CF625-B Service CF625-C Manual WWW.CFMOTO.
All rights reserved Zhejiang CFMOTO Power Co., Ltd. Aug.
FORWARD CONTENTS This manual introduces X6 EFI version( CF625B/CF625-C) maintenance information, disassembly procedure, check & adjustment methods, troubleshooting and technical specifications. There are illustrations, drawing to guide your operations. Chapter 1 mainly introduces general operation information, tools, vehicle structure and basic specifications. Chapter 2 mainly introduces check & adjustment methods and how to do vehicle maintenance.
Conversion Table Item Example Pressure 200 kPa(2.00kgf/cm2 ) 33kPa (250mmHg) Torque 18N m(1.8kgf m) Volume 419ml Force 12N(1.2kgf) Conversion 1kgf/cm2=98.0665kPa 1kpa=1000Pa 1mmHg=133.322Pa=0.133322kPs 1kgf m=9.80665N m 1ml=1cm3=1cc 1l=1000cm3 1kgf=9.
1. Maintenance Information Caution ………………………………1-1 Tightening Torque …………………1-13 Numbers Marking Locations……….1-3 Main Parameters Table……………1-4 Grease & Sealant…………………1-18 Wiring, Pipe & Cables Layout……1-19 Maintenance Parameters Table…...1-6 Failure Indicator…………………….1-23 Cautions Safety Cautions 1. Hazardous components in exhaust. Do not run the engine in a enclosed or poorly ventilated place for long time. 2.
14.Turn the inner and outer rings of ball bearing to make sure the bearing will turn smoothly. Replace if any axial or radial play is found. If the surface is uneven, clean with oil and replace if the cleaning does not help.When pressing the bearing into the machine or to the shaft. 15.Install the one-side dust-proof bearing in the right direction. When assembling the open type or double-side dustproof bearing, install with manufacturer’s mark outward. 16.
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Main Data Table Item Par ameter CF625- B/CF625- C CF625-B:2100mm CF625-C: 2300mm 1180m m 1230mm CF625-B: 1290mm CF625-C: 1490mm 196S -B 3 CF625- B/CF625- C:594cm Unle aded gasoli ne RQ- 90or above Model Length Width Height Wheel base Engine type Displacement Fuel type Dry weight CF625- B: 344 kg Number of Passengers Ma x. Load F ront Ti re T ir e Rear T ir e Mi n.
1. Maintenance Information Item Air Filter type F uel Dev ice Valve Type Diameter of mixing valve W et, Auto-Centr ifugal P aram eter Sponge element filter Type: CF188-B-173000 36mm Cl utc h O per ation Autom atic（ CVT ） +P ark ing & G ear S hifting M ode G ear s Shi ft Low Ge ar, Hi gh Gear & Reverse G ear S hift Manual /L- H- N-R M ode/order （ CVT ） T rans mis sio 2.88～ 0.70 n Ratio Final Rati o 1.333（ 24/18， Bev el G ear） Se condar y 1.952（ 41/21） Ratio Gear ing Low G ear ： 2.
Maintenance Parameters Table Lubrication System Item Eng ine Oil Capacity Volu me when repla cing Volu me when replacing filter Recomm ende d Oil（See Original） Standard Service Limit 190 0mL (2 .01Qts) 220 0mL (2 .32Qts) － － ·Specially f or 4-stroke m otorcycle SAE -15W -40 Su bstitutes m ust be used in the following ran ge.
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Front Wheel Item P la y o f w h e e l r im Fr o n t W h e e l T ir e S t a n d a rd V e rt i ca l H o r izo n t a l G ro o ve P re s su r e 1 .0 m m 1 .0 m m － 35k Pa （ 0.35k gf ／ 2 cm ） / ( 5 . 0 8 P si ) Op e ra t io n L im it 2.0mm 2.0mm 3.0mm － Rear Wheel Item P la y o f w h e e l r im R ear W heel T ir e Sta ndar d V e rt i ca l H o r izo n t a l G ro o ve P re s su r e 1 .0 mm 1 .0 mm － 3 0 kP a （ 0 . 3 0 k g f ／ cm 2 ） / (4 . 3 5 P s i) O p e r a t io n L im it 2.0mm 2.0mm 3.
1. Maintenance Information Battery, Charging Device, Pickup Coil Item AC M agneto M otor Stan dard M odel Output Charging Coi l Resis tance (2 0℃ ) P ick up Coil Res istanc e Magneto witho ut Loa d Vol tage/(Idle Speed) M ax. Output P owe r Rated Voltage P eak Voltage of Pic kup Coil ＞ 100V（ AC）， 5000r/m in 300W， 5000r/mi n 13.5V-15.0V, 50 00r/mi n Three-phase annular rectification, Silicon controlled parallel-connected regulated voltage Capaci ty Capacity B attery 3-phase AC 0.2Ω-0.
Air Inlet Device+ Cylinder Head (mm) Item Valve Diameter Valve Clearance Fit Clearance between Valve Guide and Valve Stem Internal dia. of Valve Guide Exterior dia. of Valve Stem Standard Operation Limit Intake 32.6 Exhaust 29 Intake 0.05-0.10 Exhaust 0.17-0.22 Intake 0.010-0.037 Exhaust 0.030-0.057 Intake & Exhaust 5.000-5.012 Intake 4.975-4.990 Exhaust 4.955-4.
1. Maintenance Information C ylinde r + Pis ton + Pisto n R ing + Cra nks ha ft It em Stan d ard Cylin d er Pre ssure 10 0 0kPa F it Clea ra nce b etw e en (mm ) O pe ratio n Lim it 1 96 S-B:0 .04 8-0 .0 68 Pisto n a n d C ylin de r 0. 15 1 9 6S-B:9 5 .96 0-9 5 .98 0 P isto n Skirt dia . Te sting the p oint a wa y skirt en d 9 5. 88 0 4m m In tern a l dia. o f C ylind e r 19 6 S-B: 9 6.0 18 -9 6. 03 8 Pla inn ess o f Cylin d er 0 .
Clutch + Transmission Item (mm) Standard Limit Clutch Friction plate inner dia. 140.00-140.15 140.50 Clutch Joint Rotation 1800-2400RPM Clutch engagement 3300-3900RPM Drive Belt Width 35.2 33.5 Driven Disc Spring Free Length 168 160 0.10-0.40 0.50 Shifter and fit flute gap Left Shifter Sliding Thickness 5.8-5.9 Right Shifter Sliding Thickness 5.8-5.9 Plunging Flute Width 6.0-6.2 Driven Output Gear Sliding Width 6.0-6.
1. Maintenance Information Tightening Torque Item Torque N·m(kgf·m) 5mm Bolt, nut 6mm Bolt, nut 8mm Bolt, nut 10mm Bolt, nut 12mm Bolt, nut 5(0.5) 10(1.0) 22(2.2) 34(3.5) 54(5.5) Item Torque N·m(kgf·m) 5mm Screw 4(0.4) 6mm Screw 9(0.9) 6mmSH Bolt with flange, 10(1.0) 6mm Bolt with flange, nut 12(1.2) 8mm Bolt with flange, nut 26(2.7) 10mm Bolt with flange, nut 39(4.0) For o thers not listed in the chart, refe r to t he standard tight ening t orque.
Engine Tightening Torque Table Torque Item Q’ty Screw dia.（mm） Remark （N.m） Sensor, Reverse Gear 1 M10×1.25 20 Spark Plug 1 M12×1.25 18 Water Temperature Sensor 1 Rc1/8 8 Valve Clearance Adjusting Nut 4 M5 10 Drive Disc Nut 1 M20×1.5 115 Driven Disc Nut 1 M20×1.5 115 Circle Nut, Driving Disc 1 M30×1 100 Nut, Front Output Shaft 1 M14×1.5 97 Nut, Drive Bevel Gear 1 M22×1 145 Nut, Driven Bevel Gear 1 M16×1.5 150 Fixing Nut, Clutch 1 M18×1.
1. Maintenance Information To be continued Torque Item Quantity Diameter（mm） Remark （N.m） 14 M6 10 3 M8 25 Bolt, Driven Sector Gear 1 M6 12 Mounting Bolt, Oil Filter 1 M20×1.
Engine Tools Measuring Tools No Name Type Function 1 Vernier Calipers 0-150mm Measure length and thickness 2 Micrometers 0-25mm 3 Dial gauge 25-50mm Measure max. lift range of camshaft 4 Dial gauge 75-100mm Measure piston skirt 5 Inner dia. Gauge, Cylinder 6 Inner dia.
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Lubricant Grease, Sealant Coated Sec tion T urni ng Beari ngs T hr ottle Cable Connec ting Por tion T hr ottle Pedal M ovable P arts B rak e Pedal Mo vable P arts S wing A rm M ovable Par ts Steer ing Inner Ci rc le Sur face S eat Lock Movable P arts T rans mis sion M ovable P arts Attention G r ease Multi -pur pose greas e O pe ra tion M at eria l a nd Ins tallm e nt Supp le m e nta ry of Engine E ng in e o pera tion m at eria ls inc lude lubrica nt (oil), gre as e (lubric an t gre a se ) a nd c oola n
1. Maintenance Information Wiring, Pipes, Cable Layout 3 1 2 4 1.Plug-in on Front Fender 2.Wirings in Middle Section 3.Plug-in on Rear Fender 4.Main Cable (See Pic 2) (See Pic 1) (See Pic 3) Picture 1 1 2 3 4 5 6 7 8 12 16 15 14 13 11 10 9 1.Front RH Headlight Plug-in 2.Fan Plug-in 3.Ignition Switch Plug-in 4.Backup Power Plug-in 5.Fuel Sensor Plug-in 6.LH&RH Handlebar Switch Plug-in 7.2WD/4WD Switch Plug-in 8.Dashboard Plug-in 9.2WD/4WD Switch Realy 10.4WD Locker Relay 11.
Picture 2 1 2 3 4 1.Trigger Coil Plug-in 2.Magneto Plug-in 3.Speedometer Sensor Plug-in Picture 3 3 2 1 4.Shift Switch Sensor Plug-in 4 13 12 11 10 9 8 7 6 5 1.Fan Plug-in 2.Headlight Plug-in 3.Start Servo- Relay 4.Start Relay 5.Parking Brake Plug-in 6.Battery 7.Clock Setting Plug-in 8.Fuel Pump Relay 9.Oxygen Sensor Heat Fuse 10.Parking Position Diode 11.Neutral Position Diode 12.Troubleshooting Plug-in 13.
1. Maintenance Information 1 2 13 12 3 11 4 10 9 5 8 7 6 1.Gear Shift Mechanism 2.Oxygen Sensor Plug-in 3.Water Temp Sensor 4.Throttle Body 5.MAP Sensor 6.IAT sensor 7.Idle Air Control Valve 8.Speedometer Sensor 9.Starting Motor 10.Shift Rod 11.Radiator Water Outlet Hose 12.Reservoir Tank 13.Radiator Water Inlet Hose 1 2 6 5 4 3 1.Radiator Cap 2.Dashboard 3.Radiator Water Outlet Hose 4.Radiator 5.Radiator Water Outlet Hose 6.
6 5 1 3 2 4 1.Rear Brake Hose 2.Master Cylinder 3.Brake Fluid Reservoir 4.Brake Cable 5.Four-way Connector 6.Front Brake Hose 1 1.Ignition Switch 2.
1. Maintenance Information 1 2 3 1.Parking Cable 2.Throttle Cable 3.Choke Cable 1 2 1.Rear Turn Lights 2.
1 2 1.Front Turn Lights 2.
1. Maintenance Information Failure Indicator 1 Failure Indiactor is located on the left top”1”of instrument. While the indicator flashing is faulty, failure uses 4digit flashing. For example:0650, “0” flashes 10 times, “6” flashes 6 times, “5” flashes 5 times, “0” flashes 10 times, See (Page 11-27) for the meaning of Diagnostic Trouble Code. While failure appears, use PDA to diagnose it. Connect PDA with PDA connector, the location of PDA connector (see Page 1-19) Picture 3.
2 Vehicle Body and Muffler Overhaul Info ………………………………………2-1 Footrest Board (LH, RH) …………………………2-10 Troubleshooting ……………………………………2-1 Rear Fender, Engine Skid Plate (Front, Center, Rear), Front Rack, Bolt Cap ………………………………2-2 Double Seat, Protection Plate …………………2-11 Seat, Seat Support & Rear Rack……………………2-3 Front Inner Fender (R&H), Front Protector (RH, LH)…2-13 Front Top cover, Dashboard Cover…………………2-4 Rear Protector ( RH,LH), Bumper, Bumper Protector…2-14 Side Support (LH&RH) ……………………………2-5 B u
Front Rack, Bolt Cap Bolt Cap Remove: Front Rack Remove bolt caps; Front rack bolts can now be seen. Front Fender Front Cover Bolt1 Remove fixing Bolt 1. (one for each on the left and right.) Remove fixing Bolt 2; Remove front rack. Installation: Reverse the removal procedure for installation Tightening Torque: Fixing Bolt 1, Bolt 2 35 N.m -45N.m Fixing Bolt 3, Bolt 4 25 N.m -30N.
2 Vehicle Body and Muffler Seat Seat Seat Latch Remove: Pull upward seat latch; Lift and push seat backward. Installation: Press upward seat latch; Press seat forward and down. NOTE: Shake seat left,right, front and back to make sure that the seat is firmly installed. Rear Rack Bolts 1 Remove: —Seat ( 2-3) —Bolt 1, bolt 2 Remove seat support. Bolts 2 Remove Bolt 3 for rear rack and rear fender from rear fender bottom; Remove Bolt 1; Remove Rear Rack.
Bolts Front Top Cover Remove: Front Rack 6 nuts; Front Top Cover. Assemble: Reverse the removal process and direction. Front Cover Dashboard Cover Dashboard Cover Remove: --2 pieces Bolt 1 --2 pieces bolt 2 --Dashboard Cover Bolts 1 Installation: Reverse the removal process and direction for installation.
2 Vehicle Body and Muffler Front Side Support(Left) Remove: Bolt 1; Front Side Support. Assemble: Reverse the removal process and direction. Bolts 1 Front Side Support,LH Front Side Support(Right): Same as Left Side Support.
Rear Top Cover Remove: Clips Rear Rack Seperate clasps of rear top cover from rear fender; Remove Rear Top Cover Installation: Reverse the remove procedure and direction for installation . Bolt 1 Rear Top Cover Bolt 2 Gear Shift Unit Fender Remove: Bolt 1 Bolt 1 Bolt 2 Remove Gear Shift Unit Fender. Installation: Reverse the remove procedure and direction for installation .
2 Vehicle Body and Muffler Left Side Cover Bolts Remove: Seat Left Side Cover Bolt Left Side Cover Installation: Reverse the remove procedure and direction for installation . Left Side Panel Rear Protector Rear Protector Remove: --Rear Rack --Rear Top Cover --Rear Link Plate --Rear Left Side Support --Rear Right Side Support --Rear Turning Light Connector --Bolt 1,2,1 --Rear Protector Bolts 1 Bolts 1 Installation: Reverse the remove procedure and direction for installation.
Rear Side Panel Remove: Seat Right Side Cover Fixing Bolt Bolts Right Side Panel Remove connecting Bolt 1 between Right Side Panel and Front Fender at bottom of Front Fender; Remove Right Side Panel. Bolts 1 Front Fender Installation: Reverse the remove procedure and direction for installation . Rear Side Protector,LH Rear Right Side Support Remove --Bolt 2 --Remove Rear Right Side Support Installation: Reverse the remove procedure for installation.
2 Vehicle Body and Muffler Top Cover, Fuel Tank Remove: Bolts 1 Seat Front Rack Front Top Cover Left Side Panel -Right Side Panel Bolt 1, 2 Fuel Tank Top Cover Fuel Tank Cap Bolt 3, 4 Fuel Tank Cap Bolts 2 Remove Fuel Tank Top Cover. Installation: Reverse the remove procedure and direction for installation .
Footrest,Left Side Remove: Left Side Panel Remove three Bolt 1 and 3 nuts connecting with Front Fender. Bolts 1 Bolts 1 Remove three Bolt 2 and 3 nuts connecting with Rear Fender. Bolts 2 Remove Bolt 1; Remove Left Footrest. Installation: Reverse the remove procedure for Installation. Footrest,Right Side Removal and Installation same with Left side.
2 Vehicle Body and Muffler Rear Fender Rear Fender Bolts 1 Remove: --Seat --Rear Rack --Rear Top Cover --Left,Right Side Panel --Lef,RightSide Support --Rear Protector Remove Battery Bracket and Fixing Plate Remove Battery Remove Bolt 1; Remove Nut 1; Remove Electonic Parts from Rear Fender; Loosen Cable Connector from Rear Fender; Upwardingly Remove Rear Fender. Bolts 1 Engine Front,Middle and Rear Skid Plate; Protector Plate of Double Seat. 14 13 12 4 1 2 5 6 7 11 8 9 3 10 1.Bolt1 2.
Disasembly NOTE:Side skid Plate(Front,Middle, Rear) and Double Seat Protection are located at bottom of vehicle. The mainteanace person should work under bottom of vehicle when disassemble the above parts. For safty , make sure the vehicle is firmly parked. Engine Skid Plate(Front) Remove Bolt 1, 2, 3,and 4; Remove Engine Front Skid Plate. Installation: Reverse the remove procedure for Installation. Engine Skid Plate(Middle) Remove Bolt 5 and 6; Remove Middle Engine Skid Plate.
2 Vehicle Body and Muffler Right Front Inner Fender Removal: Remove Bolt 1 ,and remove Right Front Inner Fender. Installation: Reverse the remove procedure for Installation. NOTE: Hook Water Pump with Clip of Right Inner Side Fender during Installation. Bolt 1 Right Front Inner Fender Left Front Inner Fender Removal: Remove Bolt 1 ,and remove Left Front Inner Fender. Installation: Reverse the remove procedure for Installation.
Front Left Inner Fender Removal: Bolt 1 Bolt 2 Front Rear Protection Remove Bolt 1 and 2; Remove Front Left Inner Fender Installation: Reverse the remove procedure for Installation Front Engine Skid Plate Front Right Inner Fender Removal and Installation same as Left Side. Bumper, Bumper Protector Remove: Bolts Remove two Bolts of Engine Front Skid Plate fixing into the Bumper. Remove Bolt 1, 2, 3 and 4.
2 Vehicle Body and Muffler Bumper Protector Remove: Bolts 1 --Loosen Front Turning Light Connector. --Remove Bumper and Bumper Protector. Remove tapping screw 1 from Bumper; Remove Bumper Protector. Protector,Bumper Installation: Reverse the remove procedure for Installation. Front Turnlight Bumper Protector Cap Remove: Pull the two Caps from Bumper . (There are only 2 caps in this vehicle.) Installation: Press Caps into Bumper Pipe.
Front Vent Grill Remove: --Loosen Connector of Front Head Light --Remove Front Fender --Remove Bumper --Remove Bolt 1, 2 and 3 --Remove Vent Grill Bolts 1 Front Vent Grill NOTE: For removal of front vent grille only, Just remove 2 fixing bolts of bumper and 2 center fixing bolts, then pull bumper down. Installation: Reverse the removal procedure for installation. Bolts 2 Bolts 3 WARNING: Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place.
2 Vehicle Body and Muffler Remove Fuel Line 1 and Circlip; Remove Fuel Tank. Installation: Reverse the removal procedure for installation. NOTE: Fuel Line(Circlip) Be careful not to damage main cable, pipes and hoses. Main cable, cables, pipes and hoses should be routed properly according to the routing drawing. Take precaution against fuel leakage when removing fuel Fuel Hose I. Remove: --Fuel tank --Bolt 1 --Bolt 2 --Fuel tank top cover Installation: Reverse the removal procedure for installation.
Muffler Caution: Perform disassembly only after the muffler is cooled down. Remove: --Seat (2-3) --Right side panel (2-8) --Nut1, Nut 2 for exhaust pipe elbow Bolt 1 Bolt 2 Bolt 2 Bolt 1 Remove Bolt ; Remove Bolt 2, Bolt 3 Remove muffler . Installation: Reverse the removal procedure for installation. Bolt 3 NOTE: Replace sealing gasket when installing the muffler.
2 Vehicle Body and Muffler Visible Parts: 4 7 5 3 1 6 8 9 2 21 10 15 16 20 17 14 11 13 18 19 12 1.Front Suspension Protector,LH 2.Front Rack 3.Front Top Cover 4.Dashboard Cover 5.Top Cover,Fuel Tank 6.Seat 7.Rear Rack 8.Rear Top Cover 9.Rear Protector 10.Rear Link Plate 11.Rear Suspension Protector,LH 12.Rear Side Protector 13.Rear Fender 14.Left Footrest 15.Left Side Panel 16.Front Fender 17.Front Inner Fender 18.Front Protector 19.Front Vent Grill 20.Bumper Protector 21.
3.Checks & Adjustment Overhaul Info...................................................3-1 Maintenance Interval........................................3-2 Inspection&Maintenance..................................3-3 Steering Column Brake System........................3-6 Wheels...........................................................3-8 Suspension System........................................3-10 Gear Shifting,Fuel Device.................................3-11 Check the Throttle..............................
M aintenance Interval The table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the engine at its best performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and hours, whichever occurs first. N ote: Maintenance interval should be shortened on engines that are used in severe conditions.
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Item Part Item Final shaft Drive train (Drive shaft) Electrical System Intervals Ignition Device Battery Wiring Looseness of joint parts Daily O 1/2 Year O Sway of Spline Annual O Spark plug O Ignition timing Terminal Joint Looseness and damage of joints Fuel leakage O Spark plug gap: 0.8-0.9mm/.030~. 040in.
3.Checks & Adjustment It em Part Lighting devi ce and turning indic tors Alarm and lock devic e Instrum ents Exhaus t pi pe and m uffler Frame O thers Abnormal parts whic h can be determ ined when driv ing I tem Function Function Function Loosenes s or dam age caused by im proper ins tallation Function of m uffler Looseness and/or dam age Lubric ati on & grease of fram e parts M ake sure if there is any abnorm al with relative parts.
Steering Column Park the vehicle on level place, hold steering handlebar, and shake in the direction as illustrated on the right and see if there is any sway. In case of any movement, check if it is the problem of the steering stem or other parts and then do the maintenance accordingly. In case of movement of the steering stem, tighten the locknut or disassemble the steering stem for further check. Park the vehicle on level place, slowly turn the handlebar left and right to see if it can turn freely.
3.Checks & Adjustment Master Cylinder Brake Fluid Reservoir Lower Check the Brake Fluid Level When the brake fluid level is near to the lower limit line, check master cylinder, brake hoses and joints for leakage. Remove the two mounting screws on fluid reservoir cap. Remove the cap, add DOT3 or DOT4 brake liquid till the upper limit line. Screws -Do not mix with dust or water when adding brake fluid. -Use only the recommended of brake fluid to avoid chemical reaction.
Wheels Lift front wheel on level place, and make sure there is no loading on the wheels. Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways. Not tighten enough: Tighten it Sway: Replace the rocker arm A Front Toe-in size Park the vehicle on level place, measure the front toein Toe-in: B-A=0-10mm/0-3/8in.
3.Checks & Adjustment Tire Pressure Check the pressure of the tires with a pressure gauge. NOTE: Check the tire pressure after tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause abnormal wear of the tires. Pressure Gauge Specified pressure /tire Tire Tread Check the tire tread. Tread Height: < 3mm¡úReplace with new tires NOTE: When the tread height is less than 3mm, the tire should be replaced immediately.
Wheel Nut and Wheel Axle Check front and rear wheel axle nuts for looseness; Loosened axle nuts Tighten Tightening Torque: Front wheel axle nut: 110-130N.m(11.2kgf.m-13.3kgf.m) Rear wheel axle nut: 110-130N.m(11.2kgf.m-13.3kgf.m) Axle Nut Movement of Wheel Bearing Lift the front wheel ; Make sure there is no loading on the vehicle; Shake the wheel in axial direction for any movement; In case of any movement, disassemble the front wheel and check the bearing.
3.Checks & Adjustment Adjusting the Shock Absorber Use special tools to adjust the length of shock absorber spring according to loading requirement; Turn clockwise to adjust from high to low to change spring preload of shocks. Absorber Adjust Gear Locknut Gear Shifting Shift the gear to check for flexibility and gear engagement; Adjust the gearshift rod if necessary; Release the locknut to adjust the length of gearshift rod.
Checking the Throttle Lever Throttle Lever Check the free play of throttle lever Free play: 3-5mm Out of range: Adjust Loosen locknut of throttle cable turn the adjustor and adjust free play of throttle lever 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 adjustment or if there is still stickiness with the throttle.
3.Checks & Adjustment Cooling System NOTE: Check coolant level from reservoir tank. Do not check from radiator. If the radiator cap is opened while the engine is hot (over ), the pressure of the cooling system will drop down and the coolant will get boiled rapidly. DO NOT open the radiator cap until the coolant temperature drops down. -Coolant is poisonous, DO NOT drink or splash it to skin, eyes, and clothes. -In case the coolant gets to the skin and clothes, wash with soap immediately.
When the coolant level is below the LOWER limit, remove reservoir tank cap and add coolant till upper limit. (Add coolant or diluted original liquid). Recommended coolant: CFMOTO coolant Mark”Upper” Standard density: 50% ( Freezing temperature of coolant varies according to the different mixture ratio. Adjust the mixture ratio according to the lowest temperature in the place where the vehicle is used.) If the coolant reduces very fast, check if there is any leakage.
3.Checks & Adjustment Inspection of Cooling System Check initially at 50 hours or 500km, replace coolant annually. 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.
Check Water Temperature Gauge When engine is not working, the water temperature should be in the position. Start the engine to check if the indicator works. If the indicator is not working, do the maintenance in time. Instrument Lighting System Adjusting headlight light beam Turn the headlight beam adjusting screw with a cross screwdriver and adjust the high/low beam to meet the requirement.
3.Checks & Adjustment VALVE CLEARANCE 2 1 Inspect initially at 20-hour break-in and every 100 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.
Take out the feeler gauge, measure the clearance. If the clearance is incorrect, repeat the above steps until the proper clearance is obtained. Locknut: 10 N.m CAUTION: Securely tighten the locknut after completing adjustment Install: 2 valve adjusting cover; Inspection cap; Recoil starter; Cover plate; Apply a small quantity of THREAD LOCKER to recoil starter fixing bolts. 1 2 3 4 1.Nut 2.Valve Clearance 3.Rocker Arm 4.
3.Checks & Adjustment In case of carbon deposit, clean with a proper tool. SPARK PLUG GAP Measure the spark plug gap with a feeler gauge. Out of specification: Adjust Spark plug gap: 0.8-0.9mm/.030-.040in. 0.8-0.9mm/ 0.030-0.040in. CAUTION: 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.
A--Non-flammable cleaning solvent B Engine oil SAE#30 or SAE15W/40. Never use with gasoline or low flash point solvents to clean the filter element A Inspect the filter element for tears. torn element must be replaced. B NOTE: 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. If driving under dusty conditions, clean the air filter element more frequently.
3.Checks & Adjustment Inspection: Inspect drive belt for wear and damage. If any cracks or damages are found, replace drive belt with a new one. Inspect drive belt for width, if width is out of service limit, replace drive belt with a new one. Service Limit: 33.5mm/1.32in. 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.
Inspection of Lubrication System Replace engine oil and oil filter initially at 20 hours or 250km and every 100 hours or 1000km thereafter. Inspect the engine oil at every 10 hours. 1 Check Engine Oil Level A -Keep the engine in a level position. -Remove the fixture A, fixture B, 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. -Take out oil dip rod and check if oil is between upper and lower limit.
3.Checks & Adjustment -Install oil dip rod, start the engine and allow it to run for several minutes at idling speed. -Turn off the engine and wait for about 3 minutes, and then check the oil level on the dipstick. Caution: The engine oil should be changed when the engine is warm. If the oil filter should be replaced, replace engine oil at the same time.
Inspection of cylinder pressure Check cylinder pressure is necessary. Cylinder Pressure: 1000kpa/145Psi 1 A lower cylinder pressure may be caused by: -Excessive wear of cylinder; -Wear of piston or piston ring; -Piston ring stuck in groove; -Valves not seating; -Damaged cylinder gasket or other defects. NOTE: When cylinder pressure too low, check the above items.
3.Checks & Adjustment Inspection of Oil Pressure Oil Pressure: 18.
Inspection of Clutch Engagement and Lockup Connected with Ignition Coil CF196-S engine is equipped with a centrifugal type automatic clutch. Before checking the initial engagement and clutch lock-up two inspection checks must be performed to thoroughly check the operation of the drive train.
4 Cooling and Lubrication System Overhaul Info Trouble Shooting Performance Overhaul Reservoir Tank Adding Coolant Cooling system chart Radiator and water hose check and clean Cooling fan check Water temperature transducer check Water pump Water pump check Water pump assembly and installation Lubrication system chart Engine Coolant Overhaul Info Caution: If the radiator cap is opened when the coolant temperature is above 100 ,the pressure of coolant temperature will go down and get boiled rapidly.
Trouble Shooting Water Temperature Rises Too Fast Improper radiator cap. Air in the cooling system. Malfunction of water pump. Malfunction of thermostat thermostat is not open). Clogged of radiator pipe of cooling pipe. Damaged or clogged radiator fins. Coolant is not enough. Faulty or malfunction of fan motor. No Rise or Slow Rise of Water Temperature Malfunction of thermostat(thermostat isn’t closed). Faulty circuit of water temperature display. Water Leakage Poor water seal.
4 Cooling and Lubrication System Performance Overhaul Inspection of coolant density Caution: Be sure to open the radiator cap after coolant is cooled.
Pressure testing of cooling system Apply the specified pressure(radiator cap opening pressure) for 6 seconds and make sure that there is drop in pressure CAUTION: Do not apply pressure over the specified pressure [108kPa(1.1 kgf/cm2)]/15.66Psi,or the cooling system may be damaged.
4 Cooling and Lubrication System Remove Drain Bolt Remove drain bolt, seal gasket from water pump, drain coolant. After drainage, assemble new seal gasket and drain bolt and tighten.
Adding Coolant Add coolant through filling port Start the engine and discharge air from cooling system. Check from filling port that air is fully discharge from cooling system and install the radiator cap Remove reservoir tank cap and add coolant till the upper limit Refill Port Caution: Check coolant level when the vehicle is on an level ground Discharge Discharge the air from cooling system according to the following steps: 1.Remove drain bolt and install it. Upper Limit ,discharge air 2.
4 Cooling and Lubrication System Cooling System 16 12 1.Water Inlet Hose 2.LH Crankcase 3.LH Sidecover 4.Water Pump 2.Water Pipe 6.Cylinder Body 7.Cylinder Head Cover 8.Water Temp Sensor 9.Thermostat Housing 10.Thermostat 11.Water Outlet Hose 12.Radiator 13.Fan Motor 14.Thermoswitch 15.Reservoir Tank 16.
Anti-Freeze Density Freezing Point zUse high quality ethylene glycol base antifreeze and mixed with distilled water.Never mix alcohol base antifreeze and different brands of antifreeze zThe ratio of antifreeze should not be more than 60% or less than 50% zDo not use anti-leak additive zRemove radiator cap 1 and connect tester 2 filler 55% -40 60% -55 0 -10 -20 -30 -40 -50 -60 Density 0 20 40 60 80 100 X100Pa 150 140 1.5 130 0.9 120 0.
4 Cooling and Lubrication System Inspection and Cleaning of Radiator and Water Hoses Radiator Cap 2 1 zRemove radiator cap zInstall radiator cap to cap tester zSlowly increase pressure to 108kPa and check if the cap hold the pressure for at least 10 seconds. zIf the cap can not meet the pressure requirement, repalce it. Radiator Cap Valve Opening Pressure: Standard:108kPa/15.66Psi Tool:Radiator Cap Tester Radiator Inspection and Cleaning zRemove dirt or trash from radiator with compressed air.
Inspection of Fan Motor zRemove fan motor from radiator. zTurn the vanes and check if they can turn smoothly. zCheck fan motor.Make sure that the battery applies 12 volts to the motor and the motor will run at full speed while the ammeter will indicate the ampere not more than 5A. If the motor does not work or the ampere exceeds the limit,replace the motor zInstallation:Apply a little thread locker to the bolts and tighten to the specified torque. 1.Radiator 2.Radiator Cap 3.Fan Motor 4.Mounting Bolt 5.
4 Cooling and Lubrication System Inspection of Water Temperature Sensor zPlcae a rag under water temperature sensor 1 and remove it from cyclinder head. zCheck the resistance of water temperature sensor as illustrated on theright. Connect the temperature sensor to the circuit tester,place it in a vessel with engine oil.Place the vessel above a stove. Tool: ohmmeter, thermometer zHeat the oil to raise the temperature slowly and take the reading from ohmmeter 4 and thermometer 3.
zCheck thermostat pellet for cracks.If necessary, re- 1 place it. zTest the thermostat according to the following steps: 2 Pass a string between thermostat flange as illustrated on the right. 1.Thermostat 2.String Immerse the thermostat in a beaker with water. Make sure that the thermostat is in the suspended position without contact to the vessel.
4 Cooling and Lubrication System zRemove clamps and water hoses. zRemove bolts and remove water pump. o-ring zRemove O-ring. NOTE:Do not reuse the O-ring. Overflow Tube zRemove the overflow tube. z Remove water pump cover screws,water pump cover and gasket. zRemove ring and impeller 2 zRemove seal ring 1 and rubber seal 2 .
zRemove mechanical seal with special tool. Mechanical Seal NOTE:The mechanical seal does not need to be moved,if there is no abnormal condition. NOTE:Do not reuse a removed mechanicalseal. zPut a rag on the water pump body. zReomve 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. zRemove bearing with special tool. NOTE:The bearing does not need to be removed,if there is no abnormal noise.
4 Cooling and Lubrication System Oil Seal zCheck oil seal for damaged. Pay attention to the oil seal lip. zIn case of damage or leakage, replace the oil seal Water Pump Body zChecl the mating mace of water pump body with bearing and mechanical seal.If damage,replace it. Water Pump Impeller zCheck the impeller and shaft for damage. zIf the impeller or shaft are damaged,replace a new part. Assembly and Installation of Water Pump zInstall oil seal with special too.
zInstall mechanical seal with a suitable socket wrench. NOTE:Apply sealant to side ”A” of mechanical seal. A zInstall bearing with special tool. Tool:Bearing Installer NOTE:The stamped mark on the bearing faces outside. Tool zInstall seal ring to impeller. zClean off the oil and grease from mechanical seal and install into the impeller. NOTE: ”A” side of mechanical seal faces impeller A zApply grease to impeller shaft. zInstall impeller shaft to water pump body.
4 Cooling and Lubrication System zInstall ring to water pump shaft. zInstall new gasket to water pump body. zInstall water pump cover and tighten the bolts and bleed bolt. Water Pump Cover Bolts Tightening Torque:6N. m zCheck impeller for smooth turning. zInstall the new O-ring. NOTE: zUse the new O-ring to preventleakage. zApply grease to O-ring. O-ring zInstall the overflow tubes.
zInstall water pump and tighten the bolts to the specified torque. Water pump bolts tightening torque: 10N.m NOTE:Set the water pump shaft slot end ”B” to oil pump shaft flat side ”A”. B zConnect water hoses. zAdd coolant. zInstall left side cover.
4 Cooling and Lubrication System Illustration of CF188 Engine Lubrication System 1.Oil Drain Bolt 2.Washer,Oil Drain Bolt 3.Oil Pump 4.Oil Bypass Valve 5.External Oil Pipe 6.Oil Filter 7.Clutch 8.Crankshaft 9.Cylinder Body 10.Piston 11.Camshaft 12.One-way Clutch 13.
Add oil to the engine parts(piston,cylinder body,camshaft and so on) which run at high speed Engine lubrication should be special oil. Engine oil is not only used as lubrication, but also used to wash, rustproof,seal and cool.
5 Removal and Installation of Engine,Drive Train and Gearshift Unit Overhaul Info.................................................5-1 Removal and Installation of Front and Rear Axle... 5-5 Engine Removal and Installation......................5-2 Removal and Installation of Gearshift Unit............5-7 Overhaul Info Operation Cautions Securely support the ATV with bracket when removing or installing engine.
CFMOTO Engine Removal Remove: —Plastic(-Chapter 2) —Air Filter(-Engine service chapter) —Throttle body (-Engine service chapter) —Clamp —Water Inlet Hose Water Inlet Hose Clamp Gear Shift Rod Remove screw. Remove gearshift rod . Screw Remove clamp Remove water outlet hose Remove Wiring Sleeve. Remove connectors of magneto, enriching device lead, pickup, water temperature transducer, gear sensor as illustrated on the right.
5 Removal and Installation of Engine,Drive Train and Gearshift Unit Remove spark plug cap from spark plug. Spark Plug Cap Remove protection sleeve of starter relay. Remove Nut. Disconnect positive cable of starter relay. Positive Cable,Starter Motor Remove nut. Remove negative cable of starter relay.
CFMOTO Remove engine mounting bolts 4 locations.
5 Removal and Installation of Engine,Drive Train and Gearshift Unit Engine Installation Put engine onto the frame,install the two lower mounting bolts and nuts Tightening torque: Engine lower hanger bolt:50-60N m Install: —Water outlet and inlet hoses to engine with proper clamps. —Positive and negative starting wires to engine. —Connect all the connectors. —Spark plug cap. —Gearshift rod to engine. —Air filter, throttle body and removed parts.
CFMOTO Front Diff Remove nut and bolt of front axle from frame. Front Drive Shaft Bolts Front Diff Front Drive Shaft Bolts Rear Gearcase Remove nut and bolt of rear axle from frame.
5 Removal and Installation of Engine,Drive Train and Gearshift Unit Remove the 18 bolts for drive shafts and front and rear axles(Refer to 5,bolt 3) Remove Front and rear axles,drive shafts,rear brake disc.
6 Engine Removal, Inspection & Installation 6 Eng ine Removal, Inspection and Installation △Engine Removal/Installation Orders and the Relative Page Numbers Disassembly Item DES Inspection / Maintenance Assembly Engine Water Hose/Pipe 3-2 Periphery Left Side Cover 3-2 Recoil Starter 3-2 3-49 3-68 Spark Plug 3-2 2-4 3-68 Cylinder Head Cover 3-3 3-14 3-66 2-11 Remarks 3-69 3-69 Tensioner 3-3 3-24 3-67 Engine Camshaft 3-3 3-21 3-65 Front Cylinder Head/Tensioner Plate 3-4
CFMOTO Engine Removal Preparation before engine removal Prepare a proper tray used for load of components. 7 Prepare necessary removal and assembly tools. 8 Drain engine oil 1 Drain coolant (3-15). 3 Engine Periphery Water Hose/Pipe 2 5 Remove water hose clamp 1,2,Remove water hose 4 3. Remove screw 4 and water hose 5. Left Side Cover Remove 6 bolts(M6 20)of left side cover 8 Remove left side cover 6. Recoil Starter Remove 4 bolts(M6 12)of recoil starter Remove recoil starter7.
6 Engine Removal, Inspection & Installation Cylinder Head Cover Remove valve adjusting covers. Remove12 bolts of cylinder head cover. Remove cylinder head cover. Timing Chain Tensioner Remove screw plug , insert a flat screwdriver intoslot of timing chain tensioner adjuster , turn itclockwise to lock tensioner spring. Remove tensioner bolts. Remove tensioner and gasket. Camshaft Loosen timing sprocket bolt. Remove timing sprocket bolt and lock.
CFMOTO Remove C-ring 1. 1 Remove timing sprocket from camshaft, remove camshaft. NOTE: Take care not to drop spacer, bolt, bolt lock and C-ring into crankcase. Remove cam chain guide. Cylinder Head Remove cylinder head bolts. Remove cylinder head bolts diagonally. Remove cylinder head. NOTE: Take care not to drop dowel pin into crank- case Cylinder Remove dowel pin and cylinder head gasket. Remove timing chain guide 1.
6 Engine Removal, Inspection & Installation Remove cylinder bolt. Remove cylinder. NOTE:Take care not to drop dowel pin into crankcase Remove dowel pin and cylinder gasket. NOTE:When performing above removal process,be sure to hook up timing chain to prevent it from falling into crankcase. Piston Remove piston pin circlip 1with long nosed pliers. NOTE:Put a clean rag under piston so as not to drop piston pin circlip into crankcase Remove piston pin 2 and piston 3.
CFMOTO Oil Filter Remove oil filter with special tools. Tool: Oil filter Remover Special Tool Sector Gear Remove bolt 1 of gearshift rocker arm. Remove gasket 2 and gearshift rocker arm 3. 3 2 1 Remove bolt of sector gear housing cover. Cover,Gear Shift Sector Gear Remove wire clip and sector gear housing cover. Remove dowel pin and gasket. Remove drive sector gear 4. 4 Remove bolt 5 of driven sector gear. 5 Remove washer 6 and driven sector 7.
6 Engine Removal, Inspection & Installation Water Pump Remove water pump screws. Remove water pump. Sheave Drum Remove the sheave drum by using a suitable bar. Remove washer and sheave drum. Left Crankcase Cover Remove bolts. Remove left crankcase cover. Remove dowel pin and gasket. Magneto Rotor Install attachment 1 to crankshaft end. 1 Install special tool to rotor thread; Remove rotor and woodruff key.
CFMOTO Starting Motor Gear Remove driven gear 1 and needle bearing. 4 Remove dual gear and shaft 3. Remove idle gear and shaft 4. Oil Pump Sprocket and Chain Remove drive sprocket nut 5. Remove C-ring 6. 1 2 Remove spacer 2. 5 Remove oil pump drive and driven sprockets and chain.
6 Engine Removal, Inspection & Installation Engine Right Side CVT Cover Remove bolts from CVT cover. Remove CVT cover. Remove gasket and dowel pin. CVT(Continuously Variable Transmission) Remove primary sheave nut with special tool. Remove primary sliding sheave. Tool Remove secondary sheave nut with special tools. Tool Remove secondary sheave. 1 Remove drive belt. Tool: Sheave Holder Remove primary fixed sheave 1. Remove bolts for air guide plate,Remove air guide plate.
CFMOTO 1 CVT Case Remove bolts #1 from CVT case. Remove nuts #2 from CVT case. 2 Remove outer clutch face and CVT case. Remove dowel pin, front and rear gasket. Clutch Remove clutch shoe fixing nut with special tool. Remove clutch shoe. NOTE:The clutch shoe nut has left-hand threads Timing Chain Remove timing chain.
6 Engine Removal, Inspection & Installation Engine Center Gear position bolt 1 Remove gear position bolt 1. Remove spring and steel ball. Right Crankcase Remove left crankcase bolts. Remove right crankcase bolts. Separate right crankcase with special tool. CAUTION: The Crankcase separator plate should be parallel with the end face of crankcase. Tool Crankshaft should remain in the left crankcase half. Tool: Crankcase separator Driven Bevel Gear, Front Output Shaft Remove bevel gear cover bolt.
CFMOTO 4 Remove Oil seal 1,Bearing limit nut 2(left roll). Remove Front Output Shaft 4 . 3 1 2 6 Shift Cam, Fork/Shaft Remove Shift Cam Fork /Shaft Drive Bevel Gear Remove left crankcase from driven bevel gear. Drive Shaft, Drive Shaft Remove drive shaft 7and driven shaft 8. 8 Balancer Shaft Remove balancer shaft.
6 Engine Removal, Inspection & Installation Crankshaft Separate crankshaft from left crankcase with special tool. Tool: Crankshaft Separator 1 Oil pump, Relief Valve Remove oil pump and relief valve.
CFMOTO Engine Components Inspection Cylinder Head Cover Disassembly CAUTION:Each removed part should be identi fied to its location, and the parts should be laid out in groups designated as Exhaust”, “Intake”, so that each will be restored to the original location during assembly. Remove rocker arm shaft bolts A. B A Remove rocker arm shaft by using M6 bolts B.
6 Engine Removal, Inspection & Installation Rocker Arm When checking the rocker arm, check the inner diameter of the valve rocker arm and wear of the camshaft contact surface. 1 Rocker Arm I.D. : .000~12.018mm 2 Tool: Dial Calipers Assembly NOTE:Intake rocker arm shaft A has oil holes. A Apply engine oil to rocker arms and shafts. Install rocker arms and tighten rocker arm shaft to the specified torque. Rocker Arm Shaft Bolt: 28N.
CFMOTO Remove thermostat. Compress the valve spring and remove valve retainers with tweezers. Tools: Valve Spring Compressor Tweezers Remove valve spring upper seat and valve spring. Remove valve from the other side. Remove valve stem seal ring and valve lower seat.
6 Engine Removal, Inspection & Installation Cylinder Head Distortion Clean off carbon deposit from combustion chamber. Check the gasket surface of the cylinder head for distortion with a straightedge and thickness gauge. Take clearance readings from several places. If any clearance reading is out of the service limit, replace with a new cylinder head. Cylinder Head Distortion Service Limit: 0.05mm Tool: Thickness Gauge Valve Seat Width Coat the valve seat with color uniformly.
CFMOTO Valve Stem O.D Measure valve stem O.D with a micrometer Service Limit: IN: 4.975-4.990mm EX: 4.955-4.970mm Tool: Micrometer (0-25mm) Valve Stem Run-out Support valve stem with V block as illustrated on the right. 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:--Replace Service Limit: 0.
6 Engine Removal, Inspection & Installation Valve Spring Valve Spring keeps valve and valve seat tight. Weakened spring results in reduced engine power output and chattering noise from valve mechanism. Measure the spring free length. Spring free length out of range: --Replace Service Limit: 38.8mm Tool: Vernier Caliper. a 182N-210N Measure the force to compress the spring to the specified length. Valve spring tension out of range: ---Replace Service Limit: (IN/EX) 182N-210N/31.5mm Tool: Spring Scale.
CFMOTO Install valve spring with small-pitch end (b) facing cylinder head. Big-pitch end (a) is marked. a b 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 to wedge in between seat and stem. Make sure that the rounded lip of the cotter fits into the groove in the stem end. Tool: Valve Spring Compressor 3 2 1 Tool Tweezers NOTE: Knock the valve end with rubber hammer.
6 Engine Removal, Inspection & Installation Install thermostat. Install thermostat cover. Install water temperature sensor, apply thread locker to the thread part, tighten it to the specified torque. Water temperature sensor Tightening torque: 10 N.m Apply Thread Water Temp Sensor Locker Apply Lubricant Grease Install intake pipe, apply lubricant to 0-ring. Camshaft Check camshaft for wear and run-out of cams and journals if the engines produces abnormal noise or vibration or lacks power output.
CFMOTO 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 ofcam wear is specified for both IN and EX cams in terms of cam height¡°a¡±Measure with a micrometer the cam height. Cam height service limit: IN: 33.130mm EX: 33.
6 Engine Removal, Inspection & Installation Camshaft Journal O.D. Measure camshaft journal O.D. with a micrometer. If the O.D. is out of range, replace camshaft with a new one. Camshaft journal O.D. service limit: Sprocket end: 22.959 mm-21.980mm Other end: 17.466mm-17.484mm Tool: micrometer (0-25mm) Camshaft Run-out 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.
6 Engine Removal,Inspection and Installation Chain Tensioner Inspection Check tensioner for any damage or poor function. Damage, poor function:—Replace inspect way of working stability Insert screw driver 1 into the slotted end of adjusting screw, turn it clockwise to loosen the tension and release the screwdriver. 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.
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:95.960-95.980mm Limit:95.880mm Tool:Micrometer (75-100mm) Calculate the piston to cylinder clearance according to the abovemeasurement.If the clearance is more than 0.15mm, replace the cylinder or piston, or both.
6 Engine Removal,Inspection and Installation Piston Ring Free End Gap and End Gap Before installing piston rings, use vernier caliper to measure the free end gap of each ring, and then fit ring into the cylinder. Use thickness gauge to measure each ring end gap, if any ring has an excess end gap, replace the piston ring Piston ring free end gap limit: Top ring:8.9mm 2nd ring:9.5mm Piston ring end gap limit: Top Ring:0.60mm 2nd ring:0.
ConnectingRod/Crankshaft Connecting rod small end I.D. Use a dial gauge to measure the I.D. of connecting rod small end. If the measurement exceeds the limit,replace the connecting rod. Connecting rod small end I.D. : 23.040mm Tool: Dial Gauge (18-35mm) Connecting Rod Deflection Check the movement of the small end of the rod and inspect the wear of the small end. Thismethod is also applicable to check and inspection of big end Connecting Rod Deflection: 3.
6 Engine Removal,Inspection and Installation Clutch Inspection Check clutch for chipping, scrape, uneven wear or heat discoloration. At the same time check depth of the grooves of clutch shoes. If any of the clutch shoes has no groove, replace the clutch. NOTE: clutch should be replaced as an assembly.. a Clutch Wheel Check the inner clutch wheel for scratches, scuffs or bluediscoloration or unevenwear. If anydamageis found, replace the clutch wheel with a newone.
Primary and Secondary Sheave (17) (16) (15) (12) (13) (14) (10) (11) (9) A (8) (5) B (3) (6) (4) (1) N m A 115 B C 115 100 (2) (7)
6 Engine Removal,Inspection and Installation Primary Sliding Sheave Disassemble Remove spacer Remove Cam 1 roller 2 Roller Inspection Check each roller and sliding face for wear and damage. Wear and damage:—Replace NOTE: rollers should be replaced as a set. Oil Seal inspection Check oil seal lip for wear and damage.
Primary Sliding Sheave and Fixed Sheave Check the drive face for any abnormal conditions such as damage or stepped wearing.Replace if necessary. Tool Tool Install oil seal with special tool. Tool: Bearing install set Assembly Reverse the removal procedure of primary sliding and fixed sheave for installation. Pay attention to the following: Apply grease to inner bore and oil seal lip. NOTE:Wipe off any excessive grease thoroughly.
6 Engine Removal,Inspection and Installation Install Spacer Secondary Sheave Disassembly Use special tool and holder to hold the secondary sheave. Remove secondary sheave nut with special tool CAUTION:Do not remove the ring nut before attaching theclutch spring compressor. Tool: Nut Wrench Sheave Holder Attach special tool to the secondary sliding sheave and compress it by turning in the tool handle. A B NOTE: Make sure that spring end A is inserted into slot B of the tool handle Remove ring nut.
Remove spring 1. 1 2 Remove spring seat 2. Guide Pin&Spacer Remove guide pin and spacer. 3 Remove secondary sliding sheave 3. Seal Ring O-ring and Oil Seal Check the O-ring and oil seal for wear and damage. WearandDamage: —Replace. Remove Oil Seal.
6 Engine Removal,Inspection and Installation Install oil seal with special tool. Tool: Bearing install set Tool Tool Use vernier caliper to check the spring free length. If the 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. Replace if necessary.
Install guide pin and spacer 1. 1 NOTE: To avoid damage to the oil seal lip during assembly, slide the lip with a 0.1mm steel sheet as guide. Install spring seat. Align hole A with hole B. B A Install spring and spring plate. Insert spring end into the hole. Compress spring with special tool. Align the secondary sheave end with spring plate hole. Tool Tool: Secondary sheave spring compressor Tool Tighten ring nut temporarily. Remove the special tool from secondary sheave.
6 Engine Removal,Inspection and Installation Tighten the ring nut with special tool to the specified torque. Ring Nut Tightening Torque: 100N m Tool: Ring nut wrench Sheave holder Drive belt Check belt for any greasy substance. Check contact surface of belt for any cracks and damage check belt width with venire caliper In casse of damage, width out of range, replace with new one. Belt width service limit:33.
Transmission Disassembly 3 2 1 12 13 4 14 16 11 15 17 10 18 9 8 7 6 5 Item 1 Description MAINSHAFT.
6 Engine Removal,Inspection and Installation Inspection Inspect drive bevel gear and sprocket for stains, scratch or damage, replace if necessary. Inspect reverse gear chain for damage, wear,replace if necessary. Disassemble counter shaft as illustration. Inspect bearing surfaces for stains, damage or wear and also for bearing gaskets. Replace if necessary.
Check the shift fork clearance with a thickness gauge in the groove of its gear.Replace if clearance exceeds the limit. Shiftfork to Groove clearance Standard: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 fork 1 and 2 for damage or bend, replace if necessary. Install shift fork to guide bar and move left and right.
6 Engine Removal,Inspection and Installation Put the guide bar on a flat place and roll it. In case of any bend, replace with a new one. NOTE:DO NOT attempt to correct a bent guide bar. Check shift fork spring for damage, repalce if necessary. Check shift cam groove for scratches, damage.Replace if necessary. Assembly Reverse the removal procedure for assembly. Pay attention to the following. NOTE: Use new retainers. Pay attention to the direction of the retainers.
When assembling the guide bar, take care not to assemble the two shift forks and springs in the opposite direction.
6 Engine Removal,Inspection and Installation Oil Strainer Inspection 2 Check oil strainer 1and O-ring 2 for damage, replace if necessary; 1 Clean the surface of oil strainer with engine oil. Relief Valve Check the valve body 1,valve2,spring3,0-ring 4 for damage or wearing.
8 Front Output Shaft Check bearing 7 for smooth turning and abnormal wear. Check oil seal 5 for damage. 7 5 6 Replace if necessary; 4 Apply lubrication oil to bearing 7 and oil seal 5 lip before assembly; Apply thread locker to bearing limit nut 6 (left thread) and tighten to the specified torque. (80N.
6 Engine Removal,Inspection and Installation Bevel Gear NOTE:Proper bevel gear engagement depends on that the gear backlash & 2 1 tooth contact are within the proper range. 2 Bevel Gear Backlash Install drive and driven gears to the crankcase.
Tooth Contact Inspection After adjusting the backlash, check the tooth contact according to the following procedures Remove drive and driven bevelgear shafts from crankcase; 1 Clean and degrease every tooth of drive and driven bevel gear Coat the driven bevel gear with machenist’s layout dye or paste; Install drive and driven bevel gear; 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; Contact 1 to
6 Engine Removal,Inspection and Installation Balance Shaft Remove the parts as illustrated on the right. Check each part for abnormal wear or damage. Replace if necessary. 1.Balance shaft gear 2.woodruf key 3.Balance shaft; 4.Balance shaft sprocket 5.Washer 6.Bolt Magneto Rotor Remove starter clutch nut.
Check starter clutch roller and holder for abnormal wear or damage,replace if necessary. Replace the starter clutch in the right direction. NOTE:When install the starter clutch to the magneto rotor, make sure side A is in the right direction. Face arrow mark B to the engine side. Thread Locker Apply engine oil 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.
6 Engine Removal,Inspection & Installation Electric Starter Gear Check the gear surface for nicks or damage, replace if necessary; Left crank case cover: Check magneto stator coil 2, pickup coil 3 for damage,replace circuit if necessary; Apply Thread Locker 3 Check bearing 4 for smooth turning. If it is stuck, replace with a new one; 2 Check oil seal 5 for damage. Replace if it is damaged.
Recoil Starter Disassembly is unnecessary if recoil starter works well. 10 1 3 4 2 5 7 6 1.Cap, handle 2.Handle 3.Friction plate 4.Spring clamp 5.Pawl 6.Spring 7.Sheave drum 8.Rope 9.Coil spring 10.Nut 9 8 Disassembly Remove nut 10 and the 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 parts for damage. Repalce if necessary.
6 Engine Removal,Inspection & Installation 1 Assembly 2 Reverse the removal procedure for installation and pay attention to the following: Install sheave drum 1 rope 2 coil spring 3 Damper 4. Wind the rope clockwise around the sheave drum three times and hook the rope at of 3 4 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.
CVT COVER Remove screw 5, oil seal limitator 4 .Remove oil seal 3 with sepecial tool; Check bearing 2 for free turning. In case of any abnormal, remove with special tool and replace with a new bearing; Apply lubrication oil to outer ring of bearing and install bearing with special tool. Check bearing for smooth turning. Apply grease to bearing inner side 1.CVT Case Cover 2.Bearing 3.Oil Seal 4.Oil Seal Flapping Plate 5.Screw 6.Bolt 7.Washer Apply grease oil seal lip and install bearing with special tool.
6 Engine Removal,Inspection & Installation Crankcase 1-Right crankcase 2-Bearing 3-Bearing 4-Bearing 5-Bearing 6-Bearing 7-Oilseal l8-Washer, reverse gear sensor 9-reverse gear sensor 10-O-ring 11-Gear sensor 12-Left crankcase 13-Screw 14-Oil pipe 15-Link bolt 16-Washer 17-Bearing 18-Bearing 19-Bearing 20-Bearing 21-Bearing 22-Oil dip rod 23- O-ring 24-Speed sensor 25-Bolt 26-Washer 27-Oil drainage bolt Clean and grease the bearings, turn the inner race of bearing and check the play, noise and smooth tur
Install new o-ring and apply grease; Install gear sensor; Install reverse gear sensor 9 and tighten to the specified torque Tightening torque:20N m Install speed sensor 24 Install oil pipe and tighten the link bolt to the specified torque: Tightening torque:18N m Install washer 26 and oil drainage bolt 27 and tighten to the specified torque; Tightening torque:30N m Tool:Bearing remover Bearing installer Multimeter Engine Assembly Reverse the engine removal procedure for installation.
6 Engine Removal,Inspection & Installation Crankshaft Install crankshaft to left crankcase with special tool. 4 NOTE: Do not hammer the crankshaft into crankcase with plastic mallet; Use special tool to avoid affect of conrod precision 2 5 6 3 Tool:control installer Balance Shaft Install balance shaft. CAUTION: Balancer shaft driven gear should be aligned to the mark as illustrated. Balance Shaft Drive Gear Main Shaft,Counter Shaft Install main shaft and counter shaft.
Shift Cam, Shift Fork 1 Install shift cam 1 and shift fork 2. 2 Check each part for smooth turning. Install low range driven gear to counter shaft 3. 3 Spray adequate engine oil to each part. Drive Bevel Gear Install drive bevel gear and tighten to the specified torque.
1 2 Apply sealant 1 to the mating face of right crankcase; NOTE:Apply sealant evenly in a uninterrupted thin line Install 2 dowel pins 2; Assemble crankcase and tap slightly with a rubber hammer for proper fitting; Install bolt and tighten to the specified torque: M6 N M8: m N m NOTE:Crankcase bolts should be tightened diagonally in several steps.
Intall new O-ring 6 in spacer 8. Install spacer 8 onto the clutch housing shaft, then install into CVT case 7. NOTE: align oil noter on spacer with oil hole on the shaft. 11 10 3 CVT Case Install dowel pin 4,gasket 2 gasket5,intall CVT case assembly to the right crankcase. 7 9 8 6 Install bolt 12 and nut 3. NOTE: Tighten bolt/nut diagonally 4 Use a new gasket 2 Install guide plate 10 and screw 11.
6 Engine Removal,Inspection & Installation Install secondary sheave. Install primary sliding sheave. Tighten primary sheave nut with special tool to the specified torque. Primary sheave nut tightening torque:115N m Tool Tool:CVT Holder Tighten secondary sheave nut with special tool to the specified torque. Secondary sheave tightening torque:115N m Tool Tool:Rotor holder NOTE:Turn the primary sheave until the belt is seated in and both primary and secondary sheaves move together smoothly.
Install CVT case cover bolts and tighten diagonally in several steps. Engine left Oil pump sprocket and chain Install oil pump drive sprocket; Install oil pump driven sprocket; Install oil pump drive chain; Tighten oil pump sprocket bolt; Install sprocket retainer with a long Tool Long nose pliers. Bolt nose pliers. Retainer Dual gear/idler gear 3 Install dual gear shaft 1 and dual gear 2. 4 Install idler gear shaft 3,idler gear 4 and bush 5.
6 Engine Removal,Inspection & Installation Starting Driven Gear zInstall starting driven gear. Magneto rotor zInstall woodruff key into crankshaft groove. zIntall magneto rotor 1. 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. 2 2 Left crankcase cover zInstall dowel pin 2 and gasket 3; NOTE:Use a new gasket 3 zApply lubricant grease to oil lip. zInstall left crankcase cover. zInstall bolts.
Water pump zInstall water pump. zInstall water pump retaining bolts. NOTE: Before tightening the bolts, be sure to insert oil pump shaft into groove of water pump shaft. Sector gear Install the parts as illustrated on the right.
6 Engine Removal,Inspection & Installation Oil filter Install oil filter bolt and tighten to the specified torque. Apply Grease Tightening torque:63N m zApply engine oil to O-ring. zInstall oil filter, turn it by hand until the filter gasket contacts the mating surface. Tighten the bolts. Tool:Oil filter wrench Starting motor zApply engine oil to new O-ring. zInstall starting motor. Apply Grease zInstall bolt and tighten to the specified torque. Tightening torque: 10N.
z1st and 2nd rings have letter R marked on the side. Be sure to bring the marked side to the top when fitting them to the piston. 1st Ring z 2nd Ring z zPosition 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 Blading Ring 2nd Ring z z Lower Blading Ring z z Piston Pin Center Line z z Wave-shape Gasket z zApply a light coat of moly oil to the piston pin.
6 Engine Removal,Inspection & Installation Cylinder zApply engine oil to piston skirt and cylinder wall. zHold each piston ring with proper position, insert piston into the cylinder. zTighten 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. zInstall chain guide 1. zFit the dowel pin and new cylinder cover gasket. NOTE: Use a new cylinder cover gasket to prevent oil leakage.
zInstall chain tensioner. Camshaft z Align mark A on magneto rotor with mark B on crankcase. A B NOTE:While rotating crankshaft, pull the cam chain upward, or the chain will be caught between sprocket and crankcase. zAlign the mark A on the camshaft so that they are parallel with the mating surface of the cylinder head. NOTE: Do not rotate the magneto rotor while doing this. when the sprocket is not positioned correctly, turn the sprocket.
6 Engine Removal,Inspection & Installation zInstall crankshaft C-ring 1. zInstall lock washer so that it covers the locating pin. zApply thread locker to the bolts before installing, and tighten them to the specified torque. Sprocket bolt tightening torque:15N m zBend up the lock washer to lock the bolts. Cylinder head cover zClean the mating surface of cylinder head and cylinder head cover. zInstall dowel pin to the cylinder head. zApply sealant to the mating surface of the cylinder head cover.
Gasket sealant applying place Apply sealant Chain tensioner zInsert (--) screwdriver into slotted end of chain tension adjuster, turn it clockwise to lock the tensioner spring. zInstall the chain tensioner and the new washer 1. zInstall the bolt 2, tighten it to the specified torque. Chain tensioner bolt tightening torque:10N m zAfter chain tensioner is installed, turn the (--) screwdriver counter clockwise. The tensioner rod will be advanced under spring force and push tensioner against chain.
6 Engine Removal,Inspection & Installation zInstall the new gasket 3. zInstall chain tensioner screw, tighten it to the specified torque. Chain tensioner screw tightening torque:8N m Apply lubricant Valve adjuster cover zRefer to 2-3 for valve clearance. zUse new rubber gasket and apply grease. zInstall Valve Inspection Cap. zInstall valve inspection cap bolt. Spark Plug Spark plug zInstall spark plug with special tool and tighten to the specified torque.
Left plastic cover zInstall left plastic cover 6. Water pipe and hose z Install water hose 5. z Install bolt 4. z Install water hose 3. z Install clamp 1,2.
7 Fuel System, Air Intake System Overhaul Info Troubleshooting High Pressure Fuel Line Disassembly/ Installation Throttle Body Disassembly/Installation Fuel Injector Assy Disassembly/Installation Fuel injector Assy Removal/Assembly Idle Air control valve Disassembly/Installation
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 pressure fuel line and put it in a container.
7 Fuel System, Air Intake System High Pressure Fuel Line Disassembly Loosen the special fuel line clamp on fuel injector cap. loosen the special fuel line clamp on fuel tank. Disassemble High pressure fuel line.
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 Snap Spring into it. Fuel Injector Idle Air Control Valve Disassembly Disassemble idle intake pipe and idle outlet pipe.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Overhaul ………………………………8-1 Br a k e S y s tem … …… …… …… …8 - 4 Fault Diagnosis ………………………8-2 Front Suspension System……………8-7 Front Wheel……………………………8-3 Steering System……………………8-12 Overhaul Operation Notice Attention The frame must be hold up firmly when overhauling front wheel, suspention system. Light,meter,switch overhaul or inspection refers to section10. Do not overpower on the tire, be careful not to destroy the tire.
Special Tools: Bearing Disassemble Tooling Bar Bearing Disassemble Tooling Nod 10mm Press In Tooling Lever A Press In Tooling Coat 28 30 Guide Tool 10mm Lock Nut Spanner Bearing Disassemble Tools Rotor Puller DisassembleTooling Bar Disassemble Heavy Punch Assemble Tooling Bar Fault Diagnosis Handlebar Heavy Upper screw over tightened. Steering shaft worn or damaged. Bearing inner, external race destroy, worn, step. Steering column deformed or bent. Tire pressure incorrect. Tire worn out.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Front wheel Bolts Disassemble Set up front wheel with tool, ensure without any force on the front wheel. Remove steer cap. Remove the four nuts installed in the front wheel hub, Remove front wheel. Inspection Rim Inspect the rim for damage, replace the rim if needed. Turn the wheel slowly, use centimeter measure rim jump. Service limit:axial direction: 2.0mm Radial direction:2.0mm Rim Install Bolt Installation Press the rim in the tire on special matchin.
Brake System Front Brake Caliper Disassembly Remove front wheel . Remove the 2pcs nuts installed on the arm Remove brake caliper. Front Caliper Inspection Check if the brake caliper crack is cracked, if the tightening area oil leakage, replace if needed.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Brake disc Disassemble Remove front wheel Remove brake caliper Take away brake disc together with front wheel hub. Remove brake disc’s 4pcs nut installed in front wheel hub. Remove the brake disc. Inspection Brake disc thickness: replace when less than 2.5mm. Brake Disc Bolts Installation Install the brake disc well Brake disc holding bolt torque:25-30Nm Hand Brake Master Cylinder,Front Brake Disassemble Remove bolt. Remove parking lever.
Disassembly Remove foot rest Remove front inner fender RH Remove bolt1, bolt2. Seperate pedal brake master cylinder from the body. Footbrake Master Cylinder Assembly For assembly,reverse the disassembly procedure. ATTENTION: To avoid air into the brake pump, thus you must to keep the assemble position, at the same time, fix it in the vehicle body. Brake hose trend refers to Section1 cable, wire traces. It must ensure the brake hose routing .
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Assembly For assembly,reverse the disassembly procedure. ATTENTION:Brake hose routing refers to section 1 cable, wire line traces, brake oil line must be smooth. Brake force checking is needed after finish the brake system installation, if it cannot join control, check the cross plug.
1.Bolt GB5789 M10 Bolt GB5789 M10 1.25 10 1.25 13.Brake Disc Guard 70 14.Bolt:GB5789 M6 3.Front Shock Absorber Assy 4.Nut:GB6187 M10 5.Cap,Buffering Collar 1.25 29 Dust Boot Set,Front Motion End 16.Bearing,Hub 30.Front Lower Arm,LH 18.Cotter Pin 31.Bearing Set,Motion End 32.Big Clamp,Motion End 7 Cap,Buffering Collar 19.LH Steering Knuckle 8.Front Upper Arm,LH 20.M6 Nut Clamp 9.Circlip 10.Top Ball Pin 21.Front Protector,LH 22.Front Axle,LH 11.Slot Nut 10 Washer 12 27.Small Clamp 28.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Assembly For assembly,reverse the diassembly procedure. Front left shock absorber disassembly, assembly, inspection are as same as front right shock absorber. Arm Assembly Attention:There are 8 suspension arms in the vehicle, they dismantle,inspection and assemble in the same way.So here only introduce the way to dismantle,inspection and assemble the front left upper arm and the front right lower arm. Other arm assemble refers to the above.
Inspection Ball Joint Inspect if it can rotate flexibly between top ball joint 5 and front left upper arm 22,bottom ball joint 13 and front left lower 24. Besides, the gap between top ball joint and bottom,if it cannot move freely or the gap too big, ball joint replacement is needed. Right Knuckle Inspect the right knuckle for damage, replace it if needed. Inspect if the rim shaft inside right knuckle moves freely, replace bearing if needed. 2 15 2 15 1.FRONT SHOCK ABSORBER 2.NUT 4.CIRCLIP 5.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Front Axles Attention:For this vehicle, inspection,disassembling and assembling the front&rear axles are in the same way.Below introduces how to disassemble,inspect,assemble front axle,LH. Front Axle,LH Disassembly Attention:You do not need to remove the front suspension assy from the vehicle if you only repair the front axle , LH. Remove front wheel,LH Remove front brake caliper,LH Remove fornt rim hub,LH Examine dust boot, replace with new one if damaged.
Steering System Handlebar Dashboard cover Disassemby Remove dashboard cover bolt1. Remove dashboard cover. Bolts 1 Cover,Dashboard Assembly For assembly,reverse the disassembly procedure. RH Handlebar Switch Disassembly Remove front top cover . Remove RH handlebar switch connector. Remove the two bolts installed in handlebar tube. Remove handlebar switch, RH. Handlebar Switch,RH Installation Install the handlebar switch, RH .
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Handlebar Switch, LH Disassembly Remove 2 screws. Screws Remove LH handlebar switch connector. Remove handlebar switch, LH. Install Install the LH handlebar switch Rear View Mirror Connector,Handlebar Switch Disassembly loosen the nut in counter-clockwise direction, then turn the rear mirror in counter-clockwise and you can take off the rear view mirror.
Handlebar Pipe Disassembly Remove the dashboard cover Remove RH&LH handlebar switch Seperate the right and left brake pump from the hanlebar pipe. Remove the four installation bolt, take down the handlebar. Assembly For assembly,reverse the disassembly procedure. Torque:20-30Nm(2.0-3.0kgf m ATTENTION: Main cable assy,throttle cable,brake hose must route correctly. Bolts Screws Install Throttle Cable Remove the three screws, remove RH handlebar switch cover.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Install LH Handlebar Switch Pair the LH handlebar switch stopped onto the handlebar location hole. use bolt 1 tightening from the bottom. Handlebar Switch,LH Bolts 1 Insert the LH handlebar switch’s connector into the main harness. Handlebar Switch Connector Handlebar Switch,RH Install RH Handlebar Switch Bolts 2 Install the RH handlebar switch stopped onto the handlebar location hole. Tightening through the bolt 2 from the bottom.
Install RH&LH Grip Clean inner LH grip and dry it. coat the connection with joint cement between handlebar and LH grip, put in the RH&LH grips. Brake Pump Parking Lever Grip ATTENTION: The installed RH&LH grips must be placed for hours for dry the joint cement. Install Brake Pump Install brake pump with “up” mark facing up.Make sure the distance between brake pump and handlebar switch us equal. ATTENTION: Main cable assy,throttle cable, brake hose must route correctly.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Steering System 21 1.Bolt1 21.Washer 2 2.Rubber Collar 3.Bracket Dashboard,RH 22.Nut 2 23.Steering Ball Joint 4.Bracket Dashboard,LH 5.Aluminum Cover,Handlebar 24.Nut 3 25.Tie-rod 6.Bolt2 7.Front Bracket,Dashboard 26.Nut 4 27.Steering Ball Joint 8.Bolt3 9.Lock Pad 10.Adapter Plate 11.Bush 12.Bushing,Steering Column 13.Seal Ring 14.Steering Lock 15.Screw 16.Steering Column 17.Cotter Pin 18.Nut 1 19.Washer 1 20.
Steering Column Disassembly Lock Pad Steering Bearing Seat Remove dashboard front cover . Remove front wheel . Unhook handlebar switch connector. Use straight screwdriver and hammer ,bend out the lock pad. Remove bolt1,bolt2. Remove steering column seat, plate and bush. Bolts Adapter Plate Nut Remove cotter pin. Remove steering tie-rod installation nut, washer. Press and separate the steering tie-rod from the steering column. Remove steering stem installation bolt.
8 FRONT WHEEL,BRAKE SUSPENSION,STEERING SYSTEM Steering Bearing, Oil Seal Disassembly Remove front wheel Remove steering column Remove front ADWS arm assy Use special tool separate the steering column and the oil seal from the body. Special tool: Bearing Remover Component Rotor Puller Remover Axle Remover Heavy Bob Installation For installation,reverse the disassembly procedure.
9 Rear Wheel, Rear Brake, Suspension Overhaul Info Rear Brake System Troubleshooting Rear Wheel Rear Suspension System Overhaul Information Operating Notice Note Securely support the vehicle when overhauling the rim and suspension system. Use genuine parts of bolts and nuts for rear rim and suspension. Do not overexert on the wheels to avoid possible damage to the wheels. When removing tires from rim, use special tire lever and rim protector to avoid damage to the rim.
Troubleshooting Rear Wheel Wobbles Rim bent 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 Bent Rear Shock Absorber Tire Pressure is Too High Poor Brake Efficiency Improper Brake Adjustment Worn Brake Pad or Brake Disk
9 Rear Wheel, Rear Brake, Suspension Rear Wheel Removal Refer to Front Wheel Removal Inspection Rim Damage, bent, serious scrapes Slowly turn the wheel, measure the rim runout with a dial gauge. Service Limit: Axial:2.0mm Radial:2.0mm Installation Refer to Front Wheel Installation Wheel Hub Remove: Rear Wheel Rim Axle Nut Wheel Hub Installation: Reverse the removal procedure for installation.
Rear Brake Rear Brake Caliper Remove: -Rear Left Wheel -2 Bolts from Arm. -Brake Caliper. Bolts nspection 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 Rear Brake Disc Remove: -Rear Left Wheel -Rear Drive Shaft -Rear Brake Caliper -6 Shear Bolts -Parking Brake -Rear Brake Disc Shear Bolt Rear Drive Shaft Inspection Brake Disc: Thickness 6.
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 falling down of the vehicle. 1.BOLT 2.GLAND COVER 3.RUBBER SUPPORT 4. BOLT 5.LOCK NUT 6. BOLT 7.REAR SHOCK ABSORBER 8.STABILIZER BAR 9.BALL PIN,LH 12. BOLT 13.DUST CAP 14.CENTER SPACER 15.BEARING, HUB 16.CIRCLIP 17.OIL CUP 18.HOLDER UNIT REAR WHEEL SHAFT 20.BUFFERING COLLAR 21.CAP, BUFFERING COLLAR 22.BOLT 23.REAR SUSPENSION PROTECTOR,RH 24.
Rear Right Absorber Removal NOTE:Securely support the vehicle when removing rear left and right absorbers. Suspend wheels from ground. Maintenance of rear absorbers does not require removal of rear suspension. Remove the following parts from rear right shock absorber: -Bolt10(25) -Nut7(27) -Bolt7(19) -Nut8(28) Remove bolt 6 & scre 6 of the rear right shock absorber from the vehcile body. Remove rear right shock absorber Installation Reverse the removal procedure for installation.
10 Front Differential/Rear Gearcase Overhaul information Standards Lubricating Priod Item Front Diff Rear Gearcase Interval Capacity Type SAE15W/40 SF Initial: 0.33L/Replace:0.28L or Initial: 0.30L/Replace :0.25L SAE80W/90 GL-4 Item Pcs Specification Front Diff Bolt M Front Diff Motor Screw M Pinion Shaft Screw M Front Diff nut M Diff.
Inspection & Overhaul Inspection and overhaul is needed if any of problems below happens to front diff and rear gearcase. Problem Descriptions Causes Unstable moving during accelerating, A.Bearing broken. decerating or constant speed. B.Gear clearance over/under size. C.Gear severely worn. Abnormal sound in front diff or rear gearcase. Engine power tranmission failure to D.Gear blocked. E.Drive shaft broken. F.lack of lubricant. G.Foreiggn matter in front or rear gear. front or rear wheels.
10 Front Differential/Rear Gearcase Front Diff Xploded View 24 23 22 21 20 31 16 19 17 15 (10) 18 18 14 10 9 8 13 7 25 6 12 11 26 5 28 3 27 2 4 29 30 1 Item Part Name Qty Item 15 Part Name Bolt M Bearing F1512 Front Diff Drive Pinion Gear O-ring Bearing 6007 Bearing 16007 Oil Seal Circlip 62 Coupler Drive Clutch Cover O-ring Drive Clutch Nut Washe Adjust Washer Nut M Differential.
Inspection After Front Diff Disassembly Check if there is damage or cracks on the front diffrential gear case cover and bearing bore.Replace case cover if necessary; Check if front axle bearing clearance is ok,replace bearing if needed.(Using special tools) Check if oil seal lips and O-ring are ok. Replace if necessary; Check drive pinion gear and differential gear, inspect wear surface. Replace broken or damaged gears. Check gear motor working status. Replace if necessary.
10 Front Differential/Rear Gearcase Front Diff Assembly And Adjustment Front Diff Case Cover Asselbly 15 16 17 18 19 31 20 22 21 Item”31 ”Tightening torque 80Nm Item ”24 ”Tightening torque 62Nm NOTE:Use engine oil for oil seal, bearing and drive clutch assembly;“24”Use loctite. 10 23 24 2 Front Diff Case Assembly 6 Note:Use engine oil for oil seal or bearing assembly.
Front Diff Assembly And Adjustment 1 8 As illustration shows: Tightening torque Item ”1 ” 25Nm Item”25” 13Nm Item ”30 ” 13Nm Bolt 25Nm Bolt 25Nm 7 3 10 28 29 30 27 25 26 Use loctite 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 support tools,tighening bolts( M10X1.
10 Front Differential/Rear Gearcase c Use special equipment or vehicle control circuit into 2WD position before gear motor assembly d Make sure b and c is assembled properly and using illustrated positionging screw to assemble gear motor and front axle¡£ Positioning Screw( M8X100 )
Rear axle exploded view 4 9 27 28 26 Item 1 Part Name Bolt M10 1.25 Bolt M8 25 25 Qty Item 2 18 Part Name O-ring 64.5 Qty 3 Bearing 6305 Rear Gearcase Bearing Housing Bearing Retainer O-ring 151 Drive Gear, Rear Gearcase 3 Bearing 16017/C2 Bearing Inner Race Adjust Washer(2) Bearing Outer Race Driven Gear,Rear Gearcase Adjust Gasket Adjust Washer(1) Washer14.5 Needle Bearing Bolt M14 1.25 Rear Gearcase O-ring 19 2.5 Oil Seal SD4 65 90 9 NS Bolt M20 1.
10 Front Differential/Rear Gearcase Disassembly Of Bearing a Disassemble needle bearing as left draw- ing shown when necessary. b When replacing needle bearing, rear bearing housing should be heated to 150 removing bearing. before Rear Gearcase Inspection After Disassembly Check if there are cracks or damage in rear gearcase, check mounting holes for damage . Replace gear case or right cover if necessary. Check all bearings,if rough or damaged,replace as needed.
Rear Gearcase Assembly And Adjustment Illustration 15 20 8 Tightening Torque 12 Item ”1” 40Nm Item ”2” Item”12” 25Nm 70Nm Item”15” Item”20” 25Nm 70Nm Item”31” Bolt 16Nm 25Nm Bolt 25Nm 24 1 29 31 6 Use loctite for Item”29”assembly Assembly and clearance adjustment of drive gear of rear axle a By choosing “24”washer to adjust clearance. b By choosing “6” washer to adjust clearance. c By coating color to check contact surface if Support Measurement Tool it’s ok for mating.
10 Front Differential/Rear Gearcase f Adjust item 29 as illustrated, and make sure Driven Bevel Gear its end and back clearance of drive gear is 0.30.6. Tighten item 31.
11 Electric System CHARGING SYSTEM ELECTRIC STARTING SYSTEM ELECTRICITY-SPRAYING SYSTEM ELECTRICITY-SPRAYING SYSTEM STRUCTURE ELECTRICITY-SPRAYING SYSTEM DIAGRAM ELECTRICITY-SPRAYING SYSTEM MAINTENANCE NOTICE MAINTENANCE TOOL ELECTRICITY-SPRAYING SYSTEM COMPONENTSCOMPOSITION&FUNCTION ECU THROTTLE ASSEMBLY INLET PRESSURE SENSOR INTAKE AIR TEMPERATUR SENSOR WATER TEMPERATURE SENSOR OXYGEN SENSOR TRIGGER ODOMETER SENSOR SHIFT LEVER POSITION SENSOR FULE OIL PUMP ASSEMBLY OIL ATOMIZER IDLE AIR CONTROL IGNITION
CHARGING SYSTEM CHARGING CIRCUIT DIAGRAM Fuse Regulate Magneto Voltage Regulator MAGNETO COIL RESISTANCE MEASURE TRIPHASE MAGNETOR STATOR COIL RESISTANCE IF THE RESISTANCE VALUE OUT OF PRESCRIBED VALUE, REPLACE THE STATOR COIL. INSPECT IF THE STATOR COIL AND STATOR CORE INSULATION.
11 Electric System Black Red Green White USE MULTIMETER MEASURE THE RESISTANCE BE TWEEN THE TERMINALS,AS BELOW FORM SHOWS, IF THERE IS ONE DATA OUT OF THE SETTING VALUE, REPLACE WITH A NEW ONE. AFTER ENGINE RUNNING, BATTERY FULL POWER, IF VOLTAGE BETWEEN RED LINE, GREEN LINE EX CEED 15V OR UNDER 12V,REPLACE WITH A NEW ONE. ADJUST MULTIMETER TO DIODE ATTENTION: WHEN MULTIMETER PROBE UNCONNECTED,IF THE MULTIMETER SHOWS BELLOW 1.4V, THEN REPLACE IT’S BATTERY.
STARTING SYSTEM TRIGGER CIRCUIT DIAGRAM Electric Fuel Pump Ignition Switch ECU Fuel Pump Relay Start Switch Auxiliary Relay Fuel Injector 19 18 17 16 14 5 4 3 2 1 Ignition Coil Speed Signal Trouble Lamp 12V R Gear Switch 4WD/lOCK Switch Override Switch Intake Air Temp Sensor Green Bluel +5V Power IACV 22 21 20 9 8 7 6 WPS 26 25 24 23 13 12 11 10 Trigger Map Sensor TPS O2S RPM output K Battery 12V Start Motor M STARTING MOTOR 1 3 2 1.End Cover 5 2.Brush Holder 4 3.
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. IF THERE IS WEAR OR DISCOLORATION , RE PLACE WITH A NEW AMATURE. IF THE COMMUTATOR SURFACE DISCOLOURATION, POLISH WITH SEND PAPER AND WIPE UP WITH DRY CLOTH. IF OVER WEAR, CUT PART OF B INSULATOR WITH BLADE,KAME THE DISTANCE BETWEEN A AND B TO d. d 1.
INITIATING RELAY PUT 12V TO THE SMALL TERMINALS;THERE IS CONTINUITY BETWEEN THE LARGE TERMINALS. IF THE START RELAY CONTACTS,SHOULD MAKE A CLICKING SOUND. WHEN POWER IS TAKEN AWAY FROM THE SMALL TERMINALS,THERE SHOULD BE NO CONTINUITY BETWEEN LARGE TERMINALS. 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 ELSE,IT WILL CAUSE THE RELAY OVERHEAT AND BURN THE RELAY COIL.
11 Electric System STARTING ENGINE NOTICE JOINT LINES ACCORDING TO TRIGGER CIRCUIT. BEFORE STARTING, CHECK IF ALL THE PARTS ARE CORRECT JOINTED.ELECTRICITY SPRAYING JOINT SEE BELOW: CHECK IF GAS CIRCUIT NORMAL. CHECK IF OIL CHANNEL AT FAULT. IF BLOCKED,CLEAR BLOCKED PART, SECURE FUEL CHANNEL SMOOTH. IF LEAKAGE,RELINK LEAK SECTION, SECURE THE FUEL CHANNEL NO LEAKAGE. USE FUEL PRESSURE GAUGE TO MEASURE FUEL PRESSURE. FULE PUMP OUTPUT PORT PRESSURE:0.3 0.01Bar CHANGE ENGINE SHIFT HAND LEVER TO NEUTRAL.
ELECTRONIC FUEL INJECTION SYSTEM IACV Ignition Coil MAP Sensor Air Filter Oxygen Sensor Intake Air Temp Sensor Throttle Body Assy Water Temp Sensor Trigger Fuel Pump Assy ENGINE ELECTRONIC FUEL INJECTION SYSTEM INCLUDING THREE PARTS: OXYGEN SENSOR(EXCESS AIR COEFFICIENT ABOVE 1 OR LOWER THAN 1 (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.
11 Electric System ELECTRONIC FUEL INJECTION SYSTEM DIAGRAM ECU 2 23 11 5 26 4 1213 25 3 8 7 9 6 18 201011 19 1 11 14 24 15 22 16 Auxiliary Relay Fule Pump Relay O2S Fule Injector IACV USE QUALITY COMPONENTS FOR SERVICE, OR ELSE IT MAP Sensor ELECTRONIC FUEL INJECTION SYSTEM MAINTENANCE NOTICE Ignition Coil TPS Intake Air Temp Sensor Ignition Coil Override Switch R Gear Switch 4WD/LOCK Switch Speed Signal RPM Trigger Faut Lamp Diagnostic Wire Fule Pump FUEL PIPE’S DISMANTLE AN
SERVICE TOOLS TOOL NAME:DIAGNOSTIC EQUIPMENT FUNCTION: READ CLEAR ELECTRONIC FUEL INJECTION SYSTEM T R O U B L E C O D E , O B S E R V E D ATA S T R E A M , 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 Electric System TOOL NAME:ELECTRONIC IGNITION TIMING FUNCTION: INSPECT ENGINE ELECTRONIC SPARK TIMING. TOOL NAME:CYLINDER PRESSURE GAUGE FUNCTION: CHECK CYLINDER COMPRESSION. TOOL NAME:FUEL PRESSURE GAUGE FUNCTION: INSPECT FUEL SYSTEM PRESSURE STATE,JUDGE THE FUEL SYSTEM FUEL PUMP AND FUEL PRESSURE REGULATING VALVE WORK STATE.
ELECTRONIC FUEL INJECTION PARTS STRUCTURE AND FUNCTION (1)ECU: ECU,IT IS THE BRAIN OF THE ENTIRE ELECTRONIC FUEL INJECTION SYSTEM. IT ANALYZE AND PROCESS THE INFORMATIONS PROVIDED BY THE SENSOR, REACH A CONCLUSION, THEN TRANSMIT THE CONCLUSION TO THE ACTUATOR AS INSTRUCTION,SO AS TO MAKE THE ENGINE OPERATION IN OPTIMAL STATE. 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.
11 Electric System (2)THROTTLE VALVE ASSY: JOIN THE AIR CLEANER AND ENGINE,CONTROL THROTTLE VALVE OFF AND ON ANGLE THROUGH THROTTLE CABLE. AIR DAMPER POSITION SNESOR TRANSMIT ANGLE SIGNAL TO ECU. Throttle Body Assy Connected with Connected with Air Filter Engine IACV MAP Sensor EACH PIN FUNTION: 3 1.CONNECT 5V POWER 2 2.GROUNDING 1 3.
(3)MAP Sensor: 1 2 3 MONITOR AIR PRESSURE IN MANIFOLD,PROVIDE ENGINE LOAD INFORMATION TO ECU. EACH STITCH FUNCTION: 1.CONNECT 5V POWER 2.GROUNDING MAP Sensor 3.OUTPUT VOLTAGE SIGNAL 21 1 3 2 19 THE RIGHT DRAWING IS THE CONNECTION DRAWING FOR SENSOR&ECU. P U 10 MAP Sensor Wiring Diagram 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.
11 Electric System (4)INTAKE AIR TEMPERATURE SENSOR(IAT Sensor): THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT (NTC) THERMISTANCE,IT’S RESISTANCE VALUE DECREASE WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT LINEAR RELATION.THE SENSOR HAVE 2 PINS,AND THEY CAN BE EXCHANGED USING. IAT Sensor ECU 21 THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR SNESOR&ECU. 6 1 2 IAT Sensor Wiring Diagram 10^4 THE RIGHT DRAWING IS FOR SENSOR TEMPERATURERESISTANCE PROPERTY LIST.
(5)WATER TEMPERATURE SENSOR: THIS SENSOR IS A NEGTIVE TEMPERATURE COEFFICIENT (NTC) THERMISTANCE,IT’S RESISTANCE VALUE DECREASE WHEN THE COOLANT TEMPERATURE INCREASE,BUT IT IS NOT LINEAR RELATION.ONE GROUP PROVIDE TO ECU,MONITOR ENGINE HEAT CONDITION.THE OTHER GROUP PROVIDE TO THE METER,MONITOR WATER TEMPERATURE. Water Temp Sensor A AND C IN ONE GROUP, THEY PROVIDE WATER TEMPERATURE TO ECU. B ANDTHREADED PORTION IN ONE GROUP,THEY PROVIDE WATER TEMPERATURE TO THE METER.
11 Electric System (6)OXYGEN SENSOR: THIS SENSOR USED IN ELECTRONIC CONTROL FUEL INJECTION EQUIPMENT FEEDBACK SYSTEM,TO REALIZE CLOSED-LOOP CONTROL,RAISE ECU CONTROL THE AIR-FUEL DELIVERY RATIO. IT INSTALLED IN THE EXHAUST-PIPE,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.
(7)TRIGGER: PROVIDE ENGINE ROTATE SPEED INFORMATION TO ECU,ECU DETERMINE IGNITION ANGLE,FUEL IN JECTION ANGLE ACCORDING TO THIS INFORMATION. Blue Green THE RIGHT DRAWING IS THE WIRING DIAGRAM FOR TRIGGER AND ECU. 12 13 TESTING THE THRIGGER RESISTANCE VALUE. ECU Blue Green Trigger ADJUST MULTIMETER TO TRIGGER WINDING RESISTANCE:100-130 IF THE TRIGGER RESISTANCE DONOT IN ABOVE RANGE,REPLACE WITH A NEW ONE. MEASURING TRIGGER PEAK VOLTAGE VALUE.
11 Electric System (8)ODOMETER SENSOR: PROVIDE ENGINE OUTPUT SHAFT SPEED TO ECU, ECU JUDGE VEHICLE SPEED ACCORDING TO THIS INFORMATION.IT IS A KIND OF HALL SWITCH COMPONENTS,IT OUTPUT SQUARE WAVE VIA INDUCTION FIELD. PINS FUNTION: 1 2 3 1.GROUNDING 2.OUTPUT SQUARE WAVE VOLTAGE SIGNAL( IN PUT POWER VOLTAGE 80%). 3.POWER+DC12V. Odometer Sensor +12V Power ECU THE RIGH IS THE WIRING DRAWING OF SENSOR AND ECU.
(9)GEAR SENSOR CLUSTER: PROVIDE GEAR INFORMATION TO THE METER,SOAS TO AT THE SAME TIME,COORDINATE WITH CABLE AS STARTING PROTECTION. FUNCTIONS OF THE FOOTS: YELLOW/BLUE-L(UNDERDRIVE) ORANGE/BLUE-H(HIGH POSITION) YELLOW/BLACK-P(PARK POSITION) WHITE/YELLOW-N(NEUTRAL POSITION) WHEN EACH OF THE FOUR GEAR IN A CERTAIN POSITION,GEAR CORRESPONDING FOOT CON DUCT TO THE ENGINE COVER, OR ELSE IT NONCONDUCTION WITH THE ENGINE COVER.
11 Electric System (11)FUEL PUMP ASSY: 1 2 THE OIL FUEL PUMP ASSY COMBINED OF FUEL PUMP,PLASTIC BRACKET,PREFILTRATION,PRES SURE REGULATING VALVE. IT DELIVER THE FUELTO THE ENGINE WITHACERTAIN OIL PRESSURE AND FLOW. Spout FUNCTIONS OF THE FOOT: 1.BLUE(GROUNDING) 2.
(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 Connected with Fuel Injector Cap TO SUPPLY OIL TO THE ENGINE AND ATOMIZING. THIS FUEL INJECTOR APPLY QUADRIPUNTAL,DO NOT TURN AFTER FIXED THE CLAMP. Mark ” +” FUNCTION OF PINS: ONE SIDE OF THE PLUG MARK+CONNECT FUEL PUMP RELAY OUTPUT END, WITHOUT MARK SIDE CONNECT ECU PIN 14.
11 Electric System ( 1 3 ) I D L E S P E E D C O N T R O L VA LV E (CARBON TANK CONTROL VALVE): Connected with Throttle Body 2 CONTROL PASS-BY AIR FLOW. ECU CONTROL THE 1 IDLE SPEED VALVE ACCORDING TO THE INFORMATION OF ENGINE LOAD,THE ELECTRICAL PULSE DURATION AND FREQUENCY:(DUTY RATIO).
(14)IGNITION COIL: IGNITION COIL CHANGE THE PRIMARY WIND ING LOW VOLTAGE INTO SECONDARY WINDING HIGH Connected with High Voltage Cable VOLTAGE,THROUGH SPARK PLUG DISCHARGE TO CREAT SPARK,FIRING THE FUEL AND GAS MIXTURE. FUNCTION OF PINS: 1.GROUNDING. 2.CONNECT POWER+. 3.CONNECT ECU 1 POINT; Ignition Coil THE RIGHT IS THE CONNECTION CIRCUIT DIAGRAM OF IGNITION COIL AND ECU.
11 Electric System ELECTRONIC FUEL INJECTION SYSTEM FAULT SELF-DIAGNOSIS ECU CONTINUOUSLY MONITOR THE SENSOR,ACTUATOR,RELEVENT CIRCUIT,TROUBLE LAMP,BATTERY VOLTAGE ETC,EVEN THE ECU ITSELF.ALSO THE SENSOR OUTPUT,ACTUATOR DRIVING SIGNAL,INTERNAL SIGNAL(SUCHAS CLOSED-LOOP CONTROL COOLANT TEMPERATURE,IDLING SPEED CONTROL,BATTERY VOLTAGE CONTROL ETC),DO THE RELIABILITY MEASUREMENT.
(2)DIAGNOSTIC EQUIPMENT:IT HAVE THREE PINS, POWER,GROUNDWIRE AND DATA K LINE,CONNECT WITH THE CORRESPONDING PINS IN ECU. Left Button Up Button Right Button THE RIGHT IS THE DIAGNOSTIC EQUIPMENT OPERATION FUNCTIONS INDICATOR DIAGRAM.SPECIFIC OPERATION AND IT’S FUNCTIONS PLEASE REFERS TO THE DIAGNOSTIC EQUIPMENT OPERATING MANUAL. PINS FUNCTIONS: 1.ECU 26PIN Down Button 1 2 3 2.GROUNDWIRE 3.+12V POWER Power ESC Enter KEY-PRESS FUNCTIONS: LEFT-HAND BUTTON:UPWARD TURN OVER.
11 Electric System TROUBLE CODE LIST: REF TR OUBLE C OD E INSTR UCTION 1 P00 30 OXYGEN SEN SOR HEA TIN G C ON TROL C IR CU ITOPEN CIRC UIT 2 P00 31 OXYGEN SEN SOR HEA TIN G C ON TROL C IR CU ITSH ORT TO GOUN D 3 P00 32 OXYGEN SEN SOR HEA TIN G C ON TROL C IR CU ITSH ORT CIRC UIT TO POWER 4 P00 53 OXYGEN SEN SOR HEA TIN G INTER NAL RESISTAN CE UN RE ASONABL E 5 P01 05 IN LE T PR ESSU RE SEN SOR SIGN AL N O C HAN GE（ICE UP ） 6 P01 06 IN LE T PR ESSU RE SEN SOR UN REAS ONABL E 7 P01 07 I
13 Lights,Instrument,Switches Overhaul Info Troubleshooting Bulb replacement Headlight Ignition Switch Handlebar Switch Brake Light Switch Horn Dashboard Fuel Sensor WaterTemperature sensor Overhaul Information Operation instructions Warning Headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down. Inspection of water temperature alarm may use heat source and liquid of high temperature.
13 Lights,Instrument,Switches Replacing Bulb Headlight Bulb Headlight Cautions 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 ( ) Dust Cover Disconnect headlight. Remove dust-proof cap, headlight connector, circlip and replace with a new bulb. Warning: Combined Wear clean gloves when replacing bulb. Oil stains on the glass surface may cause break of bulb.
13 Lights,Instrument,Switches NOTE: Main cable,wiring and tube should be routed properly( chapter 1) Dashboard Light Bulb Remove dashboard Remove dashboard indicator socket. Dashboard indicator:LCD Dashboard Note: If dashboard has something wrong, it’s recommended to replace whole dashboard. Reverse the removal procedure for installation Headlight Cable Headlight Nut Remove nuts as picture shown Disconnect headlight connector Disassemble headlight comp.
13 Lights,Instrument,Switches Check according to the following table if the connector terminals are in continuity. Continuity ON OFF P R BGB/W Ignition Switch Connector Lighting Switch Disassemble: Remove front cover ). Disconnect 4P connector of ignition switch. Loosen bolt and remove ignition switch. Reverse the removal procedure for installation. Starter Switch Handlebar switch Remove front cover( 2-4). Disconnect left and right handlebar switch connector.
13 Lights,Instrument,Switches Disassemble Disconnect horn connector. Remove bolt. Remove horn. Bolt Reverse the removal procedure for installation. Dashboard Connector Horn Run the vehicle at low speed and check if the speed indicator moves. Faulty speedometer: Replace. Bolt Removal and Installation Remove front top cover Remove front cover of dashboard Dashboard Disconnect dashboard wire connector. Remove fixing nut and remove dashboard in the direction as illustrated on the right.
13 Lights,Instrument,Switches Installation Put fuel sensor into installation hole of fuel tank. Fuel sensor should be fitted properly. Check for fuel leakage after installation. Connect 2P connector Fuel Sensor Connector 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.
13 Troubleshooting 1. Engine troubleshooting..........................................................................................13-2 2. Diagnosis troubles according to EFI system Trouble Code.........................................13-5 3. Diagnosis troubles according to engine fault phenomena............................................
1.Engine troubleshooting Complaint Symptom and Possible Causes Remedy Compression is Too Low 1.Worn cylinder 2.Worn piston ring Replace Replace 3.Leakage with cylinder gasket 4.Wear valve guide or improper valve seating Replace Repair or Replace 5.Loose spark plug 6.Slow cranking of starting motor Tighten Check electrical part 7.Faulty valve timing 8.
13 Troubleshooting Complaint Poor engine running in high-speed range. Exhaust smoke is dirty or thick Engine lacks power Symptom and Possible Causes 1. 2. 3. 4. 5. 6. 7. 8. 1. 2. 3. 4. 5. 6. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 1. 2. Engine overheats 3. 4. 5. 6. 7.
Complaint Symptom and Possible Causes Valve Chatter 1. Excessive valve clearance 2. Worn or broken valve spring 3. Worn rocker arm or camshaft 1. 2. 3. 4. 5. Engine is noisy Adjust Replace Replace Replace Replace Clean Replace Replace Noise from Timing chain 1. Stretched chain 2. Worn sprocket wheel 3. Faulty chain tensioner Replace chain & sprocket Replace chain & sprocket Repair or replace Noise from Clutch 1. Worn or damaged crankshaft spline 2.
13 Troubleshooting 2 Diagnosis troubles according to EFI system Trouble Code NOTE: 1. Only start inspection and fixation when trouble is steady-state; otherwise diagnosis would probably be wrong. 2. The “multimeter” mentioned below are numerical mutimeter; it is forbidden to use pointer type multimeter to make EFI system inspecting. 3.
Trouble Code: P0030 Oxygen Sens or Heating Control Circuit Broken Note Note Possible Troubles are as below Inspect as below 1）Circuit brok en between ECU Pin and Oxygen 1）Check if resistance between ECU Connector Sensor Pin 2. Pin and Oxygen Sensor Pin 2 is normal or not. 2）Circuit broken between Oxygen Sens or Pin 1 2）Check if resistance between Oxygen Sensor and Main Relay. Pin 1 and Main Relay is normal or not.
13 Troubleshooting Tro uble C ode：P0106 Air Inlet Pressure Sensor Sign al irration ally failure Note Possible Troubles are as below 1）Air leak age of Air Inlet Pres sure Sensor. 2）Air Inlet Pressure Sensor broken. 3）Air leak age from assemble point. 4 ） Air Inlet Pressure Sensor characteristically defluxion.
Tro uble C ode ：P0117 Eng ine Water Te mperat ure Sen so r C ircuit Voltage lo w. Note Note Possi bl e Tro ubles are as be low Inspe ct a s below 1）Circui t betw een ECU Pi n and grou nd sho rt. 1) Che ck resistan ce between ECU Pin and Groun d. Tro uble C ode ：P0118 Eng ine Water Te mperat ure Sen so r C ircuit Voltage high.
13 Troubleshooting Trouble Code：P0132 Oxygen Sensor C ircuit Vo ltage High Explanation： W hen engine starts, ECU chec k the Oxygen Sensor Circuit Voltage; W hen voltage i s continuously higher than 1.5 Volt, system dec ides Oxygen Sensor Circui t Voltage is short to power.
Errors coding: P0261 Control circuit of single 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 Mai
13 Troubleshooting Errors coding: P0458 Control circuit voltage of idle air control valve too low Maintenance Tips： Maintenance Tips：Check the item as follow: The possible faults may exists as follow: 1 ） Measure connected to the ECU pin-to-ground 1）Circuit ECU connected is short circuit resistance whether proper or not Errors coding: P0459 Control circuit voltage of idle air control valve too high Maintenance Tips： Maintenance Tips： The possible faults may exists as follow: Check the item as foll
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 c ertain 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.
13 Troubleshooting Erro rs coding : P2177 Self-learning value of air-fuel ratio, closed-loop control exceeds upper limit Erro rs coding : P2178 Self-learning value of air-fuel ratio, closed-loop control exceeds lower lim it Introduction of theory and fault reason: In order to make catalytic converters for HC , CO and NOx to m aximize conversion efficiency, the air-fuel ratio of m ixture should be 14.7:1.
3 .Diag nos is troub les ac c ording to e ngine fault phe nome na Be for e sta rt to d ia gn o sis fau lt, ple a se ta ke th e p rim ar y ins pe ctio n fir st: 1 .Eng ine fai lu re i nd icator l ig ht wo rks r eg ul ar ly. 2.Affirm that no er ro rs Co de h ave be e n fo un d by Diagno sis Analyze. 3 .Affirm the fau lt th a t use r comp la int is e xist, and a ffirm th e co n d ition o f fa ul t hap p ene d. Th en , take extern a l inspe ction: （1） Chec k fuel pipe fo r has fu el l ea ks.
13 Troubleshooting （ 1） Starting Failure/H ard 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 C heck the voltage between the two poles of battery by yes next no Replace battery yes next No. 1 multimeter, the voltage whether around 8-12V or not w hen engine starting. Keep ignition sw itch in engine starting station.
C heck compressio n o f cylin der a nd obs erve th e pre ssure i f is 4 disc re pa ntl y. C ontact EFI comm uta tor, open ig ni ti on swi tc h, chec k ECU5#、 5 El im inate yes no ne xt yes Diag nosis hel p 10 #、 13 # stitch, th e po we r whe the r sup ply n or ma lly or no t, Exam in e and re pa ir no ch eck 2#、21# stitch w hether Pu t u p i ron o r n ot.
13 Troubleshooting Ref no 1 2 Operation Test result Contact fuel pressure meter(contact front point of oil input yes pipe of injector), starting engine, check the fuel pressure whether is around 300kPa or not no Pull out ignition coil, and contact with spark plug, keep pole yes of spark plug 5mm away of body of engine, starting engine and check it whether has blue-white spark fire or not.
Co n ta ct fu e l pr essu r e me ter (co n ta ct fr on t po in t o f 2 oi l in pu t ye s p ip e of i nje cto r), s ta rtin g en g in e, ch e ck th e fu e l p re ssu re 3 exa mi ne a n d re pa ir wh eth e r is a ro un d 3 0 0k Pa or no t no P ul l ou t ig n itio n coi l, a n d con tac t with sp a rk plu g , ke ep po le ye s oi l sup p or t syste m o f sp a rk pl ug 5m m a wa y w ith b o dy o f e n gin e , s ta rtin g e n gin e 4 ne xt ne xt exa mi ne a n d re pa ir a nd che ck it wh e the r h
13 Troubleshooting 2 3 4 5 Yes Clean or replace no next Check spark plug, look its type and gap if accords with Yes next standard. no Adjust or replace Check throttle valve body and idle speed side air duct Yes Clean whether have carbide ac cumulated or not. no next Disass embly injector, and check the injector by spec ial Yes Fault replacement no next Yes Replace fuel no next Check idle speed valve whether clogged or not.
6 7 Check fuel and observe the fault if caused after fueling Check compression of cylinder and observe the pressure. Contact EFI commutator, open ignition switch, check 8 Yes Replace fuel no next yes Eliminate engine mechanism fault no next yes Diagnosis help ECU5#、10#、23# stitch, the power whether supply normal or not, check 2#、21# stitch whether Put up iron or not. Examine and repair no relevant wiring （8）Engine starting normally, but idle speed unsteady after warming-up.
13 Troubleshooting Possible defective part：1、idle speed valve；2、injector Overhaul: Ref no Operation Disassembly idle speed valve and check the throttle valve 1 Test result yes body, idle speed valve and idle speed side air duct whether have carbide accumulated or not. Next Steps Clean related parts no next yes Turn step no.
yes C ontact with EFI comm utator, open ignition switch, check 6 Diagnosis help ECU 5#、10#、23# s titch, the power whether supply norm al or not, check 2#、21# stitch w hether is puting up iron or not. no Exam ine and repair relevant wiring （ 11） Rotate speed can not increase o r engine power off when in acceleration.
13 Troubleshooting （ 12）Reaction slowly when in acceleration. Possible defective part：1、fuel containing water； 2、air intake pres sure s ensor and throttle pos ition sensor；3、spark plug；4、throttle valve body and idle speed side air duct；5、input air duct；6、idle s peed valve；7、fuel injector；8、ignition timing；9、muffler Overhaul： Ref no Operation Test resu lt yes 1 Check air cleaner if is clogged.
O ve rh a ul ： R ef no 1 O pe rat io n Tes t re s ult C he ck th e fa ul ts i f exi st clu tch ski d, lo w tyre p re ssu re , yes re pa ir no ne xt l ag g ed br ak e, imp ro p er tyr e size e tc. yes 2 C he ck a ir cle a ne r if is clo g ge d .
