PowerMax ROUGH-RIDER 700 UTV Maintenance Manual
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PowerMax ROUGH-RIDER 700 UTV Maintenance Manual

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ROUGH-RIDER 700 UTV
Maintenance Manual
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Summary of Contents for PowerMax ROUGH-RIDER 700 UTV

  • Page 1 ROUGH-RIDER 700 UTV Maintenance Manual...

  • Page 2: Table Of Contents

    Catalog General Information ……………………………...5 1 Description …………………………………………………..5 1.1 Identification code…...6 1.1.1. Frame No. …………………………………………………6 1.1.2. Engine No.…………………………………………………7 1.2 Special tools, instruments and meters…………………7 1.3 Periodic maintenance chart……………………………….10 Engine ………………………………………………………….11 2. Inspection and adjustment of engine …………….11 2.1 Inspection of cylinder head, intake And exhaust valve………………………………………….11 2.2 Inspection of spark Plug………………………………….14 2.3 Inspection of cylinder, piston and piston ring…….15...
  • Page 3 3. Disassembly of engine ……………………………………27 3.1 Cylinder head and block………………………………….27 3.2 Piston and connecting rod……………………………….32 3.3 starting mechanism………………………………………..33 3.4 Sensor………………………………………………….…….33 3.5 Left crankcase cover……………………………….…….33 3.6 Magneto…………………………………………………..….34 3.7 Oil pump………………………………………….……..….34 3.8 Clutch…………………………………………………...….36 3.9 Carburetor……………………………………………...….36 3.9.1 Structure of carburetor…...36 3.9.2 Inspection and adjustment of carburetor…..….37 4.
  • Page 4 4.8 Lubrication points……….102 5. Electrical system…..105 5.1 Ignition system…..108 5.2 Magneto and charging system…..109 5.3 Battery…..110 5.4 Lighting system…..111 5.5 Meter and signal system…………………………..……112 5.6 Electrical starting system…………….……..…….113 6. Appendix …...115 6.1 Specification…..115 6.2 Requirements for torque of fastener……………….121 6.3 Electrical circuits……………………………..….122...

  • Page 5: General Information

    General Information 1. Description...

  • Page 6: Identification Code

    1.1 Identification code 1.1.1. Frame No. Frame No. is carved in the lower right side of Figure 1-1...

  • Page 7: Engine No

    Figure 1-1 1.1.2. Engine NO. Engine NO. Is carved on the right side of the engine, Figure 1-2 Figure 1-2 1.2 Special tools, instruments and meters 1.2.1 Oil filter detacher To fasten and detach the oil filter 1.2.2 Height gauge...
  • Page 8 To gauge the height of various components 1.2.3 Venire To measure the length of various components 1.2.4 Outside micrometer To accurately measure external Diameter of a column 1.2.5 inside micrometer To accurately measure internal Diameter of a hole 1.2.6 Dial indicator To accurately measure a small distance 1.2.7 Torque Spanner To measure torque force...
  • Page 9 1.2.9 Multimeter To check electrical circuits and parts 1.2.10 Barometer To measure pressure of the tire 1.2.11 Magneto drawing device To detach the magneto 1.2.12 Snap ring clamp To install and detach snap rings 1．2．13 Steering wheel pull tool...

  • Page 10: Periodic Maintenance Chart

    1.3 Maintenance schedule Maintenance schedule EVERY INITAL month Whichever ITEM 1,200 2,400 2,400 4,800 ROUTINE comes first (mi) (200) (750) (1,500) (1,500) (3,000) hours ● Check valve clearance. ○ ○ ○ ○ Valves ● Adjust if necessary. ● Check condition. ○...

  • Page 11: Engine

    ● Check operation. Select lever safety ○ ○ ○ ● Adjust if necessary. system cable ● Check operation. ○ ○ ○ ○ V-belt* ● Check for cracks or damage. ● Check balance/damage/ ○ ○ ○ ○ Wheel ● Repair if necessary. ●...
  • Page 12 after starting for 4-6 times. See figure 2-1. Figure 2-1 Check the valve lash Note: when adjust valve lash, the engine must be cooled. (The temperature should be less than 35℃) Remove the seat cushion and fuel tank, unplug the vision hole cover, round the flywheel of magneto anti-clockwise to aim “T”...
  • Page 13 Figure 2-2 Remove cylinder valve cover, check the lash between the valve stem by feeler gauge. Valve clearance: inlet and exhaust valve: 0.05～0.08mm. See figure 2-3. Figure 2-3 Loose the lock nut, rotate the adjusting screw until it appears that the feeler gauge be pulled .Then fasten the adjusting screw by valve adjuster, tighten the lock nut and check the valve lash .Afterword install the cylinder valve cover , vision hole cover, the fuel tank and cushion.

  • Page 14: Inspection Of Spark Plug

    Figure 2-4 2.2 Inspection of spark Plug 1. Unplug the Spark-Plug cap: remove The spark plug by box key, look over To see if spark-plug insulator and Electrode is damaged or sooting. If so, see figure 2-5. Figure 2-5 2． Check the spark clearance By feeler gauge whether it Is between 0.6～0.7mm.Or adjust The gap, clean incrustation...

  • Page 15: Inspection Of Cylinder, Piston And Piston Ring

    standard value:mm limit value:mm item φ102～φ102.03 φ102.1 cylinder bore diameter of cylinder taper 0.0040 0.005 out of roundness 0.0035 0.005 degree of touristy 0.04 0.06 φ101.95～φ101.97 φ101.92 Piston, external diameter of piston piston ring bore diameter of piston pin φ22.002～φ22.010 φ22.010 and piston hole...
  • Page 16 Diagnosing and eliminating of malfunction: Emission of black smoke for abrasion of cylinder ● or piston, 1. Cylinder, piston of piston ring is worn out. 2. The piston ring is not properly assembled. 3. The piston or cylinder wall is scraped. overheated ●...
  • Page 17 Note: It is forbidden to damaging the piston ring when assembling. Check whether the piston and the piston groove is cracked and abraded. See figure 2-7 Figure 2-7 2. Insert piston ring into Cylinder, and measure the End gap. Repairing limit Value: the first ring/the Second ring: 0.5mm See figure 2-8.

  • Page 18: Inspection Of Crankshaft

    Figure 2-9 3. Measure the external diameter 10mm Above the bottom of the piston skirt. Extreme position: The gap between Cylinder and piston repairing Limit value: 0.1mm See figure 2-10 Figure 2-10 7 Measure the external diameter of piston pin: The gap between piston and piston pin: Repairing limit value: 0.02mm .See figure 2-11 Figure 2-11...

  • Page 19: Inspection Of Clutch

    Figure 2-12-1 Figure 2-12-2 Inspection of clutch The wear condition of shoe block and friction plate: See Figure 2-13 Figure 2-13 2.6 Inspection of carburetor 1、Inspect the idle of carburetor The engine speed should be 1500±150r/min 10 minutes after starting at normal idle and will not misfire when briskly accelerate.

  • Page 20: Inspection Of Air Filter

    That if there is a jam in Carburetor idle nozzle or a Air leakage of intake pipe. See figure 2-14 Figure 2-14 2.7 Inspection of air filter 1、Disassemble the air cleaner, remove cartridge, clean the cartridge with non-flammable cleaning solvent, and then make it dry.

  • Page 21: Inspection Of Oil Filter

    2．8 Inspection of oil filter Cleaning of lubricator oil strainer: remove clarifier (Figure 2-17), clean it to ensure a well work- condition. Then fix it up. Note: Clean the clarifier Before injecting oil Into crankcase. Figure 2-17 2.9 Inspection of lubrication system Lubricant of engine: the vehicle is oiled with lubricant of APISGSAE10W/40.

  • Page 22: Lubrication Of Engine

    r/min 1000 2000 3000 L/min 3.78 7.43 10.89 Measure clearance of the top of internal external rotor Limit value: 0.20mm 2.10 Lubrication of engine Check the oil level, start the engine and let it running for a few minutes to make it heated and lubricated completely, then misfire.
  • Page 23 0.05mm.See figure 2-19 Figure 2-19 2 Remove and examine the width of valve. Repairing limit value: 2.0mm. See figure 2-20-1, 2-20-2, and 2-20-3. If the mating surfaces are coarse, corrode or cannot contact with valve seat normally.repalce it. Figure 2-20-1 Figure 2-20-2 Figure 2-20-3...
  • Page 24 Measure the width of mating surfaces of valve Repairing limit value: 1.5mm If the valve seat is to wide or narrow or cracked, grind it to ensure impermeability. 4、 Measure bore diameter of valve guide with internal micrometer and special gauge. At last calculate clearance between valve stem and valve guide.
  • Page 25 Figure 2-21 Inspection of valve spring Measure the free height and squareness Repairing limit value :( intake and exhaust) See figure 2-22-1, 2-22－2 Free height of inlet valve spring: 32.5mm, squareness: 0.10mm Free height of exhaust valve spring: 36.2mm squareness: 0.10mm Figure 2-22-1 Figure 2-22-2...
  • Page 26 Figure 2-23 7、Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal. Repairing limit value: φ22.939mm Inspection of rocker arm. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. Note: If there is a rocker arm to be replaced, examine the peak of breaker cam Measure the bore diameter of rocker arm...

  • Page 27: Disassembly Of Engine

    Inspection of rocker arm shaft. Examine if the rocker arm if worn out or cracked. Measure the external diameter of rocker arm shaft with micrometer. Repairing limit value: φ11.96mm The repairing limit value of clearance between rocker arm shaft and hole: 0.05mm, See figure 2-25 Figure 2-25 3.
  • Page 28 Figure 2-26-1 ②Remove cylinder valve cover, cam chain wheel cover and Figure 2-27-1 ③remove valve chain wheel Figure 2-27-2 Figure 2-27-1 Figure 2-27-2 ④remove lower rocker arm shaft. See figure 2-28 Figure 2-28...
  • Page 29 ⑤Remove vision hole cover of left front cover .See figure 2-29 Figure 2-29 Alignment: adjust these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover. Alignmentment of top dead center: Rotate the crankshaft with “T” sleeve anti-clockwise until these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover .That is to say the piston of cylinder is at the top dead center.
  • Page 30 When inlet valve spring rise, rotate the crankshaft until the “T” indicator on the magneto rotor to be at the same level with the center of vision whole cover of left front cover. That is to say the piston is at the compression top dead center and there is valve clearance in these four rocker arms of cylinder head.
  • Page 31 See figure 2-33. Figure 2-33 Remove Adjuster cotter sealed ring Of cylinder head tensioner Adjuster guide board See figure 2-34. Figure 2-34 Remove cylinder block0-seal Adjuster cotter Sealed ring of cylinder head See figure 2-35. Figure 2-35...

  • Page 32: Piston And Connecting Rod

    3.2 piston and connecting rod ①remove the piston snap ring Note: block the crankcase breather with a piece of cleaning cloth to avoid the snap ring falling into the case . See figure 2-36. Figure 2-36 ②remove piston pin and piston Clean the buckle of piston and piston pin hole to facilitate the removing of piston pin.

  • Page 33: Starting Mechanism

    Figure 2-37 3.3 starting mechanism 3.4 sensor Figure 2-38 3.5 left crankcase cover See figure 2-39 Figure 2-39...

  • Page 34: Magneto

    3. 6 magneto Remove the stator coil Remove the pulse coil Remove the stator with rotor Stripper. See figure 2-40. Figure 2-40 Remove the woodruff key. See figure 2-41 Figure 2-41 3.7 oil pump Remove the bolt of oil pump cover .See figure 2-42. Figure 2-42...
  • Page 35 Remove right cover .See figure 2-43. Figure 2-43 Remove the right support frame, clutch pulley disc .See figure 2-44-1, figure 2-44-2, figure 2-44-3. Figure 2-44-1 Figure 2-44-2 Figure 2-44-3...

  • Page 36: Clutch

    3.8 clutch ①remove the clutch Remove bolts. See figure 2-45. Figure 2-45 Remove the clutch shoe Block and clutch cover. See figure 2-46 Figure 2-46 Check the wear condition Of the clutch shoe block And clutch cover. See figure 2-47. Figure 2-47 3.9 carburetor 3.9.1 Structure of carburetor...

  • Page 37: Inspection And Adjustment Of Carburetor

    1．carburetor assembly 2.oil needle component 3.Plunger spring 4. Big diaphragm 5.Plunger 6.Diaphragm circlip7.Screw on upper cover 8.Mixture ratio adjusting screw component。9 .idle metering jet 10.High speed jet 11.Liner 12.Foam pipe 13.0-ring of foam pipe 14.Float 15。Screw M4×816。Float pin 17.Big screw 18.Float seal ring 19.Fuel inlet valve component 20.High speed jet 21.Drain screw...
  • Page 38 Decomposition 1. Remove the evacuated chamber cover 2. Spring 3. Piston valve Remove permanent seat Spring Spring block Oil needle Remove pilot screw Spring Washer Note: the pilot screw is set at maximum performance. Before removing pilot screwd, note the revolutions of screw in order to fix it back.
  • Page 39 0-rings Spring Starting plunger Pilot jet Check the carburetor body Float bowl Oil passage Gas-fouling block→cleaning Chap/damage→replace the carburetor assembly Cleaning steps: Check the float damaged→replace Check the float triangular needle Triangular needle seat 0-rings Filter gauze Damaged/worn out/block→replace Check the piston valve crack→replace Diaphragm rupture→replace...

  • Page 40: Chassis

    Bent/worn out→replace Note: If the piston valve is damaged, inject the petrol into valve. Replace it when there is oil leakage. Check the main jet Main jet Pilot jet Pilot screw 0-scrapers Pilot jet Bent/worn out/damaged→replace Gas-fouling block→blow with compressed air Chassis Automobile body fastener locking moment of force Fastener...
  • Page 41 F disk and the front wheel steering knuckle R disk and the rear wheel steering knuckle F/R wheel and the wheel hub Direction column and direction stylobate Inside and outside direction column and direction column Direction and direction column M8 F/R bridge gear box and frame Front wheel hub and drive shaft M18 Engine and connecting board...

  • Page 42: Direction System

    Other uses Other uses Other uses (The behind torsion revise follow to this table) 4.1 Direction system The structure of the steering 1、 2、 Azimuth training gear drive gear 3、 Spring elastic Direction column groupware ring 4、Seal packing collar 5、Regulator cover 6、Compression spring 7、...

  • Page 43: Daily Inspection

    Compresses the pad 8、gasket 9、gasket 10、The rubber dirt-proof boot holds the band 11、 Left rubber dirt-proof boot 12、Flange bolt M10×30 13、Azimuth training gear ball head 14、tension bar locking nut M10 15、Changes the drive shaft part 16、 Flange bolt M8×20 17、Slot nut M12 18、2 Cotter pin3.2×32 The structure of Steering wheel part 、...
  • Page 44 1、Inspect it whether has the crack and the distortion 2、Inspect the ends ball whether becomes less crowded; the dustproof rubber set does appear the aging, bursts. 3、Inspects the steering wheel whether appears the crack, flexible and moves. 4、Check the steering wheel to rotate whether nimble, do not have stagnation.
  • Page 45 Warning: Any quality flaw of the steering system can cause the serious damage to the driver or send its death. 4.1.1 Dismantle, inspect, maintain and reinstall the steering system 4.1.1.1 Dismantle the parts of the steering wheel 1、Takes down the plastic center lid 2、Takes down the steering wheel fixing nut, the gasket.
  • Page 46 Attached figure4-1-2 1. Steering wheel 4.1.1.2 Inspect the steering wheel 1、 Inspects the steering wheel whether has the hidden danger which the fissure and possibly breaks, if has, must replace the steering wheel. Attached figure4-1-3 1. The framework of the steering wheel 2、...
  • Page 47 figure4-1-3) 3、 Inspects the grip part which is covered by the foam whether has damaged, if it is, must replace a new steering wheel 4、Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering Wheel.
  • Page 48 Attached figure 4-1-4 1. Front panel 2. Connecting cover parts 3. Steering wheel center covers 4. Panel 5. Steering wheel 2、 Take down the steering wheel (Attached figure4-1-4) 3、Loose the M bolt which is on the steering drive axle, the top of spinet, draws out the cross gimbal. 4 、...
  • Page 49 Attached figure4-2-6 1 steering column tube 2. Bearing 3. Central axis of the steering shaft 4. Spline 1 、 Inspect the central axis of the steering shaft whether flexible and moves. If does, dismantle and check the axis, bearing and retaining ring whether ware or damaged, according to the inspection situation to instead the parts.
  • Page 50 Attached figure4-1-7 1. The steering drive axle 2. Flange bolt M8×20 2、Loose the clamp bolt in the cross gimbal, spline on the bottom of the steering drive axle, pull out the lower of the steering drive axle. (Attached figure4-1-8) Attached figure4-1-8 1Flange boltM8×16 2.
  • Page 51 4.1.1.6 Inspect and maintain the steering drive axle 1、 Inspect the cross gimbal turn agility with no stagnation. If does, dismantle and check the cross axis, needle bearing, and the bearing hole on the cross gimbal fork whether have wear and corrosion, to instead the parts based on the check.(Attached figure4-1-9) the cross gimbal Attached figure4-1-9...
  • Page 52 Attached figure4-1-9 1. Frame jointing board 2. Connecting bolt 3. Direction machine 2、Loose the open-groove nut on the L/R turning steering knuckle, take down the steering tension rod from the steering knuckle. (Attached figure Attached figure4-1-11 1. Cotter pin 3.2×32 2.
  • Page 53 1、Inspect the drive of the gear whether angle. If it is not agile, dismantle the direction machine to see the gear and rack have wear, instead the parts according to the inspection. 2 、 Whether the inspection gear drive reverse gap does surpass the rating If it does, adjust the gap and the bolt.
  • Page 54 Attention 1、When replace the rubber set of the ball, must enter 1/2 volume in lithium grease in to the rubber. 2、When replace the direction mechanism, cleaning all the parts, and daub the lithium grease in to the movement. Attention: continue to use the hidden danger Ball pin may causes the serious accident or the death.
  • Page 55 Attached figure4-1-12-1 figure4-1-12-2 Direction machine Tension rod Set bolt Locknut Direction machine ball M10*30Bolt tight of force, 40N.m M10Nut tight of force, 36N.m 2. Connecting the steering transmission shaft and direction machine with one piece of flange boltM8³20. (Attached figure4-1-13) Attached figure4-1-13 1.
  • Page 56 column tube with one piece of flange boltM8³20, then use four pieces of flange nut M8³16 fix the steering column tube frame. (Attached figure4-1-14-1 figure4-1-14-2) Attached figure4-1-14-1 figure4-1-14-2 1. Steering transmission shaft 1. Hexagon flange nutM8×12 2. Hexagon flange nutM8×20 2. Steering column tube 3.

  • Page 57: Brake System

    Attached figure4-1-15 1. Flange self-lock nutM12×1.25 2. Steering wheel Steering wheel tight of force, 40N.m 4.2 Brake system Front Disk Brake components...
  • Page 58 1、Brake pump assembly 2、flange boltM6×20 3、tape3（L＝150） 4、） tape4 （L＝200） 5、tape3（L＝150） 6、flange boltM6×30 7、flange boltM6 ×20 8、 band 9、 flange boltM6×20 10、 brake tube seat 11、 Brake components 4.2.1 Preparation for inspection before the maintenance of the brake system. 。Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained.
  • Page 59 Attached figure4-2-1 )The brake pedal should be kept between 20mm-30mm, Otherwise, please adjust the screw to meet required travel distance.(Attached figure4-2-2) 20~30mm Attached figure4-2-2 1. Brake pedal Inspect brake pedal does maintain certain counter-tension (Attached figure4-2-2) When checks disk brake plate, the saved liquid in the oil cup will pour automatically into the pressure pipe and the liquid level along with it to reduce, the periodic inspection the disk brake plate liquid volume will be an important project.
  • Page 60 Attention, must use DOT4 Brake Fluid 5. Periodical inspection of the wear condition of rear disk brake plate is also necessary. Disk brake plate must be replaced depending on its wear condition. (Attached figure4-2-3) Attached figure4-2-3 1、Disk Brake 6. Disk brake plate uses hydraulic pressure of the brake fluid.
  • Page 61 4.2.2.1 Disassembly of front disk brake plate and the brake plate clip parts. 1. Take down the front wheel parts (Attached figure4-2-4) Attached figure4-2-4 1. Conical Nuts M10 2、Loose the tow pieces of bolts fixed the brake plate clip and take down it. (Attached figure4-2-5) Attached figure4-2-5...
  • Page 62 1. Brake plate clip 2. Bolt 3. Sequently remove the cotter pins, open-groove nuts, cushion and front wheel hub from the front wheel shaft. (Attached figure 4-2-6) Attached figure 4-2-6 3.2×32 Cotter pins Open-groove nut Direction machine ball Front Sheep horn Front wheel hub 4、Take down the brake plate from the front wheel hub.
  • Page 63 Attached figure4-2-7 Front disk brake plate 4.2.2. Dismantle the disk brake pump 1. Dismantle the disk brake pump installment place and take down the disk brake pump unit. (Attached figure4-2-8) Attached figure4-2-8 The disk brake pump The disk brake pump installment place 2.
  • Page 64 Attached figure4-2-9 Hexagon BoltM6×12 Disk brake oil cup 4.2.2.3 Dismantle the rear brake plate clip and the rear disk brake plate 1、Dismantle the rear wheel parts (Attached figure4-2-10) Attached figure4-2-10 1. Conical Nuts M10 2. Wheel hub 2、Remove rear disk brake clip from the rear bridge gearbox. (Attached figure4-2-11)
  • Page 65 Attached figure4-2-11 1、Rear Disk Brake Clip 2、Hexagon BoltM10×30 3. Loose the rear bridge gearbox on the frame, take down the middle transmission shaft parts. (Attached figure4-2-12) Attached figure4-2-12 Disk Brake Clip Disk brake plate Middle transmission shaft 4. Take down the disk brake plate installment place from the rear bridge gearbox.
  • Page 66 Attached figure4-2-13 1. The disk brake plate installment place 2. The rear disk brake plate 5. Dismantle the disk brake plate from the installment place (Attached figure4-2-14) Attached figure4-2-14 Rear disk brake plate 4.2.2.4 Dismantle the disk brake vita 1、Loose the vita fixed nut on the front arm shaft and take down the front vita.
  • Page 67 Attached figure4-2-15 Hexagon BoltM6×12 2. Loosen one piece of nut, which fixed the three Contacts tubing, and then take down it. (Attached figure4-2-16) Attached figure4-2-16 × Hexagon flange Bolt M6 Three Contacts tubing of the disk brake 3、Loose one piece of M nut, which fixed the right fuel pipe bracket on the frame and take down the fuel pipe.
  • Page 68 Attached figure4-2-17 Connecting bolt Rear disk brake vita 4、 Loosen one piece of M nut which fixed the three contacts tubing of the rear fuel pipe and take it down. (Attached figure4-2-18) Attached figure4-2-18 Two tubes of the disk brake ×...
  • Page 69 pipe whether become flexible and damaged Maintain method; fix the flexible nut, instead the damaged nut. Locking Torque: 30N.m 3、Check all Fuel Pipes for deterioration, distortion, crack, wear and other hidden defects. Maintain method, instead the fuel pipes with problems. 4、Check the Brake Plate Clip for distortion, crack, rust and stuck.
  • Page 70 6、Inspect the Brake Shoe for maximum wear, distortion and crack, in which case it must be replaced. Attention, 1.The standard thickness of the front disk brake plate is 4mm. Brake shoe must be replaced when the thickness is less than 3.5mm.
  • Page 71 pieces of M Bolts. Attention: grease the bolt with thread glue when fastening. Fastening Torque of the Bolt: 22 N.m -28N.m 3、Fix the Front wheel Hub onto the Front Wheel Shaft with gasket, open-groove nuts and cotter pins. (Attached Figure 4-2-20) Fastening Torque of the open-groove nut , 50 N.m -60N.m Attached Figure 4-2-20...
  • Page 72 Cotter pin3.2×32 Conical NutM10 Front wheel Hub 4. Fix the Plate Clip onto Front Turning Joint with four pieces of M10×22 Bolts. Fastening Torque: 18 N.m --22N.m 5、Assemble Front Wheel Components onto Front Wheel Hub with four pieces GB/T802M10 Conical Nuts.
  • Page 73 vehicle. 7.。Fix Disk Brake Plate onto the Bottom Seat with six pieces of M8 Bolts. Attention, Grease the bolt with thread glue when fastening Fastening Torque of bolt: 22 N.m -28N.m 8. Mount the Bottom Seat of disk brake plate and rear middle transmission shaft and Rear Bridge onto the rear bridge.
  • Page 74 AttachedFigure4-2-21 The Central lid 2、 Loose the two pieces M bolt, take down the parking handle. (AttachedFigure4-2-22) AttachedFigure4-2-22 1. Parking handle 3、Take down the Parking Cable from the Parking handle (AttachedFigure4-2-23)
  • Page 75 AttachedFigure4-2-23 1. Parking Cable 4. Take down the Parking Cable from the rear disk brake clip. (AttachedFigure4-2-24) AttachedFigure4-2-24 1. Parking Cable 5、Loose two pieces of inner hexagon M nuts, take down the parking institution from the rear disk brake clip. (AttachedFigure4-2-25) AttachedFigure4-2-25 1.
  • Page 76 3. Rectangle four-head bolt 4.2.3.2 Inspect and maintain the Parking system 1、 Inspect whether the Parking handle is loose or distortion carries on the adjustment to the loose and distortion part. Instead the parking handle when the adjustment can not get the request.

  • Page 77: Wheels And Tires

    4、Assemble the parking handle onto the frame with two M nuts. 5、Assemble the front of the parking cable onto the parking handle. 6、Adjust the inner hexagon nuts until the rear brake shoe exactly contact with the rear disk brake plate, then finish the adjustment with lock the inner hexagon nuts with spanner, Attention: after the adjustment, the UTV can...
  • Page 78 Check if the Wheel Hub is worn-out or damaged. (Attached Figure 4 - 2 - 21) 3. Check if the Wheel Hub is rusted or cracked. Check if the conical nuts of the Wheel Hub are loosen or distorted. 4.3.2 Disassembly, inspection assembly...
  • Page 79 Remove the tire for vibration test of the wheel hub. Should the vibration exceed 1.2mm, the wheel hub must be replaced. 5、Inspect the four conical bores on the wheel hub. In occasion of angular distortion or wear, the wheel hub must be replaced.
  • Page 80 (Attached Figure4-2-22) 4.3.3 Specifications and operation guide of Wheel Hub and Tire. Since wheels and tires are crucial to the vehicle operation, inspection for tire pressure and profile depth is necessary. Specification of Wheel and Tire （kPa/PSI） Tyre Dimension Wheel Hub Dimension Tire Pressure Front 12×6.AT...

  • Page 81: Transmission System

    profile depth of the tire is over worn, which might result in spinning, instability, lose of control and other potential security risk of the vehicle. Warnning: The profile depth falls below 3mm, please replace the tire immediately. (AttacheFigure4-2-13) 4.4 Transmission System Front Bridge Front case components...
  • Page 82 1、front axle differential components 2、2 front retarder shell2 3、retarder shell1 4、initiative gear 5、knot fork Ⅰ 6、M10×1.25flange surface self-lock Bolt 7、front bridge initiative gear"O"ring8、 1front case export axes oil envelop1 9、 front case export oil envelop210、 ） gasket with jack （0.4T） ） gasket with jack （0.2T） gasket with jack （0.3T） gasket with jack （0.1T） gasket with jack （0.5T）...
  • Page 83 components (Reference the front bridge assembly, the figure of the front box parts). 4.4.1.1 Preparation for disassembly and maintenance of front bridge components. 1.。Check if the connection between wheel hub and conical nuts is reliable and not loose. 2、If there is any distortion on the front wheel hub; the wheel hub must be replaced immediately.
  • Page 84 5. Check if there exists any slip thread on the open-groove nut. 6. Disassemble the front bridge transmission box parts, check each joggle whether contraposition and right, the joggle have no intervene. 7. Whether the oil nozzle does stop up, if so, first to use the needle to poke the material if it will not be able to solved, replace the oil nozzle to install the original position of the front box.
  • Page 85 6. Emit the oil in the differential device 7. Pull out the left and right transmission shaft from the differential device. (Attached Figure 4-4-1) Attached Figure 4-4-1 The right transmission shaft of front bridge 4.4.2.2 Inspection and maintain the front bridge 1、Check whether the dustproof rubber wrap on the left and right transmission shaft is dilapidation and aging, if so, instead the new one.
  • Page 86 Attention, 1、The dustproof rubber wrap on the ball cage is not allowed to contact with the gas and diesel oil. 2 、 The dustproof rubber wrap does not allow to be scratched, a slight scratches can damage the dustproof rubber wrap very quickly. 3、When reassembles the left and right transmission shaft, in the ball cage must sufficiently Enter 2/3 volume with the Lithium lubricating.
  • Page 87 3、Install the front bridge differential device onto the frame with two pieces of hexagon boltsM10³110,two pieces nutsM10 pieces flat gasket.(Attached Figure4-4-2) Fastening Torque of the Bolt, 40-50N.m Attached Figure4-4-2 Flange boltM10×110 Front bridge differential device Rear Bridge box parts...
  • Page 88 1、Rear axle differential components 2、Retarder shellⅠ 3、Sulfate ball bearing6305 4、Needle bearing55BM6720 5、Initiative gear 6、Sulfate ball bearing6206c3-22 7、Rear disk brake install seat 8、Rear case import axes oil envelop 9、Needle bearing55BM6720 10、Rear case initiative gear "O" ring...

  • Page 89: Reverse Mechanism Parts

    11、Ⅰrear retarder adjustment gasketⅠ 12、flange nut M12 13、rear disk brake leading install plate 14、drive piston gasket（0.25T）drive piston gasket（0.30T）drive piston gasket （0.35T）drive piston gasket（0.40T）drive piston gasket（0.45T） drive piston gasket （0.50T） 15、 bolt M8×20 16、 gasketф8.5 17、 drive piston gasket （0.25T）drive piston gasket（0.30T）drive piston gasket（0.35T） gasket with jack （1.8T）...
  • Page 90 everse mechanism operate parts Inspection and maintain of reverse mechanism(refer to the selector mechanism figure) 1、Inspect the reverse mechanism handle whether is nimbly, if it is not, disassemble the reverse mechanism to check the inner striking fork is stagnation, the steel ball is locked by something, and the spring is natural.

  • Page 91: Suspension

    6、To check the few aspect if it is not reveres, ①whether the clutch is open completely. ② whether the shifts gears to lubricate is reliably (the oil tubing in the reverse mechanism whether is stopped up).③there is any stagnation in the reverse mechanism.
  • Page 92 8、self-lock nutM8 9、rear balancing pole amortize rubber cover 10、balancing pole board 11、hexagon flange surface bolM8×16 Rear arm shaft 1、rear left upper rocker combination 2、rear right lower rocker combination 3、 rear left lower rocker combination 4、rocker rubber middle membrane5、M10×1.25 ×70 6、rocker rubber middle membrane 7、rear right upper rocker combination 8、rocker cushion collar gasket...

  • Page 93: Front Suspension

    4.6.2. Front Suspension right upper rocker combination 1、 axes using 2、 front 3、 front ball pin parts spring flange 4、axes using spring flange lower rocker combination rocker combination rocker 5、front left 6、front right lower 7、 rubber middle membrane hexagon self-lock 8、...
  • Page 94 bolt hexagon flange surface bolt M618、 M6×12 4.6.3 Disassembly, Maintenance and Assembly the supporting rocker parts 1、Disassembly and Maintenance In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. A、If the left and right rocker rocks fiercely, check the few aspect, either the bushing of the rocker is crushed, the middle rubber separate or aging and chapped.
  • Page 95 rocker with the frame. To ensure the fastening torque is 40-45Nm. 2、Connect the front shock absorber, frame and rocker with 4pieces of Hexagon Flange BoltsM10³52 and 4pieces of self-lock nutsM10. 3 、 Connect the rear shock absorber and rear lower rocker combination with 2pieces of Hexagon Flange BoltsM10³65 and 2pieces of self-lock nutsM10.
  • Page 96 1. Hexagon Flange BoltsM10×52 Hexagon Flange BoltsM10×70 1. Hexagon Flange BoltsM10×65 2. Hexagon Flange BoltsM10×70 To check whether put or not the butter before fix, then fix the upper and lower rockers and L/R front shock absorber.

  • Page 97: Cooling System Of Engine

    4.6.4Inspection and Maintenance of Rear Suspension 1、 It is similar to the front suspension Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2、 inspect the rocker bushing and the middle rubber separate is integrant.( According to the front Suspension) 3、...
  • Page 98 4.7.1.1 Disassemble the Water Cool System 4、 Disassemble bumper front faceplate(Attached Figure4-5-1) Attached Figure4-5-1 1. Bumper 2. Front faceplate 2. Take down the water tank bracket combination and slanting support combination. (Attached Figure4-5-2) Attached Figure4-5-2 1. Cooling System 2. Water tank bracket combination 3.
  • Page 99 Attached Figure4-5-3 4. Take off Cooling System. (Attached Figure4-5-2) 4.7.2 Inspection of Water Cooling System 1. Check if the rubber pipe of Water Cooling System is torn or worn out. If so, please replace with new pipe. 2. Check the tightness of the hoop on the rubber pipe connected with Water Cooling System.
  • Page 100 the frame with 2pieces of Hexagon Flange BoltsM6. 4. Use Hoops (4pcs) and Rubber Pipes (2pcs) to connect Water Cooling System with Engine. Pour the high quality refrigerating fluid into the water tank after install. Recommended antifreeze: High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.
  • Page 101 4.7.2.2 Oil Cooling System Except the Cooling System of the engine, this UTV is also equipped with Oil Cooling System. (Figure) 4.7.2.3Disassembly, Inspection and Assembly of Oil Cooling System 1、Disassemble the oil cooler 2、Disassemble the connecting steel oil pipe 3、Disassemble the connecting pressure resistance rubber pipe 4.2.2.4Inspection and maintain the Oil Cooling System 1、Check if the oil cooler is distortion and leak oil.
  • Page 102 4.2.2.5Assembly Oil Cooling System 1、To take a pressure resistance inspection to the Oil Cooling System after maintenance, the pressure is 0.3MPA.a 2、After take the pressure resistance inspection, pass over 0.03MPA compressed air through the connecting oil cooler, steel oil pipe and Rubber Pipe for 3 minutes, and do not leak. 3、...

  • Page 103: Lubrication Points

    4.8. Iubrication points The details of the chassis lubrication is as below...
  • Page 104 1、right upper rocking shaft and frame connection(plus engine oil) 2、right upper rocking shaft and Yanggakdo connection (plus butter) 3、right lower rocking shaft and frame connection (plus engine oil) 4、right lower rocking shaft and Yanggakdo connection (plus butter) 5、right steering rod and steering vertical column connection (plus butter) 6、right steering rod and Yanggakdo connection (plus butter) 7、...

  • Page 105: Electrical System

    22、rear wheel import axis and the case connection (plus engine oil) 23、rear left shock absorber and frame connection (plus butter) 24、rear left shock absorber and rocker connection (plus butter) 25、rear left upper rocker and frame connection(plus engine oil) 26、 rear left lower rocker and frame connection(plus engine oil) 27、rear left upper rocker and Yanggakdo connection(plus butter) 28、rear left lower rocker and Yanggakdo connection (plus butter) 29、rear left half shaft and wheel hub connection (plus engine oil)
  • Page 106 7. Gray┄┄Gr 24.Brown Blue┄┄ Br/L 8. Blue┄┄L 25.Red Brown┄┄R/Br 9. Brown┄┄Br 26.Yellow Red┄┄Y/R 10. Dark Green┄┄Dg 27.Green Red┄┄G/R 11. Dark Red┄┄Dr 28.Green Black┄┄G/B 12. White Green┄┄W/G 29.Black White┄┄B/W 13. White Red┄┄W/R 30.White Blue┄┄W/L 14. White Black┄┄W/B 31.Yellow White┄┄Y/W 15. Light Blue┄┄Lb 32.Green Blue┄┄G/L 16.
  • Page 107 PROBLEM cause measure remark ignition system 1.switch lock １,no spark ※ carve out a way or ★repair short circuit, connection badness ※ line bonding ★repair badness 2.CDI set ※ ★replace After electrify no noise from the CDI 3.high voltage ※ high ★replace voltage lead...

  • Page 108: Ignition System

    5.1 ignition system The key diagram of ignition elements ignition elements: Ignition pressure provided by magneto ignition coil through diode commutated, by R(red line)input CDI(capacitance discharge ignition),charge to capacitance C.at the same...

  • Page 109: Magneto And Charging System

    time ,spring coil produce spring signal ,provided to SCR as the turn on spring signal ,when reaching the ignition timing, SCR turn-on capacitance began to discharge at the elementary coil L1 caused instant lower pressure ,while at the secondary coil caused induce pressure.

  • Page 110: Battery

    to charge the battery. 5.3 Battery Under the following problems, please change the battery 1. With long time charge but the pressure do not increase to a set value. 2. At the bottom of case there is something dirty or electrode have become white or the case with a sulfate function 3.

  • Page 111: Lighting System

    rectifier damaged. And the electrolyte is venomous and dangerous. As it contains vitriol it may cause burn accident. Battery also contains explode gas, so keep it far away spark and flame and cigarette. When charge or using in house, keep the air easy floating. When work near the battery, please take care of your eyes and keep kids away from the battery.

  • Page 112: Meter And Signal System

    function blue yellow yellow black green blue yellow gray dark dark green green light flashing /red /green black green brown /red /black green /white black fast relay near light swith switch white white green green dark gray brown dark red2 /black /red green...

  • Page 113: Electrical Starting System

    When using this function, left and right turning lights will shine at the same time. Meter meet an emergency, the lamp is red (do not shine) ４、Horn Switch function yellw blue biue /red /white light yellow function green /red When press the button, the horn will move. But if without sound or with unclear sound or with little sound please check the problem according to the guide 5.6：Electrical starting system...

  • Page 114: Appendix

    Turn on the start switch on the left handlebar; the battery can supply power for the CDI. Then the CDI supply power for the stator relay, then the power from the battery can be sent to the stator motor through the stator relay and the stator motor works help the engine to work.

  • Page 115: Specification

    6.1 Specification 6.1.1 Specification of technique A）Specification of vehicle Overall length 3010mm Overall width 1460mm overall height 1840mm Wheel base 1890mm Wheel gauge F1100mm/ R1150mm Mini. Clearance to the ground 245mm Seat height 790mm turning radius 2500mm Front：Hydraulic spring swing arm Suspension Rear：Hydraulic spring swing arm )Braking pattern...
  • Page 116 handle Engine/ hand operation， Gear shift Parking brake： handle Front：Alloy/ Steel wheels Wheel Hub Rear：Alloy/ Steel wheels 25x8-12 Front 25x8-12 （Vacuum Tire） Tire dimension 25x10-12 Rear 25x10-12 （Vacuum Tire） 70kpa Front 70kpa Tire pressure 70kpa Rear 35kpa Fuel tank Vol. 29L±0.1L Dry weight 524kg...
  • Page 117 Torque（E-mark） Mini. Idle speed 1400±100r/min Fuel type Unleaded #90 Lubrication Pressure Splash Starting system Electric Start and hand recoil start Ignition C.D.I Drive train Axle Transmission continuous Belt drive 5.0695～0.7679 ratio L Drive 5.3595（30/17³41/21³ ratio： 24/18） H Drive 3.2230（26/21³41/21³ ratio 24/18）...
  • Page 118 Spark plug DR8EA Speed meter Electronic Battery 12V 32Ah Headlight 12V 35W/35W White light Front Indicator 12V 3W White light Rear Indicator 12V 5W Red light 12V 21W Brake light Red light Rear license 12V 5W White light plate light Turning light 12V 10W Amber light...
  • Page 119 6.2.2 Accelerating Performance Starting accelerate must less than14s/200m, superpass accelerate must less than 13s/200m. 6.2.3 Max. Speed 65km/h。The Max Speed is 65km/h (e-mark is 65km/h) 6.2.4 Climbing power The climbing angle must more than 18° 6.2.5 Lowest fuel oil consumption rate Lowest fuel oil consumption rate is ≤340g/Kw²h 6.2.6 Reliability The reliable actual service life is 7000KM.
  • Page 120 The acceleration travel noise is not bigger than 79dB (A), installment noise is 93dB (A), rotate speed is 2750mim 6.2.11 Radio harassment characteristic The multipurpose vehicle produces the radiated interference permissible value and the ignition system noise remover insertion loss value, the radio harassment characteristic should conform to GB14023-2006 6.2.12 parking performance...

  • Page 121: Requirements For Torque Of Fastener

    B）Front is loaded with the illuminator multipurpose vehicle to be supposed to have the low and far beam transducer and when the headlight high beam becomes the headlight low beam, all headlight high beams ought to be able also to extinguish. On the identical vehicle Front illuminator does not allow left, right to be far, and the low-beam lights.

  • Page 122: Electrical Circuits

    Rear shock absorber lower nut 45～55 left rocker upper nut 40～50 left rocker lower nut 40～50 right rocker upper nut 40～50 right rocker lower nut 40～50 engine hanging nut 35～45 Even fork and cradle 40～50 connecting nut front wheel nut 45～55 rear wheel nut 45～50...
  • Page 123 the useful time. 5. Use the pan- fuse box, each operating circuit is working independence, and easy to service, there is no connect with the inner cable and the functional line, it is hard to emerge the dummy section. OVERRIDE km/h...

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