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Hisun 450ATV-2 Maintenance Manual
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Hisun 450ATV-2 Maintenance Manual

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450ATV-2 Maintenance Manual

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Summary of Contents for Hisun 450ATV-2

  • Page 1 450ATV-2 Maintenance Manual...
  • Page 2 eneral Information 1 Description 1.1 Identification code 1.1.1. Frame No. 1.1.2. Engine No. 1.2 Special tools, instruments and meters 1.3 Periodic maintenance chart Chassis 4.1 Steering operation system 4.2 Brake system 4.3 Wheels and tires 4.4 Transmission system 4.5 Reverse mechanism 4.6 Suspension 4.7 Cooling system of engine 4.8 Parking mechanism...
  • Page 4 1.1 Identification code 1.1.1. Frame No. The frame No. is engraved in the right bottom of the supporting frame. See Figure...
  • Page 5 Figure 1-1 1.1.2. Engine No. The engine No. is engraved in the right side of the engine. See figure 1-2 Figure 1-2...
  • Page 6 1.2 Special tools, instruments and meters 1.2.1 Oil filter detacher To fasten and detach the oil filter 1.2.2 Height gauge To gauge the height of various components 1.2.3 Vernier To measure the length of various components 1.2.4 Outside micrometer To accurately measure external diameter of a column 1.2.5 Inside micrometer To accurately measure internal...

  • Page 7: Periodic Maintenance Chart For The Emission Control System

    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 tyre 1.2.11 Magneto drawing device To detach the magneto 1.2.12 Snap ring clamp To install and detach snap rings 1.2.13：...
  • Page 8 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours Check valve clearance. ○ ○ ○ ○ Valves★ Adjust if necessary. Check condition. ○ ○ ○ ○ ○ Spark plug Adjust gap and clean. Replace if necessary. Clean. Every 20-40 hours Air filter element Replace if necessary.
  • Page 9 INITIAL EVERY Whichever Month ITEM ROUTINE Comes first 1,200 2,400 2,400 4,800 (Mi) (200) (750) (1,500) (1,500) (3,000) Hours Clean. ○ ○ ○ Engine oil filter element Replace if necessary. ○ ○ ○ Engine oil strainer Clean. ○ ○ ○ ○...
  • Page 10 Steering system Structure of Steering Vertical Column Components of Steering Bar...
  • Page 11 Disassembly, inspection and assembly of Steering 4.1.1 System...
  • Page 12 4.1.1.1 Disassembly of Steering Vertical Column (Steering Bar included) 1、Remove the Front Faceplate and Meter Cover (Figure 4-1-1) Figure 4-1-1 1、 Front Mud Shield 2、 Front Faceplate 3、 Rear Mud Shield 4、 Meter cover 2、Release the hexagon flange bolt M8×30(4pcs) and remove the steering bar clip...
  • Page 13 Steering Bar Holder 1、 Steering Bar 2、 Steering Bar Clip 3、 Hexagon Flange Bolt M8×30 3、 Remove Front Brake Lever and unplug all cables and connecting wires. (Figure 4-1-3) Figure 4-1-3 1、 Throttle Cable 2、Connecting Wire 3、 Clutch Cable 4、Brake fuel pipe 4、...
  • Page 14 Steering Vertical Column. (Figure 4-1-4) Figure 4-1-4 1、Hexagon open-groove nut 2、4 cushionф14×ф32×4 3、Steering vertical column 4、 cotter pin 3.2×32 5、Lower collar sheath 5、 Release M8*32 Bolt (2pcs) and remove the supporting brackets of the steering vertical column 6、Rotate the tension rod to detach it from the balance (Figure 4-1-6)
  • Page 15 Figure 4-1-6 1、 Tension rod 7、Pull out the components of the steering vertical column from the bottom seat. Steering Vertical Column 2、Bottom Seat 4.1.1.2 Inspection of steering vertical column components: 1、Check whether the hexagon open-groove nut between the inner ball pin and tension rod is tightened...
  • Page 16 4-1-8 1、 Tension rod 2、 cotter pin 3.2*32 3、 Turning shaft 4 、 Hexagon open-groove nut 5、Ball pin In case of loosen or worn out, tighten it with proper tools or replace with identical nuts. Torque of the open-groove nut: 32-36N.m 2、Check whether the inner and outter ball pin of the tension rod is loosen or got stuck.
  • Page 17 1. Tension rod In occasion of above defects, further inspection of the exact causation must be carried out and replace with new ball pin components. Caution: Continuous use of defective ball pin might cause severe injury or death. Additionally, check whether the tension rod is bended, cracked or rusted.
  • Page 18 Caution: tension rod should not be repaired by welding 。 3、Check whether the hexagon open-groove nut and cottor pin are intact. (No crack or flaw is allowed) Figure 4-1-10 1. M14 Open-groove nut 2、Cushion 3、Steering vertical column 4、Cotter pin 3.2*32 5、collar sheath Those two components are crucial and should be replaced whenever there is a potential problem.
  • Page 19 1. inner and outter supporting bracket 2、steering vertical column Inspection method: Assemble the steering vertical column to the main frame with supporting bracket and M8 bolts etc. and rotate the steering bar to ensure the column is not stuck or swinging. In occasion of above problems, the supporting bracket must be replaced.
  • Page 20 1、Plug the steering vertical column into the bottom seat and fix it with M14 open-groove nut (1pcs),ф14×ф36 ×4 cushion (1pcs), collar sheath (1pcs) and 3.2*32 cotter pin (1pcs). Fastening Torque of M14 open-groove nut: 80-85N.m Caution: before inserting the steering vertical column into the bottom seat, both upper and lower seals...
  • Page 21 2、Fix the steering vertical column onto the frame with hexagon flange bolt M8*60 (2pcs), supporting stent (1pcs), inner and outer supporting bracket (2pcs), stop reverse piece (1pcs) and collar pipes (2pcs). Fastening Torque of M8*60 Bolt: 30-32Nm Caution: inner surface of the supporting brackets must be greased with lithium lubrication.
  • Page 22 (2sets), cushion ф12 (2pcs), M10 hexagon open-groove nuts (2pcs) and cotter pins 3.2×32 (2pcs). Fastening Torque: 28N.m Figure 4-1-14 1、 Turning shaft arms comp. 2、 Cushion ф10 3、 Hexagon open-groove nut M12 4、 Cotter pin 3.2×32 4.1.2 Disassembly, inspeciton and assembly of steering bar 4.1.2.1 Disassembly of steering bar 1、Remove the front faceplate and Meter Cover...
  • Page 23 Figure 4-1-15 1、 Front Mud Shield 2、 Front Faceplate 3、 Rear Mud Shield 4、 Meter Cover 2、 Remove steering bar clip 图4-1-16 Figure 4-1-16 1、 Steering Bar Holder 2、 Steering Bar...
  • Page 24 3、 Steering Bar Clip 4、 Hexagon Flange Bolt M8×30 Unplug all cables and wires and remove the steering bar (Figure 4-1-17) Figure 4-1-17 2、 Throttle Cable 2、Electrical wires 5、 Clutch Cable 4、Fuel Pipe 6、 Front Brake Handlebar 6、Choke Cable 7、Parking Cable 4.1.2.2 Inspection of steering bar 1、...
  • Page 25 be less than 3mm, otherwise replace the steering bar. Less than 3mm Figure 4-1-18 1. Steering Bar 3、Check if there exists any slip thread, crack or other defects on the fastening bolts, in which case the bolts must be replaced. 4、Check whether the steering bar clip is damaged.
  • Page 26 main frame with hexagon flange bolts M8*30 (4pcs) and adjust the direction of brake cables on both left and right handlebar and clutch cable Figure 4-1-20 1、 Steering bar holder 2、 Steering bar 3、 Steering bar cliop 4、 Hexagon flange boltM8×30 Fastening Torque of the M8*30 Bolt is: 26*30N.m Brake System Front Disk Brake components...
  • Page 27 4.2.1 Preparation for inspection and maintenance of the front disk brake system. 1、 Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained.
  • Page 28 The vehicle uses brake plate. Please follow the tips of inspection as below. Inspect the brake fluid box level on the right handlebar. Should the fluid level falls under the minimum mark, please refill the box with the same type of fluid as was recommended by the manufacturer (Figure 4-2-1) to ensure the fluid level is higher than the minimum mark.
  • Page 29 2mm～5mm 4-2-2 1、Adjusting Screw Inspect the elasticity of the brake handlebar. Brake fluid will be automatically injected into the brake fuel pipe in the process of abrading brake pad reducing the fluid level in the box. Therefore, periodical inspection of the fluid level is necessary. Caution: must use DOT4 Brake Fluid Periodical inspection of the wear condition of front disk brake plate is also necessary.
  • Page 30 the disk brake plate must be replaced. Figure 4-2-3 1、 Brake plate clip 2、 Hexagon self-lock nut M8 3. Front disk brake plate Disk brake plate uses hydraulic pressure of the brake fluid. Therefore, fuel pipe must be periodically inspected and replaced. Inspection Method 1、Fuel pipe must be replace when worn out, cracked or distorted.
  • Page 31 4.2.2.1 Disassembly of front disk brake plate 1、Conical nuts M10 (4pcs) must be released before removing the wheel component. (Figure 4-2-4) Figure 4-2-4 1. Conical Nuts M10 2、Release M8 Bolt and remove the disk clip from the turning joint. (Figure 4-2-5)
  • Page 32 4-2-5 1、 Brake plate clip 2、 Front disk brake plate 3、 M8* Bolt 3、 Sequently remove the cotter pins, open-groove nuts, cushion and front wheel hub from the front wheel shaft. (Figure 4-2-6) Figure 4-2-6...
  • Page 33 1. Open-groove Nut 2. Cotter pin3.2×32 3. Cushion 4、Release the M8 Special Bolts (4pcs) and remove the disk brake plate from the front wheel hub. (Figure 4-2-7) Figure 4-2-7 1. Front disk brake plate 2、M8 Special Bolt 4.2.2.2 Disassembly of the Front Disk Brake Pump (Handlebar included) and Fuel Pipe.
  • Page 34 Figure 4-2-8 1. Front Disk Brake Pump 2. Hexagon Bolt M6 2、Detach the Plate Clip from the Turning Joint. 3、Remove the ‘T’ Pipe from the frame. (Figure 4-2-9) Figure 4-2-9 1. Hexagon Bolt M6 2. ‘T’ Pipe 4、Remove the Fuel Pipe Clip from the Lower Front Shaft Arm.
  • Page 35 4-2-10 1. Fuel Pipe Clip 5、 Remove the Disk Brake System from the vehicle body. 4.2.2.3 Inspection of the Front Brake System 1、Check the Brake Fluid Box for crack, leakage and other potential defects. 2、Check Fastening Bolts of all Fuel Pipes for possible looseness or damage.
  • Page 36 is less than 1mm Figure 4-2-11 1、Brake Shoe 6、Inspect the Brake Shoe for maximum wear, distortion and crack, in which case it must be replaced. (please refer to p.78 for maximum wear value of the Brake Shoe) 4.2.2.4 Assembly of Front Brake System 1、Use Fuel Pipe Brackets (2pcs) and Hexagon Flange Bolts M8*16 (2pcs) to connect the Fuel Pipe Clip with both left and right Lower Front Shaft Arms.
  • Page 37 4-2-12 1. Brake Fuel Pipe Clip 2、Fix the Disk Brake Plate onto the Front Wheel Hub with M8 Special Bolts (4pcs) (Figure 4-2-13) Figure 4-2-13 1. Disk Brake Plate 2. Bolt Caution: grease the bolt with thread glue when...
  • Page 38 fastening. Fastening Torque Bolt: 22N.M-26N.m 3、Fix the Front Wheel Hub onto the Front Wheel Shaft with open-groove nuts and cotter pins. (Figure 4-2-14) Figure 4-2-14 1. Open-groove nut M14 2. Cotter pin3.2×32 3. Cushion Fastening Torque of Open-groove nut: 80N.m—85N.m 4、...
  • Page 39 Fastening Torque: 26N.m--28N.m 5、Assemble Front Wheel Components onto Front Wheel Hub with M10 Conical Nuts (4pcs) (Figure 4-2-15) Figure 4-2-15 1. Conical Nut M10 Fastening Torque Conical Nut: 40N.m-45N.m 6、Fix Front Disk Brake Pump onto the Right Handlebar with M5*60 hexagon bolts (2pcs) (Figure 4-2-16) Fastening Torque of the bolt is: 8N.m--10N.m...
  • Page 40 Figure 4-2-16 1. Steering Bar 2. Hexagon BoltM5×60 3. Front Disk Brake Pump Caution: 1. 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 Fluid circulating before riding the vehicle.
  • Page 41 Rear Brake System Rear Brake System Rear Brake System Rear Brake System 4.2.3 Preparation for inspection and maintenance of the Rear...
  • Page 42 Brake System 1、 Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. Rear wheels of the vehicle use brake plates mechanized by a rear brake pedal. Please follow the tips of inspection as below. a)、Inspect the brake fluid box level on the right handlebar.
  • Page 43 1、Minimum Mark 2、Brake Fluid Box B） 。Travel distance of the Rear Brake Pedal should be kept between 20mm-30mm. Otherwise, please adjust the screw to meet required travel distance. 20mm～30mm Figure 4-2-18 1、Rear Brake Pedal C）Inspect the elasticity of the brake handlebar. D）Brake fluid will be automatically injected into the brake fuel pipe in the process of abrading brake pad reducing the fluid level in the box.
  • Page 44 Figure 4-2-19 1、 Disk Brake Plate Caution: 1. If the thickness of the disk brake plate is less than 3.5mm, it must be replace.2. In occasion of crack or distortion, the disk brake plate must be replaced. Disk brake plate uses hydraulic pressure of the brake fluid.
  • Page 45 2、The life expectancy of the fuel pipe is 4 years and should be replaced in time. 4.2.4 Disassembly, Inspection and Assembly of Rear Disk Brake System: 4.2.2.1 Disassembly of Rear Disk Brake System 1、Release M6 Bolt and detach Rear Disk Brake Pump from the Frame.
  • Page 46 1. Rear Disk Brake Box 2. M6 Hexagon Flange Bolt 3、Release Security Bolt and detach the Rear Disk Brake Clip. (Figure 4-2-22) Figure 4-2-22 1、 Rear Disk Brake Clip 2、 Bolt M18×14 4、Remove Rear Disk Brake System 4.2.4.2 Disassembly of Rear Disk Brake Plate 1、Release M10 Conical Nuts (4pcs) and remove rear wheel components.
  • Page 47 Figure 4-2-23 1、 Wheel Hub 2、 M10 Conical Nuts 2、Sequently remove cotter pin, M20 open-groove nuts and cushion from the Rear Wheel Shaft, then remove Rear Wheel Hub. Figure 4-2-24 1、 M20 Open-groove Nuts 2、 Cotter pin3.2×32...
  • Page 48 3、 Cushion 4、后轮毂 Rear Wheel Hub 3、Remove Locking Nuts (2pcs) from Rear Wheel Hub. 4-2-25 1. Locking Nut M35×1.5 、Remove the Bottom Seat of Rear Disk Brake Plate from the Rear Bridge. (Figure 4-2-26) Figure 4-2-26 1. Bottom Seat of Rear Disk Brake Plate 5、Release the Special Bolts (4pcs) of the Rear Disk...
  • Page 49 Brake Plate and remove the plate from the bottom seat. (Figure 4-2-27) 4-2-27 1. Rear Disk Brake Plate 2、Special Not M8 3. Bottom Seat of Disk Brake Plate 4.2.2.3Inspection of Rear Brake System: 1、Check the Brake Fluid Box for crack, leakage and other potential defects.
  • Page 50 Figure 4-2-28 1、Brake Shoe Caution: Brake shoe must replaced when thethickness is less than 6、Inspect the Brake Shoe for maximum wear, distortion and crack, in which case it must be replaced. (please refer to p.78 for maximum wear value of the Brake Shoe) Maximum wear of Rear Disk Brake Plate is less than 3.5mm 4.2.2.4 Assembly of Rear Brake System 1 、...
  • Page 51 Fastening Torque of bolt: 22N.M-24N.M Figure 4-2-29 1. Rear Disk Brake Plate 2、Special Bolt M8 3.碟 Bottom Seat 2、Mount the Bottom Seat of Rear Disk Brake Plate onto Rear Bridge. 3、Lock Rear Disk Brake Plate with M35*1 Bolts (2pcs). (Figure 4-2-31) Locking Torque: 240N.M...
  • Page 52 Figure 4-2-31 1. Bottom Seat of Rear Disk Brake Plate 4、Mount the Disk Brake Clip onto Rear Bridge with M10*30 Bolts (2pcs). (Figure 4-2-32) Fastening Torque: 18 Nm--22 Nm Figure 4-2-32 1.M10×30 Bolt...
  • Page 53 5、Mount Fluid Box of Rear Disk Brake onto the Frame with M6 Bolt (1pcs). (Figure 4-2-33) Fastening Torque: 8N.m—12N.m Figure 4-2-33 1.Fluid Box of Rear Disk Brake 2.M6 Bolt 6、Mount Rear Disk Brake Pump onto the Frame with M6 Bolts (2pcs). (Figure 4-2-34) Fastening Torque: 12N.m—16N.m...
  • Page 54 Figure 4-2-34 1.Rear Disk Brake 2.M6 Bolt Caution: 1. 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 Fluid circulating before riding the vehicle. 2.
  • Page 55 Figure 4-3-1 2、Check if the Wheel Hub is worn-out or damaged. 3、Check if the Wheel Hub is rusted or cracked. 4、Check if the conical nuts of the Wheel Hub are loosen or distorted. 4.3.2 Disassembly, inspection assembly wheel components. 4.3.2.1 Disassembly of wheel components Remove M10 Conical Nuts (4pcs) and detach the tyre.
  • Page 56 1.M10 Conical Nuts 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 tyre has reached its maximum wear condition in which case it should be replaced. 3、Check the joining condition of the tyre and wheel hub.
  • Page 57 Attach wheel hub onto the wheel with M10 Conical Nuts (4pcs). Fastening Torque: 45～50Nm Caution: assemble the wheel in correct direction (shown as the arrow). Front and Rear Wheels are not interchangeable. (Figure 4-3-3). Figure 4-3-3 1.Conical Nut M10 Speicification and operation guide of Wheel Hub 4.3.2 and Tyre.
  • Page 58 Wheel Hub Dimension Tyre Dimension （kPa）Tyre Pressure Front 12×6.5-AT 25×8-12 Wheel Rear 12×7.5-AT 25×10-12 Wheel To ensure maximum security and longer life expectancy of the wheel, please periodically inspect the tyre pressure and profile depth. Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle (such as hard turning).

  • Page 59: Rear Bridge

    1.Height no less than 3mm 2、profile depth Figure 4-3-4 Transmission System Rear Bridge...
  • Page 60 4.4.1 Disassembly, inspection, assembly of Rear Bridge components: 4.4.1.1 Preparation for disassembly and maintenance of Rear...
  • Page 61 Bridge components: 1、Check if the connection between wheel hub and conical nuts is reliable and if there is any distortion on the rear wheel hub. Should there exists any such potential defects, the wheel hub must be replaced immediately. 2 、 Check if there exists any slip thread on the M20 open-groove nut which is used to fasten the rear wheel hub.
  • Page 62 Figure 4-4-2 1、 Open-groove nut 2、 Cotter pin 3、 Cushion 4、Rear wheel hub 4． Detach the Chain 1． Inspection of Driving Chain Length of Driving Chain Maximum length driving chain is121.9mm Over the maximum length→replace the three components of driving china, driven sprocket and driving sprocket.
  • Page 63 2． Cleanning the driving chain wash with pure water or neutral abluent. Completely grease the chain with ME-1 Sealed Chain Lubrication or SAE30-50 Engine Lubrication after cleaning. :Caution: Do NOT use steam, petrol or other volatile liquid. Do NOT use other lubrication spray from the market.
  • Page 64 3. Assembly of Driving Chain 1. Assemble the following components ① Chain connection components ② Connecting plate ③ Connecting clip 5、Remove the bolts that connect Rear Bridge and Pan fork. (Figure 4-4-3)
  • Page 65 Figure 4-4-3 1.Rear Bridge Connecting Bolt M12× 2、 Pan fork 3、 Rear Bridge 6、Detach Rear Bridge from Pan fork. (Figure 4-4-3) 7、Release M35*1.5 Bolts (2pcs) and sequently remove from the right side Bottom Seat of Rear Disk Brake Plate and Connecting Seat of Rear Bridge.
  • Page 66 Figure 4-4-4 1. Nut M35×1.5 2. Bottom Seat of Rear Disk Brake Plate 3. Bearing Seat of Rear Bridge 4. Circlip 5. Bottom Seat of Sprocket 4.4.1.3 Inspection of Rear Bridge Components 1、Check if the splines of Rear Wheel Axle is damaged, in which case Rear Wheel Axle must be replaced.
  • Page 67 4-4-5 2、Inspect the wear condition of the chain and replace when necessary. 3、Remove the Chain 1． Inspection of Driving Chain Length of Driving Chain Maximum length of Driving Chain: 121.9mm Over maximum length→Replace the Driving Chain, Driven Chain and Driving Sprocket.
  • Page 68 4、Check if there is any damage on the Wheel Hub, Bottom Seat of Disk Brake Plate and Inner Spline of Sprocket Bottom Seat. If so, replace the component immediately. 5、 。Check if bearings in the Connecting Seat of Rear Bridge work smoothly.
  • Page 69 cracked or distorted. 4.4.1.4 Assembly of Rear Bridge: 1、 Mount the Sprocket onto Sprocket Bottom Seat with Bolts (4pcs). (Figure 4-4-6) Figure 4-4-6 1.Speical Bolt 2.Sprocket Bottom Seat 2、Mount Rear Disk Brake Plate onto the Bottom Seat of Disk Brake Plate with Special Bolts (4pcs). Figure 4-4-7...
  • Page 70 1.Special Bolts 2.Bottom Seat of Rear Disk Brake 3. Disk Brake Plate 3、Press the new Oil Seal into the Bottom Seat of Rear Bridge Bearing and grease it with lithium lubrication. (Figure 4-4-8) Figure 4-4-8 1.Oil Seal 2.Rear Bridge 4、Mount the Bottom Seat of Rear Sprocket onto Rear Wheel Shaft from the left side and affix it with circlip.
  • Page 71 Figure 4-4-9 1. Bottom Seat of Rear Sprocket 2. Sprocket 3、Circlip 5、Mount Connecting Seat of Rear Bridge onto Rear Wheel Shaft from the right side and strengthen it by hitting with plastic hammer. (Figure 4-4-10) Figure 4-4-10 1. Connecting Seat of Rear Bridge 6、Mount Bottom Seat of Rear Disk Brake Plate onto the Rear...
  • Page 72 Wheel Shaft and tighten it with M35*1.5 Locking Nut. (Figure 4-4-11) Figure 4-4-11 1.Disk Brake Plate 2．M35×1.5 Nut 7、Fix Rear Wheel Hub onto Rear Wheel Axle with cushion, M20 open-groove nut and cotter pin. (Figure 4-4-12) Figure 4-4-12 1. M20 Open-groove Nut...
  • Page 73 2. Cotter Pin 3. Cushion 4、Rear Wheel Hub 8、Connect the assembled Rear Bridge onto Pan fork with M10 Bolt. (Figure 4-4-13) Figure 4-4-13 1. Hexagon Flange Bolt M10× 2、Rear Bridge 3、Pan fork 9、Mount the wheel onto Rear Bridge. (Figure 4-4-14) Figure 4-4-14...
  • Page 74 1. Wheel Rim 2. Conical Nut M10 10、Properly mount the Chain. (Figure 4-4-15) Figure 4-4-15 1.Chain Inspection and Maintenance of Reverse Mechanism. Inspection and Maintenance of Reverse Mechanism. Inspection and Maintenance of Reverse Mechanism. Inspection and Maintenance of Reverse Mechanism.

  • Page 75: Front Suspension

    Figure 4-5-1 1. Reverse Switch 2. Reverse Cable 3. Reverse Shaft 4. Supporting Ring How to inspect: 1. Check the mobility of Reverse Switch. If it is not working properly, remove the Reverse Device to check if the Reverse Cable is stuck. Replace the Reverse Device lack of mobility.
  • Page 76 Pan Fork...
  • Page 77 Disassembly, Maintenace and Assembly of Front 4.6.1 Suspension...
  • Page 78 4.6.1.1 Disassembly of Front Suspension 1、Release the M10 Bolt of Supporting Ring and remove the Front Suspension. (Figure 4-6-1) Figure 4-6-1 1.Hexagon Flange Bolt M10× 2、Remove the cotter pin located on the ball pin of the Tension Rod, M10 Open-groove Nut. Then pull out the Ball Head. (Figure 4-6-2) Figure 4-6-2 1.
  • Page 79 2. Open-groove Nut M10 3. Cotter Pin3.2×32 4. Turning Joint 3、Remove the cotter pin and M10 Open-groove Nut located on the Ball Head. Figure 4-6-3 1. Cotter Pin 3.2×32 2. M10 Open-groove Nut 4、Release the security bolt of Shaft Arm and remove them from both Front Upper and Lower Shaft Arms.
  • Page 80 Figure 4-6-4 1.Hexagon Flange Bolt M10× 2、Front Upper Shaft Arm 3、Front Lower Shaft Arm 4.6.1.2Inspection Maintenance front suspension components. 1、Inspection of Ball Head If the Ball Head is loose, replace corresponding upper or lower shaft arm. (Figure 4-6-5) Figure 4-6-5 1.Ball Pin If Rubber Sheath of the Ball Pin is worn out or cracked, plesae have it replaced immediately.
  • Page 81 Check if the conical surface of Ball Pin is abraded and seamlessly match the conical bore on the Turning Joint. If not, please replace the corresponding upper or lower shaft arm.(Figure 4-6-7) Figure 4-6-7 1. Conical surface of B all Pin 2.
  • Page 82 replace the shaft arm immediately. In case of slight rust, clean out the rust and dirt on the surface, then repaint. 3、Inspection of the Nylon Bush and Liner Pipe of Upper and Lower Shaft Arms. Nylon Bush must seamlessly match the liner pipe of the Shaft Arm.
  • Page 83 the Turning Joint is bended, in which case it must be replaced. (Figure 4-6-9) Figure 4-6-9 1.Front Wheel Shaft Inspect for any crack on the Turning Joint, in which case it must be replaced. 5、Inspection of Front Suspension: Bending of the suspension Spring must be less than 2mm.
  • Page 84 Figure 4-6-10 1.Bending less than 2mm The elasticity of suspension will degrade over time, in which case it must be adjusted with special tools. (Figure 4-6-11) Figure 4-6-11 Check if there exists any crack on the suspension in which case it must be replaced. Caustion: Both suspensions...
  • Page 85 1 、 Clean Ball Head and Rubber Sheath ,then inject 40% Lithium Lubrication and place in the Rubber Sheath. 2、Clean the liner pipe of the Shaft Arm, nylon bush and collar pipe, then press nylon bush into liner pipe and fill up collar pipe with lithium lubrication.
  • Page 86 Nut and Cotter Pin. (Figure 4-6-14) Figure 4-6-14 1.Cotter Pin 2.Open-groove Nut 3.Turning Joint 4.Head Pin of Tension Rod 6、Mount the Suspension onto the Frame and Lower Shaft Arm with M10 Bolt. (Figure 4-6-15) Fastening Torque of M10 Nut：40～45Nm...
  • Page 87 Figure 4-6-15 1.M10 Bolt 4.6.2 Disassembly, Maintenance and Assembly of Rear Suspension. 4.6.2.1 Disassembly of Rear Suspension 1、Detach Rear Bridge from Pan Fork (Refer to Page 1.3: Disassembly of Rear Bridge). 2 、 Release the M12 Bolt of both Upper and Lower Supporting Brackets of Rear Suspension and take out the Suspension.
  • Page 88 Figure 4-6-17 1.Shaft Arm of Rear Suspension 2.Hexagon Flange Bolt M10× 4、Release the M14 Nut of Pan Fork Shaft, take out the Shaft, then finish the disassembly process of Rear Suspension. (Figure 4-6-18) Figure 4-6-18 1.M14× Nut 4.6.2.2 Inspection and Maintenance of Rear Suspension 1、Inspection of Pan Fork: Check if there exists any severe distortion on the...
  • Page 89 connection of Pan Fork and Rear Bridge, in which case the Pan Fork must be replaced. 。In case of minor distortion, try to calibrate and inspect for cracks on the surface. Check Pan Fork for any crack on the surface, in which case the Pan Fork must be replaced.
  • Page 90 the Shaft Arm where the worn out must be replaced. 3、Inspection of Rear Suspension: Identical inspection process with Front Suspension (Ref: Page 119) 4.6.2.3 Assembly of Rear Suspension: 1、Clean Needle Bearing and its Inner Liner Pipe with soft cloth, grease Needle Bearing with Lithium Lubrication and place the Inner Liner Pipe into Needle Bearing.
  • Page 91 System: Cooling Fluid of the Water Cooling System must comply with the following instruction. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. Antifreeze and water mixing ratio: 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) 4.7.1.1 Disassembly of Water Cooling System...
  • Page 92 1. Front Mud Shield 2. Front Faceplate 2. Release the bolt under Fluid Tank and take off the Fluid Tank. (Figure 4-7-2) Figure 4-7-2 1.Fluid Tank 2、M6* Bolt Caution: Do NOT spoil cooling fluid onto the Frame. 3 Detach the rubber inlet pipe on the left side of the Frame to drain out the fluid.
  • Page 93 Figure 4-7-3 1. Inlet Pipe, Fluid Tank 4 Take off Cooling System. 4.7.1.2 Inspection of Water Cooling System: 1. Check if the rubber pipe of Water Cooling System is torn or worn out. If so, please replace with new pipe. 2..
  • Page 94 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. Use Hoops (4pcs) and Rubber Pipes (2pcs) to connect Water Cooling System with Engine. 3 、 Mount Fluid Tank onto the Frame and connect Communicating Pipe with Overflow Pipe using M6 Bolts.
  • Page 95 1. Oil-discharge Bolt 2、Release M6 Bolt and take off the Wind Guide Cover. (Figure 4-7-5) Figure 4-7-5 1. Wind Guide Cover 2. Oil Pot 3. Oil Gauge 3. Release the M6 Bolts on both inlet and outlet pipes of the engine and take out the two steel pipes.
  • Page 96 Figure 4-7-6 1. Steel Pipe 1 2. Steel Pipe 2 4、Release the Hoop and take off the rubber pipe connected with engine. Figure 4-7-7 1. Rubber Pipe 1 2. Rubber Pipe 2 3.Hoop...
  • Page 97 5. Detach Oil Pot ( connected with 3 Rubber Pipes) 5. Take out Oil Pot from the Frame (connected with 3 Rubber Pipes). (Figure 4-7-) 4.7.2.2 Inspection of Oil Pot: 1. Check the Oil Pot sealing with 0.03 MPA Compressed Air. Replace Oil Pots with sealing defects.
  • Page 98 1. Release M5 Bolt and take off Stop Lever from Left Handle Bar. (Figure 4-8-1) Figure 4-8-1 1. Stop Lever 2. Take off Stop Cables from Rear Bridge. (Figure 4-8-2) Figure 4-8-2 1. Stop Cable 2. Parking Device 3. Release M8 Hexagon Bolt and take off Braking Mechanism. (Figure...
  • Page 99 4-8-2) 4.8.2 Inspection of Parking Mechanism 1. Check the mobility and integrity of Stop Lever; Replace defective Stop Lever. 2. Check if Stop Cable is stuck or damaged. Replace defective Stop Cables 3、Check the mobility of Parking Mechanism and replace defective components.
  • Page 100 loaded with one personnel can be stably parked on a slope more than 12°Inclination. 4.9.1 Inspection of Oil Circulation System 1.Fuel Tank 2.Fuel Switch 3.Fuel Filter 4.Carburetor 5.Negative Pressure Pump 1. Check for Fuel Tank Clogging. 2. Check if Fuel Filter is clogged. 3.
  • Page 101 3. Check if the threads of Speed Sensor are abraded. 4.10.2 Assembly of Speed Sensor 1. Screw Speed Sensor into Connecting Seat of Rear Bridge. 2. Fasten M12*1.25 Nut. 3. Connect electrical plugs of Speed Sensor. 4.8 The electric route color indication Route color indication 1.Black┄┄Ｂ...
  • Page 102 No electrification： 1. First, Check the safety, whether the safety is good or not 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.
  • Page 103 phenomena cause measure remark ignition system 1.switch lock １,no spark ※ ★repair carve out a way or short circuit,connection badness ★repair ※ line bonding badness 2.CDI set ※ ★replace After electrify no noise from the CDI 3.high voltage ※ high ★repalce voltage lead...
  • Page 104 ※ electrode failure １． flash not ★ 1. the switch of flash lamp repair bright or weak replace emergency light contacted badness 2. lamp ※ ★replace filament lamp damaged ※ the watt of lamp larger ★replace or smaller than regulated number ２, horn sound routing...

  • Page 105: Ignition System

    ★replace damaged ３. routing ※wire ★ replace carve out a way or short circuit repair ignition system...
  • Page 106 The chart 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 time ,spring coil produce spring signal ,provided to SCR as the turnon spring signal ,when reaching the ignition timing,SCR turnon capacitance began to discharge at the elementary coil L1 caused instant lower pressure ,while at the secondary coil caused...
  • Page 107 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(yelloe ) output into the rectifier ,through rectifier into direct current pressure and output.through R1 to charge the battery.
  • Page 108 5. Charge battery before fix it. Warning If battery without electrolyte, it may cause the rectifier damaged. And the electrolyte is venomous and dangerous. As it contains vitriol it may cause burn accident. Battery also contains explode gas, so keep it far away spark and flame and cigarette.

  • Page 109: Headlight Switch

    Electrical Diagram, Wiring: 红 功能 黑 蓝 黄 灰 绿 蓝 黄红 黄绿 墨绿 深棕 绿红 绿黑 浅绿红白 黑 黑 组合闪光器 远近光 开关 熄火 绿黑 绿红 墨绿 白 白 深棕 灰 棕 开关 红2 红 电起动 绿 开关 应急 磁电机 开关...
  • Page 110 Horn Switch When press the bottom, the horn will move. But if without sound or with unclear sound or with little sound please check the problem according to the guide. 浅绿 黄红 功能 5.6 Starting system ： Starting Circuit Starting system working process Turn on the start switch on the left handlebar, the battery can supply power for the CDI.
  • Page 111 Note: 1. When electrical starting, please keep the battery with enough power and the time of pressing button will be within 55 seconds. If longer time more than 55 seconds, it may cause the damange of startor relay and the startor relay motor and may also cause the damage of the battery that it can not be charged or not charge enough.
  • Page 112 Mini. turning radius 2000mm Front：Hydraulic spring swing arm Suspension Rear：Hydraulic spring swing arm Braking pattern Front dual disk, Rear single (Normal condition) disk/front and rear linkage, Right foot/left hand operation Braking pattern Front dual disk, Rear single Primary Brake （ 1 ） ： disk/front and rear linkage, right (E-mark) foot/right hand operation...
  • Page 113 hitch)： b） Engine specification Engine Model/Brand HS1102MU/ 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) Max. power（E-mark） 13kW （5500r/min） Rated power 24kW (6000r/min-6500r/min) Max. Torque 49N·m （5000r/min） Max.
  • Page 114 Engine Drive 16.339～2.475 ratio： Clutch Wet automatic centrifugation Lubrication Comply with GB11121-1995 standard. (Crankcase) Depending 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） Components Specification Carburetor PD42J Pattern Parallel Vacuum Spark plug...

  • Page 115: Driving Method

    Turning operation Hand operating steering bar system Two wheel/ four wheel drive (2W Driving method 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...