Polar Fox 1100 GKE OutLaw, Service Manual

Page 1: ...Service Manual 1100GKE 4 4...

Page 2: ...ntains an introductory description of procedures for inspection maintenance overhaul disassembly assembly removal and installation of components and parts troubleshooting and service data together wit...

Page 3: ...g parts with the correct part number or an equivalent part We strongly recommend that you do not use replacement parts of inferior quality For Your Customer is Safety Proper service and maintenance ar...

Page 4: ...upported Use jack stands Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbo...

Page 5: ...n case of fire Warning Labels Most manufacturers attach information and warning labels to the GK These labels contain instructions that are important to personal safety when operating servicing transp...

Page 6: ...rom loosening In certain applications such as the rear axle on an GK or motorcycle the fastener must be secured in this way For these applications A cotter pin and castellated slotted nut is used To u...

Page 7: ...ce is devoid of sharp edges and carefully polished They have an easy to clean finish and are comfortable to use Quality tools are a good investment Some of the procedures in this manual specify specia...

Page 8: ...s NOTE Another way to prevent cam out and to increase the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw socket Gripper onto the screwdriver tip After loosening ti...

Page 9: ...e certain the solid jaw is the one transmitting the force Socket Wrenches Ratchets and Handles Sockets that attach to a ratchet handle Figure 7 are available with 6 point or 12 point openings Figure8...

Page 10: ...to Socket Wrenches Ratchets and handles in this section WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury Always wear eye protection when using impact...

Page 11: ...wrench to compensate for the change of lever length When using a torque adapter at a right angle to the drive head calibration is not required because the effective length has not changed To recalcul...

Page 12: ...specialized pliers with tips that fit into the ends of snap rings to remove and install them Snap ring pliers Figure 17 are available with a fixed action either internal or external or convertible on...

Page 13: ...ols provide the best results if cared for properly Improper use can damage the tool and cause inaccurate results If any measurement is questionable verify the measurement using another tool A standard...

Page 14: ...a slight drag Some calipers require calibration Always refer to the manufacturer s instructions when using a new or unfamiliar caliper To read a vernire Calipers refer to Figure 21 The fixed scale is...

Page 15: ...er The following sections describe how to adjust care for and read the measurements of various types of outside micrometers For accurate results properly maintain the measuring surfaces of the microme...

Page 16: ...ey do temperature changes and corrosion may damage the contact faces 3 Do not clean a micrometer with compressed air Dirt forced into the tool will cause wear 4 Lubricate micrometers with WD 40 to pre...

Page 17: ...in 0 025 in increments Every fourth sleeve mark is numbered 1 2 3 4 5 6 7 8 9 These numbers indicate 0 100 0 200 0 300 and so on The tapered end of the thimble has 25 lines marked around it Each mark...

Page 18: ...bore Do not over tighten the gauge because there is no built in release Excessive tightening can damage the bore surface and damage the tool Remove the gauge and measure the outside dimension Figure...

Page 19: ...The ohmmeter function tests circuits for continuity or lack of continuity and measures the resistance of a circuit Some manufacturer s specifications for electrical components are based on results usi...

Page 20: ...nd vehicle identification 1 Warning indicator light switch 2 Ignition Switch 3 Turning switch 4 Driver model turn switch 5 Light switch 6 Low beams High beams turn 7 Horn switch 8 Meter 9 Cigarette li...

Page 21: ...mber and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen Vehicle Identification Number 1100GKE LCXESAS3 En...

Page 22: ...rication Cool type Mandatory cycle of antifreeze coolant Maximal power 50Kw 6000 rpm EEC model less than 15kw Max torque 90N M 3500 4000 rpm EEC model 45N M 2240 rpm Lowest fuel consuming rate g Kw h...

Page 23: ...cooling fluid circulating Cooling fluid type antifreeze with prevent rust Out dimension 555 8 x 455 9 x 699 Net weight 80kg Output type front and rear shaft output Engine Gearing Shaft running direct...

Page 24: ...e of radiator cap 108kpa 1 1kgf cm2 Temperature valve open 72 2 C Temperature valve full open 88 C Thermostat Overall lift 3 5 4 5mm 95 C Front Rear Wheel Item Standard Service Limit Vertical 1 0mm 2...

Page 25: ...2 0 3 Rectifier Three phase annular rectification Silicon controlled parallel connected regulated voltage Capacity 12V36Ah Fully charged 12 8V Terminal point voltage Insufficient charge 11 8V Standar...

Page 26: ...50 8 CVT SECONDARY SHEAVE M10 115 1 40 50 9 FRONT LOWER UPPER ARM M10 1 25 80 8 40 50 10 JOINT ARM BALL M12 1 25 2 40 50 M12 1 25 175 4 11 REAR LOWER UPPER ARM M12 90 8 40 50 12 FRONT REAR AXLE NUT M...

Page 27: ...ALL POSITION M6 25 HEXAGON BOLTS 48 53 6 ALL POSITION M16 1 5 37 TIPE BOLT 210 230 SCREW FASTENIN G GLUE 7 ALL POSITION M12 16 SCREW 80 90 8 ALL POSITION M8 35 SMALL PAN HEAD SCREWS 24 28 9 ALL POSIT...

Page 28: ...city Remark Fuel RQ 93or upper grade lead free gasoline 35L Lubricating oil engine Gear box SAE15W 40 SF or SC 3600ml change oil 3500ml change filter Change Front 500ml Gearbox Change Rear 1300ml Lubr...

Page 29: ...the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler af...

Page 30: ...heel Remove steering wheel Installation Reverse the removal procedure for Installation Installation Note Align the front wheel first and then adjust steering wheel Reverse the removal procedure for In...

Page 31: ...e the spotlight bracket Installation Reverse the removal procedure for Installation Main Protect Pole Assy Remove Remove four bolts 1 Remove oblique of ceiling joist underprop Remove four bolts 2 Remo...

Page 32: ...IN PROTECT POLE TOP 6 BOLT M10 25 7 OBLIQUE OF CEILING JOIST UNDERPROP 8 HANDLE MAIN PROTECT POLE 9 BOLT FLANGE M6 16 10 HANDLE CAP MAIN PROTECT POLE 11 BOLT M8 20 FENDER Remove Remove bolt 1 Remove b...

Page 33: ...4 Remove driver seat Remove the passenger seat in the above way Remove three bolts 5 Remove driver seat belt Remove the passenger seat belt in the above way Installation Reverse the removal procedure...

Page 34: ...eat cover Remove three bolts 1 Remove the cover left side rear Remove two bolts 2 Remove the footrest board L Remove the other right cover in same method Installation Reverse the removal procedure for...

Page 35: ...ll the connector of meter Remove meter cover assy Remove three nuts 6 remove meter Installation Reverse the removal procedure for Installation 1 COVER METER 2 RUBBER WASHER 5 10 1 3 SCREW M4 2 16 4 SC...

Page 36: ...and brake cable 9 4 Remove one bolt 6 Remove two bolts 2 Remove two bolts 3 Remove bracket of shift gear Installation Reverse the removal procedure for Installation 1 SPRING WASHER 8 2 BOLT FLANGE M8...

Page 37: ...SHER 6 18 1 5 23 HAND BRAKE CABLE SHORT 24 ARC BLOCK 25 HAND BRAKE CABLE 26 LIMIT BAGGLE P 27 BOLT MODLE U M5 28 BOLT M5 Front decorating plate Remove Remove two bolts 1 Remove support tow Remove two...

Page 38: ...l the connector of license plate light Remove five bolts Remove rear board adorn Installation Reverse the removal procedure for Installation Spare wheel frame Remove four bolts Remove spare wheel fram...

Page 39: ...edure for Installation 1 SCREW M6 16 2 RUBBER WASHER 6 12 2 3 COVER LEFT SIDE 4 COVER RIGHT SIDE 5 FUEL TANK 6 BOLT FLANGE M8 20 7 LOCKNUT FLANGE M8 8 CAP FUEL TANK 9 FUEL PUMP 10 HOOP 11 0 SEAL RING...

Page 40: ...exhaust pipe Remove muffler Note Replace seal ring when installing the muffler Installation Reverse the removal procedure for installation 1 MUFFLER 2 OXYGEN TRANSDUCER 3 MUFFLER HEAT INSULATION COVE...

Page 41: ...till very hot when the engine is just stopped Careless contact may cause serious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine is just sto...

Page 42: ...d on vehicles that are used in severe conditions Km Initial 250km Every 500 km Every 1000 km Interval Item Hours Initial 20 hours Every 50 hours Every 100 hours Remarks Valve clearance I I IN 0 18 0 0...

Page 43: ...c Brake disc damage and wear Replace when the thickness of front brake disc is less than 3mm rear brake less than 3mm Tire pressure Front tire 145 7kPa 21 1PSI Rear tire 193 7kPa 28 1PSI Chap and dama...

Page 44: ...Looseness of joint parts Drive Train Final shaft Drive shaft Sway of Spline Spark plug Ignition Device Ignition timing Battery Terminal Joint Electrical System Wiring Looseness and damage of joints F...

Page 45: ...on Alarm and lock device Function Instruments Function Looseness or damage caused by improper installation Exhaust pipe and muffler Function of muffler Frame Looseness and or damage Others Lubrication...

Page 46: ...detents 4 With two wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Perform this procedure on the shift lever end also 5 After turning the outside jam nut 1 1...

Page 47: ...e main filter the filter should be replaced 3 Inspect main element and replace if necessary If the filter has been soaked with fuel or oil it must be replaced Installation 1 Reinstall the filter into...

Page 48: ...rdingly In case of sway of the steering stem tighten the locknut or disassemble the steering stem for further check Park the vehicle on level place slowly turn the steering wheel left and right to see...

Page 49: ...ber parts Keep the fluid away from these parts Slightly turn the steering wheel left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad Wear o...

Page 50: ...el is tightened and check whether it sways Not tighten enough Tighten it sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in...

Page 51: ...ure will reduce the comfort of operation and riding and may cause deflected wear of the tires Specified pressure tire Front wheel Rear wheel Pressure 145 7kPa 21 1PSI 193 7kPa 28 1PSI Tires sizes 27 8...

Page 52: ...heel Bearing Lift the front wheel Make sure there is loading on the vehicle shake the wheel in axial direction for any sway In case of any sway disassemble the front wheel and check the bearing Suspen...

Page 53: ...r Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the lock nut to adjust the length of gearshift Rod Fuel Device Status of the fuel s...

Page 54: ...djust Loosen locknut of throttle cable turn the regulator and adjust free play of throttle pedal After adjusting tighten locknuts and install throttle cable sleeve Replace with a new throttle cable if...

Page 55: ...into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of childre...

Page 56: ...leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiator hose for aging damages or cracks The rubber hose will naturally get aged after a period of servic...

Page 57: ...wallowed induce vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Check radiator fins for mud block and or damage Correct the bent fins Clean off...

Page 58: ...ed radiator fin Coolant is not enough Faulty or malfunction of fan motor No rise or slow rise of water temperature Faulty thermostat thermostat is not closed Faulty circuit of water temperature displa...

Page 59: ...of radiator cap Note Open the radiator cap after the coolant is fully cooled Remove Remove bolt 1 and battery panel Remove radiator cap counter clockwise Note Apply coolant on the sealing surface of r...

Page 60: ...hes Ifcoolant splashes in your eyes thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolan...

Page 61: ...install the radiator cap Remove reservoir tank cap and add coolant till the full limit Note Check coolant level when the vehicle is on an even ground Air Discharge Discharge the air from cooling syst...

Page 62: ...4 COOLING SYSTEM 4 6 Cooling System Chart...

Page 63: ...44 9 COCK WATER PIPE 10 INTAKE PIPE ENGINE FRONT 11 INTAKE PIPE ENGINE AFTER 12 CLAMP 25 38 13 CLAMP 22 32 14 PIPE RADIATOR CAP 15 RADIATOR CAP 16 STATOR RADIATOR 17 WASHER 8 20 2 18 RADIATOR RESERVE...

Page 64: ...Don t damnify the frame body of Engine bolt and cable etc Please blind up the frame when removal the engine Don t removal engine from the bodywork when operating as follows THROTTLE VALVE BODY AIR FIL...

Page 65: ...me 2 2 Remove fuel tank 2 11 Remove seat 2 5 Remove plastic covers chapter2 Remove hoop Remove water inlet hose of engine Remove bolt 1 Remove gear shift rod Remove hoop1 Remove water outlet hose of e...

Page 66: ...VAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT 5 3 Remove nut Remove the throttle cable Remove all the connector of engine Remove the bolt Remove the Protection cover of ECU Remove all the connector...

Page 67: ...TEM AND GEARSHIFT 5 4 Remove all the connector of engine Remove hoop Remove water circulatet hose of engine Remove tension spring of exhaust pipe Remove muffler Remove the connector of oxygen sensor R...

Page 68: ...oop of air inlet duct for CVT Remove bolt Remove air inlet duct of CVT Remove the CVT disassembly installation 1 CVT DRIVING WHEEL 2 CVT BOTL 3 TEETH SERRATED 12 4 WASHER 12 28 1 5 5 BUSH CVT DRIVING...

Page 69: ...M6 Remove fixing nuts of engine Remove other fixing nuts of engine as shown below Engine and gearbox disassembly installation 1 ENGINE 2 MOTOR BUSH 3 SPRING WASHER 10 4 BOLT M10 25 5 CONNEC TING PLATE...

Page 70: ...FLANGE M10 1 25 20 49 BOLT FLANGE M6 12 50 NUT CLIP M6 51 BRACKERT STEERING Removal and Installation of Front and Rear Axle Support the vehicle with jack make sure the vehicle will not fall Remove Pla...

Page 71: ...disassembly installation 1 NUT SHAFT SET M18 1 5 2 PIN SPLIT 4 30 3 SHAFT SET R REAR ATV904 4 FRONT AXLE 5 AIR HOSE AXLE 6 BOLT FLANGE M12 1 25 120 7 DEAD PLATE FRONT AXLE F 8 BOLT FLANGE M10 1 25 25...

Page 72: ...2 Disassembly 23 3 Routine Inspection 23 4 Water Pump 29 1 Structure Diagram 29 2 Disassembly 29 3 Cleanup 29 4 Routine Inspection 29 5 Assembly 29 5 Oil Pump 29 1 Structure Diagram 30 2 Disassembly...

Page 73: ...in Fit Clearance for SQR472 Engine 55 Chapter 4 Table of Measurement Parameters of SQR472 Engine 59 Chapter 5 Table of Main Fitting Torque for SQR472 Engine 61 Chapter 6 Positions on SQR472 Engine to...

Page 74: ...onents and installation status are set forth at the beginning of each chapter or section 2 The number in the figure refers to the disassembly sequence of each component The components which may not be...

Page 75: ...ion to the operation description It records the operation descriptions of cases about person accident 2 Meaning of Marks and Abbreviations Mark Original Words Intepretation RH Right Hand Right Hand LH...

Page 76: ...assembly and assembly of engine Clamp hole wrench for camshaft timing gears Disassembly of camshaft timing gears Spring bushing puller Assembly of camshaft Oil seal Valve keeper remove tool Auxiliary...

Page 77: ...il seal Crankshaft pulley holding tool Disassembly and assembly of crankshaft pulley Wrench Disassembly and assembly of crankshaft driven gear Replace valve clearance adjustment gasket Water pump pull...

Page 78: ...le or assemble the engine with roll over stand Disassemble or assemble the engine parts on the roll over stand 1 Timing Belt 1 Structure Diagram Water pump pulley Timing shroud Timing belt Torsional d...

Page 79: ...l tool Torque 25 1 5 N m 2 2 Disassembly of Timing Belt Cover Torque 6 1N m 2 3 Disassembly of torsional damper Use special tools to prevent the gear ring from rotating When disassembling the fixing b...

Page 80: ...over 2 5 2 Screw off the bolt of tension pulley and remove the tension pulley 2 6 Disassembly of timing belt Notice Do not use sharp tools like screwdriver during disassembly of belt Notice Pay attent...

Page 81: ...tly The water pump leaks water out and requires continuing infusion If the belt is spotted with much oil stains and the rubber may be damaged due to expansion you should replace the belt Timing belt m...

Page 82: ...ith bolts The tightening torque for the bolts is 100 5Nm Make sure that the clashing mark of crankshaft timing pulley aligns with the mark of oil pump 3 3 Install the tension pulley After adjust the t...

Page 83: ...deflection can not reach the standard it is necessary to adjust the fixing bolt of tension pulley mentioned above Tighten the fixing bolt of the tension pulley with the torque as specified The tighte...

Page 84: ...unt the sealing strips at the positions as indicated in the right figure The sealing strips at the position 1 and 2 should be mounted before the assembly of the cylinder head assembly and the sealing...

Page 85: ...2 Cylinder head cover gasket 3 Camshaft timing belt 4 Camshaft cover 5 Blanking cover 6 Camshaft bearing cap 7 Exhaust camshaft assembly 8 Intake camshaft assembly 9 Camshaft oil seal 10 Axial spring...

Page 86: ...move the camshaft timing gear with special tool Notice The special tool should be made as indicated in the right figure Use the special tool to prevent the camshaft from rotating 2 3 Remove the camsha...

Page 87: ...perate as indicated in the right figure Clamp the camshaft and plug the pins of special tool into the hole on gear rotate the gear to keep the meshing of driven gear and driving gear and then remove t...

Page 88: ...2 Confirm the mark forwards on the bearing cap as well as the axle number and then tighten the bolts 3 Measure the clearance of engaging tooth of the intake camshaft with dia indicator Notice Measure...

Page 89: ...bolts M5 0 8 Notice Don t damage the journal adjust the operation 3 3 Assembly of camshaft Notice Pay attention to the axial clearance of the camshaft 3 3 1 Spread grease on the gear of camshaft and...

Page 90: ...ted in the right figure After being pressed the blanking cover should be 1 1mm higher than the surface of thecylinder head 3 7 Spread the edge of the camshaft oil seal with oil and press it into the c...

Page 91: ...as indicated in the right figure and with the specified torque Torque 6 1N m 4 Inspection of valve 4 1 Standard valve clearance IN 0 18 0 05 Valve clearance EX 0 25 0 05 4 2 Make sure that the timing...

Page 92: ...head of the cylinder which exceeds the standard value faces upwards and the opening of the valve tappet face inwards 4 4 2 Rotate the crankshaft and press down the valve tappet with the crown head of...

Page 93: ...44 2 66 2 24 2 46 2 68 2 26 2 48 2 70 2 28 2 50 2 72 2 30 2 52 2 74 2 36 2 58 2 80 2 32 2 54 2 76 2 38 2 6 4 4 3 4 Adjust the valve clearance with selected adjustment gasket Notice Install the adjust...

Page 94: ...der cushion 5 Adjustment gasket 6 Valve tappet 7 Valve spring retainer 8 Valve spring seat 9 Valve Spring 10 Intake valve 11 Exhaust valve 12 Valve oil seal 13 Valve seat 14 Valve guide 2 Disassembly...

Page 95: ...seat valve spring intake valve and exhaust Valve etc with special tools 2 6 Disassembly of valve oil seal and valve spring gasket 2 7 Cleanup 2 7 1 Clean the carbon dust on the valve 2 7 2 Clean the b...

Page 96: ...meter of valve guide with dial gauge the outer diameter of valve stem with micrometer caliper 3 3 2 2 Figure out the difference of measured values and the clearance If the clearance is beyond the spec...

Page 97: ...ount the new valve guide with special tool at the place as can be seen from the right picture Notice strike the conduit slowly to the position in the cylinder head do not strike too far and be careful...

Page 98: ...orted position with inner 70and outer 30 3 3 4 6 Prepare for polishing of valve seal 3 4 Assembly of cylinder head 3 4 1 Cylinder head Pay attention to the following for installing the other auxiliary...

Page 99: ...of intake valve and exhaust valve 3 4 3 2 1 Assembly of valve spring Notice The painting is used for recognizing the different suppliers so the same engine should use the valve spring with same paint...

Page 100: ...indicated in the right figure for 3 times till the torque reaches the specified value The tightening torque for each time is set forth as follows First time 30 2Nm second time 50 3Nm third time 70 3 5...

Page 101: ...eusable 2 2 Screw off 3 bolts and disassemble water pump body 2 3 Disassembly of dust seal 3 Cleanup 3 1 Clean water pump joint surface 4 Routine Inspection 4 1 Check if it is deformed 4 2 Rotate it w...

Page 102: ...l collector spacer nonreusable Oil pump Oil pump spacer nonreusable Rear oil seal bracket 2 Disassembly 2 1 Screw off the bolts and nuts and then remove the oil pan from the cylinder body with special...

Page 103: ...ice The oil collector gasket is nonreusable 2 3 Remove the engine oil pump assembly and the engine oil pump gasket 2 4 Remove the rear oil seal bracket 3 Cleanup 3 1 Remove the old cushion from the oi...

Page 104: ...tter Pin Oil Drain Valve Spring base Oil Drain Valve Spring Slide Block Crankshaft Front Oil Seal Engine Oil Pump Housing 4 2 Disassembly 4 2 1 O ring Notice The O ring is nonreusable 4 2 2 Remove the...

Page 105: ...and oil pressure relief valve etc 4 2 6 Remove the front crankshaft oil seal Notice The oil seal removed may not be reused 4 3 Routine Inspection 4 3 1 Inspect the engine oil pump for clearance 4 3 1...

Page 106: ...he oil pressure relief valve 4 4 Installation 4 4 1 After the lip of the new oil seal for front crankshaft is spread with engine oil fix it with a special tool Notice Use new oil seal The oil seal sho...

Page 107: ...4 4 3 When the outer gear or inner gear is put into the engine oil pump its mark should be seen 4 4 4 The new weather strip should be fixed in the groove of oil pump cover 5 Disassembly of Oil Seal 5...

Page 108: ...oil seal with special tool as indicated in the right figure 6 Assembly 6 1 Assembly of the oil seal seat Spread sealant over the oil seal seat as shown in the right figure Grease Loctite 5699 Notice S...

Page 109: ...l pan with the cylinder 6 4 2 Spread sealant then assemble it Grease Loctite 5699 Notice The sealing line should be unbroken with its diameter being 3 4mm Assembly should take place fifteen minutes af...

Page 110: ...Structure Diagram Connecting rod cover Connecting rod bushing Piston connecting rod assembly Main bearing cap Crankshaft Crankshaft bearing bushing Thrust plate Cylinder body First ring Second ring S...

Page 111: ...cting rod bushing for its radial clearance 2 2 1 Remove the bushing cap Notice The components of each cylinder shall be placed in order 2 2 2 Clean the bearing bushing and the axle 2 2 3 Conduct radia...

Page 112: ...connecting rod bearing bushing 2 2 7 Put vinyl resin protecting jacket on the threaded part of the connecting rod bolt so as to prevent the bolts from scraping the cylinder hole and the crannkshaft c...

Page 113: ...m Notice After tightening the bolts the rotating torque of the crankshaft should be less than 1Nm The torque of crankshaft without piston connecting rod 2 4 4 Remove the bearing cap and measure the m...

Page 114: ...As indicated in the right figure disassemble the piston which is at the state mentioned above with special tools Remove the piston pin with special tool and then remove the piston and the connecting...

Page 115: ...b Cylindric degree A a or Reference Standard diameter of cylinder 72 00 72 01mm 4 2 Piston 4 2 1 Inspect the piston pin hole for its clearance Measure the piston pin at several positions with a micro...

Page 116: ...he ring gloove 4 2 5 1 Measure around the ring gloove with a piston ring and a feeler gauge Standard value mm Limit mm First ring 0 03 0 06 0 12 Second ring 0 03 0 06 0 11 4 2 6 Inspect the end cleara...

Page 117: ...Crankshaft 4 3 1 Inspect the proper alignment of the main axle diameter 4 3 1 1 Measure the proper alignment with a dial gauge if the proper alignment is beyond the limit replace the crankshaft Limit...

Page 118: ...chine Notice When pressing in the piston pin make sure the fitting direction is correct When the piston pin is pressed into the piston the small end of the connecting rod should be heated to 300 and t...

Page 119: ...at the side with oil gloove crankshaft shank face outwards Notice Spread the side of oil glove with oil 5 3 4 Fix the crankshaft bearing bushing lower piece in the bearing cap the bearing bushing shou...

Page 120: ...should be spread with engine oil 5 4 4 Confirm the mark forwards of the piston and strike it into the cylinder body with the piston ring striking tool Notice The cylinder number of the piston and con...

Page 121: ...Crankshaft Connecting Rod Bearing Name of Component Size and Tolerance Clearance or Value of Interferenc Remark Crankshaft connecting rod journal 37h6 0 016 0 Bearing bushing 1 5 0 006 0 Bore of conn...

Page 122: ...8 f6 005 0 014 0 Clearance 0 005 0 029 8 Radial Clearance of Camshaft Bearing Name of Component Size and Tolerance Clearance or Value of Interferenc Remark Cylinder Head 26H7 021 0 0 1st bearing cap C...

Page 123: ...t and spark plug on the cyllinder head tighten the camshaft bolt and then measure the torque of the camshaft rotating at uniform speed 32 Nm 3 Distance between the outer edge of steel ball and the fro...

Page 124: ...lug M12 1 45 3 9 Oil pan bolt M6 19 6 1 10 Bolt connecting exhaust camshaft with flange hexagonal M6 4 6 1 11 Exhaust camshaft locking nut M40X1 5 L 1 100 5 12 Cylinder head bolt M10X1 25 10 70 3 5 13...

Page 125: ...5 1 100 5 32 Water pump pulley bolt M6 4 6 1 33 Water temperature sensor M12X1 5 1 15 1 5 34 Oil pressure switch 1 30 2 35 Spark plug M14X1 25 4 20 1 36 Fixing Bolt of spark plug cover board M6 8 2 5...

Page 126: ...6 Inner wall of cylinder hole 7 Crankshaft main neck 8 Connecting rod shaft neck 9 Upper lower main bearing bushing inside 10 Upper lower connecting rod bearing bushing inside 11 Crankshaft thrust pl...

Page 127: ...tite 5699 3 4 mm 5 Joint surface of camshaft cover Loctite 5699 3 4 mm 6 Sealing surface of the bowl shaped plug of cylinder head Loctite 11747 Spread uniformly 7 Flywheel bolt Loctite 204 0 125 ml 6...

Page 128: ...2 Fuel Injector System Disassembly Installation 7 3 High Pressure Fuel Line Disassembly Installation 7 4 Throttle Body Disassembly Installation 7 4 Fuel rail with injector assy Disassembly Installatio...

Page 129: ...dishcloth or tape for avoiding the entry of other objects into the engine from the air intake side of the engine When the vehicle will be stored for more than one month the gasoline in the high press...

Page 130: ...HID 7 89 3 FIXED PIPE 4 BOLT FLANGE M8 40 5 FUEL TANK 6 BOLT FLANGE M8 20 7 LOCKNUT FLANGE M8 8 CAP FUEL TANK 9 FUEL PUMP 10 HOOP 11 O SEAL RING 6 100 12 FUEL FILTER SET 13 1 FUEL HOSE 850mm 13 2 FUEL...

Page 131: ...Remove the connector of throttle valve opening sensor Remove the connector of idling solenoid valve sensor Loosen locknut remove adjust nut and remove the throttle cable from throttle rotory sleeve Lo...

Page 132: ...with injector assy Fuel rail with injector assy installation Reverse the disassembly procedure for installation Fuel injector removal Use Slotted screwdriver to remove snap spring Remove fuel injecto...

Page 133: ...rt on the wheel Avoid any damage to the wheel When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Longitudinal 0 8mm 2 0mm Rim Vibration La...

Page 134: ...eformed frame Worn tiers Shaking of wheel bearing Vibration of Front Wheel Wheel rim distorted Faulty wheel bearing Faulty tire Improper balance of wheels Improper tightening of wheel axle Wheel Canno...

Page 135: ...rim vibra tion with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Assembly Press rim into wheel Install rim on the wheel hub Tightening Torque Bolt Wheel Hub 40 50 N m Front Wheel Hub Disassemb...

Page 136: ...em Front brake caliper Removal Remove Front wheel 8 3 2 bolts from arm Front caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage Replace if any Installation Reverse...

Page 137: ...Fixing bolt brake disc 25 30N m Brake Master Cylinder Disassembly Remove Two Nuts 1 One blot One nut 2 Do not remove brake master cylinder from vehicle unless when replacing master cylinder assembly...

Page 138: ...dal from vehicle Disassembly of front brake master cylinder 8 5 Installation Reverse the removal procedure for installation NOTE Do not put the master cylinder upside down to avoid possible entrance o...

Page 139: ...ehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Bolt1 Nut1 Shock absorber Bolt2 Nut...

Page 140: ...9 ARM SET L FR 20 ARM SET R FR Disassembly Disassembly Front Left Shock Absorber Disassembly ATTENTION You do not need to remove any other parts if you only replace the front shock absorber Park the v...

Page 141: ...f the vehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Bolt2 Nut3 Front Right Shock...

Page 142: ...ive Shaft of Front Axle only does not require removal of Front Suspension Remove Front left wheel 8 3 Front left brake caliper 8 4 Front left wheel hub 8 3 Check dust boot Damaged dust boot Replace Sh...

Page 143: ...N STEERING 8 11 Rear View Mirror Removal Remove left and right rear view mirrors Note Left rear view mirror is right threaded Turn counter clockwise for removal Note Right rear view mirror is left thr...

Page 144: ...8 FRONT WHEEL FRONT BRAKE SUSPENSION STEERING 8 12 Steering Stem Removal Remove Steering wheel 2 2 Two bolts 1 Shaft assy steering joint Four bolts 2 Steering stem...

Page 145: ...UMN 7 BOLT FLANGE M8 30 8 COVER OF STEERING COLUMN 9 BOLT M8 25 10 STEERING JOINT STEERING 11 STEERING ASSY 12 HOOP STEERING COLUMN IRON 3 SPRING WASHER 10 14 BOLT M10 1 25 25 15 NUT M12 1 25 16 STEER...

Page 146: ...ssible damage to the wheels When removing tire from rim use special tire lever and rim protector to avoid damage to the rim Overhaul standard Item Standard Limit Longitudinal 2 0mm Rim vibration Horiz...

Page 147: ...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 absorb...

Page 148: ...on with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Installation Refer to front wheel installation 8 3 Wheel hub removal Remove rear wheel 9 3 Remove mounting bolt rim Remove bolt 1 and nut 1...

Page 149: ...er to brake hose routing Rear Brake Disc Remove Rear left wheel 9 3 Remove mounting bolt rim Remove wheel hub Remove rear brake caliper 9 4 Remove Rear brake disc 8 3 Inspection Brake Disc Thickness 3...

Page 150: ...E 14 ARM SET RR LOWER L 15 ARM SET RR LOWER R 16 WIRE CLAMP 17 SCREW M6 16 18 RUBBER WASHER 6 12 2 19 FLANG REAR WHEEL LEFT 20 FLANG REAR WHEEL RIGHT 21 SPRING WASHER 12 22 BOLT FLANGE M12 1 25 25 23...

Page 151: ...Remove the following parts for rear right shock absorber 11 Bolt 1 12 Nut 2 11 Bolt 1 12 Nut 2 Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right...

Page 152: ...ANSMISSION SYSTEM 10 1 Catalog 1 Main technical parameter and specification 2 2 Tightening torque of product 2 3 Usage and maintenance 3 4 Countermark position 6 5 Appearance installation dimension ma...

Page 153: ...htening torque No code Name Spe Torque N m Assembly position Thread fastening agent 1 GB T5789 1986 Plate bolt 10 9 level M6x16 11 1 Torque cam 2 GB T 5783 2000 Plate bolt 10 9 level M6x45 11 1 Drivin...

Page 154: ...bly you should use exclusive check tool to check whether the CVT driving plate is accord with the center of driven plate The distance between driving plate and driven plate is 39 8 0 15 checked by exc...

Page 155: ...finished the belt tension should be appropriate Too loose or too tight will obvious effect the operating life of belt So the verticality of loose edge should be checked after the belt assembly is fin...

Page 156: ...ine the operating life of belt So before CVT assembly or change please clean it firstly 3 2 3 CVT 15000 15mm Belt The belt should be changed when vehicle run more than 15000 Kilometers the abrasion an...

Page 157: ...e maintenance and check the CVT as below methord maintenance Period As anyone is fisrtly expired Item Time h Mont h km Distanc e Driving drive n part 100 12 1500 Check clean change the abrasion parts...

Page 158: ...10 CVT TRANSMISSION SYSTEM 10 7 5 Appearance installation dimension map Fan shaped array 10...

Page 159: ...ice personnel to understand and familiar with Chery QQ SQR7110 models has the capability of rapid repair and maintenance specially written Chery QQ Technology Service Manual 472 engine mechanical part...

Page 160: ...other is connected with ECU signal 33 Chapter 3 Introduces the function of fault diagnosis system 34 1 control the fault lamp 34 2 Connect the diagnosis instrument 34 3 Fault code list 35 4 Erase faul...

Page 161: ...r injector circuit for the power supply circuit fault code P0268 54 2 30 Four cylinder injector circuit shorted to ground fault code P0270 55 2 31 Four cylinder injector circuit for the power supply c...

Page 162: ...rmal but any time idling instability 71 3 7 Normal starting warm process of unstable idle speed 72 3 8 Normal starting warm after the end of unstable idle speed 73 3 9 Normal starting part load such a...

Page 163: ...control functions of the system for monitoring once detected faults and confirmation the memory fault code call limp home function when the detected fault is eliminate then normal recovery using The...

Page 164: ...or control signal which includes Idle speed regulator opening Fuel injection timing and injection duration Ignition coil closed angle and ignition advance angle The carbon canister control valve openi...

Page 165: ...11 EFI SYSTEM OF SQR 472ENGINE 11 3 3 The ECU control principle diagram...

Page 166: ...11 EFI SYSTEM OF SQR 472ENGINE 11 4 4 The ECU function module layout...

Page 167: ...18 Empty 59 Upstream oxygen sensor Earth 19 Stepper motor coil A Output 60 Inlet air pressure signal Input 20 Stepper motor coil A Output 61 2 cylinder injection signal Output 21 The main relay power...

Page 168: ...11 EFI SYSTEM OF SQR 472ENGINE 11 6 39 The speed signal input Input 80 Empty 40 Empty 81 Empty 41 Empty...

Page 169: ...ature sensor the resistance value varies with the temperature of the cooling water cooling water temperature is low the resistance of the thermistor is large The cooling water temperature is high the...

Page 170: ...sealant to ensure that the assembly and disassembly and good conductivity sensor In the installation process of tightening tighten six angle plane using spanner copper sleeve May not be a plastic part...

Page 171: ...due to the lack of teeth and tooth alternation is produced by the variation of the magnetic field and the Schmidt trigger conversion by square wave signal 4 technical parameters 1 limit data be worth...

Page 172: ...htening torque of 8 2Nm Holzer type crankshaft position sensor and signal disc tooth tip of the air gap between nominal value is 1 0mm allow the range is 0 3 to 1 7mm 6 The malfunction phenomenon and...

Page 173: ...3 The camshaft position sensor 1 Diagram and pin 2 Installation position Camshaft end cover 3 Working principle The sensor makes use of the magnetic induction intensity changes by Holzer Holzer in th...

Page 174: ...000 rpm 5 Installation notes Installation method of sensor by indentation instead of hammering Recommended bolt fixed sensor M8 Tightening torque 10 14Nm The air gap between the camshaft position sens...

Page 175: ...molition to prevent the destruction of the initial setting 4 the vehicles running on certain mileage such as twenty thousand kilometers the large dust reduce it or solar term valve plate dust depositi...

Page 176: ...k Slider protecting resistor slider at zero pin B C 710 1380 Operating temperature 40 130 The power supply voltage 5 V The right extreme position of the voltage ratio 0 04 0 093 The left extreme posi...

Page 177: ...designed into can not rotate so it can only move in the axial direction so it is also called linear axis End wire rod is a plug plug and therefore can be retracted or extended cross sectional area to...

Page 178: ...pened at both ends of the pressure drop 60 kPa Gas pressure difference caused by the maximum axial force 6 28 N 5 Installation notes Idle with stepping motor actuator is installed on the solar term do...

Page 179: ...t method is open the ignition switch but not immediately start the engine wait 20 seconds and then start the engine If at this time that the engine idling bad must repeat the above steps A simple meth...

Page 180: ...output voltage is low close to 100mV 200mV Signal voltage in the theory of equivalent air fuel ratio 1 occurred near mutation see below 4 Technical parameters Limit data value measure Least typical ma...

Page 181: ...of about 0 7M s 12 W The working voltage is 15V the heating current thermal equilibrium 350 the exhaust of greenhouse gas flow velocity of about 0 7m s 5 A Fuse filament heating circuit 8 A 4 The use...

Page 182: ...be in the rapid fluctuation between 0 1 0 9V 8 The intake air temperature and absolute pressure sensor 1 Structure diagram and pin 2 Installation position The sensor consists of two sensors intake ma...

Page 183: ...and so on can not ensure the formation of condensed water pressure sensitive element Drilling and fixed on the intake manifold must be carried out in accordance with the supply in order to ensure the...

Page 184: ...4V left and right specific numerical and vehicle and then drops to about 1 5V the specific numerical and vehicle 9 The fuel rail assembly The fuel rail assembly consists of the fuel distribution pipe...

Page 185: ...s Republic of China national standard GB 17930 1999 unleaded gasoline for vehicle and the national environmental protection standards GWKB 1 1999 standard harmful substance control gasoline regulation...

Page 186: ...70 Permission temperature fuel injector in a car not working 30 130 Continuous 30 120 The working temperature of the fuel injector After the hot start about 5 minutes time 30 130 Continuous 40 110 Th...

Page 187: ...uirements should be used for the axial and radial locating clamp and the positioning of injector and fuel injector seat positioning pins are respectively located at the card groove clip in the corresp...

Page 188: ...lectric pulse duty ratio on the other hand with the carbon canister control valve between the inlet pressure and the outlet pressure difference When no electric pulse the carbon canister control valve...

Page 189: ...ratio 100 of traffic QA 2 7 3 0 3 3 m h The differential pressure 700mbar duty ratio 100 of traffic QB 3 5 3 8 4 1 m h 5 Installation notes The carbon canister control valve and the carbon canister in...

Page 190: ...n canister control valve installed in the pipe hanging on A simple method to measure remove electric connector digital multimeter to Ohm two one two pin the carbon canister control valve respectively...

Page 191: ...speed acceleration not starting idle speed is too high exhaust exceed the standard starting difficulty empty Adjustable injector control failure failure flameout Common fault 1 due to the external de...

Page 192: ...t and other components see below Pump and motor are coaxially arranged and closed in the same chassis Around the pump and motor shell are filled Full of gasoline the fuel cooling and lubrication The b...

Page 193: ...d on the eye size of not more than 60 or agreed with the customer common inlet strainer Please pay attention not to make the beam injection holes spewing oil into the oil inlet filter oil pump bracket...

Page 194: ...tion to the fuel tank and pipeline cleaning and replacing fuel filter A simple method to measure Remove connector Digital multimeter to Ohm two probes are respectively connected fuel pump two pins mea...

Page 195: ...surface temperature failure and alumina sintering Catalytic converter conversion efficiency and air fuel ratio in the ideal air fuel ratio 14 7 1 narrow area is 14 5 15 0 catalyst for CO HC and NOx co...

Page 196: ...t starting find the speed signal out if the fault lamp fault class is defined as a light mode then meet the corresponding Confirmation conditions after the fault light To connect 2 diagnostic instrume...

Page 197: ...fan relay vehicle speed signal the idle speed idle speed adjustment device system voltage ECU air conditioning compressor evaporator temperature sensor relay fault lamp 3 The fault code list number f...

Page 198: ...ircuit failure 34 P0340 Camshaft position sensor fault 35 P0351 One cylinder ignition coil circuit fault 36 P0352 Two cylinder ignition coil circuit fault 37 P0353 Three cylinder ignition coil circuit...

Page 199: ...n switch 4 According to the diagnostic tester instructions clear fault code 5 To complete the fault code is cleared exit diagnosis procedure switch off the ignition and remove the diagnosis instrument...

Page 200: ...intenance process don t ignore automobile maintenance cylinder pressure mechanical ignition timing and the influence on the system 4 Replacing ECU test If fault code can remove the fault location faul...

Page 201: ...oxygen sensor is connected between pins relative color line to supply short circuit yes Diagnostic aid 2 3 The lower the oxygen sensor heater control circuit shorted to ground fault code P0037 order n...

Page 202: ...sor connector relative to white 2 relative with the oxygen sensor cable whether to short circuit of power supply pin No Diagnostic aid 2 5 Manifold pressure sensor circuit shorted to ground fault code...

Page 203: ...o ground fault code P0112 Serial number Operation steps Inspec tion results Next step 1 Connect the diagnosis instrument the ignition switch is in the ON Next step Yes To step 5 2 The observation data...

Page 204: ...pressure sensor on wire harness electrical multimeter check sensor 3 and 4 pins of value is commensurate with its temperature with specific reference to the evaluation of repair manual No Replace the...

Page 205: ...s electrical multimeter check sensor a and c pins of value is commensurate with its temperature with specific reference to the relevant part of the repair manual No Repair or replace the wire harness...

Page 206: ...ing a multimeter to check the joint line between the a c pin is broken No Next step Yes Repair or replace the wire harness 5 Check the ECU X1_31 X1_73 between pin are respectively connected with the s...

Page 207: ...the road Party member on the coolant temperature value changes the display values should be increased after the engine coolant temperature and elevated No Replace the sensor 2 13 Solar term door posi...

Page 208: ...wire harness between ECU check X1_45 X1_38 X1_32 a b dB and sensor connector pin c whether the circuit breaker short circuit or short circuit of power supply No Next step Yes Replace the sensor 6 Usin...

Page 209: ...t system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 17 Oxygen sensor circuit output voltage is too high fault code P0132 Serial numbe...

Page 210: ...ust system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 19 The oxygen sensor circuit fault fault code P0136 Serial number Operation ste...

Page 211: ...t system blocking Fuel injector is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 21 Oxygen sensor circuit output voltage is too high fault code P0138 Serial numbe...

Page 212: ...is leaking Fuel pressure is too large Valve clearance is too small No Diagnostic aid 2 23 Pump primary line fault fault code P0230 Serial number Operation steps Test results Next step 1 Connect the d...

Page 213: ...ess 3 Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground No Next step Yes Next step 4 Using a multimeter to check a resistor betwe...

Page 214: ...inder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground No Diagnostic aid 2 26 Two cylinder injector circuit shorted to ground fault code P0264 Serial...

Page 215: ...inder injector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground Diagnostic aid 2 28 Three cylinder injector circuit shorted to ground fault code P0267 Serial n...

Page 216: ...wire harness 3 Check in between a cylinder injector connector SM pin and the main relay line is open circuit or short circuit to ground No Next step Yes Next step 4 Using a multimeter to check a resis...

Page 217: ...jector connector 2 pin and the ECU line is broken or the power supply or short circuit to ground Diagnostic aid 2 31 Four cylinder injector circuit for the power supply circuit fault code P0271 Serial...

Page 218: ...r the fault has disappeared No Diagnostic aid 2 33 The crankshaft position sensor circuit fault fault code P0335 Serial number Operation steps Test results Next step 1 Ground which is diagnostic instr...

Page 219: ...ext step Yes Diagnostic aid 6 Check the camshaft signal wheel is intact No Replace the signal disc 2 35 A cylinder ignition coil circuit fault fault code P0351 Serial number Operation steps Test resul...

Page 220: ...table to check the ignition coil 2 cylinder column and ignition anode stop should be 9 2K 20 No Replace ignition coil 2 37 Three cylinder ignition coil circuit fault fault code P0353 Serial number Ope...

Page 221: ...between the table to check the ignition coil 4 cylinder column and ignition anode stop should be 9 2K 20 No Replace ignition coil 2 39 Carbon irrigation control valve open circuit fault code P0444 Ser...

Page 222: ...multimeter to check the carbon canister control valve street is about 3 7V voltage 2 pin and cathode will the house No Next step Yes Repair or replace the wire harness 6 Between the X1_26 pin to chec...

Page 223: ...stem voltage fault fault code P0560 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch is in the OFF Next step Yes Next step 2 using a multimet...

Page 224: ...her there is a fault code No 2 45 Fault display lamp control circuit fault fault code P0650 Serial number Operation steps Test results Next step 1 Connect the diagnosis instrument the ignition switch...

Page 225: ...e changes the display values should be with the engine running down until the 5 degrees celsius Replace the sensor 2 47 Short circuit on the air conditioning evaporator temperature sensor circuit faul...

Page 226: ...between the 85 pin and the 87 pin of main relay circuit is open circuit or short circuit to ground check the fan relay between 86 positive power supply pin and whether the circuit breaker No To step 5...

Page 227: ...ector 85 between pin and ECU X_65 pin line is open circuit or short circuit to ground No Diagnostic aid 2 50 Air conditioning compressor fan relay or fan line fault fault code P1625 Serial number Oper...

Page 228: ...on 1 Check whether the fuel pipeline leak 2 Check that the vacuum line whether there is fault kink the connection is correct 3 Check the intake pipeline is blocked leakage crushed or damaged 4 The hig...

Page 229: ...motor disassembly inspection starting motor Focus on examination of whether there is open circuit or due to insufficient lubrication card dead No Next step Yes The lubricating oil for the appropriate...

Page 230: ...sensor circuit Yes Next step 3 Appropriated the sub cylinder line a cylinder which is connected to spark plug spark plug electrode distance engine body around 5mm start the engine check whether there...

Page 231: ...ir or replace the sensor line 3 Pulling off the coolant temperature sensor connector start the engine when the engine is started successfully observed a 300 ohm resistor in series or in the coolant te...

Page 232: ...n the coolant temperature sensor junction resistance to replace the coolant temperature sensor observation of the engine is successful No Next step Yes Cleaning solar term door and idle airway 4 Gentl...

Page 233: ...rmance to specification No Adjust or replace Yes Repair or replace the sensor line 5 Pulling off the coolant temperature sensor connector start the engine the engine is starting to observe No Next ste...

Page 234: ...sition No Next step Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon N...

Page 235: ...tion No Next step Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon No...

Page 236: ...tep Yes Failure to replace 5 Remove the injector injector with special cleaning analyzer to check whether the injector is there is a leak plugging or flow ultra difference phenomenon No Next step Yes...

Page 237: ...signal No Next step Yes Next step 3 Disconnect the electrical control unit X1_68 pin connecting line check the open air conditioning wiring harness end is a high level signal No Maintenance of air co...

Page 238: ...tion whether there is leakage No Next step Yes Cleaning of parts 3 Remove the idle adjuster solar term door body check idle speed regulator and idle speed was the existence of the phenomenon of carbon...

Page 239: ...lug observe its model and gap meets the specifications No Adjust or replace Yes Cleaning of parts 4 Remove the idle adjuster check the solar term door body idle speed regulator and idling bypass airwa...

Page 240: ...erve its model and gap meets the specification No Adjust or replace Yes Cleaning of parts 4 Remove the idle adjuster check the solar term door body idle speed regulator and idling bypass airway carbon...

Page 241: ...the spark plug the spark plug electrode distance engine body around 5mm start the engine check the high pressure fire intensity is normal No Maintenance of the ignition system Yes Next step 5 Check th...

Page 242: ...placing the bulb Do not replace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oi...

Page 243: ...12 LIGHTING AND SWITCHES 12 2 TROUBLESHOOTING Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch...

Page 244: ...acing bulb Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate Be sure to hold the socket firmly when removing the bulb Never pull the lea...

Page 245: ...ace turning light bulb Bulb Specification R10W 12 V Reverse the removal procedure for installation Brake light Tail light bulbs Remove Remove Brake light Tail light 12 6 Remove two bolts 1 Remove brak...

Page 246: ...emove Spotlight 12 7 According to the direction indicated by an arrow pull out the fastness cap Remove dust proof cap Remove bolt Remove spotlight connector Replace a new spotlight connector bulb assy...

Page 247: ...front turning light Remove nut Remove front turning light Remove front turning light of the another side in the above way Reverse the removal procedure for installation Brake light Tail light Remove...

Page 248: ...emove spotlight bracket 2 3 Remove nut Remove spotlight Remove three other spotlights in the above way Reverse the removal procedure for installation Note Main cables and wires should be routed proper...

Page 249: ...ove meter cover assy 2 7 Disconnect connector of warning switch Check according to the following table if the connector terminals are in continuity Reverse the removal procedure for installation 2WD 4...

Page 250: ...rs for continuity Hold the brake pedal Brake lights are open Release the brake pedal Brake light is off When hold the brake pedal the brake light is off Replace brake pump assembly Horn Inspection Rem...

Page 251: ...13 TROUBLESHOOTING 13 1 I Engine malfunction 13 2 II Malfunction in transmission system 13 5 IV Malfunction in brake system 13 6 V Malfunction in lamplight circuit and meter system 13 7 13...

Page 252: ...pump do not work Low pressure in hight pressure fuel pump blocked in hight pressure fuel pump strainer Clean or change Clean or change Clean or change Clean or change Clean or change Start difficultly...

Page 253: ...problem Dirt on plug Gap of plug not correct Ignition loop problem ECU problem Magneto problem Clean or Change Change or Adjust Change Change Change Engine power is not enough 3 Mechanical problem Gap...

Page 254: ...e chain sprocket Change chain sprocket Repair Change Noise from clutch Spline of crankshaft damaged Spline of clutch damaged Change crankshaft Change clutch Noise from Crankshaft Bearing noise Needle...

Page 255: ...radiator Change Spark weak Ignition System Fault on starter problem on spark plug Magneto problem Voltage of battery is weak Ignition loop problem Starting loop problem Change Change Change Change Ch...

Page 256: ...dial is too great Air pressure in tyre is too hig or too low Adjust or Change Change Check or adjust Check load Change Adjust or Change Change Adjust air pressure in tyre Front wheel shakes swing or j...

Page 257: ...ir pressure Adjust as the stipulation Repair or Adjust Repair or adjust Repair Check repair and fasten Verify repair and adjust Change Brake clip block Brake system Brake main pump could not return co...

Page 258: ...been damaged General wire or grounding wire has been cut off Electric bottle contacts badly or happens oxygenation Check and Change Change Repair circuit Repair Some kind of lamplight is bad or compl...

Page 259: ...s are under the meter cover 2 If a fuse is blown turn off the main switch and the switch of the circuit in question Then install a new fuse of the specified amperage Turn on the main switch If the fus...

Page 260: ......