Download
Share
Print this page
TAYO Zontes National IV ZT703-F 2024 Service Manual
  1. Manuals
  2. Brands
  3. TAYO Manuals
  4. Motorcycle
  5. Zontes National IV ZT703-F 2024
  6. Service manual

TAYO Zontes National IV ZT703-F 2024 Service Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
ZT703-F
Service Manual
2024-11-25
1 / 166

Advertisement

loading
Need help?

Need help?

Do you have a question about the Zontes National IV ZT703-F 2024 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TAYO Zontes National IV ZT703-F 2024

Summary of Contents for TAYO Zontes National IV ZT703-F 2024

  • Page 1 ZT703-F Service Manual 2024-11-25 1 / 166...
  • Page 2 PDF format in the corresponding model introduction on the ZONTES official website. Guangdong TAYO Motorcycle Technology Co., Ltd. reserves the right to modify specifications, designs, etc. at any time without prior notice to you, and does not assume any responsibility for this.
  • Page 3 User Notice This manual is compiled by Guangdong TAYO Motorcycle Technology Co., Ltd. for the guidance of dealers or service personnel . This manual cannot provide more detailed knowledge about motorcycles and is only used as a maintenance reference. If you do not have the corresponding knowledge such as electrician and mechanic, improper assembly or maintenance failure may occur during repair.
  • Page 4 Contents Contents ......................................4 1. Vehicle Information ..................................11 Pre-Service Notice ..................................11 Motorcycle body identification characters ..........................12 Technical specifications ................................13 Front wheel /steering system ............................13 Rear wheel / suspension system ............................13 Braking system .................................. 13 Battery/Charging System ................................
  • Page 5 4. Confirm the Oil Level ..............................42 Brake, Clutch, cable clearance adjustment ..........................43 Adjust the clutch handle and clutch line ........................... 43 1. Check ..................................43 2. Adjust the clutch cable clearance ......................... 43 3. Lubricate the clutch cable ............................. 43 4.
  • Page 6 2. Replace the tires ................................58 Steering mechanism.................................. 58 1. Check the steering mechanism ............................. 58 2. Adjust the steering mechanism............................. 58 3. Maintain steering bearings ............................59 4. Fault ....................................59 Front shock absorber ................................59 1. Check the appearance ..............................59 2.
  • Page 7 10. ECU ....................................92 11. Throttle body ................................93 11.1 Common fault signs ............................93 11.2 Disassembly ............................... 93 11.3 Troubleshoot the process ..........................93 11.4 Sensor ................................93 11.4.1 Throttle position sensor ......................... 93 11.4.2 Inlet air pressure sensor ......................... 94 11.4.3 Stepper motors ............................
  • Page 8 Examination .................................... 114 1. Fuel pressure test ................................ 114 2. Fuel pump inspection ..............................114 3. Oil level sensor ................................114 7. Cooling system and air intake system ............................115 Pre-Service Notice ................................... 115 Troubleshooting ..................................115 1. The engine temperature is too high:........................... 115 2.
  • Page 9 Disassembly ................................132 9. Battery/charging system ................................134 Pre-Service Notice ................................... 134 Troubleshooting ..................................135 Troubleshooting process for battery damage or attenuation ....................135 Electrical schematic ................................136 Accumulator disassembly and assembly ..........................137 1. Disassembly ................................. 137 2. Check ................................... 137 3.
  • Page 10 Rear wheel assembly inspection and maintenance ........................ 152 1. Disc brake discs ................................152 1.1 The service life of the disc brake disc ........................ 152 1.2 How to replace the disc brake disc ........................152 2. Rear wheel oil seals and bearings ..........................153 2.1 Service life of rear wheel seals and bearings ....................
  • Page 11 1. Vehicle Information Pre-Service Notice 1. Use high-quality tools or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly, etc. 2. O-rings, paper gaskets, copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly. 3.
  • Page 12 Motorcycle body identification characters ①Vehicle identification code VIN, the VIN code is engraved on the side of the front steering tube of the right frame ②The nameplate is on the right side of the frame ③The muffler regulation code is at the end of the front section of the muffler ④The engine identification code is engraved on the top of the right crankcase 12 / 166...
  • Page 13 Technical specifications Item Specifcation Front tire High seat version: 90/90-21 Low seat version: 120/70-R19 Rear tire High seat version: 150/70R18 Low seat version: 170/60-R17 Front rim specifications High seat version: MT2.15×21 Low seat version: MT:3.5×19 Complete vehicle Rear rim specifications High seat version: MT4.25×18 Low seat version: MT: 4.5×17 Brake fluid DOT4 0.22L...
  • Page 14 Lighting/Instrument/Switch Description Item Specification High beam 12V ～ 22W Headlight Low beam 12V ～ 22W Front position lights 12V ～ 9.3W Front left (right) corner light 12V ～ 8.7W White light: 12V ~ 13W Lighting (LED) Front left (right) fog lamp Yellow light: 12V ~ 16W Rear position lights 12V ～...
  • Page 15 Cable/cable/pipeline /electrical components distribution diagram 1. Lighting distribution map 1-Left front turn signal 2-Left position light 3- Center position light 4 -Left headlight 5- Left corner light 6- Left fog light (high-end version) 7- Right fog light (high-end version) 8- Right corner light 9-Right headlight 10- Right position light 11-Right rear turn signal 12- Rear position light 13- Right rear turn signal 14- Left rear turn signal 15- Rear taillight/license plate light 2.
  • Page 16 3. Brake master cylinder and brake oil pipe 1-Front disc brake master cylinder 2-FMC-HU brake hose 3-RMC-HU brake hose 4-Rear disc brake master cylinder 16 / 166...
  • Page 17 4. Calipers, brake hoses and wheel speed sensors 1- Brake disc assembly (front right) 2-Disc brake caliper (front right) 3-FC-HU brake hose 4-Wheel speed sensor ( front wheel ) 5- Disc brake caliper (front left) 6-Brake disc assembly (front left) 7-RC-HU brake hose 8 - Rear wheel A BS induction coil 9 -Brake disc (rear) 10-Rear disc brake caliper 11-Wheel speed sensor (rear wheel) 17 / 166...
  • Page 18 5. Braking system parts distribution diagram 1- Wheel speed sensor ( front wheel ) 2- FC-HU brake hose 3- FMC-HU brake hose 4- RMC-HU brake hose 5- Rear disc brake master cylinder 6- Rear brake switch 7- Brake pedal 8- RC -HU brake hose 9- Wheel speed sensor ( rear wheel ) 10- Front disc brake master cylinder 11- Front brake switch 12- Rear disc brake assembly 13- Front disc brake assembly (right) 14- Front disc brake assembly (left) 15- Hydraulic control unit 18 / 166...
  • Page 19 6. Oil supply system 6.1 Fuel evaporation 1-Electronic fuel tank lock 2-Fuel level sensor 3-Fuel pump 4- High pressure fuel pipe 5-Throttle body 6- Adsorption /vent pipe 7- Carbon canister 8-Solenoid valve outlet pipe 9-Carbon canister solenoid valve 10-Solenoid valve inlet pipe 11-Fuel tank 12-Oil- gas separator (inside the fuel tank lock) Fuel evaporation: Oil and gas →...
  • Page 20 6.2 Fuel supply Oil Supply System: Air → canister→ adsorption/ventilation pipe→ air-air separator (inside the tank lock) Fuel → fuel pump filter→ fuel pump→ high-pressure tubing→ injector → cylinder 20 / 166...
  • Page 21 7. Distribution of cooling system components 21 / 166...
  • Page 22 1-ZT703-F Main Water Tank Inlet Pipe 2-ZT703-F Small Circulation Water Pipe 3-ZT703-F Engine Water Inlet Pipe 4-Water Pump Cover Assembly 5-ZT310-R Auxiliary Water Tank Leaking Pipe 6-ZT703-F Engine Oil Outlet Pipe 7-ZT703-F Engine Oil Inlet Pipe 8- ZT703-F Oil Cooler 9-ZT703-F Main Water Tank 10-ZT703-F Water Tank Water Filling Port Connecting Water Pipe 11-ZT703-F Water Tank Water Filling Port 12- ZT703-F auxiliary water tank connected to water pipe 13-ZT703 thermostat 14-ZT703-F auxiliary water tank 22 / 166...
  • Page 23 8. Electrical device layout diagram 1-Horn 2-Windshield motor controller 3-TFT meter, 4-Faucet lock, 5-Canister solenoid valve, 6-Right hand handle switch, 7- Charging port base, 8-GPS antenna, 9-Lithium battery, 10- PKE antenna, 11-Rectifier, 12-PKE host, 13-Cushion lock, 14-Non- electric induction antenna, 15-Starting relay, 16-Side bracket flame-out switch, 17-Fuel tank lock, 18-Left handle switch, 19-Main cable 20-LCM Lighting Controller 21-Fog Lamp Controller 22-USB charging cable 23 / 166...
  • Page 24 23 - Fuel tank lock protects the substrate 24 - Buzzer 25 - Engine controller (ECU) 26 - Dump switch 24 / 166...
  • Page 25 9. Intake and exhaust systems 9.1 Intake system 1-Left intake chamber assembly 2-Air filter assembly 3-Throttle valve body assembly 4-Cylinder head 5-Make-up valve rubber hose-4 6-Make-up valve 7-Make-up valve rubber hose-3 8-Stepper motor rubber hose-2 9-Throttle make-up valve 10-Stepper motor rubber hose-1 11-Stepper motor rubber hose-3 12-Exhaust gas snorkel Air Intake System: Main air flow direction of the air intake system (red arrow) Left side intake chamber assembly→...
  • Page 26 9.2 Exhaust system 1-cylinder head 2-front muffler 3-rear muffler 4-exhaust gas snorkel 5-air filter assembly Exhaust system: The main exhaust gas emission flow direction The cylinder head → a front muffler → a rear muffler Secondary cycle exhaust emission process Cylinder heads→...
  • Page 27 Tools 125-piece tool set Torque wrench On-board tools Claw hammer Pull code Rubber hammer Dynamic balancing machine Tire scraper Oil pan Measuring cup Funnel Taps, dies micrometer Depth gauge Vernier calipers Feeler gauge PT300 Electrojet Brush Magnetic mount + dial Tire pressure gauge Writing Diagnostic 17# hexagon...
  • Page 28 Hoop pliers Inner circlip pliers Circlip pliers Clamp-on multimeter 14-side 65mm cap filter T45/50 Torx socket with Multimeter Blow guns wrench (for M350 fine filter holes replacement) T25/45/50 Torx wrench with holes Some of the above pictures are from the Internet, and the copyright belongs to the original author. Do not use for any other purpose Expansion Nail Description (1) Press the center cylinder with 4# hexagon or other tools, you can hear a sound or the center cylinder moves axially by 2mm;...
  • Page 29 2. Maintenance Pre-Service Notice 1. It is necessary to use good quality tools, or special tools and fixtures designed by our company. Using inferior tools may result in damaged parts, detached plating, inadequate assembly, etc. 2. The O-rings, paper gaskets, copper gaskets, and component sealing rings used for sealing must be replaced before assembly.
  • Page 30 Maintenance of periodic tables I: Inspection (cleaning, lubrication, adjustment or replacement if necessary) : Replacement : Fastening Initial Before ×1000km Check the items driving Annual inspection Replace it regularly ×1000mile examine Muffler anti-scald plate buffer glue Air Cleaner (Element) The clutch handle is free to travel spark plug Engine oil...
  • Page 31 lower wear of the flat fork wear block. Note 2: Inspected, cleaned, and lubricated every 10,000 kilometers (6,000 miles). NOTE 3: Check the windshield lift function every 5,000 kilometers (3,000 miles); Check whether the windshield branch is stuck/dry grinding and abnormal noise; Check whether there is too much dust and debris on the guide rail, clean it in time and add special lubricating grease.
  • Page 32 List of daily vehicle operation inspection items Check the items Check the contents Neutral light Lights up when neutral Turn signals The switch is normal and the flashing is normal horn The switch is normal, the volume is normal, and the sound quality is good Brake lights Lights up normally when braking Headlamps...
  • Page 33 Air filter element replacement Pay attention to increase the frequency of inspections when the air humidity is high. Note: ●Please replace the air filter element of the vehicle in strict accordance with the vehicle maintenance cycle. Steps: 1. Remove the corresponding parts a.
  • Page 34 Muffler overhaul and maintenance 1. Disassembly of the engine guard a. Lay down the main bracket to keep the vehicle firmly in place. If the vehicle has been started in a short period of time, please leave the vehicle for a period of time before proceeding with the following operations.
  • Page 35 4. Disassembly of the muffler a. Refer to "Removal of Engine Guard" to remove the engine guard. b. Refer to "Disassembly of Covers" to remove the left and right panels and the lower part of the left and right surrounds. e.
  • Page 36 and (8) that are fixed to the frame. Remove the muffler. Note: When removing the bolts (7) and (8), the front part of the muffler needs to be supported, and when completely removed, it is necessary to pay attention to the engine exhaust port gasket (4) at the place where the muffler is connected to the engine.
  • Page 37 d.Use a 10# sleeve to remove 2 ignition coil pressure Spark plug model: BN8RTIP-8 spark plug plates, and take out 3 ignition coils. The resistance value between the wiring screw and the central electrode: 3~7.5KΩ Clearance: 0.7-0.9mm (0.031-0.035 in) Torque: 13N.m. 3.
  • Page 38 radiators, based on ethylene glycol. Use a coolant suitable for aluminum radiators, which consists of a coolant concentrate mixed with distilled water in a certain proportion. If water needs to be added, only distilled water can be added, as other water quality may corrode the engine cooling system or cause more serious consequences.
  • Page 39 90℃ (194F), repeat the operation of refueling and draining oil and replenishing coolant,and wait until the liquid level no longer drops. Note: Do not touch the coolant in the vehicle with your hands after starting the vehicle to prevent burns. g.
  • Page 40 7. Check the water/oil pipes for leakage and aging 1-ZT703－F The connecting water pipe of the water tank filling port2-ZT703－F Connecting water pipe for the auxiliary tank3- ZT703－F Main tank inlet pipe4-ZT703－F Small circulating water pipes5-ZT703－F Engine water inlet pipe6-ZT310－R Leaky pipe in the auxiliary tank7-ZT703－F Engine inlet pipe8-ZT703－F Engine outlet pipes 40 / 166...
  • Page 41 Engine Oil and Filter Replacement f. Unscrew the engine fuel filler cover counterclockwise, remove the fuel filler cover and O-ring, and use a clean non- woven fabric to place it on top of the fuel filler port to prevent foreign objects from entering the engine. ●The vehicle must be parked on a level, stable ground or lifting platform.
  • Page 42 4. Confirm the Oil Level a. After starting the vehicle to idle for a few minutes, check whether there is leakage in all disassembled locations, and if so, it needs to be checked. b. After idling for 5 minutes, turn off the engine for 3 minutes, check whether the oil level meets the standard, and if it does not meet the standard, it needs to be withdrawn or replenished to the standard.
  • Page 43 Brake, Clutch, cable clearance adjustment the gap between the clutch cap and the core, and turn the throttle as you inject. Adjust the clutch handle and clutch line 1. Check a. Check whether the rubber sleeve and clutch cable of the left hand are damaged.
  • Page 44 d.Remove the stud with a 10# socket or torx wrench to replace the clutch handle. Big Tweaks： If the above adjustments cannot achieve the desired Adjust the brake lever, brake pedal, throttle cable effect, you can remove the throttle body assembly according 1.
  • Page 45 Fuel evaporative pollutant control system 703F fuel evaporates ●After the clearance adjustment of the throttle cable is completed, ensure that the throttle handle can automatically turn back to the closed position, and the engine idle speed cannot be increased due to adjusting the cable. ●After adjustment, the engine idle speed cannot increase when the front of the car is turned.
  • Page 46 d. After pulling out the three buckles of the left and right fuel tank decorative covers, remove the left and right fuel tank decorative covers respectively. e. Use a 4# hexagon tool to remove 2 hexagon shoulder The picture above is a schematic of the equipment with bolts.
  • Page 47 sensor (1), clamp the clamp on the carbon tube snorkel with wearing waterproof and oilproof gloves, press the anti- needle-nose pliers, unplug the snorkel, and remove the fuel release latch, and then pull out the high-pressure oil pipe at tank assembly. the end of the oil pump in the direction of the arrow.
  • Page 48 Chain, rear flat fork wear block Attention： ●Before lubricating the chain, it is necessary to ensure that the chain is completely dry. The chain is then lubricated with a special lubricant. ●Never use a new chain on a worn sprocket, or the new chain will wear out quickly.
  • Page 49 ●In order to ensure safety, the inspection and adjustment of the transmission chain should be done in advance before driving. ● Never adjust the chain while the engine is running. ●The slack of the transmission chain is too large, if the chain is off the chain, the engine may be damaged, or the rear fork is deformed or broken by the chain cutting damage caused by too much slack and high-speed movement, please check and...
  • Page 50 Braking system Attention： ●The arrangement of the brake hose on the vehicle is detailed in the distribution diagram of the brake system accessories in the "Vehicle Information" chapter of this manual. Remark: In order to facilitate after-sales tracking, all those who need to purchase brake hoses, disc brake calipers and disc brake main cylinders, and hydraulic control units need to be reviewed by our company before purchasing.
  • Page 51 is oscillation, it needs to be removed according to the steps Attention： of removing the brake disc, placed on the standard platform, ●This inspection should be handed over to a qualified measured with a dial gauge or checked with a feeler gauge to maintenance unit to complete.
  • Page 52 only one side will cause the brake to be uneven. ● If the brake pad is not in the right position, it is forbidden to operate the brake handle or pedal. Failure to do so will make it difficult for the piston to return and may result in brake fluid leakage.
  • Page 53 brake handle". handle a few times to allow the brake discs and pads to fit Brake pedal: Refer to "Lubricated rear brake pedal" and well and restore normal grip and allow the brake fluid to replace the brake pedal after removing it. circulate steadily.
  • Page 54 is necessary to pay attention to the flange should be facing outward, and if the circlip is deformed, it can be corrected with appropriate force with a hammer. l. Hold the brake lever repeatedly until braking force is restored. 5.2 Replace the rear brake pads a.
  • Page 55 are as follows: maintenance unit to complete. a. The brake pads are worn to the limit, if the brake pads ●It is strictly forbidden to flush the main pump directly with are new, check whether there are foreign objects caught high-pressure water.
  • Page 56 being careful not to remove the torx wrench. The picture above shows the brake fluid moisture content tester, the picture comes from the Internet, and the copyright belongs to the author of the original picture. Do not use for any other purpose. c.
  • Page 57 3. Brake system exhaust and the spoke tension is appropriate. Loose spokes and wheel out-of-rounding can cause instability at high speeds If the brake handle is soft and the braking performance is and may cause loss of control of the vehicle. significantly reduced, you should first check whether the The wheels do not need to be removed to perform the brake fluid level of the main cylinder is lower than the "LOW"...
  • Page 58 ●Park the vehicle on a flat and stable ground or lifting platform and put the main bracket down. ●Too little clearance of the steering mechanism will lead to inflexible steering and accelerate bearing wear. If it is too large, it will cause driving shaking, and there will be abnormal noise when braking.
  • Page 59 d. The lower plate column is deformed and needs to be removed and replaced. Front shock absorber Attention： ●Every 10,000 km (6,200 miles) and 20,000 km (12,400 miles) or every 12 months, the fork should be checked for leakage or deformation and bending, and whether the shock absorption rebound is normal.
  • Page 60 deformed. Take the left shock absorption as an example, use the end face of the front axle of the shock absorbing bottom cylinder and the end face of the front fender installation point to fix the shock absorption; Or remove the fork tube. Use the dial gauge to detect the deformation of the fork tube in the axial direction, and turn the fork tube to measure different positions.
  • Page 61 Rear shock absorber Attention： ●Every 10,000 km (6,200 miles) or every 12 months, the fork should be checked for leakage and normal shock rebound. ●If there is a lot of sediment attached to the shock absorption, it should be cleaned in time to prevent the soft and large stones from scratching the chrome parts and causing rust.
  • Page 62 Bolt/Nut/Fasteners Attention： ●Regularly check the body fasteners according to the maintenance schedule. Check the fasteners in the critical areas Check whether the front disc brake caliper bolts, front shock absorber bottom barrel bolts, upper and lower plate bolts, disc brake disc and sprocket bolts, rear axle nuts and cotter pins, and side bracket stop switch bolts are loose. Check whether the rear axle cotter pin is abnormal.
  • Page 63 Lowering the side bracket (parking position) should not be able to start the vehicle; If the side bracket (driving position) is retracted, the front or rear brake handle should not be able to start the vehicle; After starting the vehicle, the side bracket should be automatically turned off, otherwise the fault of the stop-off switch or brake switch needs to be investigated.
  • Page 64 Main bracket Attention ●Park the vehicle on a flat, stable ground or lift platform with the side brackets down. ●When disassembling and installing the spring, it is necessary to prevent personal injury caused by the sudden flying off of the spring.
  • Page 65 2. Disassemble the main bracket a.Use the T50 plum blossom socket with holes to remove the 3 bolts first, remove the left pedal assembly from the car, pay attention to flip it to the back and unplug the power out switch. b.Remove the bolt with the 8# sleeve and remove the spring pad and flat pad.
  • Page 66 d.Use the external circlip pliers to remove the circlips on both sides. Rotate the main bracket assembly block up and inward, retreating into the gap in the left frame. The main bracket can be removed from the vehicle by panning it to the right side of the vehicle. 3.
  • Page 67 Replace the main bracket return spring post Refer to the steps of removing the side bracket and foot pedal mount, and remove the main bracket counterclockwise with the 8# sleeve to reset the spring column. It is recommended to apply an appropriate amount of thread fastening glue before assembly.
  • Page 68 Inspection of sound, light and electric devices Attention: ●Before driving, check whether the lights of the whole car are normal, including turn signals, taillights, brake lights, headlights, etc. Whether the horn is normal. Whether the windshield lift is normal. 1. Check For details, see the luminaire distribution diagram in the vehicle information of this manual.
  • Page 69 c.The function of the left-hand handle switch is shown in the figure below 69 / 166...
  • Page 70 d.Check the battery voltage Open the cushion, lift the protective rubber case of the positive and negative electrodes of the battery, and use a multimeter to measure the battery voltage. The charging voltage of the charger shall not be higher than 15V. When you do not use the car for a long time, you should charge it regularly according to the requirements of the driving manual.
  • Page 71 2. Headlamp light height adjustment Attention ●Headlights that are too high or too low can affect safe driving. The height of the lights should be adjusted according to the presence or absence of occupants and changes in the weight of the driver. ●It is strictly forbidden to adjust the height of the lights during riding.
  • Page 72 3. Fuse box Attention： ●If the fuse is blown, the fuse of the same specification must be replaced, and it is forbidden to use wires such as copper and iron wires for direct connection. ●If it is fused again after replacement, it is necessary to check the fault of the vehicle cable before replacement. ●This vehicle uses a small fuse.
  • Page 73 If you need to remove the horn, if the bumper has been installed, insert a T25 wrench into the front mounting bracket of the bumper above the front fender to remove the bolts. Pull out the horn and unplug it to remove. it. 73 / 166...
  • Page 74 4.2 Light Noted: ●When using wires to detect lamps, you need to distinguish between positive and negative poles. For detailed wire colors, please refer to the electrical schematic diagram in the driving manual provided with the vehicle. The troubleshooting methods for lamps are basically the same. You can first directly lead the wires to the battery with batteries. If the lamp is normal, you need to check the cable or switch failure.
  • Page 75 4.4 Right handle switch a. Pressing the start button does not respond: Disassemble the No response Whether the Whether the Whether the handle switch and Troubleshoot when pressing Is the key insurance is battery has electric torch short-circuit the start the main cable the start button nearby...
  • Page 76 d.“ ”No response The driver's manual contains a detailed description of the PKE function, including how to start the vehicle in an emergency when the induction key runs out of power, and the specific meaning of the buzzer tone. I will not repeat it here. Bring the sensor key Replacement Right hand switch...
  • Page 77 4.5 Left hand switch The left-hand switch controls the turn signal, horn, high and low beam lights, hazard warning lights, and overtaking lights. There are many lines, making it difficult to check. 77 / 166...
  • Page 78 “SEAT”Button failure If the battery is dead and it is inconvenient to charge, or the seat lock fails and cannot be opened, you can fill in the quality feedback form and ask the engineer to guide you on how to manually open the seat. For safety reasons, this manual does not provide this method.
  • Page 79 3. EFI system Pre-Service Notice 1. The structure and working principle of the EFI system are relatively complex. Before checking and troubleshooting, you need to have a certain understanding of the working principle and structural characteristics of each EFI system. The content of this chapter requires certain maintenance experience.
  • Page 80 Fault Codes Note: ●Unlock the vehicle and turn on the ignition switch. It is normal for the EFI fault light to be on when it is not started. If it is off, the vehicle cannot be started. ●After starting the vehicle, if the fault light is on and the EFI fault is reported, it means that there is an abnormality in the EFI system.
  • Page 81 1 cylinder injector short circuit to high 2 cylinder front oxygen sensor heater short circuit to P0262 P0038 voltage fault high voltage fault 1 cylinder injector short circuit to low 3 cylinder front oxygen sensor heater short circuit to P0261 P0051 voltage/open circuit fault low voltage/open circuit fault...
  • Page 82 EFI Parts OBD Diagnostic Carbon canister Relay (KH-1A4T- Tipping switch interface (main Fuel Pump Fuel Injector solenoid valve R/normally open) cable) Water and oil Oxygen Sensor Start relay Throttle Ignition coil common sensor Relay (G8HN- Secondary air Crankshaft 1C4T-RJ/normally supply valve Position Sensor closed) 82 / 166...
  • Page 83 EFI parts layout drawing 1-Faucet locks 2-Oxygen sensor 3-Right-hand handle switch 4-Ignition coil 5-Throttle assembly 6-Relays 7-accumulator8-PKE host 9-ECU 10-Tilt switch 11-Starting relay 12-Side bracket flameout switch 13-oil pump 14-Magneto 15-Clutch rocker 16-spark plug 17-Fuel injectors 83 / 166...
  • Page 84 Fault diagnosis and troubleshooting of EFI parts Attention： ●Once the EFI parts are disassembled, the EFI system needs to be reset. For details, see the service information in this section. ●Fuel pumps, three-in-one sensors, stepper motors, ECUs and other precision parts may cause damage if disassembled without permission, and are not within the scope of the three guarantees due to human reasons.
  • Page 85 Check Remove the pour switch without disconnect the plug on. Use the OBD diagnostic device to detect if the dump switch is faulty. If there is no diagnostic instrument, use a multimeter to detect the output voltage to determine whether there is a fault. standard：...
  • Page 86 If the fuel pump needs to be removed from the vehicle, the fuel tank can be emptied with a suction pump. Flip the fuel tank assembly to the back and remove the 9 bolts with the 10# sleeve to remove the fuel pump. Note that you should not press the oil outlet pipe shown in the red circle, and once damaged, you can only replace the entire fuel pump assembly.
  • Page 87 When reassembling, it is necessary to pre-tighten diagonally first, and then tighten bolts, otherwise the uneven compression of the sealing ring of the fuel pump will easily lead to leakage and potential safety hazards. 4. Canister solenoid valve When engine performance is not good enough; Poor idling; When the air-fuel ratio is incorrect, the solenoid valve of the carbon canister should be checked.
  • Page 88 6. Injector When the engine idle speed is unstable, easy to stall, or can not start, it is necessary to check whether the injector is normal when reporting the injector failure. It is necessary to remove the seat cushion, fuel tank, air filter, etc. first. It can be judged by the following methods：...
  • Page 89 If you need to replace the injectors, wait until the engine and muffler have cooled down. Use a Phillips screwdriver to remove the two screws that hold the slide rails in place, and remove the rails and injectors together. Use a flathead screwdriver to pry open the clip of the injector to remove the injector.
  • Page 90 7. Oxygen sensor ●Always wait until the engine and muffler have cooled completely before removing the oxygen sensor. When the instrument shows that the oxygen sensor is faulty, the engine performance is poor, the idle speed is unstable, and the fuel consumption is high, the oxygen sensor needs to be checked. The fault code can be read by the diagnostic instrument to confirm whether the oxygen sensor is faulty.
  • Page 91 After removing the cover, you can see that the oxygen sensor is fixed as shown in the figure above, squeeze the mushroom head out of the fixing hole, unplug the oxygen sensor connection plug to measure, and use a multimeter to measure the pin resistance of the pin corresponding to the purple wire and the white wire of the oxygen sensor, the standard value is 12.5±1.7Ω;...
  • Page 92 Use a multimeter with two pins of room temperature resistance values：3.74～1.22kΩ（10～40℃）；1.22～0.27kΩ （40～90℃）. Due to limited space, it is recommended to use a 72-tooth 17# ratchet torx wrench counterclockwise to remove the water and oil common sensor and remove the 9×2 EPDM O-ring. When reassembling, need to replace the O-ring with a new one to avoid leakage.
  • Page 93 11. Throttle body 11.1 Common fault signs 1. During riding, the fault light is on, and there are fault codes related to the intake pressure, temperature, and throttle position sensors. 2. It cannot be started by ignition, the idle speed of the start is too low or too high, unstable, etc. 3.
  • Page 94 Throttle position sensor 11.4.2 Inlet air pressure sensor If the instrument shows fault light is on, if the fault information is displayed as 0108, 0107, 0113 fault code, and the diagnostic instrument shows that the fault exists and cannot be cleared, then check the engine data flow, find the intake manifold pressure and intake temperature parameters, in the absence of ignition, the intake manifold pressure is about the local atmospheric pressure, and the intake air temperature is about the surface temperature of the throttle.
  • Page 95 1234 12. Ignition coil No high-pressure sparks; Weak strength of high-pressure sparks; When the engine fails to start, check whether the ignition coil is normal.Generally, common faults of ignition coils, such as short circuits in coil windings, open circuits or hitching on metal parts, will lead to no high voltage electricity;In addition, the ignition coil insulation material is aging, the insulation performance becomes poor, and the ignition coil leaks, which makes the electric spark weak and the ignition energy is insufficient, resulting in unstable idling, intermittent flameout and failure to ignite.In case of this kind of failure, it is necessary to check whether the...
  • Page 96 When installing the ignition coil back, first insert the ignition coil back into the bottom, and turn the ignition coil plug towards the position shown in the figure above, then put it back into the pressure plate, and put the nut back tight, and the torque standard is 11.5±1N.m.
  • Page 97 14. Secondary make-up valve After unplugging, use a multimeter to measure whether the two-pin resistance is 20±2Ω, or blow compressed air in the direction of the arrow for ventilation detection. 15. Crankshaft position sensor When the engine fails to start and the meter does not display the speed, and the diagnostic instrument reads the crankshaft sensor to be faulty, it is necessary to check whether the crankshaft position sensor is normal.
  • Page 98 Troubleshooting process when the engine does not start and there are no signs of landing When the start button is pressed, the starter motor can drive the engine to run normally, but the engine cannot work normally, and there are no signs of landing, you can refer to the following diagnostic process to investigate the cause of the fault.
  • Page 99 Poor acceleration Rotate the right hand handle rubber sleeve, the engine speed can not be increased immediately, there is a lag phenomenon, and the acceleration is slow; You can refer to the following diagnostic process to troubleshoot the cause of the fault. Check Check if the air Poor...
  • Page 100 The idle speed is unstable and easy to stall The engine is unstable in idling and easy to stall, and it can return to normal after hot it up. You can refer to the following diagnostic process to troubleshoot the cause of the fault. 100 / 166...
  • Page 101 EFI fault indicator is always on analysis flow chart If the EFI fault“ ” indicator is always on, you should first check whether the wire plug of each EFI sensor is loose. The fault light is always on during driving Read fault code Idle speed fault Canister solenoid...
  • Page 102 4. Ignition system Pre-Service Notice 1.The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance. 2.After powering on, the parts connected to the 12V power supply should not be removed at will, so as to avoid the coil in the appliance from self-induction and instantaneous voltage damage to the ECU or sensor.
  • Page 103 Troubleshooting Check the following items before diagnosing the ignition system a. Check whether the spark plug is abnormal; b. Check whether the ignition coil high voltage cap or plug is loose; c. Check whether the high-pressure cap is flooded; d. If there is no spark, first find the ignition coil of the same model to confirm that there is no fault and install it on the faulty car to test whether there is a spark;...
  • Page 104 Ignition system layout 1-Faucet locks 2-Oxygen sensor 3-Right-hand handle switch 4-Ignition coil 5-Throttle assembly 6-Relays（There are 3 pieces inside the main harness fuse box and 2 pieces on the outside of the fuse） 7-accumulator 8-PKE host 9-ECU 10-Tilt switch 11-Start the relay 12-Side bracket flameout switch 13-oil pump 14-Magneto 15-Clutch rocker 16-spark plug 17-Fuel injectors Remarks：...
  • Page 105 Ignition system check Attention： ●If there is no spark in the spark plug, check all cable joints for loose or poor contact before checking the ignition system. ●Use a high-precision digital multimeter. For details of the ignition coil test method, please refer to the ignition coil section in the "EFI Parts Fault Diagnosis and Troubleshooting"...
  • Page 106 5. Starting system Pre-Service Notice 1. If there is a current flowing through the starter motor when the engine is not started, it can be judged that the starter motor is damaged and needs to be replaced. 2. Before repairing the starter motor, the engine shutdown switch must be turned to " "...
  • Page 107 2. Starter motor Does the Brake switch or After the vehicle is Short circuit starter motor flameout switch energized, the flameout relay work? failure switch is hit“ ” The flameout switch of the Whether the EFI Press the start Does the starting Relay failure right handle is fault light is on...
  • Page 108 Electrical schematic diagram of the starting system ECM-J1 ECM-J2 4 12 ECM 15A Clutch switch Start fuse 10A PKE 15A PKE switch Flame out switch W Bk1 Bk W Side stand switch Start switch Ignition coils 40A main fuse Motor ECM main relay Start aux relay Start relay...
  • Page 109 17 16 15 14 13 12 1-M5×98 bolt× 2 2-O ring×2 3-O ring 4-starter motor front cover 5-oil seal 6-bearing 7-rectangular sealing ring 8-starter motor outer shell 7-rectangular sealing ring 9-electric pestle 10-screw ×2 11-head screw with limit 12-washer 13-negative brush×2 14- positive brush×2 15-worm spring ×4 16-insulating brush frame 17-starter motor back cover 18-sealing rubber ring 19-insulating gasket 20 anti-loosening gasket 21 nut Examination...
  • Page 110 The connectivity check of the back cover is as follows: The positive brush is connected to the end of the cable; There is no connection between the end of the cable and the back cover; The negative brush is connected to the back cover. Negative brush Shaft bushing Positive brush...
  • Page 111 3. Check the starter relay Connect the 12V battery directly to the relay with thicker wires. Use the multimeter's buzzer to measure the green/red and red-yellow lines should be able to turn on, and should be disconnected when the battery is disconnected. The rated voltage of the starting relay is DC 12V, the operating temperature is -40~+80°C, the operating voltage is DC≤7.5V (20°C), the recovery voltage is DC≤3.5V (20°C), and the coil current is 4A (12V 20°C) or less.
  • Page 112 6. Fuel supply system Pre-Service Notice 1. Bending or twisting the control cable will affect the smooth operation and may cause a short circuit or open circuit, resulting in loss of control of the vehicle. 2. The operation should be carried out in an open and ventilated place. Smoking, phone calling, and all other behaviors that may cause sparks are prohibited at the work site.
  • Page 113 Fuel tank disassembly c. Remove 4 bolts with a 4# hexagon tool. Note: ●The dismantling site must be ventilated and fire prevention should be paid attention to. The details are described in the previous section and will not be repeated here.
  • Page 114 3. Disassemble the oil level sensor 4. Disassemble the external materials and parts Place the removed tank assembly and it is recommended to protect the fuel pump at the bottom of of the fuel tank assembly the tank. The battery rubber pad is attached to the tank shell and Remove the 4 bolts with the 10# sleeve and pull the is difficult to remove.
  • Page 115 7. Cooling system and air intake system Pre-Service Notice 1. For the corresponding precautions about coolant (antifreeze), please refer to the radiator section of the "Maintenance" chapter of this manual. 2. Check the cooling water pipe; Check the coolant level height, adding and draining the coolant is detailed in the radiator section of the Maintenance chapter and will not be repeated here.
  • Page 116 Cooling system distribution map 116 / 166...
  • Page 117 1-ZT703-F Main Water Tank Inlet Pipe 2-ZT703-F Small Circulation Water Pipe 3-ZT703-F Engine Water Inlet Pipe 4-Water Pump Cover Assembly 5-ZT310-R Auxiliary Water Tank Leaking Pipe 6-ZT703-F Engine Outlet Pipe 7-ZT703-F Engine Inlet Pipe 8-ZT703- F Oil Cooler 9-ZT703-F Main Water Tank 10-ZT703-F Water Tank Refill Connecting Water Pipe 11-ZT703-F Water Tank Refill 12- ZT703-F auxiliary water tank connected to water pipe 13-ZT703 thermostat 14-ZT703-F auxiliary water tank 117 / 166...
  • Page 118 Schematic diagram of coolant flow 1-Main water tank inlet pipe 2-Main water tank 3-Engine water inlet pipe 4-Water pump assembly 5-Thermostat assembly 6- Small circulation water pipe 703F Water Cooling System: Small circle (indicated by red arrows): Pump assemblies → small circulation water pipe→ main water tank (not cooled), → engine inlet pipe→ pump assembly Large circle (indicated by green arrows): Pump assemblies →...
  • Page 119 Disassembly of the cooling system Note: ●Before disassembly, refer to the coolant discharge step in the cooling system section of the "Maintenance" chapter to drain all the coolant. ●This chapter is to disassemble the cooling system, if you only need to disassemble a component separately, please read the whole chapter and have a certain understanding of the cooling system before disassembling it yourself.
  • Page 120 c. use hoop pliers to remove the hoop (12) of φ22 and the hoop (13) of φ32 on the small circulating water pipe (12) and the engine water inlet pipe (14); Then use hoop pliers to c. After arranging the wiring harness, use the hoop pliers remove the hoop (12) of φ22 and the hoop (13) of φ32 on to remove the φ24 hoop (24) on the small circulating water the water inlet pipe (16) of the water inlet pipe (15) of the...
  • Page 121 Cooling system accessories Note: ●Special ventilation fixtures (gas pressure reducing valves, air guns, sealing tubes) are required for testing. ●After the water soaking inspection is completed, wipe the water stains clean in time, or use a dust blowing gun to blow dry.
  • Page 122 2. Water tank filler After the cold vehicle starts, open the water inlet cover 2.1 Overall tightness inspection immediately, if the liquid level Seal the small tube and ventilate the does not fluctuate, the thermostat large tube for air tightness check. A gas is normal, otherwise it is with a pressure of 160kPa (1.63 Kgf/cm2, abnormal.
  • Page 123 Air intake system Disassembly of the air filter 1. Disassembly of the carbon canister a. Refer to the steps of "Replacing High-Pressure Oil Pipe" to remove the fuel tank assembly. b. Use the 4# hexagon to pass through the Φ59×9 pipe hoop assembly (4) on the connecting pipe assembly (5) of the air filter through the gap of the air inlet cavity assembly (2) on the left side of the air filter, and then pull out the air inlet...
  • Page 124 c.Lift the air filter slightly, use the hoop clamp to remove the hoop (5) on the rubber pipe (8) of the air supply valve, and the air filter housing can be taken out after removing the rubber pipe of the air supply valve. 124 / 166...
  • Page 125 Exploded view of air filter accessories: 1-ZT700-F Air supply valve Rubber Hose-4 2-YH Secondary Air supply valve 3-703F Air supply valve Bracket 4-Non-standard inner plum bolt M6×12 (304 stainless steel) 5-ZT700-F Air supply valve Rubber Hose-2 6-ZT700-F Air supply valve Rubber Hose-1 7- ZT369MU Nylon Tee Pipe (φ14) 8-ZT700-F Air supply valve Rubber Hose-3 9-ZT703-F Carbon Canister Assy 10-ZT703-F Air Filter Cartridge Assembly 11- ZT703-F Air Filter Left Air Inlet cavity Assembly 12-Inner Torx shoulder screw M6×14+φ8.5×2.9 (304 stainless steel) 13-59×9 Pipe Hoop Assembly 14-ZT703-F Air Filter Connecting Pipe Assembly 15-ZT703-F Air Filter Lower Housing...
  • Page 126 Air Filter System Accessories: 1. A carbon canister Check whether the adsorption pipe, desorption pipe and negative pressure pipe on the carbon canister are aging. Check whether the adsorption pipe and desorption pipe harden under the erosion of gasoline for a long time. Remove the adsorption pipe and desorption pipe on the carbon canister, block one end of the pipe with the corresponding head, and pass in compressed air with 10-...
  • Page 127 8. Braking system Pre-Service Notice 1. The content of this chapter requires certain maintenance experience, and it is recommended to go to a maintenance unit with maintenance qualifications for inspection or maintenance. 2. Frequent inhalation of the dust generated by brake pads may have a certain impact on health regardless of the composition.
  • Page 128 Troubleshooting The brake handle is soft a. Air enters the oil circuit of the braking system b. Brake fluid leakage c. Brake pads or discs are oily d. Worn brake calipers or disc main cylinder piston seals e. Worn brake pads or discs f.
  • Page 129 Front disc brake calipers disassembled b. Use a T25 torx wrench to remove the two bolts on the rear brake switch bracket, wear waterproof gloves and use a 1-bolt 2-Circlip 3-Caliper inner housing 4-φ30 Oil seals 5-φ30 12# sleeve to remove the disc brake oil pipe bolts, remove Dust-sealed 6-φ30 piston 7-Brake pads 8-Brake pad spring the copper pad and remove the RMC-HU oil pipe, and pour pads 9-Caliper outer housing 10-Pin shaft 11-φ34 Oil seals...
  • Page 130 level and flat ground. Lower the main bracket to park the vehicle securely and let the rear wheels hang in the air. Use a feeler gauge to check whether the gap between the wheel speed sensor and the ABS sensing ring gear is 0.4- 1.2mm (0.02-0.05in).
  • Page 131 b. Refer to the chapter "Removing the Covers" to remove the cushion and fuel tank, and refer to the chapter "Cooling System - Auxiliary Water Tank" to remove the auxiliary water tank. Press the buckle indicated by the arrow, turn the plug pusher in the direction indicated by the arrow, and remove the plug.
  • Page 132 short circuit. misoperation. RC-HU and RMC-HU. Wheel speed sensor (rear wheel) ●Brake fluid is toxic and need to protect yourself. For specific a. Find and unplug the rear wheel speed sensor on the precautions, please refer to the pre-service instructions. right side of the main frame next to the rear brake main ●When disassembling the brake hose fitting, be careful not pump cup.
  • Page 133 cushioning glue. 133 / 166...
  • Page 134 9. Battery/charging system Pre-Service Notice 1. Waste batteries should be disposed of properly so as not to pollute the environment. It is recommended to hand over the waste battery to a professional recycling agency for recycling. 2. It is forbidden to use a charger that has not been tested to charge the battery. 3.
  • Page 135 Troubleshooting Troubleshooting process for battery damage or attenuation Battery failure Use a Measure the multimeter to battery voltage Remove the battery and check whether Battery first, then use a battery tester to there is leakage, Check the voltage<charging measure the check the battery the leakage charging voltage...
  • Page 136 Charging system layout diagram 1-Magneto 2-Charging port base 3-accumulator 4-rectifier 5-Fuse box 6-Starting relay（40A） Electrical schematic Letter English Green Yellow 136 / 166...
  • Page 137 Accumulator disassembly and assembly the DC charging port that comes with the PKE. 1. Disassembly Attention： ●The whole vehicle must be powered off before dismantling the battery. ●The negative electrode must be removed first, and then the positive electrode. It's the other way around when it comes to installation.
  • Page 138 DC Voltage file of multimeter Red pen Black pen Main cable cathode Main cable anode Rectifier detection Battery Check the plug for looseness or corrosion. Use the DC 3. Magneto stator charging coil inspection voltage block of the multimeter to detect the 2P plug on the a.
  • Page 139 10. Front fork assembly Pre-Service Notice 1. Use high-quality tools or special tools and fixtures designed by our company. Using inferior tools may cause damage to parts, coating shedding, inadequate assembly, etc. 2. O-rings, paper gaskets, copper gaskets, component sealing rings, etc. used for sealing must be replaced before assembly. 3.
  • Page 140 Exploded view of the front fork assembly: Exploded view of the handlebar 140 / 166...
  • Page 141 Front fork exploded view 141 / 166...
  • Page 142 Lower connection board exploded view 142 / 166...
  • Page 143 Replace the handlebar Notice: ●When removing the disc brake oil cup, be sure to point it vertically upwards to prevent air from entering the brake line. ●When disassembling and assembling the handle switch, pay attention to adjusting the internal wiring harness of the switch and the turn signal wiring harness to avoid the housing or bolt column from damaging the wire sheath.
  • Page 144 3. Install the handlebar assembly ●After installation, you should check whether the throttle a. Apply a proper amount of special glue on the inner wall cable is assembled in place and whether the return is flexible. of the left handlebar rubber sleeve to prevent it from ●After the installation is completed, check the buttons of the loosening.
  • Page 145 ●After the front wheel is installed, press the brake handle repeatedly until the brake restores the braking effect. ●Soiled disc and pads can reduce braking effectiveness, so replace them with new ones and clean the soiled discs. ●After each replacement of the front wheel, it is necessary to go to a professional institution for dynamic balance testing.
  • Page 146 Inspection and maintenance of front 2.2 How to replace the oil seals and bearings of the front wheels wheel components a. Refer to "Replacing the Front Wheel" to Attention： remove the front wheel assembly. ●This inspection should be handed over to a qualified b.
  • Page 147 improve the stability and comfort of the vehicle, and d. After moving the front mud board up to the facilitate safe driving. appropriate part, pull it out in the direction of the big arrow. Remove the bolt on the wheel speed sensor with a T25 Torx a.
  • Page 148 45±5N.m (4.6±0.5 kgf.m, 33±4 lbf.ft). Attach the disc brake calipers on both sides. g. After the front fender is replaced, use a T25 Torx wrench to replace the 4 M6×14 shoulder bolts. Then use the 5# hexagon socket to replace the bolts of 2 M6×16, and finally install the oil pipe back into the left rear side fixing clip.
  • Page 149 hexagon socket, and the torque of the bolt (1) is 25N.m (2.6 turn, and finally tighten it with a torque wrench to a torque kgf.m, 18 lbf.ft). Use the 14# sleeve to remove the two bolts of 13N. m (1.3 kgf. m, 10 lbf. ft). Place a rubber pad on the (2) that fix the cushion block, and remove the gasket, buffer adjusting nut of the steering column;...
  • Page 150 11. Rear fork component Pre-Service Notice 1. High quality tools or specialized tools, fixtures, etc. designed by our company are required. Using inferior tools may cause damage to parts, peeling of coatings, improper assembly, etc. 2. O-rings, paper pads, copper pads, component sealing rings, etc. used for sealing must be replaced before assembly. 3.
  • Page 151 Replace the rear wheels 22~26 lbf.ft). Remove the 6 bolts on the sprocket with T45 perforated torx socket hexagon with torque: 30N.m (3.1 Note： kgf.m, 22 lbf.ft), remove the sprocket and sprocket seat. ●The vehicle must be parked on a level, stable ground or Note: If the nut torque is too strong, the bolt will be broken, lifting platform.
  • Page 152 brake caliper should not be higher than the disc brake oil cup, otherwise the brake will become soft or fail due to air entering the line. Due to the extremely high vacuum ●After each replacement of the rear wheel, it is necessary to requirements of the brake line, it is necessary to ensure that go to a professional institution for dynamic balance testing.
  • Page 153 b. Use a T45 torx wrench to remove the shoulder bolts of the design. the 6 M8×25s, and remove the induction coil and the c. There are many aging and cracking phenomena in the damaged disc brake disc. tire. c. After replacing the induction coil and the new disc 3.2 How to replace the rear rim and tires brake disc, use a T45 torx wrench to tighten the bolts of the 6 a.
  • Page 154 2. Remove the rear flat fork when reassembly. a. Refer to "Replacing the Rear Wheel" to remove the rear wheel assembly. b. Move the chain aside and remove the tubing and ●When disassembling the rear wheel assembly, the rear disc wheel speed sensor from the tubing clamp on the rear flat brake caliper is strictly forbidden to be higher than the disc fork (as shown by the arrow).
  • Page 155 absorbing straight connecting rod are interference press- fitting, please ensure that you have the ability to disassemble and assemble by yourself before disassembling by hand. c. If you need to replace the rear shock-absorbing straight connecting rod, you can remove the straight connecting rod according to "Maintenance - Main Bracket".
  • Page 156 12. Disassembly and assembly of vehicle covers NOTE： ●The vehicle must be parked on a level, stable ground or lifting platform. ●Operation is required until the engine and muffler have cooled down completely. ●Attention and sequence when disassembling the plastic buckle to avoid buckle breakage 1.
  • Page 157 Disassembly and assembly of vehicle covers NOTE： ●When disassembling, please pay attention to the size of the control force to prevent breaking the buckle. ●When disassembling the cover, please remove it in strict order, and do not forcibly disassemble the cover, so as to prevent irreparable damage to the corresponding cover.
  • Page 158 Disassembly of the windshield lift Disassembly of instrument trim cover assembly assembly a. Unplug the windshield controller and tire pressure a. Use a T25 Allen Torx wrench to remove the three receiver. Use the T25 Allen Torx wrench to remove the four M6×14 shoulder bolts as shown.
  • Page 159 d. The entire decorative cover assembly can be d. The breakdown of the instrumentation components is disassembled by using the cross batch, and the installation shown in the figure below. position relationship is shown in the figure below. Disassembly of instrument components a.
  • Page 160 Disassembly of the wiring board on the right side a. Unplug the connectors of the light controller and the fog lamp drive box, remove all the connectors on the wiring clamp and ECU fixing frame, remove the shoulder bolts of the two M6×14 with a T25 Allen Torx wrench, and remove the light controller.
  • Page 161 c. Unplug the decorative cover of the auxiliary water tank, and use the T25 plum hexagon to remove 2 M6×12 bolts (1), 1 M6×16 bolt (2), 1 M6×16 shoulder bolt (3), and 1 M6×14 shoulder bolt (4). d. Use a T50 Torx socket with a mid-hole to remove the 3 c.
  • Page 162 f. Use the T50 torx hexagon with the middle hole to remove 1 M10×25 bolt and remove the right guard bar. Disassembly of the guard bar assembly a. Remove the left and right surrounding panels according to the "Disassembly of the Surrounding Panel", and unplug all the joints of the fog lamp on the left and right sides.
  • Page 163 Removal of the seat cushion b. Use the T25 plum blossom hexagon to remove an M6×14 axle shoulder bolt bolt on the left side of the vehicle, a. Press the "SEAT" button on the vehicle's cushion lock note: the right M6×14 bolt has been removed when switch to open the cushion lock.
  • Page 164 Removal of the rear position lights the gap, and then pull out the C in turn. a. Use 4# hexagon to remove the shoulder bolts of 3 M6×14 that fix the tail lights; Remove the rear position light; And use a Phillips screwdriver to remove the 4 self-tapping screws that hold the taillight trim in place, and then remove the taillight trim.
  • Page 165 Removal of the rear fender a. Use a Phillips screwdriver to remove the 6 self-tapping screws, and then use the 4# hexagon to remove the 2 M6×14 inner torx shaft shoulder screws that connect to the rear fender, and remove the rear fender back shell. d.
  • Page 166 g. First, use a Phillips screwdriver to remove the bottom 2 self-tapping screws, pull out the upper part of the rear camera decorative cover from the buckle, use a Phillips screwdriver to remove the camera clamp matching bolts and its spacers, then pull out the camera interface and arrange the wiring harness, and then take out the rear camera and the lower part of the rear camera decorative cover.