AU200 Maintenance Manual
AU200 Maintenance Manual
AU200 Maintenance Manual
AU200
Maintenance Manual
1
W W W . K A Y O MOTO.COM
Version code:20180915
Version name:AU200 Maintenance manual English version.pdf
WWW.KAYOMOTO.COM
2
Kayo Moto
2018- 08
actual state of the vehicle.
Description
This manual specificially descripted
the maintenance adjustment procedures Kayo Moto
for the AU200 four-wheels vehicle (ATV), Research and Development Department
disassembly and assembly methods, 2018 - 08
inspection and maintenance points,
troubleshooting methods and
maintenance technical data, and detail
graphic data.
Please read this manual carefully and
follow the standard operating methods to
effectively extend the service life of each
component, improve engine performance
and vehicle reliability.
The first chapter mainly introduces
general work items, tools used, basic Contents
technology and maintenance parameters.
Maintenance information 1
The second chapter introduces the
assembly and disassembly operation of Body Plastic 2
the whole vehicle plastic parts.
The third chapter introduces the Regular inspection and
3
regular inspection and adjustment of the adjustment
whole vehicle. Engine periphery 4
The fourth chapter introduces the
disassembly of the engine peripheral Engine 5
assembly parts.
The fifth chapter introduces the Vehicle chassis 6
methods and notice for disassembly,
inspection, maintenance and assembly of Signal and lighting system 7
various parts of the engine.
Electrical schematic appendix
Chapter 6 introduces vehicle chassis
related information
Chapter 7 introduces the inspection
and maintenance information of the
vehicle signal and lighting system.
Appendix: Electrical Schematic
3
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浙江华洋赛车股份有限公司
Warning
However, please note that the “Danger” and “Warning” contained in this
Manual are unlikely to cover all potential risk during engine use and maintenance.
Therefore, in addition to the relevant provisions of “danger” and “warning”,
maintenance operator must also have basic mechanical safety knowledge. If you
are not sure of completing the entire maintenance operation, please consult a
more experienced senior technician.
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浙江华洋赛车股份有限公司
1 Maintenance information
1.1Notes for Operation……………………………………………………………………………1-1
1.2 Vehicle identification number…………………………………………………………………1-3
1.3 Main parameter list……………………………………………………………………………1-4
1.4 Maintenance parameter list……………………………………………………………………1-6
1.5 Tightening torque………………………………………………………………………………1-8
1.6 Lubricant, sealant………………………………………………………………………………1-10
1.7 Cable, hose, cable wiring diagram……………………………………………………………1-11
Safety Precautions
1. Work clothes (such as overalls), hats, and safety boots that are suitable for the work must be worn.
If necessary, wear protective glasses such as dust-proof glasses, dust masks, gloves, etc. to protect
your body.
2. Since the exhaust gas contains harmful components, it is forbidden to operate the engine for a long
time in a closed place and a place with poor ventilation.
3. When the engine is stopped, the temperature of the engine and muffler is still very high. Do not
touch before cooling to avoid burns.
4, Battery solution (dilute sulfuric acid) is a strong corrosive agent, there will be burns, blindness
when exposed to the skin, eyes. If the clothes and skin are inadvertently stained with the battery
solution, rinse immediately with plenty of water and go to the hospital for treatment. The battery and
battery solution should be kept strictly and must be kept in a safe place that children can't get. When
the battery is charged, it will produce flammable and explosive hydrogen. If there is a fire source or
an electric spark is approaching, there is a danger of explosion. Please charge in a well ventilated
area.
5. Since gasoline is a flammable item, fireworks are strictly prohibited at the work site. Not only pay
attention to open flames, but also pay attention to electric sparks. In addition, there is a danger of
explosion of vaporized gasoline. Please choose a well-ventilated site for work.
6. Be careful not to let the rear wheel, clutch and other rotating parts and movable parts clamp the
hands and clothes at any time during maintenance.
7. When two or more people work together, they must constantly greet each other to confirm safety.
1-1
1 维修信息
4. The gasket, O-ring, piston pin retaining ring, split pin, etc. must be replaced with new ones after
disassembly.
5. If the opening of the circlip is too large when disassembling, it will be deformed and will fall off
easily after reassembly. Please do not use elastic circlips that are already loose and lose their
elasticity.
6. After the parts are disassembled and inspected, clean them before the measurement and blow off
the cleaning agent with compressed air. Apply lubricant to the moving surface before assembly.
7. When disassembling, check the necessary places and measure the relevant data so that it can be
restored to the state before disassembly during assembly.
8. Fasteners such as bolts, nuts and screws should be pre-tensioned and then tightened according to
the specified tightening torque on the diagonal according to the principle of being large to small and
from the inside to the outside.
9. Rubber parts should be inspected for aging when disassembled, and replaced if necessary. In
addition, since the rubber parts are not resistant to corrosion by gasoline or kerosene, try not to allow
volatile oils and greases to adhere to them.
10. Apply or inject the recommended grease at the designated location in accordance with the
requirements of the service manual.
11. The correct special tools should be used for disassembly and assembly.
12. The ball bearing can be rotated by the inner ring or the outer ring with the finger to confirm
whether the rotation is flexible and smooth. If the disassembly method of applying force on the ball
is taken during disassembly, the removed bearing should not be used any more:
Replace the bearing axial and radial clearance too large.
Rotating bearings with stuck sensation should be cleaned. After cleaning, the stuck ones should
be replaced and cannot be cleaned directly.
It is originally pressed tightly with the body or shaft diameter, and the bearing should be replaced
when the fit is not tight.
13. The bearings should be coated with oil or grease before assembly. Single-sided dust-proof
bearings should pay attention to the installation direction when assembling. Open or double-sided
dust-proof bearings should be assembled with the manufacturer's logo and dimensions facing out
when assembling.
14. When installing the rectangular retaining ring, the chamfered side should face the direction of the
force. Do not use the retaining ring that has lost its elasticity. After assembly, turn the rectangular
retaining ring to confirm that it is firmly seated in the slot.
15. After assembly, it is necessary to check whether the fastening parts are tightened and the work is
normal.
16, brake fluid and coolant will damage the painted surface, plastic parts, rubber parts, etc., do not let
it adhere to such parts, in case of adhesion, immediately rinse with water.
17. The oil seal should be installed with the side marked by the manufacturer facing outward
(without oil):
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浙江华洋赛车股份有限公司
When assembling, be careful not to curl the oil seal lip and prevent the burr from scratching the
oil seal lip.
Apply grease to the oil seal lip before assembling.
18. When installing the hose parts, insert the hose into the joint root. There is a pipe clamp to install
the pipe clamp in the recessed mark of the pipe. Replace the hose without tightness during
installation.
19. Do not put dust, dirt, etc. inside the engine and the hydraulic system of the brakes.
20. The gasket material attached to the joint surface of each box of the engine should be cleaned
before assembly. The bumps on the contact surface must be uniformly removed by grinding with oil
stone.
21, The cable type should not be excessively twisted and bent. Deformed and damaged cables can
cause malfunction or breakage.
22. When assembling the cap parts, the groove must be inserted into the groove.
Engine running-in
The engine has many components for relative movement, such as pistons, piston rings,
cylinder blocks, intermeshing transmission gears, etc. Therefore, in the initial stage of its
use, it is necessary to carry out standard running-in, and the running-in can make the
moving parts adapt to each other and correct. The working gap forms a good smooth
friction surface that can withstand large loads, and the engine that has been run-in is
standardized to have excellent performance and reliability.
The recommended run-in time is 10 hours and the specifications are as follows:
0 to 10 hours: Avoid continuous operation in the state of more th an 1/2 throttle. Always
change the speed. It is not recommended to operate for a long time under a fixed throttle
position. After 1 hour of operation, cool the engine for 5 to 10 minutes; Accelerated
acceleration, the throttle change should be slow, not sudden and small, do not drag the
cargo during the running-in.
Note:
Maintenance during the running -in period according to the daily maintenance
regulations, and find out the faults in time;
After the running-in is completed, the whole machine can be ma intained after the
running-in period before entering the normal driving stage .
1-3
1 维修信息
1 VIN on chasis
2 Vehicle name plate
3 Engine number
Model AU200
VIN L6JACMLA5G ~
Engine number F1702K ~
1
2
1-4
1 维修信息
Item Parameter
Model AU200
Length(mm) 1786
Width(mm) 955
Height(mm) 1050
Wheelbase(mm) 1120
Engine model LC162FMC-2
Total displacement(ml) 200
Fuel type No.92 and above gasoline
Vehicle Dry weight (kg) 180
Number of Passenger 1 person(driver)
Maximum loading weight 1 person + 60kg = 120kg
Tire Front AT23×7-10
specifications Rear AT22×10-10
Minimum ground clearance 175mm
Turning circle diameter (nearest point
3000mm
minimum turning diameter)
Starting method Electric start
Engine type Single cylinder, four stroke, air cooling
Air distribution SOHC/Chain drive
Cylinder diameter ×
62 × 58.4
stroke(mm)
Engine Compression ratio 9.7 : 1
Lubrication method Wet
Oil pump type Rotor type
Lubricating oil filter type Full flow filter rotary
No. of machine oil SAE15W-40/SF and above
Cooling air
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Item Parameter
Air filter type Sponge filter
Model Plunger throttle
Throttle body
Mixing valve diameter 30mm
Fuel tank volume 9L
Clutch type Dry automatic clutch
Variable speed mode (CVT)
One forward gear, one neutral gear, one
Gear shift position
reverse gear
Transmission Shift mode / sequence Hand operation/F—N—R
system
(CVT)Stepless speed
0.95~2.8
ratio
Output type Rear axle output
Direction of rotation In the forward gear, it is clockwise from the
of Engine output rear of the vehicle.
inside 32°
Steering device Steering angle
outside 24°
front Hydraulic disc
Brake type
rear Hydraulic disc
Front wheel double rocker independent
Buffer mode Suspension method suspension, rear wheel non-independent
suspension
Frame Steel pipe welded
1-5
1 维修信息
Lubricating device
Brake system
1-6
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Item Standard
model Permanent magnet alternator
output Three-phase full wave
Magneto-trigger coil resistance 150
Magneto no-load voltage (engine is in cold no
Magneto state)
Magneto maximum output power 180w
Stable voltage 14.5 ±0.5V
Trigger coil Max voltage ≥1V,200r/min;≥8.5V,2000r/min
Rectifier type Full wave rectification
capacity 12V 7Ah
Battery Fully charged 14.4V
Voltage between
No Fully Less than 11.8V
terminals
charged
Ignition device
Item Standard
Ignition method CDI Electronic ignition
model Resistive spark plug
standard D8RTC
Primary Ignition
300~450V
Max voltage coil
1-7
1 维修信息
Item Standard
fuse 10A
Headlight 12V—35W
Front turnlight 12V—10W
Light, bulb Rear light / brake light 12V—2.8W
Rear turn light 12V—2.5W
Position light 12V—3W
1-8
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Tightening torque
No. Item Fastener code quantity
(N·m)
1 Suspension lower rocker bolt GB5789 M10×1.25×80 4 45~59
2 Front and rear shock absorbing bolts GB5787 M10×1.25×40 6 45~59
3 Front hub mounting slotted nut GB9457 M14×1.5×H18 2 126~218
4 Steering rod ball pin slotted nut GB9457 M10×1.25 4 33~45
5 Directional cap screw GB70-85 M8×35 4 22~30
6 Front brake caliper body bolt GB5789 M8×25 4 22~30
7 Front brake disc bolt M8×1.25×20 8 22~30
8 Rear brake caliper body bolt GB5789 M8×25 2 22-30
9 Rear brake disc mounting screw GB70-85 M8×16 4 22~30
9 Directional mounting bolt GB5783 M10×1.5×30 2 45~59
12 Oil cooler mounting bolt GB5789 M6×25 4 9~12
1-9
1 维修信息
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Engine operating materials include lubricating oil (oil), grease (butter) and coolant;
installation accessories include flat sealant, thread locker, etc.
1 2 3 4 5 6 1
1. Headlight connector 2. Left turn signal connector 3. Left hand multi-function switch
connector 4. Instrument connector 5, right turn signal connector 6, electric door lock switch
connector
Note: The front panel must be removed before inspection of the above components.
For specific disassembly,check Chapter 2 Body Covers.
11
1 维修信息
7 8 9
7, brake sensor (left one and right one) 8, throttle line 9, brake hose
1 2 3 4 5
1. Motor line 2. Crankcase exhaust pipe 3. Carburetor 4. Carburetor drain pipe 5. Magnetic
motor trigger connector
Note: The right foot pedal and the right middle guard must be removed before
inspection and maintenance of the above components.
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2 4
1 3
1、Brake light patch cord 2. Left turn signal patch cord 3. Brake light contact wire 4. Right
turn signal patch cord
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2-1
2 车体覆盖件
2-2
浙江华洋赛车股份有限公司
2.3.1 Cushion
Disassembly
Open the seat cushion hook upwards
Lift the back of the seat cushion and pull
the seat cushion back
Remove the seat cushion
Assembly 2
In reverse order of reverse disassembly,
reverse direction
Check if the seat cushion is in place,
1
secure, etc. after installation
1
2.3.2 Front shelf
Disassembly
Remove the front shelf mounting screws
1 (one left and one right)
Remove the mounting bolt 2
Remove the mounting bolt 3
Remove the front shelf 4 2
4
Assembly
Installation in reverse order of
disassembly 3
3
2 车体覆盖件
Disassembly
Remove the rear shelf mounting screws
1
Remove the mounting bolt 2
Remove the mounting bolt 3
Remove the rear shelf 4 4
Assembly 2
Installation in reverse order of
disassembly
3
decorative cover
2.4.1front cover
Disassembly
Remove the front shelf (→ 2.3.2)
Remove the 2 mounting screws1
Remove the front panel2
Assembly
In reverse order of reverse disassembly, 2
reverse direction
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浙江华洋赛车股份有限公司
Disassembly
remove the 2 screws 1
Remove the front cover of the
instrument 2
Assembly
In reverse order of reverse disassembly,
reverse direction 2
1
Disassembly 4
Remove the front cover of the
instrument (→ 2.4.2)
remove the 2 screws 3
Remove the instrument panel 4
Assembly
In reverse order of reverse disassembly, 3
reverse direction
Disassembly
Loosen the lock screw 5
Counterclockwise rotation gear shifter
combination 6
Unscrew the shift head combination 6
Remove the gear head assembly
Assembly
In reverse order of reverse disassembly,
reverse direction
6 5
2-5
2 车体覆盖件
Disassembly
Remove the gear shifter combination
(→ 2.4.4)
Remove 2 mounting screws 1
Remove the shift cover 2
2
Assembly
1
In reverse order of reverse disassembly,
reverse direction
Disassembly
Remove the seat cushion (→ 2.3.1)
Remove the screw 3
Remove the left decorative panel 4 up
Assembly
In reverse order of reverse disassembly,
reverse direction
4 6
2.5.2 Right middle guard
Disassembly
Remove the seat cushion (→ 2.3.1)
Remove the screw 5
Remove the left decorative panel 6 up
Assembly
In reverse order of reverse disassembly,
reverse direction
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Assembly
2.5.3 Left foot pedal In reverse order of reverse disassembly,
reverse direction
Disassembly 1
Remove the left middle guard (→ 2.5.1)
Remove the fastening screw 1
Remove the fixing screws 2
Remove the left foot pedal 3 from the
bottom to the top
Assembly
In reverse order of reverse disassembly,
reverse direction
1
2 4
2.5.4 Right foot pedal 3
Disassembly
Remove the right middle guard (→
2.5.2)
Remove the fastening screw 4
Remove the fixing screws 5
Remove the right foot pedal 6 from the
bottom to the top
Assembly
In reverse order of reverse disassembly,
reverse direction
5 6
bumpers
8
2.6.1 Front ventilation panel
Disassembly
Remove the mounting bolts 7 (2 on each
side)
Remove the front turn signal 8 (one on 9
each side)
Remove the front ventilation panel 9
2-7
2 车体覆盖件
2.6.1 bumper
1
Disassembly
Remove the front shelf (→ 2.3.2)
Remove the mounting bolts 1 (two on
each side)
Remove the bumper 2
Assembly
In reverse order of reverse disassembly,
reverse direction
Disassembly
Remove the mounting screws 3
Remove the fuel tank cap
Remove the fuel tank cover 4
Assembly
In reverse order of disassembly
2-8
浙江华洋赛车股份有限公司
Disassembly
Remove the front cover of the 1
instrument (→ 2.4.2)
Remove the front panel (→ 2.4.1)
Remove the left middle guard (→ 2.5.1)
Remove the right middle guard (→
2.5.2)
Remove the left foot pedal (→ 2.5.3)
Remove the right foot pedal (→ 2.5.4)
Remove the fuel tank cover (→ 2.7.1)
Remove the front assembly board 1
Assembly
In reverse order of disassembly
note
Remove the cables on the front
assembly board before disassembly,
and check the cables and connectors
after installation to prevent
misconnection.
Maintenance information
Precautions
Note
Because the exhaust gas contains toxic components such as carbon monoxide (CO),
do not operate the engine for a long time in a closed place or in a poorly ventilated
place.
When the engine is just stopped, the temperature of the muffler and the engine is
still very high. If it comes into contact with the skin, it will burn. If you must
perform maintenance when the engine is just stopped, you must wear long-sleeved
overalls and gloves to work.
Gasoline is very easy to catch fire, and fireworks are strictly prohibited in t he
workplace. Not only pay attention to open flames, but also pay special attention to
electrical sparks. In addition, due to the danger of explosion of vaporized gasoline,
the operation should be carried out in a well ventilated area.
Note
Don't let the rotating parts such as the drive system grip the hands and clothes.
Note
The vehicle must be placed in a flat, stable place on the ground.
3- 1
3 定期检查与调整
Fuel filter C C C C
Carburetor choke
Spark plug I I I I
Valve clearance I I I I
Every
Engine oil R R R R
year
Every
Lubricating oil filter C
year
clutch I I I I
Vehicles should be repaired according to the specified repair time. The meanings
of the various codes in the table are as follows:
C: cleaning
R: Replace
A: Adjustment
L: Lubrication
I: check
Note ①: When driving in dusty places, it should be cleaned frequently.
3-2
浙江华洋赛车股份有限公司
3.2 Inspection
Inspection and repair project period
daily Half One
Check parts Check item a year Benchmark
year
steering wheel Operational flexibility ○
steering damage ○
device steering system Steering system ○
installation status
Sloshing of the pin ○
Brake pedal Pedal stroke ○ ○
Braking effect ○ ○
Connecting rod looseness and damage
○ ○
and tubing
Braking Front/rear Brake fluid Brake fluid should be at
device volume ○ ○ the lower limit
Hydraulic (LOWER) or more
brake and If the working disc
brake disc wear and damage of thickness of the
Brake disc current brake disc is
less than 3mm and the
thickness of the
○ ○
working disc of the
rear brake disc is less
than 3mm, it should
be replaced in time.
Minimum brake pad
Brake pad wear and damage of (friction plate)
Brake pad thickness ≥ 1mm;
○ ○
replace when less than
1mm
Front wheel:35kPa(
Tire pressure 0.35kgf/ cm2)(5PSI)
○ ○ Rear wheel: 35kPa(
0.35kgf/ cm2)(5PSI)
Tire cracking and
Travel wheel ○ ○
damage
device
If there is no wear
Tire groove depth and indication on the tire
abnormal wear surface, the residual
○ ○
groove depth should
be no less than 3mm.
Loose of wheel nuts and
○ ○
wheel axles
Shaking of the front
○ ○
wheel bearing
Shaking of the rear ○ ○
3- 3
3 定期检查与调整
wheel bearing
Suspension Shaking of the
arm connecting part and
Buffer ○ ○
damage of the rocker
device arm
Shock absorber Oil spill and damage ○ ○
function ○
Front bridge Transmission, lubrication ○ ○
transmissi Rear bridge Transmission,
○ ○
on lubrication
Gearbox Oil leakage and oil Loosen the oil filler bolt
quantity ○ ○ port, the oil volume
should be to the top
4
浙江华洋赛车股份有限公司
5
3 定期检查与调整
handle.
3.3 Direction column, brake system
Place the car in a horizontal position, and
grasp the direction to check the presence or
absence of shaking in the direction shown.
3-6
浙江华洋赛车股份有限公司
3
Note
Do not mix dust and water when
replenishing brake fluid
To prevent chemical changes, use a
specified grade of brake fluid.
Because the brake fluid will damage the
plastic surface and rubber surface, please do
not splash it on these parts.
Turn the direction handle slightly to the left
and right, and remove the oil cup cover after
the brake pump combination is in the
horizontal state.
1, exhaust screw
2, the lower limit line
3, oil cup cover
4, observation hole
4
3- 7
3 定期检查与调整
Note
Brake pads need to be replaced
completely
3-8
浙江华洋赛车股份有限公司
3- 9 4
3 定期检查与调整
note
Brake pads need to be replaced
completely
2
3-10
浙江华洋赛车股份有限公司
3.4 wheel
Lift the front wheel with the tool in the
horizontal position, make sure that the car
body has no force on the wheel, shake the
front wheel from side to side, check whether
the front wheel connection is firm, check for
shaking.
If there is any shaking, check and tighten the
rocker arm, axle, rim bolt, nut.
If there is still shaking, check and replace:
bearing, rocker buffer sleeve, ball pin.
3-11
3 定期检查与调整
Tire pressure
Check the tire pressure using a barometer
Note
The tire pressure is checked while the tire is
cool. If it is used in a state where the tire air
pressure is not suitable, it will deteriorate the
operation and ride comfort, and cause
adverse effects such as eccentric wear of the
tire.
Tire pattern
Check the tread pattern and replace the new
tire once the pattern height is less than 3mm
note
When the tire pattern is less than 3mm, it
must be replaced immediately
3-12
浙江华洋赛车股份有限公司
Place the motor body in a horizontal position and press the motor body up and down several
times according to the position shown. If there is any sway or abnormal noise, check the
shock absorber for oil leakage, damage to each fastening part, looseness, etc.
13
3 定期检查与调整
Fuel device
Fuel system status
Remove the seat cushion (→ 2.3.1)
Check the fuel pipe for aging and damage.
When the fuel pipe is aging or damaged,
replace it with a new one. 4
Check the fuel tank vent pipe or the fuel 3
evaporating system for rupture and bending.
If there is any damage, replace it with new
ones.
3-14
浙江华洋赛车股份有限公司
3-15
3 定期检查与调整
3.8 Meter
Check meter
When the vehicle system is powered on for
the first time (or after the instrument is 1
replaced for the first time), when the engine
is not working, the speed should be in the
zero position, start the engine, pay attention
to whether the speed value indicates change,
if it does not change, it should be repaired in
time.
3-16
4 发动机周边
4 Engine periphery
Maintenance information……………………………………………………………4-1
4.1 Fuel System……………………………………………………………………4-2
4.2 Intake system……………………………………………………………………4-2
4.3 Exhaust system…………………………………………………………………4-3
4.4 Engine disassembly and installation……………………………………………4-5
Maintenance information
precautions
When repairing the operation, please ensure that the vehicle is turned off and left
still for less than 1 hour, and confirm that the heating parts are cooled before
performing maintenance to avoid injury to maintenance personnel.
Be careful not to damage the frame, engine body, bolts, cables during operation.
When the engine is disassembled, the frame should be protected against the
frame.
When the engine is removed, in order to protect the environment, the
corresponding container should be filled with coolant, oil and fuel. When
installing, the coolant and oil should be replenished as required.
Tightening torque
2
浙江华洋赛车股份有限公司
4-3
4 发动机周边
1
n
3
t
a
4
Remove the fuel tank (→4.1 Fuel tank
k
disassembly and safety)
Loading)
e
Remove the 2 mounting screws 4
Release the clamp5
5
Remove the intake pipe 6
Remove the crankcase exhaust pipe 7
s
Remove the air filter 8
y
Installation
Installation in reverse order of
s
disassembly
t
e
6
m
7
D 8
i
s
a
s
s
e
m
b
l
y
4-4 R
e
m
o
浙江华洋赛车股份有限公司
3
Remove the mounting nut 3
installation
Installation is in reverse order of
disassembly
5 4
4-5
4 发动机周边
installation
Disassembly
Remove the seat cushion, fuel tank
3
cover, instrument front cover, left
middle guard, right middle guard, left
foot pedal, right foot pedal (→ Chapter
2 Body Cover)
Remove the fuel tank ( → 4.1 Fuel
System)
Remove the air filter and carburetor (→
4.2 Intake System)
Remove the exhaust pipe assembly (→
4.3 exhaust system)
4
Remove 3 bolts 3
Remove the engine left cover 4
4-6
浙江华洋赛车股份有限公司
3 4
Remove the magneto motor trigger 5
patch cord 3
Remove the charging patch cord 4
Remove the crankcase exhaust pipe 5
Remove the motor cable 6 (Remove the
6
screw at the relay)
Remove the carburetor drain pipe 7
8
Remove the mounting bolts 8
Remove the fixing piece 9
Remove the engine 10
installation
Installation is in reverse order of
disassembly
9
10
0
4-7
浙江华洋赛车股份有限公司
5 Engine
5.1 Overview…………………………………………………………………………………5-2
5.2 Lubrication system………………………………………………………………………5-6
5.3 Check and adjust…………………………………………………………………………5-8
5.4 Fuel System……………………………………………………………………………5-12
5.5 Cylinder head and valve………………………………………………………………5-17
5.6 Cylinder and piston……………………………………………………………………5-30
5.7 Oil pump………………………………………………………………………………5-35
5.8 Right crankcase cover and magneto……………………………………………………5-38
5.9 CVT parts…………………………………………………………………………….5-40
5.10 Crankcase, crankshaft, variable speed drive…………………………………………..5-43
5.11 Fault judgment………………………………………………………………………..5-50
5- 1
5 发动机
5.1 Overrview
Maintenance
precautions……………………………………………………………………………5-2
5.1.1 Main performance technical parameters………………………………………………5-3
5.1.2 Mark torque data……………………………………………………………………5-4
5.1.3 Maintenance schedule…………………………………………………………………5-5
Maintenance precautions
2. When reassembling after disassembly, replace gaskets, seals and cotter pins;
3. When tightening bolts or nuts, it should be carried out in the order of diagonal crossing, and
gradually tighten to the specified torque in 2~3 times;
4. When cleaning parts, use cleaning liquid that cannot burn or high ignition point. Lubricate
the sliding surface of the part before assembly;
5. After assembly, check whether the parts of each part are installed correctly, and perform
rotation, movement and inspection operations.
5- 2
浙江华洋赛车股份有限公司
5- 3
5 发动机
In addition to the torque values of the important parts listed in the above table, the torque
range of the other fasteners is as follows:
5- 4
浙江华洋赛车股份有限公司
item Mileage(km)
times
Maintenance item
period 1000 4000 8000 12000 note
Fuel system
☆ I I I
access
☆ Fuel filter C C C C
☆ Carburetor choke
Spark plug I I I I
☆ Valve clearance I I I I
Per
Engine oil R R R R
year
Lubricating oil Per
C
filter year
☆ clutch I I I I
Carburetor idle
☆ I I I I
speed
The vehicle should be repaired according to the specified repair time. The meanings of
the various codes in the table are as follows:
C: cleaning
R: Replace
A: Adjustment
L: Lubrication
I: Check and, if necessary, clean, replace, adjust or lubricate
☆:The project is repaired by the personnel of the Longxin service station. If you check it
yourself, you should also refer to this manual.
☆☆: For this project, this manual is recommended to be repaired by personnel at the Longxin
service station to ensure safety.
note①:Driving in dusty areas should be cleaned frequently.
5- 5
5 发动机
Maintenance instructions
This section describes the engine lubrication system and the cleaning, inspection, and
replacement of various parts of the system. The engine should not be removed when
inspecting and cleaning the lubrication system, but the oil in the engine should be drained
before inspection and cleaning.
5.2.1Troubleshooting
First, the lubricant is consumed too fast 2, the oil filler thread is damaged
1. The engine has oil leakage Third, the lubrication is not normal
2, piston ring wear 1, the oil level is too low
3, the intake and exhaust valve guides 2, oil passage or filter blockage
wear 3, the oil pump is damaged.
4. The oil hood is worn or damaged
5- 6
浙江华洋赛车股份有限公司
Upper line
1 Lower line
4
5.3 Inspection and adjustment
Maintenance instructions……………………………………………………………………5-8
5.3.1 skills requirement………………………………………………………………………5-8
5.3.2 Spark plug……………………………………………………………………………5-9
5.3.3 Valve clearance………………………………………………………………………5-9
5.3.4 Ignition timing………………………………………………………………………5-10
5.3.5 Carburetor idle speed…………………………………………………………………5-11
5.3.6 Cylinder compression test………………………………………………………………5-11
Maintenance instructions
This section describes the inspection and adjustment of various parts of the LXCVT200
engine. At the same time, the technical requirements for adjustment and inspection are introduced.
For details on the inspection of the lubrication system, see 5.2
8
浙江华洋赛车股份有限公司
(3800±200r/min)
Gap 0.6-0.7mm
When installing the spark plug, first screw the Check if gaskets
spark plug into the hand and tighten it, then cover the are sealed
spark plug cap.
Clean: Use spark
plug cleaner or
steel wire
5.3.3 Valve clearance
9
5 发动机
Indicator
mark
T mark
10
浙江华洋赛车股份有限公司
T mark
Increase
Decreas
e
Throttle Valve Screw
Pressure gauge
5-11
5 发动机
Maintenance instructions
1. When using gasoline, special care should be taken. Always remember to carry out in a
well-ventilated environment in the air, and keep away from sparks and flames;
2. When disassembling all parts of the fuel system, pay attention to the installation position of the
“O” ring. When reassembling, it must be replaced with a new “O” ring;
The oil drain screw at the lower end of the float chamber can loosen the screw and drain the
gasoline remaining in the float chamber.
12
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5-13
5 发动机
5-14
浙江华洋赛车股份有限公司
Float Pin
assembly
Idle speed adjustment screw
5-16
Increase
Decrease
5-17
5 发动机
Maintenance instructions
The camshaft lubricant is injected into the cylinder head via a control orifice on the engine
casing. This control orifice must not be blocked.
When assembling, apply molybdenum disulfide lubricant on the cam bearing as the basic
lubrication.
Fill the cylinder head cylinder with clean engine oil for lubrication of the camshaft.
Specifications
5-18
浙江华洋赛车股份有限公司
5.5.1 Troubleshooting
cover
5-19
5 发动机
1
5.5.4 Camshaft removal
3 4
6 7
10 11
0
5-20
浙江华洋赛车股份有限公司
4
Check the rocker shaft for wear and
scratches
Measuring the outer diameter of the rocker
shaft with a micrometer
Maintenance limit: 11.93mm
The maintenance limit clearance value of the
5 rocker shaft and the hole is 0.08mm.
5-21
5 发动机
head
valve guides
5-22
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5-23
5 发动机
Combustion Chamber
grinding
5-24
浙江华洋赛车股份有限公司
Maintenance limit:1.5mm
Contact width
5-25
5 发动机
26
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5-27
5 发动机
Oil shield
Install the cylinder head and insert and
support the timing chain to prevent it from
falling into the box.
Install the cylinder block connecting bolt
2×M6
Torque value: 8~12N·m
Mounting the camshaft on the cylinder
head
Mount the rocker support bracket
Install the Ab bolt fastening nut and
gasket ring
Nut torque:28~30
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浙江华洋赛车股份有限公司
Injecting lubricant
5-29
5 发动机
Disc bolt
Maintenance instructions
The camshaft lubricating oil is injected into the cylinder head through a measuring hole in the
engine casing. This measuring holes must not be blocked. Before installing the cylinder,
install new gaskets and locating pins; do not allow dust and impurities to seep into the
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浙江华洋赛车股份有限公司
crankcase..
Specifications
5.6.1 Troubleshooting
Low or unstable compression: Overheat:
1. Cylinder or piston ring is worn 1. Excessive carbon deposit
2. The cylinder, piston or piston ring is 2, there is knocking or abnormal noise
worn 3, the piston or cylinder is worn
3. The piston ring is not installed
correctly.
4. Scratches or scratches on the piston or
cylinder wall
5-31
5 发动机
Cylinder inspection
5-32
浙江华洋赛车股份有限公司
Thick Gauge
5-33
5 发动机
piston pin
Maintenance limit: 14.96mm
Calculate the gap between the piston and the piston
pin
Maintenance limit: 0.02mm
5-34
浙江华洋赛车股份有限公司
Piston installation
Top Ring
Install the piston, piston pin and new piston retaining Second Ring
ring. Oil Ring
20mm or bigger
Note: When installing the piston, the side marked Gap
with the “IN” mark should be aligned with the
intake valve.
The end gap of the piston pin retaining ring should be
staggered from the piston incision
Clip Spring
Clip Spring
Clip Spring
Top Ring Note: When assembling after
Second Ring disassembly, be sure to use a new
Oil Ring piston
Pin retaining ring
DoClip
not Spring
let the piston pin retaining
Clip Spring
ring fall into the crankcase.
Piston mark
5.6.5Cylinder installation
5-35
5 发动机
Clearance of
Retaining ring
Loophole
5-36
浙江华洋赛车股份有限公司
Maintenance instructions
The installation and maintenance work after removing the right crankcase cover can also be
operated without removing the engine;
Do not allow dust or impurities to enter the engine when the oil pump is removed;
It is not allowed to repair the oil pump. If a certain size reaches the maintenance limit, the
entire oil pump should be replaced.
Technical specifications
Maintenance limit
item standard(mm)
(mm)
clearance between inner
— 0.12
rotor and outer rotor
Oil pump
clearance between outer
— 0.12
rotor and pump body
Axial clearance between
0.05~0.1 0.2
rotor surface and pump body
M14 NUT
Remove the oil pipe and spring
Remove the magneto motor fastening nut M
Rotor
14 and washer
Remove the magneto rotor
Remove the one-way tightening nut M 22
(left-handed) and washer Unidirectional
Remove the one-way device Washer
Remove the oil pump sprocket cover
fastening bolt 2×M6 Unidirectional
Remove the oil pump sprocket cover Device
Remove the oil pump driven wheel lock nut
M6 bolt
Remove the balance shaft lock nut M16
Sprocket Cover Fastening Oil pump
(left-handed)
bolt driven wheel
Remove the oil pump main and driven
Sprocket cover
wheels
Remove the oil pump lock bolt
Remove the oil pump
5-37
5 发动机
External Rotor
External Rotor
Internal Rotor
Locking bolt
of oil pump
Install the oil pump in the correct position
(pump mark control, mark hole on the box)
Install the oil pump lock bolt
Install the oil pump main and driven wheels
Install the balance shaft lock nut M16
Oil pump Install the oil pump driven wheel lock nut
M6
Install the oil pump sprocket cover
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浙江华洋赛车股份有限公司
5-39
5 发动机
Maintenance instructions
For the disassembly and installation of the magneto motor described in this section, simply
remove the right crankcase cover, no need to remove engine.
Torque value
Right crankcase cover fastening bolt: 8~12N·m
Magneto rotor bolt:35~40N·m
crankcase cover
5-40
浙江华洋赛车股份有限公司
installation
9×M6 bolt
9×M6 bolt
5.9 CVT parts
5-41
5 发动机
Maintenance instructions…………………………………………………………………5-40
5.9.1 Disassembly of the left crankcase cover……………………………………………5-40
5.9.2 Disassembly of CVT parts……………………………………………………………5-40
5.9.3Inspect of CVT parts…………………………………………………………………5-41
5.9.4 Install of CVT parts…………………………………………………………………5-42
5.9.5 Left crankcase cover installation……………………………………………………5-42
Maintenance instructions
The removal and detection of the left crankcase cover and CVT components eliminates the
need to remove the engine from the frame and can be disassembled and tested directly on the
vehicle.
crankcase cover
Fastening bolt
5-42
Clutch friction disc inner diameter greater Sliding drive disc sleeve
than 130.5 mm should be replaced.
5-43
Clutch
Clutch
installation
Mounting pin
Install the left crankcase cover (bolt 9×
M6) Active drive disc Driven friction disc
Torque value:8~12 N·m
Fastening bolt
5-44
Maintenance instructions
This section describes the disassembly and assembly of the transmission components and the
crankshaft. When performing the above work, the crankcase should be separated first; the
disassembly of other components of the engine should be performed before the crankcase is
disengaged.
Specifications
Maintenance limit
item standard(mm)
(mm)
Gear shift
outer diameter 11.966~11.984 11.950
fork shaft
Connecting rod small
15.014~15.022 15.06
head inner diameter
Clearance
Crankshaft
of
Radial 0.004~0.008 0.05
Connecting
rod side
5-45
5 发动机
5.10.1 Troubleshooting
Difficulty gear shifting Crankshaft has noise
1. gear shift fork bent 1, the connecting rod big end bearing
2, gear shift fork shaft bent wear
2, connecting rod bent
Gear shift abnormal
1. The gear shifting ratchet claws are Gear shifting gear is noisy
worn 1. Gear shifting gears are worn
2. The gear shift fork is bent or damaged. 2, spline bearing wear
3, gear shift fork shaft bending
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浙江华洋赛车股份有限公司
5.10.2Decomposition of the
crankcase
Blance shaft
5-47
5 发动机
Free stroke
Timing sprocket disassemblely/ installation
5-48
浙江华洋赛车股份有限公司
5.10.4 Decomposition of
transmission components
Pull out the fork shaft and take out the fork
Take out the shift drum and shift shaft
Take out the reverse intermediate shaft and
reverse drive shaft assembly
parts
Reverse
Install the components in the correct middle
position, as shown in the picture: Variable speed drum
Axle
Shift shaft Reverse
Transmission
Note: Before assembly, each part should Axle
be coated with engine oil.
Check if the shift gear can rotate freely
and without jamming.
Care should be taken to align the
marking teeth when assembling the
shifting drum and shifting shaft.
Balance shaft
5-50
浙江华洋赛车股份有限公司
Closure bolt
Left crankcase
Closure bolt
5-51
5 发动机
possible reason
5.11.1 Engine can't start or start hard 1. No fuel in the fuel tank
2, the oil switch is blocked
Check direction 3, tubing blockage
4, carburetor float needle
1、Check if the fuel reaches the carburetor → does not card jam
enter the carburetor → has entered the carburetor
possible reason
1. The spark plug is damaged
or not cleaned
2, the magnetic motor failure
3, ignition switch failure
2、Remove the spark plug and check the spark → the spark 4, sensor failure
is weak or completely no fire → the spark is normal 5, igniter failure
6, ignition coil failure
7, high voltage cable failure
8, the power circuit has a
short circuit or open circuit
possible reason
1、Check cylinder pressure → pressure is too low → 1. The valve clearance is too
pressure is normal small or has no gap
2, the valve guide Xuan bent
3. The cylinder seat and the
valve are not well matched.
4, cylinder and piston ring
wear
5, the cylinder head gasket is
2、Restart the engine → the engine can ignite but still not sealed well
can't start → the engine does not ignite 6, the assembly is not in
place
7, the timing of the valve is
not correct
possible reason
5-52
浙江华洋赛车股份有限公司
possible reason
1, the fuel system is not well
supplied
2, carburetor choke closed
2. Check the ignition timing (using the ignition timing light) 3, air filter blockage
→ the ignition switch is incorrect → the ignition timing is 4, carburetor cover air hole
correct. blockage
5, silencer blockage
possible reason
3. Check the valve clearance → the valve clearance is 1. CDI igniter is damaged
incorrect → the valve clearance is correct. 2, the magneto is faulty
3, pulse generator failure
possible reason
4. Check cylinder pressure → cylinder pressure is too low 1. Improper adjustment of
→ cylinder pressure is normal valve clearance
2, valve seat wear
possible reason
1, the valve clearance is too
small
5. Check the carburetor → carburetor blockage → 2, the valve is bent or stuck
6-53
1
5 发动机
6. Check the spark plug → the spark plug has too much
carbon or the color is wrong → the spark plug is normal possible reason
1, did not do regular maintenance
work
2, the spark plug heat value is
7. Remove the oil dipstick and check the oil volume → the wrong
oil quantity is incorrect → the oil quantity is normal. 3, the spark plug electrode gap is
too small
8. Remove the valve cover and check the lubrication of the possible reason
valve → the valve lubrication is not normal → the valve 1, the oil surface is too high
lubrication is normal 2, the oil surface is too low
3, the oil is not clean
possible reason
9 Check if the engine is overheated → the engine is 1. Oil passage is block
overheated → the engine is not hot 2. The oil pump is not working
properly.
possible reason
1. Excessive carbon deposit in the
10. During high-speed driving → the engine emits a combustion chamber
knocking sound → the engine has no knocking sound 2. The fuel used does not meet
the specifications.
3, the clutch slips
4, the mixture is too rich
5, too much oil
possible reason
1, spark plug damage
2, the magnetic motor failure
3, ignition coil failure
4, CDI failure
5, the transmitter failure
6, switch failure
7, spark plug cap failure
5.11.4 Poor performance at high engine speed 8, the power circuit has a
wrong connection or short
Check direction circuit
6-55
1
5 发动机
possible reason
abnormal noise
1. Magneto motor failure Check direction
2, CDI failure
3, sensor failure 1. The valve makes an
4, improper valve clearance abnormal sound
possible reason
1. Timing chain and timing sprocket are not installed
correctly. 5. Transmission gear and
2, gear wear is serious driven gear are different
possible reason
5, check the spark plug high-speed flashover situation → 1. Magneto motor failure
jump fire is not normal → jump fire is normal 2, CDI failure
3, sensor failure
4, ignition switch failure
5, ignition coil failure
6, spark plug cap failure
7, spark plug failure
8, the power circuit has a
5-56
浙江华洋赛车股份有限公司
possible reason
1. The machining accuracy of
the gear is not good
possible reason
1, the valve clearance is too large
2, valve worn out
possible reason
1, piston and cylinder worn out
2, piston pin and small end connecting rod worn out
3, crank connecting rod head worn out
possible reason
1. Crank connection bearing is damaged
2, camshaft bearing worn out
possible reason
1, the chain is elongated
2, timing sprocket wheel tooth worn out
3, chain adjustment plate or guide plate worn out
6-57
1
6 车辆底盘
6 Vehicle chassis
Maintenance information………………………………………………………… 6-2
6.1 Troubleshooting…………………………………………………………………6-3
6.2 Front wheel……………………………………………………………………6-3
6.3 Braking System…………………………………………………………………6-4
6.4 Front suspension system………………………………………………………6-6
6.5 steering system…………………………………………………………………6-8
6.6 Rear suspension system………………………………………………………6-12
6.7 Rear drive shaft assembly……………………………………………………6-12
6-2
浙江华洋赛车股份有限公司
Maintenance information
Attention
• When carrying out maintenance work on the front wheel and suspension system,
the frame must be securely supported before it can be used.
• Inspection, inspection and inspection of lights, instruments and switches are carried
out according to the corresponding chapters.
• Do not use excessive force on the wheels. Be careful not to damage the wheel
• When removing tires from the rim, special tire and rim protectors must be used to
avoid damage to the rim
Maintenance standard
Tightening torque
item size torque
Steering lock nut GB9457 M10 × 1.25 33~45N·m
Front brake disc bolt M8 × 20 × 1.25 22~30N·m
Front brake caliper body bolt GB5789 M8 × 16 30~36N·m
Rim shaft slotted nut GB9457-1988 M14 ×1.5 × H18 209~278N·m
Front shock absorber bolt GB5789 M10 ×1.25 × 45 Half thread 45~59N·m
Rim mounting nut GB6187-86 M10 × 1.25 45~59N·m
Lower rocker bolt GB5789 M10 × 1.25 × 80 45~59N·m
tool
inner hexagon m6 Assembly tool shaft
Open ratchet wrench s8 Pneumatic wrench s12
Open ratchet wrench s10-s12 Pneumatic wrench s14
Open ratchet wrench s14 Socket wrench m12
Open ratchet wrench s17-s19 Socket wrench m14
Open ratchet wrench s22 Socket wrench m20
6-3
6 车辆底盘
6.1 Troubleshooting
Steering is too heavy 1, poor wheel bearing
2. Improper installation of the front
1. The upper bolt of the direction wheels
column is too tight 3, brake tubing, cable clamp
2. Steering bearing damage and wear Fifth, the front suspension is too soft
3, the inner and outer races of the 1. The front shock absorber is
bearing are damaged, worn, and stepped weakened
4, the direction column deformation 2, the tire pressure is too low
5, low tire pressure Sixth, the front suspension is too hard
6, tire worn out 1. The front shock absorber is
Second, the handle bar is shaking damaged.
1. Steering bearing damage and poor 2, the tire pressure is too high
fastening Seven, the front shock absorber
2, left and right shock absorbers are abnormal sound
not supported 1. The front shock absorber is
3, tire skew defective
4, frame deformation 2. Loose parts of the shock absorber
5, tire eccentric worn out are loose
6, wheel bearing shaking Eight, poor braking effect
Third, the front wheel is jumping 1, poor brake adjustment
1, rim deformation 2, the surface of the brake disc is
2, poor wheel bearing defaced
3, bad tires 3, brake pad wear
4, improper wheel balance
5, poor fastening around the wheel
axle
Fourth, the wheel is not turning well
6-4
浙江华洋赛车股份有限公司
examination
Observe the brake1caliper for cracks, oil
Wheel inspection
Check if the rim 1 has damage, deformation,
and scratches. Replace if there is any
abnormality. Slowly turn the wheel and
measure the runout of rim 1 with a dial
gauge
Use limit: axial: 2.0mm
Radial: 2.0mm
Rim installation
Press the rim 2 into the tire on a special 2
machine
3
Front wheel mounting bracket removal
Remove the front wheel
Remove the front caliper body 3
Take out the cotter pin 4
Remove the rim shaft mounting nut 5
Brake disc and mounting bracket are
4
removed together
4
Remove the front wheel mounting bracket
Installation
Installation in reverse order of disassembly 5
Wheel rim mounting nut torque: 209N•m~ 4
278N•m
Brake disc mounting bolt torque: 30N•m~
36N•m (threaded fixative) leaks at each fastening point, and replace
Note: The rear wheel is disassembled and installation
installed similar to the front wheel, please Brake caliper fixing bolt 2 Torque: 38N•
refer to the front wheel. m~51N•m (Threaded fixing agent)
7
6- 5
6 车辆底盘
examination
Front brake disc thickness: less than 3.0mm,
replace the new brake disc 4
Installation
Install the brake disc
Brake disc fixing bolt torque: 22N•m~30N
•m of the mounting position while fixing it to
the steering handle.
Disassembly of front brake hand brake The direction of the oil pipe on the car body,
pump according to the first chapter cable, wire
Remove the bolt 5 type routing, must ensure the smooth flow of
When the front brake hand brake pump 6 is the brake oil circuit.
disengaged, the front brake hand brake When the brake system assembly is installed,
pump does not need to be removed from the the braking force must be checked.
6- 6
浙江华洋赛车股份有限公司
6- 7
6 车辆底盘
6
1
Installation
Installation in reverse order of disassembly
6- 8
浙江华洋赛车股份有限公司
6- 9
1
6 车辆底盘
Installation
Installation is in reverse order of
disassembly.
installation
Press the ball pin into the rocker arm
combination with a special tool
Installation in reverse order of disassembly
6-10
浙江华洋赛车股份有限公司
Release connector
Remove the left handle switch
multi-function plug 8
Installation
The left and right hand switch assemblies
are reversed in reverse order
Direction 2
Handle removal 4
Disassembly of the right hand switch
assembly
Remove the screw 4
Remove the bolt 5
Remove the front hand brake pump
Remove the right hand switch assembly
5
6-11
6 车辆底盘
Throttle cable
6 Disassembly
Remove the screw 4
Remove the right hand
Remove the throttle cable connector 5
Unscrew the throttle seat connector 6
Remove the throttle cable
Installation
Installation in reverse order of disassembly
6-12
浙江华洋赛车股份有限公司
Installation
Installation in reverse order of disassembly
5
Note: When installing the split pin, replace
the new split pin; after the installation is
completed, check the steering flexibility and
the left and right steering angles are the
same; cable and cable type cable according
to the first chapter cable, cable type cable;
When turning the rocker arm, be sure to
place the steering rocker arm in the center
and then assemble the steering shaft. When
assembling the steering shaft, be sure to
assemble it patiently. Make sure that the
right and left steering angles are the same,
steering system
Steering shaft assembly
Disassembly
1
Remove the meter cover
Remove the front assembly board
Remove the front wheel
Remove the direction to remove the tube
Remove the rear brake parking handle
combination 2
Remove the hydraulic brake hand brake
pump
Remove the tube and the left and right
handles
Loosen the lock nut on the steering rod 1
( left and right)
3
Remove the steering lever 2
6-13
6 车辆底盘
5 examination
Check the rear shockremoved and adjust the
adjustment cam 3 to the appropriate position
4
installation
Installation in reverse order of disassembly
disassembly
6-14
浙江华洋赛车股份有限公司
1
Remove the drive chain 4
Remove the rear brake caliper
Remove the rear shock absorber
Remove the flat fork assembly and the
frame connecting bolts and nuts
Remove the rear drive shaft assembly
2 3
4
Examination
The rear view of the rear drive shaft assembly of the vehicle is as follows
6-15
6 车辆底盘
quanti quanti
no item no item
ty ty
1 Rear hub 2 9 Flat fork guide sleeve1
2 Big nut 1 10 Rear sprocket seat 1
3 Rear disc brake disc 1 11 Screw(M8×20) 4
4 transmission shaft 1 12 Chain wheel 1
Fastening bolt
5 4 13 Plastic supporter 1
(M12×30×1.25)
6 screw 4 14 Back bridge 1
7 Steel bushing 2 15 ball 1
8 Flat fork assembly 1
Inspection after disassembly of rear drive shaft
Check if the rear hub is damaged. If it is damaged, replace it with new ones.
Check the thickness of the disc brake disc. If the thickness of the disc brake is ≤
3mm, replace the disc brake disc with a new one.
Check if the drive shaft is bent or damaged, if any, replace it with a new one.
Check the flat fork assembly. If it is damaged, replace it with a new one.
Check the rear sprocket. If the gear teeth are damaged, replace the new sprocket.
Check if the remaining parts are damaged. If there is any damage, replace the new
ones.
installation
In reverse order when the rear drive shaft is disassembled
Note: When installing the bushing, apply a lithium grease containing molybdenum disulfide
to both ends of the flat fork shaft.
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浙江华洋赛车股份有限公司
6-17
7 信号及照明系统
Maintenance instructions
When the inspection work is carried out, the whole vehicle can be energized; when
disassembling and installing the work, the whole vehicle should be powered off first,
and the hands should be dry.
Various specifications
quanti
item size note
ty
Front left turn White cover/ yellow light Light bulb can be
1
signal E4-6R-0162294 changed
Front right turn White cover/ yellow light Light bulb can be
1
signal E4-6R-0162294 changed
JUTELCA5 E4-113R-0125787 Light bulb can be
Left headlight 1
E4-7R-0225787 changed
Right JUTELCA5 E4-113R-0125787 Light bulb can be
1
headlight E4-7R-0225787 changed
LED/Red with
Rear tail light 2 Replace only
plug-inE4-7R-028580
Rear left and
LED/yellow with
right turn 2 Replace only
plug-inE4-6R-0161626
signal
Instrument, 4 pieces of magnetic sensor /
1
light for fault magnet
Electric horn 12V-1.5A EEC II-E9-00.6287 1
First, the left headlights are not bright 2, the connector is not well contacted
1, the bulb is damaged 3, the handlebar switch is damaged
7-2
浙江华洋赛车股份有限公司
Second, the right headlights are not Six, the rear left turn signal is not
bright bright
1, the bulb is damaged 1, the bulb is damaged
2, the connector is not well contacted 2, the connector is not well contacted
3, the handlebar switch is damaged 3, the handlebar switch is damaged
Third, the front left turn signal is not Seven, the rear right turn signal is not
bright bright
1, the bulb is damaged 1, the bulb is damaged
2, the connector is not well contacted 2, the connector is not well contacted
3, the handlebar switch is damaged 3, the handlebar switch is damaged
Fourth, front right turn signal Eight, the electric horn is not loud or
1, the bulb is damaged too light
2, the connector is not well contacted 1, the speaker is damaged
3, the handlebar switch is damaged 2, the connector is not well contacted
Five, the rear tail light is not bright Damaged handlebar switch
1, the bulb is damaged
2, the connector is not well contacted
3, the handlebar switch is damaged
3
7 信号及照明系统
2
Disconnect the headlamp connector 3
installation
In reverse order of disassembly
After replacing the lamp, adjust the
optical axis of the high beam by
adjusting the screw 4; adjust the optical
axis of the low beam by adjusting the
screw 5. 5
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浙江华洋赛车股份有限公司
installation
In reverse order of disassembly
7-5
7 信号及照明系统
installation
In reverse order of disassembly
Disassembly
Remove the front panel
an examination
Check the continuity of the switch lock
connector terminals as shown in the 2
table below.
The pattern is normal.
Ignition switch wiring diagram
Black/White
Black Green
Red
Install 3
In reverse order of disassembly
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浙江华洋赛车股份有限公司
Orange
3
Grey Light blue
3:Stop switch
4: electric start switch
7-7
7 信号及照明系统
Disassembly
Remove the front assembly board
Remove the electric horn connector
Remove the nut
Remove the electric horn 1
Examination
When the fully charged 12V battery is
connected, confirm that the electric horn
is ringing.
If there is any abnormality in the above
inspection, replace the electric horn.
Installation
In reverse order of disassembly
1
7.8 Meter
Start the car body, drive slowly, and
confirm that the instrument display is
normal. If there is any abnormality in
the above check, replace the instrument.
2
Disassembly
Remove the instrument mounting screw
2
Remove the meter cover
installation
In the reverse order of disassembly.
note
The main cable and cable type should be
cable, tube,
Cable type wiring diagram is correctly
assembled
3
7-8
浙江华洋赛车股份有限公司
an examination
Connect fuel sensor connector
Ignition switch is set to ON
Shake the float of the fuel sensor by
hand to confirm the position of the float,
and the scale on the fuel gauge is
consistent.
If it is inconsistent, check if the main
cable is disconnected or shorted. If there
is no abnormality, check the fuel sensor
and the fuel gauge itself. 2
Installation
Put the fuel sensor into the mounting
hole of the fuel tank, and install it in 3
place. No oil leakage is allowed.
7-9
附 录
Appendix
10