Download Print this page

Segway SNARLER ATV 2021 Series Service Manual

Table of Contents

Advertisement

Quick Links

Download this manual

SERVICE MANUAL

ATV SERIES PRODUCTS

20210804 V01

Table of Contents

Advertisement

Chapters

Table of Contents

Need help?

Need help?

Do you have a question about the SNARLER ATV 2021 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Segway SNARLER ATV 2021 Series

Page 1 SERVICE MANUAL ATV SERIES PRODUCTS 20210804 V01...
Page 2 Index Index GENERAL INFORMATION REGULAR MAINTENANCE ENGINE FRONT AND REAR AXLE FUEL SYSTEM COOLING SYSTEM INTAKE SYSTEM DRIVE CHAIN SYSTEM FRONT AND REAR SUSPENSION 9-1 WHEEL AND TIRE 10-1 10-1 BRAKE SYSTEM 11-1 11-1 STEERING SYSTEM 12-1 12-1 FRAME/BODY AND TRIM 13-1 13-1 ELECTRICAL SYSTEM...
Page 3 Therefore, if replacement parts, repair procedures or tools are to be used that are not approved or recommended by Segway, it must ﬁ rst be conﬁ rmed that there is no risk to personal safety or safe operation of the vehicle.
Page 4 REVISION INDEX RELEASE DATE CHANGES ◆ Updated the Main Harness diagram ◆ Updated the Dashboard to new version 20210709 ◆ Added brushed EPS topic ◆ Added diﬀ erential Rear Axle topic...
Page 5 TERMINOLOGY ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current Millimeter(s) ATDC after top dead center minute(s) BBDC before bottom dead center newton(s) bottom dead center Newton meters BTDC before top dead center pascal(s) degree(s) Celcius HP(PS) horsepower centrifugal variable Transmission pound(s) per square inch direct current revolution...
Page 6 NOTES BEFORE MAINTENANCE This manual includes a variety of "warnings", "attention", "tips", etc., which must be carefully followed in order to reduce the risk of injury during repair or maintenance. Improper repair or maintenance will damage the vehicle or bring safety hazards to the vehicle. WARNING WARNING WARNING indicates a potential hazard that may result in severe injury or death to the operator,...
Page 7 GENERAL INFORMATION GENERAL INFORMATION GENERAL INFORMATION Vehicle Identification Number………………………………………… 1-2 Technical parameters of vehicle…………………………………… 1-3 Unit conversion table…………………………………………………… 1-6 Torque………………………………………………………………………1-7 1 - 1...
Page 8: Vehicle Identification Number
Vehicle identiﬁ cation number The frame identiﬁ cation number is located on the frame cross under the seat cushion pipe under the seat cushion. Reference the vehicle identiﬁ cation number (VIN) when corresponding about the Segway Powersports vehicle. VEHICLE IDENTIFICATION CODE COMPOSITION *AOSAAPX1?××××××××*...
Page 9: Technical Parameters Of Vehicle
GENERAL INFORMATION GENERAL INFORMATION Technical parameters of vehicle Model Item SGW570F-A1 A2 A3 SGW570F-A4 A5 A6 SNARLER AT6 S SNARLER AT6 L Vehicle Length 87 in (2200mm) 92.52 in（2350mm） Width 50.39 in (1280mm) 50.39 in(1280mm) 51.97 in (1320mm) Height 56.3 in(1430mm) 51.18 in (1300mm) Wheel base 57.09 in(1450mm)
Page 10 GENERAL INFORMATION GENERAL INFORMATION Front Diﬀ erential gear oil type SAE 80W/90 GL-5 Front Diﬀ erential oil the volume 9.5oz (280ml) Rear Diﬀ erential gear oil type SAE 75W/90/GL-5 or SAE 80W/90/GL-5 Change the volume 8.1oz (240ml) Air ﬁ lter Paper ﬁ...
Page 11 GENERAL INFORMATION GENERAL INFORMATION Spring + oil resistance Rear shock absorber Spring + air resistance Front wheel travel 7.28in (185mm) Rear wheel travel 8.27in (210mm) Electrical System Ignition mode Electric (ECU） Charge 450W / 5500 rpm Battery 12V 32Ah Light(2 status) Light(2 status) Headlight LED 13.2W...
Page 12: Unit Conversion Table
GENERAL INFORMATION GENERAL INFORMATION Unit conversion table Torque Unit Unit coeﬃ cient coeﬃ cient Convert to Convert to N·m × 0.1020 kg·m N·m ×0.7376 ft·lbs N·m ×8.851 in·lbs kg·m kg·m ×9.807 ×9.807 N·m N·m kg·m kg·m ×7.233 ×7.233 ft·lbs ft·lbs kg·m kg·m ×86.80...
Page 13 GENERAL INFORMATION GENERAL INFORMATION Torque The following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent. MO: Apply molybdenum disulﬁ...
Page 14 GENERAL INFORMATION GENERAL INFORMATION nut M18×1.5 nut M18×1.5 145~155 145~155 14.5~15.5 14.5~15.5 107~114.3 107~114.3 16 16 nut M22×1 nut M22×1 175~185 175~185 17.5~18.5 17.5~18.5 129~136.4 129~136.4 17 17 nut M55×1.5×6-LH nut M55×1.5×6-LH 88.4 88.4 18 18 19 19 nut M65×1.5×8-LH nut M65×1.5×8-LH 13.7 13.7...
Page 15 GENERAL INFORMATION GENERAL INFORMATION Standard fastener torque of the whole vehicle Torque Torque Fastener Fastener Remark Remark N·m N·m kgf·m kgf·m ft·lb ft·lb bolt M6 bolt M6 8~12 8~12 0.8~1.2 0.8~1.2 69~103.6 in·lb 69~103.6 in·lb bolt M8 bolt M8 30 ～～ 40 3.0~4.0 22.1~29.5 22.1~29.5...
Page 16: Table Of Contents
MAINTENANCE MAINTENANCE MAINTENANCE Maintenance Periodic Table…………………………………………………………………………2-3 Check and adjust free play of throttle cable………………………………………………………2-6 Throttle Lever Free Play Inspection…………………………………………………………………2-6 Replace of air filter……………………………………………………………………………………2-7 Remove the air box cover……………..…………………………………………………………2-7 Cleaning or replacing air ﬁ lter………………….……………………………………………………2-7 Brake system……………………………………………………………………………………………2-8 Wearing inspection of front brake disc………………………………………………………………2-8 Inspection of front brake hose and connection……………………………………………………2-8 Replace brake hose…………………………………………………………………………………2-9 Check ﬂ...
Page 17 MAINTENANCE MAINTENANCE Engine Oil Level Check………………………………………………………………………………2-19 Changing engine oil&ﬁ lter…………………………………………………………………………2-20 Oli strainer clean……………………………………………………………………………………2-20 Oil ﬁ lter change………………………………………………………………………………………2-21 Front/Rear Axle Gear Oil……………………………………………………………………………2-21 Wheels/Tires Wheels/Tires…………………………………………………………………………………………2-22 Tire Inspection ………………………………………………………………………………………2-22 Propeller Shaft Joint Boot Inspection ……………………………………………………………2-22 2 - 2...
Page 18: Maintenance Periodic Table
MAINTENANCE MAINTENANCE Maintenance Periodic Table A good maintenance is vital for safety and driving. Regular maintenance is especially important. Please follow this table to make regular maintenance for your vehicle. WARNING WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
Page 19 MAINTENANCE MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CALENDAR MILES（KM） ► Brake pad wear 10 H Monthly 100 (160) Inspect periodically Battery 20 H Monthly 200 (320) Check terminals. clean. test Inspect. cycle key to pressurize Monthly Fuel System 20 H fuel pump.
Page 20 MAINTENANCE MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CALENDAR MILES（KM） Radiator ► 100 H 12 M 1000 (1600) Inspect. clean external surfaces (if applicable) Cooling hoses ► 100 H 12 M 1000 (1600) Inspect for leaks (if applicable) ►...
Page 21: Check And Adjust Free Play Of Throttle Cable
MAINTENANCE MAINTENANCE Check and adjust free play of throttle cable Throttle Lever Free Play Inspection ◆ Check that the throttle lever 【A】 moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.
Page 22: Cleaning Or Replacing Air Fi Lter
MAINTENANCE MAINTENANCE WARNING WARNING It may lead to unsafe driving conditions if throttle valve is not properly assembled and operated. ◆ Check throttle lever free play. ◆ Cover back oiler dust cap and fasten. ◆ Before assembly, lubricate throttle cable. If it is not properly adjusted, it will cause misoperation If it is not properly adjusted, it will cause misoperation cabling or cable damage which will cause unsafe driving...
Page 23: Brake System
MAINTENANCE MAINTENANCE Brake system Wearing inspection of front brake pads Standard 5.0mm Brake thickness （0.19 inch inch））（0.19 components Minimum 1.0mm thickness thickness （0.04 inch inch））（0.04 【A】Normal thickness 【B】Limit thickness ◆ Check each brake pads thickness regularly ◆...
Page 24: Replace Brake Hose
MAINTENANCE MAINTENANCE Replace brake hose ◆ D i s c h a r g e b r a k e f l u i d f r o m b r a k e h o s e f o r replacement.
Page 25: Check Rear Brake Oil Cup Liquid Level
MAINTENANCE MAINTENANCE Check rear brake oil cup liquid level The rear brake oil cup is located between LF upper The rear brake oil cup is located between LF upper fender and front shock. fender and front shock. ◆ Park vehicle in even ground and check liquid level of oil cup.
Page 26: Refill Brake Fluid
MAINTENANCE MAINTENANCE Reﬁ ll brake ﬂ uid ◆ Reﬁ ll new brake ﬂ uids in the hand brake oil cup ◆ Reﬁ ll new brake ﬂ uids in the rear brake oil cup CAUTION CAUTION When reﬁ lling brake ﬂ uid in the oil cup, use only DOT4 brake ﬂ...
Page 27: Discharge Air In The Brake System
MAINTENANCE MAINTENANCE 4. Vacuumize and reﬁ ll front right brake hose Refer to the procedures of vacuumizing front left brake hose to vacuumize and reﬁ ll front right brake hose. 5. Vacuumize and reﬁ ll front brake hose ◆ Open distribution valve dust cap and counter clockwise open air inlet bolts of distribution valve..
Page 28: Replace Of Front Brake Disc
MAINTENANCE MAINTENANCE or rear brake oil cup cap and reﬁ ll brake ﬂ uid over the MIN level. ◆ Slowly grasp hand brake shank or step on brake pedal to the bottom several times. Loosen air outlet of brake in the replaced pipeline. If any brake ﬂ uid flows out, immediately screw up air outlet bolts.
Page 29: Check Cylinder
MAINTENANCE MAINTENANCE Check Cylinder 【A】Hand brake cylinder 【B】Piston 【C】Seal ring 【D】Seal ring 【E】Dust cover 【F】Compensating hole 【G】Oiling hose 【H】Piston reset spring ◆ Disassemble hand brake pump ◆ Check if any scratch, rust or hard spots, inside and outside surfaces of hand brake cylinder 【A】and piston 【B】.
Page 30: Check Free Play Of Rear Brake Pedal
MAINTENANCE MAINTENANCE Replace brake assembly oil seal 【A】Oil seal. The oil seal【A】 around piston should be tight. If seal is not ideal, seal will be worn more and resistance will be increased in the piston so that brake and brake ﬂ uid temperature will be increased accordingly.
Page 31: Check Rear Parking Handle Work Play
MAINTENANCE MAINTENANCE Check rear parking handle free play 【A】Parking handle free play ◆ Check parking handle work play 【A】. ◆ Grasp parking handle until the parking brake is engaged. If parking handle free play is bigger, please adjust it. Standard of parking handle free play 10-20mm (0.4-0.8inch) Adjustment of free play of parking handle 【A】Brake handle...
Page 32: Cooling System
MAINTENANCE MAINTENANCE Cooling System Radiator Cleaning CAUTION CAUTION Clean the radiator screen and the radiator in accordance with the Periodic Maintenance Chart. In dusty areas, they should be cleaned more frequently than the recommended interval. After riding through muddy terrains, the radiator screen and the radiator should be cleaned immediately.
Page 33: Adding Cooling Liquid
MAINTENANCE MAINTENANCE Adding cooling liquid WARNING WARNING To avoid scalding, do not replace cooling liquid when engine is hot. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wash away any coolant that spills on the frame, engine, or wheels. Since coolant is harmful to the human body, do not use for drinking.
Page 34: Engine Oil Level Check
MAINTENANCE MAINTENANCE Engine Oil Level Check Engine Oil Level Check Engine Oil Level Check CAUTION CAUTION Running the engine with an improper oil level can cause serious engine damage. ◆ Park the vehicle on a level ground. Wait at least 5 minutes to allow the oil to ﬂ...
Page 35: Changing Engine Oil&Fi Lter
MAINTENANCE MAINTENANCE Changing engine oil & ﬁ lter CAUTION CAUTION Do not change the oil when the engine and oil are hot. Allow engine and oil to cool before changing oil. 【A】Screw 【B】Filter inspection cover 【C】Oil drain plug 【D】O-ring ◆ Put the vehicle on the ﬂ at level surface. ◆...
Page 36: Oil Fi Lter Change
MAINTENANCE MAINTENANCE Oil ﬁ lter change This procedure requires mechanical skill and professional tools such as a torque wrench as well as a means for disposing of the drained ﬂ uid. If you do not have the skills or the tools, see your dealer. Check the ﬂ...
Page 37: Tire Inspection
MAINTENANCE MAINTENANCE make the liquid level reach the bottom of the ﬁ lling hole thread. ◆ Reinstall the O-ring and ﬁ lling plug Torque to s peciﬁ cation： Filling Plug:16~20N.m ◆ Check for the leak. CAUTION CAUTION Dispose of used ﬂ uid properly. Wheels/Tires Tire Inspection 【A】Type wear mark...
Page 38 ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Exploded View......................3-1-2 Exploded View......................3-1-2 Technical Parameter ....................3-1-4 ....................3-1-4 Special Tools and Sealant...................3-1-5 Special Tools and Sealant...................3-1-5 Engine Oil Flow Chart..................3-1-6 Engine Oil Flow Chart..................3-1-6 Engine Oil and Oil Filter.................3-1-7 Engine Oil and Oil Filter.................3-1-7 Oil Level Inspection..................3-1-7 Engine Oil Change..................3-1-8...
Page 39: Exploded View
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Exploded view 3-1-2...
Page 40 ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Oil Pump Drive Gear Flat Key Spacer 10×30×3 Bolt M10×1.25×25 Oil Pump Idler Gear Shaft Circlip 15 Spacer 15×28×1 Oil Pump Idler Gear E-Ring 9 Spacer12×20×1 Oil Pump Driven Gear Oil Pump Shaft Bolt M6×20 Oil Pump Cover...
Page 41: Technical Parameter
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Technical Parameter Item Standard Engine Oil: Engine Oil: Grade API SH or SJ Viscosity SAE 10W-40 Capacity 2.0 L (1.80 US qt) (when ﬁ lter is not removed) 2.2 L (2.01 US qt) (when ﬁ lter is removed) 2.4 L (2.33 US qt) (when engine is completely dry) Oil Pressure Measurement: Oil Pressure @ 4500 r/min(rpm),...
Page 42: Special Tools And Sealant
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Special tools and sealants Oil Pr Oil Pressure Gauge, 10 kgf/cm essure Gauge, 10 kgf/cm Silicone Sealant: Silicone Sealant: E01GZ0030001 Z0030001 030001 Oil Pressure Test Hose, M10 Oil Pressure Test Hose, M10×1: E01GZ0040001 0040001 0040001 3-1-5...
Page 43: Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart Strainer Filter 7 Oil Nozzles 13 Transmission Countershaft Assembly Oil Pump 8 Piston 14 Crankshaft Oil Pressure Valve Unit 9 Camshaft-IN 15 Starter One-Way Gear Oil Filter 10 Camshaft-EX 16 Alternator Stator and Rotor Oil Cooler 11 Oil Pump Idler Gear Oil Pressure Sensor...
Page 44: Engine Oil And Oil Filter
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING WARNING Vehicle operation with insufficient,deteriorated,or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident,and injury. Oil Level Inspection Oil Level Inspection ◆...
Page 45: Engine Oil Change
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Engine Oil Change Engine Oil Change ◆ Refer to the Engine Lubrication System in the Periodic Maintenance chapter. Oil Filter Change Oil Filter Change ◆ Refer to the Engine Lubrication System in the Periodic Maintenance chapter to ﬁ ll the oil ﬁ lter. Coarse Filter Removal Coarse Filter Removal ◆...
Page 46: Oil Pressure Measurement
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Oil Pressure Oil Pressure Measurement Oil Pressure Measurement NOTE NOTE Measure the oil pressure after the engine is warmed up. ◆ Remove the oil pressure switch, and attach the oil pressure gauge【A】and adapter【B】. Special Tools- Oil Pressure Gauge,10 kgf/cm : E01GZ0030001 Oil Pressure Gauge Adapter: E01GZ0031001...
Page 47: Oil Pressure Valve
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Oil Pressure Valve Removal Oil Pressure Valve Removal ◆ Split the crankcase (see Crankshaft / Transmission chapter). ◆ Remove the oil pressure relief valve Cover. ◆ Remove the oil pressure relief valve【A】. Oil Pressure Valve Installation Oil Pressure Valve Installation ◆...
Page 48: Oil Pump
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal Oil Pump Removal ◆ Remove: Alternator Rotor and Starter Clutch Gear(see Electrical System chapter). ◆ Remove: 【A】E-Ring 9 【B】Flat Washer 12×20×1 【C】Driven Gear,Oil Pump 【D】Needle Roller 4×15.8 ◆ Remove: 【B】Oil Pump Bolts 【A】Oil Pump Cover 【E】Shaft,Oil Pump...
Page 49: Oil Pump Gear
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Oil Pump Gear Oil Pump Gear Oil Pump Gear ◆ Check the ﬂ exibility of the Oil Pump Shaft rotation ◆ Install the Oil Pump Driven Gear【A】 with the Oil Pump[B]. Oil Pump Gear Removal Oil Pump Gear Removal ◆...
Page 50: Oil Cooler
ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Oil Cooler Oil Cooler Removal Oil Cooler Removal ◆ Remove: Drain the engine coolant and oil Spring band hose clamps【A】 Screw M6×16【B】 Cooler Cooler【C】 O-Ring 19×2.5【D】 Oil Cooler Installation Oil Cooler Installation ◆ Install: 1.
Page 51 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Exploded View......................3-2-2 Exploded View......................3-2-2 Speciﬁ cations.......................3-2-8 Speciﬁ cations.......................3-2-8 Special Tools and Sealant..................3-2-10 Special Tools and Sealant..................3-2-10 Crankcase......................3-2-11 Crankcase......................3-2-11 Crankcase Disassembly...................3-2-11 Crankcase Disassembly...................3-2-11 Crankcase Assembly..................3-2-14 Crankcase Assembly..................3-2-14 Crankshaft/Connecting Rod ..............3-2-20 Crankshaft/Connecting Rod ..............3-2-20 Crankshaft Installation ................3-2-20 Crankshaft Installation ................3-2-20...
Page 52: Exploded View
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Exploded view 3-2-2...
Page 53 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION (Left) (Left) S S 8 8 20 20 (Right) (Right) 20 20 20 20 20 20 3-2-3...
Page 54 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Torque Fastener Remarks N·m kgf·m ft·lb Left Crankcase Assembly SS,O Right Crankcase & Right Cover Combination SS,O Isolator Bolt M6×65 87 in•lb Dowel Pin 6×10 Bolt M8×40 Needle Roller Bearing HK121612 Bolt M8×70 Flow Oriﬁ ce Φ1 0.25 21 in•lb Bearing 6004...
Page 55 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION 3-2-5...
Page 56 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Torque Fastener Remarks N·m kgf·m ft·lb Transmission Main Shaft Idle Shaft Needle Roller Bearing K252913 R Idle Gear Spacer 17×38×2 Transmission Countershaft Assembly Reduction Driven Gear Circlip 25×1.2 Drive Bevel Gear Shaft Drive Bevel Gear Housing Bolt M8×30 Bearing 6305 Drive Bevel Gear Shims...
Page 57 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Torque Fastener Remarks N·m kgf·m ft·lb Shiftshaft Cover Gasket Shiftshaft Cover Oil Seal 15×25×5 Bolt M6×20 87 in•lb Bolt M6×40 Shift Fork Spring Seat Shoulder Bolt Detent Pawl Detent Pawl Torsion Spring Shift Fork Shift Fork L Shift Rail L Parking Brake Arm...
Page 58 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Technical Parameter Item Standard Service Limit Crankshaft,Connecting Rods: Crankshaft,Connecting Rods: Connecting rod bend – – – TIR 0.2/100 mm Connecting rod twist – – – TIR 0.2/100 mm Connecting rod big end side clearance 0.13 ~ 0.48 mm 0.7 mm Connecting rod big end bearing, insert / Crankpin...
Page 59 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Item Standard Service Limit Transmission: Transmission: Shift fork ear thickness: 5.8 ~ 5.9 mm 5.7 mm Shifter groove width: 6.0 ~ 6.1 mm 6.2 mm 3-2-9...
Page 60 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Special tools and sealants Outside Circlip Pliers Outside Circlip Pliers Bearing Driver Set Bearing Driver Set Sealant: 5699 Sealant: 5699 Sealant: 5699 3-2-10...
Page 61: Crankcase
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Crankcase Crankcase Disassembly Crankcase Disassembly ◆ Remove: 1. Engine (see Engine Removal/Installation chapter) 2. Starter Motor (see Electrical System chapter) 3. Oil Filter (see Engine Lubrication System chapter) 4. Cylinder Blocks and Pistons (see Engine Top End chapter) 5.
Page 62 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Remove: 1. Sensor Bolts (M6×20) 【B】. 2. Gear Sensor【A】. 3. Right Crankcase Cover Bolts (M6×30)【C】. 4. Right Crankcase Cover【D】 5. Right Crankcase Cover Gasket【E】. ◆ Remove: 1. Circlip 25×1.2 【A】 2. Washer【B】 3. Gentrifugal oil-air Separator【C】 4.
Page 63 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Remove: 1. Wrap the teeth on the sprockets【B】by taping for protecting the bushing in the crankcase. 2. Using the pry points【A】, split the crankcase halves. 3. Lift oﬀ the right crankcase half. 3-2-13...
Page 64: Crankcase Assembly
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Crankcase Assembly Crankcase Assembly CAUTION CAUTION The right crankcase and right crankcase cover are machined at the factory in the assembled state, so the right crankcase and right crankcase cover must be replaced as a set. NOTE NOTE ◆...
Page 65 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Install: Oil Pressure Relief Valve【E】(see Engine Lubrication System chapter) ◆ Install: Chain Guide【A】 Chain Tensioner【C】 ◆ Tighten: Torque Chain Guide Bolts【B】 12 N·m (1.2 kgf·m, 8.7 ft·lb) Apply a non-permanent locking agent to the Bolts【B】. ◆...
Page 66 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Press and insert the new ball bearings until they are bottomed. Special Tool - Bearing Driver Set: Special Tool - Bearing Driver Set: 【A】Ball Bearing : 6206 【B】Ball Bearing : 6203 【C】Ball Bearing : 6006 × 2 ◆...
Page 67 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Install: Transmission Shaft【A】and new Bearing 6205【B】. ◆ Press and insert the bearings until they are bottomed. Special Tool - Bearing Driver Set: Special Tool - Bearing Driver Set: 【B】 Ball Bearing : 6205 ◆...
Page 68 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Press and insert the bearings until they are bottomed. Special Tool - Bearing Driver Set Special Tool - Bearing Driver Set 【A】Ball Bearing : 6305 【C】Ball Bearing : 6207 ◆ Install: Nut M65×1.5×8-LH【B】 (Left-hand Threads) ◆...
Page 69 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION CAUTION CAUTION The Driving Bevel Gear【B】and Driven Bevel Gear 【A】are machined at the factory in the assembled state, so the Driving Bevel Gear and Driven Bevel Gear must be replaced as a set. ◆ Install: 1.
Page 70 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Be sure the following parts are in place in the left crankcase half. 1. Drive Bevel Gear shaft Assembly【A】 2. Parking Brake Arm【B】, Snap Ring 12【C】, Parking Brake Shaft【D】 3. Countershaft Assembly【E】,Shift Rail L 【F】...
Page 71 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Apply engine oil to the Needle Roller Bearing 【A】,Crankshaft Rod【B】,Crankshaft Case oil passages ,Main bearing bore【E】. CAUTION CAUTION The Crankshaft and Balance Shaft Gear mark points 【D】must be aligned. ◆ Apply liquid gasket【C】to mating surface of the right crankcase half.
Page 72 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Apply a non-permanent locking agent to the area 【A】(12 mm, 0.47 in.) except for the tip【B】(2 ~ 3 mm, 0.08 ~ 0.12 in.). Right Crankcase Bolt M6×40【13】 ◆ Tighten the right crankcase bolts (M6) following the tightening sequence【1 ~ 13】...
Page 73 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Install: 【G】Shift Positioning Plate Spring 【H】Detent Pawl 【J】Shoulder Blot 【A】Positioning Star 【B】Spacer 【C】Shift Driven Gear 【D】Torsion Spring 【E】Washer 6.2×22×2 【F】Hexagon Bolt M6×40 【K】Fan Gear 【L】 Dowel Pin 6×10 ◆ Tighten: Torque Hexagon Bolt M6×40【F】 Shoulder Bolt【J】...
Page 74 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Install: 【A】Dowel Pin 6×10 【B】Centrifugal Oil-air Separator 【C】Washer 【D】Snap Ring 25×1.2 ◆ Install: Oil Seal 20×30×7【L】 Oil Seal 35×52×7【M】 ◆ Apply engine oil to the Main bearing bore【N】 ◆ Apply grease the lip of the oil seal【L】and【M】 ◆...
Page 75: Connecting Rod Big End Side Clearance
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Crankshaft CAUTION CAUTION The Crankshaft and Connecting Rod are Assembled at the factory , so the Crankshaft must be replaced as a set. Connecting Rod Big End Side Clearance Connecting Rod Big End Side Clearance ◆...
Page 76: Transmission
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Transmission Transmission Removal Transmission Removal ◆ Remove the shift lever (see Shift Lever Removal). ◆ Remove the Shiftshaft (see Crankcase Disassembly). ◆ Split the crankcase (see Crankcase Disassembly). ◆ Remove: Drive Bevel Gear Component Bolts【A】 Drive Bevel Gear Component【B】...
Page 77 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Remove: Main Shaft【A】 ◆ Remove: Countershaft Assembly【B】,Shift Rail L【C】,Shift Rail H/R【D】,Shift Drum【E】Component. 3-2-27...
Page 78: Transmission Installation
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Remove: Parking Brake Arm Shaft【A】and Snap Ring 12 【B】 Spacer12×20×1【C】 Parking Brake Arm【D】 Transmission Installation Transmission Installation ◆ Install: Insert the Parking Brake Arm Assembly in the crankcase until it is bottomed ◆ Install: Drive Bevel Gear Assembly【A】...
Page 79: Shift Fork Bending
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Install: Shift Rail Fork Assembly H/R【C】 Shift Rail Fork Assembly L 【D】 Shift Drum【A】 Countershaft Assembly【B】 Insert the Shift Forks into the groove of the Countershaft Assembly Shift Fork Bending Shift Fork Bending ◆...
Page 80: Transmission And Shift Mechanism Inspection
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Transmission and Shift Mechanism Inspection Transmission and Shift Mechanism Inspection ◆ Visually inspect: Gears Dogs of Gear and Shifter If they are damaged or worn excessively, replace them ◆ Install: 1. Install the Countershaft Assembly, Shift Rail L, Shift Rail H/R and Shift Camshaft to C.
Page 81 CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Spacer 22×32×1.5 Spacer 22×32×1.5 12 Countershaft Countershaft Shifter, H Shifter, H 13 Gear L Gear L Washer 33×1.5 Washer 33×1.5 14 Spacer 20×30×1.5 Spacer 20×30×1.5 Reduction drive gear Reduction drive gear 15 Circlip 25×1.2 Circlip 25×1.2 Spacer 28×36.5×1 Spacer 28×36.5×1...
Page 82: Ball Bearing, Needle Bearing, And Oil Seal
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION Ball Bearing, Needle Bearing, and Oil Seal Ball and Needle Bearing Replacement Ball and Needle Bearing Replacement CAUTION CAUTION Do not remove the ball or needle bearings unless it is Do not remove the ball or needle bearings unless it is necessary.
Page 83: Oil Seal Inspection
CRANKSHAFT / TRANSMISSION CRANKSHAFT / TRANSMISSION ◆ Check the needle bearings. The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.Spin【A】the bearing by hand to check its condition.
Page 84 ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Exploded View....................3-3-2 Exploded View....................3-3-2 Technical Parameter ....................3-3-4 ....................3-3-4 Special Tools......................3-3-5 Special Tools......................3-3-5 Charging System....................3-3-6 Charging System....................3-3-6 Alternator Cover Removal.................3-3-6 Alternator Cover Removal.................3-3-6 Alternator Cover Installation................3-3-6 Alternator Cover Installation................3-3-6 Alternator Rotor Removal.................3-3-7 Alternator Rotor Removal.................3-3-7 Alternator Rotor Installation................3-3-8 Alternator Rotor Installation................3-3-8 Alternator Stator Removal.................3-3-8...
Page 85: Exploded View
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Exploded view 23 23 23 23 22 22 23 23 23 23 3-3-2...
Page 86 ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Stator Cover Plug 13.3 O-Ring 35×3.5 Left Crankcase Cover Left Crankcase Cover Gasket Alternator Stator Plate Bolt M6×16 87 in•lb Bolt M6×35 113 in•lb Nut M18×1.5 18.4 Alternator Rotor Double Gear Shaft One-Way Clutch Spacer 12×18×12 Bolt M6×16...
Page 87: Technical Parameter
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Technical Parameter Item Standard Service Limit Charging System: Charging System: – – – Alternator type Three-phase AC – – – Charging voltage 14 ~ 15V (Regulator/rectiﬁ er output voltage) – – – Alternator output voltage: 36 ~ 54V 3000r/min(rpm) –...
Page 88: Special Tools
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Special tools Flywheel Holder： Flywheel Puller Assembly : E01GZ0050001 E01GZ0010001 3-3-5...
Page 89: Charging System
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Charging System Alternator Cover Removal Alternator Cover Removal ◆ Place an coolant pan under the engine left side. ◆ Drain the coolant (see Cooling System chapter). ◆ Place an oil pan under the engine left side. ◆...
Page 90: Alternator Rotor Removal
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Alternator Rotor Removal Alternator Rotor Removal ◆ Remove: 1. Alternator Cover (see Alternator Cover Removal) 2. Alternator rotor Nut M18×1.5【A】 3. Thread the flywheel puller【B】onto the alternator rotor. Special Tool - Flywheel Puller Special Tool - Flywheel Puller: : E01GZ0010001 E01GZ0010001 Flywheel Holder Flywheel Holder: : E01GZ0050001...
Page 91: Alternator Rotor Installation
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Alternator Rotor Installation Alternator Rotor Installation ◆ Clean【A】the inside of the rotor and the end of the crankshaft. ◆ Fit the rotor onto the crankshaft so that woodruﬀ key [B] ﬁ ts in the groove【C】in the hub of the rotor. ◆...
Page 92: Alternator Stator Installation
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Alternator Stator Installation Alternator Stator Installation ◆ Apply a non-permanent locking agent to the area 【A】 (12 mm, 0.47 in.) except for the tip【B】(2 ~ 3 mm, 0.08 ~ 0.12 in.) ◆ Tighten: Torque Bolts M6×35 13 N•m (1.3 kgf•m, 113 in•lb) Bolts M6×16 9.8 N•m (1.0 kgf•m, 87in•lb)
Page 93: Alternator Inspection
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Alternator Inspection Alternator Inspection There are three types of alternator failures: short, open, or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all.
Page 94 ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Stator Coil Resistance Stator Coil Resistance Connections Tester Reading Range Tester (+) to Tester (–) to One yellow Another 0.33~0.49 Ω ×1Ω lead yellow lead If there is more resistance than shown in the table, or no reading (inﬁ...
Page 95: Electric Starter System
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal Starter Motor Removal ◆ Remove Starter Motor Cable【A】 Starter Motor Mounting Bolts【B】 Starter Motor【C】 CAUTION CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged. Starter Motor Installation Starter Motor Installation ◆...
Page 96 ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM One-Way Clutch Removal One-Way Clutch Removal ◆ Remove the Alternator Rotor (see Alternator Rotor Removal). ◆ Hold the rotor with the Flywheel Holder and take out the One-Way Clutch Bolts [A]. ◆ Take out the One-Way Clutch [B]. One-Way Clutch Installation One-Way Clutch Installation ◆...
Page 97: Starter Gear Assembly
ENGINE-ELECTRICAL SYSTEM ENGINE-ELECTRICAL SYSTEM Starter Gear Removal Starter Gear Removal ◆ Remove 1. Alternator Rotor (see Alternator Rotor Removal) 2. Spacer【E】 3. Washer【D】 4. Double Gear Shaft【C】 5. Needle Roller Bearing【B】 6. Remove the Starter Gear Assembly【A】 Visually inspect the Starter Gear If the gear does not operate correctly, or if it makes noise, disassemble it and examine each part visually.
Page 98 ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Exploded View .....................3-4-2 Technical Parameter..................3-4-4 Special Tools .......................3-4-5 Water Pump ......................3-4-6 Water Pump Removal ..................3-4-6 Water Pump Removal ..................3-4-6 Water Pump Installation ................3-4-6 Water Pump Installation ................3-4-6 Water Pump Cover Removal ................3-4-7 Water Pump Cover Removal ................3-4-7 Impeller Removal..................3-4-7 Impeller Removal..................3-4-7...
Page 99: Exploded View
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Exploded view 3-4-2...
Page 100 ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Water Pump Assembly Bolt M6×60 87 in•lb Bolt M6×65 87 in•lb Bolt M6×35 87 in•lb Hose,11×20×671 Clamp,Hose O-Ring 33×2.62 Water Pump Gasket Clamp,Springband Connector,Tee Hose,12×20×147 Adapter,Water Pipe Aluminum Washer 14×21×1.5 Water Temperature Sensor Hose,12×20×455 Bolt M6×12...
Page 101: Technical Parameter
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Technical Parameter Item Standard Service Limit Coolant provided when shipping: – – – Type Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) – – – Color Green –...
Page 102: Special Tools
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Special tools Bearing Driver Set Bearing Remover Head Bearing Remover Shaft 3-4-5...
Page 103: Water Pump
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Water Pump Water Pump Removal Water Pump Removal ◆ Drain the engine coolant and oil ◆ Remove: Clamp【A】 Cooling Hoses【B】 Water Pump Bolts【C】 Water Pump【D】 Water Pump Gasket【E】 Water Pump Installation Water Pump Installation ◆ Apply engine oil to the Oil Pump O-ring【A】 ◆...
Page 104: Water Pump Cover Removal
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Water Pump Cover Removal Water Pump Cover Removal ◆ Remove: Water Pump Cover Bolts【A】 Water Pump Cover【B】 Water Pump Cover Seal【C】 Impeller Removal Impeller Removal ◆ Loosen the water pump impeller Bolt【D】counter- clockwise. ◆ Remove the Gasket【E】 ◆...
Page 105: Water Pump Shaft Removal
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Water Pump Shaft Removal: Water Pump Shaft Removal: ◆ Remove: Water Pump Shaft【A】 Washer【B】 Circlip【C】 Bearing【D】 Spacer【E】 Bearing【D】 Oil Seal【F】 ◆ Take the bearing【D】out of the Water Pump Body, using the bearing remover. Special Tools - Bearing Remover Shaft【G】 Bearing Remover Head【...
Page 106 ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM ◆ Using a suitable socket【A】 and the bearing driver 【B】, press and insert a new mechanical seal【C】 until its ﬂ ange stops at the step【D】of the hole. Special Tool - Bearing Driver Set ◆ From inside the Water Pump Body, press and insert the ball bearing【E】until it is bottomed.
Page 107: Water Pump Cover Installation
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM ◆ Clean the sliding surface of a new mechanical seal with a high flash-point solvent, and apply a little coolant to the sliding surface to give the mechanical seal initial lubrication. ◆ Apply coolant to the surfaces of the rubber seal and sealing seat【A】, and press the rubber seal【B】...
Page 108: Thermostat
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Thermostat Thermostat Removal Thermostat Removal ◆ Drain the coolant (see Cooling System in Periodic Maintenance chapter). ◆ Remove: Thermostat Housing Cover Bolts【B】 Thermostat Housing Cover【C】 Thermostat【A】 Thermostat Installation Thermostat Installation ◆ Be sure to install the O-ring【D】on the Thermostat ◆...
Page 109: Thermostat Inspection
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Thermostat Inspection Thermostat Inspection ◆ Remove the thermostat, and inspect the thermostat valve【A】at room temperature. If the valve is open, replace the valve with a new one. ◆ To check valve opening temperature, suspend the thermostat【A】and an accurate thermometer 【B】in a container of water with the heat-sensitive portions【C】in almost the same depth.
Page 110: Coolant Temperature Sensor
ENGINE-COOLING SYSTEM ENGINE-COOLING SYSTEM Coolant Temperature Sensor Coolant Temperature Sensor Removal Coolant Temperature Sensor Removal CAUTION CAUTION The coolant temperature sensor should never be allowed to fall on a hard surface. Such a shock to the part can damage it. ◆...
Page 111 ENGINE TOP END ENGINE TOP END ENGINE TOP END ENGINE TOP END Exploded View ....................3-3-5-3 Exploded View ....................3-3-5-3 Specifications ....................3-5-6 Specifications ....................3-5-6 Special Tools ....................3-5-9 Special Tools ....................3-5-9 Spark Plug / Valve Cover / Throttle Body / Camshaft ....3-5-10 Spark Plug / Valve Cover / Throttle Body / Camshaft ....3-5-10 Throttle Body Removal ..................3-5-11 Throttle Body Removal ..................3-5-11 Throttle Body Installation ................3-5-11...
Page 112 ENGINE TOP END ENGINE TOP END Cylinder Head Inspection ................3-5-21 Cylinder Head Inspection ................3-5-21 Cylinder Head Warp ..................3-5-21 Cylinder Head Warp ..................3-5-21 Cylinder Head Disassembly ................3-5-22 Cylinder Head Disassembly ................3-5-22 Cylinder Head .....................3-5-23 Cylinder Head .....................3-5-23 Valve Guide / Valve Inspection ...............3-5-23 Valve Guide / Valve Inspection ...............3-5-23 Combustion Chamber Cleaning ..............3-5-24 Combustion Chamber Cleaning ..............3-5-24...
Page 113: Exploded View
ENGINE TOP END ENGINE TOP END Exploded view 3-5-3...
Page 114 ENGINE TOP END ENGINE TOP END Torque Fastener Remarks N·m kgf·m ft·lb Bolt M6×20 87 in•lb Chain Guard Shoulder Bolt Chain Tensioner 87 in•lb Chain Guide Plate Timing Chain Pipe/Line Fixing Plate Bolt M6×25 87 in•lb Tensioner Gasket Tensioner Base Gasket R / SS Cylinder Cylinder Head Gasket...
Page 115 ENGINE TOP END ENGINE TOP END Torque Fastener Remarks N·m kgf·m ft·lb Second Conpression Ring Oil Ring Combination Piston Pin G: Apply grease for oil seal and O-ring. L: Apply a non-permanent locking agent. O: Apply engine oil. SS: Apply silicone sealant. S: Follow the speciﬁ...
Page 116 ENGINE TOP END ENGINE TOP END Technical Parameter Item Standard Service Limit Cylinder Head: Cylinder compression(usable range) Electric starter 450 ~700 kPa (4.7 ~ 7.2 kgf/cm²,65 ~ 102 psi) @ 300 r/min (rpm) – – – Cylinder head warp – – – 0.05 mm (0.002 in.) Cylinder Head Height 120.5 ±...
Page 117 ENGINE TOP END ENGINE TOP END Item Standard Service Limit Piston Pin: Piston Pin O.D. 21.995 ~ 22.000 mm (0.8659" ~ 0.8661") 21.975(0.8652") Piston Ring: Installed Gap: Top Ring 0.20 ~ 0.35 mm (0.0079" ~ 0.0138") 0.5 mm (0.0197") Second Ring 0.35 ~ 0.55 mm (0.0138"...
Page 118 ENGINE TOP END ENGINE TOP END Item Standard Service Limit Cylinder: Cylinder - Surface Warp Limit 0.05 mm (0.002") – – – Cylinder Bore - Standard: Ⅰ 98.992 ~ 99.000 mm (3.8973" ~ 3.8976") 99.08 mm (3.9008") 99.000 ~ 99.008 mm (3.8976" ~ 3.8980") 99.09 mm (3.9012") Ⅱ...
Page 119: Special Tools
ENGINE TOP END ENGINE TOP END Special tools Valve Spring Compressor Assembly Compression Gauge Valve Spring Compressor Adapter Compression Gauge Adapter, M10×1.0 3-5-9...
Page 120: Spark Plug / Valve Cover / Throttle Body / Camshaft
ENGINE TOP END ENGINE TOP END Spark Plug / Valve Cover / Throttle Body / Camshaft 3-5-10...
Page 121: Throttle Body Removal
ENGINE TOP END ENGINE TOP END Throttle Body Throttle Body Removal Throttle Body Removal ◆ Remove Clamp 50 ~ 70【A】 Throttle Body【B】 Throttle Body Installation Throttle Body Installation ◆ Install Throttle Body Clamp 50 ~ 70 Air Intake Pipe Air Intake Pipe Removal: Removal: ◆...
Page 122: Fuel Injector Removal
ENGINE TOP END ENGINE TOP END Fuel Injector / Thermostat Fuel Injector Removal Fuel Injector Removal ◆ Disconnect the Fuel Injector Lead. ◆ Remove: Fuel Injector Bolts【A】 Fixed Plate【B】 Fuel Injector Press Plate【C】 Fuel Injector Adapter【D】 Fuel Injector【E】 Fuel Injector Installation Installation Fuel Injector【E】...
Page 123: Spark Plug Removal
ENGINE TOP END ENGINE TOP END Ignition Coil / Spark Plug Spark Plug Spark Plug Removal Removal ◆ Disconnect the Ignition Coil Lead. ◆ Remove: Bolt M6 ×20【A】 Ignition Coil【B】 Spark Plug【C】 CAUTION CAUTION The Spark Plug should never be allowed to fall on a hard surface.
Page 124: Valve Cover Removal
ENGINE TOP END ENGINE TOP END Valve Cover Valve Cover Valve Cover Removal Removal ◆ Remove: Shoulder Bolts [B] (using a T40 driver) Isolators【A】 Valve Cover【C】 Valve Cover Seal【D】 Dowel Pin 10×14【E】 Valve Cover Installation: Valve Cover Installation: ◆ Replace isolators【B】and valve cover seal【C】if oil leaks are evident.
Page 125: Crank Position Sensor Removal
ENGINE TOP END ENGINE TOP END Crank Position Sensor Crank Position Sensor Removal Crank Position Sensor Removal ◆ Disconnect the Crank Position Sensor Lead. ◆ Remove: Bolt M6×16【A】 Crank Position Sensor【B】 O-Ring 17×2【C】 ◆ Remove: Stator Cover Plug【E】 O-Ring 35×3.5【D】 ◆...
Page 126: Camshaft Chain Tensioner Removal
ENGINE TOP END ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal Camshaft Chain Tensioner Removal CAUTION CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up cam chain slack.
Page 127: Camshaft Carrier Removal
ENGINE TOP END ENGINE TOP END Camshaft Carrier / Camshaft Camshaft Carrier Removal Camshaft Carrier Removal ◆ Remove the bolts M6 ×65【 A】retaining the fixed cam chain guide【B】and remove the assembly from the engine. ◆ Remove Bolts M6 ×35【C】 Camshaft Carrier【D】 Dowel Pin 8×14【E】...
Page 128: Automatic Compression Release
ENGINE TOP END ENGINE TOP END Camshaft Inspection Automatic Compression Release Automatic Compression Release The Automatic Compression Release momentarily opens the exhaust valves on the compression stroke at very low speeds. This allows some of the compression pressure to escape, making it easy to turn over the engine during starting.
Page 129: Automatic Compression Release Removal
ENGINE TOP END ENGINE TOP END Automatic Compression Release Removal Automatic Compression Release Removal ◆ Remove: Camshaft (see Camshaft Removal) Circlip【C】 Automatic Compression Release Unit【D】 Dowel Pin【E】 Automatic Compression Release Installation Automatic Compression Release Installation ◆ Install: Dowel Pin【E】 Automatic Compression Release Unit【D】 Circlip【C】...
Page 130: Cam Wear
ENGINE TOP END ENGINE TOP END Camshaft / Camshaft Bore Inspection Cam Wear Cam Wear ◆ Visually inspect each cam lobe for wear or damage. ◆ Measure the height【D】of the cam with a micrometer. If the cams are worn past the service limit, replace the camshaft.
Page 131: Cylinder Head
ENGINE TOP END ENGINE TOP END Cylinder Head Cylinder Head Removal Cylinder Head Removal NOTE NOTE The cylinder head can be serviced with the engine installed in the chassis. ◆ Remove the (2) outer M6 bolts【A】that retain the cylinder head【B】to the cylinder. ◆...
Page 132: Cylinder Head Disassembly
ENGINE TOP END ENGINE TOP END Cylinder Head Disassembly Cylinder Head Disassembly WARNING WARNING Wear eye protection during cylinder head disassembly and reassembly or when working with the valve springs. IMPORTANT: Keep mated parts together and in order with respect to their location in the cylinder head for assembly purposes.
Page 133: Valve Guide / Valve Inspection
ENGINE TOP END ENGINE TOP END ◆ Measure the free length of each valve spring with a Vernier caliper and compare to speciﬁ cation. ◆ Valve Spring Free Length: Standard: 1.726" (43.85 mm)Service Limit: 1.683" (42.75 mm) Standard Service Limit 42.5 mm (1.6732") 41.4mm (1.6299") Valve Guide / Valve Inspection...
Page 134: Combustion Chamber Cleaning
ENGINE TOP END ENGINE TOP END NOTE NOTE The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent or damaged. ◆ Measure diameter of valve stem with a micrometer in three places, then rotate 90° and measure again (take six measurements total).
Page 135: Valve Seat Reconditioning
ENGINE TOP END ENGINE TOP END Valve Seat Reconditioning Valve Seat Reconditioning ◆ Valve seat reconditioning should be performed by a technician proﬁ cient in cylinder head reconditioning techniques. Reconditioning techniques vary, so follow the instructions provided by the valve reconditioning equipment manufacturer.
Page 136: Valve Seat Repair (Valve Lapping)
ENGINE TOP END ENGINE TOP END Valve Seat Repair (Valve Lapping) Valve Seat Repair (Valve Lapping) ◆ Install pilot into valve guide. ◆ Apply cutting oil to valve seat and cutter. ◆ Place 46° cutter on the pilot and make a light cut. ◆...
Page 137 ENGINE TOP END ENGINE TOP END NOTE NOTE When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face【A】. Proper Seat Contact on Valve Face INTAKE...
Page 138 ENGINE TOP END ENGINE TOP END ◆ Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly oﬀ of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to ﬁ ve times until the valve is fully seated, and the seating surface is smooth, Then repeat process for the other valve(s).
Page 139: Cylinder And Piston
ENGINE TOP END ENGINE TOP END Cylinder and Piston Cylinder Removal Cylinder Removal ◆ Remove: Cylinder Head (see Cylinder Head Removal) Cylinder Bolt【A】 Cylinder【B】 Cylinder Base Gasket【C】 Piston Removal Piston Removal ◆ Remove the cylinder block (see Cylinder Removal). ◆ Place a piece of clean cloth under the piston and remove the piston pin snap rings【A】from the outside of the piston.
Page 140: Cylinder, Piston Installation
ENGINE TOP END ENGINE TOP END Cylinder, Piston Installation Cylinder, Piston Installation NOTE NOTE If a new piston or cylinder is used, check piston to cylinder clearance (see Piston/Cylinder Clearance), and use new piston rings. The oil ring rails have no “top” or “bottom”. ◆...
Page 141: Piston Wear
ENGINE TOP END ENGINE TOP END ◆ Install: Dowel Pins【A】 New Cylinder Base Gasket【B】 Cylinder【C】 Bolt【D】 ◆ Tighten: Torque Bolt【D】 9.8 N·m (1.0 kgf·m, 87 in·lb) CAUTION CAUTION Base gasket and surfaces must be DRY and oil free. Use care upon assembly to keep oil away. ◆...
Page 142: Piston/Cylinder Clearance
ENGINE TOP END ENGINE TOP END Piston/Cylinder Clearance Piston/Cylinder Clearance ◆ Subtract the piston diameter from the cylinder inside diameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.051 ~ 0.069 mm (0.0020" ~ 0.0027".) Piston Ring, Piston Ring Groove Wear Piston Ring, Piston Ring Groove Wear ◆...
Page 143: Piston Ring End Gap
ENGINE TOP END ENGINE TOP END If any of the measurements is less than the service limit on either of the rings, replace all the rings. CAUTION CAUTION When using new rings in a used piston, check for uneven groove wear. The rings should fit perfectly parallel to the groove sides.
Page 144: Cylinder Head Installation
ENGINE TOP END ENGINE TOP END Cylinder Head Installation Cylinder Head Installation Cylinder Head Installation ◆ Install: Dowel Pins【A】 New Cylinder Head Gasket【B】 Camshaft Chain Guide【C】 Camshaft Chain Guide【D】 Shoulder Bolts【E】(using a T40 driver) ◆ Tighten: Torque Shoulder Bolts 9.8 N·m (1.0 kgf·m, 87 in·lb) ◆...
Page 145: Camshaft Installation / Timing
ENGINE TOP END ENGINE TOP END Camshaft Installation / Timing CAUTION CAUTION If any valve train components were replaced, refer to Valve Clearance Adjustmentpage procedure. Camshaft In Camshaft Installation / Timing stallation / Timing ◆ Rotate the engine until the ﬂ ywheel Top Dead Center (TDC) mark is aligned or centered in the Crankshaft Position Sensor (CPS) mounting hole.
Page 146: Camshaft Chain Tensioner Installation
ENGINE TOP END ENGINE TOP END ◆ Tighten the camshaft carrier bolts (M6)【D】and 【E】following the tightening sequence as shown. Torque Bolts M6 9.8 N•m (1.0kgf•m, 87in•lb) ◆ Install Chain Guard【A】 Bolts M6×20【B】 ◆ Tighten: Torque Bolts M6×20【B】 9.8 N•m (1.0kgf•m, 87in•lb) Camshaft Chain Tensioner Installation Camshaft Chain Tensioner Installation ◆...
Page 147: Valve Clearance Adjustment
ENGINE TOP END ENGINE TOP END Valve Clearance Adjustment Timing View For Camshafts IMPORTANT IMPORTANT：： Always inspect valve clearance prior to camshaft installation or ﬁ nal engine assembly. ◆ Camshaft installation installation (See the Camshaft Installation Camshaft Installation / Timing / Timing) ◆...
Page 148 ENGINE TOP END ENGINE TOP END ◆ Record the 3 digit number on the bottom of the tappet【A】. ◆ Reference the valve clearance measurement recorded for that valve, along with the 3 digit tappet number. ◆ Refer to the appropriate tappet selection matrix (Intake or Exhaust) on the following pages and select the proper tappet.
Page 149: Valve Lash - Tappet Selection
ENGINE TOP END ENGINE TOP END Valve Lash - Tappet Selection IMPORTANT IMPORTANT The Valve Lash Speciﬁ cation and Measured Valve lash must be calculated in millimeters (mm), A 480 tappet means the thickness of the tappet is 4.80 mm. ◆...
Page 150: Valve Cover Installation
ENGINE TOP END ENGINE TOP END Valve Cover Installation Valve Cover Installation Valve Cover Installation ◆ Install: Spark Plug【A】 Dowel Pin 10×14【B】 Valve Cover Seal【C】 Valve Cover【D】 New Isolators【E】 Shoulder Bolts【F】 (using a T40 driver) Oil Fill Cap Seal【G】 O-Ring 22×3【H】 Oil Fill Cap【J】...
Page 151 ENGINE TOP END ENGINE TOP END Cylinder Compression ◆ The following table should be consulted if the obtainable compression reading is not within the usable range. Problem Diagnosis Remedy (Action) Carbon accumulation on piston, cylinder Remove the carbon deposits head, and in combustion chamber possibly and replace damaged parts if due to damaged valve stem oil seal and/ necessary.
Page 152 CVT SYSTEM CVT SYSTEM CVT SYSTEM CVT SYSTEM Exploded View ..................3-6-2 Exploded View ..................3-6-2 Specifications ..................3-6-6 Specifications ..................3-6-6 Special Tools ..................3-6-7 Special Tools ..................3-6-7 CVT Cover ......................3-6-8 CVT Cover ......................3-6-8 CVT Outer Cover Removal ..............3-6-8 CVT Outer Cover Removal ..............3-6-8 CVT Outer Cover Installation ..............3-6-8 CVT Outer Cover Installation ..............3-6-8 CVT Inner Cover Removal ..............3-6-9...
Page 153: Exploded View
CVT SYSTEM CVT SYSTEM Exploded view 3-6-2...
Page 154 CVT SYSTEM CVT SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb CVT Inner Cover CVT Outer Cover CVT Cover Seal CVT Inner Cover Seal Ⅰ CVT Inner Cover Seal Ⅱ O-Ring 30×3 CVT Cover Plug Seal Bolt M6×28 87 in•lb CVT Cover Plug Bolt M12×1.25×142 12.2 R,Lh...
Page 155 CVT SYSTEM CVT SYSTEM 3-6-4...
Page 156 CVT SYSTEM CVT SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Drive Fixed Sheave Drive Fixed Shaft Circlip 52 Bearing 61808-2RS Cam Pin Cam Spring One-Way Bearing Housing Spring Seat Drive Pulley Spring Bushing 60×55×20 Bushing 36×32×15 Drive Movable Sheave Counterweight Shoes Thrust Plate Shoes 0.61 Screw M4×8...
Page 157 CVT SYSTEM CVT SYSTEM Technical Parameter Item Standard Service Limit Drive Belt: Belt deﬂ ection 22 ~ 27 mm (0.87 ~ 1.06") – – – Belt height (Parallel portion) 3.0 ~ 3.5 mm (0.118" ~ 0.138") 0.65 mm(0.026") Drive Pulley: 55.005 ~ 55.095 mm (2.166"...
Page 158: Special Tools
CVT SYSTEM CVT SYSTEM Special tools Circlip Pliers : Drive Pulley Puller Bolt : E01GZ0060001 E01GZ0000008 Belt Separate Bolt : Drive Pulley Holder : E01GZ0000013 E01GZ0000012 Spring Holder Set : E01GZ0050001 3-6-7...
Page 159: Cvt Cover
CVT SYSTEM CVT SYSTEM CVT Cover WARNING WARNING Excessive imbalance or operating rpm could cause CVT pulley failure resulting in severe injury or death. The pulleys of the CVT are precision balanced components designed to operate within certain rpm limits. Disassembly/assembly and servicing procedures of the pulley assemblies must be followed closely.
Page 160: Cvt Inner Cover Removal
CVT SYSTEM CVT SYSTEM CVT Inner Cover Removal CVT Inner Cover Removal ◆ Remove the Drive Pulley and Driven Pulley (See Drive Pulley Removal) ◆ Remove: Bolts M8 ×28【A】 Remove CVT Inner Cover assembly CVT Inner Cover Disassembly: CVT Inner Cover Disassembly: ◆...
Page 161: Drive Belt
CVT SYSTEM CVT SYSTEM Drive Belt Drive Belt Removal Removal ◆ Remove the drive pulley【A】(see Drive Pulley Removal). NOTE NOTE Before removing the drive belt, observe the direction of the informations【A】(Such as manufacturers name and arrow marks) printed on the belt so that it may be reinstalled on the pulleys as originally.
Page 162: Drive Pulley And Driven Pulley
CVT SYSTEM CVT SYSTEM Drive Pulley and Driven Pulley Drive Pulley and Driven Pulley Removal Drive Pulley and Driven Pulley Removal ◆ Remove: Torque CVT Cover (see Torque Converter Cover Removal) ◆ Loosen the drive pulley bolt【E】 (left-hand threads) NOTE NOTE The drive pulley bolt has left-hand threads.
Page 163: Drive Pulley Disassembly
CVT SYSTEM CVT SYSTEM Drive Pulley Disassembly Drive Pulley Disassembly ◆ Turn clockwise from the drive pulley assembly to loosen the Nut【A】. Special Tool - Drive Pulley Holder: E01GZ0000012 ◆ Remove: Nut [A] Assembly【B】 Thrust Plate Counterweight Shoes【C】 Drive Movable Sheave【D】 Drive Pulley Spring【E】...
Page 164: Drive Pulley Inspection
CVT SYSTEM CVT SYSTEM Drive Pulley Inspection Drive Pulley Inspection ◆ If the sheave surfaces【A】appear damaged, replace the sheaves. ◆ Measure the inside diameter【B】and【C】of the Bushings. ◆ If the Drive Move Pulley Bushing is damaged or worn, replace the Drive Move Pulley. Bushing 60×55×20 inside Diameter:【C】...
Page 165 CVT SYSTEM CVT SYSTEM ◆ One-Way Bearing Inspection: ◆ If the One-Way Bearing Assembly【A】turns counterclockwise【A】freely from the Dirve Fixed Sheave, but not clockwise【B】, the One-Way Bearing is operating correctly. ◆ If the One-Way Bearing does not operate correctly, or if it makes noise, disassemble it and examine each part visually.
Page 166: Drive Pulley Assembly
CVT SYSTEM CVT SYSTEM Drive Pulley Assembly Drive Pulley Assembly ◆ Clean off any grease or dirt on the movable and ﬁ xed sheaves, and dry them with a clean cloth. ◆ Install the One-Way Bearing. 1. Install the Cam Pin【A】and Cam Spring【N】 together into the mounting hole of Drive Fixed Shaft.
Page 167 CVT SYSTEM CVT SYSTEM 6. Thrust Plate assembly: Install all three Thrust Plate Shoes【B】to the gap of the Thrust Plate【A】. Install Screws M4×8【C】,Spring Washer【D】and Spacer【E】 ◆ Tighten: Torque Screws M4×8 6 N•m (0.6kgf•m, 53in•lb) Apply a non-permanent locking agent to the Screws 【C】.
Page 168: Driven Pulley Disassembly
CVT SYSTEM CVT SYSTEM Driven Pulley Disassembly Driven Pulley Disassembly ◆ Hold the spring holder set【C】in the Driven Pulley Disassembly【B】. ◆ Put the CVT Driven Pulley Assembly【B】on the guide bar of the spring holder set. ◆ Screw the Bolt【D】of the spring holder set into the holder.
Page 169: Driven Pulley Inspection
CVT SYSTEM CVT SYSTEM Driven Pulley Inspection Driven Pulley Inspection If the sheave surfaces【A】appear damaged, replace the sheaves. ◆ Replace the sheave with uneven wear on the belt contacting surfaces. Sheave Surface【B】 Straight Edge【C】 If the sheave bushings【D】are damaged or worn, replace the movable sheave or fixed sheave.
Page 170: Driven Pulley Assembly
CVT SYSTEM CVT SYSTEM ◆ Check the guide Surfaces【D】of the Driven Pulley Guide Seat【B】 ◆ If any of the guide Surfaces appear damaged, replace the Driven Pulley Guide Seat. Circlip【A】 Dirven Pulley Guide Seat【B】 Dirven Fixed Shaft【C】 Driven Pulley Assembly Driven Pulley Assembly ◆...
Page 171 CVT SYSTEM CVT SYSTEM 4. Align the match–marks on the sheaves, made when disassembled, and the openings【A】and grooves 【B】will be matched easily. 5. Install the guide bar of the spring holder set【C】into the Dirven Pulley Guide Seat Assembly【D】. Special Tool - Spring Holder Set : E01GZ0050001 6.
Page 172: Drive Pulley And Driven Pulley Installation
CVT SYSTEM CVT SYSTEM Drive Pulley and Driven Pulley Installation Drive Pulley and Driven Pulley Installation ◆ Clean the following portions with an oil-less cleaning fluid such as trichloroethylene or acetone. Fixed Sheave Tapered Portion【A】 Crankshaft Tapered Portion【B】 WARNING WARNING These cleaning ﬂ...
Page 173 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Exploded view of Front Diﬀ erential………………....……………………4-3 Specifications …………………………………....…………………………4-4 Special tools……………………………....…………………………………4-6 Front Diﬀ erential gear oil replacement ……………….....……………………4-7 Drain gear oil…………………………....…………………………………4-7 Add gear oil……………………………....…………………………………4-7 Front Diﬀ erential Disassembly ………………………....……………………4-8 Universal Joint Removal ………………………..………………………4-8 Univerasl Joint Inspection ………………………....……………………4-8 Transfer Case Assembly Removal ……………....……………………4-8...
Page 174 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Exploded view of Rear Diﬀ erential （locking and unlocking） ......4-23 Rear Diﬀ erential gear oil replacement ..............4-24 Drain gear oil......................4-24 Add gear oil......................4-24 Inspection of parts wear..................4-25 Oil seal 37×55×7....................4-25 Disassemble.......................4-25 Assemble......................4-25...
Page 175 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Exploded view of Front Diﬀ erential Torque Fastener Remarks N·m kgf·m ft·lb FRONT DIFFERENTIAL ASSEMBLY FRONT DIFFERENTIAL DIFFERENTIAL COMBINATION DRIVE & DRIVEN BEVEL GEAR KIT UNIVERSAL JOINT COMBINATION CONNECTION FORK B UNIVERSAL JOINT CONNECTION FORK A LOCKED NUT M14×1.5 18.3...
Page 176 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Torque Fastener Remarks N·m kgf·m ft·lb PLUG M18×1.5 1.83 FRONT Diﬀ erential GEAR BOX CASE SLIDING SLEEVE DIVIDE DEVICE CONNECTION BEARING 16007 O-RING 140×2.65 FRONT Diﬀ erential GEAR BOX COVER AIR TAP PIPE 600 SPRING BAND HOSE CLAMPS BOLT M8×28...
Page 177 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Speciﬁ cations Item Standard Service Limit Front gear box: Type SAE 80W/90 GL-5 Refueling position Side of the box(PLUG M18) Oil drain position Bottom of the box(PLUG M14) Capacity 300 mL (0.32 US qt) (When there is no oil stains after internal cleaning) 280 mL (0.3 US qt) (Only when changing gear oil)
Page 178 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Special Tools Inside Circlip Plisers: Silicone Sealant: Round nut M75×1.5×6-LH sleeve T-sleeve 10mm 4 - 6...
Page 179 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Front Diﬀ erential gear oil replacement WARNING WARNING Vehicle operation with insufficient,deteriorated,or Vehicle operation with insufficient,deteriorated,or contaminated engine oil will cause accelerated contaminated engine oil will cause accelerated wear and may result in Gearbox Damage, wear and may result in Gearbox Damage, accident,and injury.
Page 180 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Front Diﬀ erential Disassembly: Universal Joint Removal: ◆ Remove 【A】Circlip 12 【B】 Needle Roller Bearing 【C】Univerasl Joint 【D】Connection Fork B 【E】Locked Nut M14 × 1.5 【F】O-Ring 14 × 6.8 【G】Connection Fork A universal joint Inspection：...
Page 181 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Front Diﬀ erential Disassembly ◆ Remove 【A】Bolt M8×28 ◆ Remove 【B】Front Diﬀ erential Gear Box Cover 【C】O-Ring 104×2.65 【D】SHIMS 【E】Diﬀ erential Gear Assy 【F】SHIMS 【G】Front Diﬀ erential Gear Box Cover Front Diﬀ erential Gear Box Case Disassembly ◆...
Page 182 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Bearing and Oil Seal Ball or Needle Bearing Inspection Since the bearings are made to extremely close tolerances,the clearance cannot normally be measured. CAUTION CAUTION Do not remove bearing【C】【D】for inspection. Removal may damage it. Check the ball bearing.
Page 183 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Oil Seal Inspection ◆ Inspect the oil seals【A】【B】 R e p l a c e a n y i f t h e l i p s a r e m i s s h a p e n , d i s c o l o r e d ( i n d i c a t i n g t h a t t h e r u b b e r h a s deteriorated), hardened, or been otherwise damaged.
Page 184 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Bevel Gear Bevel Gear Bevel Gear Inspection ◆ Visually check the bevel gears【A】for scoring, chipping, or other damage. Replace the bevel gears as a set if either gear is damaged. Bevel Gear (Backlash-related Parts) 【A】.
Page 185 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL 4 - 13...
Page 186 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Bevel Gear Adjustment ◆ The backlash and tooth contact pattern of the bevel gears must be correct to prevent the gears from making noise and being damaged. ◆ After replacing any of the backlash-related parts, be sure to check and adjust the backlash and tooth contact of the bevel gears.
Page 187 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Front Diﬀ erential Installation Front Diﬀ erential Gear Box Case Assembly ◆ Install: Grease the lip of the Oil Seal【B】and press the Seal 0.5mm inwards from the end of the boss. ◆ Press and insert the new needle bearing until it is bottomed ◆...
Page 188 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL ◆ Install Universal Joint Combination: Install the【B】cross universal joint knot assembly into the 【A】fork B. Press and insert the【C】needle bearing until it is bottomed. Install the【D】Circlip into the mounting groove of the【C】needle bearing. Front Diﬀ...
Page 189 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL ◆ Install: 【A】Divide Device Connection 【B】Sliding Sleeve ◆ Install: 【C】Fork 【D】Rack 【E】Cylindrical Pin 5×75 【F】Plug M8×10 ◆ Move the Rack to the bottom in the indicated direction【G】. ◆ Install: 【H】O-Ring 72.7×2.4 【I】Transfer Case Assembly ◆...
Page 190 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL F r o n t D i f f e r e n t i a l G e a r B o x 【A】Front Diﬀ erential Gear Box Case Assembly 【B】Diﬀ erential Gear Assy 【C】Shim(s) 61.5×50×t, (t=0.1,0.15,0.2,0.5) 【D】Shim(s) 83×71×T, (T=0.1,0.15,0.2,0.5) 【E】O-Ring 140×2.65...
Page 191 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Front Diﬀ erential Function Inspection 【A】2WD Position Switch control transfer case is in the 2WD position, Sliding Spline Sleeve【D】is in rest position,no parts engaged.there is no power output to the front wheel at this time.
Page 192 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Exploded view of Rear Diﬀ erential（locked） Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange boltsM10×1.0×20 51.6 Hexagon ﬂ ange boltsM10×1.0×30 51.6 Breathing joint 103.6 in·lb Hexagon ﬂ ange boltsM8×25 17.7 Screw plug assembly M14 13.3 Screw plug M14 G: Apply grease for oil seal and O-ring.
Page 193: Rear Diff Erential Gear Oil Replacement
FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Rear Diﬀ erential gear oil replacement WARNING WARNING Vehicle operation with insuﬃ cient,deteriorated,or Vehicle operation with insuﬃ cient,deteriorated,or contaminated engine oil will cause accelerated contaminated engine oil will cause accelerated wear and may result in Diﬀ erential Damage, wear and may result in Diﬀ...
Page 194 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Gear clearance adjustment WARNING WARNING If the gear gap is not adjusted well, it will aggravate the wear of gear parts, resulting in abnormal gear transmission noise, gear surface pitting, reduced transmission eﬃ ciency, and shortened overall life. 【A】Driving bevel gear assembly 【B】Hexagon ﬂ...
Page 195 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Exploded view of Rear Diﬀ erential（locking and unlocking） Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolts M8×25 Breathing connector Large Pan Head Hexagon Bolt M6×16 Hexagon ﬂ ange bolts M10×1.25×30 Screw plug M14 Screw plug assembly M14 Hexagon ﬂ...
Page 196 FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Rear Diﬀ erential gear oil replacement WARNING WARNING Vehicle operation with insuﬃ cient,deteriorated,or Vehicle operation with insuﬃ cient,deteriorated,or contaminated engine oil will cause accelerated contaminated engine oil will cause accelerated wear and may result in Gearbox Damage, wear and may result in Gearbox Damage, accident,and injury.
Page 197: Inspection Of Parts Wear
FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Inspection of parts wear Oil seal 37×55×7 When 【A】has gear oil leakage or oil stains, please check 【B】 oil seal 37×55×7 and replace it in time. WARNING WARNING If it is not replaced in time, it will cause abnormal wear of other parts, and the overall temperature of the gearbox will increase, which will shorten its service life.
Page 198: Assemble
FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Oil seal 44×60×7 When F has gear oil leakage or oil stains, please check D in time and replace it in time WARNING WARNING If it is not replaced in time, it will cause abnormal wear of other parts, and the overall temperature of the gearbox will increase, which will shorten its service life.
Page 199: Tooth Gap Adjustment
FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Tooth gap adjustment WARNING WARNING If the gear gap is not adjusted properly, it will aggravate the wear of gear parts, resulting in abnormal gear transmission noise, tooth surface pitting, reduced transmission eﬃ ciency, and shortened overall life. 【A】Hexagon ﬂ...
Page 200: Solenoid Valve Assembly Inspection And Replacement
FRONT AND REAR DIFFERENTIAL FRONT AND REAR DIFFERENTIAL Solenoid valve assembly inspection and replacement If the vehicle is running normally without 4WD, and the solenoid valve assembly is energized and still not working, check 【B】 and replace it in time. WARNING WARNING If it is not replaced in time, the 2WD and 4WD will not work...
Page 201 FUEL SYSTEM FUEL SYSTEM Exploded view of Fuel System…………………………………………………………5-2 Fuel Tank…………………………………………………………………………………5-4 Disassembly……………………………………………………………………………5-4 Assembly………………………………………………………………………………5-4 Fuel Pump…………………………………………………………………………………5-5 Disassembly……………………………………………………………………………5-5 Inspection………………………………………………………………………………5-5 Assembly………………………………………………………………………………5-5 Fuel Filter…………………………………………………………………………………5-6 Disassembly……………………………………………………………………………5-6 Assembly………………………………………………………………………………5-6 5 - 1...
Page 202: Exploded View Of Fuel System
FUEL SYSTEM Exploded view of Fuel System Torque Fastener Remarks N·m kgf·m ft·lb Bolt M6×30 8~12 0.8~1.2 69~103.6 in·lb Install screw cap on oil pump 5 - 2...
Page 203: Fuel Tank
FUEL SYSTEM Fuel tank ◆ Whenever the gasoline line is removed, the battery must be disconnected to prevent accidental starting of the fuel pump. ◆ Fuel leakage may occur whenever any repair or inspection is carried out on the fuel system, and welding, smoking, open fires, etc., shall not be allowed in the area.
Page 204: Fuel Pump
FUEL SYSTEM Fuel Pump Fuel leakage may occur whenever any repair or inspection is carried out on the fuel system, and welding, smoking, open ﬁ res, etc., shall not be allowed in the area. Disassembly 【A】Install screw cap on fuel pump 【B】Fuel pump 【C】Seal ring ◆...
Page 205: Assembly
FUEL SYSTEM ◆ If the resistance reading is unstable, clean the resistance scraper with alcohol and retest. If it is still incorrect, replace the fuel pump. ◆ If the fuel pump supply pressure test does not meet the required value, then replace the pump. Assembly ◆...
Page 206: Fuel Filter
FUEL SYSTEM Fuel Filter ◆ Whenever the gasoline line is removed, the battery must be disconnected to prevent accidental starting of the fuel pump. ◆ Fuel leakage may occur whenever any repair or inspection is carried out on the fuel system, and welding, smoking, open fires, etc., shall not be allowed in the area.
Page 207 COOLING SYSTEM COOLING SYSTEM Exploded view of Cooling System…………………………………………………… 6-2 Coolant Flow…………………………………………………………………………… 6-3 Technical Parameter…………………………………………………………………… 6-5 Special Tool……………………………………………………………………………… 6-7 Coolant…………………………………………………………………………………… 6-7 Coolant deterioration inspection……………………………………………………… 6-7 Coolant level check…………………………………………………………………… 6-7 Pressure test…………………………………………………………………………… 6-8 Radiator removal………………………………………………………………………… 6-9 Radiator fan removal………………………………………………………………… 6-10 Radiator fan installation……………………………………………………………… 6-10 Radiator Inspection …………………………………………………………………...
Page 208: Exploded View Of Cooling System
COOLING SYSTEM Exploded view of Cooling System Torque Fastener Remarks N·m kgf·m ft·lb Radiator fan assembly bolt M6 8~12 0.8~1.2 69~103.6 in·lb Radiator mounting bolt M6×25 8~12 0.8~1.2 69~103.6 in·lb 6 - 2...
Page 209: Coolant Flow
COOLING SYSTEM Coolant Flow Select permanent antifreeze as the coolant to prevent rust and corrosion of the cooling system. When the engine starts, the water pump rotates and the coolant circulates. The thermostat is a wax particle type, which opens or closes with the change of the coolant temperature.
Page 210 COOLING SYSTEM Coolant Flow 1.Radiator 5.Switch of radiator fan 2.Water Pump 6.Cylinder，Cylinder head 3.Radiator cover 7.Radiator fan 4.Water storage tank 8.Thermostat Black arrow: hot coolant White arrow: cold water 6 - 4...
Page 211: Technical Parameter
COOLING SYSTEM Technical Parameter Item Standard Service Limit Coolant provided during transportation： Type Permanent antifreeze (soft water and glycol for – – – aluminum engines and radiators plus corrosion – – – inhibitors and rust inhibitor chemicals) Color Green – – – Mixing ratio Soft water 50%, cooling water 50% –...
Page 212 COOLING SYSTEM Special tools and sealants Silicone Sealant 6 - 6...
Page 213: Coolant
COOLING SYSTEM Coolant Coolant deterioration inspection 【A】Water storage tank Visually inspect the coolant in the water storage tank 【A】. If whitish cotton-like fluff is observed, the aluminum parts in the cooling system are corroded. If the coolant is brown, the iron or steel parts are rusty. In either case, ﬂ...
Page 214: Pressure Test
COOLING SYSTEM Pressure test ◆ Remove the front access cover and the radiator cover, and install the cooling system pressure tester on the radiator ﬁ ller pipe. Wet the sealing surface of the cover with water or coolant to prevent pressure leakage. Slowly pressurize until the pressure rises to 123kPa (1.25kgf/cm , 18psi).
Page 215: Radiator Removal
COOLING SYSTEM Radiator removal ◆ The start and stop of the radiator fan are controlled by the vehicle ECU. When the water temperature of the engine cylinder head reaches 88°C, the fan automatically starts; until the water temperature of the cylinder head drops below 83°C, the radiator fan automatically stops.
Page 216: Radiator Fan Removal
COOLING SYSTEM Radiator fan removal 【A】Radiator fan assembly bolt 【B】Fan assembly 【C】Radiator fan mounting nut 【D】Radiator fan ◆ Remove the radiator ﬁ rst (see radiator removal) ◆ Remove the radiator fan assembly bolts【A】 ◆ Remove the fan assembly【B】 ◆ Remove the radiator fan mounting nut【C】 ◆...
Page 217: Radiator Inspection
COOLING SYSTEM Radiator Inspection ◆ Check the radiator core. ◆ If there are obstructions to air flow, remove the radiator and remove obstructions. ◆ If the corrugated fins【A】are deformed, carefully straighten them. ◆ If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed ﬁ...
Page 218 INTAKE / EXHAUST SYSTEM INTAKE / EXHAUST SYSTEM Exploded view of Intake system………………………………………………………7- 2 Disassemble Air Filter…………….....……………………………………………7- 3 Exploded view of Exhaust System……………………………………………………7- 4 Muﬄ er and exhaust pipe………………………………………………………………7- 5 Muﬄ er disassembly…………………………………………………………………… 7- 5 Exhaust pipe disassembly…………………………………………………………… 7- 6 Inspection………………………………………………………………………………...
Page 219: Exploded View Of Intake System
INTAKE / EXHAUST SYSTEM Exploded view of Intake System Torque Fastener Remarks N·m kgf·m ft·lb Installment bolts for air ﬁ lter M8×16 35 ～ 45 3.5~4.5 25.8~33.2 Type A worm drive hose hoop 80 —— —— —— Steel belt ﬂ exible hose clamp 30 ——...
Page 220: Disassemble Air Filter
INTAKE / EXHAUST SYSTEM Disassemble Air Filter Place the vehicle body in a horizontal position ﬁ rst 【A】bolt 【B】Front rack assembly ◆ Remove the bolts ◆ Remove the front rack assembly as a whole from the body 【C】maintenance cover 【D】bolt 【E】bolt 【F】Instrument cover assembly ◆...
Page 221: Exploded View Of Exhaust System
INTAKE / EXHAUST SYSTEM Exploded view of Exhaust System Torque Fastener Remarks N·m kgf·m ft·lb 30 ～ 40 3.0~4.0 22.1~29.5 Exhaust pipe connection bolt 30 ～ 40 3.0~4.0 22.1~29.5 Spring — — — — — — Fixed bolt M8×35 30 ～ 40 3.0~4.0 22.1~29.5 Seal cartridge...
Page 222: Muffl Er And Exhaust Pipe
INTAKE / EXHAUST SYSTEM Muﬄ er and Exhaust pipe Do not perform maintenance immediately after use as the exhaust components become very hot and can cause serious burns and injury. Muﬄ er disassembly ◆ Remove the exhaust pipe connection bolts【A】and spring【B】；...
Page 223: Exhaust Pipe Disassembly
INTAKE / EXHAUST SYSTEM Exhaust pipe disassembly ◆ Remove exhaust pipe retaining nut【A】 ◆ Removal of exhaust pipe【B】 Inspection ◆ Inspect the muﬄ er from the outside for cracks, holes or breakages, which will aﬀ ect the performance and emission of the engine. Replace any damaged parts. ◆...
Page 224 DRIVE SYSTEM DRIVE SYSTEM Exploded View of Drive System…………………………………………….………..8-2 Drive Axle Disassembly……………………………………………………….………8-3 Front& Rear Drive Axle Disassembly………………………………………………8-4 Front& Rear Drive Axle Assembly………………………………….…………………8-5 8 - 1...
Page 225 DRIVE SYSTEM Exploded view of Drive System Torque Fastener Remarks N·m kgf·m ft·lb Hexagon Flange Bolts M8×35 35 ～ 45 3.5~4.5 25.8~33.2 Hexagon Socket Head Screw M10×1.25×25 A：Apply Impermanent Locking Agent. 8 - 2...
Page 226 DRIVE SYSTEM Drive Axle Disassembly ◆ Do not remove the dust boot when the drive axle is removed, it is full of grease. ◆ Please do not pull out the drive axle when d i s a s s e m b l e i t , w h i c h m a y d a m a g e t h e intermediate axle clip and cause the ball cage to fall out.
Page 227 DRIVE SYSTEM Front Drive Axle Disassembly 【A】Hexagon socket head screw M10×1.25×25 【B】Hexagon ﬂ ange bolts M8×35 【C】Rear part of front drive axle 【D】Front part of front drive axle 【E】10mm diameter spring washer (4 pcs） ◆ Loosen the screws A (4 psc） ◆...
Page 228 DRIVE SYSTEM Front& Rear Drive Axle Assembly 【A】Front L& R drive axles The front and rear drive axles are installed by pushing them into the axle hole in the direction of the arrow shown in the picture until they reach the bottom, and then install the upper and lower arms and wheel support and the wheel parts.
Page 229 FRONT & REAR SUSPENSION FRONT & REAR SUSPENSION Exploded view of Front Suspension………………………………………………… 9-2 Exploded view of Rear Suspension………………………………………………… 9-4 Technical parameter…………………………………………………………………… 9-6 Special Tools…………………………………………………………………………… 9-7 Shock Absorber………………………………………………………………………… 9-8 Absorber inspection……………………………………………………………………9-8 Normal hydraulic damping absorber preloading adjustment……………………9-8 Air damping absorber preloading adjustment………………………………9-8 Measure free length of spring………………………………………………………9-9 Absorber damping adjustment……………………………………………………9-9 Compressure damping adjustment…………………………………………………9-9...
Page 230: Exploded View Of Front Suspension
FRONT & REAR SUSPENSION Exploded view of Front suspension 9 - 2...
Page 231 FRONT & REAR SUSPENSION Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange lock nuts M10×1.25 40 ～ 50 4.0~5.0 29.5~36.9 Absorber mounting bolt M10×1.25×55 40 ～ 50 4.0~5.0 29.5~36.9 Front rocker arm mounting bolt 40 ～ 50 4.0~5.0 29.5~36.9 M10×1.25×90 Rocker arm mounting bolt M10×1.25×85 40 ～...
Page 232: Exploded View Of Rear Suspension
FRONT & REAR SUSPENSION Exploded view of Rear suspension 9 - 4...
Page 233 FRONT & REAR SUSPENSION Torque Fastener Remarks N·m kgf·m ft·lb Absorber mounting bolt M10×1.25×55 40 ～ 50 4.0~5.0 29.5~36.9 Hexagon ﬂ ange lock nuts M10×1.25 40 ～ 50 4.0~5.0 29.5~36.9 Rear wheel axle steady mounting bolt 40 ～ 50 4.0~5.0 29.5~36.9 M10×1.25×100 Rear balance bar mounting boltM8×1.25×30 20 ～...
Page 234: Technical Parameter
FRONT & REAR SUSPENSION Technical parameter Item Setting Available range Front absorber: (Optional) Gear 3 Gear 1 ～ Gear 5 • Preloading setting position of normal hydraulic damping absorber spring 35 ～ 55mm • Preloading setting position of air damping absorber 45mm(1.78in.) (1.38 ～...
Page 235 FRONT & REAR SUSPENSION Dedicated Tools Slotted screwdriver Needle nose pliers Hook wrench Grease gun Internal circlip pliers Lifting jack Bearing drive kit 9 - 7...
Page 236: Shock Absorber
FRONT & REAR SUSPENSION Shock absorber Absorber inspection Because the front shock absorber is a sealed unit, it cannot be disassembled, only external inspection is required. If one unit is damaged, replace two shock absorbers together as a set. If only one unit is replaced, when the two shock absorbers are out of balance, it may cause the vehicle to become unstable at high speeds or deteriorate the overall comfort.
Page 237: Measure Free Length Of Spring
FRONT & REAR SUSPENSION Measure free length of spring 【A】Adjustment nut 【B】Lock nut 【C】Spring preload position ◆ Screw the adjustment nut【A】to the required position，and then tighten the lock nut【B】, adjust nut position【C】. Spring preload position【C】set up Standard： Front absorber: 45mm(1.78in.) Limit for the use: 35mm(1.38in.) ～...
Page 238: Rebound Damping Adjustment
FRONT & REAR SUSPENSION Rebound damping adjustment Turn the damping regulator at the bottom with a slotted screwdriver，Increase the damping in clockwise direction(H) and decrease it in counter clockwise direction (S). There are 14 gears in the compression damping regulator, which is set to the gear 9 from the factory. Tool：slotted screwdriver Absorber disassembly 【A】Front absorber...
Page 239 FRONT & REAR SUSPENSION Rear absorber scrapped As the oil container of the shock absorber contains nitrogen, do not incinerate the gas that has not been released in the container, otherwise it may explode. 【A】Valve cover ◆ Remove the absorber(Refer to absorber removal) ◆...
Page 240: Suspension
FRONT & REAR SUSPENSION Suspension Rocker arm removal 【A】Hose ﬁ xing bolt 【B】Steering knuckle / axle support assembly 【C】Steering rod nut 【D】Ball pin connecting rod bolt 【E】Rocker arm mounting bolt 【F】Rocker arm assembly ◆ Remove the brake caliper mounting bolts and remove the caliper body ◆...
Page 241: Rocker Arm Disassembly
FRONT & REAR SUSPENSION Rocker arm disassembly 【A】Rocker arm assembly mounting bolts 【B】Rocker arm buﬀ er sleeve 【C】Rocker liner 【D】Nut 【E】Elastic ring for shaft 【F】Upper and lower kingpin assembly ◆ Rocker arm buﬀ er sleeve ◆ Rocker liner ◆ Circlip ◆...
Page 242: Rocker Arm Maintenance
FRONT & REAR SUSPENSION Rocker arm maintenance 【A】Straight type grease cup ◆ Fill grease into the straight type cup with grease gun ◆ When it is found that the grease in the suspension rocker arm shaft sleeve ,axle support and axle sleeve is reducing, or after the vehicle runs every 1000km, grease the straight type oil cup in the suspension system(Including upper and lower rocker...
Page 243 FRONT & REAR SUSPENSION Hub bearing replacement If the hub bearing in the knuckle assembly and rear axle support assembly is damaged, it needs to be replaced. 【A】Take out the split ring with the circlip pliers 【B】Press out hub bearing 【C】Front knuckle 【D】Rear axle mount Dedicated tool：Circlip plier, Bearing drive kit...
Page 244: Rear Stabilizer Bar Maintenance
FRONT & REAR SUSPENSION Rear stabilizer bar Rear stabilizer bar disassembly 【A】Stabilizer bar buﬀ er sleeve 【B】Rear stabilizer bar 【C】Stabilizer bar mounting 【D】Mounting bracket ﬁ xing bolt 【E】Connecting rod assembly mounting nut 【F】Connecting rod assembly Fixing bolt of mounting base torque requirement 25N·m（2.5kgf·m，18 ft·lb）...
Page 245 WHEELS AND TIRES WHEELS AND TIRES Exploded view of Wheels and Tires…………………………………………………10-2 Technical parameters…………………………………………………………………10-4 Special tools……………………………………………………………………………10-5 Wheel alignment………………………………………………………………………10-6 Front beam inspection…………………………………………………………………10-6 Front adjustment………………………………………………………………………10-7 Wheels (rims)……………………………………………………………………………10-8 Wheels disassembly………………………………………………………………… 10-8 Wheels assembly…………………………………………………………………… 10-8 Wheel check………………………………………………………………………… 10-8 Wheel check………………………………………………………………………… 10-9 Tire………………………………………………………………………………………10-10 The tires have been removed………………………………………………………10-10 Tire installation………………………………………………………………………10-10 Tire check……………………………………………………………………………10-11 Tire detach (for rims…………………………………………………………………10-12...
Page 246: Exploded View Of Wheels And Tires
WHEELS AND TIRES Exploded view of Wheels and Tires 10 - 2...
Page 247 WHEELS AND TIRES Torque Fastener Remarks N·m kgf·m ft·lb Shaft nut M24 221. Wheel nut M12 7.0~8.0 70 ～ 80 51.6~59 Cross tie rod end nut M10 5.0~6.0 36.9~44.3 50 ～ 60 Cross tie rod adjustment lock nut M12 5.0~6.0 36.9~44.3 50 ～...
Page 248: Technical Parameters
WHEELS AND TIRES Technical parameters Item Standard Use Limit Wheel positioning: Front wheel and front bundle: 10±10mm（0.39±0.39inch） – – – Tires: Standard tire: front 25×8-12/AT26×8-12/26×8-14 Tubeless Nylon – – – rear 25×10-12/AT26×10-12/26×10-14Tubeless Nylon – – – Tire pressure (in cold state) : front 48.3kPa (0.49 kgf/cm², 7.0 psi) –...
Page 249: Special Tools
WHEELS AND TIRES Special Tools Jack 10 - 5...
Page 250: Wheel Alignment
WHEELS AND TIRES Wheel alignment Front beam inspection ◆ The front beam is the distance between the front wheels at axle height and the rear. The difference in distance is called the anterior beam value. When there is A front beam, viewed from the top of the car, the distance A (rear) is greater than B (front), as shown in the ﬁ...
Page 251 WHEELS AND TIRES Front Beam adjustment 【A】Locknut 【B】Locknut 【C】Pull rod ◆ Loosen t he loc k nut【A】【B】and turn t he adjustment lever [C] on both sides for the same number of turns to achieve the designated toe. ◆ Loosen the lock nut【A】【B】and turn the adjustment lever【C】on both sides for the same number of turns to achieve the designated toe.
Page 252: Wheels (Rims)
WHEELS AND TIRES Wheel（Rim） Wheel Disassembly 【A】 Wheel nut ◆ Loosen the wheel nut【A】 ◆ Support the vehicle with a bracket or jack to lift the wheels oﬀ the ground. Special tool: Jack. Tear down: ◆ Wheel nut ◆ wheel Wheel Assembly ◆...
Page 253 WHEELS AND TIRES The replacement of the wheel ◆ Shake the wheel with both hands for excessive or abnormal movement, check whether the hub bearing is loose or damaged, if necessary, please replace the hub bearing. ◆ Remove the wheel (see Wheel removal). ◆...
Page 254: Tire
WHEELS AND TIRES Tire Tire Disassembly ◆ Remove the Tire ◆ Loosen the valve to deﬂ ate the tire. Use the appropriate spool tool 【A】 ◆ Lubricate the tires and rims on both sides of the wheel with soap solution or water 【B】.This helps the tires slide oﬀ...
Page 255 ◆ Bleed the tire to the speciﬁ ed pressure.。 ◆ Check the tire pressure with the barometer. Segway oﬀ ers tire pressure gauges and user kits. Tire pressure (in cold state) Front: 48.3 kPa (0.49 KGF /cm2, 7.0 psi) Rear: 48.3 kPa (0.49 KGF /cm2, 7.0 psi)
Page 256 WHEELS AND TIRES Tire Disassembly (for anti-drop rims)）【A】detachable ring fastening bolts 【B】detachable coil ◆ Take oﬀ the wheel. ◆ Remove all detachable ring fastening bolts 【A】. ◆ Remove the detachable coil 【B】. ◆ Lubricate tires and rims on both sides of the wheel with soap solution or water 【C】.This helps the tires slide oﬀ...
Page 257 WHEELS AND TIRES Tyre mounting (for anti-drop rims) 【A】Rim 【B】Bracket ◆ Support the rim 【A】 on A suitable bracket【B】to prevent the tire from slipping oﬀ . ◆ Tighten the detachable ring fastening bolts in a cross way. Torque of anti-drop ring screw 20N.m（2.0kgf·m，14.8ft·lb）...
Page 258: Tire Check
◆ Bleed the tire to the speciﬁ ed pressure. ◆ Check the tire pressure with the barometer. Segway oﬀ ers tire pressure gauges and user kits.。 Tire pressure (in cold state) Front：48.3 kPa（0.49 kgf /cm ，7.0 psi）...
Page 259: Wheel Hub
WHEELS AND TIRES Wheel hub Take the wheels apart ◆ Remove the wheel (see Wheel removal). ◆ Remove cotter pin 【A】 ◆ Loosen half shaft nut 【B】 ◆ Unscrew the mounting bolts, remove the calipers 【A】, and do not let the calipers hang freely. ◆...
Page 260 BRAKE SYSTEM BRAKE SYSTEM Exploded view of Brake System…………………………………………………… 11-3 Exploded view of Parking Brake…………………………………………………… 11-4 ……………………………………………………………… Specifications 11-4 Special Tools……………………………………………………………………………11-5 Brake Fluid……………………………………………………………………………… 11-6 Master Cylinder………………………………………………………………………… 11-7 ……………………………………………………………… Disassembly 11-7 ……………………………………………………………… Installation 11-7 Master Cylinder Disassembly ……………………………………………………… 11-8 Caliper…………………………………………………………………………………… 11-9 Caliper Disassembly …………………………………………………………………...
Page 261 BRAKE SYSTEM Brake Hoses…………………………………………………………… 11-14 Brake Hose Inspection ……………………………………………… 11-14 Rear Brake Pedal…………..........………11-14 Brake Pedal Position Adjustment ..........11-14 Rear Parking cable..…………..........………11-14 Parking cable removal...............11-14 Parking cable installation............11-14 Rear brake pedal disassembly…………………...…………… 11-15 Rear brake pedal installation…………………..………………… 11-15 11 - 2...
Page 262 BRAKE SYSTEM Exploded view of Brake System Torque Fastener Remarks N·m kgf·m ft·lb Disc Mounting Bolts 27in·lb Brake Caliper Fastening Bolts 33in·lb Brake Hose Banjo Bolts 18in·lb Master Cylinder Clamp Bolts 0.90 78in·lb Distribution Valve Fastening Bolts 0.15 11in·lb Foot Brake Main Pump Bolts 33in·lb Oil Cup Bolts 0.90...
Page 263: Exploded View Of Parking Brake
BRAKE SYSTEM Exploded view of Parking Brake Torque Fastener Remarks N·m kgf·m ft·lb Parking Brake Lever Screw 78in.lb Junction Box Fastening Bolt 78in.lb Speciﬁ cations Item Standard Service Limit Brake Fluid: Type DOT 4 – – – Front Disc Brake: Pad lining thickness 4.0 mm (0.16 in.) 1 mm (0.04 in.)
Page 264: Special Tools
BRAKE SYSTEM Special tool Inside Circlip Pliers 11 - 5...
Page 265: Brake Fluid
BRAKE SYSTEM Brake Fluid When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake ﬂ uid. 2. Do not use ﬂ uid from a container that has been left unsealed or that has been open for a long time.
Page 266: Master Cylinder
BRAKE SYSTEM Handbrake Disassembly 【A】brake hose oil line banjo bolt 【B】master cylinder tightened bolt 【C】master cylinder Brake fluid will damage the painted surface quickly, any spilled fluid should be completely washed off immediately. Installation ◆ Installation of main cylinder holder, must have the “up”...
Page 267: Master Cylinder Disassembly
BRAKE SYSTEM Master Cylinder Disassembly ◆ Remove: Master Cylinder (see Master Cylinder Removal) 【A】Brake Lever Pivot Nut 【B】Brake Lever Pivot Bolt 【C】Brake Lever 【D】Dust Cover 【E】Circlip 【F】Piston 【G】Spring Do not remove the secondary cup【H】from the piston since removal will damage it. Master Cylinder Assembly ◆...
Page 268: Caliper
BRAKE SYSTEM Caliper ◆ Remove the front wheel (see Wheels/Tires chapter). ◆ Loosen the banjo bolt 【A】 at the brake hose lower end, and tighten it loosely. ◆ Unscrew the caliper mounting bolts 【B】. ◆ Detach the caliper 【C】 from the disc. ◆...
Page 269: Caliper Disassembly
BRAKE SYSTEM Caliper Disassembly ◆ Remove: Caliper (see Caliper Removal) Pads (see Brake Pad Removal) Anti-rattle Spring ◆ Using compressed air, remove the piston. Cover the caliper opening with a clean, heavy cloth 【A】. Remove the piston by lightly applying compressed air 【B】 to where the brake line ﬁ...
Page 270: Piston And Cylinder Damage
BRAKE SYSTEM ◆ Apply brake ﬂ uid to the outside of the pistons 【A】, and push them into the cylinder by hand. Take care that neither the cylinder nor the piston skirt gets scratched. ◆ Replac e t he rubber boots 【B】 if t hey a re damaged.
Page 271: Brake Pads
BRAKE SYSTEM Brake Pads Brake Pad Removal ◆ Remove front rim assembly or rear rim assembly ◆ Loosen the fasten blot from the guide rod of brake assembly, during process of loosening the bolt, the required head should always be in contact with brake caliper body and limit, otherwise it will follow because C is not limited, then it is impossible to disassemble.
Page 272: Brake Discs
BRAKE SYSTEM Brake Discs Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned oﬀ with an oilless cleaning ﬂ uid such as trichloroethylene or acetone. These cleaning ﬂ uids are usually highly ﬂ ammable and harmful if breathed for prolonged periods.
Page 273 BRAKE SYSTEM Brake Hoses Brake Hose Inspection ◆ Refer to the Brakes in the Periodic Maintenance chapter. ◆ Brake Hose Replacement ◆ Refer to the Brakes in the Periodic Maintenance chapter. Rear Brake Pedal Brake Pedal Position Adjustment ◆ Loosen the locknut 【A】, and turn the adjusting bolt 【B】...
Page 274 BRAKE SYSTEM Rear brake pedal disassembly 【A】brake pedal 【B】retainer ring 【C】ﬂ at gasket 【D】brake pedal ﬂ anging bushing ◆ Use the pliers to remove the retainer ring 【B】 ◆ Remove the ﬂ at gasket 【C】 ◆ Remove the brake pedal【A】assembly ◆...
Page 275 STEERING SYSTEM STEERING SYSTEM Exploded View of Steering System……………………………………….………..12-2 Steering System Technical Speciﬁ cation…………………………….…………...12-4 Steering System Handlebar Disassembly……………………….………………...12-5 Steering System Handlebar Assembly……………………….…………...………12-5 Steering Column disassembly………………...………….…………...………12-6 12 - 1...
Page 276 STEERING SYSTEM Exploded View of Steering System 12 - 2...
Page 277 STEERING SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Hexagon Socket Head Screw M8×45 21.4 Hexagon Flange Bolts M8×16 25.8 Hexagon Flange Bolts M8×30 25.8 Hexagon Flange Bolts M10×1.25×20 33.2 Type 1 Hexagon Slotted Nut M10 33.2 Type 1 Hexagon Nut M12×1.25 40.5 A: Apply grease.
Page 278 STEERING SYSTEM Steering System Technical Speciﬁ cation Do not remove the dust cover, it is full of grease. Steering rod end installation: Make sure the sealing ring【B】 is on the rod 【A】. Steering rod Rod length 【A】 418±1.5 mm Steering rod installation: Install the smaller taper end of the rod toward the steering knuckle and the taper hole of the steering arm.
Page 279 STEERING SYSTEM Steering System Handlebar Disassembly 【A】Lock bolt 【B】Handlebar cover 【C】Steering Handlebar ◆ Loose the handlebar locking bolt 【A】； ◆ Take oﬀ the Handlebar cover【B】； ◆ Take oﬀ the Handlebar【C】； Steering handlebar installation Assure the handlebar matches the angle of the steering rod, keep in parallel, as shown in the left picture.
Page 280 STEERING SYSTEM Steering Column disassembly First remove the screen panel plastic cover and the upper inner ﬂ ap FL. For speciﬁ c removal steps, see the vehicle disassembly chapter. 【A】Steering spherical block 【B】Ball block locking plate 【C】EPS joint assembly 【D】 EPS steering rod assembly 【E】Bolt M8×16 【F】Bolt M8×30 ◆...
Page 281 VEHICLE BODY AND FRAME VEHICLE BODY AND FRAME Exploded view of Body……………………………………………………………… 13-3 Front shelf cover……………………………………………………………………… 13-6 Rear shelf cover……………………………………………………………………… 13-6 Body plastic parts disassembly………………………………………………………13-6 Front Shelf Cover....................13-6 Rear Shelf Cover....................13-6 Backrest removal....................13-6 Install the Backrest.....................13-6 Saddle removal....................13-7 Saddle installation....................13-7 Air ﬁ...
Page 282 VEHICLE BODY AND FRAME VEHICLE BODY AND FRAME Rear Light Panel....................13-11 Rear Fender......................13-12 Rear Storage Box.....................13-12 Left and Right Pedals..................13-12 Left and Right Front Mudguards...............13-13 Headlight Mask and Front Grille................13-13 Exploded view of engine assembly………..…………………...…………………13-14 Disassembly…………………………………………………………………………13-16 Exploded view of front and rear Diﬀ erential ……………………………………13-20 Front Differential repairs……………………………………………………………13-22 Disassembly…………………………………………………………………………13-22 Installation……………………………………………………………………………13-22...
Page 283 VEHICLE BODY AND FRAME Exploded view of Body Torque Fastener Remarks N·m kgf·m ft·lb Hexagon Socket Large Pan Head Bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb Cross Recessed Hexagon Screw ST4.8×16 8~12 0.8~1.2 69~103.6 in·lb 13 - 3...
Page 284 VEHICLE BODY AND FRAME Exploded view of Body Torque Fastener Remarks N·m kgf·m ft·lb Hexagon Socket Large Pan Head Bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb 13 - 4...
Page 285 VEHICLE BODY AND FRAME Exploded view of Body Torque Fastener Remarks N·m kgf·m ft·lb Hexagon Flange BoltsM6X16 8~12 0.8~1.2 69~103.6 in·lb Hexagon Socket Large Pan Head Bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb 13 - 5...
Page 286 VEHICLE BODY AND FRAME Front Shelf Cover Put the vehicle on ﬂ at ground ﬁ rst ◆ Take out 8 pieces of front shelf cover fixing bolts 【A】; ◆ Remove the front shelf cover from the body; Rear Shelf Cover Put the vehicle on ﬂ...
Page 287 VEHICLE BODY AND FRAME Saddle removal ◆ unhook the saddle hook【A】 ◆ pull the saddle 【B】 backward and upward. Saddle installation ◆ Insert the two tabs at the front end of the saddle into the two slots on the frame ◆...
Page 288 VEHICLE BODY AND FRAME Disassembly of plastic parts of body Front Lampshade ◆ Take out the bolt 【C】 and take out the expansion screw【B】; ◆ Remove the headlight cover【A】 ◆ The removal method of the head lampshade is the same on both sides; Front Upper Mudguard ◆...
Page 289 VEHICLE BODY AND FRAME Front Panel ◆ Remove the front shelf cover; ◆ Remove the welding components of the front shelf; ◆ Remove the front access cover; ◆ Remove the left and right front side strip; ◆ Remove the instrument cover assembly; ◆...
Page 290 VEHICLE BODY AND FRAME Left Rear Guard Plate and Left Rear Grille ◆ Remove the cushion; ◆ Remove the left guard plate, and remove the left front guard plate of the engine; ◆ Take out expansion screw 【A】, take out bolt 【B】;...
Page 291: Rear Light Panel
VEHICLE BODY AND FRAME Left and Right Strips ◆ Take out expansion screw 【A】, take out bolt 【B】; ◆ Remove the left rear side strip; ◆ The removal method of the right rear side strip is the same as the left rear side strip; Tail Box Cover ◆...
Page 292: Rear Fender
VEHICLE BODY AND FRAME Rear Fender ◆ Remove the rear shelf cover; ◆ Remove the welding components of the rear shelf; ◆ Remove the seat cushion assembly; ◆ Remove the backrest assembly; ◆ Remove the left/right rear side strip; ◆ Remove the rear tail light panel and the tail box cover;...
Page 293: Left And Right Front Mudguards
VEHICLE BODY AND FRAME Left and Right Front Mudguards ◆ Remove the front/rear left strips; ◆ Remove the front access cover; ◆ Remove the air ﬁ lter cover; ◆ Remove the instrument cover assembly; ◆ Remove related electrical components; ◆ Remove the front fender; ◆...
Page 294 VEHICLE BODY AND FRAME Exploded view of Engine assembly Torque Fastener Remarks N·m kgf·m ft·lb Right foot guard bar combination mounting bolt 30 ～ 40 3.0~4.0 22.1~29.5 M8X16 Right foot guard bar combination mounting bolt 30 ～ 40 3.0~4.0 22.1~29.5 M8X25 Right pedal bracket assembly mounting bolt 30 ～...
Page 295 VEHICLE BODY AND FRAME Trailer power bracket mounting bolts 8~12 0.8~1.2 69~103.6 in·lb M6X12 Engine mounting bolts M12X1.25 50 ～ 60 5.0~6.0 36.9~44.3 Engine mounting bolts M12X1.25 50 ～ 60 5.0~6.0 36.9~44.3 Hexagon socket head cap screw M6×12 8~12 0.8~1.2 69~103.6 in·lb Engine buﬀ...
Page 296: Disassembly
VEHICLE BODY AND FRAME Disassembly ◆ Remove the middle ﬂ oor; (see the body section for details) ◆ Remove the outer and middle plastic parts; (see the body section for details) ◆ Pull out the connectors or cables on the engine, and disconnect the cables from the main cables;...
Page 297 VEHICLE BODY AND FRAME ◆ Use a suitable tool to remove the fuel injector mounting bolt 【E】, and remove the fuel injector After removing the injector, please protect the injection hole of the fuel injector; After removing the fuel injector, please protect the engine fuel injector mounting hole to prevent dust falling into the engine.
Page 298 VEHICLE BODY AND FRAME ◆ Use a suitable tool to remove the 4 mounting screws of the rear drive shaft and engine【J】Disconnect the front drive shaft from the engine; when assembling，use Thread glue to prevent the screws from loosening and falling oﬀ . ◆...
Page 299 VEHICLE BODY AND FRAME ◆ Use water pipe clamp pliers to remove the clamp 【M】to remove the engine exhaust pipe; After removing the exhaust pipe and the water inlet and outlet pipes of the radiator, please protect the connection parts ◆...
Page 300 VEHICLE BODY AND FRAME Exploded view of Front and Rear Diﬀ erential 11 12 10 11 Torque Fastener Remarks N·m kgf·m ft·lb Mounting bolts on the front Diﬀ erential 40 ～ 50 4.0~5.0 29.5~36.9 M10X1.25X25 Front Diﬀ erential mounting bracket combination 8~12 0.8~1.2 69~103.6 in·lb mounting bolt M8×16...
Page 301 VEHICLE BODY AND FRAME R e a r D i f f e r e n t i a l u n d e r m o u n t i n g b o l t s 40 ～ 50 4.0~5.0 29.5~36.9 M10X1.25X20 Rear Diﬀ...
Page 302: Disassembly
VEHICLE BODY AND FRAME Front Diﬀ erential repair Disassembly ◆ Remove the front lower right arm welding assembly and the front right upper arm welding assembly;(See Suspension section for details) ◆ Remove the front left lower arm welding assembly and the front left upper arm welding assembly;(See Suspension section for details) ◆...
Page 303 VEHICLE BODY AND FRAME Rear Diﬀ erential repair Disassemble ◆ Unplug or remove the connectors on the rear Differential assembly, and disconnect the main cables. ◆ Remove the connection between the brake assembly and the rear Diﬀ erential assembly; ◆ Remove the connection between the left and right constant velocity drive shafts and the rear Diﬀ...
Page 304 VEHICLE BODY AND FRAME Exploded view of Front and Rear Shelf Torque Fastener Remarks N·m kgf·m ft·lb Front shelf welding assembly 30 ～ 40 3.0~4.0 22.1~29.5 mounting bolt M8X16 Rear shelf welding assembly 30 ～ 40 3.0~4.0 22.1~29.5 mounting bolts M8X16 Left armrest assembly mounting bolt 30 ～...
Page 305: Disassembly
VEHICLE BODY AND FRAME Front Shelf repair Disassembly ◆ Use a suitable tool to remove the bolt 1 and remove the welding assembly of the front shelf; Assembly ◆ When assembling, please reverse assembling in the order of disassembly; Rear shelf repair Disassembly ◆...
Page 306 VEHICLE BODY AND FRAME Exploded view of Bumper Torque Fastener Remarks N·m kgf·m ft·lb Combination mounting bolts for winch 30 ～ 40 3.0~4.0 22.1~29.5 mounting plate M8X16 Front bumper welding assembly 30 ～ 40 3.0~4.0 22.1~29.5 mounting bolt M8X20 Front bumper welding assembly 30 ～...
Page 307: Disassembly
VEHICLE BODY AND FRAME Front Bumper repair Disassembly ◆ Use a suitable tool to remove the mounting bolts of the front lighting cover to make the front light disconnected from the welding assembly of the front bumper; ◆ Use a suitable tool to remove the mounting nuts for the positive and negative connecting wires of the winch motor【A】, disconnect the positive and negative wires of the winch motor from the...
Page 308: Disassembly
VEHICLE BODY AND FRAME ◆ Use suitable tools to remove the bolts 2 and 5, then remove the bolts 3 and 4, and remove the front bumper welding assembly; When removing parts 3 and 4, please gently support the front bumper welding assembly with a suitable assembly, so as not to fall when the last bolt is removed and hurt yourself or others;...
Page 309 ELECTRICAL SYSTEM ELECTRICAL SYSTEM Exploded View…………………………………………………………………...………14-3 Technical parameters………………………………………………………..………14-6 Special tools……………………………………………………………………..………14-7 Battery ……………………………………………………………………………..……14-8 Remove the battery………………………………………………………..………14-8 Turn oﬀ ignition switch……………………………………………………..………14-8 Battery charging……………………………………………………………...…………14-9 Charging condition check…………………………………………………..………14-11 Generator inspection……………………………………………………..…………14-12 Circuit diagram of charging system………………………………………………14-13 Voltage regulating rectiﬁ er inspection……………………………………………14-14 Remove……………………………………………………………………...………14-14 EFI system ……………………………………………………………………..………14-15 Schematic diagram of EFI system………………………………………………14-15 Temperature Sensor………………………………………………………………14-16 Function introduction ……………………………………………………………14-16...
Page 310 ELECTRICAL SYSTEM Three-in-one sensor…………………………………………………………..………14-30 Three-in-one sensor performance characteristics…………………………...……14-31 Idle motor………………………………………………………………………..……14-32 Idle motor ﬂ ow characteristics………………………………………………...……14-33 Fault diagnosis………………………………………………………………………14-33 Idle motor fault check………………………………………………………..……14-33 Fault code reading…………………………………………………………………14-34 Troubleshooter operation……………………………………………………..……14-34 Summary of failure codes （ ECU） …………………………………………………………14-35 Lighting system circuit………………………………………………………..……14-37 Headlamps………………………………………………………………………...……14-38 Replace……………………………………………………………………..………14-38 Tail lamp ………………………………………………………………………………14-39 Replace…………………………………………………………………..…………14-39 License plate lamp………………………………………………………….……..…14-40 Remove……………………………………………………………………..………14-40...
Page 311: Exploded View
ELECTRICAL SYSTEM Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M8×1.5×16 8~10 0.8~1.0 70.8~88.4in·lb Cross hexagon screw st4.2×19 0.4~0.5 35.4~44.2in·lb Hexagon ﬂ ange bolt M6×1.5×12 0.7~0.9 61.9~79.6in·lb Hexagon ﬂ ange bolt M6×1.5×12 0.5~0.7 44.2~61.9in·lb Hexagon ﬂ ange bolt M6×35 10~12 1.0~1.2 7.4~8.8...
Page 312 ELECTRICAL SYSTEM Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M10×1.5×20 75~85 7.5~8.5 55.3~62.7 Hexagon ﬂ ange bolt M8×1.25×20 22~28 2.2~2.8 16.2~20.7 Nut M6 0.7~0.9 61.9~79.6in·lb Nut M6 0.7~0.9 61.9~79.6in·lb Hexagon ﬂ ange bolt M6×1.5×25 0.7~0.9 61.9~79.6in·lb Hexagon socket pan head screw M6×12 3~5 0.3~0.5...
Page 313 ELECTRICAL SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M6×1.5×12 0.4~0.5 35.4~44.2in·lb Cross recessed hexagon boltS M5×12 0.3~0.4 26.5~35.4in·lb Hexagon ﬂ ange bolt M6×1.5×12 0.5~0.7 44.2~61.9in·lb Hexagon ﬂ ange bolt M6×1.5×12 8~10 0.8~1.0 70.8~88.4in·lb Nut M6 0.7~0.9 61.9~79.6in·lb Nut M6 0.7~0.9...
Page 314: Technical Parameters
ELECTRICAL SYSTEM Technical parameters Project Standard Use limit Battery: Type Sealed Battery Capacity 12 V 32 Ah Charging System: Alternator type Charging voltage Three-phase AC 14 ～ 15 V (Regulator/rectiﬁ er output voltage) Alternator output voltage 36 ～ 54 V 3 000 r/min (rpm) Stator coil resistance 0.33 ～...
Page 315 ELECTRICAL SYSTEM Special tools Multimeter ◆ When the multimeter is measuring voltage, the meter pen should not be inserted into the current measuring hole ◆ When measuring resistance, please be sure to disconnect the battery positive pole. 14 - 7...
Page 316: Battery
ELECTRICAL SYSTEM Battery Remove the battery 【A】positive（+）【B】negative（-） ◆ Turn oﬀ ignition switch. ◆ Remove seat(Please read frame and body section) ◆ Loosen the bolts on the battery seat ◆ Remove the battery bracket. ◆ First disconnect the battery negative (-) cable, then disconnect the positive (+) cable.
Page 317: Battery Charging
ELECTRICAL SYSTEM Battery charging In the case shown in the following table, to start the vehicle fully to start the engine, and it should be charged before use. However, if the battery voltage is higher than 12.6V after 10 minutes of charging, no initial charge is required.
Page 318 ELECTRICAL SYSTEM The battery is designed to withstand no abnormal damage if it is recharged as specified above. However, if charged under conditions other than those described above, the performance of the battery may degrade signiﬁ cantly. Do not remove the seal cover during recharging. If excess gas is generated due to overcharging, a safety valve ensures battery safety.
Page 319: Charging Condition Check
ELECTRICAL SYSTEM Charging condition check Battery charging status can be measured to check the battery terminal voltage. ◆ Remove the battery (refer to the section on Removing the battery). First, make sure to disconnect the negative (-) ◆ Measure the battery terminal voltage. The voltage to one decimal point is measured with a readable digital voltmeter【A】.
Page 320: Generator Inspection
ELECTRICAL SYSTEM Generator inspection There are three types of alternator faults: short circuit, disconnection, or rotor magnetic loss. Short- circuiting one of the coils or disconnecting the wire will result in low output or no output at all. A loss of the magnetic ﬁ...
Page 321: Circuit Diagram Of Charging System
ELECTRICAL SYSTEM Circuit diagram of charging system DYNAVOL T 1. Alternator 2. regulator/rectiﬁ er 3. Battery 4. Main Fuse 5. Ignition lock 6. Load 14 - 13...
Page 322: Voltage Regulating Rectifi Er Inspection
ELECTRICAL SYSTEM Voltage regulating rectiﬁ er inspection Test and Judgment Method of Charging Voltage on Whole Vehicle Test conditions and methods Output voltage 1. Connect the product according to the normal loading state, after the vehicle started, the speed will remain Output voltage:14.0-15.0V above 2000rpm;...
Page 323: Efi System
ELECTRICAL SYSTEM EFI system Schematic diagram of EFI system 14 - 15...
Page 324: Temperature Sensor
ELECTRICAL SYSTEM Temperature Sensor Function introduction The temperature sensor function is used to monitor the temperature of the engine coolant. The sensor delivers engine temperature information to the ECU to determine engine performance and the display. The temperature sensor is generally installed on the intake side of the engine block. The cylinder temperature sensor can be seen by disassembling the left side cover and seat cushion of the whole vehicle (see 【A】...
Page 325: Performance Parameter
ELECTRICAL SYSTEM Performance parameter ◆ Power: 0.25W under standard use conditions ◆ Working temperature：-30°C～+130°C ◆ Vibration level：≤600m/s2 ◆ Insulation resistance: DC voltage of 500V is applied between the A and C end circuits and the B end circuit, and the insulation resistance is greater than 10MΩ. ◆...
Page 326: Oxygen Sensor
ELECTRICAL SYSTEM Oxygen sensor Function introduction It is used in the feedback system of the electronic control fuel injection device to achieve closed-loop control and improve the control accuracy of the air-fuel ratio of the electronic control unit. It is installed on the exhaust pipe (see【A】in the figure below) close to the engine end.
Page 327: Performance Parameter
ELECTRICAL SYSTEM Performance parameter Item New oxygen 500h Durable after oxygen Exhaust temperature 350℃ 850℃ 350℃ 850℃ λ = 0.97 when the sensor 840±70 710±70 840±80 710±70 element voltage(mv) λ = 1.10 when the sensor 20±50 55±30 20±50 40±40 element voltage(mv) Internal resistance of ≤1.0 ≤0.1...
Page 328: Troubleshooting
ELECTRICAL SYSTEM Troubleshooting The electronic control unit ECU monitors various sensors, actuators, power amplifier circuits and detection circuits. Common fault codes are shown in the fault list. When the fault of oxygen sensor signal is checked, the engine should be run for at least 5-10min to ensure the completion of heating of oxygen sensor.
Page 329: Electronic Control Unit（Ecu
ELECTRICAL SYSTEM Electronic control unit（ECU） Function introduction ECU ﬁ rst collects the running data of the engine system in real time through the sensors of the engine management system, and then drives the actuator to control the engine operation according to the system calibration and the stored calibration data.
Page 330 ELECTRICAL SYSTEM ECU stitch deﬁ nition Item Name item Name 1(M1) 25(D2) Brake switch 2(L1) Oxygen sensor heating 26(C2) Auxiliary start relay control 3(M2) Ignition coil 1 27(B2) Idle motor A 4(L2) Secondary air supply solenoid valve 28(A2) Idle motor B 5(M3) Ignition ground 29(K3)
Page 331: Fuel Injector
ELECTRICAL SYSTEM Fuel injector The fuel injector provides fuel to the engine and atomizes it within a specified time according to the instruction of the ECU. The fuel injector is installed on the intake pipe, and the other end is connected to the fuel pipe through the fuel injector cap (see 【A】...
Page 332: Performance Parameters
ELECTRICAL SYSTEM Performance parameters Project Parameter Static ﬂ ow 207.8g/min Dynamic ﬂ ow 6.65mg/stroke Jet angle 23° Coil resistance 12Ω Hydraulic leak 1.8mm3/min Fault diagnosis ECU only implements fault diagnosis for the fuel injector drive stage. When the fuel injector drive stage is short- circuited or overloaded to the battery voltage, short- circuited to the ground, or open circuit, the fault ﬂ...
Page 333: Ignition Coils
ELECTRICAL SYSTEM Ignition coils The ignition coil converts the low-voltage electricity of the primary winding into the high-voltage electricity of the secondary winding, and generates sparks through the discharge of the spark plug to ignite the fuel-air mixture in the gas cylinder. The ignition coil is installed on the engine.
Page 334: Performance Parameters
ELECTRICAL SYSTEM Performance parameters Value Item Unit Rated Calibration voltage Operating voltage 16.5 Primary mΩ winding Resistance （20--25℃ Secondary 8.27 10.53 kΩ winding Primary current (Charging time 3.9ms) Secondary voltage (Load 35pF) Ignition energy (Zener voltage 1000V) Fault diagnosis The ECU does not perform the fault diagnosis function for the ignition coil, so there is no ignition coil related code in the fault code list.
Page 335: Spark Plug
ELECTRICAL SYSTEM Spark Plug The spark plug introduces the pulsed high voltage electricity generated by the ignition coil into the combustion chamber, and uses the electric spark generated by the electrode to ignite the mixture to complete the combustion. The spark plug sample diagram (see the ﬁ...
Page 336: Engine Speed Sensor
ELECTRICAL SYSTEM Engine speed sensor The working principle of the speed sensor is to use the magnetoelectric eﬀ ect. When the shaft rotates, the signal wheel is driven to rotate together, and the teeth on the signal wheel will cut the magnetic line of the sensor. This change in magnetic flux causes a certain frequency at both ends of the sensor coil.
Page 337: Oil Pressure Sensor
ELECTRICAL SYSTEM Oil Pressure Sensor The oil pressure sensor detects the size of the engine oil pressure when it is working, and it is usually screwed into the oil passage of the cylinder block. Its working principle is that there is a variable resistor inside the sensor, one end outputs the signal, and the other end is connected to the grounded sliding arm.
Page 338: Throttle Valve Body Assembly
ELECTRICAL SYSTEM Throttle valve body assembly The throttle valve body assembly is connected to the engine and the air ﬁ lter. The user can control the opening and closing angle of the throttle valve through the throttle cable to achieve diﬀ erent driving intentions. The structure and size of the main passage of the throttle body are directly related to the amount of air entering the engine, and the performance of the engine at different speeds...
Page 339: Three-In-One Sensor Performance Characteristics
ELECTRICAL SYSTEM Three-in-one sensor performance characteristics Intake temperature sensor 2kΩ±3% B25/85 3520k±2% Temperature-resistance See the left picture characteristics Throttle position sensor Linearity See the left picture Operating temperature -30℃ --+110℃ Intake pressure sensor Change sensitivity 40.5mv/kPa Output voltage characteristic See the left picture 14 - 31...
Page 340: Idle Motor
ELECTRICAL SYSTEM Idle motor The idle motor is composed of a plurality of steel stators and rotors arranged in a circle. Each steel stator is wound with a coil; the rotor is a permanent magnet, and the center of the permanent magnet is a nut. All stator coils are always energized.
Page 341: Idle Motor Fl Ow Characteristics
ELECTRICAL SYSTEM Idle motor ﬂ ow characteristics The ECU controls the number of moving steps of the stepper motor by controlling the number of times the current direction of the coil is replaced, thereby adjusting the cross-sectional area of the bypass channel and the air flow through it.The flow characteristics of stepper motors are shown on the left.
Page 342: Fault Code Reading
ELECTRICAL SYSTEM Fault code reading There is a fault indicator (【A】in the left figure) in the instrument. When the key switch is turned on, the fault indicator is always on. When the engine is running, if the vehicle electronically controlled fuel injection system has no faults, the indicator light should go out;...
Page 343: Summary Of Failure Codes（Ecu
ELECTRICAL SYSTEM Summary of failure codes（ECU） Pcode Description（UAES） fault indicator on P0030 O2 Sensor 1 Heater Contr. Circ. High √ P0031 O2 Sensor 1 Heater Contr. Circ. Low √ P0032 O2 Sensor 1 Heater Contr. Circ. Open √ P0107 Manifold Abs.Pressure or Bar.Pressure Low Input √...
Page 344 ELECTRICAL SYSTEM P0480 cooling fan control Circuit Open √ P0501 Vehicle Speed Sensor “A” Range/Performance √ P0508 Idle Air Control Circuit Low √ P0509 Idle Air Control Circuit Low High √ P0511 Idle Air Control Circuit Open √ P0560 System Voltage Malfunction √...
Page 345: Lighting System Circuit
ELECTRICAL SYSTEM Lighting system circuit 1 Battery Main Fuse 3 Lgnition lock 4 Fuse 5 Main relay Low beam relay 7 High beam relay 8 Daytime running light relay 9 Daytime running light 10 High/Low beam 11 Position lights 12 Lights switch 13 Turn switch 14 Warning switch 15 Flash CM 16 Turn Lights...
Page 346: Headlamps
ELECTRICAL SYSTEM Headlamps Rear headlight guard (see chapter "Frame") 【A】the buckle 【B】Rear headlight guard 【C】Headlight body 【D】Headlight bolt*4 【E】Light bulb guard 【F】Headlight bulb 【G】high and low light adjusting bolt Replace ◆ Lamps are divided into LED lamps and halogen lamps (please confirm according to the actual vehicle) ◆...
Page 347: Tail Lamp
ELECTRICAL SYSTEM Tail lamp Rear guard for taillights (see chapter "Frame") 【A】buckle 【B】Tail lamp rear shield 【C】Tail lamp body 【D】Tail lamp bolt*3 【E】Tail lamp holder 【F】Tail lamp bulb Replace The lamps are divided into LED lamps and halogen lamps (please conﬁ rm according to the actual vehicle) ◆...
Page 348: License Plate Lamp
ELECTRICAL SYSTEM License plate lamp 【A】License plate lamp bolt *1 【B】License plate lamp 【C】Rear license plate lamp bolt *4 【D】Rear license plate lamp holder Remove ◆ Remove the license plate lamp bolt 【A】 ◆ Remove the license plate lamp【B】 ◆ Disassembly license plate lamp Replace ◆...
Page 349: Flasher
ELECTRICAL SYSTEM Flasher Disassembly and assembly of the front shelf and front guard (please refer to the relevant sections of the body) 【A】rubber sleeve 【B】Flasher Disassembly ◆ Remove the installation rubber sleeve【A】from the installation bracket ◆ Remove the wiring harness connector ◆...
Page 350: Eps-Brushless
ELECTRICAL SYSTEM EPS-brushless The method of disassembling the EPS assembly refers to the method of disassembling the steering assembly. Only the electrical functions of the EPS are introduced here. Before disassembling the EPS assembly【A】, firstly remove the power connector【B】and power connector 【C】...
Page 351: Eps System Wiring Schematic Diagram
ELECTRICAL SYSTEM EPS system wiring schematic diagram 1. Battery 2. Fuse 50A 3. Fuse 30A 4. Fuse 5A 5. Fuse 5A 6. IG relay 7. Diode 8. Key switch 9. OBD 10. EPS 14 - 43...
Page 352: Eps Trouble Removal
M gear, when in four wheel drive locking mode, it will immediately switch to H gear; M gear and L gear are adjusted on the Segway Powersports APP (only vehicles with TBOX can be adjusted) If the EPS fault light on the meter is on, it means that the EPS is malfunctioning.
Page 353: Eps Fault Code
ELECTRICAL SYSTEM EPS fault code Power on then Fault Fault Trouble Fault description Have EPS or not restorability or rank code light Torque midpoint not written E0001 End of rotor angle is not written E0002 oﬀ Storage read and write failure E0003 The main torque sensor is E0004...
Page 354: Eps-Brush
ELECTRICAL SYSTEM EPS-brush The method of disassembling the EPS motor 【B】 refers to the method of disassembling the steering assembly. Only the electrical functions of the EPS are introduced here. Before disassembling the EPS controller 【A】, firstly remove t he connector【D】、connect or 【E】、 connector【F】、connector【G】...
Page 355 Fault light(to OBD） Vehicle speed （from vehicle speed sensor） The main torque signal The deputy torque signal motor+ motor- There is no EPS gear in the meter, and EPS gear can't to adjust on the Segway Powersports APP . 14 - 47...
Page 356: Display
ELECTRICAL SYSTEM Display Dashboard The dashboard displays key information to the user. See the next page for display functions and instructions Using a high-pressure water gun may damage the meter. You should use your hands or hoses to clean the vehicle with neutral soap. Do not use alcohol or corrosive cleaning agents, such as insect repellents, to clean the meter.
Page 357: Dashboard Indicator Light Description
ELECTRICAL SYSTEM Dashboard Indicator light description Fault Analysis of cause and trouble Item Icon Function description phenomenon shooting Check the fuse of left turning This indicator This indicator will be light, check whether PIN 29 has not on when the Left turning on when turn on the high level input, if yes, replace...
Page 358 ELECTRICAL SYSTEM Check the fuse of the right Right This indicator will This indicator not turning light ,check if PIN12 turning light be on when right on when right has high level input, if so indicator turning light is on turning light is on ,replace the meter, if No.
Page 359: Instrument Information Display
ELECTRICAL SYSTEM Instrument information display function Area Fault Toubleshouting description Showing current Time display —— —— time When using Check dashboard CAN- Power on remotely bluetooth to power H,CAN-L wire harness, if not Bluetooth by Bluetooth, this on remotely, this solve it ，replace TBOX if still icon not lights up icon lights up...
Page 360 ELECTRICAL SYSTEM Display the correctly gear L -Low speed Check gear position Gear display H -High speed No gear display sensor and related R -Reverse electric line P -Parking Check CNA-H,CAN-L No engine speed Wire harness, check Display actual engine speed display ECU, and crankshaft position...
Page 361 ELECTRICAL SYSTEM Displays the total mileage Total mileage —— —— accumulated by the vehicle EPS mode was set in the APP and the preferred mode Check CNA-H, of the rider was selected: CAN-L -Normal mode, power E P S model Wire harness EPS On normal...
Page 362: Dashboard (Meter)Button Function Introduction
ELECTRICAL SYSTEM Dashboard (meter)button function introduction Short press the【A】button: backlight brightness adjustment, 5 brightness levels, from dark to bright ◆ Short press【B】button: switch between metric and inch ◆ Long press the【A】button: clear the subtotal mileage ◆ Clock setting: Long press the【A】and【B】button to enter at the same time, the hour digit flashes first, then short press the【B】button to adjust the flashing digit, short press the【A】button to switch...
Page 363 ELECTRICAL SYSTEM Instrument Interface Deﬁ nition Description note Description note CAN-L —— Brake failure alarm Low voltage CAN-H —— 4WD LOCK signal —— —— —— 4wd signal —— Vehicle speed Pulse signal Oﬀ cushion switch Low voltage Power ground —— Oil pressure Low voltage ——...
Page 364: T-Box
ELECTRICAL SYSTEM T-BOX If multiple vehicles are repaired at the same time, do not exchange and install the T-BOX ◆ Power off the whole vehicle first and remove the front shelf assembly ◆ Pull out the connector【A】 ◆ Remove the four bolts【B】 T-BOX fault code display area T0001 GPS module failure T0002 4G module failure...
Page 365 ELECTRICAL SYSTEM Failure phenomenon and failure reason Trouble Solution Fault code T0001 Replace T-BOX Fault code T0002 Replace T-BOX Fault code T0003 Replace T-BOX Fault code T0004 Replace T-BOX Check PIN9 and PIN14 Fault code T0005 have signal Check PIN4 and PIN5 Fault code T0006 have APP can not power...
Page 366: Switch
ELECTRICAL SYSTEM Switch Power lock When the indicator does not display after the key is turned on, check the circuit failure (see page xx), and replace the power lock after conﬁ rming that the power lock is broken Check Power lock →...
Page 367 ELECTRICAL SYSTEM In the normal state, the ON gear is in the forward direction, turning 45 degrees counterclockwise is the OFF gear, pressing down the key while rotating 90 45° degrees counterclockwise is the LOCK gear 90° In the ON gear, the entire vehicle circuit is connected and the key cannot be removed;...
Page 368: Left Handlebar Switch
ELECTRICAL SYSTEM Left handlebar switch The switch is valid only when the power lock is in the ON position 【A】Turn on high beam 【B】Turn on lower beam 【C】Turn oﬀ light 【D】Turn on position light Since the switch is an integral part, any damage to the switch requires replacement of the entire switch Gr/R G B/Br Br W/L...
Page 369 ELECTRICAL SYSTEM 【E】Turn on left turning light 【G】Turn oﬀ the turning light 【F】Turn on the right turning light Check if the turning light switch work normally → When the switch is turned to the left steering position, gray and orange can be connected, while gray and FUNC light blue cannot be connected ;...
Page 370 ELECTRICAL SYSTEM 【A】Starting button 【B】Left and right turn signal switch 【C】Stop switch When the engine is running, press the stop switch button to stop the engine; when the engine is stopped, ﬁ rst pop up the stop switch button, and then press the starting button to start the engine;...
Page 371 ELECTRICAL SYSTEM 【D】Horn switch Check horn switch → Lg B/Br When the key is in the ON position, it should make a FUNC sound when pressing the horn switch; when the horn cannot make a sound, first check the related circuit; when there is no problem with the circuit, test the internal circuit of the horn switch;...
Page 372: Disassembly And Assembly Of Left Handlebar Switch
ELECTRICAL SYSTEM Disassembly and assembly of left handlebar switch 【A】Fixed bolt ◆ Remove the two ﬁ xing bolts with tools; ◆ Remove the switch from the handle; ◆ When installing a new switch, pay attention to snap the limit of the lower cover into the limit slot of the handle, and then tighten the two ﬁ...
Page 373: Right Handlebar Switch
ELECTRICAL SYSTEM Right handlebar switch The switch is valid only when the power lock is in the ON position 【A】2/4WD switch 【B】Accelerator 【C】Switching knob Check 2/4WD switch → When the knob is shifted to the left, after pressing the 2nd 4WD switch, the switch is in 4WD State, brown- LgBr red and brown-green can be conducted.
Page 374: Assembly And Disassembly Of Right Handlebar Switch
ELECTRICAL SYSTEM Assembly and disassembly of right handlebar switch 【A】fastening bolt ◆ Remove the two blots； ◆ Remove the switch from the handle; ◆ When installing a new switch, tighten the two ﬁ xing bolts with a tool; ◆ Rotate the switch around the handle tube after installation to conﬁ...
Page 375: Removal
ELECTRICAL SYSTEM Winch assembly Removal When removing the winch, first turn off the vehicle power ◆ Remove external related plastic parts ◆ First remove the battery positive electrode【A】 ◆ Remove the power cord of the winch 【B】 ◆ Remove the winch motor wire nut【C】 ◆...
Page 376 ELECTRICAL SYSTEM ◆ Remove the bolt【E】, remove the winch switch 【F】 ◆ Remove the bolt【H】, then the winch power cord 【I】, winch motor wire 【J】 and winch relay【G】 can be removed together ◆ After disassembling the bolt【P】 and the wire rope 【R】, you can remove the strap【Q], hook【O】, and rubber pad【M】...
Page 377 ELECTRICAL SYSTEM The winch work does not exceed 1min each time, and then works after an interval of 30S ◆ Rated working voltage DC12V ◆ Maximum working tension 2500LBS or 3000LBS ◆ The maximum working current ≤185 A, t he maximum working current lasts for 1 min, and work after an interval of 30 seconds.
Page 378: Fuse Box
ELECTRICAL SYSTEM Fuse Box All fuses in the vehicle are in the fuse box The fuse box is located under the front instrument mask. Remove front panel repair cover （See the body section） ◆ After the front panel repair cover is removed, the fuse box located at the bottom can be seen.
Page 379 ELECTRICAL SYSTEM Fuel box label Fuse/Relay Power Fuse/Relay Power Buzzer and OBD ICU The main fuse Start switch ECU IGNTE 2WD / 4WD 2WD/4WD relay1 12V 20A Light speaker DTS relay 12V 20A ECU-IG 7.5A IG relay 12V 20A DTS-IG Main relay 12V 20A Daytime running light...
Page 380: Wire Harness
ELECTRICAL SYSTEM Wire Harness 1. The positive and negative connections of the battery cannot be reversed, which will cause the wires to burn out All wiring screws must be tightened according to the required torque ◆ 【A】-Plug for dashboard ,black ◆...
Page 381 ELECTRICAL SYSTEM ◆ 【S】-ECU plug ◆ 【T】-12V power socket plug ◆ 【U】-USB plug ◆ 【V】-Oﬀ cushion alarm plug ◆ 【W】-Fuel injector plug ◆ 【X】-Ignition coil plug ◆ 【Y】-Air intake pressurE ◆ 【Z】-idle motor ◆ 【A1】-Coolant temperature sensor plug ◆ 【A2】-Oil pressure alarm plug ◆...
Page 382 ELECTRICAL SYSTEM ◆ See the figure below for the pin number of each plug-in The pin number of the plug-in corresponds to the Harness plug-in view direction electrical schematic diagram 14 - 74...
Page 383 ELECTRICAL SYSTEM 14 - 75...
Page 384 ELECTRICAL SYSTEM Lof wire cable ◆ 【A】-plug(black) for rear light switch ◆ 【B】-plug（gray）for LOF control modul ◆ 【C】-plug for trailer power socket ◆ 【D】-plug for rear fog light ◆ 【E】-plug for LOF trailer power socket ◆ The pin number of each plug-in is shown in the ﬁ...
Page 385: Wiring Diagram
ELECTRICAL SYSTEM WIRING DIAGRAM Color comparison table CODE R/Br COLOUR Red/Black Red/White Red/Green Red/Yellow Red/Blue Red/Brown Red/Orange CODE B/Br COLOUR Pink Black Black/Red Black/White Black/Yellow Black/Blue Black/Violet Black/Brown CODE W/Gr W/Br COLOUR White White/Red White/Black White/Green White/Yellow White/Blue White/Violet White/Gray White/Brown CODE Gr/R...
Page 386: Wiring Diagram
ELECTRICAL SYSTEM Wiring diagram 14 - 78...

This manual is also suitable for:

Snarler sgw570a1 2021 Snarler sgw570a2 2021 Snarler sgw570a3 2021 Snarler sgw570a4 2021 Snarler sgw570a5 2021 Snarler sgw570a6 2021