Linhai M565Li T3 EFI Service Manual

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2020 ATV

SERVICE MANUAL

M565Li T3 EFI

WARNING

The parts of different types/ variants/ versions maybe un-interchangeable, even some parts

have almost same appearance. Always refer to Parts Manual of each ATV model for spare

parts information and service.

PN.

F010106A27

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20.0

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Summary of Contents for Linhai M565Li T3 EFI

Page 1 2020 ATV SERVICE MANUAL 20.0 F010106A27 M565Li T3 EFI WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 2 ATV SERVICE MANUAL EUROPE 20.0 F010106A27 M565Li T3 EFI 维修手册英文版本 20.0 零件代号 F010106A27...
Page 3 Foreword This manual is designed primarily for use by the ATV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
Page 4 CONTENTS ↖ CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3……………………………………. …. ………………500 Engine ↖ CHAPTER4…………………………………………..…………………Chassis ↖ CHAPTER5………………………………………………….………Final Drive ↖ CHAPTER6………………………………………………………………Brakes ↖ CHAPTER7………………………………………………….….………Electrical...
Page 5 WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
Page 6 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 1 GENERAL INFORMATION WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 7 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
Page 8 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ①, make sure that the sharp-edged corner ② is positioned opposite the thrust ③...
Page 9 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE...
Page 10 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 V.I.N AND ENGINE SERIAL NUMBER PAGE. 1- 5 CHAPTER 1 GENERAL...
Page 11 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 M565Li VEHICLE DIMENSIONS Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. PAGE. 1- 6 CHAPTER 1 GENERAL...
Page 12 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 M565Li PAGE. 1- 7 CHAPTER 1 GENERAL...
Page 13 CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0 NOTES PAGE. 1- 8 CHAPTER 1 GENERAL...
Page 14 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 CHAPTER 2 MAINTENANCE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 15 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
Page 16 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 Item Hours When Remarks Service (Main) Brake Pre-ride System Auxiliary (Secondary) Brake / Pre-ride Parking Brake Pre-ride Tires Pre-ride Wheels Pre-ride Frame nuts, bolts fasteners Pre-ride Air Filter-Pre-Cleaner Daily ▲ Coolant/Level Daily Coolant Annually Coolant strength...
Page 17 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 Engine Oil Change 30 hrs 3 months Break-in Service at 1 month. Change oil more often in cold weather use. ▲ Oil Filter 50 hrs 6 months ▲ Engine breather hose 100 hrs 6 months Carburetor Float Bowl 50 hrs...
Page 18 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 (H/L/R/N) Brake fluid Level Pre-ride Brake fluid 200 hrs 24 months Change every two years Idle Speed Required Toe adjustment Periodic inspection, adjust when parts are Required replaced Headlight Aim Adjust if necessary Required ▲...
Page 19 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 ▲ 13.Swing Arm Grease Locate fittings and grease Monthly or 20 hours Bearing ▲ 14.Throttle Grease M Grease, inspect and replace it Monthly or 20 hours Cable if necessary 15. Rear prop shaft Grease Locate fittings and grease Every 3 months or 50...
Page 20 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.2 FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 21 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 VENT LINES AND ROLL OVER VALVE* Fuel Pump Module 1. Check fuel tank, oil tank, battery, and Description and Working Principle transmission vent lines for signs of wear, deterioration, damage leakage. Fuel Pump Module supplies fuel to engine at Replace every two years.
Page 22 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 the label available on fuel module cover. disconnecting fuel lines, please follow the “Fuel On Fuel Pump Batch code is engraved on Pressure Relief Procedure” described pump body (shell). in this section. Small amount of fuel may drip after the fuel On Fuel Pressure Regulator, batch code is engraved on regulator dome area.
Page 23 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 Fuel Module Orientation: Fuel module bolts not Connections are now safe for servicing. Upon the completion of servicing, Connect symmetrical and can be mounted only in the intended direction. Regulator side Fuel Module Connector to Vehicle Harness should be facing the Fuel Tank rear side.
Page 24 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.3TOE ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered NOTE: String should just touch side surface of rear tire on each side of the ATV. Measure from string to rim at front and rear of rim.
Page 25 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.4 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.
Page 26 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 1. First check foot brake effectiveness by applying a 25 kg (50 lb). (Approx) downward force on the pedal. The top of the pedal should be at least 1 CONTROLS inch, (25 .4m m) above the surface of the Check controls for proper operation, footrest.
Page 27 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 1. With the engine off, apply the parking brake lever and attempt to move the ATV. 2. If the rear wheels are locked, it is adjusted properly. 3. If the wheels are not locked, it must be adjusted.
Page 28 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 Adjusting To adjust (set up) the mechanical drum brake, use the following procedure. 1. Loosen the jam nuts of the adjuster on the right hand of right and left brake cable. 2. Turn the both adjusters keep the rock arm on the lever balance until 1/8”...
Page 29 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen ents. Adjust sion spring preload requirem sary. neces FRONT SUSPENSION Compress and release front suspension. Damping should be smooth throughout the range of travel.
Page 30 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.6 WHEELS Inspect all wheels for runout of damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB TORQUE TABLE Front Wheel Nuts 69 Ft.Lbs 96 N.m Rear Wheel Nuts 69 Ft.Lbs...
Page 31 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.7 TIRE PRESSURE TIRE INSPECTION CAUTION : Tire Pressure Inspection  Maintain proper tire pressure. Refer to the Front Rear warning tire pressure decal applied to the vehicle. Improper tire inflation may affect ATV maneuverability.
Page 32 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 2.8 FRAME , NUTS, BOLTS, FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. Torque （Ft-Lb）...
Page 33 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 20...
Page 34 CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0 CHAPTER 2 MAINTENANCE PAGE. 2- 21...
Page 35 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 3 ENGINE 3.1 Service information ................ 1-17 3.2 I and adjustment ............... 18-28 nspection 3.3 Engine Removal, Inspection and Installation ......... 29-89 3.4 Cooling and lubrication system ............90-100 3.5 Fuel injection system ..............101-121...
Page 36 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1 Service information...
Page 37 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Unit conversion table ................3-1 3.1.1 General precautions ..............3-2 3.1.2 Fuel, oil and engine coolant recommendation ......3-3 3.1.3 Engine running-in ............... 3-3 3.1.4 Engine shape & location of ....3-4 engine identification number 3.1.5 Engine general information ............
Page 38 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Unit conversion table Item Conversion Pressure 1kgf/cm =98.0665kPa 1kPa=1000Pa 1mmHg=133.322Pa=0.133322kPa Torque 1kgf·m=9.80665N·m Volume 1mL=1cm =1cc 1L=1000cm Force 1kgf=9.80665N DANGER/WARNING/CAUTION Please read the following notification carefully which emphasize the special meaning of DANGER, WARNING and CAUTION. Always pay attention to these notifications when servicing the engine.
Page 39 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 safety beside the notification of DANGER and WARNING. If you are not confident to complete the whole repair, please refer to the senior mechanic for support. 3.1.1 General precautions Warning: Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle.
Page 40 In order to protect the environment, do not unlawfully dispose of motor oil, · engine coolant or parts no longer used. Warning： If parts replacement is necessary, replace the parts with LINHAI · genuine parts or their equivalent. When removing parts that are to be reused, keep them arranged in an ·...
Page 41 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1.2 FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL: Use unleaded gasoline that is Graded 92 octane or higher. ENGINE OIL: Use 4-stroke motor oil, the oil need to meet API service Classification SG or higher.
Page 42 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Avoid acceleration heavily. T he accelerator should be changed smoothly, avoid changing heavily from small to bigger 10～20 hours Avoid prolonged operation above three-quarter throttle. Allow using freely but not full throttle.
Page 43 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1.4 ENGINE SHAPE & LOCATION OF ENGINE IDENTIFICATION NUMBER(EIN) Location of Engine identification number CHAPTER 3 ENGINE PAGE. 3-...
Page 44 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Engine left side Engine Right side 3.1.5 ENGINE GENERAL INFORMATION CHAPTER 3 ENGINE PAGE. 3-...
Page 45 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ITEM TYPE/SPECIFICATION Type Single-cylinder, liquid-cooled, 4-stroke, SOHC 91mm×76.8mm Bore × Stroke 499.5mL Displacement 10.3:1 Compression ratio 1500r/min±100r/min Low idling speed(Idling) Electric Starting ignition type/ ECU / BTDC1 0º 1500r/min ignition timing...
Page 46 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 park Gearshift methods/ Manual operation/L-H-N-R-P orders Drive train CVT ratio range 3.106～0.677 system Final ratio Gearshift 1.333（24/18，bevel gear） ratio Secondary 1.952(41/21)， ratio Variable L:2.53(38/15)； gear H：1.35(27/20) ；R:2.07(29/14) Total ratio L:6.595；H：3.514 ；R:5.392 Overall size L （mm）...
Page 47 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Cylinder, Piston, Piston Ring & Crankshaft (mm) Item Standards Service limit Remarks Cylinder compression 1000kPa Piston/Cylinder clearance 0.030～0.050 0.10 Dia. of Piston 90.95mm～90.979 mm down along to the piston 90.85 Inner diameter of cylinder 90～91.015...
Page 48 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Inner diameter of piston pin hole Diameter of piston pin 21.980 0.1～0.45 Inner diameter of small end of connecting rod 22.06 Gap of piston/piston pin 22.95～23.00 Small hole 0.08 connecting rod / gap of piston pin 0.08...
Page 49 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Continue (mm) To Be Item Standards Service limit Remarks Thickness of big end of 22.95～23.00 connecting rod Crankshaft beat 0～0.025 0.055 Connecting rod bearing 36.068 36.992～36.996 journal Connecting rod bearing 37.006～37.028 37.06...
Page 50 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1.6 MAINTENANCE SPECIFICATIONS Lubrication System Item Standards Service Limit － Oil Change （ without 2600mL filter replacement） Engine Oil 2700mL （ with oil filter replacement） Oil Change Capacity 3000mL Oil Capacity －...
Page 51 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 3 ENGINE PAGE. 3-...
Page 52 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 COOLING SYSTEM Item Standards Service Limit Opening temperature 65℃±2℃ Fully opening 85℃ Thermostat Travel when fully opening When 85℃,≥5mm Radiator cap opening pressure 110 kPa±15kPa(1.1kgf/cm Water Resistant of Resistant of temperature...
Page 53 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 -35℃ anti-freezing, anti Coolant type –corrosive and high boiling point CHAPTER 3 ENGINE PAGE. 3-...
Page 54 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Clutch + Transmission mechanism (mm) Item Standards Service limit Remarks Belt width 35.2 33.5 Free length of driven pulley 238.5 spring Hole dia. of driven pulley 38.30 38.10～38.14 collar Clearance between gearshift fork and 0.10～0.35...
Page 55 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Throttle Body Part NO. 1BK-13520-00 Fuel Injector Part NO. 1BK-13510-00 Idle Speed 1500 r/min ± 100r/min CHAPTER 3 ENGINE PAGE. 3-...
Page 56 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Electric system Item Sta n d a rds Remarks Type (NGK) DPR8EA-9 Gap of Sparkplug 0.8mm ～0.9mm sparkplug Characteristic ＞8mm, u n d e r 0.1MPa Primary 0.74Ω～0.78Ω Resistance of ignition coil 10.1Ω～11.1kΩ...
Page 57 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1.7 Engine tightening Torque list Torque Dia. Of Item Remarks （N·m） thread(mm) Oil drain bolt M12×1.5 M12×1.5 28～32 OIL PASSAGE BOLT M14×1.5 M14×1.5 32～36 (left case) Plug screw, oil passage Thread M6×12...
Page 58 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Bolt, timing sprocket M6×10 8~12 Bolt, decompressor, starter M8×32 28~32 Bolt, cylinder 40~45 Bolt, cylinder installation M6×132 8~12 Plug, spark M12×1.25 18~20 Sensor, water TEMP M12×1.5 16~20 Thread Stud bolt M8×42（exhaust port）...
Page 59 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Dia. Of Torque Item Remarks （N·m） thread(mm) Plug, Screw M12×1.5 M12×1.5 28~32 Bolt M6×45(thermostat cap) M6×45 6~10 Injector seat installation bolt M8×25 20~25 Bolt COMP. Cylinder head cover Thread tension plate pin...
Page 60 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 bevel gear) Nut, Driven Bevel Gear M16×1.5 140~160 Nut, Front output shaft M14×1.5 95~100 Bolt, gear orientation Thread M14×1.5 38~42 locker glue Bolt, oil pump cover Thread M5×16 locker glue Bolt, oil guard Thread M6×12...
Page 61 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.1.8 Engine Service Tools Measurement Tools Measurement Tools Description Specification Purpose Vernier Caliper 0-150mm For measuring the length and thickness Micrometer 0-25mm For measuring outer diameters of rocker arm, valve stem...
Page 62 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Special Tools Description Specifications Purpose Remove magneto rotor Rotor assy puller 1BE-85610-00 Bearing retainer, nut wrench Removal of Front output shaft Bearing retainer LH188MR FZ/24 Bearing limit nut,nut wrench For removing Bearing limit nut...
Page 63 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Materials for Operation and Fixing Materials for engine operation engine oil, grease and coolant. Fixing materials include sealant, thread locker, etc. Description Type Application Area Remark 4-stroke motor oil Cylinder rotating parts,...
Page 64 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.2 INSPECTION AND ADJUSTMENT 3.2.1 Period maintenance table ..............3-18 3.2.2 Procedure of Maintenance & Adjustment ........3-19 3.2.3 Valve clearance ................3-19 3.2.4 Engine idle speed ................3-20 3.2.5 Spark plug ..................3-20 3.2.6 Air filter ....................
Page 65 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0...
Page 66 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.2.1 Period maintenance table Engine maintenance is a periodic job, careful periodic maintenance is very important, will assure your vehicle having a good performance, reliability, economy and durability. Details are explained in below 191MR engine periodic maintenance ATTENTION：...
Page 67 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Air Filter CVT Belt Replace every 2000km system Primary Pulley, I， Driven pulley Engine oil, filter Throttle Body I， L Water volume Water pipe Cooling Radiator valve 0.75 kg/cm～1.05kg/cm System opening pressure...
Page 68 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.2.2 Procedure of Maintenance & Adjustment This section describes the maintenance procedures for each item mentioned in the periodic maintenance chart. Inspect initially at 20-hour break-in and every 40 hours or every 1000km thereafter.
Page 69 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Attention: ● The valve clearance must be adjusted when the engine is cold. ● Adjust the valve clearance when the piston is at the Top Dead Center (T.D.C.) CHAPTER 3 ENGINE...
Page 70 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● If the clearance is incorrect, bring it into the specified range using the special tool. Loosen valve adjust bolt and nut, insert a feeler gauge between the valve stem end...
Page 71 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Tool： Tachometer 3.2.5 SPARK PLUG Inspect initially at 20 hours run-in and every 100 hours or 3000km thereafter. ● Remove the spark plug(1) with a special tool； Specification: DPR8EA-9(NGK) ● Spark plug inspection：If the electrode...
Page 72 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Tool： Spark Plug Wrench Feeler Gauge Inspect every 20 hours or 750km, clean it if necessary Change it every 1500km 3.2.6 AIR FILTER If the air cleaner is clogged with dust, in-...
Page 73 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Warning: Never use with gasoline or low flash point solvents to clean the filter element. ● Inspect the filter element for tears, torn Note: Make sure that the air filter element is in good condition at all times.
Page 74 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Inspection ● Inspect CVT friction disk for wear and damage. If any cracks or damages are found, replace CVT with a new one. ● Inspect drive belt for wear and damage.
Page 75 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Caution: Fit the drive belt with the arrow on the drive belt points towards normal turning direction. Bolt, drive pulley：55~60N.m ● Screw off Driven Expander, turn pulley , until the drive belt is properly driving pulley seated.
Page 76 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ●Clean oil dip rod, insert oil dip rod but do not tighten it oil dip rod ● Take out oil dip rod and check if oil is between upper and lower limit.
Page 77 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Install oil dip rod, start the engine and allow it to run for several minutes at idling speed. ● Turn off the engine and wait for about 3 minutes, and then check the oil level the dipstick.
Page 78 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Oil Filter Element Inspection Check and clean the engine oil filter inlet 1 and outlet area 2 for dirt and other contaminations. Oil Filter Element Installation Install a NEW o-ring on oil filter cover, Apply engine oil on o-ring and the end of filter;...
Page 79 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 per and the lower limit on the reservoir tank. If the level is below lower limit, fill coolant until the level reaches the upper limit. Replacing Coolant ● Remove radiator cap (1) and reservoir tank cap (2) ●...
Page 80 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Start the engine and keep it running for several minutes. After warm up and cooling down the engine, open radiator cap and check coolant. Fill the specified coolant until the level is between the upper and lower lines on the reservoir tank.
Page 81 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Excessive wear of cylinder ● Wear of piston or piston ring ● Piston ring jam in groove ● Poor closure of valve seat ● Damaged cylinder gasket or other defects Note：...
Page 82 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Tools: Cylinder Pressure Gauge CHAPTER 3 ENGINE PAGE. 3-...
Page 83 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.3 Engine Removal, Inspection & Installation 3.3.1 Removal/Installation Orders and the Page Numbers table ....3-29 3.3.2 Engine Removal ................3-31 3.3.3 Engine Inspection ................3-41 3.3.4 Engine Installation ................3-78...
Page 84 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.3 Engine Removal, Inspection & Installation 3.3.1 Engine Removal/Installation Orders and the Relative Page Numbers Disassemb Inspection/M Assem Remark Item Description aintenance Spark Plug 3-31 3-20 3-88 Cylinder Head Cover 3-31...
Page 85 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Timing Chain 3-34 3-62 3-83 Starting Motor 3-34 3-83 Sector Gear 3-35 3-62 3-80 Water Pump 3-35 3-63 3-82 3-36 3-82 Engine Left Side Oil filter 3-36 3-63 3-82 Left Crankcase Cover/...
Page 86 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Front Output Shaft Components/ 3-38 3-70 3-79 Driven Bevel Gear Components Bevel Gear 3-39 3-71 3-79 Components Engine Transmission Main 3-39 3-72 3-78 Center Shaft Shift Drum / Shift 3-39 3-73...
Page 87 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.3.2 Engine Removal Preparation before engine removal ● Prepare a proper tray used for load of components ● Prepare necessary removal and assem bly tools ● Drain up engine oil（see5.2.8） ● Drain up coolant（see5.2.9）...
Page 88 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove tensioner and gasket CHAPTER 3 ENGINE PAGE. 3- 33...
Page 89 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Start decompression COMP ● Remove bolt (1)，Remove Start decompression COMP (2) Timing driven sprocket ● Loosen two bolts (1) of timing driven sprocket ● Remove timing driven sprocket Camshaft, rocker arm ●...
Page 90 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 diagonally ● Remove cylinder head ● Remove guide chain plate ● Remove dowel pin and cylinder head Note: Take care not to drop dowel pin into crankcase gasket CHAPTER 3 ENGINE...
Page 91 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Cylinder ● Remove cylinder Piston Put a clean rag under piston so as not to drop piston pin circlip into crankcase. Warning: Piston pin circlip is spring- loading ● Remove piston pin circlip (1) and discard it.
Page 92 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Drive pulley / driven pulley /Drive Belt ● Remove drive pulley with special tools ● Remove drive pulley / driven pulley /drive belt Tool: Drive pulley puller (3) (1BX-17653-00) CVT Case ●...
Page 93 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove bolt of CVT case ● Remove CVT case ● Remove dowel pin Remove paper gasket and discard it. Chain holder, Tension plate ● Remove bolt 1 of tension plate Remove tension plate 2 ●...
Page 94 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove starting motor Sector Gear ● Remove 4 bolts of sector gear housing cover ● Remove sector gear housing cover 1 ● Remove dowel pin and gasket ● Remove drive sector gear ●...
Page 95 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Water Pump ● Screw out bolt of water pump ● Remove water pump Side Cover ●Remove 4 bolts, remove Side Cover CHAPTER 3 ENGINE PAGE. 3- 40...
Page 96 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove 3 bolts, remove cap Oil Filter ● Screw out 3 bolts of filter cover ● Remove filter cover, O ring ● Remove oil filter Left Crankcase Cover/Magneto Stator CHAPTER 3 ENGINE...
Page 97 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove bolts of left ● Remove left crankcase cover ● Remove dowel pin and gasket Magneto Rotor ● Remove nut of Magneto Rotor ● Install special tool to rotor thread...
Page 98 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Oil pump drive gear/Oil pump dual gear ● Remove oil guard bolt ● Remove oil guard (1) ● Remove two Circlip (2) by circlip plier ● Remove oil pump drive gear (3), oil...
Page 99 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove needle bearing (5) ● Remove pin shaft (6), gasket Engine Center Gear position bolt ● Remove gear position bolt (1) ● Remove spring and steel ball Right Crankcase ● Remove left crankcase bolts CHAPTER 3 ENGINE PAGE.
Page 100 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove right crankcase bolts ● Separate crankcase carefully with rubber hammer knocking the case Front Output Shaft, Driven Bevel Gear ● Remove nut of Real output coupler( 1) ● Remove bevel gear cover bolt ●...
Page 101 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove nut 1 , gasket 2 , front output coupler 3, oil seal 4, front output shaft bearing ring 5(LH) ● Remove Front Output Shaft 6 Drive Bevel Gear ●...
Page 102 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Transmission Main Shaft ● Remove transmission main shaft 7 Shift Drum, Shift Fork, Drive counter- shaft ● Remove shift drum 8, shift fork 9, and drive countershaft 10 CHAPTER 3 ENGINE...
Page 103 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Note: Shift drum, shift fork and drive countershaft should be removed together. Crankshaft ● Remove crankshaft from left crankcase Balance Shaft ● Remove balancer shaft from left crank- case Oil bump ●...
Page 104 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Filter Net ● Screw out the bolt ● Remove filter cap (2) ● Remove filter net CHAPTER 3 ENGINE PAGE. 3- 49...
Page 105 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.3.3 Engine Inspection Cylinder Head Cover CHAPTER 3 ENGINE PAGE. 3- 50...
Page 106 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Cylinder Head Cover 2.Cylinder Head Cover Seal Ring Check if any scratch is on the cap. Check is any crack, crush or hardening on the sealer ring. If so, change accordingly.
Page 107 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Move pressure reducing arm 4. Check if pressure-reducing rocker arm and cam- shaft can move flexibly and return automatically. Timing Driven sprocket ● Check any scratch or damage on cam- shaft timing chain wheel.
Page 108 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Test tolerant clearance of camshaft sides and cylinder cap Camshaft bearing hole(timing chain side) 35.007mm～35.025 mm New part Maintenance limit 35.040 mm Camshaft bearing hole(spark plug side) New part 22.012mm～22.025 mm Maintenance limit 22.040 mm...
Page 109 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Rocker Arm Inspection ● Inspect each rocker arm for cracks and 1. Washers scored friction surfaces. If any, replace 2. Rocker Arm, Exhaust rocker arm assembly. 3. Cylinder Head Spark Plug Side 4.Big Taper to Spark Plug Side...
Page 110 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Check for scored friction surfaces; if any, replace parts. ● Measure rocker arm shaft diameter. Rocker Arm Shaft Diameter 11.973mm～11.984mm Service Limit 11.960mm Any area worn excessively will require A. Measure rocker arm shaft diameter here parts replacement.
Page 111 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Align valve spring compressor clamp with the center of Valve ● Remove valve lock clips. ● Withdraw valve spring compressor, valve spring retainer and valve spring. Valve Spring Compressor Clamp 2.Valve Spring Compressor Cup 3.Valve lock clip...
Page 112 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Valve Spring Inspection ● Check valve spring for visible damages, If any, replace valve spring. ● Check valve spring for free length and straightness. Valve Spring Free Length Normal New 40 mm Service Limit 38.2 mm...
Page 113 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove valve stem seal with Snap-on plier and discard it. Plier 1. Plier Valve Stem Seal Valve Inspection Valve Stem Seal Always install new seals whenever valves are removed Valve ●...
Page 114 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Valve Out of Round (Intake and Exhaust Valves) 0.005 mm Service limit 0.06 mm Valve Stem and Valve Guide Clearance ● Measure valve stem and valve guide in three places using a micrometer and a small bore gauge.
Page 115 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Valve Seat Area 3.Valve Face(Contact Surface to Valve Seat) Exhaust Valve Contaminated If valve seat contact width is too wide or has dark spots, replace the cylinder head. Valve Face and Seat ●...
Page 116 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Valve Contact Surface Width B. Valve Seat Contact Width NOTE: Clean valve guide area from contamination before removal. Valve Guide Removal ● Use valve guide remover and a hammer, drive the valve guide out of Valve Guide Remover cylinder head.
Page 117 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 stalling the valve guide into cylinder head. Injector Seat ● Unscrew the set bolt and remove the injector seat (1) Injector Seat Inspection ● Inspect Injector Seat for cracks or other damage.
Page 118 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Sensor. ● Water Temperature Sensor Inspection (Check 5. 4. 6) ● Thermostat Inspection (Check 3.4.7) CHAPTER 3 ENGINE PAGE. 3- 51...
Page 119 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Cylinder Head Installation Valve Guide Installation For installation, reverse the removal procedure. Pay attention to the following details. ● Use valve guide installer to install valve guide. NOTE: Apply loctite (antiseize lubricant) on valve guide prior to install it into the cylinder head.
Page 120 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1. Thrust Surface of Cylinder Head 2.Valve Guide A. Measurement from Thrust Surface to Valve Guide Top CHAPTER 3 ENGINE PAGE. 3- 53...
Page 121 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Valve guide to be adjusted in diameter by using a reamer. Valve Guide Diameter (Intake and Exhaust Valves) 5.000mm～5.012 mm Valve Installation For installation, reverse the removal procedure (Check 5-45).Pay attention to the following details.
Page 122 NOTE: Ensure to turn reamer in the right CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 direction. Use cutting oil and make brakes to clean reamer/valve guide from Valve Guide metal shavings. Valve Guide Diameter Valve Seat Valve Face(contact surface to valve...
Page 123 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Position of the Valve Spring 2.Valve Cotter ● Apply engine oil on rocker arm shaft. ●Install the rocker arm shaft with the chamfered edge first and use following procedure. 1、Insert a rocker arm pin through rocker arm pin bore.
Page 124 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Thermostat Installation ● Install Thermostat seat ( 1), Thermostat(2),Thermostat cover (3) and two bolts (4) Note: Don’t miss to install the “O” seal ring Injector Seat Installation ● For installation, reverse the removal procedure (Check 3-48).
Page 125 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Check the planeness of gasket surface, total 7 point to inspect with a straight edge and thickness gauge. Take clearance readings from several places. If any clearance reading is out of the service limit, replace with a new cylinder body.
Page 126 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Pistion Pistion Diameter ● Inspect pistion for cracks or other damage. Replace pistion and pistion ring if necessary. ●Vertical measure the pistion on the 8mm direction between pistion micrometer Replace pistion if out of service limit.
Page 127 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Service limit (Width) Pistion ring 1: 1.21mm~1.23mm Pistion ring 2: 1.51mm~1.53mm Oil ring: 2.50mm~2.52mm Service limit (Thickness) Pistion ring 1: 1.17mm~1.19mm Pistion ring 2: 1.47mm~1.49mm Tool: Straight edge Micrometer (0~25mm) Pistion ring free gap and pistion ring end gap ●...
Page 128 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Pistion Pin and Pin Bore ● To measure the inner diameter of Pistion pin bore by Bore dial indicator. To measure the outer diameter of Pistion pin by micrometer If out of service limit, replace Pistion and Pistion pin Pistion Pin Bore (service limit): 22.02mm...
Page 129 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Inspect seal ring of CVT Cover for ageing, damage. Replace a new one if necessary CHAPTER 3 ENGINE PAGE. 3-...
Page 130 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Drive Pulley, Driven Pulley, Drive Belt CHAPTER 3 ENGINE PAGE. 3-...
Page 131 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1 、Drive Pulley Fixed Sheave 10 、Driven Pulley Fixed Sheave 2 、Drive Belt 11 、Driven Pulley Sliding Sheave 12 、Spring holder 3、Ajusting Washer 13 、Locating pin 4、Spring, Drive Pulley 14 、Circlip 5、Drive Pulley Sliding Sheave...
Page 132 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Drive Pulley ● Loosen Drive Pulley Nut, remove, CVT, Drive pulley fixed And Sliding Sheave ● Remove the Cam (1) an d Centrifugal Weight (2) Centrifugal Weight Inspection ● Inspect Centrifugal Weight and Sliding...
Page 133 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Inspect the abnormal conditions of drive surface for multistep wear or other damage. Replace it if abnormal ● Inspect one-way clutch if equipped. Replace it if abnormal Drive Pulley Installation...
Page 134 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Special tool: Driven pulley spring compressor (1BA-17730-00 FZ/1) Driven Pulley Spring Compressor Driven Pulley ● Turn special tool handle to compress the cam and spring. Using a circlip remover (a plier), remove circlip.
Page 135 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Circlip Remover CHAPTER 3 ENGINE PAGE. 3-...
Page 136 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Slowly loosen tool handle to release the spring tension and remove the special tool; Remove cam; Remove guide pin; Remove spring and sliding sheave of driven pulley. 1. Cam 2.Guide Pin 3.Spring...
Page 137 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 or visible damage. Replace if necessary. NOTE: Clean fixed sheave of driven pulley before inspection. 1. Drive Face of Fixed Sheave NOTE: Driven pulley assembly is precisely matched. If only fixed sheave or sliding sheave is replaced, the vibration may increase.
Page 138 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Driven Pulley Sliding Sheave Inspection ● Inspect the drive face of sliding sheave for heavy wear and damage. Replace it if necessary. NOTE: Driven pulley assembly is precisely matched. If only fixed sheave or sliding sheave is replaced, the vibration may increase.
Page 139 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 A ≥ 1.5mm Cam Inspection ● Check spring cam sliding face for wear and other damages. Replace if necessary. CHAPTER 3 ENGINE PAGE. 3-...
Page 140 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 2.Sliding Face Driven Pulley Spring Inspection ● Check spring free length. If it is shorter than limit length, replace it. Spring free limit length A: 214.0mm. Driven Pulley Assembly Spring Reverse the disassembly procedure for driven pulley assembly.
Page 141 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Caution: Clean the Drive belt if any greasy dirt or lubricating oil. CVT Case Inspection ● Inspect Bearing Sleeve (1) and Oil seal (2).Replace it if necessary Lower Timing Chain Guide Inspection ●...
Page 142 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ageing. Replace it if necessary. Timing Chain Inspection ● To inspect the radial clearance of timing Chain. ● To inspect timing chain for excessive wear Replace timing chain and timing chain...
Page 143 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ●Periodic replacement oil filter base on requirements of Maintenance period. Crankcase (LH) Cover ● To inspect magneto coil (2) for damage or Short circuit, Replace it if abnormal. ●Smear Thread-locking Adhesives on bolts and fasten base on standard torque while assembling.
Page 144 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● To inspect the overrun clutch roller and Cam for wear or damage. Replace it if defected. ● To install the overrun clutch as right Note:To confirm the direction is right while Assemble the overrun clutch into magneto rotor.
Page 145 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Install the driven gear bearing by special tools Tool： Bearing installation & removal tool Dual Gear ● To inspect the dual gear surface for scratch or bump against. Replace it if abnormal.
Page 146 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● To inspect the gear surface for scratch, bump against or plastic ageing. Replace it if abnormal Oil Pump Dual Gear ● To inspect the gear surface for scratch, bump against or plastic ageing. Replace it...
Page 147 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 3 ENGINE PAGE. 3-...
Page 148 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Crankcase(Right) 10.Crankcase(Left) 19.Bearing Oil seal 11“ . O” ring seal 20.Bearing Bearing 12.Speed sensor 21.Bearing bush Bearing 13.Bearing bush Bearing 14.Oil strainer 22.Lower timing chain guide 6.Bearing 15“ .O” ring seal 23“...
Page 149 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1、Plain bearing bore diameter Plain Bearing Replacement Plain Bearing Removal Caution: Always support crankcase halves properly when ball bearings or plain bearings are removed .Damages to crankcase halves may occur if this procedure is not performed correctly.
Page 150 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CAUTION: Unless otherwise instructed, never use hammer to install ball bearings or plain bearing Install plain bearings with the proper plain bearing remover/installer in a cool crankcase. Do not lubricate plain bearing and /or crankcase for installation.
Page 151 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 after Cleaned and lubricated the ball bearing. Replace it if abnormal by special tools. ● To inspect all oil sealing for wear, cracks. Replace it if abnormal by special tool ●...
Page 152 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Drive Bevel Gear ● To protect the drive bevel gear shaft by one clean duster cloth and clamp by vise ● Loosen the Drive Bevel Gear Nut (3),re- move Drive Bevel Gear(4) and Adjusting spacer(5).
Page 153 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Note: Drive Bevel Gear (4) and Driven Bevel Gear should be together replaced. Front Output Shaft ● To inspect Bearing (7) for wear or well running. To inspect Oil seal (5) for damage.
Page 154 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● To install by use new oil seal(17) and “O” ring seal (13) ● To adjust Adjusting Spacer (14) if replace any one of Crankcase (Right), Driven Bevel Gear (9), Driven Bevel Gear cover (15).
Page 155 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Tool: Bevel Gear backlash measuring tool Dial indicator a=46mm ● To measure backlash by running the Note: Four points to measure on the mutual vertical direction. Driven Bevel Gear shaft. ● To adjust spacer thickness if out of ser- vice limit.
Page 156 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Gear Surface Contact Inspection To inspect Gear surface contact after back- lash adjusted. Detail as follows： ● Remove Drive and Driven Bevel Gear Shaft from Crankcase. ● Clean splodge and grease for each gears of Drive and Driven Bevel Gear.
Page 157 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 standard requirement. Drive Shaft Inspection ● To inspect gear surface for hard spot, damage, excessive wear. Replace it if necessary. Drive layshaft Combination ● To remove the layshaft as picture ● To inspect gear surface for hard spot, damage, excessive wear.
Page 158 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ●To inspect shifting fork clearance as pic- ture indication: Check fit clearance by feeler gauge. Replace shifting fork ,or gears, or together replacement if clearance out of service limit Shifting fork standard gap: 0.10mm～0.35mm...
Page 159 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Standard values: 6.05mm～6.15mm ● To measure the thickness of shifting fork by vernier caliper Standard values: 5.80mm～5.90mm To inspect shifting fork ① and ② for ● damage, curve. Replace it if with defects.
Page 160 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● To roll the shift fork rod on the slab. Re- place it if curve Caution: Don’t try to straightening the Shift fork rod. ●To inspect the shift fork spring for broken, damage.
Page 161 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Installation Reverse process for installation and removal. Attention as follows: Note: With right installation process to install the new retainer To install it base on picture indication Gears or shaft should be installed with Caution: Retainer ring couldn’t reuse if removed...
Page 162 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 NOTE: Check each bearing journal of crankshaft for scoring, scuffing, cracks and other signs of wear. NOTE: Replace the crankshaft if the gears are worn or otherwise damaged. CAUTION: Components with less than the service limit always have to be replaced.
Page 163 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 connecting rods crankshaft counterweight. Connecting Rod Big End Axial Play 1. Crankshaft 0.130mm～0.350mm 2.Connecting Rod 3.Gauge Balance Shaft ● To inspect balance shaft and balance shaft gear Replace it if damage.
Page 164 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Replace oil pump if out of service limit Bottom Clearance standard value: 0.1mm～0.15mm Limit value: 0.2mm Backlash Standard value： 0.08mm～0.15m Limit value：0.2mm 3.3.4 Engine Installation The installation essentially the reverse of CHAPTER 3 ENGINE PAGE.
Page 165 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 the removal procedure, special attention as follows: Caution: Without any grease in belt, drive and driven pulley Middle parts of Engine Installation Crankcase (right), Front output shaft, Shifting Drum, Shifting fork, Drive layshaft Driven Bevel Gear ●...
Page 166 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 5.Adjusting Spacer Land 6.Driven Bevel Gear 3.front output shaft 7. Coupler 4.Crankcase(right) 8.Bolt 9. Washer 10.Nut 11. Washer CHAPTER 3 ENGINE PAGE. 3-...
Page 167 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Drive Bevel Gear ● Install Drive Bevel (2) and tighten 4 bolts (1) Erection Bolt torque (M8X 28):40N.m Balance Shaft, Crankshaft, Connection Install balance shaft ● Turn the balance shaft into proper...
Page 168 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Mould assembling, light touch to well done by rubber hammer ● Tighten the bolt as standard torque Torque: M6:10N·m Note: opposite angles cross and grading to tighten the bolt. M8:25N·m CHAPTER 3 ENGINE PAGE.
Page 169 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Gears Set Bolt ● Put in steel ball, install the set bolt(1), tighten It as standard torque Standard torque: 40N·m Primary Strainer ● Install primary strainer and cover( 2) ● Tighten bolt as standard torque Standard torque:8N·m...
Page 170 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Engine (left parts) Installation Oil Pump ● Install oil pump as right picture indica-tion ● Tighten bolt ● Inspect oil pump for smooth running that hold by pliers. Replace and reinstall it if not Standard Torque ：...
Page 171 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Dual gear ● Install dual gear(1) and dual gear shaft Driven gear ● Install driven gear(3) Magnetor Rotor Combination ● Install woodruff key into crankshaft key groove ● Install Magnetor Rotor Combination ●...
Page 172 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Install left crankcase ● Install left crankcase fastening bolt Shaft Sleeve, Blanking Cap ● Install shaft sleeve ● Install blanking cap and tighten bolt. Installation keeps the Reverse procedure with removal CHAPTER 3 ENGINE PAGE.
Page 173 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Oil filter ● Install new oil filter and O ring seal, tighten bolt. Water Pump ● Install water pump and tighten bolt. Starting motor ● Install starting motor, tighten fixed bolt...
Page 174 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Upper guide chain ● Install upper guide chain NOTE: Hook up timing chain to prevent It from falling into crankcase Lower timing chain guide Install Lower timing chain guide Tensioner plate 1.
Page 175 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1. driven pulley expander 2. driven pulley 3. Drive belt Tool: Driven pulley expander ( 1BX-17654-00) CHAPTER 3 ENGINE PAGE. 3-...
Page 176 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Install CVT assy and tighten bolt and nut to the specified torque NOTE: Install bolt of drive pulley anticlockwise. Install nut of driven pulley clockwise. Drive pulley bolt tightening torque: 55~60N.m...
Page 177 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 of piston ring moving. ●The gaps of three rings should tagger 120°, and the gaps should not face the axial direction of piston pin or the main push surface of piston.
Page 178 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ●Apply a light coat of moly oil to the piston pin. ●Install piston pin into holes of piston and connecting rod small end NOTE: Piston and cylinder should be installed according to grouping pairing, PistonⅠwith cylinder 1 and PistonⅡwith...
Page 179 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Chain Guide ● Install upper guide chain( 2) ● Install dowel pin (1) and new cylinder gasket (3) WARNING: Use new cylinder gasket to prevent oil leakage. ● Rotating crankshaft, and rotate the piston to top dead center of crankshaft 1.
Page 180 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Camshaft, Rocker Arm ● Install camshaft ● Install rocker arm ● Install rocker shaft 1. Rocker arm 4. Adjusting screw 2. Exhaust rocker 5. Nut 3. Intake rocker 6. Camshaft ●Install camshaft holder into the groove of camshaft.
Page 181 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Timing Driven Sprocket ● Remove speed sensor and align the carved line of magneto and mark of left cover. If not alignment, rotate camshaft and make them be aligned. 1 .carved line of magneto ●...
Page 182 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1 .chain sprocket fastening bolt 2 .carved of timing chain sprocket 3 .the contact surface of cylinder head cov CHAPTER 3 ENGINE PAGE. 3-...
Page 183 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Timing Chain Tensioner ● Insert flat head screw driver into the end of tensioner groove, rotate clockwise and lock tensioner spring ● Install timing chain tensioner and new seal gasket (1) ●...
Page 184 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 8N.m Cylinder Head Cover ● Put rubber ring on cylinder head cover ● install cylinder head cover ● tighten bolt Spark plug ● install and tighten spark plug (3) CVT cover ●...
Page 185 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Blank page for technology improvement CHAPTER 3 ENGINE PAGE. 3-...
Page 186 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 3 ENGINE PAGE. 3-...
Page 187 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.4 Cooling and lubrication system 3.4.1 Engine cooling system chart 3.4.2 Engine coolant 3.4.3 Inspection of cooling circuit 3.4.4 Inspection & cooling of Radiator & Water Hoses Radiator Cap 3.4.5 Inspection of Fan Motor 3.4.6 Inspection of Water Temperature Sensor...
Page 188 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0...
Page 189 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.4.1Engine cooling system chart CHAPTER 3 ENGINE PAGE. 3-...
Page 190 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.4.2 Engine Coolant The cooling used in cooling system is mixture of 50% distilled water and 50% ethylene glycol antifreeze. This 50:50 mixture provides the optimized corrosion resistance and the fine heat protection.
Page 191 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 WARNING: Use high quality ethylene glycol base antifreeze and mixed with distilled water. Never mix alcohol base antifreeze and different brands of antifreeze The ratio of antifreeze should not be more than 60% or less than 50%...
Page 192 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 the cap hold the pressure for at least 10 seconds WARNING: When removing the radiator cap tester put a rag on the filler to pre- vent splash of coolant DO NOT allow a pressure to exceed the radiator cap re- lease pressure.
Page 193 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Tool: Radiator Cap Tester Radiator Inspection and Cleaning ● Remove dirt or trash from radiator with compressed air ● Correct the radiator fins with a small screwdriver CHAPTER 3 ENGINE PAGE. 3-...
Page 194 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 motor will run at full speed while the amme- ter will indicate the ampere not more than 5A. If the motor does not work or the am- pere exceeds the limit, replace the motor ●...
Page 195 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1. Radiator; 2. Radiator Cap; 3. Fan Motor; 4.Mounting Nut; 5. Thermo switch CHAPTER 3 ENGINE PAGE. 3-...
Page 196 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Inspection of Thermo switch ● Remove thermo switch ● Check the thermo switch for closing or opening by testing it at the bench as illustrated. Connect the thermo switch ¢Ù to the circuit tester, place it in a vessel with engine oil.
Page 197 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ture sensor as illustrated on the right. Con- nect the temperature sensor 2 to the circuit tester, place it in a vessel with engine oil. Place the vessel above a stove...
Page 198 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Heat the oil raise the temperature slowly and take the reading from ohmmeter ④and thermometer ③ Resistance Water Temperature Temperature （℃） 1 00 Resistance （Ω） 154±16 52±4 27±3 16±2 ●...
Page 199 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Remove thermostat housing ● Remove thermostat ● Check thermostat pellet for cracks. If necessary, replace it. ● Test the thermostat according to the fol- lowing steps: ☆Pass a string between thermostat flange...
Page 200 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ☆ Immerse the thermostat in a beaker with water. Make sure the thermostat is in the suspended position without contact to the vessel. Heat the water by placing the beaker above a stove and observe the temperature rise on a thermometer ①...
Page 201 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Water pump is on engine left crank- shaft cover WARNING: When engine is hot, do not remove radiator cap or loose coolant discharge plug screw to prevent from injury. Removal and Disassembly CHAPTER 3 ENGINE PAGE.
Page 202 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Drain coolant ● Remove radiator water outlet from wa- ter pump cover ●Remove mounting bolt from water pump cover ● Remove water pump Illustration 1. coolant drain plug screw 2. Seal gasket 3.
Page 203 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 3 ENGINE PAGE. 3-...
Page 204 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Check impeller for smooth turning ● install the new O-ring Use the new O-ring to prevent leakage; Apply grease to O-ring ● Install water pump and tighten the bolts and bleed bolt Water pump bolts tightening torque: 10N·m...
Page 205 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 ● Connect water tubes ● Inject coolant CHAPTER 3 ENGINE PAGE. 3-...
Page 206 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.4.9 Inspection of Engine Lubrication System CHAPTER 3 ENGINE PAGE. 3-...
Page 207 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Add oil to the engine parts (piston, cylin- der body, camshaft and so on) which run at high speed. Engine lubrication should be special oil. Engine oil is not only used as lubrication, but also used to wash, rustproof, seal and cool.
Page 208 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.4.10 Inspection of Lubrication system (Refer to 5.2.8 inspection of lubrication system) 3.4.11 Inspection of engine oil pump (Refer to 3-77) CHAPTER 3 ENGINE PAGE. 3-...
Page 209 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 FUEL INJECTION SYSTEM 3.5.1 ECU 3.3.2 INJECTOR 3.3.3 Throttle Body Assembly (with stepper motor) 3.3.4 Engine Cool ant Temperature Sensor 3.3.3 Intake Air Pressure and Temperature Sensor (MAP&MAT) 3.3.6 Oxygen Sensor 3.3.7 Ignition Coil...
Page 210 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0...
Page 211 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Below shows the layout of typical EMS for engine. The solid lines in the figure 1 below indicate the output signals from the Engine Controller and the dotted lines indicate the input signals to the controller from various sensors and switches.
Page 212 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.5.1.3 Handling – DOs & DONTs ACTION REASON DO NOT: Place the ECU close to the High temperature might reduce the life of exhaust pipe or Engine when removed the ECU and also can damage the ECU...
Page 213 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 and keep it dry 3.5.1.4 Installation requirements The ECU shall be mounted using M5 machined screws with a torque of 3.9Nm ±10%. The mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and warping the PCB.
Page 214 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 if the problem is caused by software/calibration. If it is caused by software/calibration, please refer to software/calibration reflashing procedure. In the event of ECU hardware failure or malfunction (during warranty period only) the ECU should be sent back to the vehicle manufacturer giving complete details of the ECU Part No, Serial number, Vehicle Model &...
Page 215 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 • Viton A (black). All other applications. Injector to manifold • Dimensions: • ID: 9.61 mm • OD: 14.49 mm • Cross-section: 2.44 mm • Materials: • Viton A (black or brown other applications.) 3.5.2.3 Seal rings replacement...
Page 216 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.5.2.5 Over-Voltage The Multec 3 injectors and the Multec 3.5 injectors can withstand a voltage of 26v for a maximum of one minute at a duty cycle of 100 ms pulse width and 200 ms period. The injector will be pressurized with calibration test fluid at normal operating pressure during the test.
Page 217 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Electrical wiring to the injector should be routed so that conductors are protected from excessive heat, damage, and wear. Avoid unnecessary handling (disconnecting and connecting) of the electrical connector. 3.5.2.9 Handling - DOs & DONTs...
Page 218 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 application DO: Take extra care when installing new fuel Prevent tearing seal ring during installation seal ring over injector inlet flange. DO: Use proper lubricants on seal ring surfaces Avoid damage to seal ring during installation.
Page 219 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 positive audible click from the connector retention device — this ensures that it is fully engaged. Avoid unnecessarily disconnecting/reconnecting the harness connector. Wires routed in a manner that can allow them to become pinched between components can result in a short circuit and a stuck open injector.
Page 220 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Check for fuel leaks with the key “on” and the engine “off” Start engine and verify proper operation 3.5.2.12 Interchange ability The injector should be replaced in service only with an equivalent injector of the same part number.
Page 221 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Disconnect the injector-cleaning tank from the system and install the fuel pump connections. Connect the fuel feed line to injector. Start and idle the vehicle for an additional 2 minutes to ensure the residual injector cleaner is flushed from system.
Page 222 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Throttle Position Sensor: Reference voltage: 5±0.1VDC Resistance between T1 and T2: 3k~12kΩ Idle Air Control Valve: Operating voltage: 7.5~14.2 VDC Solenoid resistance: 53Ω±10% Solenoid inductance: 33mH±20% 3.5.3.4 Operating Conditions Normal Operating Temperature: -30~120°C 3.5.3.5 Throttle Body Removal...
Page 223 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Reverse the procedure for installation noting the following: Adjust accelerator cable play Check to ensure that all removed parts are back in place. Reinstall any necessary part which have not been reinstalled 3.5.3.8 Precautions...
Page 224 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 DO NOT: Apply any voltage other than system Damage could occur voltage for testing. DO NOT: Apply excessive band clamp loading Damage could occur. DO NOT: Remove packing in a way that allows Minimum air leakage could be affected and/or contact between parts.
Page 225 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Dynamic Torque Requirement: The sensor shall be hand into the application and then driven by a driver with a maximum no load speed of 400 rpm or installed to the desired torque by a hand torque wrench (5/8”...
Page 226 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.5.5.1 Description and Working Principle This sensor has two functions. The first is the intake manifold air temperature, it provides a resistance that varies as a function of temperature within prescribed tolerance limits.
Page 227 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ± 0.1 VDC. 3.5.5.6 Sample Cleaning When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one...
Page 228 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Heater part resistance: 9.6±1.5Ω (This parameter is measured basing on 21°C) Operating temperature range: 260-850 °C 3.5.6.4 Fuel Quality Requirements Pb≤0.005g/L P≤0.0002g/L S≤0.04% (weight proportion)x MMT≤0.0085g/L Si≤4ppm Ignition Coil 3.5.7 3.5.7.1 Description and Working Principle This coil provides energy to the spark plug in the combustion chamber.
Page 229 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Output voltage: ~25~30KV Operating temperature: -30 ~110 °C Storage temperature: -40~155°C Mounting Torque: 8.8~11.8Nm 3.5.7.4 Installation requirements The vehicle frame provides the mounting surface and mounting holes. Mount coil close to the spark plug and keep the plug wire length very short (less than 6 “).
Page 230 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 can create an electrical short condition. DO NOT: Support the ignition system by the wiring These leads are not designed to support the weight harness or plug wire. of the ignition system. It can create a poor electrical...
Page 231 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 impact, moisture, or contamination DO: Avoid unnecessary disconnecting and The electrical connections are not designed for connecting of the electrical components. repeated connection and disconnection. DO: Insure the low voltage connectors are entirely This prevents intermittent electrical connections seated and the locking mechanism is engaged.
Page 232 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 - must be clear of moving parts (belts, fan, etc…) premature failure of ignition system. - must be protected from or kept at least 125 mm away from radiant heat source exceeding 400 F.
Page 233 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 to injure the electrode or the insulator tip DO: Regap spark plugs to the exact measurement - Too wide a gap could cause the plug to misfire (higher required ignition voltage).
Page 234 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Motor-Scanner is a precision instrument and should be protected from vibration and impact. If the unit does not run correctly or the screen is unstable when first turned on, disconnect it from the main lead and try again.
Page 235 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 The 6 PIN diagnostic connector link cable and USB type main unit’s software update cable are in the delivered package. Screen: 128×64 array high definition screen with back light for displaying all the information during testing.
Page 236 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Seconds later, the unit will display: 3.5.10. Functions Delphi Motor-Scanner can be used to diagnose Delphi Engine Management System with functions: Read DTC, Clear DTC, Data Stream, Status Stream, and Record Data.
Page 237 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Select ‘English’ and press key, it will display information about the diagnostic software version, press to continue, the interface will display as below: Diagnostic Function Here, we tak e ‘diagnostic function’ for demonstration.
Page 238 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Available functions are as follows: Read DTC Clear DTC Data Stream Status Stream Record Data Press key to select function you needed. 1. Read DTC Select ‘Read DTC’, and press , it will display fault code as below: Press key to move ‘.’...
Page 239 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 2. Clear DTC Select ‘Clear DTC’ and press, it will display as below: 3. Data Stream Select ‘Data Stream’ and press , it will display as below: Press key for page up/down to view more. Press key to exit.
Page 240 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Press key to enter code, when the first number of the code was set, press to confirm and continue to input the sequent numbers, till all the 7 numbers were input.
Page 241 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 After that, ‘Enter Week’ follows, as below: Till now, the ‘date input’ was completed, and it starts to record data, press to stop recording. Check malf code meaning by reading the below table.
Page 242 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 P0032 O2S Heater Circuit High Voltage P0031 O2S Heater Circuit Low Voltage P0201 Injector 1 Circuit Malfunction P0202 Injector 2 Circuit Malfunction P0230 FPR Coil Circuit Low Voltage or Open P0232...
Page 243 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 3.6 Troubleshooting Complaint Symptom and Possible Causes Remedy Compression is Too Low 1. Worn cylinder Replace Replace 2. Worn piston ring Replace 3. Leakage with cylinder gasket Replace or repair 4. Wear valve guide or improper valve seating 5.
Page 244 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1.Improper valve clearance Adjust 2.Improper valve seating Replace or Correct Replace 3.Faulty valve guide Replace 4.Worn rocker arm or rocker arm shaft 5.Fouled spark plug Engine stalls easily Replace 6.Improper spark plug gap...
Page 245 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Complaint Symptom and Possible Causes Remedy 1. Weak valve spring Replace Replace 2. Worn camshaft Clean or replace 3. Fouled spark plug Adjust or replace 4. Insufficient spark plug gap Adjust 5.
Page 246 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 1. Improper valve clearance Adjust Replace 2. Weak valve spring Adjust 3. Improper valve timing Replace Replace 4. Worn cylinder Replace or Correct 5. Worn piston ring Clean or replace 6. Improper valve seating...
Page 247 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 Complaint Symptom and Possible Causes Remedy Valve Chatter Adjust 1. Excessive valve clearance Replace 2. Worn or broken valve spring Replace 3. Worn rocker arm or camshaft Noise from Piston 1. Worn piston...
Page 248 CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0 2. Worn rollers in primary sheave Replace Noise from Transmission Replace 1. Worn or damaged gear Replace 2. Worn or damaged input or output shafts Replace 3. Worn bearing 1. Worn or damaged clutch shoes...
Page 249 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 4 CHASSIS M565Li T3 EFI WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 250 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 4.1 A-RM REPLACEMENT (MacPherson) MANTENANCE-FREE PIVOT DESIGN 1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup.
Page 251 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 4.3 FRONT STRUT REPLACEMENT ATV500 1. Hold strut rod with wrench and remove top 2. Compress spring. 3. Remove upper strut pivot assembly. 4. Remove coil spring and collapse strut body.
Page 252 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV500 1. Loosen front wheel nuts. 2. Elevate and safely support ATV under footrest/frame area. . CAUTION: Serious injury may result if ATV tips or falls. Be sure ATV is secure before beginning this service procedure.
Page 253 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 4.5 STEERING POST ASSEMBLY Note: 1, Hand tighten the crown nut of the steering post. 2, Align cotter pin hole. 3, Install cotter pin. Bend both ends of cotter pin around nut in opposite directions.
Page 254 CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0 NOTES CHAPTER 4 CHASSIS PAGE. 4-...
Page 255 CHAPTER 5 FINAL DRIVE M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 5 FINAL DRIVE M565Li T3 EFI WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 256 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 69 Ft.Lbs 96 N.m Front W heel Nuts 69 Ft.Lbs 96 N.m Rear W Front Hub Nut on Spindle/ outer CV joint Refer to FRONT HUB INSTALLATION Rear Hub Retaining Nut...
Page 257 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 7. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. Do not damage the surface of the seal. Clean the hub. 8. Drive bearing out through opposite side of hub and discard.
Page 258 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 bearing for moisture, dirt, or corrosion, or roughness is evident. 5.3 b. FRONT HUB INSTALLATION 4X4 1. Inspect the hub strut bearing surface for wear or damage. 2. Apply grease to drive axle spindle. 3.
Page 259 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.4 FRONT HUB BEARING REPLACEMENT 4X4 1. Remove outer snap ring. 2. Form the back side, tap on the outer bearing race with a drift punch in the relief as shown. 3. Drive bearing out evenly by tapping on outer race only.
Page 260 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.5 FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/ INSPECTION (4X4) NOTE The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1.
Page 261 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 horizontal and straight out from the front differential during removal. 3. Hold the drive shaft straight out. 4. Place a tire lever between the inner CV joint and the differential housing, with a small piece of wood against the housing to help get "leverage"...
Page 262 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.6 FRONT DRIVE AXLE INSTALLATION (4X4) CAUTION To avoid damage to the front differential oil seal and the strut oil seal, hold the front drive shaft horizontal and straight into the strut during installation. 1.
Page 263 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5. Remove the inner CV joint. 6. Remove the circlip and slide off the bearing assembly. Be careful not to drop Inspect groove any of the steel balls from the bearing cage. 7.
Page 264 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 for wear or damage. Check the movement of the joint 10. Check the stopper ring in the end of the inboard joint. Make sure it seats in the groove correctly, if damage the ring must be replaced.
Page 265 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 follows: a. Position the bearing race and install the race into the bearing case. Align the steel ball receptacles in both parts. b. Install the steel balls into their receptacles in the bearing case. c.
Page 266 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 tabs facing toward the rear of the vehicle . 15. Move the small boot band onto the boot. Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer.
Page 267 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.9 RE AR HUB INSPECTION 1. Remove rear wheel. 2. Remove the cotter pin on the rear wheel driving shaft nut, than remove the nut. 3. Remove the rear disc brake caliper. 4.
Page 268 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 7. Using hub extractor to take down the rear hub. 8. Remove oil seal. 9. Remove the snap spring of the rear hub. 10. Using bearing extractor to take down the hub bearing. Notice: when reassembling hub bearing that were removed and rear hub, which are need replaced.
Page 269 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.10 REAR GEAR CASE COMPONENT IDENTIFICATION REAR GEARCASE EXPLODED VIEW NUT M12×1.25 DRIVE BEVEL GEAR ASSEMBLY WASHER 12.5×30×4 ADJUST SHIM60.5x50.3 COUPLER, REAR AXLE BEARING 6010 BOLT M8×30 O-RING 151×3 BEVEL GEAR BEARING HOUSING REAR GEAR BEARING HOUSING OIL SEAL Φ35×Φ61×9 OIL SEAL 30x50x13.5...
Page 270 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.11 REAR GEAR CASE Important: Before staring any operation On the gearbox， make sure that never clean the gearbox with a high pressure water jet. 1. Remove the oil drain plug A and let the oil drain from the gearbox.
Page 271 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Fig 4 5. Remove the six bolts M8×25 Q and the two bolts M10×1.25×25 R. Remove the ring gear bearing housing T from the rear gear case S. →Fig 5 Fig 3 4.
Page 272 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Fig 6 7. Remove the adjust shim W from the bevel gear comp.-driven X. Remove the bevel gear comp.-driven X from the ring gear bearing housing T. Remove the adjust shim Y from the bevel gear comp.-driven X.
Page 273 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 3. Mount the needle bearing H and the needle bearing Ⅰ into the suited hole of the rear gear case G. →Fig 3 Fig 1 2. Mount the adjust shim D in the shaft neck of the bevel gear comp.-driven E.
Page 274 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Fig 4 Apply some Loctite 510 silicone sealant on Fig 6 the shaft neck of pipe joint N for the 7. Tighten the six bolts M8×25 Q to a torque of installation. 20~25N.m.
Page 275 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Fig 7 Mount the bevel gear-driving V into the hole 8. Mount the axle sleeve U of the inner & outer of the bearing W. →Fig 10 race in the neck of the bevel gear-driving V. →Fig 8 Fig 10 11.
Page 276 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Fig 13 13. Mount the coupler of the rear axle f with 14. Mount the oil seal 65×90×9 j in the ring the bevel gear-driving V. gear bearing housing C on the right. →Fig 14 Mount the washer 12.5×30×4 g.
Page 277 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.13 FRONT GEAR CASE DISASSEMBLY FRONT GEARCASE EXPLODED VIEW CHAPTER 5 FINAL DRIVE. 5- 23...
Page 278 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 Screw Bearing Retainer Gear Motor Bevel Gear -Driving O-Ring φ81.2×1.9 Oil Seal Bolt Coupler Screw O-Ring Pin Shaft Nut Washer Shift Fork Drive Clutch Bearing 61912 O-Ring φ141×2.4 Drive Gear Adjust Shim(83×71) Bolt Adjust Shim(61×48) Bracket,Differential...
Page 279 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 5.14 FRONT GEARCASE DISASSEMBLY 2. Remove the COUPLER A. →Fig 2. Important: Before staring any operation On the gearbox make sure GEAR MOTOR A is protected (if mounted). Never clean the gearbox with a high pressure water jet.
Page 280 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 4. Remove the COUPLER A. 6. Remove the four SCREW A. →Fig 4. →Fig 6. Fig 6 Fig 4 7. Remove the GEAR MOTOR A. →Fig 7. 5. Remove the OIL SEAL A. →Fig 5.
Page 281 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 8. Remove the six bolts H（M8 L28）. 11. Remove ADJUST SHIM A →Fig 8. →Fig 11. Fig 8 9. Remove the GEAR CASE ASSY, FRONT Fig 11 AXLE A and CASE COVER ASSY, 12.
Page 282 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 14．Remove the DRIVE CLUTCH A. 16．Remove the DRIVE CLUTCH COVER A. →Fig 14. →Fig 16. Fig 16 Fig 14 17．Remove the ADJUST SHIM A. →Fig 17.. 15．Remove the RETAINER 62 B . →Fig 15.
Page 283 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 19．Remove the BEARING RETAINER A with 21. Remove the BEARING 61912 A . →Fig 21. tool B. →Fig 19. Fig 21 22. Remove the six BOLTS A. →Fig 22. Fig 19 20. Remove the DRIVE PINION GEAR A. →Fig 20.
Page 284 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 23. Remove the PIN A. 25. Remove the DRIVEN GEAR A and washer →Fig 23. B and SHIM C and ADJUST SHIM D and DIFFERENTIAL GEAR E. →Fig 25. Fig 25 Fig 23 24.
Page 285 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 2. Put driven gear A and washer B and shim C 5.15 FRONT GEARCASE ASSEMBLY and adjust shim D and differential gear E as shown. →Fig 2. 1. Mount the the drive gear A and wearing ring B and gear(center), differential C and gear shaft(center), differential D and pin E and bracket,differential F,then mount pin T...
Page 286 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 →Fig 4 6. Mount the drive clutch A. →Fig 6. Fig 4 5. Mount the retainer 62 A . →Fig 5. Fig 6 7.Mount the pin shaft A and the shift fork B . →Fig 7.
Page 287 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 8.Mount the screw A . →Fig 8. Fig 8 9. Mount the adjust shim A. →Fig 9. Fig 9 10. Mount the differential gear assy A to the gear case assy C ,do not forget put adjust shim I to the case cover assy B, then make Fig 10 B and C together...
Page 288 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 11. Mount the six bolts to a torque of 20~25Nm 13. Mount the four screws A . →Fig 11. →Fig 13. Fig 11 Fig 13 12. Mount the gear motor A. 14. Mount the oil seal A. →Fig 14.
Page 289 CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0 16. Mount the O-ring A. →Fig 16. Fig 16 17. Apply some Loctite 263 thread locker on Fig 18 screw thread, mount the nut A, tighten it to a torque of 50~60Nm. →Fig 17.
Page 290 CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0 NOTES CHAPTER 5 FINAL DRIVE. 5- 36...
Page 291 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 6 BRAKES NOTE Also See Chapter 2 for Maintenance Information. 6.1 SPECIFICATIONS 6.2 TORQUE 6.3 BRAKE SYSTEM SERVICE NOTES 6.4 BURNISHING PROCEDURE 6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE 6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION 6.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION...
Page 292 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 6.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness 0.150- 0.164"/3.810- 4.166m B rake Disc Thickness 0.140"/3 .556m m Brake Disc Thickness Variance 0.002 "/ .051m m...
Page 293 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 Check and adjust master cylinder reservoir fluid level after pad service. Make sure atmospheric vent on reservoir is unobstructed. Adjust foot brake after pad service. Test for brake drag after any brake system service and investigate cause if brake drag is evident.
Page 294 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE NOTE : When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. CAUTION Always wear safety glasses. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV.
Page 295 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 Reservoir Cover Torque 5 in. lbs. (.6 Nm ) 7. Slowly pump brake lever (D) until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever.
Page 296 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION CAUTION: The master cylinder is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
Page 297 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 Master Cylinder Mounting Bolt Torque 55 in. lbs . (6 N m) Brake Line Banjo Bolt Torque 15 ft. lbs. (21 Nm ) 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure, Check all connections for leaks and repair if necessary.
Page 298 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
Page 299 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 REMOVAL/ REPLACEMENT 1. Removal caliper and hub. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc.
Page 300 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 PROCEDURE, And field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation.
Page 301 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 Hand and (or) Foot Brake Master Cylinder(s) Fluid Level: Between MIN and MAX lines 4. Install wheels, burnishing procedure should be performed. See BURNISHING PROCEDURE, And field test unit for proper braking action before putting into service.
Page 302 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 brake drags, recheck assembly installation. REMOVAL / REPLACEMENT 6.12 REAR BRAKE DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1"...
Page 303 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 6.13 FOOT BRAKE PEDAL FOR B-TYPE ADJUSTING If the push rod joint is reinstalled, adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt hole and joint pin hole is 80±1mm.After adjustment, tighten the joint...
Page 304 CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0 NOTES CHAPTER 6 BRAKES PAGE. 6- 14...
Page 305 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 CHAPTER 7 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM COOLING SYSTEM LIGHTING SYSTEM GEAR SHIFT SWITCH TEST SPEEDOMETER SYSTEM 7.10 MAIN SWITCH AND HANDLE SWITCH 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR...
Page 306 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 7.1 PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT 1. . ‘Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip① before dismounting the bulb.
Page 307 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 7.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
Page 308 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. To refill use only distilled water. Tap water contains minerals which are harmful to a battery.
Page 309 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 7.3 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark  Spark plug gap incorrect  Fouled spark plug  Faulty spark plug cap or poor connection to high tension lead ...
Page 310 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 IF THE IGNITION SYSTEM FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 7.Pickup coil resistance 2. Battery 8.Main switch 3. Spark plug 9.Engine stop switch 4. lgnition spark gap 10.Wiring connection 5.
Page 311 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 4.lgnition spark gap  Disconnect the spark plug cap from the spark plug Connect the ignition tester 1 as shown. 2 Spark plug Turn the main switch to "ON". Check the ignition spark gap .
Page 312 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 Tester (+) lead B/Y Terminal Tester ( -) lead Green 6. Ignition coil resistance Terminal Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (1) to the ignition coil.
Page 313 CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0 7. Pickup coil resistance  Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead → BI/Y Terminal ...
Page 314 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable.
Page 315 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 CHARGING SYSTEM Procedure Check: 1. Fuse (Main) 4.Stator coil resistance 2. Battery 5.Wiring system (entire charging system) 3.Charging voltage 1. fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION"...
Page 316 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) the stator coil Tester (+) lead –yellow terminal Tester (-) lead –yellow terminal OUT OF SPECITICATION Measure the stator coil resistance Stator coil resistance 0.5-0.8Ω（20 ℃...
Page 317 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.5 ELECTRICS STARTING SYSTEM D I A G R A M CHAPTER 7 ELECTRICAL PAGE.7- 13...
Page 318 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN GEAR SHIFT SWITCH IS IN NEUTRAL OR THE FRONT/REAR SWITCH IS ON IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check: 7. gear shift switch 1. Fuse (Main) 8.
Page 319 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 WARNING 4.Starter relay A wire used as a jumper lead Disconnect the relay unit coupler from must have the equivalent the wire harness. capacity as that of the battery Connect the pocket tester (Ωx1) and lead or more, otherwise it battery (12V) to the relay unit coupler may burn.
Page 320 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 6. Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 7.Gear shift switch CHECK SWITCHES NO CONTINUITY Replace the handlebar switch 8 Front /rear brake switch NO CONTINUITY CHECKING SWITCHES Replace the brake switch 9.
Page 321 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check: 1. Fuse (Main, Fan) 2. Battery 4. Fan motor (inspection) 3. Main switch 5. Thermo switch 6. relay 7. Wiring connection (entire cooling system) CHAPTER 7 ELECTRICAL PAGE.7- 17...
Page 322 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 1. fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION" section Clean battery terminals Recharge or replace the battery 3 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 4.1 Fan motor(inspection 1)
Page 323 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 5. Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (ΩX1) to the thermo switch. Immerse the thermo switch in the water  Check the thermo switch for continuity. NOTE: Measure temperatures while heating the coolant with the temperature gauge...
Page 324 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7. Wring connection UPPER CONNECTION Check the connection of the entire cooling system. Refer to “CIRCUIT DIAGRAM” Correct IF THE HEAT ALARM UNIT WORKING When the main switch is turned on, the temperature of the engine begins to go up. As it comes to 88±3℃...
Page 325 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 Handle the thermo unit with 4.Thermo unit special care. Drain the coolant and remove the Never subject it to strong thermo unit from the cylinder head. shocks or allow it to be Immerse the thermo unit in the dropped.
Page 326 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 LIGHTING SYSTEM CHAPTER 7 ELECTRICAL PAGE.7- 22...
Page 327 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch 2. Battery 5.Dimmer switch 3. Main switch 6. Wiring connection (entire lighting system) 1.fuse refer “CHECKING SWITCHES” NO CONTINUITY section Replace the fuse 2. Battery Check the battery condition.
Page 328 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 POOR CONNECTIONS 6. Wiring connection Check the connection of the entire lighting system correct 7. check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1.
Page 329 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 2. the taillight fails to come on 1. Bulb and bulb socket NO CONTINUITY CHECK SWITCHES Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the bulb socket connector.
Page 330 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.8 GEAR SHIFT SWITCH TEST D I A G R A M CHAPTER 7 ELECTRICAL PAGE.7- 26...
Page 331 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 Switch table CHAPTER 7 ELECTRICAL PAGE.7- 27...
Page 332 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the engine Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
Page 333 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 METER Dial Meter Item Vol value Unit Operating voltage 10V~18V ≤ Operating current 500mA ℃~ 65℃ ℃ Operating Environmental temperature ≤11.5V Battery warning voltage LCD Meter For M565 T3 EFI 1. Neutral indicator light 11.
Page 334 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.10 MAIN SWITCH AND HANDLE SWITCH HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL CHAPTER 7 ELECTRICAL PAGE.7- 30...
Page 335 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR 1. Remove the fuel level sensor from the fuel tank. Measure the resistance with an ohmmeter across the sensor terminal and its body. If the reference values are not indicated, the sensor is faulty Resistance Reference...
Page 336 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT (Fig 1) 1, The rider shifts 2WD to 4WD by the Switch on handlebar. 2. When shift 2WD/ 4WD or Diff Lock, the mechanics in the front gear box maybe still engaged/ disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or rides in reverse.
Page 337 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 7.13 WIRING DIAGR CHAPTER 7 ELECTRICAL PAGE.7- 33...
Page 338 CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0 CHAPTER 7 ELECTRICAL CTRICAL PAGE 8- 34...

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