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Cectec KINGCOBRA Service Manual

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KINGCOBRA / ESTOC
SERVICE MANUAL
V1.3

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Summary of Contents for Cectec KINGCOBRA

  • Page 1 KINGCOBRA / ESTOC SERVICE MANUAL V1.3...
  • Page 2 TOPIC Ⅰ POWER TRAIN Ⅱ ENGINE Ⅲ CHASSIS Ⅳ SUSPENSION / TRANSMISSION Ⅴ ELECTRICAL Ⅵ MAINTENANCE Ⅶ SPECIAL TOOLS...

  • Page 3: Table Of Contents

    POWER TRAIN Engine Specification………………… Ⅰ Engine Lubrication System………… Engine Breather System……………. CVT System…………………………… Start System…………………………... Injection System……………………… Emission Control System………….. Cylinder Head / Block……………….. EMS System…………………………..
  • Page 4 Engine Specification Ⅰ Type：4 Stroke / Single Cylinder / SOHC / 4 Valves Displacement：497cc Bore x Stroke：ø90mm x 78mm Compression Ratio：10.0 Max. rev.：7500rpm Transmission：CVT / V-belt Emission：2002 / 51 / EC Weight：67kg Ⅰ...

  • Page 5: Engine Lubrication System

    Engine Lubrication System Left Side Right Side Ⅰ Piston、Liner Camshaft Cylinder Con-Rod Crankshaft Crankshaft Pressure S/W Balancer Balancer Gear Box Oil Filter Oil Pump Release Valve Oil Peak-up Oil Sump Lubrication：Wet Sump Oil Inlet： Oil Pump：Rotor Type Oil Return： Oil Filter：Paper Type Oil Type：10w / 40 Oil Volume：3.0L / 3.5L (Replace Filter) Pressure Release：4.5 kg/cm...

  • Page 6: Engine Breather System

    Engine Breather System Ⅰ Intake Side Exhaust Side Air Box Piston Air Filter Con- Rod Breather Hose Blow-by Gas Engine Oil Crankshaft Ⅰ...

  • Page 7: Cvt System

    CVT System Ⅰ CVT Belt Drive Wheel Driven Wheel CVT Belt Type：DAYCO 5324 Drive Wheel Tightening Torque：40~45Nm Driven Wheel Tightening Torque：120Nm Ratio：0.316(min)~1.581(max) Engine Speed Limit：7500rpm Ⅰ...

  • Page 8: Start System

    Start System Ring Gear Ⅰ Starter Spin Nose Rewind Starter Handler Starter Output：0.7KW Operation Voltage：12V Temperature Range：-10 ~ +120 ℃ Starter Circuit Diagram： Key S/W Starter S/W Relay Starter Battery Ⅰ...

  • Page 9: Injection System

    Injection System Ⅰ Injector Cylinder Head Idle Air Control Valve Intake Valve (IACV) Intake Port Fuel Injection Throttle Body ASM Intake Air Air Flow Temperature IACV or TPS Air Temp Coolant Temp …..etc To Calculate Air Flow And Necessary Fuel Flow Fuel Injection Control Injector Ⅰ...

  • Page 10: Emission Control System

    Emission Control System Injector Ⅰ Throttle Body ASM Ignition Coil ASM O2 Sensor Catalyst Emission Relational Part： ECU / Throttle Body ASM / Spark Plug / Ignition Coil ASM / O2 Sensor / Catalyst Catalyst：100 cells/in2 Catalyst Volume：116cc Emission：Updated 2002 / 51 / EC Ⅰ...

  • Page 11: Cylinder Head / Block

    Cylinder Head / Block Ⅰ Spark Plug Intake Valve Spark Plug Exhaust Valve Cast-in Liner Cylinder Head ASM：Aluminum Alloy < AC4B+T6 > SOHC / Chain Drive / 4 Valves Spark Plug Type：Champion PRG7C Cylinder Block ASM：Liner Material < FC250 > Aluminum Alloy <...

  • Page 12: Ems System

    EMS System Block Diagram Ⅰ Ⅰ...
  • Page 13 EMS System Ⅰ Pin Assignment Ⅰ - 10...
  • Page 14 Ⅰ Map Sensor Connector Connector ECU Type: ECU Pin 28: MC21 1030 Ⅰ - 11...
  • Page 15 Ⅰ Part Introduction ECU Type：MC21 1030 Assembly： Electrical Characteristic Operation Voltage Range：9~16V Storage Temperature Range：-40~+70℃ Operation Current：＜500mA Ⅰ - 12...
  • Page 16 Injector Identification Code: Ⅰ MPR: 28140652 ECU Pin 28: Part Introduction Identification Code：28140652 Injector Holes：4ea Circuit Diagram： Main Power Relay Injector Pin 28 Measurement Resistance：12.0 ± 0.6Ω Ⅰ - 13...
  • Page 17 Throttle Body ASM Ⅰ Idle Air Control Valve < IACV > (Step Motor) Throttle Position Sensor Throttle Body (TPS) Ⅰ - 14...

  • Page 18: Table Of Contents

    Throttle Body – TPS 、 Step Motor Ⅰ Step Motor ECU Pin 21 Pin 33 Pin 34 Pin 25 Pin 24 ECU Pin6 : 5V Part Introduction TPS Circuit Diagram： Pin 6 Pin 21 Step Motor Circuit Diagram： Pin 24 Pin 25 Pin 33 Measurement TPS Resistance：...
  • Page 19 Rollover (Fuel-Cut) Sensor Ⅰ Output Left View Top View Part Introduction Sensor Voltage：12V Sensor Pitch Angle：65° ± 10° Sensor Roll Angle：-20°~+20° Sensor Temperature：-10~+60℃ Circuit Diagram： Vcc：12V Rollover OUTPUT Sensor Pin11 Assembly Bolt：M4 Bolt x 2 Tighten Torque：1.5~2.5Nm Measurement Resistance：3.9Ω ( Vcc + Output ) Ⅰ...
  • Page 20 Fuel Pump Sensor + Pump + Fuel Connector Meter Pin24 Ⅰ Fuel Filter Fuel Level Sensor - Pump - Part Introduction Pump Characteristic Voltage：12V Feed Fuel Pressure：250 ± 10Kpa Feed Fuel Rate：30.6 L/hr (min) Circuit Diagram： Sensor + meter Sensor - Fuel Pump + Relay...
  • Page 21 Ignition Coil Ⅰ PBT Black + Spark Side PBT Green - Part Introduction Sensor Characteristic Voltage：12V Sensor Temperature：-10 ~ +60 ℃ Circuit Diagram： PBT Black + Spark Side 12 V Primary Secondary Coil Pin27 PBT Black - Assembly Bolt：M4 Bolt x 2 Tightening Torque：10 ±...
  • Page 22 Alternator Crank Sensor Ⅰ Connector Rectifier Connector CNKN CNKP Crank Sensor Ⅰ - 19...
  • Page 23 Alternator Part Introduction Ⅰ Electric Characteristic Voltage：12V Output：16V / 1500rpm ↑ Circuit Diagram Rectifier： Vehicle Crank Sensor： Ⅰ - 20...

  • Page 24: Table Of Contents

    ENGINE DISMANTLE CVT Cover Dismantle.……….……….. CVT Belt Dismantle.……………..……. CVT Driven Pulley Dismantle.……..Ⅱ CVT Driving Pulley Dismantle.….…… Rewind Starter Dismantle.……..…..Timing Check.……………………..Accessory Cover Dismantle.………… Discompressor Dismantle…………… Alternator Rotor Dismantle……..…. Cam Shaft Dismantle.……..…..... Chain Dismantle.………..……………... Cylinder Head Dismantle.…....Balancer Dismantle.………..…………. The Oil Pump Dismantle.……………..

  • Page 25: Table Of Contents

    ENGINE ASSEMBLY The Piston And Connection Rod Assembly……………………………….. The Balancer Assembly…………..… Ⅱ The Main Shaft Assembly……………. The Lay Shaft Assembly……………... The Rear Driveshaft Assembly……… The Cylinder Head Assembly……..… The Water Pump Assembly……….…. The Shift Drum And Fork Assembly... The Transmission Gear Assembly..The Gear Idle Gear Assembly…….….

  • Page 26: Cvt Cover Dismantle

    ENGINE - Dismantle CAUTION： Only trained and certificated technician can disassembly the CECTEK 500 EFI ENGINE. Improper disassembly may damage the engine. CECTEK can not provide the warranty to the engine Ⅱ which has not been properly disassembled and assembled by trained and certificated technician. CVT COVER DISMANTLE Loosen the CVT cover bolts Remove the CVT cover...

  • Page 27: Cvt Belt Dismantle

    ENGINE - Dismantle CVT BELT DISMANTLE Tighten the Belt Removal Tool to end to open the driven pulley then removal the belt Ⅱ The belt ※Reinstall , the installer must can read the printed word on the belt CVT DRIVEN PULLEY DISMANTLE Loosen the driven pulley bolt , then remove the driven pulley The Driven pulley...
  • Page 28 ENGINE - Dismantle CVT DRIVING PULLEY DISMANTLE Loosen the driving pulley bolt Ⅱ Tighten the CVT Puller by air wrench to remove the drive pulley The drive pulley Ⅱ...

  • Page 29: Rewind Starter Dismantle

    ENGINE - Dismantle REWIND STARTER DISMANTLE Loosen the rewind starter bolts Ⅱ The rewind starter TIMING CHECK ※before dismantle engine must be check the chain timing Loosen the cam cover bolts, then remove the cam cover Ⅱ...
  • Page 30 ENGINE - Dismantle Loosen the taper plug for check the timing Ⅱ Use the Rewind Starter Stopper clockwise rotate crankshaft then check chain timing ALT rotor mark meet the accessory cover mark When ALT mark correct , then check cylinder head sprocket have six pieces counter from cylinder head six pieces...

  • Page 31: Accessory Cover Dismantle

    ENGINE - Dismantle ACCESSORY COVER DISMANTLE Loosen the accessory cover bolts Ⅱ Raise the accessory cover by screwdriver from the prominence of case When remove the accessory cover be care the spin nose antithrust spring and washer Ⅱ...

  • Page 32: Discompressor Dismantle

    ENGINE - Dismantle DISCOMPRESSOR DISMANTLE Loosen the discompressor mechanism bolt by open wrench Ⅱ Pull out the discompressor mechanism The discompressor mechanism, and notice the spring Ⅱ...

  • Page 33: Alternator Rotor Dismantle

    ENGINE - Dismantle ALTERNATOR ROTOR DISMANTLE Loosen the ALT rotor nut by air wrench ※The socket deep 85mm Ⅱ Tighten Crankshaft Protector to end on crankshaft Tighten the ALT Puller to end on ALT rotor Tighten the CVT Puller on ALT Puller by air wrench , then remove the ALT rotor Ⅱ...

  • Page 34: Cam Shaft Dismantle

    ENGINE - Dismantle CAM SHAFT DISMANTLE Loosen the tensioner cover , O-ring and notice the spring and O-ring Ⅱ spring cover Loosen the tensioner bolts , then remove the tensioner Loosen the cam sprocket bolts , then remove the cam sprocket Loosen the cam antithrust plate Bolt , then remove the plate...
  • Page 35 ENGINE - Dismantle Pull out intake and exhaust rock arm shaft by magnet Ⅱ Pull out the cam shaft The rock arms and cam thrust plate The cam shaft Ⅱ - 10...

  • Page 36: Chain Dismantle

    ENGINE - Dismantle CHAIN DISMANTLE Loosen the chain guide bolt , then remove the chain Ⅱ Notice the boss The chain Ⅱ - 11...

  • Page 37: Cylinder Head Dismantle

    ENGINE - Dismantle CYLINDER HEAD DISMANTLE Loosen the cylinder head bolts Ⅱ Remove the cylinder head , and notice the lock pins Remove the gasket and chain guide The cylinder head gasket and gasket chain guide guide Ⅱ - 12...

  • Page 38: Balancer Dismantle

    ENGINE - Dismantle BALANCER DISMANTLE Loosen the balancer cover bolts Ⅱ Raise the balancer cover by screwdriver from the prominence of case Loosen the water pump idle bolt pulley bolt and unclip the oil pump gear clip clip The oil pump gear The water pump idle gear Ⅱ...

  • Page 39: The Oil Pump Dismantle

    ENGINE - Dismantle Loosen the balancer bolt by use screwdriver stop the balancer Ⅱ The balancer THE OIL PUMP DISMANTLE Loosen the oil pump bolts and unclip the oil pump gear clip The oil pump and back plate Ⅱ - 14...

  • Page 40: The Driveshaft Dismantle

    ENGINE - Dismantle Remove the spin nose and washer Ⅱ THE DRIVESHAFT DISMANTLE Loosen the front driveshaft yoke bolts , then remove the yoke Loosen the front driveshaft seal cover bolts , then remove the cover The yoke The seal cover Ⅱ...
  • Page 41 ENGINE - Dismantle Pull the front driveshaft and remove the 4WD gear Ⅱ The 4WD gear Remove the rear driveshaft yoke and seal cover ( same procedure of front driveshaft ) Loosen the starter bolts , then remove the starter Ⅱ...

  • Page 42: The Oil Main Circuit Dismantle

    ENGINE - Dismantle Loosen the shift drum cover bolts Ⅱ Loosen the shift drum antithrust plate THE OIL MAIN CIRCUIT DISMANTLE Loosen the oil filiter cover Remove the oil filter Ⅱ - 17...

  • Page 43: The Cylinder Block Dismantle

    ENGINE - Dismantle Loosen the main circuit bolt , then remove the main circuit Ⅱ The main circuit THE CYLINDER BLOCK DISMANTLE Remove the rear driveshaft yoke and seal cover Turn the engine over , and loosen the oil sump bolts Ⅱ...
  • Page 44 ENGINE - Dismantle Use scraper and hammer to open the oil sump Ⅱ The oil sump ※When reinstall must clean the surface of the oil sump Loosen the crankcase bolts Raise the crankcase by screwdriver from the prominence of case Ⅱ...

  • Page 45: The Transmission Gear Dismantle

    ENGINE - Dismantle The crankcase ※When reinstall must clean the surface of the crankcase Ⅱ THE TRANSMISSION GEAR DISMANTLE Remove the main shaft Remove the lay shaft Remove the rear shaft Ⅱ - 20...
  • Page 46 ENGINE - Dismantle The cylinder block ※When reinstall must clean the surface of the crankcase Ⅱ Loosen the shift fork bolt , then pull out the shift fork shaft and remove the fork The shift fork Loosen the shift position rotor bolt , then remove the parking shaft plate Ⅱ...

  • Page 47: The Oil Release Valve Dismantle

    ENGINE - Dismantle The parking shaft Ⅱ Pull out the shift drum from the cylinder block The shift drum THE OIL RELEASE VALVE DISMANTLE Loosen the oil release valve bolt , then remove the oil release valve by magnet Ⅱ - 22...

  • Page 48: The Crankshaft Dismantle

    ENGINE - Dismantle The oil release valve Ⅱ THE CRANKSHAFT DISMANTLE Loosen the connecting rod bolts Remove the connecting rod cap , then remove the crankshaft The cylinder block ※When reinstall must clean the surface of the crankcase Ⅱ - 23...

  • Page 49: The Piston Dismantle

    ENGINE - Dismantle THE PISTON DISMANTLE Pull out the piston ※Must clean the carbon on piston Ⅱ Piston ring inspection The second ring top side Loosen the speed sensor bolt , then remove the speed sensor Ⅱ - 24...

  • Page 50: Assembly

    ENGINE - Assembly CAUTION： Only trained and certificated technician can disassembly the CECTEK 500 EFI ENGINE. Improper disassembly may damage the engine. CECTEK can not provide the warranty to the engine Ⅱ which has not been properly disassembled and assembled by trained and certificated technician. THE PISTON AND CONNECTION ROD ASSEMBLY PART NAME PART NO.
  • Page 51 ENGINE - Assembly 5.The piston size mark on top ( A or B ) 6.Confirm：when you face the piston , the piston (4,5) exhaust mark is in the Ⅱ down side 7.Confirm：the connecting rod (1) right side mark R is same side of piston 8.Install one clip (3) into the piston clip groove firmly...
  • Page 52 ENGINE - Assembly THE BALANCER ASSEMBLY PART NAME PART NO. RETAIN E-RING RES009 GEAR (37T) 40150030 Ⅱ 40130083 BALANCER SHAFT ASSY. 40128004 1.Install pin (2) into balancer shaft (1) 2.Install gear-oil pump driver (3) into balancer , reference to figure A 3.Clip the E-ring (4) check the retain E-ring install into the groove of balancer shaft...
  • Page 53 ENGINE - Assembly THE BALANCER ASSEMBLY PART NAME PART NO. CRANKSHAFT 40110023 40110108 Ⅱ GEAR (36T) 40120018 CAM CHAIN SPROCKET 41010004 NUT (M30) 40110024 1.Install key (2) into crankshaft (1), keep the key parallel with crankshaft-taper 2.Install gear (3) into crankshaft (1) , gear groove must be alignment key of crankshaft...
  • Page 54 ENGINE - Assembly THE MAIN SHAFT ASSEMBLY PART NAME PART NO. MAIN SHFAT 46030001 BEARING 46030034 SPACER 46010003 LIP SEAL 40016004 Ⅱ RETAIN C-RING RCS025 WASHER 46030010 NEEDLE BEARING (CAGE TYPE) 46030030 HIGH SPEED DRIVE GEAR (27T) 46030003 LOW SPEED DRIVE GEAR (18T) 46030004 NEEDLE BEARING (OPEN TYPE) 46030028...

  • Page 55: The Lay Shaft Assembly

    ENGINE - Assembly THE LAY SHAFT ASSEMBLY PART NAME PART NO. LAY SHFAT 46030002 CYLINDRICAL ROLLER BEARING CRBNU1007NR NEEDLE BEARING (HALF CAGE TYPE) 46030031 LOW SPEED DRIVEN GEAR (45T) 46030007 Ⅱ RETAIN C-RING RCS030 HIGH SPEED DRIVEN GEAR (36T) 46030005 WASHER 46030010 HNEEDLE BEARING (CAGE TYPE)
  • Page 56 ENGINE - Assembly THE LAY SHAFT ASSEMBLY Ⅱ Before install gear and bearing , please lubricate with 10W/40 oil 5.Install washer (7) into lay shaft , then install needle bearing (8) into lay shaft 6.Install reversal gear (9) into lay shaft , then put a washer (7) into lay shaft , shall be install reversal gear (9) of groove side into bevel gear side 7.Install retain C-ring (10) into lay shaft of groove...

  • Page 57: The Rear Driveshaft Assembly

    ENGINE - Assembly THE REAR DRIVESHAFT ASSEMBLY PART NAME PART NO. DRIVE SHAFT ASSY. 46058001 BEARING DGB6205 Ⅱ GEAR 46050023 WASHER 46050007 BOLT BFH080251094 WASHER 46050009-19 BEARING DGB6305 O-RING 46050025 Before install gear and bearing , please lubricate with 10W/40 oil 1.Press the bearing (2) into the shaft (1) thoroughly.

  • Page 58: The Cylinder Head Assembly

    ENGINE - Assembly THE CYLINDER HEAD ASSEMBLY PART NAME PART NO. CYLINDER HEAD ASSY. 40058011 VALVE STEM SEAL 40056002 Ⅱ SEALING BALL 40070031 HEXAGON SOCKET SCREW SC050121291 VALVE SPRING WASHER 40050140 Please clean up correlative parts and lubricate with 10W/40 oil 1.Knock the 2 balls (3) into cylinder head (1) 2.Paste the screw (4) with LT272 , tighten to cylinder head with 3.Install the washer (5) on the valve spring seat...
  • Page 59 ENGINE - Assembly THE CYLINDER HEAD ASSEMBLY PART NAME PART NO. VALVE (INTAKE) 40050133 VALVE (EXHAUST) 40050134 Ⅱ SPRING 40050135 SPRING CAP 40050136 COTTER 40056003 Please clean up correlative parts and lubricate with 10W/40 oil 1.Install valve spring (3) x4 on the valve spring washer 2.Install cotter (5) x2 on the spring cap (4) (4pcs) 3.Install assembled spring cap (4) on the spring , with jig press it into the valve stem seals until a clear "click"...
  • Page 60 ENGINE - Assembly THE CYLINDER HEAD ASSEMBLY PART NAME PART NO. CAM SHAFT 40070068 ROCKER ARM ASSY. (INTAKE) 40078016 ROCKER ARM ASSY. (EXHAUST) 40078017 Ⅱ SHAFT 40070063 PLATE 40070065 FLAT HEAD SCREW SCF060160883 Please clean up correlative parts and lubricate with 10W/40 oil 1.Install cam (1) through cam bore 2.Install intake rocker (2) on the cam shaft , the rocker face toward intake side.

  • Page 61: The Water Pump Assembly

    ENGINE - Assembly THE WATER PUMP ASSEMBLY PART NAME PART NO. ACCESSORY COVER 40010053 40136011 MECHANICLA SEAL Ⅱ SHAFT 40130075 PROPELLER 40130071 WASHER 40130077 40130083 40130063 GEAR (35T) 40070064 RETAIN C-RING RCS012 12.1mm Please clean up correlative parts and keep dry 1.After install mechanical seal (2) on water pump shaft (3) and check the shaft have 12.1mm between mechanical seal and water pump shaft...

  • Page 62: The Shift Drum And Fork Assembly

    ENGINE - Assembly THE SHIFT DRUM AND FORK ASSEMBLY PART NAME PART NO. SHIFT DRUM ASSY. 46078002 46070013 SHAFT (SHIFT FORK) SHIFT FORK (MAIN SHAFT) 46070001 Ⅱ SHIFT FORK (LAY SHIFT) 46070002 PARKING BREAK SHAFT 46070005 THRUST PLATE 46070022 BFH060120884 BOLT 46070015 SHIFT LOCATING SPRING...

  • Page 63: The Transmission Gear Assembly

    ENGINE - Assembly Shift locating rotor install position Ⅱ Install fork shift by plastic hammer and all parts lubricate THE TRANSMISSION GEAR ASSEMBLY Install lay shaft to cylinder block Then push it to position Ⅱ - 38...
  • Page 64 ENGINE - Assembly Install rear drive shaft to cylinder block , then push it to position Ⅱ Install main shaft and push the needle bearing to position Lubricate oil release valve and install valve、spring guide into cylinder block Then tighten the bolt ※Torque 10Nm Ⅱ...
  • Page 65 ENGINE - Assembly THE REAR IDLE GEAR ASSEMBLY PART NAME PART NO. SHAFT 46030009 O-RING 46030027 Ⅱ NEEDLE BEARING 46030032 REVERSE GEAR (27T) 46030006 WASHER 46030011 RCH020 RETAIN C-RING Please clean up correlative parts and lubricate with 10W/40 oil Ⅱ - 40...

  • Page 66: The Crankcase And Cylinder Block Assembly

    ENGINE - Assembly THE CRANKCASE AND CYLINDER BLOCK ASSEMBLY PART NAME PART NO. CRANKCASE 40018014 MAIN BEARING (BLACK) 888.4001.607 Ⅱ MAIN BEARING (NO COLOR) 888.4001.608 MAIN BEARING (GREEN) 888.4001.609 No groove bearing for low crankcase The crankshaft mark position , have 3 marks EX：A 2 B ALT side...
  • Page 67 ENGINE - Assembly The cylinder block mark CVT side position , have 3 number EX：1 A 1 Ⅱ ALT side CYLINDER BLOCK CRANKCASE N：No color G：Green B：Black Choose bearing color and install to crankcase EX：cylinder block mark is 1 A 1 crankcase mark is A 2 B so we choose ALT side bearing color is No color (1&A)
  • Page 68 ENGINE - Assembly THE CRANKCASE AND CYLINDER BLOCK ASSEMBLY PART NAME PART NO. CYLINDER BLOCK 40018014 MAIN BEARING (BLACK) 888.4001.613 Ⅱ MAIN BEARING (NO COLOR) 888.4001.614 MAIN BEARING (GREEN) 888.4001.615 CONROD ASSY. 40098013 BEARING (BLACK) 40096025 BEARING (YELLOW) 40096024 BEARING (BLUE) 40096023 Groove bearing for cylinder block...
  • Page 69 ENGINE - Assembly The connecting rod mark position EX：A Ⅱ CONNECTING ROD CRANKCASE Y：Yellow BL：Blue B：Black Choose bearing color and install to connecting rod EX：connecting rod mark is crankcase mark is A 2 B so we choose the bearing color is blue (A&2) A 2 B ※up and low bearing install the same color Ⅱ...

  • Page 70: The Bearing And Crankshaft Assembly

    ENGINE - Assembly THE BEARING AND CRANKSHAFT ASSEMBLY Lubricate all bearing Ⅱ Install crankshaft Lubricate all rotation position Before tighten the two bolts , be lubricate connecting rod bolts ※Torque 20Nm + 90° + 90° (tighten the two bolts equally) Ⅱ...
  • Page 71 ENGINE - Assembly Lay the Case Assembly Glue on cylinder block according figure A and glue diameter about 1mm Ⅱ Keep away the main gallery Figure A Lay the glue diameter about 1mm Glue Path Main Gallery Install crankcase to cylinder block Ⅱ...
  • Page 72 ENGINE - Assembly Lubricate the bolt and washer, then tighten it ※Torque 35Nm + 90° (tighten the bolts equally) Ⅱ Install the cylinder block bolts The tighten torque 20Nm Install shift drum anti-thrust plate ※Torque 10Nm Ⅱ - 47...
  • Page 73 ENGINE - Assembly Lay the Case Assembly Glue on shift drum cover ※Glue diameter about 1mm Ⅱ Install the shift drum cover ※Torque 10Nm Reverse the engine , then tighten the cylinder bolt ※Torque 20Nm Install the main circuit ※Torque 20Nm Ⅱ...
  • Page 74 ENGINE - Assembly Lubricate the balancer Ⅱ Install balancer gear , then check crankshaft gear mark to balancer half of gear position Lay the Bolt Glue on the bolt , then install the balancer plate ※Torque 20Nm Lubricate the oil pump and rotor Ⅱ...
  • Page 75 ENGINE - Assembly ※ The bolts torque 10Nm Ⅱ Install the oil pump gear , then clip the E-clip Install the water pump idle gear , then tighten the bolt ※Torque 10Nm Install the chain guide ※Torque 10Nm Ⅱ - 50...
  • Page 76 ENGINE - Assembly Install the chain guide into cylinder block and notice the lock position Ⅱ Install the cylinder head gasket and lock pins Install the cylinder head Lubricate the cylinder head bolts and washer Ⅱ - 51...
  • Page 77 ENGINE - Assembly Tighten the cylinder bolts ※Torque 35Nm + 90° + 90° (tighten the four bolts equally) Ⅱ ※The M6 bolts torque 10Nm Lubricate cam shaft Install the cam shaft into cylinder head Lubricate the rock arms and shafts , then install into cylinder head Ⅱ...
  • Page 78 ENGINE - Assembly the mark Check the crankshaft gear mark and balancer mark Ⅱ Between balancer mark to five gears crankcase mark line have five gears crankshaft sprocket mark Crank sprocket mark must correct to blue mark of chain When crank sprocket mark correct , then check cylinder head sprocket have six pieces counter from cylinder head...
  • Page 79 ENGINE - Assembly Install the tensioner and tighten the bolts , then put the spring and screw the cover ※The bolts torque 10Nm Ⅱ ※The cover torque 10Nm Install discompressor Lay Bolt Glue LT272 on discompressor bolt , then screw it ※Torque 5Nm Install the thermostat ※Torque 10Nm...
  • Page 80 ENGINE - Assembly Install the cylinder head cover , then tighten the bolts ※Torque 10Nm Ⅱ Install the spark plug ※Torque 10~12Nm Lubricate the spin nose , then install into cylinder block Install the fly wheel assy. and ALT rotor , then tighten the nut ※Torque 200Nm Ⅱ...
  • Page 81 ENGINE - Assembly Check 4WD gear groove correct to low crankcase groove Ⅱ Lay the Case Assembly Glue on accessary cover ※Glue diameter about 1mm Install accessary cover , then tighten the bolts ※Torque 10Nm Install the drive shaft seal cover , then tighten the bolts ※Torque 10Nm Ⅱ...
  • Page 82 ENGINE - Assembly Lay the Bolt Glue on drive yoke bolt , then install drive yoke Ⅱ ※Torque 20Nm Lay the Case Assembly Glue on balancer cover ※Glue diameter about 1mm Install balancer cover , then tighten the bolts ※Torque 10Nm Lay the Case Assembly Glue on oil sump cover ※Glue diameter about 2mm...
  • Page 83 ENGINE - Assembly Install oil sump , then tighten the bolts Ⅱ ※Torque 10Nm Install the CVT drive pulley , then tighten the bolt ※Torque 120Nm Install the driven pulley , then tighten the bolt ※Torque 45Nm Tighten the Belt Removal Tool to end to open the driven pulley , then install the belt Ⅱ...
  • Page 84 ENGINE - Assembly Then rotate driven pulley check the belt on position ※The driven pulley can be free rotate Ⅱ Install the CVT cover , then tighten the bolts ※Torque 10Nm Install the rewind starter, Then tighten the bolts ※Torque 10Nm Off Road Type On Road Type The engine assembly complete...
  • Page 85 CHASSIS SEAT DISMANTLE......... AIR CLEANER COVER DISMANTLE…. FRONT DECK DISMANTLE……………. METER DISMANTLE…………………….. FRONT COVER DISMANTLE………….. LHS COVER DISMANTLE……………… RHS COVER DISMANTLE……………… Ⅲ HEAD LAMP DISMANTLE……………… UPPER MUDFLAP DISMANTLE………. PROTECTOR DISMANTLE…………….. FOOT REST PEDAL DISMANTLE…….. FRONT FENDER DISMANTLE………… INNER MUDFLAP DISMANTLE………... REAR LAMP DISMANTLE………………...
  • Page 86 CHASSIS SEAT DISMANTLE Use the key to open the seat lock Remove the seat Ⅲ The seat The tool bag under the seat Ⅲ...
  • Page 87 CHASSIS AIR CLEANER COVER DISMANTLE Dismantle the rivets, and pull out the air cleaner cover Ⅲ Dismantle the connector of main switch Air cleaner cover assembly Ⅲ...
  • Page 88 CHASSIS AIR CLEANER COVER DISMANTLE Dismantle the cover, then turn it over Press the flange, Ⅲ then remove the main switch The main switch Ⅲ...
  • Page 89 CHASSIS FRONT DECK DISMANTLE Dismantle the rivets of front deck Pull out the front deck Ⅲ The front deck The front box Ⅲ...
  • Page 90 CHASSIS METER DISMANTLE Dismantle the bolts of bracket ※Torque = 10 Nm Push the pin to dismantle the Ⅲ connector Be careful about the orange O-ring of the wire harness connector The meter Ⅲ...
  • Page 91 CHASSIS METER DISMANTLE Dismantle the meter, then turn it over Dismantle the screws, Ⅲ then remove the cover The meter cover Ⅲ...
  • Page 92 CHASSIS FRONT COVER DISMANTLE Release the tenon from the brake oil reservoir Pull out the brake oil reservoir Ⅲ Dismantle the bolt ※Torque = 10 Nm Dismantle the screws from two sides of the cover Ⅲ...
  • Page 93 CHASSIS FRONT COVER DISMANTLE Dismantle the screws under the front cover from the two sides of the cover Pull out the front cover Ⅲ Dismantle the connector of power supply The front cover Ⅲ...
  • Page 94 CHASSIS FRONT COVER DISMANTLE Dismantle the front cover, then turn it over Turn counterclockwise to Ⅲ dismantle the power supply The power supply Ⅲ...
  • Page 95 CHASSIS LHS COVER DISMANTLE Dismantle the rivets & screw, then pull out the panel The mudguard panel, LH Ⅲ Dismantle the bolt & rivet, then pull out the left side cover The side panel, LH Ⅲ - 10...
  • Page 96 CHASSIS LHS COVER DISMANTLE Dismantle the screws Release the tenon of left cover Ⅲ Then pull out the cover The side cover, LH Ⅲ - 11...
  • Page 97 CHASSIS LHS COVER DISMANTLE Dismantle the bolts, then remove the cover The engine cover, LH Ⅲ Ⅲ - 12...
  • Page 98 CHASSIS RHS COVER DISMANTLE Dismantle the rivet Ⅲ Release the tenon, then pull out the cover The engine cover, RH Ⅲ - 13...
  • Page 99 CHASSIS RHS COVER DISMANTLE Dismantle the rivets and screw, then remove the panel Ⅲ The mudguard panel, RH Dismantle the rivets, then remove the cover The upper engine cover, RH Ⅲ - 14...
  • Page 100 CHASSIS RHS COVER DISMANTLE Dismantle the bolt and rivet, then remove the panel Ⅲ The panel Dismantle the screws Push the revolve lever from the cover inside Ⅲ - 15...
  • Page 101 CHASSIS RHS COVER DISMANTLE Dismantle the center bolt from the revolve lever ※Torque = 10 Nm Ⅲ Revolve lever alignment Opposite side of revolve lever The revolve lever and button Ⅲ - 16...
  • Page 102 CHASSIS RHS COVER DISMANTLE Screw contraclockwise the shift bar (2/4WD) of the rod The shift bar (2/4WD) Ⅲ Release the tenon, then pull out the cover The side cover, RH Ⅲ - 17...
  • Page 103 CHASSIS HEAD LAMP DISMANTLE Dismantle the bolts ※Torque = 10 Nm Dismantle the screws from the Ⅲ two sides of the cover Dismantle the screws from the two side of the cover Dismantle the head lamp connector Ⅲ - 18...
  • Page 104 CHASSIS HEAD LAMP DISMANTLE The front nose Turn it over Ⅲ Press the tenon, then remove the grille The grille Ⅲ - 19...
  • Page 105 CHASSIS HEAD LAMP DISMANTLE Dismantle the screws from the back of the lamp Dismantle the screw from Ⅲ the front of the lamp The head lamp assy The head lamp angle adjustment bolt ※Upper = clockwise Lower = counterclockwise Ⅲ - 20...
  • Page 106 CHASSIS UPPER MUDFLAP DISMANTLE Dismantle the bolt ※Torque = 10 Nm Pull out the tenon, Ⅲ then remove the mudflap The upper mudflap, R Ⅲ - 21...
  • Page 107 CHASSIS UPPER MUDFLAP DISMANTLE Dismantle the bolt ※Torque = 10 Nm Pull out the tenon, Ⅲ then remove the mudflap Upper mudflap, L Ⅲ - 22...
  • Page 108 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts, Then remove the cover ※Torque = 10 Nm The protector cover, RHF Ⅲ Dismantle the bolts, then remove the cover The protector cover, LHF Ⅲ - 23...
  • Page 109 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts ※Torque = 10 Nm Dismantle the bottom bolt, Ⅲ then remove the cover ※Torque = 10 Nm The protector cover, RHR Ⅲ - 24...
  • Page 110 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts ※Torque = 10 Nm Dismantle the bottom bolt, Ⅲ then remove the cover ※Torque = 10 Nm The protector cover, LHR Ⅲ - 25...
  • Page 111 CHASSIS PROTECTOR DISMANTLE Dismantle the bolts, Then remove the cover ※Torque = 10 Nm The front protector cover Ⅲ Dismantle the bolts, then remove the cover ※Torque = 10 Nm The engine protector cover Ⅲ - 26...
  • Page 112 CHASSIS PROTECTOR DISMANTLE Dismantle the rear bolts ※Torque = 10 Nm Dismantle the bolts from two Ⅲ sides of the cover ※Torque = 10 Nm The rear protector cover Ⅲ - 27...
  • Page 113 CHASSIS FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the front Dismantle the rivets and screw Ⅲ of the rear Dismantle the bottom bolts, Then remove the right foot rest ※Torque = 10 Nm The right foot rest Ⅲ...
  • Page 114 CHASSIS FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the front Ⅲ Dismantle the rivets and screw of the rear Dismantle the bottom bolts, then remove the left foot rest ※Torque = 10 Nm The left foot rest Ⅲ...
  • Page 115 CHASSIS FRONT FENDER DISMANTLE Pull out the tenon Dismantle the upper bolt, Ⅲ then remove the fender ※Torque = 10 Nm The front fender, RH Ⅲ - 30...
  • Page 116 CHASSIS FRONT FENDER DISMANTLE Pull out the tenon Dismantle the upper bolt, Ⅲ then remove the fender ※Torque = 10 Nm The front fender, LH Ⅲ - 31...
  • Page 117 CHASSIS INNER MUDFLAP DISMANTLE Dismantle the bolt ※Torque = 10 Nm Pull out the tenon, Ⅲ then remove the mudflap The inner mudflap, RH Ⅲ - 32...
  • Page 118 CHASSIS INNER MUDFLAP DISMANTLE The inner mudflap, RH Dismantle the screws, Ⅲ then remove the ventilator The ventilator, RH Ⅲ - 33...
  • Page 119 CHASSIS INNER MUDFLAP DISMANTLE Dismantle the bolt ※Torque = 10 Nm Pull out the tenon, Ⅲ then remove the mudflap The inner mudflap, LH Ⅲ - 34...
  • Page 120 CHASSIS INNER MUDFLAP DISMANTLE The inner mudflap, LH Dismantle the screws, Ⅲ then remove the ventilator The ventilator, LH Ⅲ - 35...
  • Page 121 CHASSIS REAR LAMP DISMANTLE Dismantle the rivet Dismantle the bottom bolts of Ⅲ the bracket Dismantle the connectors The rear lamp housing, RH Ⅲ - 36...
  • Page 122 CHASSIS REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the bolts, Ⅲ then remove the cover The rear lamp cover, RH The rear lamp, RH Ⅲ - 37...
  • Page 123 CHASSIS REAR LAMP DISMANTLE Dismantle the screw Dismantle the bottom bolts of Ⅲ the bracket Dismantle the connectors The rear lamp housing, LH Ⅲ - 38...
  • Page 124 CHASSIS REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the screws, Ⅲ then remove the cover The rear lamp cover, LH The rear lamp, LH Ⅲ - 39...
  • Page 125 CHASSIS REAR COVER DISMANTLE Dismantle the bolts, then remove the hooks ※Torque = 10 Nm The hook, carrier Ⅲ The hook alignment Dismantle the bottom screws from two sides of rear cover Ⅲ - 40...
  • Page 126 CHASSIS REAR COVER DISMANTLE Dismantle the upper bolts ※Torque = 10 Nm Screw out the fuel cap Ⅲ Avoid any dirt, Cover the fuel tank The fuel cap Ⅲ - 41...
  • Page 127 CHASSIS REAR COVER DISMANTLE Pull up the rear cover Ⅲ Avoid any dirt, reinstall the fuel cap The rear cover Ⅲ - 42...
  • Page 128 CHASSIS REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Ⅲ Push the tenon, then remove the cover The rear cover, RH Ⅲ - 43...
  • Page 129 CHASSIS REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Ⅲ Push the tenon, then remove the cover The rear cover, LH Ⅲ - 44...
  • Page 130 CHASSIS REAR COVER DISMANTLE Dismantle the rear cover The mesh Ⅲ Turn over the rear cover, then push the tenon The meshes (RHS & LHS) Ⅲ - 45...
  • Page 131 CHASSIS REAR COVER DISMANTLE Dismantle the rear cover The slipproof on the rear cover Ⅲ Turn over the rear cover, then push the tenon to remove the slipproof The slipproof pad Ⅲ - 46...
  • Page 132 CHASSIS TAIL LAMP ASSEMBLY DISMANTLE Pull out the wire, then remove the seat wire Dismantle the bottom bolt Ⅲ from two sides of bracket Dismantle the connector, then remove the tail lamp The tail lamp assy. Ⅲ - 47...
  • Page 133 CHASSIS TAIL LAMP ASSEMBLY DISMANTLE Turn over the tail lamp Pull out the plate of lock Ⅲ When reinstall the wire, make sure the wire into the position The lock Ⅲ - 48...
  • Page 134 CHASSIS TAIL LAMP ASSEMBLY DISMANTLE Turn over the lamp Dismantle the nuts Ⅲ ※Torque = 10 Nm The tail lamp Ⅲ - 49...
  • Page 135 CHASSIS ELECTRICAL HOUSING DISMANTLE Dismantle the negative wire, to protect the electrical parts ※Torque = 10 Nm Dismantle the connector Ⅲ After dismantle all connector Dismantle the nuts, then remove the wire of start relay ※Torque = 10 Nm Ⅲ - 50...
  • Page 136 CHASSIS ELECTRICAL HOUSING DISMANTLE Dismantle the screws of fuse Remove the small wire harness Ⅲ Lift the rear of electrical housing, to remove other wire harness The electrical housing Ⅲ - 51...
  • Page 137 CHASSIS THROTTLE BODY DISMANTLE Dismantle the bolts of air cleaner ※Torque = 10 Nm Dismantle the connector of Ⅲ sensor Release the screw of clamp Release the screw of clip, then remove the hose and pull out the air clenaer Ⅲ...
  • Page 138 CHASSIS THROTTLE BODY DISMANTLE Pull out the air cleaner The air cleaner Ⅲ Ⅲ - 53...
  • Page 139 CHASSIS THROTTLE BODY DISMANTLE Dismantle the connector of IACV and TPS Dismantle the bolts of throttle Ⅲ cable cover Be careful about the O-ring of the throttle cable cover The throttle cable cover Ⅲ - 54...
  • Page 140 CHASSIS THROTTLE BODY DISMANTLE Release the nuts to loosen the throttle cable, then remove the throttle cable Release the screw, then Ⅲ remove the throttle Avoid any dirt, Cover the intake pipe The throttle Ⅲ - 55...
  • Page 141 CHASSIS MUFFLER DISMANTLE Release the bolt of clip ※Torque = 15 Nm Dismantle the bolts of muffler Ⅲ ※Torque = 25 Nm Then remove the muffler The muffler Ⅲ - 56...
  • Page 142 CHASSIS MUFFLER DISMANTLE Check the gasket of muffler The gasket Ⅲ Dismantle the connector of O2 sensor Dismantle the nuts of exhaust pipe ※Torque = 20 Nm Ⅲ - 57...
  • Page 143 CHASSIS MUFFLER DISMANTLE Then remove the exhaust pipe The exhaust pipe Ⅲ Ⅲ - 58...
  • Page 144 CHASSIS FUEL PUMP DISMANTLE Use Spanner-Fuel Retainer to dismantle the retainer Then turn counterclockwise Ⅲ Pull out the fuel pump half way Then turn counterclockwise Ⅲ - 59...
  • Page 145 CHASSIS FUEL PUMP DISMANTLE Pull out the fuel pump Ⅲ Turn counterclockwise, then take out the fuel gauge carefully Be careful about the O-ring of the fuel pump The fuel pump Ⅲ - 60...
  • Page 146 CHASSIS FUEL PUMP ASSEMBLY Install the O-ring, then use oil to lubricate Put in the fuel gage first Ⅲ Then turn counterclockwise Put in the fuel pump half way Ⅲ - 61...
  • Page 147 CHASSIS FUEL PUMP ASSEMBLY Turn counterclockwise And pull out the fuel pump Ⅲ half way Then put in the fuel pump to Turn clockwise Ⅲ - 62...
  • Page 148 CHASSIS FUEL PUMP ASSEMBLY Then install the retainer Ⅲ Make sure the mark of fuel tank match the output pipe of fuel pump Use the special tool to tighten the retainer ※Torque = 25 Nm Ⅲ - 63...
  • Page 149 SUSPENSION / TRANSMISSION DISMANTLE FRONT WHEEL DISMANTLE....FRONT CALIPER DISMANTLE………... FRONT HUB DISMANTLE………………. FRONT DISK & COVER DISMANTLE..FRONT KNUCKLE DISMANTLE…….…. FRONT ABSORBER & UPPER ARM DISMANTLE……. FRONT LOWER ARM DISMANTLE……. Ⅳ FRONT DIFFERENTIAL DISMANTLE…. REAR WHEEL DISMANTLE..…………... REAR CALIPER DISMANTLE………….. REAR HUB DISMANTLE………………...
  • Page 150 SUSPENSION / TRANSMISSION LHF & RHF WHEEL DISMANTLE Dismantle the nuts of wheel, then remove the wheel ※Torque 60Nm The wheel Ⅳ / Off Road / Remove the wheel cap / On Road / Push the cap from the back of wheel The wheel cap ON ROAD...
  • Page 151 SUSPENSION / TRANSMISSION LHF & RHF CALIPER DISMANTLE Dismantle the upper bolt of caliper ※Torque 25Nm Dismantle the lower bolt of caliper, then remove the caliper Ⅳ ※Torque 25Nm Avoid any knock, suspend the caliper with cloth Avoid any knock, suspend the caliper with cloth Ⅳ...
  • Page 152 SUSPENSION / TRANSMISSION LHF & RHF HUB DISMANTLE Dismantle the pin of nut Dismantle the nut of hub by 1.Reinstall the caliper, then use brake to hold the Ⅳ ※Torque 100Nm Dismantle the nut of hub by 2.Reinstall the nuts of wheel, then use big screw-driver to hold the hub ※Torque 100Nm...
  • Page 153 SUSPENSION / TRANSMISSION LHF & RHF HUB DISMANTLE NUT SIDE The flange of washer is lower, when install the washer must in the right direction HUB SIDE HUB SIDE The flange of washer is lower, when install the washer must in the right direction Ⅳ...
  • Page 154 SUSPENSION / TRANSMISSION LHF & RHF DISK & COVER DISMANTLE Turn the hub over dismantle the bolts of disk, then remove the disk The disk Ⅳ ※Torque 20Nm Dismantle the bolts of cover, then remove the cover The cover ※Torque 10Nm Ⅳ...
  • Page 155 SUSPENSION / TRANSMISSION LHF & RHF KNUCKLE DISMANTLE Turn the knuckle Then dismantle the pin and nut of knuckle Ⅳ ※Torque 25Nm The pin、washer and nut WASHER Use the tool to dismantle the ball joint of tie rod Ⅳ - 6...
  • Page 156 SUSPENSION / TRANSMISSION LHF & RHF KNUCKLE DISMANTLE Dismantle the lower pin and nut of knuckle ※Torque 50Nm The pin and nut Ⅳ Use the tool to dismantle the ball joint of lower arm, then remove the knuckle Ⅳ - 7...
  • Page 157 SUSPENSION / TRANSMISSION LHF & RHF KNUCKLE DISMANTLE Dismantle the upper pin and nut of knuckle ※Torque 30Nm The pin、washer and nut Ⅳ WASHER Use the tool to dismantle the ball joint of upper arm The knuckle Ⅳ - 8...
  • Page 158 SUSPENSION / TRANSMISSION LHF & RHF ABSORBER & UPPER ARM DISMANTLE Dismantle the nuts and bolts of absorber, then remove the absorber ※Torque 70Nm The absorber Ⅳ Dismantle the nut and bolt of arm, then remove the arm ※Torque 70Nm The upper arm Ⅳ...
  • Page 159 SUSPENSION / TRANSMISSION LHF & RHF LOWER ARM DISMANTLE Dismantle the nuts and bolts of arm, then remove the arm ※Torque 70Nm The lower arm Ⅳ Ⅳ - 10...
  • Page 160 SUSPENSION / TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Dismantle the bolt of differential to drain the gear oil The bolt and washer Ⅳ ※Change new washer By check the gear oil to know the stative of differential Then reinstall the bolt Ⅳ - 11...
  • Page 161 SUSPENSION / TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Pull out the CV-Joint horizontally Or use the screw-driver to open the CV-Joint Ⅳ The CV-Joint Avoid any dirty, cover the differential Ⅳ - 12...
  • Page 162 SUSPENSION / TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Dismantle the bolts of shaft 1.By use the screw-driver to lock the shaft ※Torque 25Nm Dismantle the bolts of shaft 2.By shift the gear position to engage reverse gear and 4 wheel driver Ⅳ Then pull out the shaft The propeller shaft Ⅳ...
  • Page 163 SUSPENSION / TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Dismantle the connector of differential Dismantle the nuts and bolts of differential Ⅳ ※Torque 40Nm Lift the differential Turn the counterclockwise side Ⅳ - 14...
  • Page 164 SUSPENSION / TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Remove the differential The differential Ⅳ Ⅳ - 15...
  • Page 165 SUSPENSION / TRANSMISSION LHR & RHR WHEEL DISMANTLE Dismantle the bolts of wheel, then remove the wheel ※Torque 60Nm The wheel Ⅳ / Off Road / Remove the wheel cap / On Road / Push the cap from the back of wheel The wheel cap ON ROAD...
  • Page 166 SUSPENSION / TRANSMISSION LHR & RHR CALIPER DISMANTLE Dismantle the upper bolt of caliper ※Torque 25Nm Dismantle the lower bolt of caliper, then remove the caliper Ⅳ ※Torque 25Nm Avoid any knock, suspend the caliper with cloth Avoid any knock, suspend the caliper with cloth Ⅳ...
  • Page 167 SUSPENSION / TRANSMISSION LHR & RHR HUB DISMANTLE Dismantle the pin of nut Dismantle the nut of hub by 1.Reinstall the caliper, then use brake to hold the Ⅳ ※Torque 100Nm Dismantle the nut of hub by 2.Reinstall the nuts of wheel, then use big screw-driver to hold the hub ※Torque 100Nm...
  • Page 168 SUSPENSION / TRANSMISSION LHR & RHR HUB DISMANTLE NUT SIDE The flange of washer is lower, when install the washer must in the right direction HUB SIDE HUB SIDE The flange of washer is lower, when install the washer must in the right direction Ⅳ...
  • Page 169 SUSPENSION / TRANSMISSION LHR & RHR DISK & KNUCKLE DISMANTLE Turn the hub over and dismantle the bolts of disk, then remove the disk ※Torque 20Nm The disk Ⅳ Dismantle the nuts and bolts of knuckle, then remove the knuckle ※Torque 70Nm The knuckle Ⅳ...
  • Page 170 SUSPENSION / TRANSMISSION LHR & RHR ABSORBER & UPPER ARM DISMANTLE Dismantle the nuts and bolts of absorber, then remove the absorber ※Torque 70Nm The absorber Ⅳ Dismantle the nut and bolt of arm, then remove the arm ※Torque 70Nm The upper arm Ⅳ...
  • Page 171 SUSPENSION / TRANSMISSION LHR & RHR LOWER ARM DISMANTLE Dismantle the nuts and bolts of arm, then remove the arm ※Torque 70Nm Use the open wrench to lock the ball joint, then dismantle the nut Ⅳ The lower arm Ⅳ - 22...
  • Page 172 SUSPENSION / TRANSMISSION REAR STABILIZER BAR DISMANTLE Dismantle the bolts of bar from two sides ※Torque 30Nm The stabilizer bar Ⅳ Dismantle the nut of ball joint ※Torque 70Nm The ball joint Ⅳ - 23...
  • Page 173 SUSPENSION / TRANSMISSION REAR GEAR BOX DISMANTLE Dismantle the bolt of gear box to drain the gear oil The bolt and washer Ⅳ ※Change new washer By check the gear oil to know the stative of gear box Then reinstall the bolt Ⅳ...
  • Page 174 SUSPENSION / TRANSMISSION REAR GEAR BOX DISMANTLE Pull out the CV-Joint horizontally Or use the screw-driver to open the CV-Joint Ⅳ The CV-Joint Avoid any dirty, cover the differential Ⅳ - 25...
  • Page 175 SUSPENSION / TRANSMISSION REAR GEAR BOX DISMANTLE Dismantle the bolts of shaft 1.By use the screw-driver to lock the shaft ※Torque 25Nm Dismantle the bolts of shaft 2.By shift the gear position to engage reverse gear Ⅳ Then pull out the shaft The propeller shaft Ⅳ...
  • Page 176 SUSPENSION / TRANSMISSION REAR GEAR BOX DISMANTLE Dismantle the upper bolt of gear box ※Torque 25Nm Dismantle the lower nuts and bolts of gear box Ⅳ ※Torque 40Nm Lift the gear box Turn the contraclockwise side Ⅳ - 27...
  • Page 177 SUSPENSION / TRANSMISSION REAR GEAR BOX DISMANTLE Then remove the gear box The gear box Ⅳ Ⅳ - 28...
  • Page 178 ELECTRICAL CONNECTOR……………………………. WIRE CIRCUIT…………………………… ECU PIN…………………………………… LAMP PIN………………………………… DIFF PIN………………………………….. OTHER PIN………………………………. ADJUSTMENT FOR TIRE CIRCUMFERENCE………. INJECTION PARTS POSITION………… ELECTRIC PARTS POSITION…………. Ⅴ GROUND WIRE POSITION……………...
  • Page 179 ELECTRICAL-Connector Ⅴ Ⅴ...
  • Page 180 ELECTRICAL-Wire circuit Ⅴ Ⅴ...
  • Page 181 ELECTRICAL-ECU pin Ⅴ Ⅴ...
  • Page 182 ELECTRICAL-Lamp pin Ⅴ Ⅴ...
  • Page 183 ELECTRICAL-DIFF pin Ⅴ Ⅴ...
  • Page 184 ELECTRICAL-Other pin Ⅴ Ⅴ...
  • Page 185 Adjustment Tire Circumference ADJUSTMENT FOR TIRE CIRCUMFERENCE Turn off the main switch Dismantle the connector of speedometer Turn on the main switch Ⅴ Press the two buttons at the same time Ⅴ...
  • Page 186 Adjustment Tire Circumference ADJUSTMENT FOR TIRE CIRCUMFERENCE Install the connector of speedometer Release the two button at the same time while install the connector of speedometer, then show the three-figure number ( The Tire Circumference ) A：shift the flashing position Ⅴ...
  • Page 187 Injection Parts Position (1) THROTTLE BODY INJECTOR Ⅴ ECU ( ECM ) O2 SENSOR Ⅴ...
  • Page 188 Injection Parts Position (2) SPARK PLUG IGNITION COIL Ⅴ FUEL CUT SENSOR WATER TEMP. SENSOR Ⅴ - 10...
  • Page 189 Electric Parts Position OIL PRESS. SENSOR HORN Ⅴ FUEL PUMP RECTIFIER Ⅴ - 11...
  • Page 190 Ground Wire Position Maintenance Step 1.Dismantle the wire 2.Use the sand-paper to clean the position 3.Use the sand-paper to clean the ground wire 4.Lay the grease on the position and wire Ⅴ Ⅴ - 12...
  • Page 191 MAINTENANCE Regular Maintenance Table………... Engine Oil Type………………………. Differential Oil Type…………………. Coolant Type…………………………. Engine Torque Table………………... Chassis Torque check……………… Spark Plug Exchange………………. Oil Filter Exchange………………….. Air Filter Exchange………………….. Ⅵ...
  • Page 192 Regular Maintenance table 300km 1500km 3000km 6000km ITEM ENGINE Engine Oil Engine Oil Filter Valve Adjustment Coolant Water CVT Drive Belt FUEL Air Filter Throttle Body ELECTRICAL Spark plug Battery Control Switches Lights DRIVE Front Propeller L / I L / I L / I Rear Propeller L / I...
  • Page 193 Engine Oil Type The Engine Original Oil Type：10w / 40 ※The viscosity of oil should follow the temperature range of your area according to below chart. ※Recommended engine oil classification API service SJ type or higher Ⅵ Total Engine Oil Capacity (with filter)：3500cc Ⅵ...
  • Page 194 Engine Oil Type Engine Oil Drain Bolt Ⅵ Engine Oil Fill & Dipstick ※The Engine Oil Drain Bolt Torque = 20 Nm ※Put The Vehicle On The Flatland. Make Sure The Oil Level Between Max and Min Level Of Dipstick, While Engine Is Cold. Ⅵ...
  • Page 195 Differential Oil Type The Front and Rear Differential Gear Original Oil Type：PENNZOIL 80w / 90 ※The approved oil： PENNZOIL 4096 80w / 90 SAE GRADE 80W-90 API SERVICE GL-5 GRAVITY,API VISCOSITY@40℃, cSt VISCOSITY@100℃, cSt 14.5 VISCOSITY INDEX POUR POINT, ℃ FLASH POINT, ℃...
  • Page 196 Differential Oil Type Differential Oil Drain Bolt Ⅵ Differential Oil Fill Plug ※The Differential Oil Drain Bolt Torque = 40 Nm Ⅵ - 5...
  • Page 197 Coolant Type THE RADIATOR PART NAME PART NO. RADIATOR ASSY. 60046001 BOLT BFH060200884 CAP ASSY. 60046002 BOLT BFH060120882 HOSE, RADIATOR OUTLET 60040005 CLIP CC02003209 HOSE, RADIATOR INLET 60040004 CLIP CC02504009 Ⅵ Connect to Thermostat Cover Connect to Water Pump Cover Ⅵ...
  • Page 198 Coolant Type The Coolant type：Ratio 50:50 (50%water / 50%antifreeze) Required engine coolant solution capacity Total capacity 3550c.c. Engine Coolant 1775c.c. Water 1775c.c. Reservoir Tank Level Ⅵ Radiator Cap Reservoir Tank Cap ※Make Sure The Coolant Between Max And Min Level Of Reservoir Tank, While Engine is Cold. Ⅵ...
  • Page 199 Engine Torque Table ITEM POSITION TORQUE Ⅱ- 28 Chain Sprocket 250Nm Ⅱ- 31 Lay Shaft Flat Head Ⅱ- 32 Rear Drive Shaft 20Nm Ⅱ- 39 Oil Release Valve 10Nm Ⅱ- 45 20Nm + 90°+ 90° Ⅱ- 47 35Nm + 90 ° Engine Block (M10) Ⅱ- 47 Engine Block (M8)
  • Page 200 Chassis Torque Check TORQUE ITEM 70 N-m 1.LHF Suspension Bolts x 2 25 N-m 2.LHF Caliper Bolts x 2 60 N-m 3.LHF Wheel Rim Nuts x 4 40 N-m 4.Front Differential Bolts x 2 45 N-m 5.LHS Engine Bolts x 2 40 N-m Ⅵ...
  • Page 201 Chassis Torque Check TORQUE ITEM 70 N-m 1.RHR Suspension Bolts x 2 25 N-m 2.RHR Caliper Bolts x 2 60 N-m 3.RHR Wheel Rim Nuts x 4 4.RHS Footrest Bolts x 4 40 N-m 5.RHS Engine Bolts x 2 45 N-m Ⅵ...
  • Page 202 MAINTENANCE-Spark Plug SPARK PLUG EXCHANGE Dismantle the screws and bolt of LHS upper mudflap Then remove the LHS upper mudflap Pull out the spark plug hat Ⅵ Clean up around the spark plug, then dismantle the spark plug Ⅵ - 11...
  • Page 203 MAINTENANCE-Spark Plug SPARK PLUG EXCHANGE The spark plug ※Type：Champion PRG7C ※ Gap：0.6~0.7mm Assemble The spark plug ※Torque 12N-m Ⅵ Ⅵ - 12...
  • Page 204 MAINTENANCE-Oil Filter OIL FILTER EXCHANGE From the LHS of vehicle, after dismantle the LHS engine cover Or from the RHS of vehicle Clean up around the oil filter cover to avoid any dirt, then dismantle the cover Ⅵ Pull out the oil filter, then clean the old oil inside Ⅵ...
  • Page 205 MAINTENANCE-Oil Filter OIL FILTER EXCHANGE Assemble the new oil filter, use some oil lubricate the front rubber of filter Push the oil filter to end, then add some oil to the filter Before assembly the cover, lubricate the O-ring Ⅵ Tighten the cover to end Ⅵ...
  • Page 206 MAINTENANCE-Air Filter AIR FILTER EXCHANGE Dismantle 1.The air cleaner cover 2.The front deck 3.The front cover Push the revolve lever from the cover inside Dismantle the center bolt from the revolve lever Ⅵ Screw counterclockwise the shift bar (2/4WD) of the rod Ⅵ...
  • Page 207 MAINTENANCE-Air Filter AIR FILTER EXCHANGE Release the RHS tenon Release the LHS tenon Dismantle the LHS bolt of seat holder Ⅵ Dismantle the RHS bolts of seat holder Ⅵ - 16...
  • Page 208 MAINTENANCE-Air Filter AIR FILTER EXCHANGE The seat holder Release the clips of cover, then remove the air cleaner cover Pull out to open the clip Ⅵ Change the air filter Ⅵ - 17...
  • Page 209 SPECIAL TOOLS TOOL PHOTO TOOL NUMBER & NAME 991000001 EMS DIAGNOSTIC KIT ASSY. ※Include：991000002 991000003 991000004 991000002 EMS DIAGNOSTIC SOFTWARE 991000003 EMS DIAGNOSTIC CABLE 991000004 EMS DIAGNOSTIC USB ADAPTOR Ⅶ Ⅶ...
  • Page 210 SPECIAL TOOLS TOOL PHOTO TOOL NUMBER & NAME 991000005 REMOVER – ALTERNATOR ROTOR ASSY. ※Include：991000006 991000007 991000008 991000006 CRANKSHAFT PROTECTOR 991000007 HOLDER – ALTERNATOR REMOVER 991000008 PULLER – CVT & ALTERNATOR Ⅶ M12＊1.5 Ⅶ...
  • Page 211 SPECIAL TOOLS TOOL PHOTO TOOL NUMBER & NAME 992000001 SPANNER – FUEL RETAINER 992000002 REWIND STARTER STOPPER 888.4002.653.B1 CASE ASSEMBLY GLUE ( 1207F ) Brand：ThreeBond Type：1207F (Liquid Gasket Black Silicone Type) Volume：333ml 888.4002.670.B BOLT GLUE ( T272 ) Ⅶ Brand：Loctie Type：272 Volume：250ml Ⅶ...
  • Page 212 http://www.cectekpowersports.com/...

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