PowerMax 500 Rough-Rider, Maintenance Manual

Page 1: ...1 500ROUGH RIDERUTV Maintenance Manual ...

Page 2: ...ent of engine 11 2 1 Inspection of cylinder head intake And exhaust valve 11 2 2 Inspection of spark Plug 12 2 3 Inspection of cylinder piston and piston ring 14 2 4 Inspection of crankshaft 17 2 5 Inspection of clutch 18 2 6 Inspection of carburetor 18 2 7 Inspection of air filter 19 2 8 Inspection of oil filter 20 2 9 Inspection of lubrication system 20 2 10 Lubrication of engine 21 2 11 Inspect...

Page 3: ...m of Engine 97 3 Disassembly of engine 27 3 1 Cylinder head and block 27 3 2 Piston and connecting rod 31 3 3 Manual starting mechanism 32 3 4 Sensor 32 3 5 Left crankcase cover 33 3 6 Magneto 33 3 7 Oil pump 34 3 8 Clutch 35 3 9 Carburetor 36 3 9 1 Structure of carburetor 36 3 9 2 Inspection and adjustment of carburetor 37 3 Disassembly of engine 27 3 Disassembly of engine 27 3 Disassembly of eng...

Page 4: ...on system 108 5 2 Magneto and charging system 109 5 3 Battery 110 5 4 Lighting system 111 5 5 Meter and signal system 112 5 6 Electrical starting system 113 6 Appendix 115 6 1 Specification 115 6 2 Requirements for torque of fastener 121 6 3 Electrical circuits 122 ...

Page 5: ...5 General Information 1 Description ...

Page 6: ...6 ...

Page 7: ...entification code 1 1 1 Frame No The frame No is engraved in the right bottom of the supporting frame See Figure 1 1 1 1 1 1 2 Engine NO The engine No is engraved in the right side of the engine See figure 1 2 ...

Page 8: ...ten and detach the oil filter 1 2 2 Height gauge To gauge the height of various components 1 2 3 Venire To measure the length of various components 1 2 4 尺 Outside micrometer To accurately measure external Diameter of a column 1 2 5 inside micrometer To accurately measure internal ...

Page 9: ...rately measure a small distance 1 2 7 Torque Spanner To measure torque force 1 2 8 Feeler gauge To measure gap width 1 2 9 Multimeter To check electrical circuits and parts 1 2 10 Barometer To measure pressure of the tire 1 2 11 Magneto drawing device ...

Page 10: ...eplace if necessary Air filter element Clean Replace if necessary Every20 40hours More often in wet of dusty areas Carburetor Check and adjust idle speed starter operation Adjust if necessary Crankcase breather system Check breather hose for cracks of damage Replace if necessary Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Spark arrester Clean Fuel line Check...

Page 11: ...e if necessary Front and rear suspension Check operation Correct if necessary Steering system Check operation Replace if damaged Check toe in Adjust if necessary Drive shaft universal joint Lubricate with lithium soap based grease Axle boots Check operation Replace if damaged Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary Lights and switches Check operation Ad...

Page 12: ... 6 times See figure 2 1 Figure 2 1 Check the valve clearance Note when adjust valve clearance the engine must be cooled The temperature should be less than 35 Remove the seat cushion and fuel tank unplug the vision hole cover round the flywheel of magneto anti clockwise to aim T At the signal of fore cover on the left Note The piston must be fixed to the top dead enter Figure 2 2 ...

Page 13: ... 05 0 08mm See figure 2 3 Figure 2 3 Loose the lock nut rotate the adjusting screw until it appears that the feeler gauge be pulled Then fasten the adjusting screw by valve adjuster tighten the lock nut and check the valve clearance After installing the cylinder valve cover vision hole cover the fuel tank and cushion See figure 2 4 ...

Page 14: ... over whether the spark plug insulator and electrode is damaged If so see figure 2 5 Figure 2 5 1 Check the spark clearance by feeler gauge whether it is between 0 6 0 7mm Or adjust the gap clean incrustation with spark plug cleaner and steel wire brush and check if the spark plug sealing washer Figure 2 6 ...

Page 15: ...15 Figure 2 6 3 Swirl the spark plug and tighten to 18 20N m by spanner then fix the spark plug cap when assembling 2 1 3 Cylinder piston piston ring Specification ...

Page 16: ...roundness 0 0035 0 005 degree of warp 0 04 0 10 Piston piston ring and piston pin Outside diameter of piston φ84 47 φ84 45 φ84 35 φ84 25 Inner diameter of piston pin hole φ20 002 φ20 01 φ20 05 φ20 1 gap between piston pin and piston pin hole 0 002 0 019 0 03 Piston ring end clearance Top ring the second ring 0 2 0 4 0 5 0 7 gap between piston ring and piston groove oil ring 0 03 0 15 0 3 0 5 top r...

Page 17: ...directions of right angle intersection Repairing limit value 0 05 mm out of roundness 0 005 mm 0 05mm taper 0 005mm Inspection of piston and piston ring 1 Measure the gap between piston ring and piston groove 2 The first ring 3 The second ring Note It is forbidden to damaging the piston ring when assembling Check whether the piston and the piston groove is cracked and abraded See figure 2 9 ...

Page 18: ...sert piston ring into cylinder and measure the end gap Repairing limit value the first ring the second ring 0 5mm See figure 2 10 Figure 2 10 Measure the bore diameter of piston pin hole Repairing limit value see figure 2 11 ...

Page 19: ... of the piston skirt Extreme position the gap between cylinder and piston Repairing limit value 0 1mm See figure 2 12 1 Figure 2 12 7 Measure the external diameter of piston pin The gap between piston and piston pin 0 02mm Repairing limit value 0 02mm See figure 2 13 ...

Page 20: ...Check that whether crank and connecting rod can rotate without stuck and whether the clearance between crank and connecting rod is 0 5 0 6mm The hop of crank shaft should be 0 05mm If not so replace it See figure 2 14 1 figure 2 14 2 Figure 2 14 1 Figure 2 14 2 ...

Page 21: ...etor The engine speed should be 1500 150r min 10 minutes after starting at normal idle and will not misfire when briskly accelerate If not so rotate the carburetor idle adjusting screw clockwise to raise the idle anti clockwise to lower When adjusting is unavailable check that if there is a jam in carburetor idle nozzle or an air leakage of intake pipe See figure 2 16 ...

Page 22: ...d then make it dry Note Petrol is forbidden 2 Dip the air filter element into 20 oil then take it out and squeeze the excessive oil assemble it orderly Impermeability is necessary See figure 2 17 Figure 2 17 2 1 8 Inspection of oil clarifier Cleaning of lubricator oil strainer remove clarifier Figure 2 18 1 clean it to ensure a well work condition Then fix it up ...

Page 23: ...SAE10W 40 Others are forbidden The capacity is 1 9L after disassembly and assembly 2 The capacity is 1 8L when fueling up after drain Inspection of oil pump Flow of oil pump L min 1500 2000 2500 3000 3500 4000 4500 L min 2 8 4 0 5 0 6 0 7 1 8 2 9 1 Measure clearance of the top of internal external rotor Limit value 0 20mm ...

Page 24: ...eaning and dip it into the oil case again Then unplug the dip stick and look whether oil level is lower than the indicator See figure 2 20 Note Ensure that the engine is landed by both four wheels in flat ground Figure 2 20 2 1 11 Inspection of cylinder head 1 Check whether the spark plug and valve seat is cracked and whether the cylinder head is out of shape Examine the flatness Indicator of oil ...

Page 25: ...iring limit value 0 05mm See figure 2 21 Figure 2 21 2 Remove and examine the width of valve Repairing limit value 2 0mm See figure 2 21 1 2 21 2 2 21 3 Figure 2 21 1 Figure 2 21 2 If the mating surface is coarse corrode or cannot contact with valve seat normally Replace it ...

Page 26: ...ge At last calculate clearance between valve stem and valve guide Repairing limit value intake 0 12mm exhaust 0 14mm Note eliminate carbon in the pipe before measuring If the pipe will be replaced grind the valve seat again 5 Check whether the valve is bent burn or the valve stem is worn out Check the motion of valve and measure external diameter Repairing limit value intake 6 92mm exhaust 6 9mm S...

Page 27: ...ree height of external spring 43mm squareness 0 8mm Free height of inner ring 39 5mm squareness0 8mm Figure 2 23 1 Figure 2 23 2 6 Examining lifting distance of cam Measure the length of fillet with micrometer and check if it is worn out Repairing limit value inlet lifting distance 8 25mm Exhaust lifting distance 8 18mm See figure 2 24 ...

Page 28: ...the oil hole is blocked Note If there is a rocker arm to be replaced examine the peak of cam Measure the bore diameter of rocker arm φ12 0 038mm 0 020mm Repairing limit value φ12 0 038mm 0 020mm See figure 2 25 Figure 2 25 7 Inspection of rocker arm shaft Examine if the rocker arm if worn out or cracked ...

Page 29: ...eter Repairing limit value φ12 051 0 067 0 The repairing limit value of clearance between rocker arm shaft and hole 0 09mm See figure 2 26 Figure 2 26 3 1 disassembly of engine 3 1 1 Cylinder head and block Unplug the intake pipe and spark plug Figure 2 27 1 2 27 2 ...

Page 30: ...inder valve cover cam sprocket cover and remove timing sprocket Figure 2 28 1 Figure 2 28 2 remove lower rocker arm shaft See figure 2 29 1 Figure 2 29 1 Remove vision hole cover of left front cover See figure 2 30 ...

Page 31: ...vel with the symbol on cylinder cover that is to say the piston of cylinder is at the top dead center Inspection of compression top dead center When the 1 indicator on the magneto rotor to be at the same level with the symbol on the crankshaft case that is to say the piston is at the compression top dead center and there are valve clearance in these two rocker arms of cylinder head If there is def...

Page 32: ...e above mentioned steps See figure 2 31 1 Figure 2 31 1 Remove chain tensioner adjuster See figure 2 32 Figure 2 32 Remove the cylinder head Loosen the bolt by intersection manner before remove the bolt See figure 2 33 ...

Page 33: ...33 Figure 2 33 Remove dowel pin Cushion cylinder head Chain guide board See figure 2 34 Figure 2 34 Remove ...

Page 34: ...e figure 2 35 Figure 2 35 3 1 2 Piston and connecting rod remove the piston circlip Note block the crankcase breather with a piece of cleaning cloth to avoid the circlip falling into the case See figure 2 36 Figure 2 36 remove piston pin and piston ...

Page 35: ...piston and piston pin hole to facilitate the removing of piston pin Note it is forbidden to knock the piston pin with a hammer See figure 2 37 Figure 2 37 3 1 3 Remove pull out hand start assembly See figure 2 38 Figure 2 38 ...

Page 36: ... crankshaft case cover See figure 2 40 Figure 2 40 3 1 6 Magneto Remove the stator coil Remove the pulse coil Remove the stator with rotor stripper See figure 2 41 Figure 2 41 Remove the woodruff key See figure 2 42 ...

Page 37: ...37 Figure 2 42 3 1 7 Oil pump Remove the bolt of oil pump cover See figure 2 43 Figure 2 43 Remove right cover See figure 2 44 ...

Page 38: ...Figure 2 44 Remove the right bracket clutch pulley disc See figure 2 45 1 figure 2 45 2 figure 2 45 3 Figure 2 45 1 Figure 2 45 2 Figure 2 45 3 3 1 8 Clutch remove the clutch Remove screws See figure 2 46 ...

Page 39: ...39 Figure 2 46 Remove the clutch shoe block and clutch cover See figure 2 47 Figure 2 47 Check the wear condition of the clutch shoe block and clutch cover See figure 2 48 Figure 2 48 ...

Page 40: ...40 3 9 carburetor 3 9 1 Structure of carburetor ...

Page 41: ...16115 F12 0000 main spray nozzle 1 17 16116 F12 0000 screw upper cover 2 18 16117 F12 0000 air measure hole idle speed 1 19 16118 F12 0000 rubber tube fuel drain 1 20 16119 F12 0000 screw M4 10 3 21 16120 F12 0000 dense column filler 1 22 16121 F12 0000 measure hole starting motor 1 23 16122 F12 0000 fuel drain screw 1 24 16123 F12 0000 screw M4 8 3 25 16124 F12 0000 seal gasket door hinge room co...

Page 42: ...42 3 2 2 Inspection and adjusting carburetor Decomposition Remove the evacuated chamber cover 1 spring 2 piston valve Remove permanent seat Spring Spring seat Oil needle ...

Page 43: ...Remove pilot screw Spring Washer 0 rings Note The pilot screw is set at maximum performance Before removing pilot screwed note the revolutions of screw in order to fix it back Remove pontoon chamber cover ...

Page 44: ...44 Shim Remove pontoon pin Pontoon Triangular needle Remove the cover Nut 0 rings Spring Starting plunger Pilot jet ...

Page 45: ...45 Check the carburetor body Pontoon chamber Oil passage Gas fouling block cleaning Chap damage replace the carburetor assay Cleaning steps Check the pontoon damaged replace ...

Page 46: ...Triangular needle seat 0 rings Filter net Damaged worn out block replace Check the piston valve crack replace Diaphragm rupture replace Piston valve oil needle Bent worn out replace Note If the piston valve is damaged inject the petrol into ...

Page 47: ...47 valve Replace it when there is oil leakage Check the main jet Main jet Pilot jet Pilot screw 0 ring Pilot jet Bent worn out damaged replace Gas fouling block blow with compressed air ...

Page 48: ...tside direction column and direction column M8 33 Direction and direction column M8 33 F R bridge gear box and frame M10 55 Front wheel hub and drive shaft M18 120 Engine and connecting board M6 10 The setting base of the engine and the frame M10 45 The engine and the setting base M10 45 King pin ball head M10 45 F R shock absorber and and frame rocker shaft M10 45 Rear steering knuckle and M10 45...

Page 49: ...3 Azimuth training gear ball head 14 tension bar locking nut M10 15 Changes the drive shaft part 16 Flange bolt M8 20 17 Slot nut M12 18 2 Cotter pin3 2 32 The structure of Steering wheel part 1 Flange bolt M8 16 2 mast jacket part 3 Steering wheel part 4 gasket ф12 5 5 Flange self locking nut M12 1 25 6 Plastic center lid Daily inspection ...

Page 50: ...e do not have stagnation 5 Inspects the torque of the steering wheel whether obviously increases Attention The steering force cutting which exerts to transfers in steering wheel outflow boundary is smaller than 245N 6 Inspects the reverse running clearance whether does surpass the limited stipulation Attention The reverse running clearance is smaller than 30mm If find some problems in the daily in...

Page 51: ...stall the steering system 4 1 1 1 Dismantle the parts of the steering wheel 1 Takes down the plastic center lid 2 Takes down the steering wheel fixing nut the gasket Attached figure 4 1 1 Attached figure 4 1 1 1 gasketф12 5 2 Flange self locking nut M12 1 25 3 Use the special tools attached figure1 2 14 pull out the steering wheel Attached figure1 2 14 ...

Page 52: ... steering wheel whether has the hidden danger which the fissure and possibly breaks if has must replace the steering wheel Attached figure4 1 3 1 The framework of the steering wheel 2 Inspect fastens nut of the steering wheel whether does have flaw and fissure if it is must replace Attached ...

Page 53: ...r have damaged if the attrition is serious must replace the steering Wheel The tolerance clearance between the internal spline on the steering wheel and outer spline on the steering column is smaller than 0 1MM 4 1 1 3 Dismantle the steering column parts 1 Takes down the parts of the front panel engine covers the connection covers part the display board and the steering wheel center covers attache...

Page 54: ...ose the M bolt which is on the steering drive axle the top of spinet draws out the cross gimbal 4 loose the fastening four piece M8 16bolt on the steering column take down the steering column from the frame Attached figure4 1 5 Attached figure4 1 5 1 Flange nut M8 16 2 Steering column parts 3 Frame 4 1 1 4 Inspection and maintain the steering column parts Attached figure4 2 6 ...

Page 55: ...ends of the spline on the central axis whether is wear out if so instead the central axis 3 Check the spline in the tow ends of the central axis whether have wear if dose instead the central axis 4 Inspect the steering column tube and welding line of the branch whether have cracked and corrosion if it does instead the steering column tube 4 1 1 5Dismantle the steering drive axle 1 Loose the clamp ...

Page 56: ...ve axle 2 Flange bolt M8 20 2 Loose the clamp bolt in the cross gimbal spline on the bottom of the steering drive axle pull out the lower of the steering drive axle Attached figure4 1 8 Attached figure4 1 8 1Flange boltM8 16 2 Flange boltM8 20 ...

Page 57: ...r and corrosion to instead the parts based on the check Attached figure4 1 9 Attached figure4 1 9 Attention Install the cross gimbal dab the lithium grease on the surface of the bearing 2 Inspect the transmission shaft whether have cracked and distortion If it does instead the parts 4 1 1 7 Dismantle the direction machine part 1 Loosen the four bolts dismantle the direction machine from the frame ...

Page 58: ...he open groove nut on the L R turning steering knuckle take down the steering tension rod from the steering knuckle Attached figure Attached figure4 1 11 1 Cotter pin 3 2 32 2 Open groove nutM12 3 Direction machine ball 4 Steering knuckle 4 1 1 8 Inspect and maintain the direction machine parts ...

Page 59: ...the gear rack 3 Inspects the dustproof rubber set whether gets older and dehiscence Replace the older and dehiscence rubber wrap 4 Inspect the tow balls on the steering tension rod whether rotates nimbly with no loose If it is not replace the ball 5 Inspects the dustproof rubber set of the ball whether gets older and dehiscence Replace the older rand dehiscence rubber wrap 6 Inspect the steering t...

Page 60: ...aub the lithium grease in to the movement 4 1 1 3Reinstalls the steering system parts 1 Connecting the direction machine with four pieces bolt M10 30 on the frame then use tow pieces of locknut to connect the direction machine ball and the rod Attached figure4 1 12 1 Figure4 1 12 2 Attention continue to use the hidden danger Ball pin may causes the serious accident or the death ...

Page 61: ...e 40N m M10Nut tight of force 36N m 2 Connecting the steering transmission shaft and direction machine with one piece of flange boltM8 20 Attached figure4 1 13 Attached figure4 1 13 1 Direction machine 2 Hexagon flange nutM8 20 3 Steering transmission shaft M8 20 Bolt tight of force 32N m 3 Connecting the steering transmission shaft and steering ...

Page 62: ... 14 2 Attached figure4 1 14 1 figure4 1 14 2 1 Steering transmission shaft 1 Hexagon flange nutM8 12 2 Hexagon flange nutM8 20 2 Steering column tube 3 Steering column M8 Bolt tight of force 32N m 4 Use one piece of flange self lock nutM12 1 25 fix the steering wheel on the steering column tube then cover the direction column plastic center lid Attached figure4 1 15 ...

Page 63: ...57 Attached figure4 1 15 1 Flange self lock nutM12 1 25 2 Steering wheel Steering wheel tight of force 40N m 4 2 Brake system Front Disk Brake components ...

Page 64: ...al to the life safety of the operator and therefore must be periodically inspected and maintained This vehicle uses the double return route hydraulic pressure disc brake system Please follow the tips of inspection as below a To check the amount of liquid in the oil cup If it is lower than the minimum mark Attached figure4 2 1 refill the box with the same type of fluid as was recommended by the man...

Page 65: ...ached figure4 2 2 1 Brake pedal Inspect the brake pedal does maintain the certain counter tension Attached figure4 2 2 When checks disk brake plate the saved liquid in the oil cup will pour automatically into the pressure pipe and the liquid level along with it to reduce the periodic inspection the disk brake plate liquid volume will be an important project 20 30mm ...

Page 66: ...s wear condition Attached figure4 2 3 Attached figure4 2 3 1 Disk Brake 6 Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection method If the oil tubing has the aging crack or Distortion must replace the oil tubing 4 2 2 Disassembly inspection maintenance and assembly of the hydraulic brake system ...

Page 67: ...ate and the brake plate clip parts 1 Take down the front wheel parts Attached figure4 2 4 Attached figure4 2 4 1 Conical Nuts M10 2 Loose the tow pieces of bolts fixed the brake plate clip and take down it Attached figure4 2 5 Attached figure4 2 5 ...

Page 68: ...ts cushion and front wheel hub from the front wheel shaft Attached figure 4 2 6 Attached figure 4 2 6 1 Cotter pins3 2 32 2 Open groove nutM12 3 Direction machine ball 4 Front Sheep horn 5 Front wheel hub 4 Take down the brake plate from the front wheel hub Attached figure 4 2 7 ...

Page 69: ...antle the disk brake pump installment place and take down the disk brake pump unit Attached figure4 2 8 Attached figure4 2 8 1 The disk brake pump 2 The disk brake pump installment place 2 Loosen the bolt M 6 12 which fixed the tighten disk brake oil cup and take down it Attached figure4 2 9 ...

Page 70: ...p 4 2 2 3 Dismantle the rear brake plate clip and the rear disk brake plate 1 Dismantle the rear wheel parts Attached figure4 2 10 Attached figure4 2 10 1 Conical Nuts M10 2 Wheel hub 2 Remove rear disk brake clip from the rear bridge gearbox Attached figure4 2 11 ...

Page 71: ...r bridge gearbox on the frame take down the middle transmission shaft parts Attached figure4 2 12 Attached figure4 2 12 1 Disk Brake Clip 2 Disk brake plate 3 Middle transmission shaft 4 Take down the disk brake plate installment place from the rear bridge gearbox Attached figure4 2 13 ...

Page 72: ...sk brake plate 5 Dismantle the disk brake plate from the installment place Attached figure4 2 14 Attached figure4 2 14 1 Rear disk brake plate 4 2 2 4 Dismantle the disk brake vita 1 Loose the vita fixed nut on the front arm shaft and take down the front vita Attached figure4 2 15 ...

Page 73: ... three Contacts tubing and then take down it Attached figure4 2 16 Attached figure4 2 16 1 Hexagon flange Bolt M6 20 2 Three Contacts tubing of the disk brake 3 Loose one piece of M nut which fixed the right fuel pipe bracket on the frame and take down the fuel pipe Attached figure4 2 17 ...

Page 74: ...t down Attached figure4 2 18 Attached figure4 2 18 1 Two tubes of the disk brake 2 Hexagon flange Bolt M6 20 5 Break out the hydraulic brake system from the bodywork 4 2 2 3 Inspect and maintain the hydraulic brake system 1 Inspect the brake oil cup whether have crack and leak oil if so replace the back oil cup 2 Inspect all fixed nuts on the two ends of the fuel ...

Page 75: ...en defects Maintain method instead the fuel pipes with problems 4 Check the Brake Plate Clip for distortion crack rust and stuck Maintain method instead the brake plate with problems 5 Inspect the Disk Brake Shoe for wear condition Brake shoe must be replaced when worn out Attached figure4 2 19 Attached figure4 2 19 1 Brake Shoe Attention Brake shoe must be replaced When the thickness is less than...

Page 76: ... and crack Attention 1 The standard thickness of disk brake plate is 7 5mm Disk brake plate must be replaced when the thickness is less than 6 8MM 2 Replace the disk brake plate when it is distortion and crack 4 2 2 4 Assembly of front Brake System Use two nylon tape connect the fuel pipe clip with both left and right higher front shaft arms Attention Fuel Pipe must avoid physical contact with oth...

Page 77: ...stening Torque of the Bolt 22 N m 28N m 3 Fix the Front wheel Hub onto the Front Wheel Shaft with gasket open groove nuts and cotter pins Attached Figure 4 2 20 Fastening Torque of the open groove nut 50 N m 60N m Attached Figure 4 2 20 1 Front Wheel Shaft 2 Gasket 3 open groove nut ...

Page 78: ...r pieces of GB T802M10 Conical Nuts AttachedFigure4 2 20 Fastening Torque of Conical Nut 50 N m 55N m 6 Fix Front Disk Brake Pump onto the frame with two pieces of M M10 55 bolts Fastening Torque of the bolt 40N m Attention Do not operate the vehicle immediately after assembling the brake system Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Flui...

Page 79: ...ate and rear middle transmission shaft and Rear Bridge onto the rear bridge AttachedFigure4 2 12 9 Mount the Disk Brake Clip onto Rear Bridge with two pieces of M bolt Fastening Torque 18 N m 12 N m 10 Sequently fix the F R three contacts of front fuel pipe F R fuel pipe 4 2 3 Dismantle inspect maintain and inspect the Parking system 4 2 3 1 Dismantle the parking system 1 Take down the central lid...

Page 80: ...e4 2 21 1 The Central lid 2 Loose the two pieces M bolt take down the parking handle AttachedFigure4 2 22 AttachedFigure4 2 22 1 Parking handle 3 Take down the Parking Cable from the Parking handle AttachedFigure4 2 23 ...

Page 81: ...m the rear disk brake clip AttachedFigure4 2 24 AttachedFigure4 2 24 1 Parking Cable 5 Loose two pieces of inner hexagon M nuts take down the parking institution from the rear disk brake clip AttachedFigure4 2 25 AttachedFigure4 2 25 1 Rear disk brake clip 2 Connecting bolt ...

Page 82: ...covering of the cable Pour some lubricating oil to increase the flexibility of the cable 3 Inspect the parking institution After cleaning the parking brake check whether the rectangle four head thread in it is worn out and install it 4 2 3 3 Reinstall the Parking system 1 Grease the Lithium lubricating on the rectangle four head thread Then load it in the parking bracket AttachedFigure4 2 25 2 Ass...

Page 83: ...y contact with the rear disk brake plate then finish the adjustment with lock the inner hexagon nuts with spanner Attention after the adjustment the UTV can parking stabilized in the 12 pitch with the fully loaded The total quality is 920KG 4 3 Wheel and Tire parts 4 3 1 Preparation for maintenance of wheel 1 Inspect the wear condition of the tire Attached Figure 4 2 21 Attached Figure 4 2 21 ...

Page 84: ...tached Figure 4 2 20 4 3 2 2 Inspection of wheel components 1 Check if the wheel hub has any distortion rust crack or other potential defects If so please replace the wheel hub 2 Check if the tire has reached its maximum wear condition in which case it should be replaced 3 Check the joining condition of the tire and wheel hub If the joint of tire and wheel hub is loose replace the tire immediately...

Page 85: ...cal bores on the wheel hub In occasion of angular distortion or wear the wheel hub must be replaced The angle of the conical bores is 60 4 3 2 3 Assembly of wheel Attach the wheel hub onto the wheel with four pieces of M10 Conical Nuts and a dustproof lid Caution assemble the wheel in correct direction shown as the arrow Attached Figure4 2 22 ...

Page 86: ...nsure maximum security and longer life expectancy of the wheel please periodically inspect the tire pressure and profile depth Insufficient tire pressure can result in not only intensified wearing of the tire but also instability during the course of operating the vehicle such as hard turning Excessive tire pressure can also reduce the friction force between the tire and ground causing spinning or...

Page 87: ... result in spinning instability lose of control and other potential security risk of the vehicle Warnning The profile depth falls below 3mm please replace the tire immediately AttacheFigure4 2 13 4 4 Transmission System Front Bridge Front case components ...

Page 88: ...g6007R 24 sulfate ball bearing 6912 25 sulfate ball bearing 16007 26 needle bearing15BM2112 27 bolt M14 15 28 copper gasketф14 2 29 power divider coupling 30 gasket with jackⅡ 0 1T gasket with jackⅡ 0 2T gasket with jackⅡ 0 3T gasket with jackⅡ 0 5T gasket with jackⅡ 1 0T 1 5T gasket with jack Ⅱ 1 5T 31 axes fork 32 front bridge cross gimbal combination 33 boltM14 15 34 copper gasketф14 2 35 tube ...

Page 89: ...e with the sheep horn whether the sheep horn bearing exists stagnation check for noise if bearing is unreliable and must disassemble the front bridge Assembly refer to the front bridge assembly the figure of the front box parts then instead the bearing to use Check the sheep horn whether have rupture if so instead it 4 Whether the constant velocity joint does coordinate to be correct to the positi...

Page 90: ... front box 8 If there are any problems with the sensor it must be inspected and maintained by the special serviceman 9 The gear is easy to wear out and it is in the transmission system 4 1 2 Disassemble inspection and assembly of the front bridge 4 4 2 1 Disassemble the front bridge 1 Take down the left and right front wheel parts 2 Sequently remove the front disk brake clip cotter pin open groove...

Page 91: ...ction and maintain the front bridge 1 Check whether the dustproof rubber wrap on the left and right transmission shaft is dilapidation and aging if so instead the new one 2 Check whether the inner and outer ball cage of the left and right transmission shaft movement is smooth less If it is stagnation and obvious becoming less loosen replace it 3 Disassemble the left and right transmission shaft cl...

Page 92: ...ge must sufficiently Enter 2 3 volume with the Lithium lubricating 4 Open the differential device and inspect the damage of the gears axes and gasket instead those parts according to the check 4 4 2 3 Assemble the front bridge parts 1 Put the left and right transmission shaft in the front bridge differential device Attached Figure4 4 1 2 Pour 0 32L SAE 80 API GL 4 the high quality gear grease into...

Page 93: ...he frame with two pieces of hexagon boltsM10 110 two pieces of nutsM10 and two pieces of flat gasket Attached Figure4 4 2 Fastening Torque of the Bolt 40 50N m Attached Figure4 4 2 1 Flange boltM10 110 2 Front bridge differential device Rear Bridge box parts ...

Page 94: ...etarder shellⅠ 3 Sulfate ball bearing6305 4 Needle bearing55BM6720 5 Initiative gear 6 Sulfate ball bearing6206c3 22 7 Rear disk brake install seat 8 Rear case import axes oil envelop 9 Needle bearing55BM6720 10 Rear case initiative gear O ring ...

Page 95: ...l filler hole O ring 20 rear retarder pipe 21 retarder shell Ⅱ22 column axes boltM8 23 gasketф8 5 24 flange nut M825 1rear case export axes oil envelop1 26 sulfate ball bearing 16017c2 27 rear case cover O ring 28 circle bearing 0 25T circle bearing 0 30T circle bearing 0 40T 29 boltM8 25 30 gasket ф8 5 31 flange nutM10 22 32 boltM8 30 33 gasket ф8 5 34 compression spring 35 rear bridge middle tra...

Page 96: ...the parts and try again if still not good to inform the special serviceman to service the reverse mechanism 2 If the reverse mechanism appears lacks files adjust the connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again 3 Disassemble the reverse mechanism to check the connecting rod of the reverse mechanism whether is rupture if so instead the connectin...

Page 97: ...is stopped up there is any stagnation in the reverse mechanism If so inform the special serviceman to service 4 6 Suspension 4 6 1 Rear Suspension 1 simple rear shock absorber left right 2 hexagon flange surface boltM12 1 25 70 3 hexagon flange surface bolt M12 1 25 65 4 self lock nutM12 1 255 rear balancing pole 6 left ball pull rod balancing pole 7 right ball pull rod balancing pole ...

Page 98: ...on flange surface bolM8 16 Rear arm shaft 1 rear left upper rocker combination 2 rear right lower rocker combination 3 rear left lower rocker combination 4 rocker rubber middle membrane5 M10 1 25 70 6 rocker rubber middle membrane 7 rear right upper rocker combination 8 rocker cushion collar gasket ...

Page 99: ... front right lower rocker combination 7 rocker rubber middle membrane 8 hexagon flange surface bolM10 70 9 hexagon self lock nutM10 1 25 10 rocker cushion collar gasket11 hexagon self lock nutM10 1 25 12 cotter pin 3 2 3213 simple front shock absorber left right parts 14 hexagon self lock nutM10 1 25 15 hexagon flange surface bolt M10 52 16 Rocker baffle 17 hexagon flange surface ...

Page 100: ...e if it is not instead the same spec cotter pin C The problem with the shock absorber and maintain method whether it can returns to the position under the pressure and the tensional spring is ruptured If it s ruptured or nearly to ruptured replace the shock absorber Whether it leak oil if so instead the same spec shock absorber According to the different request if there is an oil cup on the rocke...

Page 101: ...utsM10 3 Connect the rear shock absorber and rear lower rocker combination with 2pieces of Hexagon Flange BoltsM10 65 and 2pieces of self lock nutsM10 4 Connect the rear shock absorber and frame with 2pieces of Hexagon Flange BoltsM10 70 and 2pieces of self lock nutsM10 Attention A Put on the butter to each part when it is assemble B Do not scratches the surface of the spare part surface ...

Page 102: ...nge BoltsM10 52 2 Hexagon Flange BoltsM10 70 1 2 1 Hexagon Flange BoltsM10 65 2 Hexagon Flange BoltsM10 70 To check whether put or not the butter before fix then fix the upper and lower rockers and L R front shock absorber ...

Page 103: ...he head of the install axis which in the rear shock absorber whether is credible Attention After disassemble the rear shock absorber check if there exists any distortion or crack on the frame connection hole and the rear shock absorber if so inform the special serviceman to inspect and service first or install the rear shock absorber on the frame after instead Attention the bolts must be the speci...

Page 104: ...re4 5 1 1 Bumper 2 Front faceplate 2 Take down the water tank bracket combination and slanting support combination Attached Figure4 5 2 Attached Figure4 5 2 1 Cooling System 2 Water tank bracket combination 3 Water tank slanting support combination 3 Take down the rubber water pipe and water tank inductor Attached Figure4 5 3 ...

Page 105: ...with Water Cooling System If loosen please have the hoop tightened immediately 3 Inspect if ventilator is damaged If so please replace with new ventilator 4 7 2 1 Assembly of Water Cooling System 1 Mount Water system onto the Frame with buffer cushion 4pcs Collar Sheath 4pcs ф6 Cushion 4pcs and Hexagon Flange Bolt M6 20 4pcs 2 Connect the water tank bracket combination on the frame with 2pieces of...

Page 106: ...rrosion inhibitors for aluminum engines Antifreeze and water mixing ratio 1 1 Total amount 1 8L 1 58 lmp qt 1 90 US qt Coolant reservoir capacity Up to the maximum level mark 0 3L 0 26lmp qt 0 32 US qt Start engine when pour full the refrigerating fluid loose the exhaust nut on the pipe the water level will get lower at this time Supply the refrigerating fluid until the water level stop to change ...

Page 107: ...ipe 4 2 2 4Inspection and maintain the Oil Cooling System 1 Check if the oil cooler is distortion and leak oil To adjust the distortion one and welding the leak one If it cannot solve instead the oil cooler Check if the steel oil pipe is distortion and leak To adjust intead the serious distortion one and leak oil pipe Check if Rubber Pipe is torn aged worn out or distorted 4 Check if the O rubber ...

Page 108: ...ance inspection pass over 0 03MPA compressed air through the connecting oil cooler steel oil pipe and Rubber Pipe for 3 minutes and do not leak 3 According to the disassembling order reverse carries on the assembly 4 When it is finished assembly pour the L engine oil then start the engine for 10 minutes to check whether leaks If it is not the Oil Cooling System maintenance is finish ...

Page 109: ...103 4 8 Iubrication points The details of the chassis lubrication is as below ...

Page 110: ...connection plus butter 10 front right shock absorber and rocker connection plus butter 11 steering vertical column and frame connection plus butter 12 left upper rocker and frame connection plus engine oil 13 left upper rocker and Yanggakdo connection plus butter 14 left lower rocker and frame connection plus engine oil 15 left lower rocker and Yanggakdo connection plus butter 16 left steering rod...

Page 111: ...ection plus engine oil 31 rear right shock absorber and frame connection plus engine oil 32 rear right shock absorber and rocker connection plus butter 28 33 rear right upper rocker and frame connection plus engine oil 34 rear right lower rocker and frame connection plus engine oil 35 rear right upper rocker and Yanggakdo connection plus butter 36 rear right lower rocker and Yanggakdo connection p...

Page 112: ...R 30 White Blue W L 14 White Black W B 31 Yellow White Y W 15 Light Blue Lb 32 Green Blue G L 16 Light Green Lg 33 Purple V 17 Black Yellow B Y Troubleshooting and repair No electrification 1 First check the safety 2 Second if the safety is good then check the battery whether it is power on 3 Finally check the switch lock and electric route whether they are bad Other troubleshooting and causations...

Page 113: ...termittence 2 high voltage bag high voltage lead wire insulated badness replace replace electrification system 1 discharge self 2 uncharge or shortage charge 1 cover polluted or drenched by rain 1 carve out a way or short circuit caused by connected wire badness 2 rectifier damaged 3 baterry lower electrolyte electrode failure water proof keep clean of the cover and replace electrolyte repair repl...

Page 114: ...m The key diagram of ignition elements ignition elements Ignition pressure provided by magneto ignition coil through diode commutated by R red line input CDI capacitance discharge ignition charge to capacitance C at the same ...

Page 115: ...t pressure up to 10000V sparkover at the clearance of sparkplug 0 6mm so the engine ignited Charge system The key diagram of charge elements 5 2 magneto and charge system The elements of charge When the engine running driven magnet rotor circumgyrate so on the stator coil produce alternating current then induce electromotive force come into to being the pressure Through 3 lines Y yellow output int...

Page 116: ...function 3 Electrode former scratched or scratched by press or insulation without work Pay attention when using 1 Long time out of using but without charge is not correct 2 Too much charge so long time charge is not correct generally if battery empty the normal charge time hours 3 Do not charge under a much higher pressure or electric current 4 Keep battery at a low temperature and dry place 5 Cha...

Page 117: ...easy floating When work near the battery please take care of your eyes and keep kids away from the battery If under such accidents please deal with it as follows or ask for help from the doctors 1 Exterior wash lots of cleaning water 2 Interior drink milk or water and then milk of magnesia or egg or rap oil and hospitalize as soon as possible 3 Eyes wash cleaning water at least 15 minutes and hosp...

Page 118: ...hing relay battery 12V 12Ah black brown blue red1 function switch 10A signal 25A Ignition 5A 2 4draver 25A frontlight biue black1 red red white red brown brown blue yelow red brown blue white M M B 15A black red1 yellow yellow green blue yellow2 green yellow 12V 18W black 12V 1 7W oil temperature switch front light1 purple front left right turn light 12V 18W 12V 5W 21W 12V 10W front light2 rearlig...

Page 119: ...o not shine ４ Horn Switch When press the button the horn will move But if without sound or with unclear sound or with little sound please check the problem according to the guide 5 6 Electrical starting system Starting Circuit Starting system working process yellow red light green function OFF function yellw red blue white biue ...

Page 120: ...er and the time of pressing button will be within 55 seconds If longer time more than 5 seconds it may cause the damage of stator relay and the stator relay motor and may also cause the damage of the battery that it can not be charged or not charge enough 2 When starting if heard some noises from the stator relay the battery must be without enough power Please stop starting and change a powerful b...

Page 121: ...wing arm Rear Hydraulic spring swing arm Braking pattern Normal condition Front dual disk Rear single disk front and rear linkage Right foot left hand operation 1 E mark Braking pattern Primary Brake 1 E mark Front dual disk Rear single disk front and rear linkage right foot right hand operation Emergency brake hand operation Braking hand operation 2 Primary Brake 2 Front dual disk Rear single dis...

Page 122: ...a Fuel tank Vol 29L 0 1L Dry weight 524kg Max loading weight 300kg Total weight including hitch 843kg B Specification and model of engine Engine Model Brand HS1102MU 2 HSUN Pattern Single cylinder water cool dual exhaust four stroke Bore Stroke 102mm 84mm Compression Ratio 9 2 1 Volume 686ml Max power 25kW 5000r min 5500r min E mark Max power E mark 13kW 5500r min Rated power 24kW 6000r min 6500r ...

Page 123: ...0 17 41 21 24 18 H Drive ratio 3 2230 26 21 41 21 24 18 R Drive ratio 3 8282 25 17 41 21 24 18 Engine Drive ratio 16 339 2 475 Clutch Wet automatic centrifugation Lubrication Crankcase Comply with GB11121 1995 standard Depending on regional weather condition choose either SAE 5W 40 or SAE 10W 30 Cold region SAE 20W 40 Warm region Oil capacity 1 9L Engine dry weight 71kg C Specification and model o...

Page 124: ...r Red light D Specification and model of other parts and structure Disk brake hydraulic oil DOT4 Turning operation system Hand operating steering bar Driving method Two wheel four wheel drive 2W means two wheel drive 4W means four wheel drive Shaft arms Front and Rear dual shaft arms Parking brake Mechanical Frame Steel pipe Magneto Rotate DC output Spark plug gap 0 6 0 7 mm Safety fuse 30A 6 2 Pe...

Page 125: ... actual service life is 7000KM The testing method carries on according to GB T5374 1995 6 2 7 Durability The durability actual service life is 16000KM the testing method carries on according to GB T4570 1995 6 2 8 Exhaustion The pollutant limiting value should conform to GB 14621 2002 the GB14622 2002 request a idle speed discharges CO 3 8 HC 800 rpm b The operating mode discharges CO 7 0 g km HC ...

Page 126: ... two directions maintains static fixed is motionless meantime between many to 5min 6 2 13 the side leans the steady constant angle The multipurpose vehicle under the idling the static condition and right flank inclines the biggest side to left side to lean the steady constant angle not to have to be smaller than 25 6 2 14 Front illuminator performance 6 2 14 1 The vehicle should be loaded with con...

Page 127: ...does not allow dazzling e The shines position of the front headlight low beam light beam the front illuminator shines when is away from 10m on the screen the first illuminator headlight low beam light beam light and shade closure line corner or the center point highly should be 0 6H 0 8H H is front illuminator datum center highly f The front headlight high beam light beam and the headlight high be...

Page 128: ... of the electrical circuits 1 Actualize the electrical starting when it in Neutral or parking and brake 2 When it is in the H gear the H gear switch of the engine is on the ground the H gear is lighting by the CDI inner transistor to control the dash light earth connection 3 The function of the diode in this circuitry is that after parking and brake to actualize the electrical starting 4 The relay...

Page 129: ...Use the pan fuse box each operating circuit is working independence and easy to service there is no connect with the inner cable and the functional line it is hard to emerge the dummy section L2 L1 CDI 30A mph km h OVERRIDE ...