSI Chap and damage O No wear indication on surface of tire the remained depth of groove should not be less than 3mm Groove depth and abnormal wear Loosened wheel nut and axle Sway of front wheel bearing Sway of rear O wheel bearing Buffer Suspension Sway of joint O System arm parts rocker arm damage Shock Oil leakage and O absorber damage Function Drive Tr Front axle Transmission lubrication system Rear axle Transmission lubrication Gear box Transmission lubrication 3 3 3 INSPECTION amp ADJUSTMENT Check Item Intervals Standard Part Item Daily 1 2 year Annual Drive Train Final shaft Looseness of O O O Drive joint parts shaft Sway of O Spline Electrical Ignition Spark plug O O System Device Ignition O O timing Battery Terminal Joint O Wiring Looseness O and damage of joints Engine Fuel device Fuel leakage O Throttle O Cooling Coolant level O O O system Coolant O leakage 3 4 3 INSPECTION amp ADJUSTMENT
14. 1 CVT Cover 2 Bearing 3 Seal 4 Limitator Oil Seal 5 Screw 1 Oil Seal 5 2 Clutch Housing 3 Screw 4 Bearing Retainer CVT 5 Bearing 6 CVT Case 1 Oil Seal 6 ENGINE REMOVAL INSPECTION amp 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 O ring 6 Bearing 15 Link Bolt 24 Speed sensor 7 Oil Seal 16 Washer 25 Bolt 8 Washer Reverse Gear Sensor 17 Bearing 26 Washer 9 Reverse Gear Sensor 18 Bearing 27 Oil Drainage Bolt e Clean and grease the bearings turn the inner race of bearing and check the play noise and smooth turning In case of any abnormal remove bearing with special tool and replace Check all the oil seals for over wear or damage In case of any over wear or damage remove with special tool and replace with a new oil seal Remove gear sensor 11 and check for continuity with reverse gear sensor 9 with a multimeter Remove link bolt and oil pipe 14 and check oil pipe for crack or clog Replace with a new if any Remove oil drainage bolt 27 and clean it Note Check bearing for smooth turning after installation 6 52 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION e Install new O ring and apply grease e Install gear sensor e Install reverse gear senso
15. Apply Lubricant grease to oil sea lip e Install left crankcase cover e Install bolts Recoil Starter e Install recoil starter 1 e Install O ring 2 Note Use a new O ring and apply lubricant grease to the O ring e Install washer 3 and bolt 4 tighten to the specified torque Recoil starter bolt tightening torque 55N m 6 60 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Water Pump e Install water pump e 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 e Install the parts as illustrated on the right 1 sector gear cover and gasket 2 dowel pin 3 drive sector gear 4 driven sector gear 5 driven sector gear bolt Note When the shift cam is in the neutral position the mark of drive sector gear should be between the two marks of the driven sector gear Driven sector gear tightening torque 14N m e Install gearshift rocker arm e Install rocker arm bolt washer 8 6 61 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Oil Filter e Install oil filter bolt and tighten to the specified torque Oil filter bolt tightening torque 63 N m e Apply engine oil to O ring e Install oil filter turn it by hand until the filter gasket contacts the mating surface Tighten the bolts to the specified torque Tool Oil Filter Wrench Starting Motor e Apply engine oil to new O rin
16. 1 825 2 155 0 303 0 326 110 0 1 0 1383 0 1451 11 16 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 THE PINS FUNCTION 1 CONNECT HEATING POSITIVE SOURCE WHITE 2 CONNECT HEATING NEGATIVE SOURCE WHITE 3 OUTCOMING SIGNAL NEGATIVE POLE GRAY 4 OUTCOMING SIGNAL POSITIVE POLE BLACK THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR SENSOR AND ECU THE BELOW SHEET IS THE SENSOR PERFORMANCE CHARACTERISTIC VALUE 11 ELECTRIC SYSTEM Oxygen Sensor Quantity After 500Hours Bench Test ensor Voltage mv When 0 97 840 70 710 70 840 80 1 Sensor Voltage MV When 1 10 20 50 55 CO 1 1 0 30 Sensor Internal Resistance k 0 510 501 Response Time ms 150 150 600mv 300mv Response Time ms lt 150 150 300mv 600mv 11 17 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 1x100Q TRIGG
17. CONTENTS Vehicle Service Information Vehicle Body Muffler Inspection amp Adjustment Cooling amp Lubricating System Removal and Installation of Engine Transmission System amp Gearshift Removal Inspection and Assemble of Engine Carburetor Fuel System Air Intake System Front Wheel Front Brake Suspension Steering OANA RWND Rear Wheel Rear Brake Suspension E e Front and Rear Axle Electric System E N Lighting amp Switches Troubleshooting 1 SERVICE INFORMATION A few Words About Safety 1 1 Tightening 555555555555555555522 1 9 VIN Number Engine Number 1 3 Lubricating oil and brake 1 12 Main Data Table 1 4 Cables Pipes Cable Routing 1 13 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 Attempting service or repairs without the proper training tools and equipment could cause injury to you or others It could also damage the vehicle or create an unsafe condition This manual describes the proper methods and procedures for performing service maintenance and repairs Some procedures require the use of specially designed tools and dedicated equipment Any p
18. 6 32 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Remove spring 1 Remove spring seat 2 D e Remove guide pin and spacer Guide Pin 8 Spacer e Remove secondary sliding sheave 3 O ring and Oil Seal Oil Seal Check the O ring and oil seal for wear and damage Wear and Damage Replace e Remove Oil Seal 6 33 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Install oil seal with special tool Tool Bearing install set Secondary Sheave Spring e Use vernier caliper to check the spring free length If xthe length is shorter than the service limit replace with a new one Service Limit 145 4mm Secondary Sliding and Fixed Sheave Check drive face for any abnormal condition such as stepped wear or damage Wear or damage Replace Assembly e Install a new O ring e Apply lubricant grease to O ring oil seal lip and guide pin groove Material lubricant grease 6 34 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e 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 e Install spring seat Align hole A with hole B e Install spring and spring plate Insert spring end into the hole e Compress spring with special tool e Align the secondary sheave end with spring plate hole Tool Secondary sheave spring compressor e Tighten ring nut temporarily e Remove the spec
19. 2 2 Holder meter amp Engine cover 2 3 Front side support L amp R 2 5 Seat driver amp passenger 2 6 Gearshift Dni 2 7 Handle parking brake amp skid plate 2 8 Rear fender amp fender cargo box 2 9 Cargo DOK in 2 10 Overhaul Information Operation Cautions Warning 2 VEHICLE BODY MUFFLER Side door R amp L 2 11 Bumper amp Fuel tank err eh 2 12 2 Headrest driver amp Backrest passenger 2 13 Safety Delbe 2 14 rex vp EXE 2 15 Bumper PIotectOE e Ro dx S 2 17 Cargo ase s 2 18 i ERR 2 19 Description of visible parts 2 20 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 Remove and Install muffler after it 15 fully cold e This chapter is on the disassembly and installation of rack visible parts exhaust pipe Muffler and fuel tank e Hoses cables and wiring should be routed properly e Replace the gasket with a new one after muffler is removed e After muffler is installed check if there is any exhaust leakage Tightening torque
20. Fuel Sensor Fuel Tank 2P Connector fuel sensor fuel sensor 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 Warning e Coolant must reach the switch thread and the depth from vessel bottom to sensor top should be over 40mm Keep liquid temperature for three minutes before measuring and do not raise tempe Water Temperature Transducer rature sharply e The thermometer should not contact the vessel bottom Disassembly Remove seat driver and skid plate chapter 2 Multimeter Disconnect and remove transducer Put the transducer into a vessel with coolant slowly heat up the liquid and measure the transducer resistance Temperature Resistance _ 5 50C 154 160 ER 80C 522440 L 100C 27 40 120 C 16 440 Transducer out of range Replace Install transducer Connect water temperature transducer connector Fill coolant and discharge air Reverse the removal procedure for installation of plastic parts and seat 12 10 13 TROUBLESHOOTING 1 Engine troubleshooting 2 Diagnosis troubles according to EFI system Trouble 13 14 3 Diagnosis tro
21. Item Description Disassembly Inspection Assembly Remarks Maintenance Engine Water Hose Pipe 6 2 3 24 6 69 Periphery Left Side Cover 6 2 6 69 Recoil Starter 6 2 6 49 6 68 Engine Spark Plug 6 2 3 17 6 68 Front Cylinder Head Cover 6 3 6 14 6 66 Side Tensioner 6 3 6 24 6 67 Camshaft 6 3 6 21 6 65 Cylinder Head Tensioner Plate 6 4 6 15 6 23 6 64 Cylinder Timing Chain Guide 6 4 6 24 6 23 6 64 Piston 6 5 6 25 6 62 Engine Starting Motor 6 5 14 2 6 62 Left Oil Filter 6 6 3 22 6 62 Side Sector Gear 6 6 6 62 Water Pump 6 7 4 7 6 61 Sheave Drum 6 7 6 48 6 60 Left Crankcase Cover Magneto Stator 6 7 6 48 6 60 Magneto Rotor 6 7 6 47 6 60 Starting Driven Gear 6 8 6 47 6 59 Starting Dual Gear Idle Gear 6 8 6 48 6 59 Oil Pump Sprocket and Chain 6 8 6 59 Engine CVT Cover 6 9 6 51 6 58 Right Drive Belt 6 9 6 36 6 57 Side Primary Sheave Secondary Sheave 6 9 6 30 6 57 CVT Housing Clutch Outer Face 6 10 6 51 6 57 Clutch 6 10 6 28 6 56 Timing Chain 6 10 6 23 6 56 Engine Gear Position Bolt 6 11 6 56 Center Right Crankcase 6 11 6 52 6 56 Front Output Shaft Components 6 11 6 43 6 55 Driven Bevel Gear Components 6 11 6 43 6 55 Shift Cam 6 12 6 40 6 55 Guide Bar Fork 6 12 6 39 6 55 Drive Bevel Gear Components 6 12 6 42 6 55 Main Transmission Shaft 6 12 6 38 6 54 Transmission Counter Shaft 6 12 6 38 6 54 Balancer Shaft 6 12 6 46 6 54 Crankshaft 6 13 6 27 6 54 Oil Pump Pressure limiting Valve 6 13 6 41 6 53 Left Crankcase 6 52 Not
22. Muffler Rear Fixing Bolt 20 25N m Muffler Exhaust Pipe Nut 20 25N m Troubleshooting Loud exhaust noise e Broken muffler e Exhaust leakage Insufficient power e Distorted muffler e Exhaust leakage e Muffler clogged 2 1 2 VEHICLE BODY MUFFLER Center cover steering wheel 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 just steering wheel Reverse the removal procedure for Installation Decorate cover steering stem Remove Remove bolt 2 Remove decorate cover steering stem Installation Reverse the removal procedure for Installation BOLT 2 Decorate cover steering stem 2 2 2 VEHICLE BODY MUFFLER Holder meter Front fender Remove Remove eight bolts 1 Loosen all electronic component and plugs in holder meter Remove holder meter Bolt 2 Engine cover Engine cover Remove four bolts 1 Remove two bolt 3 Loose cables on the engine cover i Bolt 3 2 3 2 VEHICLE BODY MUFFLER Remove two bolts 4 Removetwo muts Panel engine cover Nut 4 Bolt 4 Remove panel engine cover L Remove two bolts 4 Remove two nuts 4 Remov
23. attention to the seal face e Incase of leakage or damage replace the mechanical seal If necessary also replace the seal ring 4 9 4 COOLING AND LUBRICATIING SYSTEM Oil Seal Check oil seal for damage Pay special attention to the oil seal lip e Incase of damage or leakage replace the oil seal Water Pump Body Check the mating mace of water pump body with bearing and mechanical seal Damage Replace Impeller Check the impeller and shaft for damage Damage Replace Assembly and Installation of Water Pump Install oil seal with special tool Tool Oil Seal Installer Note The stamped mark on the oil seal faces outside Apply a little grease to the oil seal 4 10 4 COOLING AND LUBRICATIING SYSTEM e Install mechanical seal with a suitable socket wrench Note Apply sealant to side A of mechanical seal e Install bearing with special tool Tool Bearing Installer Note The stamped mark on the bearing faces outside e Install seal ring to impeller e Clean off the oil and grease from mechanical seal and install it into the impeller Note side of mechanical seal faces impeller e Apply grease to impeller shaft Apply Grease e Install impeller shaft to water pump body 4 11 4 COOLING AND LUBRICATIING SYSTEM e Install E ring to water pump shaft e Install new gasket to water pump body e Install water
24. 8 BOLT M12x60 T 20 FR ROCKER BUTTONHEAD 9 FRONT SHOCK ABSORBER 10 BOLT M10x1 25x40 11 LOCKING NUT 8 21 CALIPER BRAKE L 22 CALIPER BRAKE R 23 BRAKE PAD LEFT 24 BRAKE PAD 12 SPRING WASHER 13 SPRING WASHER RIGHT 14 SPRING WASHER 15 HEX FLANGE 25 COVER L FR LOWER SWING 26 1 COVERR FR LOWER SWING BOLT M10x1 25x30 24 23 21427 20 8 10 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 Refer to Left Constant Velocity Drive Shaft for removal inspection and installation of other drive shafts Left Constant Velocity Drive Shaft Front Axle Removal NOTE Maintenance of Left Constant Velocity Drive Shaft of Front Axle only does not require removal of Front Suspension Remove Front left wheel 8 3 Front left brake caliper 8 4 Front left wheel hub 8 3 Check dust boot Damaged dust boot Replace Shake constant velocity drive shaft check the agility of rzeppa universal joint free turning of bearing and any gap between rzeppa constant velocity joint and spline Stagnated turning noise gap with spline Replace Warning An accident may occur if the
25. Check fuel and observe fault if caused after yes Replace fuel 6 fueling no next Check compression of cylinder and observe yes Eliminate engine 7 pressure mechanism fault no next Contact EFI commutator open ignition switch yes Diagnosis help 8 check ECUS 108 23 stitch the power Examine and repair whether supply normal or not check 2 21 m relevant wiring stitch whether Put up iron or not 8 Engine starting normally but idle speed unsteady after warming up Possible defective part 1 fuel containing water 2 engine water temperature sensor 3 spark plug 4 throttle valve body and idle speed side air duct 5 input air duct 6 idle speed valve 7 engine mechanism part Overhaul Ref no Operation Test result Next Steps Check air cleaner and input air duct whether are clogged yes Examine and repair 1 or not air input system no next Check spark plug look its type and gap if accords with yes next 2 standard no Adjust or replace Disassembly idle speed valve and check the throttle valve yes Clean related parts 3 body idle speed valve and idle speed side air duct whether have carbide accumulated or not io Pull out connector of engine water temperature sensor yes 4 starting engine observe idle speed whether is unsteady or not when engine is in warming up no Disassembly injector and check the injector by special yes 5 washing analysis instrument if
26. Errors coding P0560 Voltage signal of system battery illogicality Errors coding P0562 Voltage signal of system battery is too low Errors coding P0563 Voltage signal of system battery is too high Maintenance Tips Maintenance Tips The possible faults may exists as follow Check the item as follow 1 Magneto damaged and disable to starting or 1 Check the capability of generate electricity of battery electric leakage Magneto measure voltage of Magneto after 2 Magneto stator coil open circuit starting 3 Regulator of Magneto damaged Errors coding P0627 Control circuit of oil pump relay open circuit Errors coding P0628 Control circuit of oil pump relay short to ground Errors coding P0629 Control circuit of oil pump relay short circuit Maintenance Tips Maintenance Tips The possible faults may exists as follow Check the items as follow 1 Open circuit short to ground short circuit 1 Measure resistance or voltage of oil pump relay between control circuit of oil pump relay control circuit connected to ECU connected to ECU and oil pump 2 resistance between relay and main relay 2 Open circuit between relay and main relay 3 resistance between the toes of relay 3 Magnet coil of relay open circuit Errors coding P0650 MIL lamp driver circuit fault Maintenance Tips Maintenance Tips The possible faults may exists as follow Check the item as follow 1 Open circuit short to ground short circ
27. bracket differential wearing situation on the differential gear assembly Replace parts if necessary Check inside and outside spline washer wearing status in front axle Replace parts if necessary Check gear motor working status Replace with new parts if necessary Gear motor inspection must be carried out with special equipment or acted on the vehicle Check other parts Replace broken parts of necessary 10 4 10 Front axle assembly and adjustment Front axle case cover assembly 18 19 31 20 2221 Item 31 tightening torqueSs Nm 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 Note Use engine oil for oil seal or bearing assembly Differential gear assembly M10x1 25x22 Tightening torque45Nm GEAR CENTER DIFFERENTIAL Note Use engine for bearing and dif ferential gear WAR Sa RY e 2 Use proper washer to make gear working au freely GEARINGRING 0 BOLT M10x1 25 Adjust washer 01 02 03 04 thickness 0 5 1 0 10 5 Front axle assembly and adjustment Illustration Tightening torque Item 1 25Nm 25 13Nm Item 30 13Nm Bolt 25Nm Bo
28. 4WD switch 6 W 4 WD LOCK 4W e No continuity Change switch Brake Lght 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 gt 2 3 Disconnect horn Connect with a fully charged 12V battery and check if the horn sounds Faulty Horn Replace 12 8 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 Non conformity check main cable for damage or short circuit Check fuel sensor and fuel gauge Remove fuel sensor 2P connector Connect multimeter between 3P connector terminals Shake float with hand and measure the resistance of float at different positions Connection Terminal Upper 3 2Q 20 C 0 Lower 110 5 Q 20 C Faulty fuel sensor Replace Installation Put fuel sensor into installation hole of fuel tank Fuel sensor should be fitted properly No fuel leakage is allowed Connect 2P connector 12 9 12 LIGHTING AND SWITCHES
29. 6305 1 4 O Ring 151x 3 1 20 Bearing retainer 1 16017 2 1 21 Drive bevel gear 1 6 Adjust washer 2 1 2 22 Inner race NA5903 1 7 Ring gear rear axle 1 23 Outer NA5903 1 8 Adjust washer 1 1 24 Adjust gasket 14553 9 Needle bearing55BTM6720A 1 25 Washer 14 5 21x 1 5 1 10 Rear gear case 1 26 Bolt M14x 1 25x 12 1 11 Oil sealSD4 65x 90x 9 NS 2 27 O ring 19x 2 5 1 12 Nut M12x 1 25 1 28 20 1 5 12 1 13 Washer12 5x 30x 4 1 29 HEx Screw 8 45 1 14 Coupler rear axle 1 30 Washer 8 2x 15x 1 5 1 15 BoltM8x 35 4 31 Screw 8 1 16 35 61 9 5 14 1 10 8 10 Needle bearing removal a Disassemble needle bearing 55BTM6720 as illustration if necessary b Disassemble needle bearing NA5903 as illustration after heating upto 150 C Rear axle inspection after disassembly Check if there is crack or damage in rear gear case see mounting hole is Replace gear case or right cover if necessary Check if bearing clearance is normal and turing stability rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required Check rear axle if bearing clearance is normal t
30. COOLANT TEMPERATURE 5 ENSOR UNREASONA BLE ENIGNE COOLANT TEMPERATURE S ENSOR C IRCUIT VOLTAGE TOO LOW 5 m ENIGNE COOLANT TEMPERATURE S ENSOR C IRCUIT VOLTAGE TOO H IGH Uu E THROTTLE POSITION S ENSOR CIRCUIT VOLTAGE UNDER LIMINAL VALUE THROTTLE POSITION 8 ENSOR CIRCUIT VOLTAGE L IMINAL VALUE 16 P0130 OXYGEN SENSOR SIGNAL UNREASONA BLE 17 P0131 OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO LOW 18 P0132 OXYGEN SENSOR SIGNAL CIRCUIT VOLTAGETOO HIGH 19 P0134 OXYGEN SENSOR CIRCUIT SIGNAL TROUBLE 20 P0201 1 CY LINDER OIL ATOMIZER CONTROL CIRCUIT OPE N CIRCUIT 21 SE 1 CY LINDER OIL ATOMIZER CONTROL CIRCUIT S HORT CIRCUIT TO GOUND 22 m 1 CY LINDER OIL ATOMIZER CONTROL CIRCUIT S HORT CIRCUIT TO POWER 23 P0321 TRANSIENT SPEED S IGNAL REFERENCE POINT TROUBL 24 5 TRIGGER VEHICLE 5 PEED PULSE SIGNAL OPEN CIRCUIT OR SHORT CIRCUIT 25 0501 VEHICLE SPEED SENSOR SIGNAL UNREASONAB LE m nm IDLE SP EED CONTROL ROTATING SPEED LOWER THAN TARGET IDLE SPEED IDLE SP EED CONTROL ROTATING SPEED HIGHER THAN TARGET IDLE SP EED 11 26 11 ELECTRIC SYSTEM REF TROUBLE CODE INSTRUCTION 1 1 28 P0560 SYSTEM BATTERY VOLTAGE SIGNA L UNREASONABLE 29 P0562 SYSTEM BATTERY VOLTAGE TOO LOW 30 P0563 SYSTEM BATTERY VOLTAGE TOO HIGH 31 P0602 ECU CODING TROUBLE 32 P0627 OIL PUMP RELAY CONTROL CIRCUIT OPENING 33 P0628 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO GROUN
31. 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 ECU EACH STITCH FUNCTION 1 IGNITION COIL CONTROL SIGNAL 2 GROUND 3 VEHICLE SPEED SIGNAL 4 TROUBLE LAMP 5 IGNITION SWITCH POWER 6 INTAKE AIR TEMPERATURE SENSOR SIGNAL 7 REVERSE GEAR 8 4WD DEAD LOCK SWITCH SIGNAL 9 ASSISTOR SWITCH SIGNAL 10 45 VPOWER OUTPUT 11 IGNITION SWITCH POWER 12 TRIGGER SIGNALA 13 TRIGGER SIGNALB 14 0IL ATOMIZER 15 0XYGEN SENSOR HEATING 16 SUPPLEMENTARY RELAY 17 IDLE SPEED CONTROL VALVE CARBON TANK CONTROLVALVE 18 WATER TEMPERATURE SENSOR SIGNAL 19 INLET PRESSURE SENSOR SIGNAL 20 AIR DAMPER POSITION SENSOR SIGNAL 21 SENSOR 22 0IL PUMP 23 POWER 24 0XYGEN SENSOR 25 ENGINE SPEED OUTPUT LIMIT DATA 11 ELECTRIC SYSTEM ECU EIER S n N l 1 ECU Connector Nommal Operation I Overvoltage and Time WoringTemp Storage Temp DISALLOW TO ADD LOAD ON CRUST OR COVER BOARD HANDLED CAREFULLY AND AVOID TO DROP ON THE FLOOR 11 12 14 0 1 Withstanded Limited Function Such As Diagnosis 5 0 11 ELECTRIC SYSTEM 2 THROTTLE VALVE ASSY JOIN THE AIR CLEANER AND ENGINE
32. Gear change type Gear lever with hand Clutch type Wet hoof centrifugal type Primary speed change ratio 0 703 2 88 stepless speed change Speed change ratio Total speed reduce ratio Engine H Gear 3 514 2 47 10 12 LGear 5 857 4 12 16 87 RGear 3 828 2 69 11 02 Cooling type Closed cooling fluid circulating Cooling fluid type Antifreeze with prevent rust Out dimension 610 568 519 Net weight 70kg Output type Front and rear shaft output Shaft running direction Clockwise from back of engine Fuel Air Filter type Sponge element filter Device Valve Type CF188 B 173000 of Omm mixing valve Clutch Type Wet Auto Centrifugal Operation Automatic CVT Parking amp Gear shifting mode Gears shift Low Gear High Gear amp Reverse Gear Shift Manual L H N R Mode order 2 88 0 70 Transmission Ratio RARE Final Ratio 1333 24 18 Bevel Gear Secondary 1 952 41 21 transmission Gears Low Gear 2 25 36 16 High Gear 1 350 27 20 Reverse Gear 1 471 25 17 Total Low Gear5 857 High Gear 3 514 Reverse Gear 3 828 Front Axle 33 9 3 667 Axle Ratio Rear Axle 33 9 3 667 1 5 1 SERVICE INFORMATION Item Parameter Engine Output Mode Front Rear Shaft Gearing Direction of Output Rotation Clockwise on forward shift Steering Steering Right 3
33. Intake and exhaust system leaks 3 Inlet or back of intake valve has carbon build up needs to be decarbonized 4 Engine parts deviation 5 Valve clearance deviation 6 Fuel system pressure deviation 13 13 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 2 3 4 5 6 Check fuel pipe for has fuel leaks Check vacuum tube if rupture kink or incorrect connection Check air intake pipe whether clogged leaked been staved or damaged or not Check ignition c oil of ignition system whether rupture aged or not firing sequence whether correct or not Check ground of wiring harness make sure it s c lean and tight Check connections for loose or poor contacts or not Notice Pleas e maintain the faults as above in advance If not the further fault diagnosis will be affected Diagnosis help 1 Engine has no fault records 2 Affirm the complaint of fault happened 3 Do not ignore vehicle maintenance working cylinder pressure mechanism timing fuel etc effect against system during overhaul 4 Replace ECU and test it If Trouble Code is cleared it
34. Oxygen Sensor Pin Main Relay is normal or not 3 Check if resistance between Oxygen Sensor Pin and Pin 2 is normal or not Trouble Code P0031 Oxygen Sensor Heating Circu it Short to Ground Note Possible Troubles are as below 1 Circuit connect to ECU Pin are short to ground Note Inspect as below 1 Check if resistance of ECU Pin to ground is normal or not Trouble Code P0032 Oxygen Sensor Heating Circuit Short to Power Note Possible Troubles are as below 1 Short Circuit between ECU Pin and Oxygen Sensor Pin 1 2 Short Circuit between ECU Pin and other circuit Note Inspect as below 1 Check if resistance of ECU is normal or not 2 Check if resistance between ECU Pin and Oxygen Sensor Pin 1 circuit is normal or not Trouble Code P0053 Inner Resistance of Oxygen Sensor Heating not correct Explanation ECU system measure the Oxygen Sensor Heating Resistance to decide if heating output is correct or not In some conditions Heated Oxygen Sensor would be damaged by precipitate especially while making cold start Note Possible Troubles are as below 1 Oxygen Sensor Heating function disable Note Possible Troubles are as below 1 Check if resistance between Oxygen Sensor Replace Oxygen Sensor Pin and Pin 2 is normal or not Trouble Code Inlet Pressure Sensor signal variable Note Note Possible Troubles are as below 1
35. SETTED WHEN IT LEAVE THE FACTORY IT INITIAL POSITION CANNOT BE CHANGED EASILY WHEN INSTALLING THE BATTERY THE POSITIVE AND THE GROUND CANNOT BE INSTALLED WRONG THIS SYSTEM APPLYS NEGATIVE GROUND WHEN ENGINE RUNNING DON T UNHOOK THE BATTERY CABLE BEFORE CARRY OUT ELECTRONIC WELDING ON THE VEHICLE YOU ARE REQUIRED TO UNHOOK THE BATTERY POSITIVE TERMINAL NEGTIVE TERMINAL AND ECU DONOT USE METHOD IMPALE LEAD CUTICULAR TO TEST COMPONENTS S INPUT AND OUTPUT ELECTRICAL SIGNAL SET UP ENVIRONMENTAL PROTECTION CONSCIOUSNESS TREATING THE WASTE AFTER MAINTENANCE 11 9 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 11 10 11 ELECTRIC SYSTEM TOOL NAME ELECTRONIC IGNITION d 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 11 11 ELECTRONIC FUEL INJECTION PARTS STRUCTURE AND FUNCTION 1 ECU ECU IT IS THE BRAIN OF THE
36. Starter Jet GS 1 9 Enriching Diaphragm 1 18 Pilot Air Jet 1 7 3 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM 2 Inspection e 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 float float tang 2 for damage Damage Replace e Check valve seat needle valve O ring for damage abnormal wear or dirt Damage or wear or dirty Replace Note Valve set D needle valve should be replaced as a set e Check piston valve for scratches abnormal wear or damage Scratches wear or damage Replace e Check diaphragm for tears Tears Replace Check vacuum chamber cover spring for damage or cracks Damage or cracks Replace 7 4 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM Check the diaphragm for tears Tears Replace Check the spring cover 8 for damage and tears Damage or tears Replace e Check the jet needle mail jet needle jet pilot 3 air jet pilot jet starter jet starter plunger for wear and bends Wear or bends Replace e Check above jets for clog Blow out the jets with compressed air e Insert piston valve into carburetor body and check the free movement e Check free movement of throttle valve Replace with a new one if it s stuck 3 Measurement and Ad
37. and adjust free play of throttle pedal After adjusting tighten locknuts and install throttle cable sleeve Replace with a new throttle cable if the specified free play could not be acquired by adjusting the regulator or if there is still stickiness with the throttle 3 12 3 INSPECTION amp 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 Check the valve clearance at the period indicated above and adjust the valve clearance to specification if necessary Remove cover plate recoil starter Remove inspection cap on left crankcase Remove 2 valve adjusting cover 4 Turn the crankshaft until the line of T D C on rotor is aligned with mark 6 of inspection hole on left crankcase Insert feeler gauge to check the clearance between the valve stem end and the adjust bolt on the rocker arm Valve Clearance When cold IN 0 05 0 10mm 0 17 0 22mm Note e The valve clearance must be adjusted when the engine is cold e Adjust the valve clearance when the piston is at the Top Dead Center T D C on the compression stroke If the clearance is incor
38. and check it whether has blue white high spark no Examine and repair Ignition system 13 15 13 TROUBLESHOOTING Check compression of cylinder and observe pressure yes Eliminate engine 4 if is discrepantly mechanism fault no next Contact EFI commutator open ignition switch check yes Diagnosis help 5 5 108 13 stitch the power whether supply normally or not check 2 21 stitch whether Put up iron Examine and repair or not relevant wiring 3 Hard Starting in normal status Possible defective part 1 fuel containing water 2 fuel pump 3 engine water temperature sensor 4 ignition coil Overhaul Ref no Operation Test Next Steps result Contact fuel pressure meter contact front point of oil yes next 1 input no examine and pipe of injector starting engine check the fuel pressure repair oil support whether is around 300kPa or not system Pull out ignition coil and contact with s park plug keep yes next pole of spark plug 5mm with body of engine starting 2 engine and check it whether has blue white high pressure no Examine and fire or not repair ignition system Pull out connector of engine water temperature sensor yes Examine and starting engine observe engine whether succeed starting repair wiring or 3 or not at this moment or in series a 300Q resistant replace sensor instead of engine water temperature s
39. belt from secondary sheave 3 16 3 INSPECTION amp 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 1f width is out of service limit replace drive belt with a new one Service Limit 33 5mm Tool Vernier Caliper Installation Reverse the removal procedure for installation Pay attention to the following Insert drive belt as low as possible between secondary sliding sheave and primary fixed sheave Hold secondary sheave with a special tool and tighten the nut to the specified torque Nut Secondary Sheave 115 N m Install primary sheave and nut Hold the primary sheave with a special tool and tighten the nut to the specified torque Nut Primary Sheave 115N m Turn primary sheave until the drive belt is properly seated and both the primary and secondary sheaves rotate together smoothly and without slipping Caution Fit the drive belt with the arrow the drive belt points toward normal turning direction The drive belt contact surface of the driven face should be thoroughly cleaned Install CVT cover 3 17 3 INSPECTION amp 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 fix
40. cable of starter rely Fixing bolt of engine Remove fixing bolt of engine 5 3 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Remove hoop of air inlet and outlet duct for air filter CVT Remove carburetor Remove air filter Remove muffler 2 18 Remove gearshift 2 7 air outlet duct air inlet duct for for CVT carburetor 5 4 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 r upper bracke of engine 35 45N m Adown fixing bolt of engine 50 60N m Install water inlet and out let hose in the en gine by hoop Install anode and cathode cable of starting Joint the connector of electrical cable Install cap of spark plug Install shift of gearshift Install air filter carburetor and other parts after remove 1 nut 2 bolt1 3 bolt2 4 front axle 5 blot3 6 front drive shaft 7 hoop 8 breather hose of front axle M Removal and Installation of Front and Rear axle Disassembly Hang the bodywork in the air by jack keep it doesn t falling Remove cover parts Chapter 2 Remove front and rear wheels and rocker gt Chapter 8 Chapter 9 Remove air filter Remove carburetor Remove engine Remove rear brake caliper gt Chapter 9 9 bolt4 10 rear axle 11 treather hoseof rear axle 12 rear brake dise 13 bolt
41. carburetor joint engine intake manifold 4 throttle valve cover throttle cable 6 Carburetor joint air filter carburetor 8 drain hose 9 fuel inlet hose gt U TA A l SA 202204 6777 TS Note Align installation mark of carburetor and carburetor joint 6 Carburetor Parameters Type MIKUNI BSR36 89 Aperture No 07G0 Throat size 36mm Pilot r min 1300 r min 100 r min Float height mm 10 1 Fuel level mm 3 5 0 5 Main jet MJ N102221 130 Main air jet MD13 24 35 Jet needle JN J8 5E26 Needle jet NJ 785 401011 P OM Pilot jet PJ N224103 22 5 Pilot screw PS 604 16013 1A Pilot airjetl MD13 24 65 Pilot air jet N211100 165 7 7 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM High Pressure Fuel Line Disassembly Special Fuel Line Clamp 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 High Pressure Fuel Line Installation Reverse the disassembly procedure for installation Use OETIKER clamp calliper to install the special fuel line clamp Throttle Body Disassembly Loosen the strap and remove throttle valve connector Loosen locknut remove adjust nut and remove the throttle
42. cylinder head cover and tighten bolts evenly and diagonally to the specified torque Tightening torque 10 N m Remove cylinder head cover read the width of the compressed plastic gauge with envelop scale The reading should be taken from the widest part Tool Plastid Gauge Note Do not turn the camshaft with plastic gauge in place If the camshaft journal oil clearance exceeds the limit measure the outer diameter of camshaft Replace either cylinder head set or the camshaft if the clearance is not correct 6 22 6 ENGINE REMOVAL INSPECTION amp 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 Measure the run out with a micrometer Replace camshaft is the run out is out of range Service limit 0 10mm Timing Sprocket and Chain Check timing sprocket and chain for wear or damage Replace with new parts if abnormal wear or damage is found Chain Tensioner Tensioner and Chain Guide Check contact surface of tensioner and chain guide 2 for wear and damage Replace with news parts if abnormal wear or damage is found Chain Guide 6 23 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Chain Tensioner Inspection e Check ten
43. err comete 7 2 Carburetor Removal ex bet ra S ME oH Uu E ES 7 3 o vada o 7 4 Measurement and INEM dex ua 7 5 Carburetor Assembly d i 7 6 Carburetor Installation 7 7 Carburetor Paramelets os cin Ha eR PR XOT Eu pa d 7 7 High Pressure Fuel Line Disassembly 7 8 Throttle Body 7 4 7 8 Fuel Injector Assy Disassembly Installation eese 7 9 Fuel injector Assy 1 2 2 7 9 Idle Air control valve 7 9 7 1 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 Do not over twist or bend the cables The twisted cables may cause poor operation Loose the high pressure fuel line before disassembly discharge the fuel in the high
44. leakage In case of oil leakage check the water pump oil seal O ring In case of coolant leakage check the water seal 4 7 4 COOLING AND LUBRICATIING SYSTEM Remove clamps and water hoses e Release bolts and remove water pump e Remove O ring Note Do not reuse the O ring e Remove the overflow tube Release water pump cover screws water pump cover and gasket Remove E ring and impeller e Remove seal ring Dand rubber seal 4 8 4 Remove mechanical seal with special tool COOLING AND LUBRICATIING SYSTEM Note The mechanical seal does not need to be removed if there is no abnormal condition Mechanical Seal Note Do not reuse a removed mechanical seal e Puta rag water pump body e Remove oil seal Note The oil seal does not need to be removed if there is no abnormal condition Oil Seal Note Do not reuse a removed oil seal Remove bearing with special 1001 Note The bearing does not need to be removed if there is no abnormal noise Note Do not reuse a removed bearing Inspection of Water Pump Bearing e Check the play of bearing by hand while it is still in the water pump body e Turn inner race of bearing to check for abnormal noise and smooth rotation e Replace the bearing if there is abnormal condition Mechanical Seal Check mechanical seal for damage pay special
45. next 8 standard no examine and repair ignition timing Contact EFI commutator open ignition switch Yes Diagnosis help 9 check 5 10 13 stitch the power whether Examine and repair supply normal or not check 2 21 stitch whether Put up iron or not relevant wiring 7 Engine works regularly but unsteady idle speed when engine is in warming up Possible defective part 1 fuel containing water 2 engine water temperature sensor 3 spark plug 4 throttle valve body and idle speed side air duct 5 input air duct 6 idle speed valve 7 engine mechanism part Overhaul Ref no Operation Test result Next Steps Check air cleaner and input air duct whether are yes Examine and repair 1 clogged or not air input system no next Check spark plug look its type and gap if yes next 2 accords with standard no Adjust or replace Disassembly idle speed valve and check the yes Clean related parts 3 throttle valve body idle speed valve and idle speed side air duct whether have carbide no next accumulated or not Pull out connector of engine water temperature yes Examine and repair sensor starting engine observe idle speed wiring or replace 4 whether is unsteady or not when engine is in sensor warming up no next Disassembly injector and check the injector by yes Fault replacement 13 19 13 TROUBLESHOOTING 5
46. not wiring harness Remove starter motor and check its working yes Repair or replace 3 condition if circuit break or starter motor locked Starter Motor because of improper lubricate no next Fault only happens on winter please check yes Replace appropriate 4 lubricating oil if is improper for engine which caused grade of lubricating high resistance of starter motor oil no next Check the resistance inside of engine mechanism yes Overhaul the 5 whether is high or not which makes starter motor resistance inside of stop rotates or rotate slowly engine mechanism no Repeat above steps 2 Engine can rotate but starting failure Possible defective part 1 no gasoline in tank 2 Fuel pump 3 Trigger 4 Ignition coil 5 engine mechanism part Overhaul Ref Operation Test Next Steps result Contact fuel pressure meter contact front point of oil yes next input pipe of injector open ignition switch and repeat it 1 if possible or starting engine check the fuel pressure no examine and repair oil whether is around 300kPa or not support system Contact Electronic injection diagnostic meter observe yes next item of engine rotate speed starting engine and 2 observe the rotate speed signal if is normally output no examine and repair sensor wiring of rotate speed Pull out ignition coil and contact with spark plug keep yes next pole of spark plug 5mm with body of engine starting 3 engine
47. of oil strainer with engine oil Relief Valve Check the valve body valve 2 and spring O for damage or wear Damage or wear Replace Drive Bevel Gear Use a clean rag to protect the drive bevel gear shaft clamp it to the pliers 1 Drive bevel gear cover 5 Adjust washer e Loosen drive bevel gear nut 3 remove the drive 2 Output driven gear 6 Drive bevel bevel gear 4 and adjust washer 5 3 Drive bevel gear nut 7 Bearing press 4 Drive bevel gear 8 Bearing Check the drive bevel gear 4 and output driven gear 2 for rust scratch wear or damage Replace if any Check if the bearing 8 turns smoothly replace with a new bearing if necessary e Adjust Washer 5 if any of right crankcase drive bevel gear 4 or drive bevel gear cover 1 is replaced Refer to bevel gear adjustment for details e Apply engine oil to bearing 8 when assembling and tighten nut 3 to the specified torque Drive bevel gear nut Tightening torque 145N m 6 42 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Front Output Shaft Check bearing 7 for smooth turning and abnormal wear Check oil seal 5 for damage Wear or damage Replace e Apply lubrication oil to bearing 7 and oil seal 5 lip before assembly e Apply thread locker to bearing limit nut 6 left thread and tighten to the specified torque Bearing limit nut Tightening torque 80N m Tighten Nut 1 to the specified torque Front output
48. out of range Replace Note Cylinder head cover and cylinder head should be replaced together Rocker Arm Shaft e Measure out diameter of rocker arm shaft with a micrometer Rocker Arm Shaft O D IN EX Limit 11 973 11 984mm Tool Micrometer 0 25mm 6 14 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Rocker Arm When checking the rocker arm check the inner diameter of the valve rocker arm and wear of the camshaft contact surface e Rocker Arm I D 000 12 018mm Tool Dial Calipers Assembly Note Intake rocker arm shaft A has oil holes e Apply engine oil to rocker arms and shafts e Install rocker arms and tighten rocker arm shaft to the specified torque Rocker Arm Shaft Bolt 28N m Zhu Cylinder Had Disassembly e Remove intake pipe e Remove water temperature sensor Dand thermostat cover 2 6 15 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION e 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 e Remove valve from the other side Remove valve stem seal ring and valve lower seat 6 16 6 ENGINE REMOVAL INSPECTION amp 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
49. plug gap Adjust or replace high speed 5 Improper valve timing Replace range 6 Faulty ignition coil Adjust 7 Weak high pressure fuel pump Adjust or replace resulting in poor fuel supply 8 Dirty air filter Clean or replace 1 Excessive engine oil Check oil level and drain Exhaust smoke 2 Worn piston ring Replace is dirty or thick 3 Worn valve guide Replace 4 Scored or scuffed cylinder wall Replace 5 Worn valve stem Replace 6 Worn valve stem oil seal Replace Improper valve clearance Adjust Weak valve spring Adjust Improper valve timing Adjust Worn cylinder Replace Replace Engine lacks Improper valve seating 1 2 3 4 5 Worn piston ring 6 7 Fouled spark plug 8 9 Replace or Correct Clean or replace power Improper spark plug gap Clean or replace Clogged fuel injector Clean or replace 10 Dirty air filter Adjust fuel level 11 Worn rocker arm or rocker arm Clean or replace shaft 12 Air leakage from air intake pipe Tighten or replace 13 Excessive engine oil Check oil level and drain 1 Carbon deposit on piston top Clean 2 Insufficient or excessive engine Check level add or Engine oil overheats 3 Faulty oil pump drain 4 Clogged oil passage Replace 5 Air leakage from air intake pipe Clean 6 Incorrect engine oil 7 Faulty cooling system 7 5 Tighten or replace Change engine oil 13 3 13 TROUBLESHOOTING Complaint Symptom and Possible Caus
50. pressure fuel line and put it in a container When the body of throttle valve is disassembled the air intake shall be covered by dishcloth or tape for avoiding the entry of other objects into the engine from the air intake side of the engine When the vehicle will be stored for more than one month the gasoline in the high pressure fuel line and cap of the fuel injector must be discharged Otherwise the gasoline will age and form colloidal elements which may block the nozzle of fuel injector therefore the engine cannot start or the rotate speed is unstable Overhaul Info Engine Starting Failure Hard Starting Stall After Starting Unsteady Too much fuel in the engine Idle Speed Ail filter clogged Idle air pipe clogged Idle air pipe clogged Fuel system clogged No fuel in the injector Ignition system not functioning properly Fuel filter clogged Fuel tank cap clogged High pressure fuel line clogged Fuel injector clogged 7 2 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM 1 Carburetor Removal Disassemble the carburetor in the following serial number Serial No Description Qty Serial No Description Qty 1 Idle Adjust Shaft 1 10 Drain Screw 1 2 Vacuum Chamber Cover 1 11 Float Chamber 1 3 Spring 1 12 Float 1 4 Jet Needle Holder 1 13 Needle Valve Set 1 5 Spring 1 14 Main Jet MJ 1 6 Jet Needle Set 1 15 Needle Jet NJ 1 7 Vacuum Diaphragm 1 16 Pilot Jet PJ 1 8 Piston Valve 1 17
51. pss pre 4 E Rear ghi 05 893 iz pt ort es bos FIN m To Brake lanp switch E ur lt Wiper notor 58 Fj 6125 6125 2 uris 210 E Polo VOS T UE I 085 a ios E 1 EIL 5 vas s 42 FEE iy 5 Left MP3 speaker R25 SE is omis 8 005 8 5 E b Right 903 speaker M 8 Ros E d t gt y 2 BOS 505 S T ROS 545 5 5 Front turn v Bos 805 nus 005 005 5 59 di 2 9 Aten the E s 895 145 1 r El 5 mm 45 To te drecton e F 5 5 Sb 05 H To the drecton deter Ble Front sgl i ale 5 5 _ i After the turn sro 49 4 Bos 899 5 e o 99 5 1 21 ba E 8 2 8125 8125 125 z B i lt 125 4 vs v 5 7 3 105 gt E lt ERES i gus 8 E 2 8 aaa RAD d
52. pump cover and tighten the bolts and bleed bolt Water Pump Cover Bolts Tightening Torque 6N m Check impeller for smooth turning e Install the new O ring Note e Use the new O ring to prevent oil leakage e Apply grease to O ring Overflow Tube 4 12 4 COOLING AND LUBRICATIING SYSTEM Install water pump and tighten the bolts to specified torque Water pump bolts tightening torque 10N m Note Set the water pump shaft slot end B to oil pump shaft flat side e Connect water hoses e Add coolant e Install left side cover 1 x 4 2 ae D 4 ic jase AK rA 4 13 4 COOLING AND LUBRICATIING SYSTEM Illustration of CF 188 Engine Lubrication System Oil Drain Bolt Washer Oil Drain Bolt 11 Oil Pump Oil Bypass Valve 1 2 3 4 5 External Oil Pipe 6 Oil Filter 7 Clutch 8 Crankshaft 9 Cylinder Body 10 Piston 11 Camshaft 12 One way Clutch 13 Dip Rod Inspection of Lubrication System 3 18 Inspection of Oil Pump and Relief Valve 6 41 4 14 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 S 5 5 Removal and Installation of Gearshift 5 7 Inspection Information Note e When removal Engine please use jack to support
53. special tool Specification DER7EA 9 NGK If the electrode 15 extremely worn or burnt or spark plug 3 14 3 INSPECTION amp 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 0 8 0 9mm Check the thread size and reach when replacing the spark plug If the reach is too short carbon will be deposited on the screw portion of the spark plug hole and engine damage may result Installation Caution To avoid damaging the cylinder head threads first tighten the spark plug with fingers and then tighten it to the specified torque using the spark plug wrench Tool Spark Plug Wrench Feeler Gauge Air Filter Inspect every 40 hours or 1000 km clean it if necessary If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air filter as following Remove fixing clamp and top cover Note Be careful not to drop the o ring into the air filter box that is attached to the air filter top cover Loosen screw S remove filter element separate support filter element 6 and filter element seat 7 e Fill a wash pan of a proper size with a non flammable cleaning solvent A Immerse the filter elemen
54. 0 55 60 front and rear break sub pumps 6 Bolts on front steering joint 10 30 45 50 connector and beam 7 Nuts of front and rear 4 MI8 180 200 sub axles 8 Nuts of pulling rode connector 2 MIO 45 50 9 Bolts Steering assy 4 M1030 45 50 10 Bolts on steering transfer fork 2 8 25 23 25 Screws on steering column 2 10 25 45 50 12 Nuts front absorber 2 M8 23525 13 Screw of winch 4 8 16 23 25 14 Screw of main brake pump 2 10 60 45 50 15 Bolt on push rode of main M10 45 50 brake 16 Bolt on beam pin of push rode 8 20 23 25 of main brake 17 Nuts of flange of drive shaft 4 MI4 100 18 Nuts on tyre 16 MI2 55 62 19 Bolts on ceiling 4 8 55 20 25 20 Bolts on hand brake 2 8 20 20 25 21 Bolts on bumper 2 10 20 50 22 Bolts on driving axle 2 8 25 30 23 Bolts flange and rear wheel 12 90 45 50 upper swing arm 24 Bolts flange and rear wheel 2 12 180 45 50 lower swing arm 25 Nuts on front axle gear box 2 M10 45 50 26 Screw on front axle motor 4 8 20 10 13 27 Screw front and rear axle 12 8 22 20 25 Spread pin shaft thread glue 29 Nut on front axle 1 M14x1 5 55 62 30 Bolt on oil intake of front axle 1 14 1 25 12 23 25 1 SERVICE INFORMATION 31 Drain bolt on front axle 1 10 1 25 23 25 32 Bolts on rear axle box 2 10 1 25 25 35 40 33 Bolts on rear axle box 4 8
55. 1 Remove gearshift knob Installation Reverse the removal procedure for Gearshift knob 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 Gearshift unit Remove TP Gearshift Remove bolt 4 Remove bolt 3 Loosen nut 3 Remove gearshift unit 2 VEHICLE BODY MUFFLER Handle parking brake Handle parking brake Bolt 5 Remove Remove nut 1 Loosen cable parking brake Remove bolt 5 Remove handle parking brake Skid plate L BOLT 1 Remove fuel tank Remove bolt 1 Remove bolt 2 Remove skid plate L Installation Reverse the removal procedure for BOLT 2 Skid plate L BOLT 3 Skid plate R Remove Remove bolt 3 Remove bolt 4 Remove skid plate R Installation Reverse the removal procedure for Installation Skid plate BOLT 4 2 8 2 VEHICLE BODY MUFFLER Rear fender L Rear Remove fortem 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 Installati
56. 25 23 25 34 Nut rear axle input shaft 1 12 1 25 58 62 35 Bolts on base of rear axle 4 8 30 20 25 input shaft 36 Bolt on rear axle positioning 1 M65x 5x10 85 90 37 Nut 1 M8 12 16 38 Drain bolt on rear axle 1 14 1 25 12 23 25 39 Bolt on oil intake of rear axle 1 20 1 5 12 23 25 Specification moment M6 8 12N m th Other screws 8 8 grade NT KONM M10 40 50N m M12 50 60N m Specification and usage quantity for fuel lubricating oil and brake liquid Category Specification Capacity Remark Fuel 93 upper grade 22L Content of lead free gasoline fuel box Lubricating oil engine SAEISW 4A0 SF or Gear box SC 1900ml change oil 2000ml change filter 2200ml repair engine SAE15W 40 SF SAE80W 90 GL 4 Lubricating oil front main driver First 0 33L change 0 28 Lubricating oil Rear main driver First 0 30L change0 25 Brake liquid GB1083 JG3 1 1L Engine coolant Distilled water Glycol 1 1 1 SERVICE INFORMATION Cables Pipes Cable Routing WINDSHIELD WIPER SWITCH EMERGENCY LIGHT SWITCH HIGH BEAM LOW BEAM SWITCH SWITCH INCREASE POWER FROM 4WD TO 2WD SWITCH SWITCH IGNTION MP3 SWITCH HORN SWITCH TURNING SWITCH ciam SWITCH OF WINCH SPEEDOMETER SWITCH WINCH AND UPHOLD SWITCH OF UPHOLD STICK RESERVOIR TANK BRAKE PUMP PIPELINE BRANK FUEL CUP PIPELINE BRANK COPPER OIL TUBE YDRA
57. 5 device angle Left 35 Brake type Front Hydraulic Disc Rear Hydraulic Disc Bumper Device Suspension Swing Arm Frame type Welded steel tube and plate Overhaul Datasheet Lubricating device Item Standard Service limit Engine Volume when replacing 1900ml Full it 2200ml Capacity ull capacity m Recommended Oil see original 1 10 ETE i Viscosity ai j T X em 30 20 10 0 10 20 30 40 2 50 68 86 104 e Specially for 4 stroke motorcycle SAE 10W 40 20W 50 Substitutes must be used in the following range eAPI type SE or SF grade eSAE type Choose from the left chart according to the environmental temperature Gap between inner 0 03 0 10mm 0 15mm and outer rotors Oil pump Gap between outer 0 03 0 10mm 0 12mm rotor and body Rotor Oil pressure 130 170 18 85 51 24 66 51 at 3000RPM 1 6 1 SERVICE INFORMATION Air Inlet System Item Standard Fuel Tank Capacity Full capacity 22L 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 45 Opening pressure of radiator cap 10
58. 5 14 rear drive shaft 5 5 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 5 6 ws L Front axle Drive shaft Bolt front shaft front Bolt Rear axle Rear axle Drive shaft rear Bolt 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 45 m Bolt Gearshift Nut gearshift rod Disassembly Remove seat driver gt 2 6 Remove seat passenger gt 2 6 Remove decorate cover gearshift 2 7 Remove Bolt Remove nut Remove gearshift rod Remove the 3 bolts Remove gearshift unit Installation Reverse the removal procedure for installation Make sure that gearshift is flexible Need to inspect agility of gearshift if not In case of any inflexibility adjust the gearshift rod to ensure the gear engagement 5 7 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION A Engine Removal Installation Orders and the Relative Page Numbers
59. 6 1 1 Throttle Body Assy CONTROL THROTTLE VALVE OFF AND ON ANGLE THROUGH THROTTLE CABLE AIR Snnnaibdsdi DAMPER POSITION SNESORTRANSMIT ANGLE Engine SIGNAL TO ECU IACV 7 d RD MAP Sensor dece Se Connected with Air Filter EACH PIN FUNTION s 1 CONNECT 5V POWER 2 y 2 GROUNDING 1 3 OUTPUT VOLTAGE SIGNAL gt THE RIGHT DRAWING IS THE WIRING DIAGRAM WITH ECU TPS Wiring Diagram IDLE SPEED LIMIT SCREW NOT ALLOWED TO BE ADJUSTMENT ENGINE IDLE SPEED COMPLETELY DEPEND UPON ELECTRONIC SPRAYING SYSTEM ADJUSTMENT DO NOT ADJUST THE IDLE SPEED SCREW Idle Speed Ajuster 11 13 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 MAP Sensor 3 VOLTAGE SIGNAL THE RIGHT DRAWING IS THE CONNECTION DRAWING FOR SENSOR amp ECU THE RIGHT DRAWING IS THE PERMIT FITTING LIMIT IN THIS WAY CAN ENSURE THERE IS NO CONDENSED WATER INSIDE THE SENSOR THE CONDENSED WATER CAN DESTROY SENSOR INNER PRESSURE SENSING DEVICE THE PICTURE BELOW IS THE RECIPROCAL DIAGRAM DRAWING FOR PRESSURE AND OUTPUT VOLTAGE Allowed Range of Setting Angle MONITOR PRESSURE RANGE 10 115kPa 4 65 Output Voltage Uout in V e 0 10 Absolute Pressure Pabs in Kpa 115 11 14 INTAKE AIR TEMPERATURE SENSOR IAT Sensor THIS SENSOR IS A NE
60. 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Oil Filter e 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 Remove wire clip and sector gear housing cover Remove dowel and gasket Remove drive sector gear 4 Remove bolt 5 of driven sector gear Remove washer 6 and driven sector 7 6 6 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Water Pump e Screw out bolt of water pump e Remove water pump Sheave Drum Remove the sheave drum by using a suitable bar Remove washer and sheave drum Left Crankcase Cover Remove bolts e Remove left crankcase cover Remove dowel and gasket Magneto Rotor Install attachment 1 to crankshaft end e Install special tool to rotor thread Remove rotor and woodruff key Tool Rotor Remover 6 7 6 ENGINE REMOVAL INSPECTION amp INSTALLATION a Starting Motor Gear Remove driven gear 1 and needle bearing 7 Remove spacer 2 2020 ao 00 O6 O9 8000 0000 60 v b 4 Remove dual gear and shaft 3 Remove idle gear and shaft 4 Q 8200 0000 Ge oc 2020 00 00 an 00 8 8 8 8 8 8 8 8 8 8 2 Pump Sprocket and Chain wooo Remove drive sprocket nut 5 Remove C ring 6 Remove oil pump drive and driven sprockets and
61. 6 3 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Remove C ring e Remove timing sprocket from camshaft remove camshaft Note Take care not to drop spacer bolt bolt lock and C ring into crankcase e Remove tensioner plate Cylinder Head e Remove cylinder head bolt e Remove cylinder head bolts diagonally e Remove cylinder head Note Take not to drop dowel pin into crankcase Cylinder Remove dowel and cylinder head gasket e Remove timing chain guide 6 4 6 ENGINE REMOVAL INSPECTION amp INSTALLATION gt e 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 e Remove piston pin circlip Dwith long nosed pliers Note Put a clean rag under piston so as not to drop piston pin circlip into crankcase e Remove piston pin and piston Notes e When installing piston make sure its identification conforms to that of cylinder When removing piston pin clean off burrs of piston pin hole and groove If it s difficult to remove the piston DO NOT hammer use a special remover Tool Piston Pin Remover AEngine Left Side Starting Motor e Remove 2 bolts of starting motor e Remove starting motor Starting Motor 6 5
62. 60 or less 5 50 g Do not use anti leak additive 70 Warning Density 770 00 DO NOT open radiator cap when the engine is still C hot Or you may be injured by scalding fluid or 150 x100Pa steam e Coolant is harmful DO NOT swallow or stain your skin or eyes with coolant In case of accidental swallow or stains flush with plenty of water and consult the doctor immediately e Keep coolant awav from reach of children Boiling Point Inspection of Cooling Circuit e Remove radiator 1 and connect tester 2 to filler w W gt EN Density Warning Do not open the radiator cap when the engine is still hot e Give a pressure of 120 kPa and check if the cooling system can hold this pressure for 10 seconds e If the pressure drops during this 10 seconds it indicates that the there 15 leakage with the cooling system In this case check the complete system and replace the leaking parts or components Warning When removing the radiator cap tester put a rag on the filler to prevent splash of coolant Warning Do not allow a pressure to exceed the radiator cap release pressure 4 COOLING AND LUBRICATIING SYSTEM Inspection and Cleaning of Radiator and Water Hoses Radiator Cap e Remove radiator cap e Install radiator cap to cap tester e Slowly increase pressure to 108 kPa and check if the cap can hold the pressure for at least 10 sec
63. 8 Lubrication System si oce 3 18 Suspension System 3 10 Cooling 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 Operation Cautions Note e DO NOT keep the engine running for long time in a poorly ventilated or enclosed place because of the harmful components like CO etc in the exhaust gas e The muffler and engine are still very hot when the engine is just stopped Careless contact may cause serious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine 15 just stopped e Gasoline is highly flammable smoking is strictly forbidden in the work place Keep alert on the electrical sparks Besides vaporized gasoline is highly explosive so work should be done in a well ventilated place e Be careful that your hands or clothes not get nipped by the turning or movable parts of the driving system Note The vehicle should be parked on hard and level ground Replace parts regularly Parts replacement time is subject to time or kilometers whichever occurs first 3 Regular Maintenance Table 3 INSPECTION amp ADJUSTMENT 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 Ma
64. 8kpa 1 1kgf em Temperature valve open 7242 C Thermostat Temperature valve full open 88 Overall lift 3 5 4 5mm 95 C iso Close Open 88 C 190 4F Round 88 C Round Thermostat Open Close 82 C 179 6F Round 82 C Round lant 35 anti freeze antisepsis high boil coolant Type Front Rear Wheel Item Standard Service Limit Play of wheel Vertical 1 0mm 2 0mm Front e Horizontal 1 2 0mm Wheel Tire Groove 3 0mm Pressure 21 1PSI 145 6 9KPa Play of wheel Vertical 1 0mm 2 0mm a Horizontal 1 0mm 2 0mm Rear Wheel Tire Groove 3 0mm Pressure 28 1PSI 193 6 9 KPa 1 7 1 SERVICE INFORMATION Brake System Item Standard Service Limit Brake disc thickness 17mm 16mm Brake Pedal Play 0mm Brake disc thickness 17mm 16mm Battery Charging System Item Standard AC magneto Model Permanent magnet AC type Motor Output 3 phase AC Charging coil Resistance 20 C 0 2 0 3Q Rectifier Three phase annular rectification Silicon controlled parallel connected regulated voltage Battery Capacity 12V36Ah Terminal point Fully charged 12 8V voltage Insufficient lt 11 8V charge Charging Standard 0 9A 5 10H current time Ignition system Item Standard Ignition Carburetor CDI ignition Ignition EFI ECU ignition Spark Plug Type DPR7EA 9 NGK Optional DR8E
65. A D7RTC Spark plug gap 0 8 0 9mm Ignition Max advanced angle 32 CA timing Carburetor Ignition timing EFI BTDC10 CA 1500r min Peak voltage Ignition Above 200V Pulse Generator 2V Starter Relay Coil 30 50 Resistance Secondary Starter Relay 900 1000 Coil Resistance 1 8 Screwing moment of important bolts 1 SERVICE INFORMATION Engine Sequence Item Quantity Thread diameter Torque Remark number mm Nm 1 Sensor of reverse 1 10 1 25 20 gear 2 Spark plug 1 12 1 25 18 3 Sensor of water 1 1 8 8 Spread thread temperature glue 4 Adjust nuts of air 4 M5 10 valve gap 5 Nut of driving disk 1 20 1 5 115 6 Nut of driven disk 1 20 1 5 115 7 Round nut of driven 1 30 1 100 disk 8 Nut of front output 1 14 1 5 97 axle 9 Nut of driving prick 1 22 1 145 gear 10 Nut of driven prick 1 16 1 5 150 gear 11 Fixed nut of clutch 1 18 1 5 70 Turn left 12 Nut of position 1 60 110 Put on thread limitation of driven sealing glue gear 13 Nut of position 1 55 80 Put thread limitation of front sealing glue output bearing left 14 Bolts of swing arm 2 14 1 25 28 axle 15 Drain bolt 1 12 1 5 30 16 Clutch installing 6 M8 26 Spread thread bolts glue 17 Stator of magneto 3 M6 10 Spread thread Bolts glue 18 Screws on 3 M6 10 Spread thread stopping wind board glue 19 Oil pipe connecting 2 14 1 5 18 bolts 20 Oil pump installing 3
66. AGRAM DISTANCE 2 5mm ADJUST MULTIMETER ROTATE THE GEAR SLOWLY MEASURE THE VOLT AGE VALUE BETWEEN FOOT 2 AND FOOT 3 TO SEE IF IT IS VARY FROM OV 12 IF NO CHANGES THEN THE SENSOR IS DAMAGED YOU WILL BE REQUIRED TO REPLACE WITH A NEW ONE 11 19 11 ELECTRIC SYSTEM 11 Odometer Sensor 12V Power all Odometer Sensor Wiring Diagram Gear 2 5 1 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 Gear Sensor ELSE IT NONCONDUCTION WITH THE ENGINE COVER 10 REVERSE GEAR ASSEMBLE PROVIDE GEAR REVERSEINFORMATION TO A ECU AND METER THE ESTRICT VEHICLE SPEED ACCORDING TO THIS INFORMATION NORMALLY A B POINT CONDUCTION DONOT CONDUCT WITH THE CASE e NORMALLY C LENGTH IS 3 5mm IF LENGTH 3mm OR IF B SLIDE BLOCK YOU HAVE TO CHANGE IT TO A NEW WHEN ENGINE BACK GEAR A POINT NON CON DUCTION WITH THE ENGINE CASE OR ELSE IT IS CONDUCT WITH THE CASE 11 20 11 ELECTRIC SYSTEM 11 FUEL PUMP ASSY THE OIL FUEL PUMP ASSY COMBINED OF FUEL PUMP PLASTIC BRACKET PREFILTRATION PRES S
67. 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 MEASURING SECONDARY IGNITION VOLTAGE CONNECT THE ENGINE ACCORDING TO THE ELEC TRONIC SPRAY ELEMENTARY DIAGRAM CONNECT THE PEAK VOLTAGE GUAGE ACCORD ING TO THE RIGHT DIAGRAM START THEENGINE AFTERSTARTS THE SECONDARY IGNITION VOLT AGE SHOULD BE 15000V IGNITION COIL PARAMETER LIST Rated Voltage 11 ELECTRIC SYSTEM Connected with High Voltage Cable Grounding Positive Terminal Primary 1 L ME E Voltage O Ignition Coil Wiring Peak Voltage Tester Spark Plug Value 1 Working Voltage 4 T 11 24 11 ELECTRIC SYSTEM ELECTRONIC FUEL INJECTION SYSTEM FAULT SELF DIAGNOSIS 1 1 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 THE FAULT CANBE DIVIDED INTO TWO TYPES j
68. Air Inlet Pressure Sensor frozen or jammed 2 Air Inlet Pressure Sensor seriously aging Possible Troubles are as below 1 Re install the Air Inlet Pressure Sensor after ice melted with indoor temperature 13 6 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 Trouble Code P0107 Low Voltage of Air Inlet Pressure Sensor Circuit Note Possible Troubles are as below 1 ECU found Air Inlet Pressure Sensor signal circuit short to ground Note Inspect as below 1 Resistance between ECU Pin and Ground Trouble Code P0108 High Voltage of Air Inlet Pressure Sensor Circuit Note Possible Troubles are as below 1 ECU found Air Inlet Pressure Sensor signal circuit short to power Note Inspect as below 1 Resistance of ECU Pin Trouble Code P0112 Air Inlet Temperature Sensor Signal Voltage Low Note Possible Troubles are as below 1 Circuit between ECU Pin and Air Inlet Temperature Sensor Signal short to ground Note Inspect as below 1 Check Resistance of circuit between ECU Pin Sensor Signal and Ground Trouble Code P0113 Air Inlet Temperature Sensor Signal Voltage High Note
69. Bolt3 Nut2 Front Left Arm Bolt2 Nut to Bolt2 for Front Left Arm Upper Bolt2 Nut to Bolt2 for Front Left Arm Lower Nutl Slotted nut2 Steering rod Pull out steering knuckle from constant ve locity drive shaft Remove front left suspension 8 7 8 FRONT WHEEL I BOLT 10 1 25 30 2 WHEEL HUB 3 GRIP BRAKE 4 HOOP 5 BEARING 6 TRIFURCATE SHAFT LEFT 7 TRIFUR CATE SHAFT RIGHT 8 BOLT M12x60 9 FRONT SHOCK ABSORBER 10 BOLT M10x1 25x40 11 LOCKING NUT 8 12 SPRING WASHER 13 SPRING WASHER 14 SPRING WASHER 15 HEX FLANGE BOLT M10x1 25x30 Disassembly Front Suspension Removal Note Replacing front shock absorber does not require removal of other parts Park the vehicle on a level ground and se FRONT BRAKE SUSPENSION STEERING L FR LOWER SWING ARM 19 R FR LOWER SWING ARM 20 FR ROCKER BUTTONHEAD 21 CALIPER BRAKE L 22 CALIPER BRAKE R 23 BRAKE PAD LEFT 24 BRAKE PAD RIGHT 25 COVER L FR LOWER SWING 26 COVER R FR LOWER SWING curely support front part of the vehicle Remove Bolt 8 and Nut 16 Remove front right shock absorber Inspection Oil leakage aged oil seal damage Replace 16 NUT MI2 17 BUFFER COVER 18 8 8 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 Rocke
70. D 34 P0629 OIL PUMP RELAY CONTROL CIRCUIT SHORTCIRCUIT TO POWER 35 P0650 MIL LAMP DRIVING STAGE TROUBLE 36 P2177 AIR FUEL RATIO CLOSED LOOP CONTROL SELF LEARNING V ALUE EXCEED UPP ER LIMIT 37 P2178 AIR FUEL RATIO CLOSED LOOP CONTROL SELF LEARNING V ALUE UNDER LOWER LIMIT 38 P1117 IDLE AIR CONTROL TEV SHORT CIRCUIT TO GROUND 39 P1118 IDLE AIR CONTROL TEV OPEN C IRCUIT 11 27 mg Por gor 2 2 amp 8 2 2 i 2 5 z Ls aevum vus F Es 8 a y ate 4 7 M sedit E S Tos pus 11 5 E 52 9 X jv W 085 5 ee ci vies vis PL ac 5 vis 5 g 085 1 085 wb 3 085 Se icd vos deus 15 F 5 5 A 5 805 Br 05 c oo e NM H w Poston thts Before the ight D 5 5 25 Bas License lt rp SS 305 6 4 wo 4
71. Do not rotate the magneto rotor while doing this when the sprocket is not positioned correctly turn the sprocket Engage the chain on the sprocket with the locating pin B as illustrated on the right e Recheck if the position of mark A and is correct If not reassemble until it is correct 6 65 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install crankshaft C ring Install lock washer so that it covers the locating pin e Apply thread locker to the bolts before installing and tighten them to the specified torque Sprocket bolt tightening torque 15 N m Bend up the lock washer to lock the bolts Cylinder Head Cover Clean the mating surface of cylinder head and cylinder head cover e Install dowel pin to the cylinder head e Apply sealant to the mating surface of the cylinder head cover Install cylinder head cover bolts tighten diagonally to the specified torque Cylinder head cover bolt tightening torque 10 Note When tightening the cylinder head cover bolts the piston must be at top dead center on the compression stroke 6 66 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Gasket Sealant Applying Place ply Sealant to the ating Surface Chain Tensioner Insert screwdriver into slotted end of chain tension adjuster turn it clockwise to lock the tensioner spring e Install the chain tensioner and the new washer 1 e I
72. E SPEED CONTROL VALVE CARBON TANK CONTROL VALVE Connected with Throttle Body CONTROL PASS BY AIR FLOW ECU CONTROL THE IDLE SPEED VALVE ACCORDING TO THE INFORMATION OF ENGINE LOAD THE 1 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 PULSE IDLE SPEED VALVE CLOSE FUNCTION OF PINS 1 CONNECT PIN 17 2 CONNECT OIL PUMPRELAY OUTLET END Airflow Direction Connected with Air Filter THE RIGHT IS THE WIRING DIAGRAM FOR IDLE SPEED VALVE AND ECU e WHEN FIXING THE IDLE SPEED CONTROL VALVE IT CANNOT INSTALLED LIKE THE RIGHT DIAGRAM CONNECTOR VERTICALLY DOWNWARD TO AVOID DESTROY THE ELECTRONIC COMPONENT TO AVOID SOLID BORNE SOUND TRANSMISSION YOU CAN INSTALL THE IDLE AIR CONTROL VALVE SUSPENDED IN THE TUBE OR USE RUBBER BOOT TO FIX IT TO THE ENGINE OR THE FRAME IDLE SPEED CONTROL VALVE PARAMETER LIST Incorrect Installation Quantity Rated Voltage 13 Resistance at 20 C Rated Current Pulse Control Frequency Typical Pulse Control Width Pressure Difference 700mbar Share Air Ration 10096 Flow m3 h 11 23 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
73. ED PART SECURE FUEL CHANNEL SMOOTH IF LEAKAGE RELINK LEAK SECTION SECURE THE FUEL CHANNEL NO LEAKAGE USE FUEL PRESSURE GAUGE TO MEASURE FUEL PRESSURE Fuel Pressure Gauge FULE PUMP OUTPUT PORT PRESSURE 0 3 0 01 CHANGE ENGINE SHIFT HAND LEVER NEUTRAL e USE DIAGNOSTIC EQUIPMENT CHECK IF AT FAULT IF YES CLEARING OF FAULT ACCORDING TO DIAGNOSTIC TROUBLE CODE e CLOSE THROTTLE TURN OFF THE IGNITION SWITCH PRESS START SWITCH 3 5 SECONDS e START THE ENGINE WARM UP TO IDLE SPEED STABLE EXAMINE IDLING SPEED IDLING SPEED 1400 100rpm 11 7 AAELECTRONIC FUEL INJECTION SYSTEM IACV Intake Air Temp Sensor Throttle Body Assy 24 2 ENGINE ELECTRONIC FUEL INJECTION SYSTEM INCLUDING THREE PARTS 1 SENSOR TRANSFORM THE ENGINE NON ELECTRICITY PHYSICAL QUANTITY TO ELECTRICITY QUANTITY AND PROVIDE ALL THE INFORMATIONS TO THE ELECTRONIC CONTROL UNIT IT IS THE ELECTRONIC CONTROL S SPY INCLUDING THE FOLLOWING SENSORS INLET PRESSURE SENSOR LOADING INFORMATION INLET AIR TEMPERATURE SENSOR AIR DENSITY INFORMATION THROTTLE POSITION SENSOR LOADING INFORMATION LOADING RANGE INFORMATION CCELERATION AND DECELERATION INFORMATION TRIGGER BENT AXLE PHASE POSITION INFORMATION WATER TEMPERATURE SENSOR ENGINE TEMPERATURE INFORMATION ODOMETER SENSOR OUTPUT SHAFT SPEED INFORMATION GEAR SENSOR GEAR INFORMATION INCLUDING GEA
74. ER WINDING RESISTANCE 100 1300 20 C IF THE TRIGGER RESISTANCE DONOT IN ABOVE RANGE REPLACE WITH A NEW ONE MEASURING TRIGGER PEAK VOLTAGE VALUE CONNECT MULTIMETER AND PEAK VOLTAGE ADAPTER ACCORDING TO THE RIGHT DRAWING PROBE GREEN LEAD WIRE PROBE BLUE LEAD WIRE ATTENTION WHEN USE PEAK VOLTAGE ADAPTER REFERS TO OPERATION MANUAL ADJUST MULTIMETER TO ALTERNATE V ADJUST THE GEAR TO NEUTRAL ADJUST IGNITION SWITCH TO ON PRESS ON STARTING BUTTON AND LET THE ENGINE RUNNING FOR FEW SECONDS THEN START TO MEASURE THRIIGER COIL PEAK VOLTAGE REPEATED TIMES MEASURE GET THE HIGHEST TRIGGER COIL PEAK VOLTAGE VALUE TRIGGER COIL PEAK VOLTAGE 2V 300rpm IF THE TRIGGER PEAK VOTAGE DONOT IN THE ABOVE RANGE REPLACE WITH A NEW ONE 11 18 11 ELECTRIC SYSTEM LL Green Trigger Magneto Trigger Resistance Peak Voltage Tester Magneto Trigger Peak Voltage 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 0UTPUT SQUARE WAVE VOLTAGE SIGNAL IN PUT POWER VOLTAGE 80 3 POWER DC12V THE RIGH IS THE WIRING DRAWING OF SENSOR AND ECU ODOMETER SENSOR TESTING GROUNDING FOOT 1 CONNECT FOOT 3 12V FIXED ONE GEAR TO ODOMETER ACCORDING TO THE RIGHT DI
75. GTIVE 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 amp ECU THE RIGHT DRAWING IS FOR SENSOR EMPERATURE RESISTANCE PROPERTY LIST 11 15 11 ELECTRIC SYSTEM IAT Sensor ECU IAT Sensor Wiring Diagram Resistance Value 1074 1073 402 20 0 20 40 60 80 100 120 120 C 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 Water Temp Sensor CONDITION THE OTHER GROUP PROVIDE TO THE METER MONITOR WATER TEMPERATURE A AND C IN ONE GROUP THEY PROVIDE WATER TEMPERATURE TO ECU Connected with Meter B ANDTHREADED PORTION IN ONE GROUP THEY PROVIDE WATER TEMPERATURE TO THE METER THE RIGHT DRAWING IS THE WIRING DRAWING FOR SENSOR ECU AND METER Connected with ECU Temp Range B to Case End Resistance 0 50 0 2 176 280 THE RIGHT DRAWING IS END AND CRUST 80 0 2 63 4 81 4 TEMPERATURE PROPERTY LIST SIGNAL PASS TO THE METER 110 0 2 emen Resistance 0 THE RIGHT DRAWING IS END AND THE 13 71 16 94 TEMPERATURE PROPERTY LIST SIGNAL PASS TO THE ECU
76. ISTANCE PIPE EVEN IF THE ENGINE DOES NOT WORK THERE IS STILL REMOVE FUEL PUMP RELAY START THE HIGH PRESSURE ON THE FUELCHANNEL THEREFOR DONOT ENGINE AND RUN ENGINE ON IDLE UNTILL DISMANTLE THE FUEL PIPE DURING SERVICING EASILY THE ENGINE GO OUT IT SELF BEFORE SERVICE THE FUEL SYSTEM YOU REQUIRED DOFUEL PRESSURE RELIEF THE METHOD IS AS BELOW Fuel Pump Relay Fuel Pump Assy Kill Switch Ignition Switch 11 21 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 THIS FUEL INJECTOR APPLY QUADRIPUNTAL DO NOT TURN AFTER FIXED THE CLAMP FUNCTION OF PINS ONE SIDE OF THE PLUG MARK CONNECT FUEL PUMP RELAY OUTPUT END WITHOUT MARK SIDE CONNECT ECU PIN 14 OIL ATOMIZER RESISTANCE 12 19 20 C THE RIGHT IS THE WIRING DIAGRAM FOR FUEL INJECTOR AND ECU FUEL INJECTOR INSTALLATION INSTALL THE FUEL INJECTOR BY PUSHING IN HAND WHEN DISASSEMBLE AND ASSEMBLING THE FUEL INJECTOR YOU MUST REPLACE THE O RING WHEN DISMANTLING FUEL INJECTOR IF NECESSARY DO PRESSURE RELIEF IN ADVANCE CHECK FOR FUEL LEAKS AFTER INSTALLING 11 22 11 ELECTRIC SYSTEM Connected with Fuel Injector Cap Mark Connected with Fuel Injector Seat Connected with Fuel Pump Relay Fuel Injector 11 ELECTRIC SYSTEM 13 IDL
77. Install handle and handle cap e Tieaknot 2 on handle and release knot 3 e Lead rope through the hole of the starter housing and tie a knot so that the rope would not be drawn back 6 50 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION CVT Cover Remove screw 5 oil seal limitator 4 Remove oil seal 3 with special tool e Check bearing 2 for free turning In case of any abnormal remove with special tool and replace with a new bearing e Apply lubrication oil to outer ring of bearing and install bearing with special tool Check bearing for smooth turning e Apply grease to bearing inner side e Apply grease to oil seal lip and install oil seal with special tool Note Use a new oil seal Install oil seal limitator and tighten screw after applying thread locker Tool Bearing Remover Oil Seal Remover Bearing Installer CVT Case e Check bearing 5 for smooth turning In case of any abnormal remove screw 3 and bearing retainer 4 and replace with a new bearing e Check oil seal 7 In case of any damage replace it e Apply grease to oil seal lip and install with special tool Apply lubrication oil to bearing 5 and install with special tool Check bearing for smooth turning The seal side of bearing 5 should face bearing retainer 4 e Install bearing retainer 4 and screw 3 Install oil seal 1 into clutch housing 2 with special tool Tool Oil Seal Installer Bearing Installer 6 51
78. LECTRIC SYSTEM CHARGING SYSTEM CHARGING CIRCUIT DIAGRAM Magneto Voltage Regulator MAGNETO COIL RESISTANCE MEASURE TRIPHASE MAGNETOR STATOR COIL RESISTANCE IF THE RESISTANCE VALUE OUT OF PRE SCRIBED VALUE REPLACE THE STATOR e INSPECT IF THE STATOR COIL AND STATOR P CORE INSULATION vow gt TURN MULTIMETER 1 100 N MAGNETO COIL RESISTANCE 0 5 1 50 d YEL LOW YELLOW INSULATING RESISTANCE Q YELLOWGROUND MAGNETOR NON LOADED PER FORMANCE e START THE ENGINE LET IT GOES TO 5000Rpm USE MULTIMETER MEASURE MAGNETO STATOR COIL THREE OUTPUT LINE VOLTAGE e IT THE RESULT VALUE BELLOW THE SETTING VALUE CHANGE A NEW MAGNETO ADJUST MULTIMETER TO ALTERNATING VOLT AGE GRADE MAGNETOR NON LOADED STATE COIL VOLT AGE VALUE S000Rpm 200V ALTERNATING CURRENT 11 2 11 ELECTRIC SYSTEM Black Red White e USE MULTIMETER MEASURE THE e 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 NEW ONE ADJUST MULTIMETER TO DIODE ATTENTION WHEN MULTIMETER PROBE UNCONNECTED IF THE MULTIMETER SHOWS BELLOW 1 4V THEN REPLACE IT S BATTERY See p Pe Se Pete on om ow ow T
79. M6 10 bolts 1 9 1 SERVICE INFORMATION 21 Bolts pressure 2 6 10 limiting valve 22 Bolts principal 4 M8 32 prick gear cover 23 Bolts on driven prick 4 M8 25 gear cover 24 Gear positioning bolt 1 14 1 5 18 25 Bolt on hand start 1 10 1 25 55 disk 26 Bolts on crankcase 14 M6 10 3 M8 25 27 Bolt on Gear 1 M6 12 changing sector gear 28 Bolt on oil filter 1 20 1 5 63 29 Bolts on start motor 2 M6 10 30 Bolts cylinder 4 M10 38 cover 31 Nuts cylinder 2 M6 10 cover 1 8 25 32 Bolts on cylinder 4 M6 10 33 Bolt on cover of 12 M6 10 cylinder 34 Bolts on chain 2 6 10 adjuster 35 Nuts on chain 1 8 8 adjuster 36 Bolts on fan motor 3 6 10 37 Bolts constant 2 M6 10 temperature unit 38 Bolts on pump cover 3 M6 6 39 Bolts on pump 2 M6 10 40 Bolts on 2 6 13 Put thread circulationunit glue 41 Other Bolts 5 4 5 6 6 8 12 8 18 25 1 10 1 SERVICE INFORMATION FRONT REAR SUSPENSION We Qt Thread diameter Torque Remark 5 4 mm Nm Bolts on front steering joint 4 12 60 45 50 and absorber 2 Bolts on front and rear brake 16 M10x30 45 50 disk 3 Bolts on front brake Caliper 4 10 30 45 50 4 Bolts on rear brake Caliper 4 M1230 55 60 5 Bolts on support frame of 4 12 2
80. N EX 182N 210N 31 5mm Tool Spring Scale Measure valve spring incline Spring incline out of range Replace Valve Spring Incline Limit 2 5 1 7mm Assembly of Cylinder Head e Install each valve spring seat e Apply moly oil to valve stem seal and fit into position Material Moly oil Note Do not reuse the valve stem seal e Insert the valves with stems coated with moly oil all around Note When inserting the valve be careful not to damage the lip of the stem seal 6 19 Moly Oil eed Moly Oil 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install valve spring with small pitch end b facing cylinder head Big pitch end is marked e 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 D to wedge in between seat and stem Make sure that the rounded lip of cotter fits into groove 9 in the stem end Tool Valve Spring Compressor Tweezers NOTE Knock the valve end with rubber hammer Make sure valve cotter is fit into groove e Check the sealing effectiveness of cylinder head Dip clean solution into valve IN EX D and check for any leakage of valve seat 2 after a few minutes 6 20 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION e Install thermostat e Install thermostat cover e Install wat
81. OE OI UR LEES 4 5 Inspection of Water Temperature 4 6 Inspection of Thermostat iier ete ree nennen enne S 4 6 4 7 Water Pump Removal and Disassembly 4 7 Inspection 4 9 Water Pump Assembly Installation 4 10 Lubrication System 4 2 4 14 4 1 4 COOLING AND LUBRICATIING SYSTEM Cooling System Illustration j8ejsouueu j OL JOJEIPEY esoH ANQ dey sojyeipey YUBL JIOAJOSO OSOH 0 JOON 4 2 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 If the vehicle will be operated at the environmental temperature below 35 the mixing ratio of coolant should be increased to 55 or 60 according to the figure on the right Note Use high quality ethylene glycol base antifreeze and mixed with distilled water Never mix an alcohol base antifreeze and different brands of antifreeze The 5 ratio of antifreeze should not be more than
82. Possible Troubles are as below 1 Circuit between ECU Pin and Inlet Temperature Sensor Signal short to power Note Inspect as below 1 Check if voltage of Sensor Signal of ECU Pin is normal or not Trouble Code Engine Water Temperature Sensor Indicated Temperature irrationally failure Note Possible Troubles are as below 1 Water Temperature Sensor need replacement 13 7 13 TROUBLESHOOTING Trouble Code P0117 Engine Water Temperature Sensor Circuit Voltage low Note Possible Troubles are as below 1 Circuit between ECU Pin and ground short Note Inspect as below 1 Check resistance between ECU Pin and Ground Trouble Code P0118 Engine Water Temperature Sensor Circuit Voltage high Note Possible Troubles are as below 1 Short Circuit between ECU circuit and other circuit Note Inspect as below 1 Check if voltage connected to ECU pin is normal or not Trouble Code P0122 Voltage o f Throttle Control Positioning Sensor Circuit lower than the lower limit Note Possible Troubles are as below 1 ECU Pin short to ground Note Inspect as below 1 Check resistance between ECU pin and ground Trouble Code P0123 Voltage o f Throttle Control Positioning Sensor Circuit higher than the higher limit Note Possible Troubles are as below 1 Circuit between ECU Pin and other power circuit short Note Inspect
83. R SENSOR AND REVERSE GEAR SENSOR j MAP Sensor Air Filter r1 11 ELECTRIC SYSTEM Ignition Coil L2 Trigger 1 27 Fuel Pump Assy LE OXYGEN SENSOR EXCESS AIR COEFFICIENT ABOVE 1 OR LOWER THAN 1 FOUR WHEEL DEAD LOCK 4WD DEAD LOCK INFORMATION ASSISTOR SWITCH RELIEF SPEED LIMIT INFORMATION 2 ECU ELECTRONIC CONTROL UNIT IT IS THE BRAIN OF THE ENGINE MANAGEMENT SYSTEM IT ANALYZE AND PROCESS KINDS OF INFORMATIONS PROVIDE BY THE SENSORS REACH A CONCLUSION AND THEN TRANSMIT THE CONCLUTION TO THE ACTUATOR SO AS TO ENSURE THE ENGINE OPERATION UNDER OPTIMAL STATE 3 ACTUATOR EXECUTE THE ECU INSTRUCTION THE ACTUATOR IS THE HAND OF ECU THE MAIN ACTUATORS ARE FUEL PUMP ASSY SUPPLY HIGH PRESSURE FUEL FUEL INJECTOR INJECTQUOTAL FUEL MAKE FUEL SPRAY EXCELLENT IGNITION COIL PROVIDE HIGH PRESSURE IGNITION ENERGY TO SPARK PLUG IDLE SPEED CONTROL VALVE PROVIDE IDLE SPEED AIR INPUT 11 8 ELECTRONIC FUEL INJECTION SYSTEM DIAGRAM AIO gt I 20 Em es 5059 8 8 4 2 9 5 m 4 8985 93 O E 73 ELECTRONIC FUEL INJECTION SYSTEM MAINTENANCE NOTICE USE QUALITY COMPONENTS FOR SERVICE OR ELSE IT CANNOT GUARANTEE THE ELECTRONIC FUEL INJECTION NORMAL OPERATION IN THE COURSE OF MAINTENANCE NEVER TRY TO BREAK DOWN THE ELECTRONIC PAR
84. SHOULD pi MAKE A CLICKING SOUND i d T 4 WHEN POWER IS TAKEN AWAY FROM THE ire SMALL TERMINALS THERE SHOULD BE NO CONTINUITY BETWEEN LARGE TERMINALS IF BOTH ABOVE TWO ITEMS ARE OK IT INDICATES THE RELAY IS OKAY ADJUST MULTIMETER TO DIODE GRADE WARNING RELAY VOLTAGE LOADED CANNOT EXCEED 2MINS OR WILL CAUSE THE RELAY OVERHEAT USE MULTIMETER MEASURING STARTING RELAY COIL RESISTANCE IF THE VALUE OUT OF THE SETTING RANGE REPLACE WITH A NEW ONE ADJUST MULTIMETER TO 1 100 START AUXILIARY RELAY COILRESISTANCE 3 50 START AUXILIARY RELAY FULE PUMP RELAY APPLY 12VOLTS TO THE TWO TERMINALS USE MULTIMETER MEASURE IF CONTACTS A B IS MEET ADJUST MULTIMETER TO DIODE GRADE IF THE STARTING RELAY CLICKS WHEN NON LOADED 12V VOLTAGE THE TWO CONTACTS UNCONNECTED EITHER OF THE ABOVE TWO ITEMS IS SHOWS THE RELAY IS FINE ADJUST MULTIMETER TO 1X100 MEASURING Earthing THE COIL RESISTANCE AUXILIARY RELAY COIL RESISTANCE 90 1000 ATTENTION AT THE BACK OF AUXILIARY RELAY PARALLEL TO THE Connect Battery Anode DIODE DIRECTION IT IS THE RELAY COIL S ANODE 11 6 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 BLOCK
85. STEADY FAULTj AND RANDOM FAILURE ACCORDING TO IT S EMERGENCE FREQUENCY SUCH AS CAUSED BY BRIEF WIRE TURNOFF OR BAD CONNECTION OF THE CONNECTOR THROUGH DIAGNOSTIC EQUIPMENT AND THE TROUBLE LAMP YOU CAN FIND THE TROUBLE PART QUICKLY ELECTRONIC FUEL INJECTION SYSTEM FAULT DIAGNOSIS MAINLY APPLY DIAGNOSTIC EQUIPMENT USB Port Vedio Port Printer Port Right Key DIAGNOSTIC EQUIPMENT THE RIGHT IS THE DIAGNOSTIC EQUIPMENT OPERATION FUNCTIONS INDICATOR DIAGRAM SPECIFIC OPERATION AND IT S FUNCTIONS PLEASE REFERS TO THE DIAGNOSTIC EQUIPMENT OPERATING MANUAL Right Ke Up Key 5 2 Left Key Down Key EXIT Key OK Key Kain Cable Port Switch 11 25 TROUBLE CODE LIST 11 ELECTRIC SYSTEM REF TROUBLE CODE INSTRUCTION 1 0030 OXYGEN SENSOR HEA TING CONTROL CIRCUITOPEN CIRCUIT 2 0031 OXYGEN SENSOR HEATING CONTROL CIRCUITSHORT TO GOUND OXYGEN SENSOR HEA TING CONTROL CIRCUITSHORT CIRCUIT TO 3 P0032 POWER US OXYGEN SENSOR TING INTERNAL RESISTANCE UNREASONABLE 5 P0105 INLE T PRESSURE SENSOR SIGNAL NO CHANGE ICE UP 6 P0106 INLE T PRESSURE SENSOR UNREASONABLE 7 P0107 INLE T PRESSURE SENSOR UNREASONABLE 8 P0108 INLE T PRESSURE SENSOR SHORT CIRCUIT TO POWER 9 P0112 INLE T AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO LOW 10 P0113 INLE T AIR TEMPERATURE SENSOR SIGNAL VOLTAGE TOO HIGH 11 P0116 ENIGNE
86. TS IN THE COURSE OF MAINTENANCE THE ELECTRONIC COMPONENTS MUST BE HANDLED CAREFULLY WHEN CUT DOWN OR CONNECT UP PLUG CONNECTOR YOU MUST TURN OFF THE IGNITION SWITCH OR ELSE THE ELECTRONIC FUEL INJECTION COMPONENTS WILL BE DAMAGED WHEN TAKE DOWN THE ELECTRIC FUEL PUMP DONOT ENERGIZE THE FUEL PUMP IT CAN GENERATE SPARK AND CAUSE FIRE FUEL PUMP NOT PERMITTED DO OPERATION TEST UNDER DRY STATE OR IN WATER OR ELSE WILL SHORTEN IT S LIFE BESIDES THE OIL FUEL PUMP TWO EXTREMES CANNOT REVERSE CONNECTION ELECTRONIC FUEL INJECTION SYSTEM FUEL SUPPLY PRESSURE IS HIGH AROUND 300kPa THE FUEL PIPE ALL APPLY HIGH PRESSURE RESISTANCE PIPE SO DO NOT DISMANTLE THE PIPE WHEN THE FUEL SYSTEM NEEDED TO BE REPAIRED YOU HAVE DO FUEL PIPE PRESSURE RELIEF BEFORE DISMANTLE THE OIL PIPE PRESSURE RELIEF METHOD IS AS FOLLOWING REMOVE FUEL PUMP RELAY STARTING THE ENGINE AND LET IT IDLE UNTILL THE ENGINE DIES ITSELF 11 ELECTRIC SYSTEM Jopefuj 4 FUEL PIPE S DISMANTLE AND FUEL FILTER S REPLACEMENT SHOULD BE CARRY ON BY PROFESSIONAL PERSON IN WELLVENTILATED PLACE WHEN INSPECTING THE IGNITION SYSTEM ONLY IF NECESSARY DO SPARK TEST AND SHOULD BE AS FAST AS POSSIBLE DONOT OPEN AIR SAMPER WHEN TESTING OR ELSE PLENTY OF UNBURNED FUEL WILL ENTER THE VENT PIPE AND DAMAGE THE TRIPLET CATALYST IDLE SPEED REGULATION COMPLETELY CARRY OUT BY ELECTRONIC FUEL INJECTION SYSTEM THROTTLE VALVE GUN LIMIT SCREW ALREADY
87. ULIC PRESSURE BRAKE COPPER OIL TUBE BRAKE FRONT MAIN CABLE ASSY WATER HOSE 1 13 1 SERVICE INFORMATION WATER INSET HOSE RADIATOR FILLER WATER HOSE RADIATOR RESERVOIR TANK BRAKE PIPE d MEL vet HH HH WINCH 1 SERVICE INFORMATION SEAT FRAME REGULATOR AIR CLEANER Carburetor Condition AIR HOSE SUPPLY M HOSE LON VE HOSE VALVE SUPPLY AIR AIR CLEANER SUPPLY AIR OUTLET DUCT AIR HOSE ENTER 1 15 Carburetor Condition FUEL HOSE EFI Condition 1 SERVICE INFORMATION GEARSHIFT ROD e A FUEL HOSE FUEL FILTER FUEL HOSE FUEL PUMP 1 SERVICE INFORMATION Carburetor Condition IGNITION COIL CARBURETOR CHOKE CABLE SPEEDOMETER SENSOR THROTTLE CABLE MAGNETO CABL CARBURETOR DRAIN hose WATER TEMPERATURE TRANSDUCER SMALL CIRCULATION hose IGNITION SWITCH CONNECTOR CIGARETTE LIGHT IN CABLE TOP PUMP IN CABLE SPEEDOMETER CABLE THE TOP LINE OF THE PUMP TRACTOR WINCH PLUG IN CABLE 1 17 1 SERVICE INFORMATION IGNITION SWITCH CONNECTOR FUSE BOX ASSY TENOR HORN 2WD 4WD DEIVE CONVERSION RELAY WINCH RELAY TENOR HORN Overhaul 2 1 Troubleshooting tetra tee 2 1 Center cover steering wheel
88. URE REGULATING VALVE IT DELIVER THE FUEL TO THE Spout 1 ri Za ENGINE WITH A CERTAIN OIL PRESSURE AND FLOW cal FUNCTIONS OF THE FOOT 1 BLUE GROUNDING 2 CONNECT FUEL LEVEL SENSOR 3 4 ED CONNECT THE OIL PUMP RELAY OUTPUT ENDING PERFORMANCEPARAMETER FLOW 35L h PRESSURE REGULATING VALVE OPENING PRESSURE 0 340 01 MPa THIS FUEL PUMP ASSY ALL USED INSIDE THE FUEL TANK DONOT RUN THE FUEL PUMP ASSY IN DRY C HANDLE GENTLY DONOT DROP THE FUEL PUMP ds ASSY ONTO THE GROUND THE RIGHT DIAGRAM IS THE WIRING DIAGRAM OF THE OIL PUMP ASSY OIL PUMP Connected with ECU PIN 22 BATTERY SUPPLY POWER VIA FUEL PUMP RELAY ELECTRIC OIL FUEL PUMP CIRCUIT CLOSE ONLY WHEN STARTING AND THE ENGINE RUNNING MEASURING THE FUEL PRESSURE CONNECT FUEL PRESSURE GAUGE TO THE FUEL PUMP FUEL DISCHARGE PORT LOCK WITH CLAMP ENSURE THERE IS NO LEAKAGE IN CONNECT AREA LINK THE CIRCUIT ACCORDING TO THE ABOVE DIAGRAM TURN OFF THE IGNITION SWITCH AND KILL SWITCH AT THIS FUEL PUMP WILL WORKING FOR 5 SECONDS WHEN IT STOP THE FUEL PRESSURE SHALL REACH THE AUTHORIZED PRESSURE OR ELSE REPLACE Battery Terminal THEENTIRE FUEL PUMP ASSY WHEN STOPED OPERATION PRESSURE HOLDING AT LEAST 0 2MPa 5 MINUTES IF NOT REPLACE THE FUEL PUMP ASSY OIL FUEL PIPE PRESSURE RELIEF BECAUSE OF THE HIGH PRESSURE OF FUEL SUPPLY THE FUEL PIPES ARE ALL HIGH PRESSURE RES
89. WHEEL 3 REAR BRAKE DISC 4 BUSH THICK 5 UPPER SWING L 6 UPPER SWING ARM R 7 TAPPING SCREW ST4 2x10 8 WIRE CLAMP 9 LOCKING NUT 12 1 25 10 BOLT MI2x90 11 BOLT FLANGE 10 1 25 55 12 LOCKING NUT 10 1 25 13 REAR SHOCK ABSORBER 14 BUFFERING COLLAR 15 SPRING WASHER 12 16 NUT M12 17 REAR LEFT ARM LOWER 18 REAR RIGHT ARM LOWER 19 WASHER 12 20 NUT M10 21 STABILIZER Bar 22 NUT M14 23 SPRING WASHER 14 24 BOLT M14x50 25 JOINT BEARING 26 RUBBER GASKET 27 FLANG REAR WHEEL LEFT 28 FLANG REAR WHEEL RIGHT 29 CENTER SPACER 30 BOLT FLANGE 12 1 25 30 31 BOLT FLANGE 10 1 25 180 32 BRAKE PAD LEFT 33 BRAKE PAD RIGHT 34 CALIPER BRAKE L 35 CALIPER BRAKE R 36 BEARING DAC3562 37 38 BOLT FLANGE M12x1 25x90 39 COVER REAR RIGHT ARM LOWER 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 Remove the following parts for rear right shock absorber 11 Bolt 12 Nut 11 Bolt 12 Nut Remove rear right shock absorber Installation Reverse th
90. accumulated or not Check air intake pressure sensor throttle position yes next 5 sensor and their wiring whether works regularly or not no examine and repair wiring or replace sensor Disassembly injector and check the injector by special yes Fault replacement 6 washing analysis instrument if exists the phenomena of no next leaks clogs or flux discrepantly Check fuel and observe the fault if caused after fueling yes Replace fuel 7 no next Check engine ignition timing if accords with standard yes next 8 no examine and repair ignition timing Check the exhaust gas from muffler if exhausts yes next 9 smoothly no Repair or replace muffler Contact with EFI commutator open ignition switch yes Diagnosis help 10 check 5 107 23 stitch the power whether supply normal or not check 27 21 stitch whether is no Examine and repair putting up iron or not relevant wiring 13 No power and poor performance when in acceleration Possible defective part 1 fuel containing water 2 air intake pressure sensor and throttle position sensor 3 spark plug 4 ignition coil 5 throttle valve body and idle speed side air duct 6 input air duct 7 idle speed valve 8 fuel injector 9 ignition timing 10 muffler 13 23 13 TROUBLESHOOTING Overhaul Ref no Operation Test Next Steps result Check the faults if exist clutch ski
91. ace Check reverse gear chain for any damage or over wear Damage or over wear Replace e Disassemble driven shaft as illustrated Check each gear surface for any damage or over wear Check bearing and collar for any wear or damage Damage or over wear Replace 6 38 6 ENGINE REMOVAL INSPECTION 4 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 Measure shift fork groove width with vernier caliper Standard shift fork groove width 6 05 6 15mm Measure shift fork thickness with vernier calipers Standard fork thickness 5 80 5 90mm Check shift damage or bend Damage bend Replace Install shift fork to guide bar and move left and right In case of any unsmooth moving replace with a new one 6 39 6 ENGINE REMOVAL INSPECTION 4 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 e Check shift fork spring for breakage damage Broken or damaged Replace e Check shift cam groove for scratches damage Scratch or damage Replace Assembly Reverse the removal procedure for assembly Pay attention to the following e Use new retainers Pay at
92. are damaged worn or stepped Steering stem is distored e Tire pressure is too low e Worn tire Shaking Steering Wheel Steering wheel is not well tightened Bearing is damaged Deflected tires Deformed frame Worn tiers Shaking of wheel bearing Vibration of Front Wheel Wheel rim distorted Faulty wheel bearing Faulty tire Improper balance of wheels e Improper tightening of wheel axle Steering stem is loosened or not well installed Mount seat steering wheel is not well tightened Right and left shock absorbers are not matched 8 2 Wheel Cannot Turn Freely e Faulty wheel bearing e Front wheel axle is bended e Brake drag e Faulty steering structure Front Suspension is Too Soft e Weakened front shock absorbers e Tire pressure is too low Front Suspension is Too Hard e Front shock absorber is bended e Tire pressure is too high Noise with Front Absorbers e Faulty front shock absorbers e Loosened tightening parts of front absorbers Poor Brake Efficiency e Faulty brake adjustment e Stained brake disc Worn brake shoes e Air in brake hose 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 Brake Dis
93. as below 1 Check if ECU Pin voltage is normal or not Trouble Code P0130 Oxygen Sensor Signal irrationally failure Explanation When Oxygen Sensor Signal happens with situations as below System decide Oxygen Sensor Signal irrationally failure Oxygen Sensor Signal Circuit coupling with Heating Circuit Note Possible Troubles are as below 1 Check if Oxygen Sensor Connector is correct or not 2 Check if Oxygen Sensor Signal Circuit coupling with Heating Circuit Trouble Code P0131 Oxygen Sensor Circuit Voltage Low Note Possible Troubles are as below 1 Signal Circuit connected with ECU Pin is short circuit to ground Note Inspect as below 1 Check resistance between Signal Circuit connected with ECU Pin and ground 13 8 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 1 Short Circuit between Signal Circuit connect to ECU Pin and Oxygen Sensor Oxygen Sensor Pin 1 2 Short Circuit between Signal Circuit connect to ECU Pin and other power circuit Inspect as below 1 gt Check resistance between Signal Circuit connect to ECU Pin and Oxygen Sensor Oxygen Sensor Pin 1 2 Check resistance
94. at you are wearing appropriate clothing and using safety equipment When performing any service task be especially careful of the following e Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely 1 1 1 SERVICE INFORMATION e 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 e Use other protective wear when necessary for example gloves or safety shoes Handing hot or sharp parts can cause severe burns or cuts Before you grab something that looks like it can hurt you stop and put on gloves e Protect yourself and others whenever you have the vehicle up in the air Any time you lift the vehicle either with a hoist or a jack make sure that it is always securely supported Use jack stands Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine e Burns from hot parts or coolant Let the engine and exhaust system cool before working in those areas e Injury from moving parts If the i
95. ature sensor e Avoid contact of temperature sensor with thermometer or vessel e After installation check the coolant level Fill coolant if necessary Inspection of Thermostat e Remove thermostat case e Remove thermostat 4 6 4 COOLING AND LUBRICATIING SYSTEM AU 9 Check thermostat pellet for cracks Test the thermostat in the following steps e Passastring between thermostat flange as illustrated on the right e Immerse the thermostat in a beaker with water Make sure that the thermostat 1s in the suspended position without contact to the vessel Heat the water by placing the beaker above a stove and observe the temperature rise on a thermometer e Take temperature reading from thermometer when the thermostat valve opens 1 Thermostat 2 String Thermostat Valve Opening Temperature 68 74 C e Keep heating the water to raise the water temperature e Just when the water temperature reaches the specified value the thermostat valve should have been lifted by 3 5 4 5mm Valve Lift Installation Reverse the removal procedure for installation Apply coolant to the rubber seal of thermostat e Install thermostat case Tighten to the specified torque Tightening Torque 10N m Water Pump Removal and Disassembly Remove engine left side cover Left Side Cover e Drain coolant gt 3 20 Note Before draining coolant check water pump for oil or coolant
96. c Brake Caliper Service limit Axial 2 0mm Radial 2 0mm Assembly Press rim into wheel Install rim on the wheel hub Tightening Torque Bolt Wheel Hub 60 65 N m Front Wheel Hub Mounting Bolt Rim Wheel Hub Disassembly Bolt Brake Disc Remove Front wheel 8 3 Front brake caliper 8 4 Rim axle nut Brake disc and wheel hub 4 bolts from front brake disc Wheel hub Installation Reverse the removal procedure for installation Torque Rim axle nut 180 200N m 8 3 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 Tightening Torque Fixing Bolt Brake Caliper 45 50 m 8 4 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Bolt Brake Disc Front wheel 8 3 Brake caliper gt 8 4 Front brake disc and wheel hub 4 bolts from brake disc Brake disc Inspection Brake Disc Brake disc thickness lt 16mm Replace Master Cylinder Installation Install brake disc Tightening Torque gt Bolt Fixing bolt brake disc 45 50N m Front Brake Master Cylinder Disassembly Remove Blot 1 Nut 1 Do not remove front brake master cyl
97. cable from throttle rotory sleeve Disassemble idel air outlet pipe on throttle valve Loosen air intake connect clamp air cleaner connect clamp and remove throttle valve body NOTE Do not adjust the bolt on throttle body Do not remove the cap on throttle body Throttle Body Installation Air Filter Clamp Reverse disassembly procedure for installation Fuel Injector Assy Disassembly Disassemble the special high pressure fuel Remove the strap and fuel injector connector Disassemble bolts and remove fuel injector cap and injector Fuel Injector Assy Installation Reverse the disassembly procedure for installation 7 8 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 Fuel Injector Cap 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 into it Snap Spring Fuel Injector Idle Air Control Valve Disassembly Disassemble idle intake pipe and idle outlet pipe Loosen the strap disassemble idle air control valve and check idle air control valve Replace it when there is abnormal noise or it doesnot work Idle Air Outlet Pipe Idle Air Control Valve Installation Reverse the disassembly procedure
98. cedure for Installation Backrest passenger 500L 500UEL Remove Remove bolt 1 Remove backrest passenger Installation Reverse the removal procedure for Installation 2 13 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 Remove bolt 5 Remove safety belt fastener Installation Reverse the removal procedure for installation 2 VEHICLE BODY MUFFLER Safety belt driver safety belt passenger Roll over bar 500UTV 500U E Remove Remove bolt 1 Remove bolt 2 Loosen nut 11 Remove bolt 5 Remove roll over bar Installation Reverse the removal procedure for Installation 2 VEHICLE BODY MUFFLER Rear mirror LH Remove Remove rear mirror L 48 Rear mirror RH Remove Remove rear mirror R 49 2 15 2 VEHICLE BODY MUFFLER Roll over bar S00LUTV S00UEL Remove Remove bolt 1 Remove bolt 2 Remove bolt 3 Remove roll over bar Installation Reverse the removal procedure for Installation f Jj f j 1 if j 4 wo b Y j Rear mirror LH Remove Remove rear mirro
99. crometer 0 25mm Valve Stem Run out e Support valve stem with V block as illustrated on the right Check the run out with a dial gauge Service Limit 0 05mm Tool Magnetism Stand Dial Gauge 1 100 V block Valve Head Radial Run out Measure the valve head radial run out as illustrated on the right Valve head Radial Run out out of range Service Limit 0 03mm Tool Dial Gauge 1 100 Magnetic Stand V Block Valve Face Wear e Check each valve face for wear or damage Replace valve with a new one if it is found to have abnormal wear Measure valve head thickness T Valve head thickness out of range Replace Service Limit 0 5mm Tool Vernier Caliper Valve Stem End e Check valve stem end for pitting or wear In case of any pitting or wear resurface the valve stem end If the length T is less than service limit replace valve with a new one Valve Stem End Length Service Limit 2 1mm Tool Vernier Caliper 6 18 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Valve Spring e Valve Spring keeps valve and valve seat tight Weakened spring results in reduced engine power output and chattering noise from valve mechanism e Measure the spring free length Spring free length out of range Replace Service Limit 38 8mm Tool Vernier Caliper e Measure the force to compress the spring to the specified length Valve spring tension out of range Replace Service Limit I
100. d low tyre yes repair 1 pressure lagged brake improper tyre size etc no next Check air cleaner if is clogged yes Examine and repair 2 air input system no next Contact fuel pres sure meter contact front point of oil yes next 3 input pipe of injector starting engine check the fuel pressure whether is around 300kPa or not no examine and repair oil support system Pull out ignition coil and contact with s park plug yes next 4 keep pole of spark plug 5mm away with body of as engine starting engine and check high pressure inion syai fire whether is norm al o r not Check spark plug look its type and gap if accords yes next Adjust or replace Disassembly idle speed valve and check the throttle yes Clean related parts 6 valve body idle speed valve and idle speed side air nekt duct whether have carbide accumulated or not Check air intake pressure sensor throttle position yes next 7 sensor and their wiring if works regularly no examine and repair wiring or replace sensor Disassembly injector and check the injector by yes Fault replacement 8 special washing analys is instrument if exists the phenomena of leaks and clogs i Check fuel and observe the fault if caused after yes Replace fuel 9 fueling no next Check engine ignition timing if ac cords with yes next 10 standard no examine and repair ignition timing Check the exhaust gas from muffler if exhausts yes next smoothly no Repair
101. der or piston or both Piston Ring to Groove Clearance Use a thickness gauge to measure the side clearance of top ring and 2 ring e Ifthe clearance exceeds the limit replace both piston and piston rings Service Limit Top ring 0 18mm 2nd ring 0 15mm 6 25 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Piston Ring Free End Gap and End Gap e Before installing piston rings use vernier caliper to measure the free end gap of each ring and then fit ring into the cylinder e Use thickness gauge to measure each ring end gap if any ring has an excess end gap replace the piston ring Piston ring free end gap limit Top ring 8 9mm 2 ring 9 5mm Piston ring end gap limit Top Ring 0 60mm 2 ring 0 60mm Tool Vernier caliper Thickness gauge Piston Pin and Pin Bore Use bore gauge to measure the inner diameter of piston pin bore e Use micrometer to measure outer diameter of piston pin e Ifoutof limit replace both piston and piston pin Piston pin bore limit 23 030mm e Use micrometer to measure piston pin outer diameter at three points Piston pin outer diameter limit 22 980mm Tools Bore gauge 18 35mm Micrometer 0 25mm 6 26 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Connecting Rod Crankshaft Connecting rod small end I D Use a dial gauge to measure I D of connecting rod small end If the measurement exceeds the limit replace the connecting rod C
102. e e oil to raise the temperature slowly and take the reading from thermometer 2 when the Amperometer thermoswitch closes and opens Tool ammeter Thermoswitch Operating Temperature Standard OFF ON Approx 88 C ON OFF Approx 82 Note Avoid sharp impact on thermoswitch e Avoid contact of thermoswitch with thermometer or vessel e Installation Use a new O ring and tighten the thermoswitch to the specified torque Thermoswitch Tightening Torque 17N m Check coolant level after installation of thermoswitch Fill coolant if necessary 4 5 4 COOLING AND LUBRICATIING SYSTEM Inspection of Water Temperature Sensor e Place a rag under water temperature sensor and remove it from cylinder head Check the resistance of water temperature sensor as illustrated on the right Connect the temperature sensor to the circuit tester place it in a vessel with engine oil Place the vessel above a stove e Heat the oil to raise the temperature slowly and take the reading from thermometer 3 and ohmmeter 4 Water Temperature and Resistance 59 80 100 120 Resistance Q 154416 52 4 2743 16 2 Installation Apply a little thread locker and install it to the cylinder head by tightening to the specified torque Water Temperature Sensor Tightening Torque 10N m Note e Avoid sharp impact on temper
103. e SS 11 3 11 ELECTRIC SYSTEM STARTING SYSTEM TRIGGER CIRCUIT DIAGRAM iBattery 12V STARTING MOTOR End Cover 2 3 4 5 6 1 8 9 Holder Brush Spring O ring Brush Terminal Stating Motor Cylinder Washer Armature Washer 10 Inner Cover 11 O ring 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 a IS WEAR DISCOLORATION 4 REPLACE WITH NEW AMATURE IF THE COMMUTATOR SURFACE DISCOLOURATION POLISH WITH SEND PAPER AND WIPE UP WITH DRY CLOTH IF OVER WEAR CUT PART OF INSULATOR WITH BLADE KAME THE DISTANCE BETWEEN A TO 4 d 1 5mm ARMATURE COIL USE MULTIMETER CHECKING IF IT IS INTERCOMMUNICATION BETWEEN THE TERMINALS BETWEEN TERMINALS AND ARMATURES IF THEY NOT COMMUNICATION REPLACE WITH A NEW ARMATURE OIL SEAL CHECKING IF OIL SEAL LIP DESTROY OR OIL LEAK IF THERE IS DESTROY OR 7 LEAKAGE REPLACE WITH A NEW STARTING DYNAMO 11 5 11 ELECTRIC SYSTEM INITIATING RELAY PUT 12V TO THE SMALL TERMINALS THERE IS r 1 L CONTINUITY BETWEEN THE LARGE TERMINALS IF THE START RELAY CONTACTS
104. e panel engine cover R Panel engine cover Bolt 5 Nut 5 Remove engine cover Installation Reverse the removal procedure for installation 2 4 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 Remove front side support RH amp LH gt 2 5 Remove nut 1 from front cover Remove front vent cover Installation Reverse the removal procedure for Installation 2 5 2 VEHICLE BODY MUFFLER BOLT2 Front side support LH 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 latch puller to unlock the seat lock Remove eight bolts 2 Remove seat passenger Installation Reverse the removal procedure for Passenger seat installation Seat passenger 500L seat Passenger Remove Use the latch puller to unlock the seat lock Remove eight bolts 3 Remove seat passenger Installation Reverse the removal procedure for installation 2 6 2 VEHICLE BODY MUFFLER Gearshift knob Remove Remove bolt
105. e removal procedure for installation Rear Right Arm Refer to front right Arm in Chapter 8 for the removal inspection and installation of Rear Right Arm Rear Left Suspension Refer to Rear Right Suspension for the removal inspection and installation of Rear Left Suspension 9 6 Front Rear Axle Overhaul Information 10 FRONT REAR AXLE Standard Lubricating Period Papam T mE Front Axle SAEISW 40 SF 1 0 33L R 0 28L Or 350km 5000Km Rear Axle SAE80W 90 GL 4 1 0 30L R 0 25L I Initial R Replaced Tightening Torque Table Item Qty Type Torque N m Remark Fornt axle bolt 6 8 28 25 Screw 4 M8x20 13 Screw 1 8 10 13 Front screw 1 14 1 5 62 Glue Bolt 6 10 1 25 22 45 Front axle bolt 1 M14x1 25x12 25 Bolt 1 10 1 25 29 Bearing Retainer 1 64 1 5 7 80 Rear axle 2 M10x1 25x25 40 Rear axle bolt 4 M8x25 25 1 12 1 25 70 Bolt 4 8 30 25 Bearing Retainer 1 M65x1 5x10 70 Nut 1 8 16 Rear axle bolt 1 M20x1 5x12 25 Rear drain bolt 1 M14x1 25x12 25 10 1 10 Inspection amp Overhaul 10 Inspection and overhaul if any of problems below happens to front rear axle Descriptions Causes Bearing broken Gear clearance over under size Gear severely worn Gear blocked Drive shaft broken lack of lubricant Foreign matter in front or rear g
106. ear 1 Unstable moving during accelerating decelerating or constant speed 2 Abnormal sound in front rear axle 3 Engine power transmission failure to front or rear wheels gt Note problems hard to distinguish Analysis is needed based on actual break down catagories Make sure engine works all right before disassembly of front or rear axle Observation and Judgement 1 Never ignore abnormal sound a Abnormal sounds during accelerating decelerating have little to do with engine working but possibly with gear worn b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembling Note Wrong assembly or adjustment of the front or rear axle will aggravate gear worn and block c Slight sounds will be noticed during low speed driving and should not be heard during high speed driving This is caused by gear block Note In case of above mentioned times stop the vehicle immediately for inspection until they are solved or will cause accident 2 Check lubrication 3 Check lubricant leakage a Rear axle surface oil stain inspection before through inspection b Oil stain on ground on the parking lot c Lubricant splash inspection Check if there is gear case or oil seal leakage Replace broken parts if necessary 10 2 10 Disassembly of front axle
107. eck 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 Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the locknut of tie rod Note After the toe in has been adjusted slowly run the vehicle to check whether the direction of vehicle can be controlled by steering wheel 3 8 3 INSPECTION amp ADJUSTMENT gt 1 e STEERING ROD LOCKNUT 3 INSPECTION amp 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 m Tire Pressure Gauge the comfort of operation and riding and may cause deflected wear of the tires Specified pressure tire Rear wheel Pressure 193kPa 28 IPSI Tires 25 8 12 25 10 12 517 5 205 80 12 255 65 12 Tire Tread Check the tire tread Tread Height if lt 3mm then Replace with new tires ee Note Over 3mm When the tread height is less than 3mm the tire should be replaced immediately 3 9 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
108. ection 2 Measure resistance of idle speed valve 13 10 Errors coding P0458 Control circuit voltage of idle air control valve too low 13 TROUBLESHOOTING Maintenance Tips The possible faults may exists as follow 1 Circuit ECU connected is short circuit Maintenance Tips Check the item as follow 1 Measure connected to the ECU pin to ground resistance whether proper or not Errors coding P0459 Control circuit voltage of idle air control valve too high Maintenance Tips The possible faults may exists as follow 1 Short circuit between ECU circuit connected and No 1 pin of idle air control valve 2 Short circuit between circuit ECU pin connected and other electrical source circuits Maintenance Tips Check the item as follow 1 Measure the voltage of ECU pin whether normal or not 2 Measure resistance between ECU pin and No 1 pin of idle air control valve Errors coding P0501Speed sensor signal improper Explanation When loose throttle and keep direct to free wheel ECU measure engine rotate speed and vehicle speed together If engine lasting higher speed but vehicle speed display 0 or too low obviously system will judge that vehicle speed signal faults Maintenance Tips The possible faults may exists as follow 1 The signal circuit ECU connected and vehicle speed sensor short to ground or open to ground Maintenance Tips C
109. ection Process 15 only suitable when Air Inlet Pressure Sensor Canister Control Valve and Oxygen Sensor and so on has not shown with Trouble Code If there is any other Trouble Code solve other Troubles first and then inspect Fuel Route correct or not Trouble Code P0201 Cylinder Injector Control Circuit Open Note Possible Troubles are as below 1 Injector Coil Open Circuit 2 Injector Connector Sock et to ECU Pin bad connection 3 Injector Connector Socket to Main Relay bad connection Note Inspect as below 1 Check resistance of Injector 2 Check cable is connected or not 13 9 Errors coding P0261 Control circuit of single 13 TROUBLESHOOTING cylinder injector short to ground Maintenance Tips The possible faults may exists as follow 1 All drivers ECU pin connected short to ground Maintenance Tips Check the item as follow 1 Measure ECU pin connected resistance to ground Errors coding P0262 Control circuit of single cylinder injector short circuit Maintenance Tips The possible faults may exists as follow 1 Short circuit between circuit ECU connected and other electrical source circuits Maintenance Tips Check the item as follow 1 Measure the voltage of circuit ECU pin connected Errors coding P0321 reference point of rotate speed sensor fault Maintenance Tips The possible faults may exists as follow 1 Circuits connec
110. el 2 2 Installation of Rear View Mirror Install rear view mirror C 2 15 8 16 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Steering System 1 STEERING WHEEL 2 STEERING COLUMN 3 DECORATE COVER STEERING COLUMN 4 SCREW M6x12 5 LOCKING NUT M8 6 HOLDER STEERING COLUMN 7 BOLT FLANGE MS8x35 8 RUBBER CUSHION COLUMN 1 2 6 N 290 or lt gt 4 8 ert 4 xn 9 E Vay LK 12 6 11 12 J 13 1 en 13 on 107 15 7 i 16 17 2 17 K 22 18 a CE M M gt 17 9 8 25 10 SPRING WASHER 11 STEERING JOINT 12 10 30 13 SPRING WASHER 10 14 10 15 HOOP STEERING COLUMN CIRON 16 PIN SPLIT 3 5x16 17 SOLT NUT MI2 18 HOOP STEERING COLUMN LEATHER 19 STEERING ASSY 8 17 9 REAR WHEEL REAR BRAKE SUSPENSION Overhaul Infor i3 Rn 9 Rear brakes i oae 2 9 2 Rear 1 R ar wheel ii 9 3 Overhaul info Note Securely support the vehicle when overhauling the rim and suspension system e Use genuine parts of bolts and nuts for rear rim and suspension Do not overexert the wheels to avoid possible damage to the
111. en Bevel Gear Front Output Shaft Remove bevel gear cover bolt e Remove driven bevel gear 8 e Remove front output shaft nut 4 6 11 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Remove Oil seal Bearing limit nut e Remove Front Output Shaft 4 Shift Cam Fork Shaft e Remove Shift Fork Shaft 6 Drive Bevel Gear e Remove left crankcase from driven bevel gear Drive Shaft Drive Shaft e Remove drive shaft and driven shaft 2 Balancer Shaft e Remove balancer shaft Balancer Shaft 6 12 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Crankshaft e Separate crankshaft from left crankcase with Special tool Tool Crankshaft Separator Oil bump Relief Valve Remove oil bump and relief valve 6 13 6 ENGINE REMOVAL INSPECTION 4 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 e Remove rocker arm shaft bolts A e Remove rocker arm shaft by using M6 bolts B Cylinder Head Cover Distortion Clean off sealant from the fitting surface of cylinder head cover place cylinder head cover on a surface plate and measure distortion with a thickness gauge Cylinder head Cover Distortion Limit 0 05mm Tool Thickness Gauge Distortion
112. ensor observe no Next engine whether succeed starting or not at this moment a Next Check fuel and observe the fault if caused after fueling yes Replace fuel 4 no next Contact EFI commutator open ignition switch check yes Diagnosis help 5 102 13 stitch the power whether supply no Examine and normally or not check 27 21 stitch whether Put up iron or not repair relevant wiring 4 Hard Starting in cold status Possible defective part 1 fuelcontaining water 2 fuel pump 3 engine water temperature sensor 4 injector 5 ignition coil 6 throttle valve body and idle speed side air duct 7 engine mechanism part Overhaul 13 16 13 TROUBLESHOOTING Ref no Operation Test Next Steps result Contact fuel pressure meter contact front point of oil input yes next 1 pipe of injector starting engine check the fuel pressure 6 f no examine and repair whether is around 300 or not oil support system Pull out ignition coil and contact with spark plug keep yes next 2 pole of spark plug 5mm away of body of engine starting no Examine and repair engine and check it whether has blue white spark fire or aM 1gnition system not Pull out connector of engine water temperature sensor yes Examine and repair starting engine observe engine whether succeed starting or wiring or replace 3 not at this moment or in series a 2500Qresistant instead of sensor eng
113. eplacing the bulb adjust headlight beam Inspection of Headlight Turn the ignition switch to ON position turn light switch to the illuminating position and check if the headlight is on ON Normal Still off short circuit of main cable or broken main cable 12 3 12 LIGHTING AND SWITCHES Brake Light Tail Light Bulb Remove 2 tapping screws Brake Light Tail Light Bulb 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 Replace front turning light bulbs Bulb Specification 12 V 10 W Rear Turning Indicator Bulbs Remove screw Remove rear turning indicator cover Replace rear turning indicator bulbs Bulb Specification 12V 10W Reverse the removal procedure for installation 12 4 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 gt 1 Reverse the removal procedure for installation Dashboard Indicator Bulb Remove dashboard 13 9 Remove dashboard indicator socket Remove indicating light bulb and replace with new one Bulb specification 12V 3 4W Re
114. er e Tighten secondary sheave nut with special tool to the specified torque Secondary sheave tightening torque 115 Tool Rotor Holder Note Turn the primary fixed sheave until the belt is seated in and both primary and secondary sheaves move together smoothly without slip CVT Case Cover e Install the new gasket and dowel pins Gasket 6 58 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION e Install CVT case cover bolts and tighten diagonally in several steps Engine Left Oil Pump Sprocket and Chain e Install oil pump drive sprocket Install oil pump driven sprocket 8 7 Install oil pump drive chain e Install oil pump sprocket bolt e Install sprocket retainer with a long nose pliers Tool Long Nose Pliers Dual Gear Idle Gear e Install dual gear shaft and dual gear 8 e Install dual gear dual gear bush Starting Driven Gear 2 8 8 8 id 8 8 8 8 8 4 e Install starting driven gear 6 6 59 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install starting driven gear Driven Gear Magneto Rotor e Install woodruff key into crankshaft groove e 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 Left Crankcase Cover Install dowel pin2 and gasket 3 Note Use a new gasket
115. er temperature sensor apply thread locker to the thread part tighten it to the specified torque Water temperature sensor Tightening torque 10 N m Apply Thread Locke Water Temperature e Install intake pipe apply lubricant to 0 ring Peine Apply Lubricant Grease Camshaft Check camshaft for wear and run out of cams and journals if the engines produces abnormal noise or vibration or lacks power output Any of these symptoms could be caused by wear of camshaft 6 21 6 ENGINE REMOVAL INSPECTION 4 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 The limit of cam wear is specified for both IN and EX cams in terms of cam height Measure with a micrometer the cam height Cam height out of range Replace Cam height service limit IN 33 130mm EX 33 200mm Tool micrometer 25 50mm Camshaft Journal Wear Check whether each journal is worn to the limit by measuring camshaft journal oil clearance with the camshaft installed Camshaft journal oil clearance Service limit 0 15mm Check according to the following steps e Clean off materials from cylinder head and cover e Install camshaft with plastic gauge Install
116. erson who intends to use a replacement part service procedure or a tool that is not recommended by XinYang must determine the risks to their personal safety and the safe operation of the vehicle If you need to replace a part use genuine XinYang parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality For Your Customer is Safety Proper service and maintenance are essential to the customer is safety and the reliability of the vehicle Any error or oversight while servicing a vehicle can result in faulty operation damage to the vehicle or injury to others For Your Safety Because this manual is intended for the professional service technician we do not provide warnings about many basic shop safety practices e g Hot parts wear gloves If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice we recommended that you do not attempt to perform the procedures described in this manual Some of the most important general service safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing service and repair and procedures Only you can decide whether or not you should perform a given task can cause you to be seriously hurt or killed Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and th
117. es Arrowhead direction is for engine removal orders Reverse the direction for assembly and installation 6 1 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Engine Removal APreparation before engine removal e Prepare a proper tray used for load of components e Prepare necessary removal and assembly tools e Drain up engine oil 3 18 e Drain up coolant 3 20 Engine Periphery Water Hose Pipe e Remove water hose clamp Mand e Remove water hose 3 e Remove screw 4 and water hose 5 Left Side Cover e Remove 6 bolts M6X20 of left side cover 6 e Remove left side cover 6 Recoil Starter e Remove 4 bolts M6X12 of recoil starter e Remove recoil starter 7 Inspection Plug e Remove inspection plug with screwdriver AEngine Front Side Spark Plug Remove spark plug with special wrench Tool Spark Plug Wrench e Turn crankshaft align T D C line A on magneto rotor with mark B of left crankcase 6 2 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Cylinder Head Cover hz Remove valve adjusting cover Removel2 bolts of cylinder head cover Remove cylinder head cover Timing Chain Tensioner e Remove screw plug insert a flat screwdriver into slot of timing chain tensioner adjuster turn it clockwise to lock tensioner spring e Remove tensioner fix bolt e Remove tensioner and gasket Camshaft e Loosen timing sprocket bolt e Remove timing sprocket bolt and lock
118. es 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 Carbon deposit in combustion chamber Clean 4 Worn piston pin or pin hole Replace 5 Worn piston ring or piston ring groove Replace Noise from Timing chain 1 Stretched chain Replace chain amp Engine is sprocket noisy 2 Worn sprocket wheel Replace chain amp sprocket 3 Faulty chain tensioner Repair or replace Noise from Clutch 1 Worn or damaged crankshaft spline Replace crankshaft 2 Worn inner race spline Replace inner race Noise from Crankshaft 1 Rattling bearing Replace 2 Worn or burnt crank pin bearing Replace 3 Excessive thrust clearance Replace Noise from CVT 1 Worn or slipping drive belt Replace 2 Worn rollers in primary sheave Replace Noise from Transmission 1 Worn or damaged gear Replace 2 Worn or damaged input or output shafts Replace 3 Worn bearing Replace 4 Worn bushing Replace 1 Worn or damaged clutch shoes Replace Slipping 2 Weakened clutch shoe spring Replace Clutch 3 Worn clutch housing Replace 4 Worn or slipping drive belt Replace 13 4 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 nu
119. exists the phenomena of leaks clogs or flux discrepantly no Check fuel and observe the fault if caused after fueling yes 6 no Check compression of cylinder and observe the pressure yes 7 if it is discrepantly no Contact EFI commutator open ignition switch check yes 8 ECUS 10 23 stitch the power whether supply normal not check 2 21 stitch whether Put up iron or no not 9 Engine starting normally but unsteady idle speed or power off when engine in partly loading such as opening head light 13 20 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 yes Clean related parts 1 valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next Observe output power whether is increasing or not yes Turn step no 4 when begin loading work namely observe the 2 movement of ignition advance angle injection pulse 2 width and air intake flowrate by EFI diagnosis no Examine and repair instrument air condition system Disassembly injector and check the injector by special ye Fault replacement 3 washing analysis instrument if exists the phenomena of leaks clogs or flux discrepantly no next Contact EFI commutator open ignition switch check yes Diagnosis help 4 108 23 stitch the power whether sup
120. for installation Pay attention not to bend the intake and outlet pipe of idle air control valve 7 9 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Overhaul 8 1 Brake Systemic 8 4 8 2 SUSHENSTON 8 7 Front Wheel eee oerte eru ESSE 8 3 a E dd 8 12 Overhaul Information Operating cautions Notes e Securely support the vehicle when overhauling the front wheel and suspension system e Refer to chapter10 for overhaul and inspection of lighting instruments and switches e Do not overexert on the wheel Avoid any damage to the wheel e When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Rim Longitudinal Vibration Lateral Remained groove 21 1PSI 145 6 9KPa Tire pressure 28 1 51 193 6 9 KPa are Free play brake lever Tightening Torque Nut Tie rod 40 45 N m Lock nut steering stem 45 50N m Nut front wheel axle 180 200 N m Fixing bolt nut absorber front 23 25 Nm Fixing bolt nut absorber rear 30 35 Nut front rear rim 60 65 N m Nut rear wheel axle 180 200 N m 8 1 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Troubleshooting Heavy Steering Steering bearing is damaged or worn Inner amp outer bearing races
121. form disassembly only after the muffler is cooled down exhaust pipe Remove bolt 2 Bolt 2 protector 0 part 2 Remove muffler Note Replace sealing gasket when installing the muffler Muffler 2 19 2 VEHICLE BODY MUFFLER Description of visible parts Ceiling Rear mirror L Driver headrest Switch Engine cover Driver seat Front vent cover Headlight L Rear turni signal L Taillight Front 5 signal L seer LR 51 Cable motor Front side support L support L Front suspension 1 Skid plate 1 Passenger Passenger headrest Hand Hold Passenger seat Rear mirror R Seat belts Passenger Rear turning signal R Headlight R WC Taillight R AN Ei v SHS Rear side H Front turr support R X EEN Front sic Rear suspension 514 Front suspension Rear fender R Skid plate 2 20 3 INSPECTION amp ADJUSTMENT Overhaul Info iere 3 1 Valve 1 3 13 Maintenance 3 2 Engine Idle amp Spark plug 3 14 Inspection amp Maintenance 3 3 Air Falter T 3 15 Steering 3 6 Carburetor hose amp Driving Belt 3 16 occae eec o 3
122. g e Install starting motor e Install bolt and tighten to the specified torque Tightening torque 10N m Engine Top Side Piston e Install the piston rings the order of oil ring ring and Dring e The first member to go into the oil ring groove is spacer after placing the spacer fit the two side rails 0 Warning when installing the spacer D do not overlap its two ends in the groove Install the second ring A and first ring B Note Ist ring and 2nd ring differ in shape 6 62 Apply Grease Incorrect 1 Correct o e _ e 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e stand 2nd rings have letter 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 Before installing the piston into the cylinder check that the gaps are so located Upper Sida Rall Piston Pin Centerline Apply a light coat of moly oil to the piston pin e Install piston pin into holes of piston and conrod small end Note When installing the piston the IN mark on piston top is located to the intake side e Place a clean rag beneath piston and install piston pin circlip 1 Note while rotating crankshaft pull the cam chain upward or the chain will be caught between sprocket and crankcase e Install the dowel pins and the new cylinder gasket N
123. ge 2 in spark plug hole and tighten nut Keep throttle full open e Press start button crank the engine a few seconds Record the maximum reading of cylinder pressure Tools Cylinder Pressure Gauge Adaptor 3 21 Inspection of Pressure Oil Pressure 130 170kpa at 3000r min Lower or higher oil pressure may be caused by I pressure is too low Clogged oil filter Leakage from oil passage Damaged O ring Oil pump failure Combination of above items II Oil pressure is too high e Oil viscosity is too high e Clogged oil passage e Combination of above items Testing Oil Pressure Remove bolt D e Connect tachometer with ignition coil e Install oil pressure gauge and joint seat to main oil gallery e Warm up engine as per following Summer 10 minutes at 2000r min Winter 20 minutes at 2000r min After warming up increase engine speed to 3000r min and record readings of oil pressure gauge After testing apply thread locker to the thread in the hole of main oil channel Install bolt and tighten to the specified torque Tighten torque 23N m Tools Oil pressure gauge Tachometer 3 22 3 INSPECTION amp ADJUSTMENT 3 INSPECTION amp 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 o
124. he bolt to the specified torque Gear positioning bolt tightening torque 18M m Engine Right Timing Chain e Put on timing chain 2 Clutch e Install clutch 1 and nut 2 Tighten the nut to the specified torque left thread Clutch nut tightening torque 70N m 6 56 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install new o ring spacer 8 6 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 4 gasket 2 and gasket to the right crankcase Install CVT case assembly to right crankcase e Install bolt 2 and nut Note e Tighten bolt nut diagonally Use anew gasket e Install air guide plate and Primary Sheave Secondary Sheave Drive Belt Install primary fixed sheave 1 as illustrated on the right Install drive belt between secondary sliding fixed sheave and tap with a plastic hammer to keep the belt as low as possible Note e Install the drive belt with the arrow on the belt turn in the clockwise direction e Drive belt contact surface should be free from any stains 6 57 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install secondary sheave e Install primary sliding sheave e Tighten primary sheave nut with special tool to the specified torque Primary sheave nut tightening torque 115 Ne m Tool Rotor Hold
125. he 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 Do not mix with dust or water when adding brake fluid Use only the recommended of brake fluid to avoid chemical reaction Brake fluid may cause damages to the surface of the plastic and rubber parts Keep the fluid away from these parts Slightly turn the steering wheel left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad lt Wear of brake pad gt Check the brake pad wears from the mark as indicated Replace the brake pad if the wear has reached position of wear limit trough Note The brake pad must be replaced with a whole set Checking and replacing the brake disc Front brake disc thickness lt 16 mm Replace Rear brake disc lt 16 mm Replace Min limited thickness of the front brake disc 16mm Min limited thickness of the rear brake disc 16mm Change the Brake Fluid lt Changing Brake Fluid gt Change the brake fluid once every year 3 7 3 INSPECTION amp ADJUSTMENT BRAKE FLUID RESERVOID CAP BRAKE CYLINDER REAR BRAKE FLUID RESERVOID FRONT BRAKE FLUID RESERVOID REAR BRAKE 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 ch
126. heck the item as follow 1 Check circuit resistance that connecter of ECU joint to vehicle speed signal sensor 2 Check resistance to ground of ECU pin Errors coding P0506 Rotate speed of idle air control valve slower than target idle speed Explanation Engine rotate speed of idle speed control valve works by closed loop control And it indicates fault if ECU performs idle speed controlling after a certain time but the actual engine speed still slower than target idle speed Maintenance Tips The possible faults may exists as follow 1 Idle air control valve not work 2 Check adjust bolt of throttle valve throttle cable throttle operating condition etc whether are in condition or not 3 Too dirty inside of throttle valve body 13 11 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 Maintenance Tips The possible faults may exists as follow 1 Check adjust bolt of throttle valve throttle cable throttle operating condition etc whether are in condition or not 2 Too dirty inside of throttle valve body 3 Check crankcase enforced air flue whether breaks off or leaks
127. ial tool from secondary sheave 6 35 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e 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 Check belt width with vernier caliper Damage width out of range Replace Belt width service limit 33 5mm Tool vernier caliper Caution If belt surface is stained with grease or oil degrease the belt thoroughly 6 36 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Transmission 2 2 Gp 3 S gt um 2 S Z Description Qty Description Qty 1 MAIN SHAFT GEARSHIFT 1 10 DRIVEN GEAR RANGE 1 2 SHIFT 1 11 DRIVEN GEAR LOW RANGE 1 3 1 12 SPRING SHIFT FORK 1 4 LEFT CRANKCASE 1 13 RIGHT SHIFT FORK 1 5 1 14 GUIDE BAR 1 6 SPROCKET REVERSE GEAR 1 15 DRIVEN SHAFT 1 7 CHAIN REVERSE GEAR 1 16 SPRING SHIFT FORK 1 8 DRIVEN OUTPUT GEAR 1 17 LEFT SHIFT FORK 1 9 DRIVE SECTOR GEAR 1 18 SHIFT FORKASSEMBLY 1 6 37 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Inspection Check main shaft gear and sprocket surface for any damage or over wear Damage or over wear Repl
128. inder from vehicle unless when replacing master cylinder assembly Note Do not hang master cylinder on brake hose Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position Refer to Chapter1 for proper routing of brake hose Check brake efficiency after installation 8 5 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Brake Pedal Removal Remove Bolt 1 and Nut 1 Bolt 2 and Nut 2 Spring 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 Keep the master cylinder in the installation position Refer to Chapter1 for proper routing of brake hose Check brake efficiency after installation Master Cylinder gt Bolt 8 6 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Front Left Suspension Bolt Shock Absorber 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 Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Nut to Bolt3 Nut to Bolt3 Bolt2
129. ine water temperature sensor observe engine whether succeed starting or not at this moment no next Draw accelerograph gently observe 1t whether starting yes Clean throttle valve 4 engine easily or not body and idle speed air duct no next Disassembly injector and check the injector by special yes Replace 5 washing analysis instrument if exists the phenomena of leaks or clogs no next Check fuel and observe the fault if caused after fueling yes Replace fuel Check compression of cylinder and observe pressure if yes Eliminate engine 7 it is discrepantly mechanism fault no next Contact EFI commutator open ignition switch check yes Diagnosis help ECUS 102 13 stitch the power whether supply 8 normally not check 2 21 stitch whether Put up iron dst no Examine and repair relevant wiring 5 Regularly rotate speed but engine starting hard at any time Possible defective part 1 fuel containing water 2 fuel pump 3 engine water temperature sensor 4 injector 5 ignition coil 6 throttle valve body and idle speed side air duct 7 input air duct 8 ignition timing 9 spark plug 10 engine mechanism part Overhaul Ref no Operation Test result Next Steps Check air cleaner and input air duct whether are clogged yes Examine and repair 1 not air input system no next 13 17 13 TROUBLESHOOTING
130. intenance 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 Interval Km Initial Every Every Remarks 250km 500 km 1000 km Item Hours Initial 20 Every 50 Every 100 hours hours hours Valve clearance I I IN 0 05 0 10 0 17 0 22 Idle Speed I I 1300 100r min 1400 100r min EFI Spark plug I I No carbon deposit R Every 6000km Gap 0 8 0 9mm Air Filter I C R every 20000km Fuel Hose carburetor I Clutch I R every 4 year Drive Belt 1 Oil Filter R R Oil change R R Coolant Level I I Water Hose amp Pipes I I Coolant R every 2 year I Check and adjust or replace if necessary R Replace C Clean 3 2 3 INSPECTION amp ADJUSTMENT Inspection amp Maintenance Interval Check Item Interval Standard Part Item Daily 1 2 Year Annual Steering Steering Operation agility O 9 System wheel Steering Damage O O System Installation O O condition of steering system Sway of ball stud O Brake pedal Free play O Pedal rear end System Brake Efficiency O Connecting Looseness rod oil pipe Slack and damage amp Hose Hydraulic Front and rear
131. justment e Keep the carburetor in a upside down position Measure distance from the mating surface of float chamber without gasket to the top of float Note The float arm should rest on the needle valve Do not compress the needle valve Float Height 10 1mm 7 5 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM e If float height 15 not within the specification check the valve seat and needle valve e If either of valve seat or needle valve is worn replace both e If both are fine adjust float height by bending the float tang Don the float e Measure float height again till it s within the specification Fuel Level e Place carburetor on a level surface Connect fuel level gauge D with drain pipe Tool Fuel Level Gauge e Loosen drain screw 3 e Keep fuel level gauge vertical next to the float chamber line and read the fuel level Fuel Level 3 5 0 5mm e Ifthe fuel level is not within the specification adjust the fuel level e Remove carburetor Check valve seat and needle valve e lfeither of valve seat or needle valve is worn replace both e If both are fine adjust float height by bending the float tang Don the float e Install carburetor Check again the fuel level Carburetor Assembly Reverse the disassembly procedure for assembly 7 6 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM Carburetor Installation D vacuum breather hose 2 cable 8
132. l Filter Wrench Engine Oil Capacity When replacing oil 1 9L When replacing oil filer 2 0 L Engine overhaul 2 2 L Inspection of External Oil Pipe Check external oil pipe for leakage or damage Leakage or Damage Replace 3 19 3 INSPECTION amp ADJUSTMENT External Oil Pipe 3 INSPECTION amp 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 If the level is below lower limit fill coolant until the level reaches the upper limit Replacing Coolant Remove radiator cap and reservoir tank cap 2 Place pan below water pump and drain coolant by removing drain plug water hose e Drain coolant from reservoir tank Warning Do not open radiator cap when engine 15 hot you may be injured by escaping hot liquid or vapor e Engine coolant is harmful If coolant splashes in your eyes or clothes thoroughly wash it away with water and consult a doctor If coolant is swallowed induce vomiting and get immediate medical attention Keep coolant away from reach of children Clean radiator with fresh water if necessary e Connect water hose and tighten drain bolt securely Fill the specified coolant into the radiator Loosen bleed on wa
133. l to starter clutch Apply thread locker to bolt and tighten to the specified torque Tightening torque of starter clutch bolt 26N m Material Thread Locker Install the starter driven gear e Make that the starter driven gear turns in the opposite direction of the arrow mark The gear cannot turn in the direction of the arrow Check starter driven gear bearing In case of anything unusual replace the bearing e Remove starter driven gear bearing with special tool Install starter driven gear bearing with special tool Tool Bearing Installer Remover 6 47 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Electric Starter Gear Check the gear surface for scrap or damage Scrape or Damage Replace LEFT CRANKCASE COVER e Check magneto stator coil 2 pickup coil 3 for damage burn or short circuit if any replace with new e Check bearing 4 for smooth turning If it is stuck replace with a new one Check oil seal 5 for damage Replace it if it s damaged Apply thread locker to the bolt when assembling Tightening torque for magneto coil bolt 10N m e Apply lubrication oil to bearing 4 and lubricant grease to lip of oil seal 5 when assembling Recoil Starter ES Thread Disassembly Locker 1 Recoil starter 2 Bolt 3 Washer 4 Starter pully Inspection Check sheave drum for burrs cracks or rust In case of any abnor
134. ll set Assembly Reverse the removal procedure of primary sliding and fixed sheave for installation Pay attention to the following e Apply grease to inner bore and oil seal lip Note Wipe off any excessive grease thoroughly Apply Lubricant Grease Take care not to attach any lubricant grease to contact surface of drive belt Material Lubricant grease e Position 8 rollers the primary sliding sheave Cam Damper Roller e Install 4 dampers 2 to cam 3 e Install cam to primary sliding sheave Notes When inserting the spacer press down the cam so that the rollers will not come out of position 6 31 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Install spacer Secondary Sheave Disassembly e 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 e Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle Note Make sure that spring end A 15 inserted into slot B of the tool handle Remove ring nut Tool Secondary sliding sheave spring compressor Note Since a high spring force applies to the secondary sliding sheave take special care that the secondary sliding sheave will not come off abruptly Slowly loosen tool handle and remove the special tool
135. lt 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 Drive bevel gear clearance measurement Install sup port tools tightening bolts M10 1 25 x60 put up dial indicator make sure 21 mm is between measuring point and support tools Turn support tools counter clock and read the data Standard 0 10 0 25 Adjust washer thickness 0 1 0 5 0 2 1 0 0 3 0 4 b Shift fork and drive clutch assembly should be against tightly to the arrow shape illustration 10 6 10 FRONT REAR AXLE 10 Use special equipment or vehicle control circuit into two stroke position before gear motor assembly POSITIONING SCREW M8 X 100 d Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle 10 7 10 Disassembly of rear axle Ref No Description QTY Ref No Description QTY 1 Bolt M10x 1 25x 25 2 17 Bevel gear bearing hous 1 2 Bolt M8x 25 4 18 O ring 64 5x 3 1 3 Rear gear case cover R 1 19 Bearing
136. mal replace 6 48 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Recoil Starter e Ifthe recoil starter works normally it s not necessary to disassemble it Cap Handle Handle Friction Plate Spring Clamp Sheave Drum Coll Spri Col rin DISASSEMBLY Remove nut 10 Remove parts from the starter housing WARNING The coil spring may quickly unwind and cause injury when the sheave drum is opened Wear proper hand and eye protection beforehand Inspection Check all the parts for damage Damage Replace 6 49 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Assembly e Reverse the removal procedure for installation and pay attention to the following e Install sheave drum 2 coil spring S damper 4 e Wind the rope clockwise around sheave drum three times and hook the rope at of sheave drum WARNING The coil spring may quickly unwind and cause injury when the sheave drum is opened Wear proper hand and eye protection beforehand Install coil spring Dand sheave drum 2 e Apply lubricant grease to spring e Hook coil spring end 8 to the starter housing wind the coil spring clockwise e Hook the other end of coil spring to hook part of sheave drum e Install spring clampQ friction plate 2 and bolt e Turn sheave drum three times for pretension of coil spring e
137. means defective on ECU If Trouble Code is not cleared put back original ECU and repeat inspecting procedure to start again overhaul inspections Troubleshooting Starting Failure Hard Starting Engine can rotate but will not start Hard Starting when hot Hard Starting when cold Hard Starting all the time Engine work s regularly but unsteady idle speed all the time Engine work s regularly but unsteady idle speed when engine is in warming up Engine starting normally but idle speed unsteady after warming up Engine starting normally but unsteady idle speed or power off when idles Engine starting regularly but idle speed 15 too high Rotate speed can not increase or engine power off when in acceleration Reaction slowly when in acceleration No power and poor performance when in acceleration 13 14 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 Operation Test result Next Steps Check the voltage between the two poles of battery yes next 1 by multimeter the voltage whether around 8 12V or not when engine starting Keep ignition switch in engine starting station yes next 2 Check positive pole of Starter motor by multimeter no Repair or replace the voltage whether above 8V or
138. merical mutimeter it is forbidden to use pointer type multimeter to make EFI system inspecting 3 When Trouble Code tells Low Voltage means probably it s Short Circuit to Ground or Broken Circuit When Trouble Code tells High Voltage means probably it s Short Circuit to Power When Trouble Code tells Circuit Error means Circuit Broken or Various Errors Exist Diagnosis Help 1 Trouble Code cannot be cleared means trouble is steady state Focusing on the connector wires possible looseness if trouble is incidental 2 When making inspections do not ignore possible affect from vehicle maintenance condition cylinder pressure mechanism timing 3 If Trouble Code is cleared it means defective on ECU If Trouble Code is not cleared put back original ECU and repeat inspecting procedure to start again overhaul inspections Following are implications of EFI System Trouble Code Diagnosis Measurements Possible Reasons and their Solutions as references 13 5 13 TROUBLESHOOTING Trouble Code P0030 Oxygen Sensor Heating Control Circuit Broken Note Possible Troubles are as below 1 Circuit broken between ECU Pin and Oxygen Sensor Pin 2 2 Circuit broken between Oxygen Sensor Pin 1 and Main Relay 3 Circuit broken between Oxygen Sensor Pin 1 and Pin 2 Note Inspect as below 1 Check if resistance between ECU Connector Pin and Oxygen Sensor Pin 2 is normal or not 2 Check if resistance between
139. moving the switches from the vehicle After the inspecting and overhauling of each part cables and wires should be routed properly chapter 1 Refer to Chapter 2 for removal and installation of taillight and rear turning lights Overhaul Standard Item Standard Mail switch fuse 30A Fuse Sub fuse Headlight 12 V 35 W 35W x 2 Brake light Tail light Light bulb Turning light 12V 5 Wx 2 Dashboard Indicator Indicators 12 1 TROUBLESHOOTING Head Light Cannot Turn On e Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch 12 2 12 LIGHTING AND SWITCHES 12 LIGHTING AND SWITCHES Replacing Bulb Headlight 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 Dust Cover Headlight Disconnect headlight Remove dust proof cap headlight connector circlip and replace with a new bulb Warning Wear clean gloves when replacing bulb Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate e Make sure that the three pins of the bulb should be in line with the three positioning holes in the socket when replacing the bulb Bulb specification 12 V 35 W 35W Reverse the removal procedure for installation After r
140. nstall the bolt 2 tighten it to the specified torque Chain tensioner bolt tightening torque 10 N m e After chain tensioner is installed turn the screwdriver counter clockwise The tensioner rod will be advanced under spring force and push tensioner against chain 6 67 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Install the new gasket 3 e Install chain tensioner screw tighten it to the Specified Torque Chain tensioner screw tightening torque 8 Valve Adjuster Cover Refer to 11 3 for valve clearance Use new rubber gasket and apply grease e Install Valve Inspection Cap e Install valve inspection cap bolt Spark Plug e Install spark plug with special tool and tighten to the specified torque Note To avoid damage to the cylinder head thread screw in the spark plug with hand first then tighten it to the specified torque with spark plug wrench Spark plug tightening torque 18N m Tool Spark Plug Wrench Engine Periphery Recoil Starter e Install recoil starter Apply thread locker to the bolts and then tighten Valve Inspection Cap Install valve inspection cap 6 68 Left Plastic Cover e Install left plastic cover 6 Water Pipe and Hose e Install water hose 5 Install bolt 4 e Install water hose 3 Install clamp 1 and 2 6 ENGINE REMOVAL INSPECTION amp INSTALLATION 6 69 7 CARBURETOR FUEL SYSTEM AIR INTAKE SYSTEM
141. nstruction tells you to run the engine be sure your hands fingers and clothing are out of the way Gasoline vapors and hydrogen gases from batteries are explosive To reduce the possibility of a fire or explosion be careful when working around gasoline or batteries e Use only a nonflammable solvent not gasoline to clean parts e Never drain or store gasoline in an open container Keep all cigarettes sparks and flames away from the battery and all fuel related parts Conversion Table Item Example Conversion Pressure 200Kpa 2 00kgf cm Ikgf cm 98 0665 33kpa 250mmHg Ikpa 1000pa ImmHg 133 322Pa 0 133322Kps Torque 18N m 1 8kgf m m 9 80665N m Volume 419ml cm 1 1 1000 12N 1 2kgf Ikgf 9 80665N 1 2 1 SERVICE INFORMATION Identification number records Record the vehicle identification number and engine number in the spaces provided for assistance 1 when ordering spare parts from your dealer or for reference in case the vehicle is stolen ENGINE NUMBER mh VIN NUMBER Vehicle Identification Number SOOUTV LCXRSTS1 Vehicle Identification Number SOOLUTV LCXLSTS1 Vehicle Identification Number 500UE LCXRSTS3 Vehicle Identification Number 500UEL LCXLSTS3 Engine Number CF188 Engine Number EFI CF188 B NOTE The vehicle identification number is used to identify your machine 1 3 1 SERVICE INFORMATION
142. nut 180 200N m 18 3kgf m 20 3kgf m Sway of Wheel Bearing Lift the front wheel Make sure there 15 loading on the vehicle shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspension System Park the vehicle on lever place press the vehicle Several times up and down as illustrated on the right In case of any rocking or abnormal noise check whether there is any oil leakage from absorbers or any damage or looseness of tightening parts 3 10 3 INSPECTION amp ADJUSTMENT AXLE NUT 3 INSPECTION amp 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 rod Fuel Device Status of the fuel system Remove the seat 2 6 Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check if there is cracks or bending with the vacuum tube Cracked or bended vacuum tube Replace 3 11 CLOCKWISE FUEL HOSE FUEL FILTER 3 INSPECTION amp 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
143. o the speed sensor hole 1 of left crankcase to fix the drive bevel gear e Install special tool 3 and micrometer Tool Bevel gear side clearance dial gauge Micrometer a 46mm e Turn the driven bevel gear in each direction and measure the backlash NOTE Measure four points in the mutual vertical direction e Ifthe backlash is not within the specification adjust the thickness of the driven bevel gear adjust washer Re check the backlash until the backlash is correct Bevel Gear Backlash 0 1 0 2mm Adjustment Measured Backlash Washer Thickness Adjustment lt 0 1mm Decrease washer thickness 0 1 0 2m Correct gt 0 2mm Increase washer thickness 6 44 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Tooth Contact e 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 Coat the driven bevel gear with machinist s layout dye or paste Install drive and driven bevel gear e Rotate the driven bevel gear several turns in both directions Remove drive and driven bevel gear shafts and check the coated teeth of the drive bevel gear e Refer to the illustration on the right for tooth contact pattern 1 and D Incorrect contact at tooth top 2 Correct 3 Incorrect contact at tooth bottom e If
144. of Signal Circuit connect to ECU Pin Trouble Code P0133 Oxygen Sensor Aging Explanation Normally Air Fuel Ratio of Fuel and Air is shifting between Dense and Dilute accordingly Oxygen Sensor signal variate among different values When Oxygen Sensor is aging it goes less sensitive to Fuel Air Mixture which makes signals variate lower ECU makes average cycle calculations to Signal Variation when it finds cycling slower as set it decides Oxygen Sensor Aging Note Possible Troubles are as below 1 Oxygen Sensor Aging need replacement Trouble Code P0134 Oxygen Sensor Signal Failure Explanation When engine starts ECU check the Oxygen Sensor Circuit Voltage When ECU finds voltage stays between 0 4 0 6 volt it decides Oxygen Sensor Signal Circuit Short Note Possible Troubles are as below 1 Short Circuit between Oxygen Sensor connected to ECU Pin 2 Bad connection of Oxygen Sensor Connectors Socket Oxidized Note Inspect as below 1 Check resistance between connector and Oxygen Sensor 4 Trouble Code making End o f Line Testing P0170 Self Studying found Closing Loop control Air Fuel Ratio irrational when Trouble Code P0171 Self Studying found Closing Loop control Air Fuel Ratio too dulate when making End o f Line Testing Trouble Code P0172 Self Studying found Closing Loop control Air Fuel Ratio too dense when making End o f Line Testing Note This Insp
145. on Reverse the removal procedure for Installation Screw 3 2 9 2 VEHICLE BODY MUFFLER Fender cargo box R Fender cargo box R Remove Remove screw Remove fender cargo box R Installation Reverse the removal procedure for Installation Cargo box Cargo box 1 Bolt 2 Remove Remove nut 1 Remove bolt 2 Remove cargo box Installation Reverse the removal procedure for Installation 2 10 2 VEHICLE BODY MUFFLER Side door LH 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 2 VEHICLE BODY MUFFLER Bumper Remove Remove bolt 1 Remove bumper Installation Reverse the removal procedure for installation Bumper Fuel tank Remove Remove skid plate L gt 2 8 Loosen fuel pipe Loosen fuel sensor connector Remove bolt 2 Remove fuel tank Installation Reverse the removal procedure for installation 2 12 2 VEHICLE BODY MUFFLER Headrest driver Driver headrest Remove Remove nut 1 Remove headrest driver Installation Reverse the removal procedure for Installation Passenger headrest Headrest passenger Remove Remove nut 2 Remove headrest passenger Installation Reverse the removal pro
146. onds e Ifthe cap cannot meet the pressure requirement replace it Radiator Cap Valve Opening Pressure Standard 108 kPa Tool Radiator Cap Tester Radiator Inspection and Cleaning Remove dirt or trash from radiator with compressed air e Correct the radiator fins with a small screwdriver Radiator Hose Inspection Check radiator hoses for leakage or damage Leakage or Damage Replace e Check tightening of clamps Replace the clamps if necessary e After inspection and cleaning of radiator and hoses check coolant level Fill coolant if necessary 4 4 4 COOLING AND LUBRICATIING SYSTEM Inspection of Fan Motor Remove fan motor from radiator e Turn the vanes and check if they can turn smoothly 1 t Fan Motor 5 Thermoswitch 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 If the motor does not run or the ampere exceeds the limit replace the motor e Installation Apply a little thread locker to the bolts and tighten to the specified torque Fan Motor Bolt Tightening Torque 10N m Inspection of Thermoswitch e Remove thermoswitch Check the thermoswitch for closing or opening by testing it at the bench as illustrated Connect the thermoswitch to the circuit tester place it in a vessel with engine oil Place the vessel above a stov
147. onnecting rod small end I D 23 040mm Tool Dial Gauge 18 35mm Connecting Rod Deflection Check the movement of the small end of the rod and inspect the wear of the small end This method is also applicable to check and inspection of big end Connecting Rod Deflection 3 0mm Tools Dial Gauge Magnetic stand V block Connecting Rod Big End Side Clearance e Push the big end to one side and use thickness gauge to measure the other side clearance Ifout of limit replace with a new crankshaft Connecting Rod big end side clearance 1 0mm Tool Thickness Gauge Crankshaft Run out e Support crankshaft with V blocks as illustrated Put the dial gauge slowly turn the crankshaft and measure run out with a dial gauge e Ifthe run out exceeds the limit correct or replace the crankshaft Run out limit 0 08mm Tools dial gauge Magnetic stand V block 6 27 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Clutch Clutch Shoes Check clutch for chipping scrape uneven wear 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 Clutch Wheel Check the inner clutch wheel 1 for scratches scuffs or blue discoloration or uneven wear If any damage is found replace the clutch wheel with a new one Check oil seal lip for wear or damage Wear or Damage Replace e Use
148. or replace muffler Contact with EFI commutator open ignition switch yes Diagnosis help 12 check ECUS 108 23 stitch the power whether supply normal or not check 2 21 stitch whether is no Examine and repair putting up iron or not relevant wiring 13 24
149. ote Use a new cylinder gasket to prevent oil leakage 6 63 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Cylinder e Apply engine oil to piston skirt and cylinder wall e Hold each piston ring with proper position insert piston into the cylinder e 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 e Install chain guide 0 e Fit the dowel pin and new cylinder cover gasket Note Use a new cylinder cover gasket to prevent oil leakage Cylinder Head e Install the cylinder cover tighten the cylinder head bolts diagonally to the specified torque Cylinder head bolt tightening torque Initial 25 N m Final 38 e Tighten the cylinder head nuts to the specified torque Cylinder head nuts tightening torque M6 10 N m 8 Initial 10 Final 25 Tighten the cylinder top nuts and cylinder base to the specified torque Tightening torque 10 N m 6 64 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION e Install chain tensioner Camshaft e 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 e Align the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head Note
150. peration of the drive train To Ignition Coil I Initial Engagement Inspection e Connect tachometer to ignition coil e Start engine e Shift gear lever to High position e Slowly increase throttle and note down the engine speed r min when the vehicle starts to move forward Engagement speed 1800r min 2400r min If the engagement speed is out of the above range check the following e Clutch shoes Clutch shoe wheel Primary and secondary sheave Refer to Chapter 12 for inspection of clutch II Clutch Lock up Inspection e Connect the tachometer to ignition coil Start the engine Shift gear lever to High position Apply front and rear brakes as firmly as possible Fully open the throttle for a brief period and note the maximum engine speed obtained during the test cycle Lock up Speed 3300r min 3900r min Warning Do not apply full power for more than 5 seconds or damage to clutch or engine may occur If the lock up speed is out of the above range check the following e Clutch shoes Clutch wheel e Primary and secondary sheave Refer to Chapter 12 for inspection of clutch Tool Tachometer 3 23 4 COOLING AND LUBRICATIING SYSTEM Cooling System 42 rn ees 4 2 Engine oot soon DIU End 4 3 Inspection of Cooling E a 4 3 Inspection and Cleaning of Radiator and Water Hoses 4 4 Inspection of Fan iurc Er tH
151. ply normal or not check 2 21 stitch whether is putting Examine and repair piron relevant wiring 10 Engine starting regularly but idle speed is too high Possible defective part 1 throttle valve body and idle speed side air duct speed valve 4 engine water temperature sensor 5 ignition timing 2 injector seat 3 idle Overhaul Ref no Operation Test result Next Steps Check the throttle cable if is clipped or too tight yes adjust 1 next Check air intake system and connector of injector yes Examine and repair 2 seat the air if is leaking air intake system no next Disassembly idle speed valve and check the throttle yes Clean related parts 3 valve body idle speed valve and idle speed side air duct whether have carbide accumulated or not no next Pull out connector of engine water temperature yes Examine and repair 4 sensor starting engine observe idle speed whether is wiring or replace unsteady or not when engine is in warming up sensor no next Check engine ignition timing if accords with yes next 3 standard no examine and repair ignition timing 13 21 13 TROUBLESHOOTING Contact with EFI commutator open ignition switch check ECUS 107 23 stitch the power whether supply normal or not check 2 21 stitch whether is putting up iron or not yes Diagnosis help no Examine and repair relevant wiring
152. r L 48 Rear mirror RH Remove Remove rear mirror R 49 2 16 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 2 17 Cargo box Remove Remove nut 3 Remove side support L 1 Installation Reverse the removal procedure for Installation Rear side support R Remove Remove nut 3 Remove rear side support 8 Installation Reverse the removal procedure for installation Protector L dump box Remove Remove bolt 3 and bolt 4 Remove protector L cargo box 2 2 VEHICLE BODY MUFFLER B 15 16 17 3 45 2 28 Installation Reverse the removal procedure for installation Protector R cargo box Remove Remove bolt 3 and bolt 4 Remove protector R cargo box 7 Installation Reverse the removal procedure for installation Bracket cargo box Remove Remove nut driver 30 Remove bracket cargo box 21 Installation Reverse the removal procedure for installation 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 Per
153. r 9 and tighten to the specified torque e Reverse gear sensor tightening torque 20N m e Install speed sensor 24 e Install oil pipe and tighten the link bolt to the specified torque Link bolt tightening torque 18M m Install washer 26 and oil drainage bolt 27 and tighten to the specified torque Drain bolt tightening torque 30N m Tool Bearing Remover Bearing Installer Multimeter III Engine Assembly Reverse the engine removal procedure for installation Caution Clean all the parts before assembly Make sure that the parts are in good condition without any damage Apply engine oil to the moving parts before assembly Apply grease to oil seal lip and O ring Caution Make sure that drive belt primary and secondary sheaves are not stained with grease Engine Center Oil Pump and Relief Valve oe A S e Install oil pump and relief valve to left crankcase as e 1 Left Crankcas illustrated on the right Tighten to the specified 2 Oil Pump tordue 3 Oil Pump Washer OTUS 4 Pressure Strip Relief Valve 5 Relief Valve Oil pump bolt 10N m Relief valve bolt 10N m 6 53 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Connecting Rod e Install connecting rod to left crankcase with special tool Note e Donot hammer the conrod into crankcase with plastic mallet e Use special tool to avoid affect of conrod precision Tool Conrod Installer Balancer Shaft e Install balancer shaft Ca
154. readings from several places If any clearance reading is out of the service limit replace with a new cylinder head Cylinder Head Distortion Service Limit 0 05mm Tool Thickness Gauge Valve Seat Width Coat the valve seat with color uniformly Fit the valve and tap the coated seat with the valve face in a rotating manner To get a clear impression of the seating contact use a valve lapper to hold the valve head The ring like dye impression the valve face should be continuous without any break The width of the dye ring which is the visualized seat width should be within the following range Valve Seat Width 0 9 1 1mm Tool Valve Lapper Valve Stem and Valve Guide e Lift the valve about 10mm from valve seat Check the valve stem deflection in the directions of X and Y perpendicular to each other with a dial gauge If the deflection measured is out of the limit replace either the valve or the valve guide If the valve stem is worn to the limit and the clearance is found to be in excess of the limit replace the valve If the valve stem is within the limit replace the valve guide Double check the clearance after replacing the valve stem or the guide Valve Stem Deflection IN amp EX 0 35mm Tool Micrometer Magnetic Stand 6 17 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Valve Stem O D e Measure valve stem O D with a micrometer Service Limit IN 4 975 4 990mm EX 4 955 4 970mm Tool Mi
155. rect bring it into the specified range using the special tool Loosen valve adjust bolt and nut insert a feeler gauge between the valve stem end and valve adjusting bolt tighten valve adjust bolt make sure it slightly contacts the feeler gauge tighten bolt and nut 3 13 3 INSPECTION amp 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 x gt Caution 7 Securely tighten locknut after completing adjustment Install 2 valve adjusting cover Inspection cap Recoil starter Cover plate Apply a small quantity of THREAD LOCKER to recoil starter fixing bolts 1 Nut 2 Valve Adjust Screw 3 Rocker Arm 4 Valve Tools Valve adjuster Feeler gauge Material Thread Locker To Ignition Coil ENGINE IDLE SPEED Inspect initially at 20 hours run in and every 40 hours or 1000km thereafter Start the engine and warm it up for several minutes measure engine speed with a tachometer Set the engine idle speed between 1200 1400 r min by turning the throttle stop screw of carburetor Engine idle speed 1300r min 100r min Note Make this adjustment when the engine is hot Tool Tachometer SPARK PLUG Inspect initially at 20 hours run in and every 80 hours or 2000km thereafter Replace every 6000km Remove the spark plug with a
156. rzeppa constant velocity joint cannot turn freely because of the loss of control of wheel steering Installation Press ball pin into arm with special tool Reverse the removal procedure for installation Note No shaking with the installed left and right arms Replace arms if any Tightening Torque 45 50N m 8 11 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 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Rear View Mirror 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 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Steering Stem Removal Remove Steering wheel 2 2 cover steering stem gt 2 2 Combination switch 2 3 Bolt Shaft assy steering joint Steering stem Shaft assy steering joint 8 14 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 8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING Installation of Steering Wheel Install steering whe
157. shaft nut tightening torque 97N m Driven Bevel Gear Remove nut 19 washer 18 coupler 17 and oil seal 16 e Protect end thread of driven bevel gear with proper Device 2 Fix bevel gear cover 14 and press out driven bevel gear Place a clean rag 1 under bevel gear cover Remove bearing limit nut 10 with special tool and remove bearing Check driven bevel gear 8 surface for scratches wear Scratch or wear gt Replace e Check free turning of bearing 9 and 11 Replace with a new one if any abnormal is found e Use new oil seal 16 and O ring 12 when assembling Adjust washer 13 if any of right crankcase driven bevel gear 8 or driven bevel gear cover 14 is replaced Refer to bevel gear adjustment for details Apply lubrication oil to bearing 9 and 11 and oil seal 16 O ring Apply thread locker to nut 10 and tighten to the specified torque Tightening torque 110N m Tool driven bevel gear nut wrench Driven bevel gear nut tightening torque 150N m Bevel Gear Washer Adjustment e Adjust washer D and 2 when replacing crankcase and or bevel gear and or bevel gear cover 6 43 6 ENGINE REMOVAL INSPECTION amp 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 e Install drive and driven gears to the crankcase Wrap a screwdriver with a rag 2 and insert it int
158. sioner for any damage or poor function Damage poor function Replace e Insert screw driver into the slotted end of adjusting Screw turn it clockwise to loosen the tension and release the screwdriver e Check the push rod movement If the push rod is stuck or there is a failure with spring mechanism replace the chain tensioner with a new one Cylinder Cylinder Distortion e Check the gasket face of cylinder for distortion with a straightedge and thickness gauge and take clearance readings at 7 points as illustrated If the largest reading at any of the 7 points of the straightedge is out of the range replace the cylinder Cylinder Distortion Service Limit 0 05mm Tool Straightedge Thickness Gauge Cylinder Bore Check cylinder wall for scratches nicks or other damage Replace with a new one if any e Measure cylinder bore diameter at three points of upper middle and lower Standard Cylinder Bore 87 500 87 522mm Tool Cylinder Gauge Set 6 24 6 ENGINE REMOVAL INSPECTION amp 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 Calculate the piston to cylinder clearance according to the above measurement e Ifthe clearance is more than 0 15mm replace the cylin
159. special tool to remove oil seal Tool Oil seal remover e Use special tool to assemble oil seal Tool Oil seal installer set e Check the turning of bearing Abnormal damage Replace Oil Seal Assembly e Apply lubricant grease to oil seal when assembling 6 28 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Primary and Secondary Sheave 6 2 Secondary Sliding 2 Damper 4 pcs Sheave Nut Primary Sheave 8 Spacer 12 Guide Pin 4 pcs B Nut Secondary Sheave O Ring Nut Secondary Sheave 4 Roller 8 pcs 3 Spacer 4 pcs 5 Seal 2 pcs 4 O ring 2 pcs 8 Primary Sliding Sheave 15 Spring Seat Drive Belt 16 Spring Primary Fixed Sheave I7 Spring Plate 9 Secondary Fixed Sheave 6 29 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Primary Sliding Sheave Disassembly e Remove spacer Remove Roller 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 e Check oil seal lip for wear and damage Wear and damage Replace e Remove the oil seal 6 30 6 ENGINE REMOVAL INSPECTION 4 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 insta
160. t Arm Note This vehicle has 6 rocket arms The removal disassembly inspection and installation of the 6 rocket arms are the same This service manual will only introduce the removal disassembly inspection and installation of Front Right Arm Lower Refer to Front Right Arm Lower for removal disassembly inspection and installation of other rocket arms Front Right Arm Removal Remove Front right shock absorber 8 8 Bolt 8 and Nut16 Bolt7 27 and Nut3 29 Bolt6 28 and Nut2 30 Remove wheel brake caliper and wheel hub be fore removing shock absorber Remove steering rod before removing bolts Pull out steering knuckle from constant velocity drive shaft before removing front right arm Remove Front Right Arm 8 9 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 Replace Check wheel hub bearing for free turning and clearance Bearing cannot turn freely or clearance out ofrange Replace I BOLT 10 1 25 30 2 WHEEL HUB 16 NUT MI2 17 BUFFER COVER 18 3 GRIP BRAKE 4 HOOP 5 BEARING L FR LOWER SWING ARM 19 R FR LOWER 6 TRIFURCATE SHAFT LEFT 7 TRIFUR SWING ARM SHAFT RIGHT
161. t in cleaning solvent and wash it Press the filter element between the palms of both hands to remove the excess solvent Do not twist or wring the element or it will tear e mmerse the element in engine oil B and then squeeze out the excess oil leaving the element slightly wet 3 15 3 INSPECTION amp 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 The surest way to accelerate engine wear Is to operate the engine without the element or with torn element Make sure that the air filter element is in good condition at all times Remove the drain plug of air box to drain any water Fuel Hose Inspect every 80 hours or 2000 km replace every 4 years Inspect the fuel hose for damage and fuel leakage If any damages are found replace the fuel hose with a new one Drive Belt Removal Remove CVT cover Hold the primary sheave with special tool and loosen primary sheave nut Special Tool Rotor Holder Remove primary sliding sheave 1 Hold the secondary sheave with special tool and loosen secondary sheave nut Remove secondary sheave together with drive belt Special Tool Rotor Holder Remove drive
162. t intermittently short circuit or intermittently open circuit 2 Fixed position of crankshaft signal ring deviation declination 3 Fixed position of rotate speed sensor declination Maintenance Tips Check the items as follow 1 Check the connection or breaking of cable related connection 2 Check the quantity of magneto flywheel Errors coding P0322 Non rotate speed sensor pulse signal short circuit or open circuit Explanation After starting engine ECU will measure signal of trigger and other signals together judging the losing of trigger signal by signal rationality system Maintenance Tips The possible faults may exists as follow 1 Trigger rotate speed sensor ECU cable connected open circuit 2 Trigger circuit ECU connected short circuit 3 Trigger coil open circuit Maintenance Tips 1 Measure resistance between trigger and ECU cable connected 2 Measure resistance of trigger 3 Measure trigger peak value voltage Errors coding P0444 Control circuit voltage of idle air control valve open circuit Maintenance Tips The possible faults may exists as follow 1 Open circuit between ECU circuit connected and no 2 pin of idle air control valve 2 The circuit that no 1 pin of idle air control valve connected to main relay open way 3 Electromagnetism coil between 1 pin and no 2 pin open way Maintenance Tips 1 Check connection or breaking of cable related conn
163. te 05 Late Mots a 1 05 55 me E 2 E 5 MNT o Me ts wes TS ae n Malfunction lar LI tenperatwre ig os 61 15 ter tera Ae mm Tuque ages UV 05 me 10000000004 a os TN E wis esl cy DSTI jg 8 Paring Ut teh 085 ir 065 s 5 0315 a05 dide Left turn signal turn sorai PI aN gt fight suen sign wn oss ih ten in Lus 5 ean sut cor AU D im 9 switch ie wring coer 00805 5 8 ight woes vaas 3 o 05 D 185 5 vids wy us 05 05 3c 4 3 99 lights 4 vas p e Poston its 15 E as ign 05 qae 05 a E i E i gardes ey 085 EN MD ies vim I i 8 ig 95 vibe 05 05 le E 55 ns 085 GA 65 P gt 13 5 81 1 wv os kas P crv ass c tis qe 1 om Hg P oF 2 i 1 zi DX mm 140009 80009 18000 40005 12 LIGHTING AND SWITCHES Overhaul 12 1
164. tention to the direction of the retainers Fit to the side where the thrust is as illustrated Coat gears and shafts with engine oil before assembly Note Do not reuse the retainers Do not expand of the gap end of new retainers too Sharp Edge wide when assembling Make sure that all the retainers are properly fitted 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION When assembling the guide bar take care not to assemble the two shift forks and springs in the opposite direction UD 1 Guide bar 2 Retainer 1 3 shift fork 4 Shift fork Spring small 5 Right shift fork 6 shift fork spring big N 7 Spring seat OIL PUMP Disassembly oil pump as illustrated 1 Oil pump housing 2 Dowel pin 3 pump shaft 4 Straight pin 5 Inner rotor oil pump 6 rotor oil pump 7 Oil pump cover Check oil pump housing and cover for cracks and damage Crack or damage Replace Measure top clearance between inner and outer rotors and side clearance b between outer rotor and oil pump housing If the clearance exceeds the limit replace with new one Top Clearance 0 03 0 10mm Service Limit 0 15mm Side clearance 0 03 0 10mm Service Limit 0 12mm 6 41 6 ENGINE REMOVAL INSPECTION 4 INSTALLATION Oil strainer e Check oil strainer and O ring 2 for damage Damaged oil strainer Replace e Clean the surface
165. ter pump when coolant flow from bleed bolt tighten the bolt Install radiator cap securely after filling coolant Start the engine and keep it running for several minutes After warm up and cooling down the engine open radiator cap and check coolant Fill the specified coolant until the level is between the upper and lower lines on the reservoir tank Caution Repeat the above procedures several times and make sure the radiator is filled with coolant and air is discharged 3 20 3 INSPECTION amp 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 e Excessive wear of cylinder e Wear of piston or piston ring 1 Piston ring jam in groove e Poor closure of valve seat Damaged cylinder gasket or other defects Note When cylinder pressure too low check the above items Testing Cylinder Pressure Note Before testing of cylinder pressure make sure that cylinder head bolts are tightened to the specified torque and valve clearance has been properly adjusted Warm up the engine before testing Make sure battery is fully charged Remove spark plug 1 Install cylinder pressure gau
166. the bodywork Don t damnify the frame body of Engine bolt and cable etc e Please blind up the frame when removal the engine e Don t removal engine from the bodywork when operating as follows OIL PUMP CARBURETOR AIR FILTER COVER CYLINDER HEAD CYLINDER HEAD CYLINDER CAMSHAFT CVT SYSTEM LEFT SIDE COVER DECELERATE BOX RIGHT SIDE COVER AC MAGNETO WATE PUMP PISTON PISTON RING PISTON PIN e Separately the engine from the bodywork when operating as follows CRANKCASE TIGHTEN TORQUE INSTALL BOLT UNDER ENGINE 50 60N m JOINT NUT OF CUSUION MAT 45 50 5 1 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 Oil hose Water inlet hose of engine Remove bolt Remove shift of gearshift Remove hoop Remove water outlet hose of engine HOOP water outlet hose of engine Remove magneto connector speed sensor connector trigger connector water temperature sensor connector gear position sensor and so on Bush Connector 5 2 5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT Remove spark plug Separate jacket of starter relay remove nut remove anode cable of starter relay Anode cable Cathode cable of starter rely of starter rely Remove bolt and cathode
167. tooth contact is correct Contact continue the next procedure e If tooth contact is not correct 2 and adjust the thickness of washer of drive bevel gear Repeat above steps to check tooth contact until it is correct Adjustment Tooth Contact Washer Adjustment Contact at tooth top Increase Thickness Contact at tooth Decrease Thickness bottom 8 Note e After adjusting the tooth contact the backlash must be checked again e Ifthe backlash is adjusted but tooth contact is still out of specification replace the drive and driven bevel gears Both tooth contact and backlash should be within the required specification 6 45 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Balancer Shaft e Remove the parts as illustrated on the right Check each part for abnormal wear or damage Wear or damage Replace Balancer shaft gear Woodruff key Balancer shaft Balancer shaft sprocket Washer Bolt 0 8 Magneto Rotor e Remove starter clutch nut 6 46 6 ENGINE REMOVAL INSPECTION 4 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 15 in the right direction Face arrow mark to the engine side Apply engine oi
168. tor and make sure distance from indicator Adjust washer Sea point tomeasuringtoolcenteris22mm Counter clock 24 thickness turn the toll and read the data 10 10 10 Adjust 29 as illustrated and Driven Bevel Gear make sure its end and back clearance of drive gear is 0 3 0 6 Tighten item 31 10 11 11 ELECTRIC SYSTEM CHARGING SYSTEM is sessascccescccdensecdsnsseneessseesdstewsseosncdeacecedeccsenstscesseecgseensedeadevess 11 1 ELECTRIC STARTING 11 3 ELECTRICITY SPRAYING 5 8 eese restes 11 8 1 ELECTRICITY SPRAYING SYSTEM 2 11 8 2 ELECTRICITY SPRAYING SYSTEM 11 9 3 ELECTRICITY SPRAYING SYSTEM MAINTENANCE 11 9 4 MAINTENANCE 1 11 10 5 ELECTRICITY SPRAYING SYSTEM COMPONENTSCOMPOSITION amp FUNCTION 11 12 OU a a E sees 11 12 THROTTLE ASSEMBLY o orreri seiirt Enie Tut E EEEE ENESE ETETEN 11 13 INLET PRESSURE 5 5 ae 11 14 INTAKE AIR TEMPERATUR 5
169. ture A fixture then remove the left side cover 1 Remove oil dip rod 2 Clean oil dip rod insert oil dip rod but do not tighten it e Take out oil dip rod and check if oil is between upper and lower limit e If the engine oil is insufficient fill more oil until the sufficient oil is obtained Engine Oil SAE10W 40 classification SF or SG gt a Upper Limit Note Lower Limit Keep the engine in a plan position Do not tighten oil dip rod when measuring oil level Replacing Engine Oil Remove left side cover 1 oil dip rod 2 drain bolt 3 and washer 4 e Drain out the engine oil while the engine is still warm Clean oil dip rod drain bolt and washer with solvent Install washer and drain bolt Drain Bolt 30 N m Fill engine oil about 1900ml Install oil dip rod start the engine and allow it to run for several minutes at idling speed e Turn off the engine and wait for about 3 minutes and then check the oil level on the dipstick 3 18 The engine oil should be changed when 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 Remove oil filter with the special tool Install washer and drain bolt Install new oil filter with the special tool e Fill engine oil about 2000ml and check see Replacing Engine Oil Tool Oi
170. ubles according to engine fault 13 1 13 TROUBLESHOOTING 1 Engine troubleshooting Complaint Compression is Too Low Engine will not start or is hard to start Symptom and Possible Causes 1 Worn cylinder 2 Worn piston ring 3 Leakage with cylinder gasket 4 Wear valve guide or improper valve seating 5 Loose spark plug 6 Slow cranking of starting motor 7 Faulty valve timing 8 Improper valve clearance No Spark from Spark Plug 1 Fouled spark plug 2 Wet spark plug Remedy Replace Replace Replace Repair or Replace Tighten Check electrical part Adjust Adjust Clean or Replace Clean and dry or replace 3 Defective ignition coil Replace 4 Open or short circuit with pickup coil Replace 5 Faulty generator Replace 1 Improper valve clearance Adjust 2 Improper valve seating Replace or Correct 3 Faulty valve guide Replace Engine stalls easily or 4 Worn rocker arm or rocker arm shaft Replace has unstable idle 5 Fouled spark plug Replace speed 6 Improper spark plug gap Replace or Adjust 7 Faulty ignition coil Replace 8 Clogged idle vale inlet amp exhaust pipe Adjust Fuel level 9 Faulty magneto Replace 13 2 13 TROUBLESHOOTING Complaint Symptom and Possible Causes Remedy 1 Weak valve spring Replace 2 Worn camshaft Replace Poor engine 3 Fouled spark plug Clean or replace running in 4 Insufficient spark
171. uit on 1 Measure resistance or voltage of MIL circuit of MIL lamp driver connected to ECU lamp driver control circuit connected to ECU 2 Open circuit between MIL and main relay 3 MIL lamp burnout 13 12 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 When the engine occurs parts manufacturing deviation deposition of fuel colloid on fuel injector intake or back of valve gas leak of intake and exhaust system will cause the air fuel ratio 14 7 1 deviation in various degrees partial dilute or partial concentration which will lead to emission deterioration and poor engine performance Engine control system will amend and self learning fuel charge based on the extent and character is tics of air fuel ratio deviation When self learning value reach the limit of system setting gas mixture partial dilute or partial concentration system amends the fuel charge constantly till Max system will judge that self learning value transfinite fault Maintenance Tips The possible faults may exists as follow 1 Injector clog needs cleaning 2
172. uring status rollway stellball bearing as well Replace bearing if necessary Special tools are required Check worn status of drive bevel gear and ring gear rear axle Replace if necessary Check oil seal lips o ring shape Replace parts if necessary Check cylIndrical surface of rear axle and oil seal lips Replace if necessary Check inner and outsider spline Replace if necessary Check other parts Replace if necessary 10 9 10 Rear axle assembly and adjustment e Illustration eee torque Item 1 40Nm d NY Item 2 25Nm dug 12 70Nm A mm7 Item 15 25Nm 20 70Nm 7 S S VN Item 31 16Nm T Bolt 25Nm Bolt 25Nm Use glue for Item 29 assembly Assembly clearance and adjustment of drive bevel gear assembly rear axle a Adjust installing by 24 thickness b Adjust gear clearance by choosing 6 thickness c Inspect installing clearance by check ing bevel gear clearance Standard 0 1 0 2 of Keep installing point bearing clear M14x1 25x60 ance 0 1 0 2 by choosing 8 thickness 6 02 03 04 d Drive bevel gear clearance measure ment thickness illustration see above Install measuring 48 1012141618 tools tightening torque M14 x1 25x60 Put up dial thickness indica
173. ution Balancer shaft driven gear should be aligned to the mark as illustrated Main Shaft Counter Shaft e Install main shaft and counter shaft 6 54 Drive Gear Crankshaft Balancer Driven Gear Crankshaft Balancer 6 ENGINE REMOVAL INSPECTION amp INSTALLATION Shift Cam Shift For e Install shift can and shift fork 2 Check each part for smooth turning e Install low range driven gear to counter shaft 3 e Spray adequate engine oil to each part Drive Bevel Gear e Install drive bevel gear and tighten to the specified torque Drive bevel gear tightening torque 32N m Right Crankcase Driven Bevel Gear e Install driven bevel gear and tighten to the specified torque Driven bevel gear tightening torque 25N m Check bevel gear backlash Refer to 12 44 Front Output Shaft e Install front output shaft to right crankcase 6 55 6 ENGINE REMOVAL INSPECTION amp INSTALLATION e Apply sealant Dto the mating face of right crankcase Note Apply sealant evenly in an uninterrupted thin line Install 2 dowel pins e Assemble crankcase and tap slightly with a rubber hammer so that the crankcase is properly fitted e Install bolt and tighten to the specified torque Crankcase bolt tightening torque M6 10N m 8 25N M Note Crankcase bolts should be tightened diagonally in several steps e Place the steel ball and install gear positioning bolt and tighten t
174. verse the removal procedure for installation Headlight Remove Front fender 2 8 3 fixing bolts of headlight cover Headlight cover Fixed bolt headlight headlight connector Headlight Connector Headlight Headlight 12 5 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 gt 3 Main cables and wires should be routed properly chapter 1 Ignition Switch Inspection Remove front amp rear top cover 2 5 Disconnect 4P connector of ignition switch 12 6 12 LIGHTING AND SWITCHES Check according to the following table if the connector terminals are in continuity 1 2 Continuity T R25 __ Remove Remove holder meter gt 2 3 Disconnect 4P connector of ignition switch Reverse the removal procedure for installation Combined Switch Remove front amp rear cover of steering rack 2 2 Remove combined switch 2 3 Disconnect connector of combined switch Check according to the following table if the connector terminals are in continuity R2 5 L4 15 12 7 12 LIGHTING AND SWITCHES Horn Button wiper switch horn botton 5 slow LG Y 2WD 4WD 4WD Diff Lock Switch 2
175. wheels When removing tire from rim use special tire lever and rim protector to avoid damage to the rim Overhaul standard 2 0mm Rim Longitudinal vibration Tire Remained Rear Tire Tread wheel Tire 21 1PSI 145 6 9K Pa pressure front coe 28 1PSI 193 6 9 KPa pressure rear Rear brake Brake pedal Free Play 0mm Tightening torque Rear wheel axle nut 180 200N m Rim mounting bolt 60 65N m Front mounting bolt Shock absorber 23 25N N m Rear mounting bolt Shock absorber 30 35N m 9 1 9 REAR WHEEL REAR BRAKE SUSPENSION Troubleshooting 9 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 Weak spring Oil leakage from rear shock absorber Rear shock absorber is too hard e Bent rear shock absorber e Tire pressure is too high Poor brake efficiency Improper brake adjustment e Stained brake pad or brake disk Worn or damaged brake pad 9 2 9 REAR WHEEL REAR BRAKE SUSPENSION Rear wheel removal Refer to front wheel remove gt 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 Wheel hub removal
176. xt Check engine ignition timing if accords with standard yes next 8 no examine and repair ignition timing Check the exhaust gas from muffler if exhausts yes next 9 smoothly no Repair or replace muffler Contact with EFI commutator open ignition switch yes Diagnosis help check 5 108 23 stitch the power whether 10 supply normal not check 2 21 stitch whether is no Examine and repair putting up iron or not relevant wiring 13 22 12 Reaction slowly when acceleration 13 TROUBLESHOOTING 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 yes Examine and repair 1 air input system no next Contact fuel pressure meter contact front point of oil yes next 2 input pipe of injector starting engine check the fuel i EE pressure whether is around 300kPa or not na Check spark plug look its type and gap if accords with yes next 3 standard no Adjust or replace Disassembly idle speed valve and check thethrottle yes Clean related parts 4 valve body idle speed valve and idle speed side air no next duct whether have carbide

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