Segway VILLIAN SSV Series Service Manual

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SERVICE MANUAL

SSV

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Page 1 SERVICE MANUAL...
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 RIM 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 TERMINOLOGY ampere(s) pounds(s) ABDC after bottom dead center meter(s) alternating current Millimeter(s) minute(s) ATDC after top dead center 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 5 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 6 GENERAL INFORMATION GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER/ENGINE SERIAL CODE…… 1-2 TECHNICAL PARAMETERS OF VEHICLE………………………… 1-3 UNIT CONVERSION TABLE……………………………………………… 1-6 TORQUE……………………………………………………………………1-7 1 - 1...
Page 7: Vehicle Identification Number/Engine Serial Code
Vehicle identiﬁ cation number The frame number is stamped on the frame cross tube under the right cargo box at the rear of the vehicle. Reference the vehicle identiﬁ cation number (VIN) when corresponding about the Segway Powersports vehicle. VEHICLE IDENTIFICATION CODE COMPOSITION...
Page 8: Technical Parameters Of Vehicle
GENERAL INFORMATION TECHNICAL PARAMETERS OF VEHICLE PARAMETERS ITEM SGW1000F-S1 SGW1000F-S2 Length×width×height 3375mm×1630mm×1800mm 3380mm×1850mm×1850mm Wheelbase 2590mm Front wheelbase 1340mm 1570mm Rear wheelbase 1350mm 1575mm Curb weight 860kg 880kg Ground clearance 360mm 380mm Turning diameter 12000mm 13000mm 560mm(EPA)/ Height of seat from ground 620mm 670mm(T1a\T1b) Steering wheel diameter...
Page 9 GENERAL INFORMATION Front Double wishbone independent suspension Suspension type Rear Multi-link independent suspension Front Hydraulic spring-external airbag Shock absorber type Rear Hydraulic spring-external airbag Air ﬁ lter type Paper ﬁ lter type Muﬄ er type Impedance Engine type Parallel double cylinder, water cooling, four stroke Engine model 293MY Displacement...
Page 10 GENERAL INFORMATION Headlamp Driving beam 28.4W Headlamp Passing beam 14.9W Front position lamp 2.4W Headlight Daytime running lamp 27.6W Front durection indicator 21.6W Illumination of headlamp (single)cd 21.6W Rear brake light color/speciﬁ cation Red/12.78 W Rear light Rear position light color/speciﬁ cation Red/2.12 W Rear turn signal color/speciﬁ...
Page 11: Unit Conversion Table
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 ×86.80 in·lbs...
Page 12: Torque
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 13 GENERAL INFORMATION 1. 25 1. 25 1. 2.5 1. 2.5 1. 18.4 1. 18.4 2. 45 2. 45 2. 4.5 2. 4.5 2. 33 2. 33 Through Through bolt M10 bolt M10 3. Tighten 3. Tighten 3. Tighten 3. Tighten 3.
Page 14 GENERAL INFORMATION Standard fastener torque of the whole vehicle Torque Torque Fastener Fastener Remarks Remarks N·m N·m kgf·m kgf·m ft·lb ft·lb Bolt 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 Bolt M8 30 ～～ 40 3.0~4.0 22.1~29.5 22.1~29.5 Bolt...
Page 15 GENERAL INFORMATION EPS Install bolt M8×16 EPS Install bolt M8×16 20~26 20~26 2.0~2.6 2.0~2.6 14.7~19 14.7~19 Steering wheel lock nut M14×1.5 Steering wheel lock nut M14×1.5 65 ～～ 75 6.5~7.5 6.5~7.5 40.5 40.5~55.3 ~55.3 Steering column mounting bolt Steering column mounting bolt 20~26 20~26 2.0~2.6...
Page 16: Table Of Contents
MAINTENANCE MAINTENANCE MAINTENANCE PERIODIC TABLE ................2-3 Maintenance Reference ....................2-6 Grease .......................... 2-8 GENERAL VEHICLE INSPECTION AND MAINTENANCE ..........2-9 Pre-Ride / Daily Inspection ................... 2-9 Frame, Nuts, Bolts, and Fasteners ................2-9 Shift Cable Inspection / Adjustment ................2-10 FUEL SYSTEM AND AIR INTAKE .................
Page 17 MAINTENANCE COOLING SYSTEM ....................... 2-23 Cooling System Hoses ....................2-23 Cooling bottle coolant ....................2-24 PVT / FINAL DRIVE / WHEEL AND TIRE..............2-25 CVT belt ........................2-25 The CVT dry ....................... 2-25 PVT / FINAL DRIVE / WHEEL AND TIRE ..............2-25 Drive Shaft Boot Inspection ..................
Page 18 MAINTENANCE PERIODIC MAINTENANCE Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine parts available from your authorized dealer.
Page 19 MAINTENANCE 保养周期表 MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS MILES HOURS CALENDAR （KM） Steering Pre-Ride Front suspension Pre-Ride Rear suspension Pre-Ride Visually inspect, test, Tires/ Wheels/ or check components. Pre-Ride fasteners Make adjustments and/ or schedule repairs Brake ﬂ uid level Pre-Ride when required Brake system...
Page 20 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM REMARKS HOURS CALENDAR MILES（KM） Inspect; adjust; replace as Drive belt 50 H 500 (800) needed Inspect coolant strength Cooling system 50 H 1000(1600) seasonally; pressure test system yearly ► Engine oil change 100 H 1800(3000) Change the oil and ﬁ...
Page 21: Maintenance Reference
MAINTENANCE Maintenance Reference Item Recommended Model Capacity Inspection Method Schedule 3 qts. Refer to Maintenance SAE10W-40/SG Maint ain level in safe Engine Oil (3300 ml) Schedule Or higher grade range on dipstick 8.63 qts. Refer to Maintenance M a i n t a i n t h e l e v e l Engine Coolant (9500 ml) Schedule...
Page 22 MAINTENANCE Item Recommended Model Capacity Inspection Method Schedule Maintain the level between Refer to Maintenance Brake ﬂ uid DOT4 —— Schedule the ﬁ ll lines. Front axle Maintain the fluid to the Fill Refer to Maintenance 0.16 qts. SAE 75/80W-90 GL5 Schedule ( 180 mL ) gear oil...
Page 23: Grease
MAINTENANCE Grease The front and rear suspension arms, balance rods and driving shafts of the vehicle are designed with fueling nozzles. Grease these parts with lubricating oil regularly, make sure these parts are dry before ﬁ lling. Item Recommended Model Capacity Inspection Method Schedule...
Page 24: General Vehicle Inspection And Maintenance
MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. ◆ Engine Oil - Check for proper level on dipstick located in oil tank (refer to “Engine Oil Level” procedure) ◆...
Page 25: Shift Cable Inspection / Adjustment
MAINTENANCE Shift Cable Inspection / Adjustment Shift cable adjustment may be necessary if symptoms include: No gear position or AWD display on instrument cluster Ratcheting noise on deceleration Inability to engage into a gear Excessive gear lash (noise) Gear selector moving out of desired range 【A】pivot bushings 【B】dust boot 【C】shift cable...
Page 26: Fuel System And Air Intake
MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel System Gasoline is very ﬂ ammable under certain conditions ◆ You must be extremely careful when dealing with gasoline. ◆ When refueling, the engine must be shut oﬀ and must be done outdoors or in a well-ventilated area. ◆...
Page 27: Fuel Lines
MAINTENANCE Fuel Lines 【A】Main fuel tank 【B】Auxiliary fuel tank 【C】Rear high pressure oil pipe 【D】Negative pressure connection hose for negative pressure pump ◆ First check whether there is leakage at the pipeline connected onto the fuel tank, and check whether the fuel pipeline connected to the fuel tank is worn, deteriorated, or damaged.
Page 28: Engine Intake Pre-Filter Service
MAINTENANCE Engine Intake Pre-Filter Service It is recommended to check the engine intake pre- filter regularly. The filter should be inspected using the following procedure: The primary air filter is located under the rear storage box. 【A】Primary air ﬁ lter The primary ﬁ...
Page 29: Engine
MAINTENANCE ENGINE Engine Oil Level Always check the oil level when the engine is cold. If the engine is hot when the oil level is checked, the level will appear to be overfull. Access the oil tank dipstick through the oil tank access panel located in the left front corner of the cargo box.
Page 30: Engine Oil Change
MAINTENANCE Engine Oil Change Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil ﬁ lter whenever changing the engine oil. The oil tank drain plug is located on the bottom of the oil tank.
Page 31: Replace Oil Fi Lter/Oil Strainer
MAINTENANCE Replace oil ﬁ lter/oil strainer Change the oil ﬁ lter and clean the oil strainer every time you change the oil Change Oil Filter The oil filter is located inside the left rear wheel of the vehicle. Please refer to the fluid recommendation table for capacity and plug torque.
Page 32: Add Engine Oil
MAINTENANCE Add engine oil The engine oil adding port is located under the cargo engine maintenance cover. ◆ Unscrew the oil cap counterclockwise. ◆ Add an appropriate amount of the recommended type of oil and do not overﬁ ll it. The oil level between the upper scale and the lower scale is appropriate.
Page 33: Engine / Oil Tank Breather Hose Inspection
MAINTENANCE Engine / Oil Tank Breather Hose Inspection The engine and oil tank are equipped with a breather hose. Inspect the breather hoses for possible kinks or wear. The hoses are form ﬁ tted for proper ﬁ t. 【A】Engine 【B】Engine breather hose 【C】Air ﬁ...
Page 34: Spark Arrester
MAINTENANCE Spark arrester Spark eliminator prevents random sparks from entering other vehicles parts. Regular maintenance can prevent carbon accumulation, whereas delayed maintenance will reduce engine performance. Make sure the exhaust pipes are cool. The engine has just stopped working and the pipes can overheat and cause people burn.
Page 35: Transmission And Front Gearcase
MAINTENANCE TRANSMISSION AND FRONT GEARCASE Check and replace the demand drive ﬂ uid at intervals in the periodic maintenance diagram. CAUTION If the front gearbox makes too much noise during 4WD operation, change the demand drive fluid.If the noise continues, please check the service of your dealer or other qualiﬁ...
Page 36: Check The Level Of Front Gear Box
MAINTENANCE Check the level of front gear box The front axle gearbox filling plug is located on the left side of the front gearbox, keeping the lubricating oil level ﬂ ush with the bottom of the ﬁ lling plug. 【A】Front axle gearbox 【B】Filling plug 【C】O ring 1.
Page 37 MAINTENANCE Front axle oil ﬁ lling 【A】Filling plug 【B】 Drain Plug 【B】O-ring Torque of Filling Plug/Drain pulg 16-20N.m(11.8-14.8ft·lb) 1. Position the vehicle on a horizontal plane. Remove the drain plug. 2. Place the drain tray under the demand drive unit. Remove the drain plug【B】.
Page 38: Cooling System
MAINTENANCE COOLING SYSTEM Cooling System Overview The engine coolant level is controlled, or maintained, by Sub water tank the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator Engine oil raditor pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery...
Page 39: Cooling Bottle Coolant
MAINTENANCE Cooling bottle coolant The coolant bottle is located under the cargo bed at the rear of the vehicle. 1. After removing the cargo bed, observe the liquid level in the bottle. 2. If the liquid level is low, remove the cap and add the coolant as needed.Keep the coolant level between the MIN and MAX mark on the bottle (while the liquid cools).
Page 40: Pvt / Final Drive / Wheel And Tire
MAINTENANCE PVT / FINAL DRIVE / WHEEL AND TIRE CVT belt Replace the CVT drive belt according to the time speciﬁ ed in the vehicle maintenance schedule. If the CVT belt is damaged, it should also be replaced. When replacing the belt, clean the pipe and clutch and the engine compartment for debris.
Page 41: The Cvt Dry
Belt skid test.If the belt slides, repeat the process. 8. Your segway dealer can help if your vehicle needs service. Drive Shaft Boot Inspection Inspect the front and rear drive shaft boots for damage, tears, wear or leaking grease.
Page 42: Wheel
MAINTENANCE Wheel Driving a vehicle with incorrect tire pressure may result in the following consequences: ◆ Reduce fuel eﬃ ciency ◆ Reduce driving comfort and shorten tire life ◆ Safety reduction When checking tire pressure, follow the following instructions: ◆ Inspection can only be carried out after the tire cools down.
Page 43: Electrical And Ignition System
MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery disassembly If the electrolyte overﬂ ows, immediately wash it oﬀ with a solution of 1 tablespoon baking soda and 1 cup water to prevent damage to the vehicle. The battery is located behind the driver seat. If you want to replace or maintain the battery,please follow the following steps: Cut oﬀ...
Page 44: Battery Installation
MAINTENANCE Battery installation To reduce the chance of sparks: Whenever the battery is removed, disconnect the black (negative) cable ﬁ rst. When reinstalling the battery, finally install the black (negative) cable. 1. Clean battery cables and terminals with a hard wire brush.Corrosion can be removed with a solution of 1 cup water and 1 tablespoon baking soda.Rinse well and dry thoroughly.
Page 45: Spark Plug Inspection
MAINTENANCE Model spark plug clearance Spark Plug 0.7-0.9mm Removal of rear cargo bed Rear Cargo The cargo bed is a snap-in quick-release structure. Hold the groove on the top of the cargo bed with both hands and move it backward to remove it. Remove the rear Cargo Bed Loosen the M6×35 bolts fixing the air filter housing assembly with a tool, and remove the bolts and bushings.
Page 46 MAINTENANCE 【D】Spark plug sleeve The spark plug is located under the rear cargo bed and the air ﬁ lter. First remove the rear storage box, and then remove the air filter。The twin-cylinder engine has two spark plugs. When replacing the spark plugs, please replace both spark plugs at the same time.
Page 47: Brake System
MAINTENANCE BRAKE SYSTEM The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. Brake ﬂ uid levels must be checked periodically: overﬁ lling of the brake cylinder may cause brake resistance or brake locking, which may result in serious injury or death.
Page 48: Brake Oil
MAINTENANCE Brake oil Use the recommended brake oil: Brake Oil DOT4 No adjustment is required for the hydraulic assisted braking system. Check the brake oil level of the auxiliary braking system frequently. If the level is shown to be low, perform the following operations.
Page 49 ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM Exploded view......................3-1-2 Exploded view......................3-1-2 Technical parameter....................3-1-4 Technical parameter....................3-1-4 Special Tools....................3-1-5 Special Tools....................3-1-5 Engine oil flow chart...................3-1-6 Engine oil flow chart...................3-1-6 Oil and oil filter.....................3-1-7 Oil and oil filter.....................3-1-7 Oil level check..................3-1- ..................3-1-7 Engine oil change..................3-1- ..................3-1-8 Remove the oil filter..................3-1- ..................3-1-8...
Page 50: Exploded View
ENGINE LUBRICATION SYSTEM Exploded view 3-1-2...
Page 51 ENGINE LUBRICATION SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Bolt m6×16 87 in•lb Bolt m6×40 87 in•lb Oil pump chain guard plate Bolt m6×20 87 in•lb Oil pump chain assembly Oil pump driven sprocket Washer 6.5 Oil pump shaft Needle roller p4×15.8 Oil pump cover ⅱ...
Page 52: Technical Parameter
ENGINE LUBRICATION SYSTEM Technical parameter Technical parameter Item Parameter Engine Oil: Engine Oil: Grade API SJ Or higher Viscosity SAE 10W-40 Filling amount 3.3 L (3.0 US qt) (First time，no residual oil in the engine） 3 L (2.72 US qt) (Regular oil change) Oil pressure measurement (working More than 69 kPa (10psi) @1400r/min (rpm) More than 276 kPa (40 psi) @7000r/min (rpm)
Page 53: Special Tools
ENGINE LUBRICATION SYSTEM Special Tools Special Tools Oil pressure gauge, 10 kgf/cm Thread fastening glue Oil pressure gauge connector Oil pressure gauge connector Oil ﬂ iter wrench F02G00500003 3-1-5...
Page 54: Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM Engine oil ﬂ ow chart Engine oil ﬂ ow chart Balance shaft bearing Crankshaft connecting rod journal 1 Free end main bearing Piston and connecting rod small end 1 Piston nozzle Piston and connecting rod small end 2 Intermediate main bearing Output side main...
Page 55: Oil And Oil Filter
If the oil level is too high, the excess oil can be released through the oil drain plug If the oil level is too low, you can replenish the oil through the oil ﬁ ller. Using Segway Specialize Lubricant Oil Synthetic Blend Engine Oil 10W-40 is highly recommended.
Page 56: Engine Oil Change
ENGINE LUBRICATION SYSTEM Engine oil change ◆ Please refer to the Engine Oil Replacement Chapter in the Regular Maintenance chapter. Remove the oil ﬁ lter ◆ Please refer to the engine oil ﬁ lter removal chapter in the regular maintenance chapter to refuel the oil ﬁ...
Page 57: Oil Pressure
ENGINE LUBRICATION SYSTEM Oil pressure Oil pressure Measure oil pressure ◆ Connect the oil pressure gauge connector 【C】 to the oil pressure gauge 【B】 ◆ Clean the area around the oil pressure sensor 【A】 and remove the oil pressure sensor ◆...
Page 58: Oil Pump
ENGINE LUBRICATION SYSTEM Oil pump Oil pump Remove the oil ﬁ lter assembly ◆ Disassemble：【A】 Bolt M6×16 【B】 Oil strainer assembly 【C】 Oil strainer seal ring Install the oil ﬁ lter assembly Put 【C】 on the 【B】 tube, the larger side of the outer ring is in contact with the upper ﬂ...
Page 59: Remove The Main Engine Oil Pump Rotor
ENGINE LUBRICATION SYSTEM Remove the main engine oil pump rotor ◆ Disassemble：【A】 BoltM6×20 【B】 Oil pump coverⅠ 【C】 Cylindrical pin 6×10 【D】 Main engine oil pump outer rotor 【E】 Inner rotor of main engine oil pump 【F】 Roller pin Install the main engine oil pump rotor ◆...
Page 60: Remove The Auxiliary Oil Pump Rotor
ENGINE LUBRICATION SYSTEM Remove the auxiliary oil pump rotor ◆ Disassemble：【A】 Bolt M6×20 【B】 Oil pump cover Ⅱ 【C】 Cylindrical pin 6×10 【D】 Outer rotor of auxiliary oil pump 【E】 Inner rotor of auxiliary oil pump 【F】 Roller pin Install the auxiliary oil pump rotor ◆...
Page 61: Oil Cooler Assembly
ENGINE LUBRICATION SYSTEM Oil cooler assembly Oil cooler assembly Remove the oil cooler assembly ◆ Drain the engine coolant and oil ◆ Disassemble 【A】 Oil cooler assembly 【B】 Bolt M6×40 【C】 Bolt M6×16 【D】 OO-ring 19×2.5 Install the oil cooler assembly ◆...
Page 62 EFI SYSTEM EFI SYSTEM EFI SYSTEM Exploded View........................3-2-2 Exploded View........................3-2-2 EFI SYSTEM......................3-2-4 EFI SYSTEM......................3-2-4 Disassemble the ignition coil..................3-2-4 Disassemble the electronic throttle body assembly..........3-2-4 Install the ignition coil................3-2-4 Install the electronic throttle body assembly.............3-2-4 3-2-1...
Page 63 EFI SYSTEM Exploded view Exploded view 3-2-2...
Page 64 EFI SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Bolt M6×20 87 in•lb Ignition coils Electronic throttle body assembly Fuel injector Intake air temperature pressure sensor Accelerator pedal assembly G: Use grease suitable for oil seals and O-rings L: Use fastening agent. O: Apply oil.
Page 65 EFI SYSTEM EFI system EFI system Remove the ignition coil ◆ Remove the two bolts 【A】, pull out the ignition coil 【B】 Disassemble the electronic throttle valve assembly ◆ Loosen the clamps on the intake pipes and disassemble the electronic throttle valve assembly Install the ignition coil ◆...
Page 66 STARTING SYSTEM STARTING SYSTEM Exploded view......................3-3-2 Exploded view......................3-3-2 Special Tools........................3-3-4 Special Tools........................3-3-4 Remove the starter motor.....................3-3- .....................3-3-5 Starting system......................3-3-5 ......................3-3-5 Install the starter motor....................3-3- ....................3-3-5 Disassemble the starting overload protector and the double gear assembly....3-3- ....3-3-6 Install starting overload protector and double gear assembly........3-3- ........3-3-6 Disassemble the magneto rotor..............3-3- ..............3-3-7...
Page 67: Exploded View
STARTING SYSTEM Exploded view 3-3-2...
Page 68 STARTING SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Magneto rotor assembly Flat Washers 12×24×1 Needle bearing HK121612 Double gear shaft Starter motor Starting overload protector Starting double gear Starting overrunning clutch assembly Starting driven gear assembly Hexagon socket head screw M6×16 87 in•lb Bolt M6×35 87 in•lb...
Page 69: Special Tools
STARTING SYSTEM Special Tools Special Tools Magneto rotor puller Flywheel anti-rotation wrench E02J23002001 E01GZ0010001 3-3-4...
Page 70: Remove The Starter Motor
STARTING SYSTEM Starting system Remove the starter motor ◆ Disconnect the connecting wire harness on the starter motor and remove the two bolts 【A】 ◆ Pull out the starter motor 【B】 and remove the starter motor Install the starter motor ◆...
Page 71: Disassemble The Starting Overload Protector And The Double Gear Assembly
STARTING SYSTEM Disassemble the starting overload protector and the double gear assembly ◆ Remove the gasket and gear shaft, take out the double gear assembly 【A】 and the starting overload protector 【B】 ◆ Check whether the gear is damaged, check the clearance of the gear shaft hole, if the clearance is too large, you need to replace the gear assembly Install starting overload protector and double...
Page 72: Disassemble The Magneto Rotor
STARTING SYSTEM Disassemble the magneto rotor ◆ Remove the left crankcase cover sub-assembly (see the chapter on crankcase assembly) ◆ Use the magneto rotor anti-rotation wrench 【A】 to fix the magneto rotor 【B】, and at the same time turn the wrench clockwise to remove the bolt 【C】 ◆...
Page 73: Disassemble The Starting Overrunning Clutch
STARTING SYSTEM Disassemble the starting overrunning clutch ◆ Take out the starting driven gear assembly 【A】 from the overrunning clutch ◆ Check whether the bearing surface of the starting driven gear and the bushing surface are worn, check whether the bearing surface of the starting driven gear and the bushing surface are worn and damaged ◆...
Page 74 CRANKCASE\CRANKSHAFT\BALANCE SHAFT CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view....................3-4-3 Explosive view of Up and down the case sub-assembly ...........3-4-3 Explosive view of Left crankcase cover sub-assembly ..........3-4-5 Explosive view of Upper crankcase cover sub-assembly ..........3-4-7 Explosive view of Lower crankcase cover sub-assembly ..........3-4-8 Explosive view of Oil pan sub-assembly ............3-4-9 Technical parameter....................3-4-10 Technical parameter....................3-4-10...
Page 75: Explosive View
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view 3-4-2...
Page 76: Explosive View Of Up And Down The Case Sub-Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view of Up and down the case sub-assembly 3-4-3...
Page 77 CRANKCASE\CRANKSHAFT\BALANCE SHAFT Torque Fastener Remarks N·m kgf·m ft·lb Piston injector pressure regulating valve Piston injector assembly 14.8 Bolt M6×35 87 in•lb Dowel Pin 6×10 Bolt M6×75 18.4 Bolt M6×75 87 in•lb Bolt M6×16 87 in•lb Oil Seal 13.8x2.5 oil pipe assembly oil outlet pipe Screw plug M14 13.3...
Page 78: Explosive View Of Left Crankcase Cover Sub-Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view of Left crankcase cover sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Left crankcase cover gasket Bolt M6X 35 87 in•lb Magneto stator assembly Steel belt elastic hose clamp 19 Oil cooler inlet pipe Bolt M6X 12 87 in•lb water pipe clamp A worm drive hose hoop 50...
Page 79 CRANKCASE\CRANKSHAFT\BALANCE SHAFT Magneto line pressing plate hole circlip 20 Deep groove ball bearings 629-2RS Bolt M6X 20 87 in•lb crankshaft position sensor O-Ring 17X2 overﬂ ow pipe Bolt M6X25 87 in•lb Sensor wire harness clamp inspection cover O-Ring 35X3.5 Bolt M6X 55 87 in•lb Left crankcase cover assembly OIL duct plug...
Page 80: Explosive View Of Upper Crankcase Cover Sub-Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view of Upper crankcase cover sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Upper crankcase cover gasket Oil gauge assembly Oil gauge pipe assembly Oil gauge pipe gasket Bolt M6×16 87 in•lb Bolt M6×25 87 in•lb Watercourse connector gasket Bolt M6X 55 87 in•lb Upper crankcase cover...
Page 81: Explosive View Of Lower Crankcase Cover Sub-Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view of Lower crankcase cover sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Lower crankcase cover gasket Lower crankcase cover assembly bolt M6×25 87 in•lb Connecting water pipe joint Aluminum Spacer 14×21×1.5 O-ring 19X2.5 Oil cooler assembly bolt M6×16 87 in•lb bolt M6×40 87 in•lb...
Page 82: Explosive View Of Oil Pan Sub-Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Explosive view of Oil pan sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Oil pan gasket Oil pan Bolt M6X20 87 in•lb O-Ring 13.8X2.5 Screw plug M14 assembly 11.8 G: Use grease suitable for oil seals and O-rings L: Use fastening agent. O: Apply oil.
Page 83: Technical Parameter
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Technical Parameter Item Standard Crankcase: spindle bore Ⅰ group： 51.007 ~ 51.012 mm (2.0082'' ~ 2.0083'') Ⅱ group： 51.012 ~ 51.017 mm (2.0083'' ~ 2.0085'') Ⅲ group： 51.018 ~ 51.026 mm (2.0086'' ~ 2.0089'') Ⅰ group： 41.000 ~ 41.008 mm (1.6142'' ~ 1.6145'') Balance shaft bore Ⅱ...
Page 84: Special Tools
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Special tools Special tools Sealant crankshaft oil seal pressure-installment tool F02B14000001 3-4-11...
Page 85: Left Crankcase Cover
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Left Crankcase Cover left crankcase cover Disassembly ◆ ◆ Loosen the clamp in two places Loosen the clamp in two places 【【 B B 】】 , remove the , remove the water pump outlet pipe water pump outlet pipe 【【 A A 】】 ◆...
Page 86: Check Left Crankcase Cover
CRANKCASE\CRANKSHAFT\BALANCE SHAFT check left crankcase cover ◆ ◆ Check the state of bearing Check the state of bearing 【【 A A 】】 , wire harness , wire harness 【【 B B 】】 , stator coil , stator coil 【【 C C 】】 . . ◆...
Page 87: Crankcase Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Crankcase\crankshaft\balance shaft Crankcase Assembly ◆ ◆ Remove oil drain plug Remove oil drain plug 【【 A A 】】 from oil pan to drain oil from oil pan to drain oil in oil pan. in oil pan. ◆...
Page 88 CRANKCASE\CRANKSHAFT\BALANCE SHAFT ◆ ◆ Remove 4 through-tubing mounting bolts and Remove 4 through-tubing mounting bolts and remove through-tubing assembly remove through-tubing assembly 【【 D D 】】 . . ◆ ◆ Remove 11pcs M6 bolts and 2pcs M8 bolts from the Remove 11pcs M6 bolts and 2pcs M8 bolts from the upper crankcase upper crankcase...
Page 89: Remove Balance Shaft
CRANKCASE\CRANKSHAFT\BALANCE SHAFT ◆ Remove 10 bolts 【E】, take lower crankcase cover assembly 【F】. ◆ ◆ Remove crankshaft piston connecting rod (see Remove crankshaft piston connecting rod (see crankshaft Connecting Rod Piston Assembly crankshaft Connecting Rod Piston Assembly section). section). ◆ ◆ Remove the upper crankcase. Remove the upper crankcase.
Page 90: Check Balance Shaft
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Check balance shaft ◆ Check whether the balance shaft gear is damaged. ◆ Measurement of shaft diameter 【B】, 【C】 size, the measurement of the interval of 90° in two directions. If the journal size exceeds the limit, the balance shaft needs to be replaced.
Page 91: Check The Crankshaft
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Check the crankshaft ◆ ◆ Chec Check the timing sprocket tooth k the timing sprocket tooth 【【 A A 】】 , balance , balance driving gear driving gear 【【 B B 】】 and sprocket tooth and sprocket tooth 【...
Page 92: Mounting Balancing Shaft
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Mounting balancing shaft ◆ According to the grouping mark on the crankcase, select the corresponding balance bearing bush (see the optional bearing bush). ◆ Clean the surface of the balance shaft hole on the upper crankcase, select the corresponding group of balance shaft bush and install it into the bearing hole.
Page 93: Crankcase Assembly
CRANKCASE\CRANKSHAFT\BALANCE SHAFT ◆ Align the large end of the connecting rod with the crankshaft connecting rod journal and install the corresponding connecting rod cover. ◆ Install connecting rod bolts 【E】 and tighten them as required. The connecting rod bolt one step: 25 N·m (2.55 kgf·m, 18.4 ft·lb ft·lb) two step：45 N·m (4.59 kgf·m, 33 ft·lb ft·lb)
Page 94 CRANKCASE\CRANKSHAFT\BALANCE SHAFT ◆ ◆ Align the position and load the lower crankcase. Align the position and load the lower crankcase. ◆ The rubber hammer can be gently tapped around the crankcase to ensure that there is no gap on the sealing surface of the upper and lower cases.
Page 95 CRANKCASE\CRANKSHAFT\BALANCE SHAFT ◆ ◆ Tighten the bolts in sequence to the speciﬁ ed torque. Tighten the bolts in sequence to the speciﬁ ed torque. Bolt M8 25 N·m (2.5 kgf·m, 18.4 ft·lb ft·lb) Bolt M6 9.8 N·m (1 kgf·m, 89 in·lbs in·lbs) 10 10 12 12...
Page 96: Bearing Selection
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Bearing selection Group identiﬁ er Crankcase grouping ◆ The upper and lower box sub-assembly has two rows of grouping marks at the output end, and one row of grouping marks for the main shaft hole, numbered 1, 2, 3 and 4. Another behavior balance shaft hole group identiﬁ...
Page 97: Spindle Bushing Selection
CRANKCASE\CRANKSHAFT\BALANCE SHAFT Spindle bushing selection ◆ Select the appropriate crankshaft bush according to the grouping marks on the crankcase and crankshaft. Spindle bushing selection table Crankshaft main diameter grouping Crankcase main shaft hole grouping Correct bearing bush color identiﬁ cation yellow blue blue...
Page 98 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Exploded view.......................3-5-3 Explosive view of Cylinder head cover sub-assembly..........3-5-4 Explosive view of Cylinder head sub-assembly............3-5-5 Explosive view of Cylinder sub-assembly..............3-5-7 Explosive view of Valve Mechanism................3-5-8 Explosive view of Piston connecting rod assembly............3-5-9 Technical Parameters....................3-5-11 Technical Parameter....................3-5-12...
Page 99 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder head inspection..................3-5-25 Check the cylinder head deformation..............3-5-25 Remove the intake pipe assembly................3-5-26 Install the intake pipe assembly................3-5-26 Disassemble the thermostat and water temperature sensor........3-5-26 Install thermostat and water temperature sensor............3-5-26 Thermostat check....................3-5-27 Disassemble the spark plug..................3-5-27 Install spark plug......................3-5-27 Remove the valve....................3-5-28...
Page 100: Exploded View
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Exploded view 3-5-3...
Page 101: Explosive View Of Cylinder Head Cover Sub-Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Explosive view of Cylinder head cover sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Hexagon socket pan head stepped bolt 87 in•lb Washer 10.6×18×1 Bolt rubber gasket 10 Cylinder head cover Fuel ﬁ ller cap Fuel ﬁ...
Page 102: Explosive View Of Cylinder Head Sub-Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Explosive view of Cylinder head sub-assembly 3-5-5...
Page 103 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Torque Fastener Remarks N·m kgf·m ft·lb Bolt M6×25 87 in•lb Type A worm drive hose hoop 70 Intake pipe assembly Water temperature sensor assembly Exhaust valve Intake valve Thermostat components bolt M6×135 87 in•lb Bolt M6×20 87 in•lb...
Page 104: Explosive View Of Cylinder Sub-Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Explosive view of Cylinder sub-assembly Torque Fastener Remarks N·m kgf·m ft·lb Oil Pressure Sensor Cylindrical pin 6×10 Cylinder head gasket assembly Bolt M6×25 87 in•lb cylinder block Cylinder block gasket G: Use grease suitable for oil seals and O-rings L: Use fastening agent.
Page 105: Explosive View Of Valve Mechanism
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Explosive view of Valve Mechanism Torque Fastener Remarks N·m kgf·m ft·lb Chain guide plate assembly Exhaust camshaft combination Intake camshaft combination Timing chain assembly Cylindrical pin 5×8 Hexagon ﬂ ange bolt M6×12 87 in•lb Timing chain assembly Chain tensioner...
Page 106: Explosive View Of Piston Connecting Rod Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Explosive view of Piston connecting rod assembly 3-5-9...
Page 107 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Torque Fastener Remarks N·m kgf·m ft·lb piston Piston pin Piston pin retaining ring Connecting rod tile Connecting rod bolt Half-round key Bolt M12x1.25x30-LH 15.3 Crankshaft parts Connecting rod assembly Balance shaft assembly Piston ring combination Piston set Crankshaft connecting rod assembly...
Page 108: Technical Parameters
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Technical Parameters Item Standard Limit Cylinder head: Cylinder pressure value (use range) Electric starter 1.1 ~ 1.3 MPa (11~13 kgf/cm², 159~188 psi) – – – Deformation of cylinder head – – – 0.1 mm (0.004 in.) Cylinder head height 120.5 ±...
Page 109: Technical Parameter
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Technical Parameter Item Standard Limit Camshaft: Camshaft lobes height: exhaust 40.08 ± 0.04 mm (1.5780" ± 0.0015") 39.99 mm (1.5744") Intake 40.36 ± 0.04 mm (1.5890" ± 0.0015") 40.27 mm (1.5854") Camshaft journal diameter-all: 22.954 ~ 22.975 mm (0.9036"...
Page 110: Special Tools
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Special tools Valve spring presser assembly Cylinder pressure gauge Valve spring press ﬁ tting head Cylinder pressure gauge connector， M10×1.0 Camshaft ﬁ xing tool Circlip pliers E02A40000001 screwdriver 3-5-13...
Page 111: Cylinder Head Cover
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder head cover Remove the cylinder head cover ◆ Disassembly: 【A】 Hexagon socket pan head stepped bolt 【B】 Washer 10.6×18×1 【C】 Rubber gasket 10 【D】 Cylinder head cover 【E】 Cylinder head cover sealing ring Install the cylinder head cover: ◆...
Page 112: Camshaft Cover / Camshaft
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Camshaft cover / camshaft Remove the tensioner CAUTION CAUTION This is a non-return type timing chain tensioner. Once the push rod of the tensioner extends out of the tensioning chain, it cannot return to the initial position. Observe all the following rules: When removing the tensioner, do not unscrew only part of the mounting bolts.
Page 113: Disassemble Camshaft
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Disassemble camshaft ◆ Disassembly 【A】 Bolt M6×16 【B】 Chain guide plate assembly Ⅱ ◆ Disassembly 【C】 Bolt M6×35 【D】 Camshaft cover assembly 【E】 Cylindrical pin 6×10 TIPS Loosen the bolts that secure the camshaft cover evenly, and carefully lift the camshaft cover from the camshaft.
Page 114: Camshaft Sprocket Inspection
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Camshaft sprocket inspection ◆ Check whether the camshaft sprocket teeth are worn or damaged. If wear or damage is found, replace the timing chain and sprocket with a new one. Camshaft / camshaft lobe inspection ◆...
Page 115: Install Camshaft Sprocket
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON ◆ Calculate the clearance value by subtracting the camshaft shaft diameter from the camshaft bearing bore, and compare it with the speciﬁ cation Standard Limit 0.025~ 0.067 mm (0.0009" ~ 0.0026") 0.10 mm (0.0039") CAUTION CAUTION Cylinder head and camshaft cover are combined...
Page 116: Camshaft Installation / Timing Adjustment
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Camshaft installation / timing adjustment CAUTION CAUTION If any parts in the valve train have been replaced, please refer to the valve clearance adjustment procedure sequence. Camshaft installation/timing adjustment ◆ Rotate the engine so that the top dead center (TDC) mark of the magneto rotor is aligned or in the center of the crankshaft position sensor (CPS) mounting hole.
Page 117 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON ◆ Insert the camshaft fixing tool 【D】 into the camshaft end groove shown in the figure to fix the intake and exhaust camshafts. If necessary, use an open-end wrench to turn the camshaft. ◆...
Page 118: Valve Clearance Adjustment
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Valve clearance adjustment CAUTION CAUTION Before installing the camshaft or ﬁ nally assembling the engine, be sure to check the valve clearance ◆ Camshaft installation (see camshaft installation/ timing adjustment) ◆ C a m s h a f t c o v e r i n s t a l l a t i o n ( s e e c a m s h a f t installation/timing adjustment) ◆...
Page 119: Optional Tappet Specifi Cations
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON are adjusted. ◆ Reinstall the camshaft and camshaft cover, and tighten the bolts as required. ◆ Tightening torque: Bolt (M6) 9.8 N•m (1.0kgf•m, 87in•lb) ◆ Measure and confirm that each valve clearance is within the required range.
Page 120 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON valve clearance (mm)before adjustment 3-5-23...
Page 121 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON valve clearance (mm)before adjustment 3-5-24...
Page 122: Cylinder Head
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder head ◆ Remove the cylinder head TIPS Maintenance of the cylinder head can be carried out on the entire vehicle. ◆ Disassembly: 【A】 Bolt M6×90 【B】 Cylinder bolt M11×1.25×150 【C】 Bolt M6×16 ◆...
Page 123: Remove The Intake Pipe Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Remove the intake pipe assembly ◆ Disassembly: 【A】 Bolt M6×25 【B】 Intake pipe assembly Install the intake pipe assembly ◆ Install the intake pipe assembly 【B】, and tighten the bolt 【A】. ◆ Tightening torque Intake pipe assembly bolt 9.8 N·m (1.0 kgf·m, 87 in·lb) D i s a s s e m b l e t h e t h e r m o s t a t a n d w a t e r...
Page 124: Thermostat Check
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Thermostat check ◆ Remove the thermostat and check the thermostat 【A】 at room temperature. ◆ If the thermostat is turned on, please replace it with a new one. ◆ Check the opening temperature of the thermostat, p u t t h e t h e r m o s t a t 【...
Page 125: Remove The Valve
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Remove the valve WARNING When disassembling and assembling the cylinder head or operating the valve spring, you need to wear goggles. TIPS In order to ensure that the parts can be installed back to the original position, the matching parts should be put together and arranged according to their position on the cylinder head.
Page 126: Valve Guide / Valve Inspection
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON ◆ Measure the free length of each valve spring with a vernier caliper and compare it with the standard value. ◆ Free length of valve spring:standard:1.726" (43.85 mm)，service limit:1.683" (42.75 mm) Standard Limit 42.5 mm (1.6732") 41.4mm (1.6299")
Page 127: Combustion Chamber Cleaning
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON TIPS If necessary, the valve can be re-dressed or ground. If it is severely worn, burned, bent or damaged, it must be replaced ◆ Use a micrometer to measure the diameter of the valve stem at three places, and then turn it 90°...
Page 128: Seat Ring Repair
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Seat ring repair ◆ S e a t r i n g r e p a i r s h o u l d b e c a r r i e d o u t b y professionals who are proficient in cylinder head repair technology.
Page 129: Seat Ring Repair (Valve Grinding)
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Seat ring repair (valve grinding) ◆ Insert the guide into the valve guide. ◆ Apply cutting oil to the seat ring and tool. ◆ Place the 46° tool on the guide and perform light cutting.
Page 130 CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Intake 【A】 30° 【B】 45° 【C】 60° 【D】 1.0 ~ 1.1mm (0.0394" ~ 0.0433") limit: 1.4mm (0.055") 【A】 30° Exhaust 【B】 45° 【C】 60° 【E】 1.5 ~ 1.6mm (0.0591" ~ 0.0630") limit: 1.9mm (0.075") ◆...
Page 131: Cylinder Head Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder head assembly WARNING When disassembling and assembling the cylinder head or operating the valve spring, you need to wear goggles. ◆ Install a new valve oil seal 【C】 on the valve guide, and press the valve oil seal into place with a special tool.
Page 132: Cylinder Block And Piston
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder block and piston Cylinder block removal ◆ Remove the cylinder head gasket 【A】. ◆ Remove the two M6 connecting bolts 【B】. ◆ Disassemble the crankshaft (see the chapter of crankshaft connecting rod piston assembly). ◆...
Page 133: Disassemble The Piston
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON two directions (front and back, left and right), each cylinder There are a total of 6 holes for measurement. ◆ Cylinder hole grouping marks (I or Ⅱ) are marked on the steps on the intake side of each cylinder of the cylinder block.
Page 134: Piston Measurement
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON ◆ Use your fingers to carefully open the opening of the piston ring 【C】, then lift the piston ring up and remove it from the piston. ◆ Remove the remaining piston ring in the same way. CAUTION CAUTION When disassembling the piston ring, do not open it too...
Page 135: Measure The Gap Of The Piston Ring Groove
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON ◆ Check the grouping mark on the top surface of the piston, and compare the measurement result with Outer diameter group identiﬁ cation the grouping value of the outer diameter of the piston.
Page 136: Measure The Piston Pin
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Measure the piston pin ◆ Measure the diameter of the piston pin in three positions and two directions (90° apart). If the limit is exceeded, the piston pin needs to be replaced. Piston pin diameter standard：...
Page 137: Piston Ring Installation
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Piston ring installation TIPS When installing the piston ring, apply clean engine oil to the surface. Check the clearance of the piston ring groove (see "Measuring the clearance of the piston ring groove"). If assembling a used piston, the carbon deposits in the piston ring groove and the oil hole of the oil ring groove should be cleaned ﬁ...
Page 138: Cylinder Block Assembly
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder block assembly ◆ According to the grouping mark of cylinder bore and O u t e r d i a m e t e r piston, select the combination of piston and cylinder group identiﬁ...
Page 139: Cylinder Pressure Measurement
CYLINDER HEAD, CYLINDER, PISTON CYLINDER HEAD, CYLINDER, PISTON Cylinder pressure measurement TIPS Fully charge the battery before measuring ◆ Warm up the engine completely, then stop it. ◆ Disassemble the spark plug (refer to the spark plug chapter). ◆ Connect the cylinder pressure gauge and the connector ﬁ rmly to the spark plug hole. ◆...
Page 140 CVT SYSTEM CVT SYSTEM Exploded view......................3-6-2 Special tools.......................3-6-5 disassemble the CVT cover..................3-6-6 Install the CVT cover..................3-6-6 disassemble the CVT inner cover..............3-6-7 Install the CVT inner cover..............3-6-7 Transmission belt.......................3-6-8 Disassemble the drive belt................3-6-8 Check the drive belt..................3-6-8 Install the drive belt.....................3-6-8 Disassemble the drive pulley and the driven pulley...........3-6-9 Install drive pulley and driven pulley.................3-6-10 3-6-1...
Page 141: Exploded View
CVT SYSTEM Exploded view 3-6-2...
Page 142 CVT SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb CVT drive pulley assembly bolt M12 Washer 12×28×6 CVT driven pulley bolt M10×1.25×80 SPACER 10.5×36×8 CVT driven pulley assembly Ball (Hongzheng) Adjustment mats Transmission belt G: Grease the oil seal and o-ring. L: Use a non-permanent locking agent.
Page 143 CVT SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb cvt inner cover sealⅠ cvt inner cover seal Ⅱ cvt inner cover o-ring 8×2 CVT temperature sensor plug assembly Bolt M6×20 87 in•lb Plug cvt cover plug seal Bolt M6×28 53 in•lb CVT cover seal Baﬄ...
Page 144: Special Tools
CVT SYSTEM Special tools CVT belt replacement tool kncok-out pin for drive pulley E02E30300001 E02E30005001 CVT standstill locking E02E25000002 3-6-5...
Page 145: Disassemble The Cvt Cover
CVT SYSTEM CVT box CVT box WARNING WARNING Excessive imbalance or excessive speed may cause the failure of the CVT pulley, resulting in serious injury or death. The CVT pulley is a precisely balanced component designed to operate within a speciﬁ c speed range.
Page 146: Disassemble The Cvt Inner Cover
CVT SYSTEM disassemble the CVT inner cover ◆ Disassemble the CVT drive pulley and driven pulley (refer to the drive pulley and driven pulley section) ◆ disassemble the CVT inner cover mounting bolts 【A】, remove the baﬄ e 【B】, CVT inner cover 【C】, CVT inner cover sealing ring Ⅰ...
Page 147: Transmission Belt
CVT SYSTEM Transmission belt Disassemble the drive belt ◆ Remove the CVT cover. ◆ Remove the handle on the CVT belt replacement tool 【B】, and manually screw the CVT belt replacement tool 【B】 into the thread of the CVT driven pulley 【A】. ◆...
Page 148: Disassemble The Drive Pulley And The Driven Pulley
CVT SYSTEM Drive pulley and driven pulley assembly Drive pulley and driven pulley assembly Disassemble the drive pulley and the driven pulley ◆ ◆ disassemble the CVT cover (see CVT cover disassemble the CVT cover (see CVT cover chapter). chapter). ◆...
Page 149: Install Drive Pulley And Driven Pulley
CVT SYSTEM Install drive pulley and driven pulley ◆ Install the CVT driven pulley 【B】 on the gearbox shaft, and lock the CVT driven pulley 【B】 with the CVT stop tool 【A】. ◆ Install the washer 【C】 and the driven pulley bolt 【D】, and tighten the driven pulley bolt 【D】...
Page 150 WATER PUMP ASSEMBLY WATER PUMP ASSEMBLY Exploded view.......................3-1-2 Special tools.......................3-1-4 Water pump assembly....................3-1-5 Disassemble the water pump..................3-1-5 Install the water pump.....................3-1-6 3-7-1...
Page 151: Exploded View
WATER PUMP ASSEMBLY Exploded view 3-7-2...
Page 152 WATER PUMP ASSEMBLY Torque Fastener Remarks N·m kgf·m ft·lb Water pump cover Bolt M6×30 87 in•lb Bolt M6×95 87 in•lb Bolt M6×12 87 in•lb Aluminum washer 6 Steel belt elastic hose clamp 30 Small circulating water pipe Water pump cover sealing ring Bolt M6×16 87 in•lb Disc spring 12.5×6.4×1...
Page 153: Special Tools
WATER PUMP ASSEMBLY Special Tools Special Tools Oil seal press tool15-28-5 Oil seal press tool15-30-5 F02H00010003 F02H00010004 3-7-4...
Page 154: Disassemble The Water Pump
WATER PUMP ASSEMBLY Water pump assembly Disassemble the water pump WARNING Make sure that the engine has cooled down before disassembly. Hot coolant and steam can cause serious injury. ◆ Disassemble the two clamps and remove the small circulating water pipe 【A】. ◆...
Page 155: Install The Water Pump
WATER PUMP ASSEMBLY Install the water pump ◆ Insert the water pump shaft 【A】 into the left crankcase cover, and install the ﬂ at washer 【B】. ◆ Take a new O-ring 【C】, apply appropriate amount of engine oil on the surface, and install it into the O-ring groove of the water pump shaft.
Page 156 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Exploded view of front axle....................3 Special tools........................6 Replacement of front axle gear oil..................7 Drain the old gear oil......................7 Add new gear oil.......................7 Inspection of parts wear.....................8 Disassemble........................8 Install..........................8...
Page 157 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the right gearbox combined bearing..............19 Install the parking mechanism..................20 Install the bearing plate of the left box body..............20 Install the countershaft assembly...............21 Assemble the rear axle output gear assembly..............21 Install the left box connector..................21 Install the gear set......................22 Assemble the HR shift fork shaft assembly..............22...
Page 158: Exploded View Of Front Axle
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Exploded view of front axle Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt m8×25 Oil seal 30×55×7 Breathing joint 1.53 11.1 Front axle end cover Rectangular gasket Deep groove ball bearings 16010 Limiting liner Hexagon ﬂ...
Page 159 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Torque Fastener Remarks N·m kgf·m ft·lb Deep groove ball bearings 16008 Front axle housing Bushing ⅱ (φ15) Drive bevel gear shims Bearing 3306 Circlip 30 Round nut m75×1.5×6-Lh Oil seal 30×78×7 Bolt m6×16 Vehicle speed sensor assembly O-ring 12×2...
Page 160 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Technical speciﬁ cations Item Standard Service limit Front axle: Front axle: Type Sae 80w/90/gl-5 Fill position Side of the box (screw plug m14) Drain position Bottom of the box (screw plug m14 assembly) Volume 180 ml (0.19 Us qt) (when there is no oil stains after internal cleaning)
Page 161: Special Tools
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Special tools ALLEN WRENCH 8mm / 12mm: SILICONE RUBBER FLAT SEALANT： SCREWDRIVER EXTERNAL CIRCLIP PLIERS ROUND NUT M75×1.5×6-LH SLEEVE T-SLEEVE 10mm 4 - 6...
Page 162: Replacement Of Front Axle Gear Oil
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Replacement of front axle gear oil WARNING WARNING Vehicle operation with insuﬃ cient,deteriorated,or contaminated gear oil will cause accelerated wear and may result in Gearbox Damage, accident,and injury. 【A】 o-ring 13.8×2.5 【B】...
Page 163: Inspection Of Parts Wear
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Inspection of parts wear 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. 【A】...
Page 164: Adjustment Of Gear Clearance
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Adjustment of gear clearance 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...
Page 165: Exploded View Of Rear Gearbox
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Exploded view of rear gearbox Torque Fastener Remarks N·m kgf·m ft·lb Bolt m10x1.25X45 33.3 4.59 Bolt m8×125 2.55 18.5 Bolt m8×40 2.55 18.5 Right gearbox assembly machining parts Oil seal 42×55×8 Oil seal 27×60×7 Deep groove ball bearings 6206 Nut m33×1.5...
Page 166 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Torque Fastener Remarks N·m kgf·m ft·lb Shift drum Spacer 15×28×1 Needle roller bearing hk1516 Circlip 12 Shift fork spring seat Shift fork spring Hr gear shift fork assembly Hr gear shift fork shaft Parking guide shaft Push rod seat assembly Scroll wheel...
Page 167 FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Torque Fastener Remarks N·m kgf·m ft·lb Deep groove ball bearings 6207 Hexagon socket large pan head bolt m6×16 1.22 8.86 Main shaft Shift positioning wheel Bushing Shift driven gear Shift torsion spring Spacer 6.5×22×2 Hexagon head bolt m6×40 1.53...
Page 168: Replacement Of Gearbox Gear Oil
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Replacement of gearbox gear oil WARNING Vehicle operation with insufficient,deteriorated,or contaminated speed gearbox oil will cause accelerated wear and may result in Gearbox Damage, accident,and injury. 【A】O-ring seal 13.8×2.5 【B】Screw plug m14 assembly 【C】Oil dipstick 【D】O-ring seal 18×3.5 Drain the gearbox oil...
Page 169: Dismantling The Gearbox
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Dismantling the gearbox Gear setting ◆ Tool: gear wrench ◆ Hang the gear counterclockwise to the end as P gear. Dismantling the driven bevel gear cover assembly 【A】Bolt M8×40 【B】 Bolt M10X1.25X45 【C】Bolt M8×125 【D】Driven bevel gear cover assembly ◆...
Page 170: Dismantling The Shift Mechanism
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Dismantling the shift mechanism 【A】 Shift positioning wheel 【B】 Bushing 【C】 Shift driven gear 【D】 Shift torsion spring 【E】 Washer 6.5×22×2 【F】 Hexagon head bolt M6×40 【G】 Shift positioning plate spring 【H】...
Page 171: Dismantling The Right Gearbox Connector
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Dismantling the right gearbox connector 【A】Gear sensor assembly 【B】 Bolt M6×16 【C】 Circlip 30×2.5 【D】 Washer 30×40×1.5 【E】L gear driven gear 【F】Needle roller bearing K28×33×17 ◆ Tools: 8mm sleeve, external circlip pliers. ◆...
Page 172: Dismantling The Shifting System
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Dismantling the shifting system 【A】Parking guide shaft 【B】 HR gear shift fork shaft assembly 【C】 L gear shift fork shaft assembly 【D】Push rod seat assembly 【E】 Shift drum assembly 【F】 Washer 15×28×1 ◆...
Page 173: Dismantling The Countershaft Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Dismantling the countershaft assembly 【A】 RL gear engagement sleeve 【B】 Circlip 35×2.5 【C】 Washer 32×42×1.5 【D】R gear driven gear 【E】 Needle roller bearing K35×40×13 【F】Parking gear 【G】 H gear driven gear 【H】...
Page 174: Assemble The Gearbox
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Assemble the gearbox Install the left box bearing 【A】Left gearbox body 【B】 Deep groove ball bearing 6305 【C】 Deep groove ball bearing 6307 【D】Needle roller bearing HK1516 ◆ Tools: bearing tooling 6305, bearing tooling 6307, needle bearing indenter HK121612.
Page 175: Install The Parking Mechanism
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Installation 【A】Right gearbox 【B】 Deep groove ball bearing 6305 ◆ Tools: Bearing tooling 6305. ◆ Lay the box 【A】 flat, with the inner cavity facing upwards, and press into the bearing 【B】. Install the parking mechanism 【A】Push rod guide seat 【B】Parking arm return torsion spring...
Page 176: Install The Countershaft Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the countershaft assembly 【A】 RL GEAR COUPLING SLEEVE 【B】 Circlip 35×2.5 【C】 Washer 32×42×1.5 【D】R gear driven gear 【E】 Needle roller bearing K35×40×13 【F】Parking gear 【G】 H gear driven gear 【H】...
Page 177: Install The Gear Set
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the gear set 【A】 Countershaft assembly 【B】 Third axis assembly 【C】 Fourth axis assembly ◆ After putting 【C】into the left box body ﬁ rst, install 【A】and【B】into the left box body together as shown in the ﬁ...
Page 178: Install The Hr Shift Fork Shaft Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the HR shift fork shaft assembly: 【A】 HR gear shift fork shaft assembly Push rod assembly 【B】 Countershaft assembly 【C】 Countershaft assembly ◆ Assemble 【A】【C】 as shown in the ﬁ gure, then put it into the left box and connect with 【B】.
Page 179: Install The Parking Shaft And Shift Drum Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the parking shaft and shift drum assembly 【A】 Washer 15×28×1 【B】 shift drum 【C】Parking guide shaft ◆ Assemble 【A】【B】 as shown in the ﬁ gure and install it into the left box body, and then put 【C】 into the left box body.
Page 180: Install The Main Shaft Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the main shaft assembly 【A】 Bushing 【B】 Main shaft ◆ Tools: copper hammer. ◆ Press 【A】 into 【B】 according to the icon. Install the gear assembly 【A】Reverse gear idler shaft assembly 【B】...
Page 181: Install The Countershaft Low-Speed Gear
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the countershaft low-speed gear: 【A】 Washer 30×40×1.5 【B】 Needle roller bearing K28×33×17 【C】L gear driven gear 【D】 Washer 30×40×1.5 【E】 Circlip 30×2.5 ◆ Tools: external circlip pliers. ◆ Load 【A】, 【B】, 【C】, 【D】, and 【E】 into the countershaft in the order shown in the ﬁ...
Page 182: Install The Driven Bevel Gear Cover Oil Seal
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the driven bevel gear shaft 【A】 Oil seal 27×60×7 【B】 Driven bevel gear shaft 【C】 Cylindrical pin 6×10 【D】 Driving bevel gear shaft adjustment pad 42×48×0.6 【E】 Driving bevel gear 【F】...
Page 183: Install The Gear Sensor And Rotary Shaft Oil Seal
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the gear sensor and rotary shaft oil seal 【A】 Bolt M6×20 【B】 Gear sensor assembly 【C】 O-ring 29.6×2.4 【D】 Oil seal 38×55×7 【E】 CVT driven wheel bushing 【F】 O-ring 31×2.5 ◆...
Page 184: Install The Oil Pump Assembly
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Assemble the oil pump components 【A】 Oil pump 【G】 Oil pump shaft 【B】 Flow oriﬁ ce φ1 【H】 Needle roller P4×15.8 【C】 Oil seal 15×25×5 【I】 O-ring 52×2 【D】 Cylindrical pin 6×10 【J】...
Page 185: Install The Needle Bearing And Locating Pin
FRONT AXLE AND REAR GEARBOX FRONT AXLE AND REAR GEARBOX Install the needle bearing and locating pin 【A】 Needle roller bearing HK121612 【B】 Cylindrical pin 6×10 Tools: Needle bearing indenter-HK121612, copper hammer. ◆ Press 【A】 into the box, and put two cylindrical pins 【B】...
Page 186 FUEL SYSTEM FUEL SYSTEM EXPLODED VIEW OF FUEL SYSTEM ............. 5-2 FUEL TANK ....................5-3 Disassembly ......................5 - 3 Assembly ........................5 - 3 FUEL PUMP ....................5-4 Disassembly....................5-4 Inspection ........................5 - 4 Assembly ........................5 - 5 FUEL FILTER .................... 5-6 Disassembly ......................5 - 6 Assembly ........................5 - 6 5 - 1...
Page 187: Exploded View Of Fuel System
FUEL SYSTEM EXPLODED VIEW OF FUEL SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Bolt M6×35 8~12 0.8~1.2 69~103.6 in·lb Install screw cap on oil pump 5 - 2...
Page 188: 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 189: Fuel Pump
FUEL SYSTEM FUEL PUMP Whenever any maintenance or inspection of the fuel system is carried out, fuel leakage may occur, and there must be no welding, smoke, open flames, etc. in this area. Disassembly 【A】Oil pump installation screw cap 【B】Fuel Pump 【C】Sealing ring ◆...
Page 190: Assembly
FUEL SYSTEM ◆ Test the pressure of the fuel pump supply port through the pressure gauge【D】, and the test pressure value is 330±20Kpa under the power-on state. ◆ If the resistance reading shows unstable, please clean the resistance wiper with alcohol and retest. If it is still incorrect, please replace the fuel pump.
Page 191: Fuel Filter
FUEL SYSTEM FUEL FILTER ◆ Whenever the gasoline pipeline is removed, the battery must be disconnected to prevent the fuel pump from starting accidentally. ◆ Whenever any maintenance or inspection of the fuel system is carried out, fuel leakage may occur, and there shall be no welding, smoke, open ﬂ...
Page 192 COOLING SYSTEM COOLING SYSTEM EXPLODED VIEW OF COOLING SYSTEM .......... 6 - 2 COOLANT FLOW .................. 6 - 3 TECHNICAL PARAMETER ..............6 - 5 SPECIAL TOOLS AND SEALANTS ............. 6 - 6 COOLANT ..................... 6 - 7 Coolant deterioration inspection ................6 - 7 Coolant level check .....................
Page 193: Exploded View Of Cooling System
COOLING SYSTEM EXPLODED VIEW OF COOLING SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Radiator mounting bolt M6X30 8~12 0.8~1.2 69~103.6in.I Radiator fan assembly bolt M6 8~12 0.8~1.2 69~103.6in.I 6 - 2...
Page 194: Coolant Flow
COOLING SYSTEM COOLANT FLOW Choose 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 type of wax pellets, which opens or closes as the temperature of the coolant changes.
Page 195 COOLING SYSTEM COOLANT FLOW 1. Engine radiator 2. Water pump 3. Oil radiator cover 4. Water storage tank 5. Oil radiator 6. Radiator air duct 7. Engine radiator fan 8. Cylinder & Cylinder head 9. Thermostat 10. Radiator fan switch Black arrow: hot coolant White arrow: cold coolant 6 - 4...
Page 196: 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 197: Special Tools And Sealants
COOLING SYSTEM SPECIAL TOOLS AND SEALANTS Silicone Sealant: Special tools and sealants： 6 - 6...
Page 198: 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 199: 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 (1.25 kgf/cm , 18psi).
Page 200: 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 201: Radiator Fan Removal
COOLING SYSTEM breather pipe and the engine radiator water inlet and outlet hoses. ◆ Remove the mounting bolts of the upper bracket of the radiator, and remove the upper bracket of the radiator. ◆ Remove the engine radiator. Do not touch the radiator core. This may damage the radiator, resulting in reduced cooling eﬃ...
Page 202: 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 203 INTAKE / EXHAUST SYSTEM INTAKE/EXHAUST SYSTEM EXPLODED VIEW OF INTAKE SYSTEM .............. 7-2 Air ﬁ lter element replacement ................7-3 AIR INLET FILTER DISASSEMBLY ..............7-3 Air cleaner disassembly ..................7-4 EXPLODED VIEW OF EXHAUST SYSTEM ............7-5 Disassemble ...................... 7-6 Rubber buﬀ...
Page 204: Exploded View Of Intake System
INTAKE / EXHAUST SYSTEM EXPLODED VIEW OF INTAKE SYSTEM Torque Fastener Remarks N·m kgf·m ft·lbs Bolt M6×30 Bolt M6×30 Bolt M6×30 Clamp 7 - 2...
Page 205: Air Filter Element Replacement
INTAKE / EXHAUST SYSTEM AIR INLET FILTER DISASSEMBLY Place the vehicle in a ﬂ at road 【A】Cargo box hand shank 【B】Air inlet ﬁ lter ◆ Rotate handle shank【A】in the right to overturn the cargo box. ◆ Take out air inlet ﬁ lter screen【B】. ◆...
Page 206: Air Cleaner Disassembly
INTAKE / EXHAUST SYSTEM ◆ Take out air ﬁ lter bracket【C】 ◆ Replace air ﬁ tler【D】 Make sure air ﬁ lter and end cover clamp are assembled in right position or it will cause engine failure or reduce lifetime. Please shorten interval to check air ﬁ lter if the vehicle is working in heavy dust environment.
Page 207 INTAKE / EXHAUST SYSTEM 排气系统爆炸图 Torque Fastener Remarks N·m kgf·m ft·lbs Cap Nut M8 Spring Exhaust pipe connection bolt Hexagon flat round head assembly screw M6×14 Hexagon ﬂ at round head screw M6×20 Hexagon ﬂ ange bolt M8x16 Hexagon ﬂ ange bolt M8x40 Nut M8 7 - 5...
Page 208: Muffler
INTAKE / EXHAUST SYSTEM MUFFLER DISASSEMBLY Do not perform maintenance immediately after use as the exhaust components become very hot and can cause serious burns and injury. 【A】Bolt 【B】Spring ◆ Disassemble bolt【A】and remove spring【B】【C】Nut M8 【D】Hexagon ﬂ ange bolt M8x40 ◆...
Page 209: Air Exhaust Disassembly
INTAKE / EXHAUST SYSTEM Air exhaust disassembly When you check or maintain parts of air exhaust system, you must check if the part is overheat in case of scald. ◆ Remove rear storage box (see 7-3) ◆ Remove the air ﬁ lter (see 7-4) ◆...
Page 210: Air Exhaust System Inspection
INTAKE / EXHAUST SYSTEM AIR EXHAUST SYSTEM INSPECTION 1. Check externally if any crack, hole or damage in the muﬄ er then replace related parts. This will aﬀ ect engine performance and emmission. 2. Shake the muﬄ er then replace related parts to check if any looseness, noise or debris inside.
Page 211 DRIVE SYSTEM DRIVE SYSTEM EXPLODED VIEW OF DRIVE SYSTEM..........8-2 DISASSEMBLY OF THE REAR SECTION OF THE DRIVE SHAFT....8-3 DISASSEMBLY OF THE FRONT SECTION OF THE DRIVE SHAFT..8-4 DISASSEMBLY OF THE MIDDLE SECTION OF THE DRIVE SHAFT...8-6 BEARING REPLACEMENT............8-7 FRONT DRIVE SHAFT REMOVAL............8-8 DRIVE SHAFT EXPLODED VIEW............8-9 DRIVE SHAFT REMOVAL............8-10 INSTALLATION OF DRIVE SHAFT.............8-12...
Page 212: Exploded View Of Drive System
DRIVE SYSTEM EXPLODED VIEW OF DRIVE SYSTEM Torque Fastener Remarks N·m kgf·m ft·lbs Bolts M8×35 Bolts M10×1.25×20 L：Apply Impermanent Locking Agent. 8 - 2...
Page 213: Disassembly Of The Rear Section Of The Drive Shaft
DRIVE SYSTEM DISASSEMBLY OF THE REAR SECTION OF THE DRIVE SHAFT Put the vehicle in a horizontal position ﬁ rst 【A】 Right rear wheel assembly 【B】 Right rear rocker arm assembly 【C】 bolt 【D】 the rear segment of the drive shaft ◆...
Page 214: Disassembly Of The Front Section Of The Drive Shaft
DRIVE SYSTEM DISASSEMBLY OF THE FRONT SECTION OF THE DRIVE SHAFT 【A】 plastic parts 【B】 Bearing seat bolt 【C】 bearing seat 【D】 the middle part of the drive shaft ◆ Disassemble the plastic part【A】 ◆ Disassemble the middle part of the drive shaft Bearing seat bolt 【B】...
Page 215 DRIVE SYSTEM 【A】 Front right wheel assembly 【B】 Drive shaft mounting bolt 【C】 the front section of the drive shaft ◆ Removal of front right wheel Assembly 【A】; ◆ Remove the installation bolt of the drive shaft and the front axle end 【B】 rotate the drive shaft 180°, remove another ﬁ...
Page 216: Disassembly Of The Middle Section Of The Drive Shaft
DRIVE SYSTEM DISASSEMBLY OF THE MIDDLE SECTION OF THE DRIVE SHAFT 【E】Bearing seat 【F】 Butter nozzle Remove bearing seat [E] ◆ Need to check whether the bearing has abnormal noise or large gap or excessive wear, if any defects need to replace the bearing seat as a whole.
Page 217: Bearing Replacement
DRIVE SYSTEM BEARING REPLACEMENT 【A】Retaining ring for hole 【B】Spline fork 【C】Bearing 【D】Welding fork ◆ Retaining ring for disassembly hole【A】 ◆ Fix the welding fork【D】on the clamp, hit the spline fork【B】, and take out the roller needle bearing group to separate the spline fork from the ten-byte bearing;...
Page 218: Front Drive Shaft Removal
DRIVE SYSTEM FRONT DRIVE SHAFT REMOVAL 【A】Split pin 【B】Nut 【C】Washer 【D】Bolt 【E】Wheel hub mount ◆ Park the vehicle in a horizontal position and use a jack or support frame to support the vehicle so that the wheels do not touch the ground, and then remove the front tires ◆...
Page 219: Drive Shaft Exploded View
DRIVE SYSTEM 传动系统 DRIVE SHAFT EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lbs Retaining ring Rear left/right inner ball cage assembly Retaining ring Rear axle corrugated sleeve repair kit large clamp small clamp Intermediate shaft Outer cage components 8- 9...
Page 220: Drive Shaft Removal
DRIVE SYSTEM DRIVE SHAFT REMOVAL ◆ The removal method of the front and back constant speed drive shaft is the same; 【A】 cotter 【B】 nut 【C】 gasket 【D】 bolt 【E】 Hub mounting seat ◆ Park the vehicle in the horizontal position, with a jack or support frame to raise the vehicle, so that the wheels do not touch the ground, and then remove the front tire;...
Page 221 DRIVE SYSTEM 【A】 bolt 【B】 Slotted nut 【C】 front knuckle 【D】 bolt 【E】 Constant speed drive shaft ◆ Remove the fixed bolts of the upper and lower kingpin 【A】, so that the upper and lower rocker arm is separated from the steering knuckle; ◆...
Page 222: Installation Of Drive Shaft
DRIVE SYSTEM INSTALLATION OF DRIVE SHAFT ◆ Install a new retaining ring in the spline groove 【A】, apply anti-biting agent on the spline; ◆ The spline of the driving shaft is aligned with the diﬀ erential spline, push inward along the horizontal arrow direction, and load the driving shaft;...
Page 223: Inboard Cv Joint Drive Shaft Repair
DRIVE SYSTEM INBOARD CV JOINT DRIVE SHAFT REPAIR The drive shaft is a precision component. It is necessary to ensure cleanliness when replacing and installing, and operate in strict accordance with the instructions. Do not use a hammer or sharp objects for disassembly and installation, which will affect the performance and service life of the half shaft ◆...
Page 224 DRIVE SYSTEM INBOARD CV JOINT DRIVE SHAFT REPAIR ◆ After removing the retaining ring, you can directly pull out the intermediate shaft, pay attention to the steel ball on the cage and star sleeve not to fall, and clean the grease in the universal joint and the dust cover If you only replace the grease, you need to clean the remaining grease inside the universal joint, and it is...
Page 225 DRIVE SYSTEM ◆ First install the small clamp, adjust the position of the dust cover to ensure that the dust cover is stuck in the groove of the intermediate shaft, and then use clamp pliers to clamp the small clamp ◆...
Page 226 FRONT & REAR SUSPENSION FRONT & REAR SUSPENSION EXPLODED VIEW OF FRONT SUSPENSION ............9 - 2 EXPLODED VIEW OF REAR SUSPENSION ............9 - 4 TECHNICAL PARAMETER ..................9 - 6 DEDICATED TOOLS....................9 - 7 SHOCK ABSORBER ....................9 - 8 Absorber inspection ....................
Page 227: Exploded View Of Front Suspension
FRONT & REAR SUSPENSION EXPLODED VIEW OF FRONT SUSPENSION 9 - 2...
Page 228 FRONT & REAR SUSPENSION Torque Fastener Remarks N·m kgf·m ft·lbs Hexagon socket screws with cylindrical 22 ～ 28 2.2~2.8 head M8×25 Shock absorber mounting bolt 112~128 11.2~12.8 82.6~94.4 M12×1.25×95 Shock absorber mounting nut M12x1.25 112~128 11.2~12.8 82.6~94.4 Shock absorber mounting nut M12x1.25 8~12 0.8~1.2 balance bar Mounting bolt M8x35 22 ～...
Page 229: Exploded View Of Rear Suspension
FRONT & REAR SUSPENSION EXPLODED VIEW OF REAR SUSPENSION 9 - 4...
Page 230 FRONT & REAR SUSPENSION Torque Fastener Remarks N·m kgf·m ft·lbs Hexagon socket screws with cylindrical head 22 ～ 28 2.2~2.8 16.2~20.7 M8×25 mounting 112~128 11.2~12.8 82.6~94.4 Shock absorber mounting bolt M12×1.25×95 112~128 11.2~12.8 82.6~94.4 balance bar Mounting bolt M8x35 22 ～ 28 2.2~2.8 16.2~20.7 Bolt M12×1.25×75...
Page 231: Technical Parameter
FRONT & REAR SUSPENSION TECHNICAL PARAMETER Item Setting Available range 20 ～ 45mm Front absorber: 64"：35mm(1.4in.) (0.8 ～ 1.8in.) • Preloading setting position of normal hydraulic damping absorber spring (From the bottom of 65 ～ 95mm the upper mounting seat to the position of the 72"：85mm(3.34in.) (2.6 ～...
Page 232: Dedicated Tools
FRONT & REAR SUSPENSION DEDICATED TOOLS Needle nose pliers slot type screwdriver Hook wrench grease gun Internal circlip pliers Lifting jack Bearing drive kit sleeve 9 - 7...
Page 233: 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 234 FRONT & REAR SUSPENSION If the spring action feels too soft or too hard, set it to: Position Spring Environment Load Terrain Speed ↑ Soft Soft Light Flat ↑ ↑ ↑ ↑ ↑ standard position ↓ ↓ ↓ ↓ ↓ Hard Hard Heavy...
Page 235 FRONT & REAR SUSPENSION absorber damping adjustment To accommodate a variety of riding conditions, the spring preload can be adjusted for shock absorbers or spring replacements. The damping force can also be easily adjusted without changing the oil viscosity. Compression damping adjustment ◆...
Page 236 FRONT & REAR SUSPENSION Absorber disassembly 【A】 Airbag mounting bolt M8x25 【B】 Shock absorber mounting bolt ◆ Raise a vehicle with a jack or support frame so that the wheels do not touch the ground. ◆ Remove the upper and lower installation bolts of the shock absorber with A tool 【A】...
Page 237: Absorber Scrapped
FRONT & REAR SUSPENSION Absorber scrapped As the oil container of the rear 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 shock absorber (see shock absorber removal) ◆...
Page 238: Front Suspension
FRONT & REAR SUSPENSION FRONT SUSPENSION Front Rocker arm disassembly 【A】 front brake calipers 【B】 Front knuckle assembly 【C】 Brake hose ﬁ xing bolt 【D】 Steering pull rod nut 【E】 Ball pin connecting rod bolt 【F】 Rocker arm mounting bolt ◆...
Page 239 FRONT & REAR SUSPENSION REAR SUSPENSION Rear Rocker arm disassembly 【A】 rear brake calipers 【B】 Rear axle support assembly 【C】 Brake hose ﬁ xing bolt 【D】 Axle support mounting bolt 【E】 Rear stabilizer bar ball pin connecting rod 【F】 Rocker arm mounting bolt 【G】...
Page 240 FRONT & REAR SUSPENSION Front Rocker arm disassembly 【A】 rocker arm buﬀ er sleeve 【B】 Rocker arm liner 【C】 dust cover 【D】 oil cup 【E】 on the kingpin 【F】 Under the kingpin 【G】 Retainer ring for shaft ◆ Removal of Dust Cover from both ends 【A】; ◆...
Page 241 FRONT & REAR SUSPENSION ◆ The rocker maintenance ◆ Add grease ◆ When it is found that the lubricating grease in the shaft sleeve of the suspension rocker arm and the bearing sleeve of the wheel axle is reduced, or every 1000Km of the vehicle, it is necessary to fill the grease through the butter nozzle in the suspension system 【A】...
Page 242 FRONT & REAR SUSPENSION FRONT / REAR STABILIZER BAR DISASSEMBLY Front stabilizer bar disassembly 【A】 ﬁ xed bolt 【B】 Mounting seat for stabilizer bar 【C】 buﬀ er sleeve for front stabilizer bar 【D】 front stabilizer bar 【E】 Mounting nut for front connecting rod assembly 【F】...
Page 243 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 bundle adjustment ..................10-7 WHEEL（RIM） ......................10-8 Wheel Disassembly ....................10-8 Wheel Assembly ....................
Page 244: Exploded View Of Wheels And Tires
WHEELS AND TIRES EXPLODED VIEW OF WHEELS AND TIRES 10 - 2...
Page 245 WHEELS AND TIRES Torque Fastener Remarks N·m kgf·m ft·lb Shaft nut M24X2 221. Wheel nut M12X1.25 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 ～...
Page 246: Technical Parameters
WHEELS AND TIRES TECHNICAL PARAMETERS Item Standard Use Limit Wheel positioning: Front wheel and front bundle: 10±10 mm（0.39±0.39 inch） – – – Tires: Standard tire: （1）SGW1000F-S1/ SGW1000F-S3/SGW1000F-S5： front 29×9.00R14 Tubeless Nylon – – – rear 29×11.00R14 Tubeless Nylon – – – （2）SGW1000F-S2/ SGW1000F-S4/SGW1000F-S6：...
Page 247: Special Tools
WHEELS AND TIRES SPECIAL TOOLS Jack 10 - 5...
Page 248: 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 249: Front Bundle Adjustment
WHEELS AND TIRES Front bundle adjustment [A] lock nut [B] lock nut ◆ 【C】 Pull rod ◆ Loosen the lock nut [A] [B] and adjust the pull rod [C] the same number of turns on both sides to reach the speciﬁ...
Page 250: Wheel（Rim
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 251: The Replacement Of The Wheel
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 252: Tire Disassembly
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 253 ◆ Apply soap solution around the tire tire rim, and then check for air bubbles. ◆ 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: 120Pa（1.2kgf /cm ，18psi）...
Page 254: Tire Disassembly (For Anti-Drop Rims)
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 255: Tyre Mounting (For Anti-Drop Rims)
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 256: 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: 120Pa（1.2kgf /cm ，18psi）...
Page 257: Wheel Hub
WHEELS AND TIRES WHEEL HUB Remove rim mounting seat assembly ◆ Remove the wheel (see wheel removal). ◆ Unplug: split pin [A] ◆ Loosen half axle nut [B] ◆ Unscrew the mounting bolt, remove the caliper [D], and let the caliper hang freely Hang up. ◆...
Page 258 BRAKE SYSTEM BRAKE SYSTEM EXPLODED VIEW OF BRAKE SYSTEM ..............10-2 EXPLODED VIEW OF PARKING BRAKE ............... 10-3 SPECIFICATIONS ..................... 10-4 SPECIAL TOOLS ...................... 10-4 BRAKE FLUID ......................10-5 CALIPER ........................10-6 CALIPER INSTALLATION ..................10-6 Caliper Disassembly .................... 10-7 Caliper Assembly ....................
Page 259 BRAKE SYSTEM EXPLODED VIEW OF BRAKE SYSTEM Torque Fastener Remarks N·m kgf·m ft·lb Disc Mounting Bolts 27in·lb Brake fastening bolt 33in·lb Brake Hose Banjo Bolts 18in·lb 1. Brake disc bolts, brake main pump bolts, and brake fastening bolts need to be inspected and tightened regularly；...
Page 260: Specifications
BRAKE SYSTEM 驻车制动爆炸图 Torque Fastener Remarks N·m kgf·m ft·lb Parking Brake Lever Screw 78in.lb Parking handle 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.) Disc thickness 4.8~5.2mm (0.19～...
Page 261: Special Tools
BRAKE SYSTEM SPECIAL TOOLS Inside Circlip Pliers 11 - 4...
Page 262: 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. 3.
Page 263: 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 264: 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 265: 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 266: Brake Pad Removal
BRAKE SYSTEM BRAKE PADS Brake Pad Removal ◆ Remove the front rim assembly or the rear rim assembly. ◆ Loosen the fastening bolt【D】from the guide rod of the brake assembly【C】. In the process of loosening the bolt【D】, the head of【C】must always be in close contact with the brake caliper body【B】and limit.
Page 267: Disc Cleaning
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 268: Brake Hose Inspection
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. BRAKE PEDAL Brake Pedal Position Adjustment ◆ Loosen the locknut 【A】, and turn the adjusting bolt 【B】...
Page 269 STEERING SYSTEM STEERING SYSTEM EXPLODED DIAGRAMS (EPS MODELS)………....…………………12-2 STEERING WHEEL DISASSEMBLY......….…......12-3 STEERING SHAFT DISASSEMBLY……………….….……………………… 12-4 BEARING REPLACEMENT……………………….….….….……………………… 12-6 EPS DISASSEMBLY…………………..….….….…..………………………12-7 STEERING MACHINE DISASSEMBLY……………….….….….……………...…… 12-8 STEERING SYSTEM INSTALLATION…………….….….….………………………12-9 12 - 1...
Page 270 STEERING SYSTEM EXPLODED VIEW OF STEERING SYSTEM（NON-EPS MODELS） Torque Fastener Remarks N·m kgf·m ft·lbs Nut M14×1.5 Step bolt M8 Thread fastening glue Step boltM6 Bolt M8×35 Bolt M8×16 Thread fastening glue Bolt M8×25 Bolt M10×1.25×105 Bolt M10×1.25×25 Slotted nut m12 12 - 2...
Page 271 STEERING SYSTEM STEERING WHEEL REMOVAL (NON-EPS MODELS) This procedure is suitable for non-EPS models, using this procedure to operate the EPS models vehicle may cause damage to the EPS or power steering system. 【A】Steering wheel cover 【B】Nut 【C】Steering wheel ◆ Remove the steering wheel cover【A】in the direction of the arrow ◆...
Page 272 STEERING SYSTEM STEERING SHAFT DISASSEMBLY (EPS MODELS) 【A】Display instrument assembly 【B】Direction stud 【C】Gas spring bolt 【D】 Steering upper shaft bolt nut 【E】Steering shaft 【F】Steering wheel ◆ Disassemble interior parts such as instrument panel, see 【xx-xx】; ◆ Disassemble the display instrument assembly 【A】; ◆...
Page 273 STEERING SYSTEM STEERING SHAFT REMOVAL (NON-EPS MODELS) 【A】Circlip for shaft 【B】Upper section of steering shaft 【C】Bolt 【D】Lower section of steering shaft ◆ Remove the circlip for the shaft【A】, and remove the upper section of the steering shaft【B】 ◆ Remove the ﬁ xing bolt【C】, and remove the lower part of the steering shaft【D】...
Page 274 STEERING SYSTEM 【A】Bolt 【B】EPS motor ◆ Remove the ﬁ xing bolt 【A】; ◆ If you need to replace the EPS motor, remove the ﬁ xing bolt 【A】; ◆ Disassemble the wiring harness connector of the EPS motor; ◆ Remove the EPS motor in the direction of the arrow 【E】;...
Page 275 STEERING SYSTEM BEARING REPLACEMENT 【A】Steering column 【B】Steering ◆ Clamp the steering column【A】with a vise, use a suitable crowbar to go deep into the steering column, and knock out the bearings【B】at both ends; ◆ Using a bearing driver, press the bearings【B】at both ends into the steering column on the pressure equipment【B】...
Page 276 STEERING SYSTEM STEERING MACHINE DISASSEMBLY (EPS MODELS) 【A】Nut 【B】Steering rod 【C】Bolt 【D】Direction machine ◆ Remove the nuts on both sides of the steering rod wheel 【A】, and knock the steering rod in the direction of the arrow with a hammer to separate the steering rod from the cone of the steering knuckle;...
Page 277 STEERING SYSTEM INSTALLATION OF STEERING SYSTEM ◆ Reverse install steering machine according to removal procedure ◆ Install the steering rod in the reverse direction of the removal procedure, and check the left and right steering rods to be the same length before installation ◆...
Page 278 VEHICLE BODY AND FRAME VEHICLE BODY AND FRAME EXPLODED VIEW OF CAR BODY………….…..…...…...…..………………………13-2 Seat removal………......….…………....………………………… 13-11 Front shelf cover………….…………....……...…...……………………… 13-12 Brake fluid sight hole cover………………………...…...…...……………………… 13-12 Power switch……………..………………………...…...…...…………………………… 13-12 Electrical repair cover..………………...…...…...………………………………….13-13 Foot pedal drain cover..…………………...…...…...…………………………………..13-13 Battery repair cover..………………………...…...…...………………………………...13-13 Gasoline pump repair cover.…………………...…...…...………………..…………..13-14 Regular engine maintenance.………………...…...…...……………………………….13-14 EXPLODED VIEW OF ROLL CAGE………………...…...…...……………………………13-15 Roll cage removal.…………………………………...…...…...………………………….13-16...
Page 279 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Front panel Front lampshade Front ventilation grille Front left mudguard Front right mudguard Right front headlight tail cover Front right air deﬂ ector Power-oﬀ switch cover Front right mudguard rubber Right door front cover 13 - 2...
Page 280 VEHICLE BODY AND FRAME Right car door inner front cover Brake ﬂ uid sight hole cover Front left mudguard rubber Inner front cover of left door Left door front cover Front left bezel Front center baﬄ e Front right bezel front bezel Left front headlight tail cover Front left air deﬂ...
Page 281 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Dashboard Storage box sealing strip Storage box cover Instrument panel left lower cover Upper left decorative strip Instrument cable guard Instrument cover trim strip Mobile phone switch cover Phone cover 13 - 4...
Page 282 VEHICLE BODY AND FRAME Glove box sealing strip Mobile phone sealing strip Blank cover Box cover pin mobile phone cushion Electrical repair cover Glove box cover 12V power output socket Large pan head hexagon socket bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb M6 nut clamp Waist I-shaped rubber ring spring buckle...
Page 283 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Middle guard plate Left guard plate decoration board Charging base cover Cargo box front cover B-pillar upper left lining height B-pillar lower lining height Large pan head hexagon socket bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb...
Page 284 VEHICLE BODY AND FRAME Front bottom plate Foot pedal left drain cover Left foot pedal Foot pedal cap Right foot pedal Right guard plate Right guard plate lining Drive shaft right cover Gasoline pump maintenance cover Foot pedal drain cover Fuel ﬁ...
Page 285 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Top beam upper cover Top beam upper lining Roof B-pillar lower left lining B-pillar upper left lining B-pillar left outer guard plate B pillar right outer guard plate (high) B pillar right upper lining (high) B pillar right lower lining (high) Large pan head hexagon socket bolt m6×16...
Page 286 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Rear cargo box Right rear guard plate Right rear mudguard Left rear mudguard Taillight upper left baﬄ e Left front cover of tail light cover Tail light upper right baﬄ e Tail lamp cover right front cover Rear storage box sealing ring Rear storage box...
Page 287 VEHICLE BODY AND FRAME BODY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Main driver's seat assembly Seat mounting bracket assembly Driver buckle assembly Driver lock assembly Passenger buckle assembly Passenger lock assembly Hexagon ﬂ ange bolt m10×25 40～50 4.0~5.0 29.5~36.9 Hexagon ﬂ...
Page 288: Seat Removal
VEHICLE BODY AND FRAME Seat removal 【A】Driver Seat ◆ Move the seat forward through the seat adjustment lever 【B】Hexagon ﬂ ange bolts M10×25 ◆ Remove the ﬁ xing bolts under the seat belt【B】 ◆ Remove the seat belt from the seat 【C】Dish-shaped round wing screw M8×20 【D】T type screw sleeve M8-φ20×17 【E】Flat padφ8...
Page 289: Power Switch
VEHICLE BODY AND FRAME Front ventilation grille Put the car body in a horizontal position ﬁ rst ◆ Remove the front bumper ﬁ rst ◆ Remove three M6 ﬁ xing bolts with a suitable tool [B] ◆ Remove the front ventilation grille【A】 Brake ﬂ...
Page 290: Electrical Repair Cover
VEHICLE BODY AND FRAME Electrical repair cover Adopt pin and hook and mushroom head installation method; ◆ Reach out to the arrow and pull out forcefully; ◆ Take out the electrical repair cover【A】 Foot pedal drain cover There is a water drain cover on the sides of the left and right footboards of the vehicle, which are installed by pins and hooks;...
Page 291: Gasoline Pump Repair Cover
VEHICLE BODY AND FRAME Gasoline pump repair cover 【A】 Gasoline pump repair cover ◆ Use suitable tools to take out 4 expansion buckle components [B]; ◆ Take out the gasoline pump repair cover【A】 Regular engine maintenance 【A】 Hand clasp position of rear storage box ◆...
Page 292 VEHICLE BODY AND FRAME EXPLODED VIEW OF ROLL CAGE Torque Fastener Remarks N·m kgf·m ft·lb Hexagon socket head screw M8×12 20~26 2.0~2.6 14.7~19 Hexagon ﬂ ange bolt M8×16 20~26 2.0~2.6 14.7~19 Hexagon ﬂ ange bolt M12×1.25×75 50～60 5.0～6.0 37～45 Hexagon ﬂ ange bolt M12×1.25×30 50～60 5.0～6.0 37～45 Hexagon ﬂ...
Page 293: Roll Cage Removal
VEHICLE BODY AND FRAME Roll cage removal ◆ Remove the bolts of the A-pillar decorative panel (hexagonal socket head screws M8×12) and remove the A-pillar decorative panel; remove the bolts (hexagonal ﬂ ange bolts M8×16) connecting the left and right upper mounting bracket components of the cargo box.
Page 294 VEHICLE BODY AND FRAME EXPLODED VIEW OF FRAME ACCESSORIES Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M10×1.25×25 40～50 4.0～5.0 30～37 Hexagon ﬂ ange bolt M10×1.25×75 40～50 4.0～5.0 30～37 Hexagon ﬂ ange bolt M10×1.25×40 40～50 4.0～5.0 30～37 Hexagon ﬂ ange face lock nut M10×1.25 40～50 4.0～5.0 30～37 Hexagon ﬂ...
Page 295: Frame Attachment Removal
VEHICLE BODY AND FRAME Frame attachment removal ◆ Remove the bolts of the upper bracket of the rear storage box (hex ﬂ ange bolt 4-M6×16) and remove the upper bracket of the rear storage box. ◆ Remove the bolts of the seat belt fixing bracket assembly (hex flange bolt 4-M10×1.25×25) and remove the seat belt ﬁ...
Page 296 VEHICLE BODY AND FRAME ◆ Remove the bolts of the seat mounting bracket assembly (hex flange bolt 4-M8×40) and remove the seat mounting bracket assembly. Before this, you need to remove the seat, middle guard and other plastic parts, the shifter and cable, the parking mechanism and the pipeline fixed to the seat mounting bracket assembly (refer to the relevant chapters for details)
Page 297 VEHICLE BODY AND FRAME ◆ Remove the bolts of the middle bottom plate assembly (large pan-head hexagon socket bolts 6-M6×16), and remove the middle bottom plate assembly (one for each on the left and right). ◆ Remove the decorative plug ﬁ xing screw (hexagon socket countersunk head screw 2-M6×16) and remove the decorative plug;...
Page 298 VEHICLE BODY AND FRAME FRONT BUMPER EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M10×1.25×20 40～50 4.0～5.0 30~37 Hexagon ﬂ ange bolt M10×1.25×25 40～50 4.0～5.0 30~37 Hexagon ﬂ ange face lock nut M10×1.25 40～50 4.0～5.0 30~37 Large pan head hexagon socket bolt M6×16 8~12 0.8~1.2...
Page 299: Front Bumper Removal
VEHICLE BODY AND FRAME Front bumper removal ◆ Remove the lock nut of the winch motor cable, and remove the winch motor cable. After removing the motor wire of the winch, the head of the cable should be protected to prevent short circuit. ◆...
Page 300 VEHICLE BODY AND FRAME ◆ Unplug the pin of the winch hook, remove the winch hook and the winch rubber pad. ◆ Remove the mounting bolts of the winch guide wheel (hexagon ﬂ ange bolt M10×1.25×20), the winch guide wheel ◆...
Page 301 VEHICLE BODY AND FRAME EXPLODED VIEW OF REAR BUMPER ASSEMBLY Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M10×1.25×20 40～50 4.0～5.0 30~372 Hexagon ﬂ ange bolt M8×20 22～30 2.2～3.0 ～22 Large pan head hexagon socket bolt M6×16 8~12 0.8~1.2 69~103.6 in·lb Cross recessed pan head screw M5×30...
Page 302: Removal Of Rear Bumper Assembly
VEHICLE BODY AND FRAME Removal of rear bumper assembly ◆ Remove the mounting bolts of the rear bumper assembly (hex flange bolts M10×1.25×20 and hexagon flange bolts M8×20) and remove the rear bumper assembly. Before this, you need to unplug the rear license plate light and trailer power socket cable connector (refer to the relevant chapters for details)
Page 303 VEHICLE BODY AND FRAME EXPLODED VIEW OF FRONT AXLE DISASSEMBLY Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M8×20 22～30 2.2～3.0 ～22 Hexagon ﬂ ange bolt M10×1.25×215 40～50 4.0～5.0 30~37 H e x a g o n f l a n g e f a c e l o c k n u t 40～50 4.0～5.0 30~37 M10×1.25...
Page 304: Front Axle Disassembly
VEHICLE BODY AND FRAME Front axle disassembly ◆ Remove the front drive shaft and the front drive shaft (see the chapter on transmission system for details). ◆ Unplug the cable input plug on the front axle. ◆ Use suitable tools to remove the hoop, and remove the front axle vent pipe;...
Page 305 VEHICLE BODY AND FRAME Front axle disassembly ◆ Carefully remove the front axle from the lower part of the frame (the removal process may require you to rotate and move the front axle) ◆ Remove the bolt D of the front axle box body. ◆...
Page 306 VEHICLE BODY AND FRAME ENGINE ASSEMBLY EXPLODED VIEW Torque Fastener Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M12×1.25×85 50～60 5.0～6.0 37～45 Hexagon ﬂ ange bolt M12×1.25×220 50～60 5.0～6.0 37～45 H e x a g o n f l a n g e f a c e l o c k n u t 50～60 5.0～6.0 37～45...
Page 307: Engine Disassembly
VEHICLE BODY AND FRAME Engine disassembly ◆ Remove the rear body plastic parts such as the rear cargo box. (See related chapters for details) ◆ Remove the air ﬁ lter assembly. (See related chapters for details) ◆ Remove the muﬄ er assembly. (See related chapters for details) ◆...
Page 308 VEHICLE BODY AND FRAME ◆ Loosen the hoop and remove the CVT air inlet pipe and CVT air outlet pipe. (See related chapters for details) After removing the CVT air duct, please effectively protect the air inlet and outlet of the CVT to prevent sundries from falling into the engine, thereby damaging the engine ◆...
Page 309 VEHICLE BODY AND FRAME ◆ Remove the rear section of the front drive shaft and the rear drive shaft. (See related chapters for details) ◆ Remove the rear section of the front drive shaft and the rear drive shaft. (See related chapters for details) ◆...
Page 310 VEHICLE BODY AND FRAME ◆ Remove the mounting bolts (hexagon flange bolts M10×1.25×40) and nuts (hexagon flange lock nuts M10×1.25) of the engine front mounting seat assembly, and remove the engine front mounting seat assembly. ◆ Remove the mounting bolts (hexagon flange bolts M10×1.25×160) and nuts (hexagon flange lock nuts M10×1.25) of the engine rear mounting seat assembly, and remove the engine rear mounting...
Page 311 ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL SYSTEM........................14-1 EXPLODED VIEW ........................14-4 TECHNICAL PARAMETERS.......................14-8 SPECIAL TOOLS..........................14-9 Multimeter............................14-9 BATTERY ............................14-10 Remove the battery........................14-10 Battery installation........................14-10 BATTERY CHARGING ........................14-11 Charging condition check......................14-13 Generator inspection........................14-14 Circuit diagram of charging system ....................14-15 Voltage regulating rectiﬁ er inspection...................14-16 Remove............................14-16 LIGHTING SYSTEM CIRCUIT......................14-17 HEADLIGHT............................14-18...
Page 312 ELECTRICAL SYSTEM STARTING RELAY........................14-36 Disassemble..........................14-36 Start relay troubleshooting......................14-36 START MOTOR..........................14-37 Disassemble..........................14-37 installation.............................14-37 ECU..............................14-38 Disassemble the ECU......................14-38 Install ECU..........................14-38 ECU connector removal skills.......................14-38 FUEL PUMP ASSEMBLY........................14-39 Disassemble..........................14-39 Fuel pump assembly inspection...................14-40 fuel pump assembly........................14-41 TRAILER POWER SOCKET......................14-42 Remove trailer power socket......................14-42 Install trailer power socket......................14-42 EFI SYSTEM............................14-43 Schematic diagram of EFI system....................14-43...
Page 313 ELECTRICAL SYSTEM Remove and install spark plugs.....................14-57 ENGINE SPEED SENSOR........................14-58 Technical performance test ......................14-58 Fault diagnosis..........................14-58 ELECTRONIC THROTTLE VALVE BODY ASSEMBLY..............14-59 Disassembly requirements......................14-59 INLET PRESSURE TEMPERATURE SENSOR................14-60 Three-in-one sensor performance characteristics................14-61 Fault diagnosis..........................14-61 THROTTLE POSITION SENSOR AND THROTTLE ACTUATOR.............14-62 Throttle Position Sensor Performance Characteristics..............14-62 Throttle actuator (DC motor) technical performance parameters..........14-63 Fault diagnosis..........................14-63 ELECTRONIC ACCELERATOR PEDAL ...................14-64...
Page 314: Exploded View
ELECTRICAL SYSTEM EXPLODED VIEW 14 - 4...
Page 315 ELECTRICAL SYSTEM Torque PART'S NAME Remarks N·m kgf·m ft·lb Right headlight Left headlight EPS controller Horn T-BOX Flasher Circular reﬂ ector (amber) uzzer Central control display 10 Central control display Instrument Control Module 12 Emergency switch 13 Mode switch 14 Power oﬀ switch 15 Horn switch 16 Antenna combination 17 Start button switch...
Page 316 ELECTRICAL SYSTEM Torque PART'S NAME Remarks N·m kgf·m ft·lb Hexagon ﬂ ange bolt M6×20 Hexagon socket head screw M8×25 Hexagon ﬂ ange bolt M6×35 Hexagon ﬂ ange bolt M5×16 Rear fog lamp Cross recessed pan head screw M5×30 14 - 6...
Page 317 ELECTRICAL SYSTEM Torque PART'S NAME Remarks N·m kgf·m ft·lb Winch power cord Winch relay Winch motor wire Winch hook Winch strap Winch guide wheel Winch motor Main cable Winch switch socket Winch wireless control module (including wireless switch) Winch switch Starter motor positive and negative wire Battery positive and negative wire Battery positive and negative wire...
Page 318: 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 319: Special Tools
ELECTRICAL SYSTEM SPECIAL TOOLS Needeer 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 - 9...
Page 320: Battery
ELECTRICAL SYSTEM BATTERY Remove the battery 【A】Positive pole 【B】Negative pole ◆ Turn oﬀ the ignition switch. ◆ Remove seat (see the Frame Section) ◆ Loosen the bolt of the battery seat. ◆ Remove battery ﬁ xing tape. ◆ Disconnect the battery negative (-) cable first, and then disconnect the positive (+) cable.
Page 321: 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 322 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 323: 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 324: 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 field of the rotor may be caused by a drop or by placing the AC generator near the electromagnetic field, thereby hitting the magnetic field of the AC generator or simply due to...
Page 325: 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 - 15...
Page 326: 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 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 Qualiﬁ...
Page 327: Lighting System Circuit
ELECTRICAL SYSTEM LIGHTING SYSTEM CIRCUIT Battery Main Fuse Lgnition lock Fuse Main relay Low beam relay High beam relay Daytime running light relay Daytime running light High/Low beam Position lights Lights switch turn switch Warning switch Flash CM turn sLights 14 - 17...
Page 328: Headlight
ELECTRICAL SYSTEM HEADLIGHT Headlamp rear guard (see "Frame" chapter) 【A】Mounting bolt 【B】Headlamp rear guard 【C】Headlamps 【D】Headlamp bolts*4 【E】High-Low beam adjustment bolt Replace ◆ The lamps are LED lamps ◆ The far and near light of the LED headlights are damaged, only the headlights can be replaced ◆...
Page 329: Tail Light
ELECTRICAL SYSTEM TAIL LIGHT Rear guard for taillight (see the "Frame" chapter 【A】Taillight guard bolt*4 【B】Tail light shield 【C】Tail light lamp body 【D】 Tail light bolt*5 Replace The lamps are LED lamps The LED tail light source is damaged, only the tail light can be replaced.
Page 330: Licence Lamp
ELECTRICAL SYSTEM LICENCE LAMP 【A】Licence Lamp Bolt*2 【B】Licence Lamp Remove ◆ Remove the licence lamp bolt 【A】 ◆ Remove Licence Lamp【B】 ◆ Remove licence lamp wire harness Replace ◆ Place the l icence lamp in the licence lamp ◆ installation position ◆...
Page 331: Flasher
ELECTRICAL SYSTEM FLASHER Remove front cover (see the "Frame" chapter) 【A】Install rubber sleeve 【B】Flasher Disassembly Remove the installation rubber sleeve【A】from the installation bracket Remove the wiring harness connector Replace the ﬂ asher【B】 TEST → ◆ If the turn signal does not flash or flashes abnormally on the whole vehicle (the normal turn signal ﬂ...
Page 332: Power Lock
ELECTRICAL SYSTEM SWITCH Power lock When the indicator does not display after the key is turned on, check the circuit failure and replace the power lock after conﬁ rming that the power lock is broken → Check Power lock After unplugging the connector, turn the multimeter to the conduction position.
Page 333 ELECTRICAL SYSTEM The switch is valid only when the ignition lock is in the ON position 【A】Headlight 【B】Position Light 【C】High Beam 【D】Low beam 【E】Left turn signal 【F】Right turn signal 【G】Hazard warning lights 【H】Horn 【J】"S" mode 【K】"E" mode Since the switch is an integral part, any damage to the switch requires replacement of the entire switch 14 - 23...
Page 334: Flameout Switch
ELECTRICAL SYSTEM Flameout Switch When the engine is running, press the stop switch button to stop the engine When the engine is stopped, first press the stop switch button and then press the start button to start the engine; When the function fails, check the related circuit ﬁ rst When there is no problem in the inspection circuit, test the internal circuit of the ﬂ...
Page 335: Start Switch
ELECTRICAL SYSTEM Start switch When the flameout switch is turned on, press the start switch button and the engine starts to run When the function fails, check the related circuit ﬁ rst When there is no problem in the inspection circuit, test the internal circuit of the start switch O n l y w h e n t h e f l a m e o u t s w i t c h i s i n w o r k i n g condition,the engine can be started by pressing the start...
Page 336: 2Wd/4Wd Drive Mode Switch Removal And Installation
ELECTRICAL SYSTEM 2WD/4WD drive mode switch removal and installation 【A】Fixing bolts 【B】2WD/4WD Drive mode switch ◆ Remove the three ﬁ xing bolts with tools. ◆ Remove the switch from the plastic part. ◆ When installing a new switch, tighten the three ﬁ xing bolts with a tool 14 - 26...
Page 337: Starting System Layout
ELECTRICAL SYSTEM STARTING SYSTEM LAYOUT 【A】Power lock 【B】Instrument　【C】Flameout switch 【D】ECU 【E】Oil pump 【F】Start button 【G】Start relay 【H】Fuse box 【K】32Ah battery Description of engine starting process： 1. Turn on the power lock 【A】, power on the whole vehicle, and check whether the upper gear of the instrument 【B】...
Page 338: Schematic Diagram Of Starting System
ELECTRICAL SYSTEM SCHEMATIC DIAGRAM OF STARTING SYSTEM STARTING SYSTEM TROUBLESHOOTING If the engine cannot be started by pressing the start button, first check whether the flameout switch is turned on, and the engine cannot be started when the ﬂ ameout switch is oﬀ When the ﬂ...
Page 339 ELECTRICAL SYSTEM ◆ Secondly, check whether the gear display on the instrument is in N gear. The starting strategy is to start the engine only in N gear; Before starting the engine, ﬁ rst make sure that the gear is in the N gear. ◆...
Page 340: Switch Position Diagram
ELECTRICAL SYSTEM SWITCH POSITION DIAGRAM 【A】lighting switch 【B】hight and low beam switch 【C】Turn signal switch 【D】Emergency switch 【E】2WD/4WD switch 【F】Start button 【G】Power lock 【H】Horn switch 【J】Mode switch 【K】Flameout switch 【M】thrust augmentation switch 14 - 30...
Page 341: Electrical Wiring
ELECTRICAL SYSTEM ELECTRICAL WIRING Wiring check ◆ Visually inspect the wiring for signs of ablation, wear, etc. ◆ Remove each connector 【 A 】 and check for corrosion, dirt and damage. ◆ Remove each connector 【 A 】 and check for corrosion, dirt and damage. 如果损坏，请更换。...
Page 342: Disassembly Of Power Lock, Start Button, Various Switches, Etc
ELECTRICAL SYSTEM DISASSEMBLY OF POWER LOCK, START BUTTON, VARIOUS SWITCHES, ETC 【A】Power lock 【B】Gasket 【C】Power lock cover 【D】Start button 【E】Lock cover 【F】Secondary lock cover 【G】Limit card 1. When removing the power lock, hold the power lock 【A】 from the inside of the instrument panel, and turn the power lock cover 【C】...
Page 343: Fuse Box
ELECTRICAL SYSTEM FUSE BOX Combination fuse box main body segment 【A】Combination fuse box body 【B】Relay (four-way) 【C】Medium fuse 【D】Micro fuse 【E】Fuse Combination fuse box cover inner part 【F】 Combination fuse box cover 【G】Special tool for fuse removal 【H】Spare fuse The fuse specification and label function position are subject to the actual product.
Page 344: Fuse Continuity Test
ELECTRICAL SYSTEM After turn on the power lock, if the dashboard ◆ does not display, please conﬁ rm whether the fuse is damaged； The fuse box is under the dashboard, first ◆ open the electrical repair cover 【A】 Press the fuse box cover lock 【B】 and ◆...
Page 345 ELECTRICAL SYSTEM 7.5A A U X I L I A R Y R E M O T E Brake S T A R T P O W E R - O N Trailer 2,4WD Speed R E L A Y 12V USB R E L A Y Flameout...
Page 346: Disassemble
ELECTRICAL SYSTEM STARTING RELAY Disassemble 1. Remove the harness plug 【A】 2. Open the 【B】 and 【C】 end rubber sleeves respectively 3. Remove the wires at the 【B】 and 【C】 ends respectively 4. Remove the bolts 【D】 separately; installation ◆ Installation bolt【D】 ◆...
Page 347: Start Motor
ELECTRICAL SYSTEM START MOTOR Disassemble ◆ The starter motor 【A】 is installed on the engine 【B】, and the disassembly method is detailed in the engine chapter; ◆ Remove the CVT 【E】, see the engine chapter;； ◆ Remove the positive and negative wires of the starter motor 【C】;...
Page 348: Ecu
ELECTRICAL SYSTEM Disassemble the ECU ◆ The ECU is installed on the right rear side of the vehicle, ﬁ rst remove the right rear mudguard 【B】, see the plastic parts chapter for details; ◆ Disconnect the battery wiring; ◆ Loosen the ECU connector lock buckle, and unplug the EFI auxiliary cable connector 【D】...
Page 349: Fuel Pump Assembly
ELECTRICAL SYSTEM FUEL PUMP ASSEMBLY Disassemble ◆ This model has two fuel tanks, the main fuel tank 【D】 and the auxiliary fuel tank 【E】. The fuel pump is pre-installed on the main fuel tank in advance and is located under the passenger seat; ◆...
Page 350: Fuel Pump Assembly Inspection
ELECTRICAL SYSTEM Fuel pump assembly inspection ◆ Structural drawing of the front view of the fuel pump assembly【J】. ◆ Definition diagram of pin function of fuel pump electrical connector【I】. ◆ Remove the driver's seat assembly and the lower cover of the driver's seat then use a multimeter set to the resistance ohm position to check the fuel level sensor of the fuel pump according to the following steps.
Page 351: Fuel Pump Assembly
ELECTRICAL SYSTEM During the process of disassembling any part of the fuel system, fuel leakage may occur. Wipe oﬀ the residual fuel with a cloth. fuel pump assembly 【B】Fuel pump installation screw cap ◆ Conﬁ rm that the sealing ring 【C】 is installed on the fuel tank port; ◆...
Page 352: Trailer Power Socket
ELECTRICAL SYSTEM TRAILER POWER SOCKET ◆ The trailer power supply 【A】 is located at the rear of the vehicle, on the trailer power supply mounting bracket assembly 【B】. Remove trailer power socket ◆ Use a screwdriver to loosen the 3 screws that ﬁ x the trailer's power socket 【A】;...
Page 353: Efi System
ELECTRICAL SYSTEM EFI SYSTEM Schematic diagram of EFI system Intake air temperature pressure sensor Fuel rail assembly Ignition coils Oxygen Sensor Electronic Speed sensor controller Electronic throttle body Fault light Fuel pump bracket CAN communication Fuel pump Coolant temperature Pressure regulating sensor valve Electronic accelerator pedal...
Page 354: Coolant Temperature Sensor
ELECTRICAL SYSTEM COOLANT TEMPERATURE SENSOR Function Description The coolant temperature sensor function is used to monitor the temperature of the engine coolant,on the one hand, the output signal enables the electronic system to make a judgment on the working condition of the engineon the other hand, the output signal to the instrument allows the operator to directly judge the working state of the engine by visual inspection.
Page 355: 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 356: 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 ﬁ...
Page 357: 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 358: Electrical Characteristics
ELECTRICAL SYSTEM Electrical characteristics The electronic control unit ECU monitors various sensors, actuators, and power ampliﬁ er circuits and detection circuits. When the oxygen sensor fails, the system performs open-loop control, and the corresponding fuel consumption will increase. Common fault codes are shown in the fault summary table.
Page 359: Electronic Control Unit（Ecu
ELECTRICAL SYSTEM ELECTRONIC CONTROL UNIT（ECU） Function Description The engine electronic control unit (ECU for short), as a key component of the engine control management system, is used to detect and control the normal operation of the engine system.load information is collected through sensors to predict the driver's driving intention and at the same time ensure the best fuel economy to meet the emission standards required by regulations.The engine management system is equipped with sensors and actuators necessary for ECU work,the ECU calculates the required air-fuel mixture ratio and the ignition advance angle of the engine according...
Page 360: Electrical Characteristics
ELECTRICAL SYSTEM Electrical characteristics Working voltage: ◆ Rated voltage: 13.5V ◆ Full-function working voltage range: 9 V ～16 V ◆ Function limited voltage range: 6 V～9 V, 16 V～18 V ◆ Guaranteed diagnostic function voltage range: 8 V～16 V Working current: ◆...
Page 361: Ecu Pin Defi Nition
ELECTRICAL SYSTEM ECU pin deﬁ nition Item Name Item Name CAN1H CAN（HIGH） BRAKE LIGHT NEUTRAL SWITCH SIGNAL MAIN RELAY REVERSE GEAR SWITCH FOUR-WHEEL DRIVE SWITCH ACCELERATOR PEDAL SENSOR2 GROUND FOR PEDAL 1 CRUISE CONTROL INPUT SAFETY BELT SWITCH IGNITION SWITCH INTAKE MANIFOLD PRESSURE2 SENSOR SUPPLY FOR PEDAL 2 SENSOR SUPPLY FOR PEDAL 1...
Page 362 ELECTRICAL SYSTEM Item Name Item Name MIL FUNCTION INDICATOR LAMP GROUND FOR SENSOR GROUND FOR MANIFOLD GROUND FOR THROTTLE THROTTLE ACTUATOR FAN RELAY CONTROL INTAKE MANIFOLD PRESSURE1 CRANK RELAY GROUND FOR PEDAL2 CANISTER PURGE VALVE ECU MAIN GROUND 2 ENGINE SPEED SENSOR A ECU MAIN GROUND 1 ENGINE SPEED SENSOR B IGNITION COIL2...
Page 363: 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 (see A in the ﬁ gure below) is installed on the electronic throttle body, and the other end is connected to the fuel pipe through the injector rail (see B in the ﬁ...
Page 364: Performance Parameter
ELECTRICAL SYSTEM Performance parameter project parameter Static ﬂ ow 207.8g/min Dynamic ﬂ ow 6.65mg/stroke（冲程） Jet angle 23° Coil resistance 12Ω Hydraulic leak 1.8mm /min Fault diagnosis ECU only performs 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 disconnected, the fault ﬂ...
Page 365: 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, and the ignition coil installed on the engine can be seen after disassembling the cargo box (see A in the ﬁ...
Page 366: Performance Parameters
ELECTRICAL SYSTEM Performance parameters Value Item Unit Rated Max Calibration voltage Operating voltage 16.5 P r i m a r y 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...
Page 367: 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 368: 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 369: Electronic Throttle Valve Body Assembly
ELECTRICAL SYSTEM ELECTRONIC THROTTLE VALVE BODY ASSEMBLY The electronic throttle valve body assembly is connected to the engine and the air filter, and the electronic throttle body is installed in the intake system of the engine.the air ﬂ ow into the cylinder is controlled by adjusting the angle of the throttle valve plate.its main function is to adjust the opening and closing angle of the throttle valve plate according to the driver's driving intention to meet the intake demand of the engine under diﬀ...
Page 370: Inlet Pressure Temperature Sensor
ELECTRICAL SYSTEM INLET PRESSURE TEMPERATURE SENSOR The intake air pressure and temperature sensors include: intake air pressure and intake air temperature sensors. The pin diagram is shown at【A】in the left ﬁ gure. 1: Inlet pressure signal output OUTPUT SIGNAL 2: Supply voltage SUPPLY VOLTAGE 3: Thermistor NTC 3: Sensor ground GROUND The core of the intake air temperature sensor is the...
Page 371: Three-In-One Sensor Performance Characteristics
ELECTRICAL SYSTEM Three-in-one sensor performance characteristics Intake temperature sensor 2kΩ±3% B25/85 3520k±2% Te m p e r a t u r e - r e s i s t a n c e See the left picture characteristics Intake pressure sensor Change sensitivity 40.5mv/kPa Output voltage characteristic...
Page 372: Throttle Position Sensor And Throttle Actuator
ELECTRICAL SYSTEM THROTTLE POSITION SENSOR AND THROTTLE ACTUATOR The throttle position sensor is a Hall sensor with a linear output, pass【A】voltage of 5V is applied to both ends of the sensor to form a Hall voltage when the throttle rotates Output, like an Angle potentiometer.
Page 373: Throttle Actuator (Dc Motor) Technical Performance Parameters
ELECTRICAL SYSTEM Throttle actuator (DC motor) technical performance parameters 1. electronic throttle body connector on the motor PIN between the (room temperature) resistance name Mean value R = 1.4Ω±0.3. 2. I n d u c t a n c e L = 1 . 1 ± 0 . 1 M H 3 a t 1 K H z ( r o o m temperature), working in the opposite direction the allowable force on: <...
Page 374: Electronic Accelerator Pedal
ELECTRICAL SYSTEM ELECTRONIC ACCELERATOR PEDAL Electronic accelerator pedal connector pin deﬁ nition: 【A】: 5V power supply for accelerator pedal 2 【B】 : 5V power supply of accelerator pedal 1 【C】 : accelerator pedal 1 ground wire 【D】 : Acceleration pedal sensor 1 【E】: Acceleration pedal 2 ground wire 【F】: Acceleration pedal sensor 2 Remove and install the accelerator pedal...
Page 375: Technical Performance Parameters
ELECTRICAL SYSTEM Technical performance parameters 1. Permissible pedal pressure in the working direction: < 500 N (400N①). 2. Allowable force perpendicular to the rotation plane: < 200 N 3. Allowable force in the opposite direction of work: < 200 N. 4.
Page 376: Fault Code Reading
ELECTRICAL SYSTEM Fault code reading There is【A】fault indicator light in the meter (Fig. 【A】 on the left). When the key switch is turned on. Trouble indicator light is always on.When the engine is running, the vehicle electronically controls the fuel. If there is no fault in the jet system, the indicator light should be extinguishedIndicator light in case of failure.
Page 377: Summary Of Failure Codes
ELECTRICAL SYSTEM SUMMARY OF FAILURE CODES Pcode Description（UAES） fault indicator on P0108 17 Manifold Absolute Pressure/Barometric Pressure Circuit High √ P0107 16 Manifold Absolute Pressure/Barometric Pressure Circuit Low √ P2A0D 17 Mass or Volume Air Flow “B” Circuit Low √ P2A0C 16 Mass or Volume Air Flow “B”...
Page 378 ELECTRICAL SYSTEM 20 P0412 12 Secondary Air Injection System Switching Valve “A” Circuit √ 21 P0414 11 Secondary Air Injection System Switching Valve “A” Circuit Shorted √ 22 P0413 13 Secondary Air Injection System Switching Valve “A” Circuit Open √ 23 P0262 12 Cylinder 1 Injector Circuit High √...
Page 379 ELECTRICAL SYSTEM 41 P0222 16 Throttle/Pedal Position Sensor/Switch "B" Circuit Low √ 42 P0221 29 Throttle/Pedal Position Sensor/Switch "B" Circuit Range/Performance √ 43 P2106 12 Throttle Actuator Control System Forced Limited Power √ 44 P2106 19 Throttle Actuator Control System Forced Limited Power √...
Page 380 ELECTRICAL SYSTEM P 0 6 0 6 ECM/PCM Processor √ P 0 6 0 6 ECM/PCM Processor √ P 0 6 0 6 ECM/PCM Processor √ P 0 6 0 6 ECM/PCM Processor √ P 0 6 0 6 ECM/PCM Processor √...
Page 381 ELECTRICAL SYSTEM 83 P0051 11 O2 Sensor Heater Control Circuit Low Bank 2 Sensor 1 √ 84 P0050 13 O2 Sensor Heater Control Circuit Bank 2 Sensor 2 √ 85 P0152 17 O2 Sensor Circuit High Voltage Bank 2 Sensor 1 √...
Page 382: Eps
ELECTRICAL SYSTEM The method of disassembling the EPS motor【B】 refers to the method of disassembling the steering assembly. Only the electrical functions of the EPS controller 【A】are introduced here. ◆ The steps to disassemble the EPS controller are as follows: ◆...
Page 383: Eps System Wiring Schematic Diagram
ELECTRICAL SYSTEM EPS system wiring schematic diagram 1. Battery 2. Fuse50A 3. Fuse 40A 4. Fuse 5A 5. Fuse 5A 6. IG relay 7. Diode 8. Key switch 9. OBD 10. EPS 11.Motor 14 - 73...
Page 384: Eps Trouble Removal
ELECTRICAL SYSTEM EPS trouble removal TROUBLE SHOOTING → If the EPS is not working, ﬁ rst check whether the EPS fault light【E】 on the meter is on. If the fault light is not on, check whether the 5A fuse【A】and 50A fuse 【B】in the fuse box are blown, and check whether there is engine speed on the meter【C】display, if there is no engine speed display, EPS will not work,...
Page 385 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 386: Display And Human-Computer Interaction Assembly
ELECTRICAL SYSTEM DISPLAY AND HUMAN-COMPUTER INTERACTION ASSEMBLY Torque Fastener Remarks N·m kgf·m ft·lb INSTRUMENT COMBINATION 4～5 0.4～0.5 35.4～44.2in.lb CROSS RECESSED HEXAGON 4～5 0.4～0.5 35.4～44.2in.lb SCREW ST4.8×16 INSTRUMENT CONTROL MODULE 14 - 76...
Page 387: Instrumentation
ELECTRICAL SYSTEM Instrumentation The dashboard displays key information to the user.See next page for display features and instructions The use of a high-pressure water gun may damage the meter.The vehicle should be cleaned with neutral soap, either by hand or through a hose.Do not use alcohol or corrosive detergents, such as insect repellent, to clean your meter.
Page 388 ELECTRICAL SYSTEM ◆ Check the CNA-H,CAN-L wiring Fuel harness shows the current oil quantity ◆ Ch e c k o il l e v e l a c c o rd i ng t o quantity fuel 油量不显示 indicator electrical schematic diagram line ◆...
Page 389 ELECTRICAL SYSTEM diagram function describes the fault fault cause analysis and project Diagram phenomenon solution Check left turn to the lamp This light when left With the turn signal protection wire, check PIN16 is Left turn turn signal is turned on the indicator a high level input, if Yes, replace Indicator...
Page 390 ELECTRICAL SYSTEM The braking • Low brake ﬂ uid level system • Failure of braking —— —— Warning lights system Indicates that the EPS EPS System system has a fault warning light —— —— (Optional equipment, if equippeda) ABS Indicates a failure of the following system: ◆...
Page 391: Technical Parameters
ELECTRICAL SYSTEM Technical parameters ◆ Working voltage range: DC 8V-18V ◆ Maximum resistance voltage: DC 24V < 60 seconds ◆ Static current: less than 1mA ◆ General current consumption: 120mA + 20mA ◆ Maximum current consumption: 175mA±20mA ◆ Storage temperature- 30 ℃ to + 80 ℃ ◆...
Page 392 ELECTRICAL SYSTEM Description Note Description Note —— —— high beam level high level —— —— position lamp high level OPC Cushion Switch low level —— —— Parking low level Engine failure light low level key power —— buzzer alarm output low level voltage ——...
Page 393: Central Control Display
ELECTRICAL SYSTEM CENTRAL CONTROL DISPLAY Torque PART'S NAME Remarks N·m kgf·m ft·lb Central control display Instrument desk Hexagon socket ﬂ at head screw M6×12 14 - 83...
Page 394: Disassembly And Installation Of Central Control
ELECTRICAL SYSTEM Before disassembling the central control, be sure to the vehicle is power oﬀ . Disassembly and installation of central control ◆ Power oﬀ the whole vehicle ﬁ rst; ◆ Remove related plastic parts; ◆ Unplug the central control connector; ◆...
Page 395: Function Introduced
ELECTRICAL SYSTEM Function introduced ◆ 10.4 inch ultra clear color screen touch ◆ Local audio playback ◆ Bluetooth music, phone ◆ Mixer FM/AM ◆ Dual USB interface ◆ Customized map ◆ Mixer V2V team ◆ Mixer DMR intercom ◆ Bluetooth headset adaption ◆...
Page 396: Performance Parameter
ELECTRICAL SYSTEM Performance parameter Items Description Rated voltage DC12V Working voltage DC 9-16V Turn oﬀ ACC for about 1 hour Dark current (i.e. standby) ACC OFF:≤3mA and enter standby mode Turn ACC into hibernation mode Sleeping current ACC OFF:≤10mA for about 30S Peak current Display Speciﬁ...
Page 397: Fm Performance Index
ELECTRICAL SYSTEM FM performance index Test Item Unit 87.5-108MHz (FM1、FM2、FM3)步长 Frequency range 0.1MHz Intermediate frequency 10.7±0.3 Finite noise sensitivity (30dB S/N) ≤6 dBμV Signal impetuous ratio (monophonic) ≥55 Static sensitivity ≤20 Stereo noise limit sensitivity (S/N=30dB) ≤15 Stereo noise limit sensitivity (S/N=50dB) ≤26 Stereo Signal to Noise Ratio (A weight) ≥50...
Page 398: Tbox
ELECTRICAL SYSTEM TBOX If more than one vehicle is maintained at the same time, do not replace and install the TBOX. ◆ Power off the whole vehicle first, and remove the relevant plastic parts; ◆ Unplug the connector; ◆ Remove the four bolts【A】 Description Note Check whether the...
Page 399: Tbox Fault Code Display Area
ELECTRICAL SYSTEM TBox fault code display area Failure phenomena and causes Trouble solution phenomenon when the meter Replace the TBOX appears T0001 when the meter Replace the TBOX appearsT0002 when the meter Replace the TBOX appearsT0003 when the meter Replace the TBOX appearsT0004 check whether PIN9 and when the meter...
Page 400: Winch Assebly
ELECTRICAL SYSTEM WINCH ASSEBLY When removing the winch, ﬁ rst turn oﬀ the vehicle key. The wireless control module is removed ◆ Remove external related plastic parts ◆ Remove the nut【A】from the terminal with a tool ◆ Remove the positive wire of the power cord【B】 ◆...
Page 401 ELECTRICAL SYSTEM ◆ Remove two nuts【H】with tools ◆ The motor wire【J】can be removed ◆ Cut off the wire tie, then the relay【G】can be removed ◆ Remove external related plastic parts ◆ First remove the self-tapping screw【A】 ◆ Unplug the plug-in【B】 ◆...
Page 402: Winch Motor Position
ELECTRICAL SYSTEM Winch motor position ◆ The winch motor【A】is located under the front of the car Removal of winch motor ◆ First remove the bumper【D】and the three M8 bolts【C】on the top of the frame and on the left and right sides according to the disassembly and assembly sequence of plastic parts and body accessories.
Page 403: Install Winch Motor
ELECTRICAL SYSTEM Install winch motor ◆ The order of assembly and disassembly is reverse, install the winch motor and connect the cables; ◆ Then connect the battery. ◆ winch work shall not exceed 1min each time, and shall work after 30S interval ◆...
Page 404 ELECTRICAL SYSTEM Instructions for use of winch remote control switch: ◆ Press the 2 buttons at the same time and keep it there for 3S to activate the remote control switch, at this time the indicator light will ﬂ ash 3 times ◆...
Page 405: Schematic Diagram Of Trailer System
ELECTRICAL SYSTEM SCHEMATIC DIAGRAM OF TRAILER SYSTEM Lb/Gr Lb/R B/Br B/Br O/Gr B/Br B/Br B/Br B/Br LR P light RR P light LOCK Main Fuse B/Br 14 - 95...
Page 406: Color Comparison Table
CTRICAL SYSTEM COLOUR mparison table R/Br Red/Black Red/White Red/Green Red/Yellow Red/Blue Red/Brown Red/Orange B/Br Pink Black Black/Red Black/White Black/Yellow Black/Blue Black/Violet Black/Brown W/Gr White White/Red White/Black White/Green White/Yellow White/Blue White/Violet White/Gray Gr/R Gr/B Gr/W Br/R Br/B Br/Y Gray Gray/Red Gray/Black Gray/White Brown Brown/Red...
Page 407: Electric Schematic Diagram
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Villian sx10 e 64 S301000-20100a

Segway VILLIAN SSV Series Service Manual

General Information

Maintenance

Engine Lubrication System

Starting System

Crankcase\Crankshaft\Balance Shaft

Cylinder Head, Cylinder, Piston

Cvt System

Water Pump Assembly

Front Axle and Rear Gearbox

Fuel System

Cooling System

Intake / Exhaust System Intake/Exhaust System

Drive System

Front & Rear Suspension

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Chapters

Troubleshooting

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Summary of Contents for Segway VILLIAN SSV Series