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1
GO-KART [XYKD260] Repair Manual
2
1 Service Notice
Position of Identification Number Lubrication diagram
Main Features Structure Drawing
Standard Torque Rating Troubleshooting
Position of Identification Number
Vehicle Identification Number Engine Identification Number
3
Main features Vehicle Dimensions [mm] KD260-1 KD260-2 KD260-3 Overall Length………………………….………………………………………………..2470 2690 2550
Overall Width……………………………………………..……………………………..1570 1510 1670
Overall Height……………………………………………………………………………1535 1460 1440
Wheelbase………………………………………………………………………………..1870 1950 2010
Front Track……………………………………………………………………………….1345 1270 1485
Rear Track……………………………………………………………………………….1250 1250 1263
Ground Clearance…………………………………………………………………………200 220 200
ENGINE
Type…………………………………………………………………….……………..Water cooling, four stroke
Engine capacity……………………………………………………………………….260cc
Bore *Stroke………………………………………………………………………….70mm*66.8mm
Displacement………………………………………………………………………….257cm³
Corrected compression ratio…………………………………………………………9:1
Max output power…………………………………………………………………..11kw/7000rpm
Max Torque…………………………………………………………………………..17Nm/5000N.m/r/min
Starting………………………………………………………………………………..Electric Start
Ignition………………………………………………………………………………..C.D.I
Lubrication…………………………..………………………………………………..pressure splash
Transmission…………………………..………………………………………………. Automatic C.V.T System
Spark plug…………………………..……………………………………………….DPR5EA-9(NGK)
Plug gap…………………………..……………………………………………….0.6-0.8mm
Fuel type…………………………..……………………………………………….RQ90 (leadless)
Lubricate oil…………………………..……………………………………………….SAE15W-40/SF
Capacities Maximum load…………………………..……………………………………………….Two seats/200Kg
Fuel tank…………………………..……………………………………………………...9.5L
Engine oil…………………………..……………………………………………………..1180mL
Starting Time…………………………..……………………………………………………..<10s
Climbing…………………………..……………………………………………………..20º-25°
Battery…………………………..……………………………………………………..12V 14Ah
Head Light…………………………..……………………………………………………..12V 35W
Tail Light…………………………..……………………………………………………..12V 21W/5W
Fuse…………………………..……………………………………………………..10A
Brake Track…………………………..……………………………………………………..7m at 30KM/h
Top speed…………………………..…………………………………..75KM/h (Or as customer requirement)
CHASSIS
Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control
Front tire ……………………………………………… AT21X8-10
Rear tire ………………………………………………AT22X11-10
Front Suspension ………………………………………… Independent dual-A arm
Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock
4
Restraint System ……………………………………… Double quincunx safety belts Final Drive ………………………………………………… shaft drive
TIRE PRESSURE[kPa] off-road Tire Road Tire
Front …………………………………………………… 25 200
Rear …………………………………………………… 30 225
WEIGHT[KG] KD260-1 KD260-2 KD260-3
Net Weight …………………………………355 346 365
G.W. …………………………………… 380 370 380
5
Standard Torque Rating
SER
NUM Position
XYKD
Diameter of screw
(mm)
Torque(N.m)
1 Screw used between Exhaust pipe and Front Cylinder 8 20-26
2 Igniter plug 10 18-20
3 Screw used between Front wheel hub and front universal
joint
14 80-100
4 Screw used for Rear wheel hub and Constant-velocity joint 18 120-140
5 Universal joint fastening bolt 8 20-26
6 Bolt of protective parts of steering mechanism 8 30-40
7 Screws between handle ball and gimbal 10 50-60
8 Screws of wheel and wheel rim[Front and rear] 10 50-60
9 Screws of support parts[Front wheel] and vehicle body 10 50-60
10 Connection of brake pump parking brake and front gimbals,
elevation
8 20-26
11 Screws of handle adjusting line 10 30-40
12 Screws exhaust pipe and engine rear support part 8 20-26
13 Screw used on Front Vibration Damper 10 30-40
14 Screw used on Rear Vibration Damper 12 50-60
15 Connecting screws between rear support part and vehicle
body
16 110-130
16 Screws of rear support parts of engine 10 30-40
17 Screws of front support parts of engine 10 30-40
18 Screws of back brake disc and back wheel rim 8 30-40
19 Screws of front brake disc and front wheel rim 6 20-26
6
Lubricating oil and How to do lubrication
1、Engine
Position Description of Lubricating Oil Remark
Crankcase Only 15W/40SF Full capacity:1.0L
Gear case Only 15W/40SF or 85W/140 Full capacity:0.22L
Parts of Clutch Li oil ZL-3H(SY 1413) 4.5~5.0g
2、Vehicle Body The parts, described [not limited] as following, should be added lubricating oil.
If no special requirement, please use the multiple functions lubricating oil. In order to prevent the unusual sound and improve the durability, lubricating oil also should be used in other transmission parts.
Connection part between Steering gear parts and handle ball
Steering wheel nylon bushing
Brake pedal Accelerator pedal Accelerator cable Parking brake cable
Front lower swing arm
Front Wheel Support Part
Front wheel axle
Main seat slide rail
Constant speed
gimbal
Rear wheel rim axle
Rear swing arm axle
Sub seat slide rail
7
Structure Drawing
Pipe of
cooling liquid
kettle
Water tubing
Temperature
Control
Switch
Rear brake oil
tube
Brake cable
8
Fuse 15A
Flash apparatus
Relay
CDI
BATTERY
Ignition coil
rectifier
Electric parts
case
Quadric air-intake
mechanism
Throttle cable
Reverse cableParking
brake cable
9
Troubleshooting
Can not or difficult to start
Main cable Speed Sensor cable
Description Adjustment Reasons
Whether oil run in carburetor. Take down vent bolt to check.
Take off spark plug to check sparkle or not
Yes
● ● No oil in oil tank
● Jam between oil tank and carburetor
● Oil tank hole jammed
● Oil filter jammed
● Oil cleaning net jammed
● Pressure oil switch not work
● Spark plug not work
● CDI parts not work
● Spark plug not clean
● Trigger not work
● Spark plug coil broken or short-circuit
● Ignition coil broken or short circuit
● Igniter switch not work
● Magneto coil not work
● Valve gap not enough
No
Yes No or not enough
Pressure Value
10
Description Routine
Power is not strong, not speed up
● Damage of cylinder, piston rings
● cylinder head gasket works not well
● Valve is damaged
● Mixing air time not good
●EEV of carburetor not work
● Valve socket not good
●Air leakage of minus pressure tube
●Ignition time not good
●Vent bolt of carburetion not work
● 化油器过满溢出
OK No or not enough
Start according right method
No explosion No start with explosion
Take off spark plug again
火花塞是干的 火花塞湿
●Too many oil in carburetor
●EEV of carburetor not work
●Value of throttle is unusual.
Dry Wet
◆
Reasons
Check Ignition time [Ignition led]
● Battery connection badness
● Air filter jammed
● Vent hole of oil tank cover jammed
● CDI parts not work
● Trigger not work Yes No
● Valve gap not good
● Shape of valve changed Yes No
Check Valve Gap
Check Compress pressure Value in Plunger
Yes
●
● oil tube jammed
● minus Pressure line not connected well
● Carburetor jammed
No
Let engine work at high speed
11
Description Routine
◆
● Plunger ring is damaged
● Air leakage from gasket position Yes No or Lower
● Parts of Carburetor jammed No Yes
● Spark plunger polluted/damaged
● Temperature of spark plunger wrong
Clean Dirt
● Valve socket not work well
● Mix air time not good
Check spark plunger
Check Carburetor jammed.
Engine is too hot or not
● Oil is not replaced
● Mix air rare
● Quality of oil bad No Yes
Speed up or work at high speed
Check oil quantity level and quality
OK
●
● Too many oil
● Oil is not enough No
● Plunger or Cylinder damaged
● Too many carbon powers in firebox
● Ignition time wrong
● Mix air rare
● Ignition time wrong
● Quality of oil is bad
● Too many carbon powers in firebox
● Cooling liquid not enough
Reasons
12
Description Routine
Egine works unusually(such as idle and low speed)
No sound Unusual sound
Ignition Time OK?
Yes
●
● CDI parts not good
● Magnetor not good No
● Mixed air is rare[Take screws down]
● Mixed air is thick[Take screws up] Yes No
● Carburetor is loosed
● Airproof parts not good No Yes
● “O” gasket not good
● Air leakage in vacuum parts
Vent screw of carburetor OK?
Air leakage in carburetor gasket?
Sparks OK?
Reasons
13
Description Routine
Engine works unusually [High speed]
OK No or less spark ● Ignition coil not good
● Ignition coil is broken or in short
● CDI parts not good
● Spark plunger not good or polluted
● Ignition trigger not good
● Air tube jammed or damaged
Yes
● Cut Air Valve not good
● Vacuum line jammed or damaged No
◆
Cut Air Valve OK?
Ignition time OK?
Yes
●
● CDI parts not good
● Magnetor not good No
● Adjustment not good
● Value socket damaged Yes No
● Oil line or oil filter jammed
● Vent hole is jammed OK Unusual
● Not enough oil in oil tank
● minus Pressure line switch not work
Handspike gap OK?
Check oil automatic screw function?
● Clean carburetor socket No Yes
Carburetor socket jammed?
Reasons
14
Description Routine
Not move with high speed
● Protruding sprocket wheel and magneto
flywheel position not match Yes No
Mixed time right?
● Spring not good Yes No
Spring of valve good?
◆
Engine works at high speed or easy to stop?
Engine works at high speed
●
● Ignition coil wrong connection
● Spark plug bad connection
No high speed or easy to stop
reverse gear OK
Check reverse operation system
●Length of reverse cable is not suitable reverse position wrong
● Connection of battery not good
● Oil line not good
No Yes
Any unusual sound of engine gear case
●Differential gear damaged
●reverse gear damaged
●Connector sheath of reverse gear damaged
●Differential damaged
Reasons
15
Description Adjustment
No power in battery
◆
Open side cover of engine and check clutch strap broken or not
Start engine and check voltage of battery
Battery can not charging
●
●Check battery whether out of usage
●Battery not good Normal
● Connection of line is not good
Normal
● Stator not good
● Yellow line is broken Unusual
Resistance value of coil
Yes ● Blue/yellow or Green line is broken No
Voltage between Blue/yellow and Green li
Yes
● Booster not good
● connection-peg not good No
Whether any looseness of booster and connection-peg?
● Magneto not good
Reasons
16
Description Adjustment
The charge is not good ( Overcharge )
No spark
● Measure of voltage between rectifier polarities
Voltage is usual when ignition switch is “On”
No voltage when ignition switch is “On”
● black line of main cable is broken
Any looseness or default of booster connection-peg
No Yes ● connection-peg not
good
● booster not good
Use a new spark plunger then check i
No or less sparks
●
Sparks OK
No
Any looseness between lid of spark and between high-voltage lines
● Lid of spark is loosen Yes
● previous Spark Plunger broken
Connection of CDI parts OK?
Yes No ● Connecter is not good
Check statement and features of connecter of CDI and measure the resistance
Reasons
17
Item
2 Inspections and Adjustment Check & Repair method Transmission System Brake System
Electronic System Wheel System Engine
Cushion System Others
Check & Repair method
Maintenance period List
Maintained time ITEM
Requirements
Km ( remark )
1000Km 4000Km 8000Km 12000Km remark
Oil System I I I
Carburetion System I I I
Carburetor I I I I
Core of air filter often R
Spark plug I R I
Lubricating oil in engine First time1000Km; then per 2000 Km
Clean net of lubricating oil Per year R C C C
Gap of valve I I I I
Battery I I I
Brake system I I I I
OK No
Yes No
Related parts OK?
● Ignition switch not good
● Magneto coil not good
● Trigger not good
● Ignition coil not good
● cable is broken
● Connection of coupling parts not good
● CDI not good
18
Brake DISC. I I I
Brake lighter switch I I I
Main lighter Per month I I I I
Clutch I
Suspend parts I I I
Support parts I I I
Screw and bolt Per month I I
Wheel/spoke Trimester I I I
Vent hole of crankcase C C C
Idle of carburetor I I I I
The vehicle should carry on the periodic maintenance according to the stipulation time.
Before the maintenance the vehicle should be cleaned thoroughly.
Definition of Letters:
I: to check, clean, adjust lubricate or change apart.
C:cleaning
R:use a new part
A:make an adjustment
L:Lubricating
Note: When the odometer reading surpasses the maximum features listed in the table,
the maintenance should be done repeatedly according to the table.
Brake System
Adjustment
Check pedal free travel:
20~30 mm If it is beyond of this distance, please take down/up adjustment screw.
When air enters the brake cylinder piston or the brake oil pipe, resulting in
brake failure, it is necessary to discharge the air in the brake in the following
manner: first step on the brake pedal with foot, loosen the exhaust screw
of the brake cylinder, open the brake cylinder oil cup, screw up the exhaust
screw until there is no brake liquid and air outflowing, release the accelerator
pedal and repeat the procedures until there is no air out-flowing.
Vent bolt
20~30mm
Adjustment Bolt
19
Parking Brake System
When stop vehicle on 20º-25°ground and can not park it. Please check parking brake system for safety: 1 Take down/up adjustment bolt near by brake handle
2 Take down/up adjustment bolt near by brake caliper
Parking Brake system is complexes; adjust parts in a whole system to Make PB system work well.
Wheel System
Wheel
Check tire with air pressure gauge.
Standard information:
Spec. of Tire Pressure Value
(off-road)
Pressure Value
(Road)
Front AT21X8-10 28kPa 200kPa Rear AT22X11-10 35kPa 225kPa
Check mental hexad flange screws of front wheel and axle. tight them as per required torque.
Cushion System
Brake oil pump
Attention!
When exhaust, you must guarantee that there is
enough brake fluids in brake pump oil cup.
Adjustment bolt of brake
Attention! Please make sure that length of rear wheel
brake line is out about 3-5mm.
Attention! Please make sure that tire is cold before checking.
Metal hexad flange screws
Front/rear axe screws
Brake Handle
Adjustment bolt
20
Leakage or Damage of Vibration Damper Steps on with foot to the vehicle forehead, compress several times, inspect
its movement, and whether or not any oil leak, damage, loose or unusual sound;
Steps on with foot to the vehicle back position, compress several times, inspect its
its movement, and whether or not any oil leak, damage, loose or unusual sound
Transmission System
Transmission case leakage and capacity
Stop the engine and take down oil position screw. If oil level reach at standard position it is OK; otherwise pour in oil.
OIL TYPE:85W-140 or 15W/35S Put on oil position screw after checking airproof gasket
Replacement of lubricating oil
Take down oil position screw Take down vent bolt and put oil out Put on vent bolt with revolving
Pour oil according to standard value:
Attention! Make sure that ground is plainness.
Oil position screws Air proof gasket
Attention! Make sure that no damage in airproof gasket
21
Full capacity:1.2 Liter Standard capacity:1.1 Liter Put on oil position screw with revolving Try running and confirm no oil leakage Check oil level
Driving/Driven Wheel
Take off left cover Check driving/driven condition
Electronic System
Ignition System
Station of Spark Plug
Take off spark plug Check sparks plug and clean dirt,
carbon with special cleaner or steel wire brush.
Spark Plug:Distance should be 0.6 mm to 0.8 mm
Ignition Timing
Take off ignition screw Check ignition LED to confirm ignition time: When idle speed is 1500±100rpm,it matches “F” well.
Function of Ignition Advance Angle
Driving wheel
Driven wheel
Check gap, whether any dirt and Carbon
Chechecks any broken Checks gasket
Important! When install spark plunger, please tight it by plug socket after hand.
Important! Because of CDI system function, there is no necessary to adjust ignition time. If any problem, please check ignition system.
Ignition Screw
22
Same to Ignition system, put on Ignition LED. Then start engine and make speed up to 7500 to 8000 rpm, system works well if LED reach at standard position.
Engine
Engine Body
Low speed and speed up condition
Start engine without transmission [Warm condition]
Adjust idle screw and set idle speed according standard value: 1600 ± 10% If idle condition is not steady, please adjust vent screw. Replacement of air filter core Open six clips and take off air filter cover. Take off filter core Change filter core if it is dirty or damaged. Standard period of change filter core:per 4000 KM If road condition is not good, you should change filter core early
Lubricating System
Standard Position
Note: idle speed adjustment shall be made when the engine is warmed up. And Carburetor adjustment following inspection shall be made after adjustment of the airscrew.
Idle Screw
Air filter screws
Clips
Filter Core
Caution: since the filter paper of the filter core contains
oil (viscous); it cannot clean with air.
23
Lubricating oil quality and quantity
Do not revolve in the vernier when checking it. If the oil level below the lower limit line, you must supplement the lubricating oil from the note entrance to the upper limit line.
If lubricating oil is dirty, please change it.
Oil filter Jammed
Take off spring, filter net. Clean it Put filter net, spring, and filter net lid and revolve tight
Pour lubricating oil.
Replacement of lubricating oil
Take off filter lid and let oil out Take up filter lid with revolving
Pour in lubricating oil.
Full capacity:0.8 Liter,Type:85W-140 Start engine to make sure no leakage problem Stop engine and check oil quantity.
Attention! During check oil quantity, you should guarantee the vehicle is in the horizontal position. Let the engine works 2-3 minutes, then stops the engine. After 2-3 minutes, then check oil quantity.
Oil vernier
Max Position
Min Position
Attention! Open parts of net should be inside.
Filter net lid
Spring Filter net
Air proof gasket
Attention! Put lubricating oil out on warm condition.
Attention! Check air-proof gasket and change it if any broken.
Oil vernier
24
Accelerator operation system
status of accelerator pedal
Check free pedal travel of the accelerator pedal.
Free travel: 30~40 mm
When the free travel is outside the specified, range, the requirement may be
met by adjusting the adjustment nut or checking whether the accelerator pedal
stopper is correct or not.
If footplate is not working fluently, please add lubricating oil from the Oiling
hole
Cooling System
Water Level
Guarantee the vehicle is in the horizontal position.
Inspect kettle liquid surface whether between upper limit and lower limit. On the kettle has two across, above is the
upper limit, and under is the lower limit. If the radiator liquid is insufficient, must pour the kettle liquid to upper limit. The coolant liquid should fit the engine.
Water Leakage
Check cooling line whether any broken, damage or leakage.
Range
Pedal limit screw
Screw
Oiling position
Adjustment bolt
Screw
Adjustment bolt
kettle
Reverse gear handle
25
Reverse System After days of running, it is possible that reverse or other transmissions are not good because: reverse line is changed in length or shape. Herewith you need to make screw adjustments.
3 Oil System
Maintenance information Electricity enrichment valve Floater Room
Troubleshooting Cut air valve Oil tank
Carburetor Vacuum room Oil switch
Maintenance Information
.Remember position of “O” gasket and use a new one in installation.
.Take down vent screws of floater room; clean carburetor before disassembly.
.Do not take off auto double starter valve.
Troubleshooting
Can not start engine No power and engine stops when accelerate max
﹒No fuel in oil tank ﹒septum of vacuum piston is destroyed ﹒No oil flow into ﹒Pressure entrance is jammed
﹒Too much oil in cylinder ﹒Oil switch is not working
﹒Air filter is jammed Mixed air is little
﹒Oil is not clean ﹒Ejector parts are jammed
Important! No spark when use fuel.
Rear adjustment screw
Front adjustment screw
26
﹒Oil switch is not working ﹒Vent hole of tank cap is jammed
Engine Idle is not steady and﹒Oil line is not working
Work abnormally ﹒Floater is not working
﹒Adjustment of idle is not working ﹒No enough oil
﹒Mixed air is rare
﹒Air filter is jammed
﹒Air in plug Mixed air is thick
﹒Oil is polluted ﹒EEV is on for long time
﹒Cut air valve is not working,disc valve is not working ﹒Floater is not working
﹒Vacuum lines or connecter are jammed ﹒Oil is too many
Accelerator is heavy ﹒Air filter is jammed
﹒Installation of carburetor is not good ﹒Wrong installation of support
part in EEV.
﹒Switch of carburetor destroys cam-drum wheel
Disassembly of Carburetor
Take off oil line
Take off pressure three-way line
Take down Oil drain bolt and drain oil out from Carburetor
Take off carburetor line
Take off clips of air filter
Take off clips of engine
Oil Line
Clips of Air filter
Clips of engine Pressure three-way line
Plug of electricity enrichment valve
Throttle cable
Oil drain bolt
27
Take off plug of electricity enrichment valve
Take off carburetor
Electricity Enrichment Valve
Inspection
Check connected line of electricity enrichment value. Resistance value: Stop the engine and after 10 minutes then test resistance. Value
should not higher than 10 omegas. If no connection or resistance value is deviated 10 omegas, you must use a new electricity enrichment valve.
Disassembly
Take down screws of support pats and take down support part. Take down electricity enrichment valve.
Inspection of Valve
Check any damage on electricity enrichment valve and pin of EEV. If any, please use a new EEV.
Installation
Do installation in oppositive turn in disassembly.
E.E.V. Connecter
Screws of support part Support part
E.E.V. Pin
E.E.V.
Attention! Press EEV at bottom and fix its channel outside with support part.
28
Cut Air Valve
Inspection
Take off cut air valve from Pressure line and vent line Connect pressure line and vacuum pump Connect vent line and vacuum pump Add air by vacuum pump:
Minus pressure value:400~600mmHg
With pressure no air in vent line and without pressure air in vent line, valve is ok.
Replacement
Take down two screws and take off cut air valve Take off “O” gasket Use a new “O” gasket and fix valve on carburetor with screws
Vaccum Room
Disassembly
Take down two screws and take off vacuum room cover
Cut air valve
Bolt
Cut air valve
“O” gasket
Cover of Vacuum Room
Screw
29
Take off spring and vacuum plunger.
Take off support pats, spring and ejector pin
Inspection of Vacuum Plunger
Check carburetor valve, ejector pin, no any destroyed and broken Check septum without scar, olden and broken
Installation of Vacuum Plunger
Do installation in oppositive turn. Support bottom of vacuum plunger, make sure that it is open and put septum to chimp position of
carburetor completely Put on spring Match septum hole with cover and fix cover
Floater Room
Take off four screws and floater room.
Inspection of Pin Valve
Check station of valve socket
Plunger Spring
Important! Please protect septum of vacuum plunger. Vacuum Plunger
Septum Nozzle Pin Spring
Support pats
Important! Support vacuum plunger till fix all screw of cover.
Bolt Floater Room
Bolt
Pin valve
30
Take off main ejector, pin ejector socket, pin ejector, sub ejector and vent screws.
Clean ejector with extractive oil.
Clean carburetor pass way with huffing air.
Installation
Install pin ejector, pin ejector socket, main ejector, sub ejector and vent screws.
Install pin valve, floater and pin. Install carburetor in oppositive turn in disassembly. Do adjustment as following:
.Accelerator line adjustment
.Idle adjustment
Oil Tank
Disassembly
Main Ejector
Sub Ejector
Main Ejector Socket
Vent bolt
Important! . To protect ejector and screws .Note down zip number when take down screws. If drives vent-screws strongly, it would be destroyed.
Attention! Extractive oil should be fresh one.
Attention! Please install vent screws according to zip number noted down when disassembly.
Vent bolt
Sub Ejector Main Ejector Socket
Main Ejector
Oil tank
31
Takes down four screws of oil tank
Take oil line and pressure line part from oil switch.
Take off oil tank
Oil Switch
1 Stops the engine, dismantles the oil line from the carburetor and check whether the oil stream to leave. After oil
switch and line is clean, there should be no oil leakage. Otherwise you should clean pressure line.
2 Dismantles the pressure line from the carburetor. With pressure oil leakage and without pressure no oil leakage,
then the switch is normal.
3 Switch negative pressure value: Above 130kpa.
4 Cooling System Replacement of cooling liquid in Radiator
Oil Line
Pressured line
Oil switch
Important! NO SPARK!
Important! Before take off radiator lid please make sure that cooling liquid is NOT HOT.
Radiator Lid
32
Take off radiator lid . Connect Out-water line and fix it tightly In pouring cooling liquid till it is full.
Carries on pumping air according to the following main point:
1 starts the vehicle, carries on high speed on the smooth road, at least 200 meters. 2 stops and checks foam whether vanishes, as well as liquid surface water level is
whether steady, 3 do the vehicle the system closure, pours into the radiator liquid, until
the radiator this note population border is Stops. 4 fix radiator lid
5 checks enough water in sluice bottle.
Function Inspection
Radiator Lid
Put lid on is inspector and it is good that keep on SIX seconds under standard pressure.
Standard pressure of Radiator lid valve:
73.5-103Kpa
Radiator Inspection
Connect Inspector and radiator, add air and it is good that keep on SIX seconds under standard pressure. Standard pressure:73.5-103 Kpa
Important! Before take off radiator lid please make sure that cooling liquid is NOT HOT.
NOICE!
Before checking please put some water on lid airproof surface.
Important! Do not use too high pressure; otherwise radiator will be destroyed on condition of high pressure.
Out-water line
Radiator Inspector
Radiator Lid
Sluice bottle
33
Temperature Control Switch
Disassembly
Drain radiator liquid out
Dismantles switch wiring.
Dismantles the switch
5 Engine Disassembly
Dismantles Earth Line from the battery Lift back vehicle with Left and Right support parts, and make sure rear Wheel takes off; Take down screws and take off rear wheel; Take down screws and take off rear brake; Take down rear bone [left and right], break connection between rear bone and engine
Take off gimbals [left and right]
Take apart water line and out cooling liquid
Rear Wheel Screw
Support Part
Attention! When 80°C, the fan can automatically
open; if failed, it needs the prompt inspection.
Rear Brake
Rear Bone
34
Take off spark plug cap Take off Temperature Control Sensor Take off lines of carburetion
Take off auto-restarted plug Take off transmission line Take off earth line Take off line between engine and battery Take down screws of bumper
Take down screws between air filter, support part and Vehicle body.
Erath Line Power Line
Bumper
Water Line
Air Filter Screw
Muffle Screw
35
Take down screws between engine and rear suspend part
Take down front suspend part of engine
Take down suspend part under engine Take off engine with muffle, air filter and carburetion
Take down screws of muffle and take it from engine Take down screws of muffle and take it part from engine Take down clips of carburetion, take carburetion, exhaust line, and air filter.
Installation
Installation is in oppositive turn and please makes sure that screws are fixed according to standard strength.
Rear Suspend Screw
Front Suspend
ATTENTION! The engine is heavy, so multi-people coordination is import to disassemble, in order to avoid offends somebody or the damage engine.
Muffle Screw
Suspend Part under Engine
36
6 Front Wheels and Steering System
37
Disassenmbly
Support front part of vehicle and make front wheel take off. Take apart four screws of front wheel[Left wheel for example]
Front wheel rim screws
38
Take down the cotter pin locked screws of the front wheel hub.
Take down two screws and take off front brake pump assembly.
Take off assembly of front wheel hub and brake disc.
Take down two screws and take off front brake pump assembly.
Take down the cotter pin locked screws of the steering assembly.
Take down the locked screws and take apart front vibration
Damper.
Take down two screws between support parts and vehicle body.
Take down two screws between down support part and vehicle body. Take apart down support part and front bone assembly. Take down screws between up-down support part and front bone.
Front Wheel Rim
Brake Disc
Important! It is connected by bearing You should use special tools.
Screws
Front Vibration Damper
Bolt Up Support Part
Down Support Part
Important! It is connected by wimble, please pay attention to bone when knock the assembly.
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Take apart U/D support part and front bone.
It is same to RIGHT WHEEL. Take down three screws and take apart steering support nips.
Take down screws between steering assembly and gimbal.
Take apart steering assembly.
Take down screws between steering bearing and gimbal.
Take off gimbals. Take down screws between steering bearing and vehicle body. Take apart steering assembly.
Front Bone
U/D Support Part
Fix part of S.S.
Steering assembly Bolt
Gimbal
Fixing parts of S.W.
Bolt
Gimbal
Screw
Steering assembly
Important! It is connected by wimble please knock assembly carefully.
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Take down six screws and gather respective assembly
Installation
Do it as opposite procedure compared with DISASSEMBLY.
7 Seat System Disassembly
Steering Wheel
Screw
Steering Wheel
Screw
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Safety Belt
Disassembly safety bolt on seat right. Disassembly safety bolt on seat back. Disassembly safety bolt on vehicle body.
Take off seat.
Handle counter-clock wise rotation, may carry on to the seat
adjustment, back or front.
Bolt
Bolt
Man Handle
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Disassembly setting screws of safety belt on left side of seat
Take off safety belt.
It is same to take off left seat and safety belt.
8 Rear Drive Line System
Screw
Man handle
Slide Rail
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Disassembly
To support behind the entire vehicle, and make the trailing wheel to take off.
Dismantles 4 front wheels fixing g screws. (Left side Wheel )
Take down the cotter pin of the front wheel hub locking screws. Front wheel screw
Rea wheel rim screw
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Dismantles 2 setting screws, and take down the brake to pump.
Dismantle locking screws, take down the trailing wheel. Dismantle two setting screws and take down brake pump.
Dismantle two setting screws and take down rear brake pump.
Dismantle four setting screws of rear bone
Take down rear bone, rear wheel rim and brake disc assembly. Take down rear bone off rear wheel rim
Dismantle four setting screws and take off brake disc.
Take off SPEED SENSER ASS.
Parking Brake
Rear brake pump Screw
Screw
Rear BoneBrake Disc
Rear Wheel Rim
Screw
Important! IT IS CONNECTED WITH AXLTREE;
YOU SHOULD USE PROFESIONAL TOOL.
Parts of speedometer
Parking Brake Screw
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It is same on right side. Take off seat. Take down two setting screws of tranquilization part.
Take off fixed part and rubber sheath.
Disassembly setting screws on left and right tranquilization part. Take of tranquilization part.
Disassembly setting screws of rear vibration damper.[L&R ]
Take off left and right rear vibration damper.
Disassembly setting screws and take off rear support part. Left is same with Right.
Installation
Do it as opposite procedure compared with DISASSEMBLY
Universal Joint
Screw
Rubber sheath Fixed part
Rear Support Part
Screw Tranquilization part
Rear Vibration Damper
Screw
Screw
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9 Electric System
Repair Information Battery Troubleshooting Charge System
Repair Information
IMPORTANT!
.Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the connection, you must pay attention to the color of the line cables. The coupling must meet on the same coupling.
.The test condition may usually lead to differences between observed data and standard features.
.Magneto installment and disassemble.
.As to other problems, please view more information in CHARTER 1.
Battery .Do periodic inspection electrolyte the capacity, make sure line is between the scale division line, if
lower than the scale division, please supplement the distilled water.
.When charging the battery, you must dismantle the battery from the vehicle, but do not take off the
liquid lid.
.Expect for in emergency cases, do not carry on the rapid charge rate to the storage battery.
.When charging battery, please do it according to standard datum.
.During voltage inspection, you must uses the digital multitester.
.When battery is out of usage, you must use a new one.
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Specification
Item Standard Value
Battery
Capacity 14AH
Voltage (in full) At least 12.5V
Charge current Standard 1.4A
Charge time Standard 13 hours
Rectifier of Voltage Model Semiconductor switch type
Control voltage 14.0-15.0V
Resistance value of Charge Coil
(20℃)
0.1-1.0Ω
Troubleshooting
No Power(Ignition trigger is “OFF”) Voltage is lower
-The battery is at the electric discharge condition .The battery charge is not good or at the electric
discharge condition
-Storage battery leakage .Voltage Rectifier not to good
-Voltage Rectifier not good .The magnetic stator not good
-The magnetic stator not good .Coupling connection is not good
-Battery not good
.Battery line cable connection falls off Electric current not steady-going on
.Fuse in short .Line cable connection not good
.Line cable in short .Charge system not good
.Ignition trigger not good .Ignition system not good or in short
.Coupling connection is not good or short
Charge system
Leakage examination Put ignition switch to OFF, and take out positive or cathode electrode line of battery. Take out your digital multitester and put switch to “mA” position, connect battery line and battery to examine its leakage flow value. If value is bigger than 15mA that means that the entire vehicle has the leakage problem, you should promptly arrange looks up.
Control voltage inspection
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Carries on the warm start and make sure that other electricity components are at the off-position. (For instance lights, speaker). The engine control in Idle speed the condition, the digital multitester twists to the DC voltage files and then connect in parallel fashion to the storage battery beginnings and ends. The storage battery must be in fills the electricity in the situation, gradually speeds up the engine speed, biggest charging voltage should be 14 to 15V.
10 Ignition System
Maintenance Information Troubleshooting Features of Igniter
Maintenance Information
IMPORTANT!
Because of CDI ignition system, you can not make an adjustment at the ignition time. If something occurs during the ignition exceptionally, you should inspect the connect line, the CDI part, the trigger, protruding parts of the flying wheel whether some of them has the distortion or the damage. If any you must carry on the replacement.
.Maintains of Igniter。
.Maintains of Spark Plug。
.Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the connection, you must pay attention to the color of the line cables. The coupling must meet on the same coupling.
.The test condition may usually lead to differences between observed data and standard features.
Features of Igniter Item Standard Value
Resistance value of
Ignition coil(20℃)
Original coil 0.1-0.2Ω
Sub-coil With spark plug 7.3-11KΩ
Without spark plug 3.6-4.6KΩ
Resistance value of pulse trigger winding coil(20℃) 50-170Ω
Resistance value of magneto stator(20℃) 50-350Ω
Troubleshooting
No spark or not enough The revolution is unusual.
.The line connection is bad, broken line or in short.
-CDI and Igniter coil[Black and Yellow ] -Ignition coil
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-CDI and Igniter trigger [Black and White] -Bad connection between lines -CDI and Magneto Stator [Black and Red] -CDI is not good.
-CDI and Trigger [Green/White,Blue/Yellow] .Sub Ignitions line
-CDI and Grounding line [Green] -Spark plug is not good
.Ignition Switch is not good -Trigger is not good
.CDI is not good -Spark coil is not good
.Trigger is not good Ignition
-CDI is not good. -Trigger is not good -Magneto Stator is not good
Main features of Igniter
Dismantles the accumulator cell fixed belt; Dismantles the electric appliance lid.
ITEM Checking Position Standard Value
Igniter switch Black/White-Green Electric current bleed when
switch is off.
Magnetor coil Black/Red-Green 50—350Ω(20℃)
Trigger Green/White-Blue/Yellow 50—170Ω(20℃)
Igniter coil
Main coil Black/Yellow-Green 3.6—4.6kΩ
Sub-coil with cap of spark
plug Black/Yellow-cap of Spark plug 7.3—11kΩ
If no barriers after inspecting as above, you need a application detector to check
Igniter.
Igniter