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GAOKIN E02 Maintenance Manual

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E02（GK194MS）
Maintenance Manual
Edited：Li LinJun
Verified：Hu Xianyong
Approved：Li Xuelong
第 - 1 - 页

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Summary of Contents for GAOKIN E02

  • Page 1 E02（GK194MS） Maintenance Manual Edited：Li LinJun Verified：Hu Xianyong Approved：Li Xuelong 第 - 1 - 页...

  • Page 2: Table Of Contents

    Engine outline drawing ......................- 7 -  3.1 Engine model and countermark position ..................- 7 -  3.2 E02 engine outline drawing ....................... - 7 -  4． Engine assembly requirement and accessory ................- 8 -  4.1 Engien assembly ........................- 8 - ...

  • Page 3: Overview

    GK194MS engine works stable, with high torque, long life, low consumption, can be used in wide range. 1.2 Types、application、Specification  GK194MS engines including two series E02、E03 and 8 models，E02 is the engine with gears. It is applied to two wheels motorcycles、sports ATV、applicability ATV、UTV。 Details please refer to the following table:...

  • Page 4: Affect To Environment And Energy

    EFI（with battery above 45A.h）-30～40°C。 Apply to sea level elevation，engine with carburetor in 4000m；engine with EFI in 5000m。 Engine must be installed and fixed on vehicle or testing-bed, assembled all accessories and filled in enough correct lubricating oil and coolant. 1.5 Effect to environment and energy  Polluted air like COx、CxHy、NOx will be emitted when engine works and consumes fuel.

  • Page 5: Main Structure Parameter

    Items Parameter/Description Remark idling r/min 1500±150 Vehicle Exhaust limited Carb. Euro II，EFI Euro.III calibrating Vehicle Noise limited Db(A) ≤80 calibrating 2.2Main structure parameter    Items Parameter/Description Remark Vertical、1 cylinder、SOHC、4 Stroke 、4 Type valves、water cooling E02C E02F Outline size(L x b x h)mm 380x420x500 Net weight kg Bore diameter mm...

  • Page 6: Transmission System Parameter

    Fuel volume L Generator output 14V 330W (5000r/min) Starting generator power 12V 650W model：NGK CR7E，clearance：0.7～ Spark plug mm 2.3 transmission system parameter    The follow table shows E02 engine transmission parameter Parameter/Description Items Remark E02C E02F Manual wet-type oil bath multiple Clutch type...

  • Page 7: Fuel And Lubricating Oil Parameter

    Coolant inlet ≤90 temperature °C Coolant outlet ≤105 temperature °C Thermostat Open /full open 71/85℃，lift 3.5mm 3. Engine outline      3.1Engine model and countermark location  E02engine,please look at engine left side 3.2 E02 engine outline drawing  See attached file 1 E02outline drawing (EFI) 第 - 7 - 页...

  • Page 8: 4． Engine Assembly Requirement And Accessory

    To main fixed hole diameter、coordinate 4.2 Inlet and exhaust system  Items Parameter/Description Remark Box type with exhaust gas Structure connector Model 17100-E02-0000 original 1685 resistance Pa Air filter A Air inlet rate m /h 300 volume L Filter element Foam type Box type with exhaust gas Structure connector、scavenge port...

  • Page 9: Fuel Supply System

    Items Parameter/Description Remark inlet rate Small end internal diameter Connecting tube (throttle valve) ≥ Φ 40mm ， length about 140mm volume L filter element Paper and foam Model 18000-E02B-00C0 Exhaust Exit 100mm backpressure original resistance Pa muffler Pipe diameter mm Inner diameter ≥...

  • Page 10: Coolant System

    Items Parameter/Description Remark filter B) Stroke mm Oil supply L Mouth Φ40 diameter mm Oil pipe inner Φ7 diameter mm Accelerating bump Electric injector supply oil See 4.5 4.4 Coolant system    Items Parameter/Description Remark Integration thermo switch、 liquid adding Structure hole、pressure regulating valve Model 19600-E02B-00A0 Radiating area -...

  • Page 11: Efi System

    Items Parameter/Description Remark Wire connection（electric） See annex 2（carburetor） 、annex schematic diagram 3（EFI） Digital control electric structure ignition igniter Install fixed、far away exhaust pipe、 Can be shielded （carburetor） requirement ventilate good external Model 33200-E02B-0001 Open magnetic circuit ， Structure inductance Model Delphi 28140972 Ignition ≥15...
  • Page 12 Items Parameter/Description Remark 36 needle pin，pin definition see Structure wire connection schematic diagram Shock proof：fixed on vehicle frame Water proof：dry，difficult to get wet，connector adown； Install Anti high temperature：surroundings requirement max. temperature lower than 85℃； Anti electromagnetic interference： 150mm away from spark plug Integration valve block、location Structure Throttle...
  • Page 13 Items Parameter/Description Remark Connect to vehicle instrument ， 12Vsquare wave，rotate each 1(duty Engine RPM signal output ratio about 50%，high level about 12V，low level about 0V；current less than 30mA)。 Water temperature alarm Without output Distance to engine exhaust port Refer to O2 sensor per requirement 200-500mm、straight reach、upward 4.6-01...

  • Page 14: 5． Engine Usage、Maintenance And Fault Solution

      5．Engine usage、maintenance and fault solution  5.1Engine usage and cautions  5.1.1 Engine Running-in Check oil level with oil level window lines. If the oil level lower than the underline, add fuel to the upper line. It is not allowed to increase load at cold engine state, preheating engine for 1-3 minutes first.
  • Page 15 high speed。 5.1.2 Engine starting Prohibit The engine can be only started with electricity. It is not allowed to press the electric start button for a long time. Start engine in N-shift. If it is not in N-shift, ensure the clutch is off before starting engine.

  • Page 16: Maintenace

    5.1.6 Gear shift operation E02 engine with 5 gearshifts, shift way is international, catch or step by left foot, the order is: 1-N-2-3-4-5，neutral position Nis between shift 1 and shift 2， it only takes half shift。If reverse shift is set, reverse shift R will occupy shift 1，2 to 5 will be changed as shift 1 to shift 4，the order will be changed to be...
  • Page 17 Remark ：replace oil filter element can’t be used again 3) Replacement operation a) Dismantle oil pan nut： Use 12mmhexagonal head wrench to dismantle b) filter element replacement picture： E02 series： Use10 Thexagonal socket wrench to dismount filter cover, replace oil filter element, use fastening torque10-14N.m to assemble 5.2.2...
  • Page 18 to drink Note A. This operation must be done at cold or low temperature. B. if it is stick to painting surface careless, please wash and clean it with water 1) Cooling water check, put vehicle on the ground, check if the water level is between above and under carved lines, it is better to be at the middle.
  • Page 19 GB/T6177.1-2000 20±3 Hexagon flange nut Hexagon socket head cap GB/T70.1-2000 10±2 Tightener M6 x25 screws Inlet/outlet Valve clearance adjusting 90302-E02-0000 7±1 rocker Oil pan cover 11001-E02-0000 18±3 View hole cover Left front cover 11002-E02-0000 8±1 Left front cover View hole cover...
  • Page 20 5mm screw 3.5～5 6mm screw 7～11 6mm plate bolt and nut 10～14 8mm plate bolt and nut 20～30 10mm 30～40 plate bolt and nut 5.3common fault solution  5.3.1 1)、 Starting difficult or unable starting Item Cause Solution Operate Improper operation Operate per instruction No fuel in tank Add fuel Fuel tank switch closed...
  • Page 21 Item Cause Solution Starting transmission gear damaged（with Check and replace abnormal sound） Starting one way clutch failure （motor Check and replace idling） Starting motor failure Replace Starting relay failure Replace Insurance off Replace Trigger signal connection wires not good Check connection Ensure high voltage...
  • Page 22 Item Cause Solution Piston ring or cylinder Replace piston ring wall abraded seriously cylinder 5.3.2 Engine working unstable Item Cause Solution Fuel contains moisture Use new fuel Fuel Fuel deposited for a long time Use new fuel Dredge clean fuel Fuel supply Fuel supply circuit half blocked supply circuit...
  • Page 23 Remove carbon, adjust Sparkplug carbon deposited or failure clearance to specified value or replace spark plug Throttle valve sensor failure (EFI) Check and replace Intake pressure sensor failure and tube Check and replace fault(EFI) Water temperature sensor fault (EFI) Check and replace O2 sensor fault Check and replace Idling actuator fault(EFI)
  • Page 24 Item Cause Solution overload Clutch slipping Adjust or replace Dredge and remove carbon Muffler blocked deposition Adjust carburetor or ECU Fuel system Mixed gas too thick or too rare data Lubricating oil too less Add to upper line Lubrication Lubricating oil grade incorrect or quality Replace correct grade...

  • Page 25: Annex Files

    gear Friction plate thickness improper Replace f ilur 5.3.7 Gear shift fault Item Cause Solution Shifting fork deformed or broke off Check and replace Gearshift Variable shaft active plate reset spring Check and replace failure dropped /cracked Variable shaft reset spring slip off Check and replace Solve per clutch trouble Clutch separated not completely...

  • Page 26: Annex 1 E02 Outline Drawing

      Annex 1  E02 Outline drawing 外形接口图 第 - 26 - 页...

  • Page 27: Annex

    Annex 2  Carburetor wires connection schematic Diagram 化油器接线原理图  第 - 27 - 页...

  • Page 28: Annex

    Annex 3  EFI wires connection schematic Diagram 电喷接线原理图  第 - 28 - 页...

  • Page 29: Annex 4 Carburetor Wires And Connector Model

    Annex 4  Carburetor wires and connectors model 化油器线束及接插件型号  第 - 29 - 页...

  • Page 30: Annex 5 Efi Wires And Connector Model

    Annex 5  EFI wires and connectors model 电喷线束及接插件型号  第 - 30 - 页...

This manual is also suitable for:

Gk194ms

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