Cectec ESTOC Service Manual Download

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Ⅱ

- 56

Check 4WD gear groove
correct to low crankcase
groove

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

ENGINE - Assembly

Summary of Contents for ESTOC

Page 1: ...KINGCOBRA ESTOC SERVICE MANUAL V1 3 ...

Page 2: ...TOPIC POWER TRAIN ENGINE CHASSIS SUSPENSION TRANSMISSION ELECTRICAL SPECIAL TOOLS MAINTENANCE Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ Ⅵ Ⅶ ...

Page 3: ...WER TRAIN Ⅰ Engine Specification Engine Lubrication System Engine Breather System CVT System Start System Injection System Emission Control System Cylinder Head Block EMS System P1 P2 P3 P4 P5 P6 P7 P8 P9 ...

Page 4: ...e 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 1 ...

Page 5: ...r Balancer Crankshaft Con Rod Cylinder Piston Liner Crankshaft Camshaft Release Valve Left Side Right Side Lubrication Wet Sump Oil Pump Rotor Type Oil Filter Paper Type Oil Type 10w 40 Oil Volume 3 0L 3 5L Replace Filter Pressure Release 4 5 kg cm Pressure S W 0 2 kg cm Oil Inlet Oil Return Ⅰ 2 2 2 ...

Page 6: ...Engine Breather System Ⅰ Engine Oil Exhaust Side Intake Side Air Box Air Filter Breather Hose Piston Con Rod Crankshaft Blow by Gas Ⅰ 3 ...

Page 7: ...VT 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 4 ...

Page 8: ... Output 0 7KW Operation Voltage 12V Temperature Range 10 120 Starter Circuit Diagram Start System Ⅰ Rewind Starter Handler Starter Spin Nose Ring Gear Starter GND Battery GND GND Key S W Relay Starter S W Ⅰ 5 ...

Page 9: ...ake Valve Throttle Body ASM Idle Air Control Valve IACV Intake Air Intake Port Fuel Injection Fuel Injection Control Air Flow Temperature IACV or TPS Air Temp MAP Coolant Temp RPM etc ECU To Calculate Air Flow And Necessary Fuel Flow Injector Ⅰ 6 ...

Page 10: ...lyst Throttle Body ASM Injector Ignition Coil ASM O2 Sensor 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 7 ...

Page 11: ...ntake Valve Exhaust Valve Spark Plug Cast in Liner Spark Plug 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 ADC12 Ⅰ 8 ...

Page 12: ...EMS System Ⅰ Block Diagram Ⅰ 9 ...

Page 13: ...EMS System Ⅰ Pin Assignment Ⅰ 10 ...

Page 14: ...ECU Ⅰ ECU Type MC21 1030 ECU Pin 28 Map Sensor Connector ECU Connector Ⅰ 11 ...

Page 15: ...ECU 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: ...ication Code 28140652 ECU Pin 28 MPR Injector Ⅰ Part Introduction Identification Code 28140652 Injector Holes 4ea Circuit Diagram Measurement Resistance 12 0 0 6Ω ECU Injector Pin 28 MPR Main Power Relay Ⅰ 13 ...

Page 17: ...Throttle Body ASM Ⅰ Throttle Body Throttle Position Sensor TPS Idle Air Control Valve IACV Step Motor Ⅰ 14 ...

Page 18: ... 25 Throttle Body TPS Step Motor Ⅰ TPS ECU Pin6 5V GND ECU Pin 21 ECU 5V GND Pin 24 Pin 25 Pin 34 Pin 33 Pin 21 Pin 6 Part Introduction TPS Circuit Diagram Step Motor Circuit Diagram Measurement TPS Resistance 1 2Ω ECU Pin21 GND ECU Ⅰ 15 ...

Page 19: ...ensor Roll Angle 20 20 Sensor Temperature 10 60 Circuit Diagram Assembly Bolt M4 Bolt x 2 Tighten Torque 1 5 2 5Nm Measurement Resistance 3 9Ω Vcc Output Vcc GND Output Top View Left View Rollover Fuel Cut Sensor Ⅰ Rollover Sensor ECU Pin11 Vcc 12V GND OUTPUT Ⅰ 16 ...

Page 20: ...10Kpa Feed Fuel Rate 30 6 L hr min Circuit Diagram Measurement Resistance 4 10Ω Full Stop 93 100Ω Empty Stop Fuel Pump Ⅰ Fuel Level Fuel Filter Fuel Connector Sensor Pump Pump Fuel Pump ECU Pin1 12V GND meter Relay GND END S W Pump Pump Sensor Sensor Sensor Meter Pin24 Ⅰ 17 ...

Page 21: ... Temperature 10 60 Circuit Diagram Assembly Bolt M4 Bolt x 2 Tightening Torque 10 2 Nm Measurement Primary 2 9 Ω 10 Secondary 15 KΩ 10 PBT Black Spark Side Ignition Coil Ⅰ PBT Green Coil Primary Secondary ECU Pin27 12 V PBT Black PBT Black Spark Side GND Ⅰ 18 ...

Page 22: ...Alternator Ⅰ Rectifier Connector Crank Sensor Connector Crank Sensor RTV GVB GND CNKP CNKN Ⅰ 19 ...

Page 23: ...Part Introduction Electric Characteristic Voltage 12V Output 16V 1500rpm Circuit Diagram Rectifier Crank Sensor Alternator Ⅰ Vehicle RTA GVB GND Ⅰ 20 ...

Page 24: ...tle Alternator Rotor Dismantle Cam Shaft Dismantle Chain Dismantle Cylinder Head Dismantle Balancer Dismantle The Oil Pump Dismantle The Driveshaft Dismantle The Oil Main Circuit Dismantle The Cylinder Block Dismantle The Transmission Gear Dismantle The Oil Release Valve Dismantle The Crankshaft Dismantle The Piston Dismantle P1 P2 P2 P3 P4 P4 P6 P7 P8 P9 P11 P12 P13 P14 P15 P17 P18 P20 P22 P23 P2...

Page 25: ...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 The Crankcase And Cylinder Block Assembly The Bearing And Crankshaft Assembly P25 P27 P29 P30 P32 P33 P36 P37 P38 P40 P41 P45 ...

Page 26: ...e CECTEK 500 EFI ENGINE Improper disassembly may damage the engine CECTEK can not provide the warranty to the engine 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 The CVT cover ...

Page 27: ... Belt Removal Tool to end to open the driven pulley then removal the belt 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 Ⅱ Ⅱ 3 CVT DRIVING PULLEY DISMANTLE Loosen the driving pulley bolt Tighten the CVT Puller by air wrench to remove the drive pulley The drive pulley ...

Page 29: ...smantle Ⅱ Ⅱ 4 REWIND STARTER DISMANTLE Loosen the rewind starter bolts The rewind starter TIMING CHECK before dismantle engine must be check the chain timing Loosen the cam cover bolts then remove the cam cover ...

Page 30: ...plug for check the timing 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 ...

Page 31: ... Ⅱ Ⅱ 6 ACCESSORY COVER DISMANTLE Loosen the accessory cover bolts 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 ...

Page 32: ...ENGINE Dismantle Ⅱ Ⅱ 7 DISCOMPRESSOR DISMANTLE Loosen the discompressor mechanism bolt by open wrench Pull out the discompressor mechanism The discompressor mechanism and notice the spring ...

Page 33: ... DISMANTLE Loosen the ALT rotor nut by air wrench The socket deep 85mm 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 ...

Page 34: ...er spring O ring Loosen the tensioner cover and notice the spring and O ring 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 Ⅱ Ⅱ 10 Pull out intake and exhaust rock arm shaft by magnet Pull out the cam shaft The rock arms and cam thrust plate The cam shaft ...

Page 36: ...ENGINE Dismantle Ⅱ Ⅱ 11 CHAIN DISMANTLE Loosen the chain guide bolt then remove the chain Notice the boss The chain ...

Page 37: ...smantle Ⅱ Ⅱ 12 CYLINDER HEAD DISMANTLE Loosen the cylinder head bolts Remove the cylinder head and notice the lock pins Remove the gasket and chain guide The cylinder head gasket and chain guide guide gasket pin ...

Page 38: ...DISMANTLE Loosen the balancer cover bolts Raise the balancer cover by screwdriver from the prominence of case Loosen the water pump idle pulley bolt and unclip the oil pump gear clip The oil pump gear The water pump idle gear clip bolt ...

Page 39: ...NE Dismantle Ⅱ Ⅱ 14 Loosen the balancer bolt by use screwdriver stop the balancer The balancer Loosen the oil pump bolts and unclip the oil pump gear clip The oil pump and back plate THE OIL PUMP DISMANTLE ...

Page 40: ...e Ⅱ Ⅱ 15 Remove the spin nose and washer 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 THE DRIVESHAFT DISMANTLE ...

Page 41: ...ismantle Ⅱ Ⅱ 16 Pull the front driveshaft and remove the 4WD gear The 4WD gear Remove the rear driveshaft yoke and seal cover same procedure of front driveshaft Loosen the starter bolts then remove the starter ...

Page 42: ...ENGINE Dismantle Ⅱ Ⅱ 17 Loosen the shift drum cover bolts Loosen the shift drum antithrust plate Loosen the oil filiter cover Remove the oil filter THE OIL MAIN CIRCUIT DISMANTLE ...

Page 43: ...ntle Ⅱ Ⅱ 18 Loosen the main circuit bolt then remove the main circuit The main circuit Remove the rear driveshaft yoke and seal cover Turn the engine over and loosen the oil sump bolts THE CYLINDER BLOCK DISMANTLE ...

Page 44: ...antle Ⅱ Ⅱ 19 Use scraper and hammer to open the oil sump 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 ...

Page 45: ...ENGINE Dismantle Ⅱ Ⅱ 20 The crankcase When reinstall must clean the surface of the crankcase Remove the main shaft Remove the lay shaft Remove the rear shaft THE TRANSMISSION GEAR DISMANTLE ...

Page 46: ...der block When reinstall must clean the surface of the crankcase 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 ...

Page 47: ... Dismantle Ⅱ Ⅱ 22 The parking shaft Pull out the shift drum from the cylinder block The shift drum Loosen the oil release valve bolt then remove the oil release valve by magnet THE OIL RELEASE VALVE DISMANTLE ...

Page 48: ... Ⅱ Ⅱ 23 The oil release valve 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 THE CRANKSHAFT DISMANTLE ...

Page 49: ...ENGINE Dismantle Ⅱ Ⅱ 24 Pull out the piston Must clean the carbon on piston Piston ring inspection The second ring top side Loosen the speed sensor bolt then remove the speed sensor THE PISTON DISMANTLE ...

Page 50: ...ISTON AND CONNECTION ROD ASSEMBLY NO PART NAME PART NO 1 CONROD ASSY 40098013 2 PISTON PIN 40090024 3 CLIP 40090027 4 PISTON A 40096011 5 PISTON B 40096012 6 PISTON RING TOP 40096013 7 PISTON RING SECOND 40096014 8 PISTON RING OIL CONTROL 40096015 4 Make sure the liner size mark on the cylinder block 1 Before assembly must confirm if the piston 4 5 is matching the category of liner 2 A category pi...

Page 51: ...side mark R is same side of piston 8 Install one clip 3 into the piston clip groove firmly 9 Install pin 2 into pin groove 10 Install the clip 3 into the other side groove to stop the pin 2 11 Then sequentially install parts 8 7 6 the crevice position of each ring as figure A shows 12 The opening of ring 8 of spacer shall be upward as figure B shows ENGINE Assembly ...

Page 52: ...3 40150030 GEAR 37T 2 RES009 RETAIN E RING 1 PART NO PART NAME NO 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 ENGINE Assembly ...

Page 53: ...must be alignment key of crankshaft 3 Install cam chain sprocket 4 into crankshaft 1 shall be install long side into gear side of crankshaft reference to figure A 4 Screw nut 5 to crankshaft 1 tighten torque 250Nm NO PART NAME PART NO 1 CRANKSHAFT 40110023 2 KEY 40110108 3 GEAR 36T 40120018 4 CAM CHAIN SPROCKET 41010004 5 NUT M30 40110024 ENGINE Assembly ...

Page 54: ...to main shaft 1 the bearing of ring side shall be install to main shaft of gear side 2 Install spacer 3 into main shaft then install seal 4 into spacer 3 3 Install a C ring 5 into main shaft of groove then put a washer 6 into main shaft 4 Install needle bearing 7 and high gear 8 into main shaft shall be install high gear of raised side into main shaft of gear side 5 Install a washer 6 into main sh...

Page 55: ...WASHER 46030016 26 12 BEARING DOUBLE ROW ANGULAR 46030029 13 WASHER 46030012 14 WASHER SCF060200883 Before install gear and bearing please lubricate with 10W 40 oil 1 Install bearing 2 into lay shaft 1 be shall install bearing of long side into bevel gear side 2 Install needle bearing 3 into lay shaft then install low gear 4 into lay shaft be shall install low gear 4 of plane into bevel gear side ...

Page 56: ... 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 8 Measure and calculate gear back clearance then choose and install adjusting washer 11 9 Install bearing 12 into lay shaft 10 Install washer 13 and screw flat head screw 14 into lay shaft tighten torque 9Nm THE LAY SHAFT ASSEMBLY ENGINE Assembly ...

Page 57: ...bolt 5 with washer 4 on the shaft 1 the tighten torque 20Nm 4 Install the washer 6 which thickness shall be measured in advance into shaft 1 then press the bearing 7 into shaft 1 finally install the O ring 8 N0 PART NAME PART NO 1 DRIVE SHAFT ASSY 46058001 2 BEARING DGB6205 3 GEAR 46050023 4 WASHER 46050007 5 BOLT BFH080251094 6 WASHER 46050009 19 7 BEARING DGB6305 8 O RING 46050025 ENGINE Assembl...

Page 58: ...G 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 5Nm 3 Install the washer 5 on the valve spring seat 4 Knock valve stem seal 6 into valve guide keep distance between the bottom of seal and the top of cylinder head within 12 7 0 5 mm ENGINE Assembly ...

Page 59: ...lease 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 sound was heard 4 check the cap is firmly installed on the stem with jig ENGINE Assembly ...

Page 60: ...il 1 Install cam 1 through cam bore 2 Install intake rocker 2 on the cam shaft the rocker face toward intake side 3 Install exhaust rocker 3 on the cam shaft the rocker face toward exhaust side 4 Install shaft rocker assy 4 x2 through intake rocker 2 and exhaust rocker 3 5 Install the screw 6 through plate 5 and tighten to 9Nm attention for the bottom of plate shall be clipped onto the groove of c...

Page 61: ...FT 40130075 4 PROPELLER 40130071 5 WASHER 40130077 6 PIN 40130083 7 GEAR 35T 40130063 8 CAP 40070064 9 RETAIN C RING RCS012 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 ENGINE Assembly ...

Page 62: ...SSY 46078002 2 SHAFT SHIFT FORK 46070013 3 SHIFT FORK MAIN SHAFT 46070001 4 SHIFT FORK LAY SHIFT 46070002 5 PARKING BREAK SHAFT 46070005 6 THRUST PLATE 46070022 7 BOLT BFH060120884 8 SHIFT LOCATING SPRING 46070015 9 SPRING BLADE 46070014 10 RETAIN C RING RCS010 ENGINE Assembly ...

Page 63: ... THE TRANSMISSION GEAR ASSEMBLY Shift locating rotor install position Install fork shift by plastic hammer and all parts lubricate Install lay shaft to cylinder block Then push it to position ENGINE Assembly ...

Page 64: ...t to cylinder block then push it to position 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 ENGINE Assembly ...

Page 65: ...LY N0 PART NAME PART NO 1 SHAFT 46030009 2 O RING 46030027 3 NEEDLE BEARING 46030032 4 REVERSE GEAR 27T 46030006 5 WASHER 46030011 6 RETAIN C RING RCH020 Please clean up correlative parts and lubricate with 10W 40 oil ENGINE Assembly ...

Page 66: ...NAME PART NO 1 CRANKCASE 40018014 2 MAIN BEARING BLACK 888 4001 607 3 MAIN BEARING NO COLOR 888 4001 608 4 MAIN BEARING GREEN 888 4001 609 The crankshaft mark position have 3 marks EX A 2 B CVT side ALT side No groove bearing for low crankcase ENGINE Assembly ...

Page 67: ...all 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 1 A 1 A 2 B and CVT side bearing color is Green 1 B 1 A 1 A 2 B up and low bearing install the same color CVT side ALT side The cylinder block mark position have 3 number EX 1 A 1 ENGINE Assembly ...

Page 68: ...YLINDER BLOCK 40018014 2 MAIN BEARING BLACK 888 4001 613 3 MAIN BEARING NO COLOR 888 4001 614 4 MAIN BEARING GREEN 888 4001 615 5 CONROD ASSY 40098013 6 BEARING BLACK 40096025 7 BEARING YELLOW 40096024 8 BEARING BLUE 40096023 Groove bearing for cylinder block ENGINE Assembly ...

Page 69: ...A CONNECTING ROD Y Yellow BL Blue B Black B Y Y BL Choose bearing color and install to connecting rod EX connecting rod mark is A crankcase mark is A 2 B so we choose the bearing color is blue A 2 A A 2 B up and low bearing install the same color ENGINE Assembly ...

Page 70: ...ND CRANKSHAFT ASSEMBLY Lubricate all bearing 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 ENGINE Assembly ...

Page 71: ...Assembly Glue on cylinder block according figure A and glue diameter about 1mm Install crankcase to cylinder block Keep away the main gallery Figure A Glue Path Main Gallery Lay the glue diameter about 1mm ENGINE Assembly ...

Page 72: ...Lubricate the bolt and washer then tighten it Torque 35Nm 90 tighten the bolts equally Install the cylinder block bolts The tighten torque 20Nm Install shift drum anti thrust plate Torque 10Nm ENGINE Assembly ...

Page 73: ...ase Assembly Glue on shift drum cover Glue diameter about 1mm Install the shift drum cover Torque 10Nm Reverse the engine then tighten the cylinder bolt Torque 20Nm Install the main circuit Torque 20Nm ENGINE Assembly ...

Page 74: ...e balancer 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 ENGINE Assembly ...

Page 75: ...Ⅱ Ⅱ 50 The bolts torque 10Nm 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 ENGINE Assembly ...

Page 76: ... Install the chain guide into cylinder block and notice the lock position Install the cylinder head gasket and lock pins Install the cylinder head Lubricate the cylinder head bolts and washer ENGINE Assembly ...

Page 77: ...er bolts Torque 35Nm 90 90 tighten the four bolts equally 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 ENGINE Assembly ...

Page 78: ...nkshaft gear mark and balancer mark Between balancer mark to crankcase mark line have five gears 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 ENGINE Assembly ...

Page 79: ...hten the bolts then put the spring and screw the cover The bolts torque 10Nm The cover torque 10Nm Install discompressor Lay Bolt Glue LT272 on discompressor bolt then screw it Torque 5Nm Install the thermostat Torque 10Nm ENGINE Assembly ...

Page 80: ...ead cover then tighten the bolts Torque 10Nm 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 ENGINE Assembly ...

Page 81: ...to low crankcase groove 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 ENGINE Assembly ...

Page 82: ...hen install drive yoke 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 ENGINE Assembly ...

Page 83: ...bolts 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 ENGINE Assembly ...

Page 84: ...belt on position The driven pulley can be free rotate Install the CVT cover then tighten the bolts Torque 10Nm Install the rewind starter Then tighten the bolts Torque 10Nm ENGINE Assembly The engine assembly complete Off Road Type On Road Type ...

Page 85: ...PPER MUDFLAP DISMANTLE PROTECTOR DISMANTLE FOOT REST PEDAL DISMANTLE FRONT FENDER DISMANTLE INNER MUDFLAP DISMANTLE REAR LAMP DISMANTLE REAR COVER DISMANTLE TAIL LAMP ASSEMBLY DISMANTLE ELECTRICAL HOUSING DISMANTLE THROTTLE BODY DISMANTLE MUFFLER DISMANTLE FUEL PUMP DISMANTLE FUEL PUMP ASSEMBLY P1 P2 P4 P5 P7 P10 P13 P18 P21 P23 P28 P30 P32 P36 P40 P47 P50 P52 P56 P59 P61 ...

Page 86: ...CHASSIS Ⅲ SEAT DISMANTLE Use the key to open the seat lock Remove the seat The seat The tool bag under the seat Ⅲ 1 ...

Page 87: ...CHASSIS Ⅲ AIR CLEANER COVER DISMANTLE Dismantle the rivets and pull out the air cleaner cover Dismantle the connector of main switch Air cleaner cover assembly Ⅲ 2 ...

Page 88: ...CHASSIS Ⅲ AIR CLEANER COVER DISMANTLE Dismantle the cover then turn it over Press the flange then remove the main switch The main switch Ⅲ 3 ...

Page 89: ...CHASSIS Ⅲ FRONT DECK DISMANTLE Dismantle the rivets of front deck Pull out the front deck The front deck The front box Ⅲ 4 ...

Page 90: ...CHASSIS Ⅲ METER DISMANTLE Dismantle the bolts of bracket Push the pin to dismantle the connector Be careful about the orange O ring of the wire harness connector The meter Ⅲ 5 Torque 10 Nm ...

Page 91: ...CHASSIS Ⅲ METER DISMANTLE Dismantle the meter then turn it over Dismantle the screws then remove the cover The meter cover Ⅲ 6 ...

Page 92: ...CHASSIS Ⅲ FRONT COVER DISMANTLE Release the tenon from the brake oil reservoir Pull out the brake oil reservoir Dismantle the bolt Dismantle the screws from two sides of the cover Ⅲ 7 Torque 10 Nm ...

Page 93: ...CHASSIS Ⅲ FRONT COVER DISMANTLE Dismantle the screws under the front cover from the two sides of the cover Pull out the front cover Dismantle the connector of power supply The front cover Ⅲ 8 ...

Page 94: ...CHASSIS Ⅲ FRONT COVER DISMANTLE Dismantle the front cover then turn it over Turn counterclockwise to dismantle the power supply The power supply Ⅲ 9 ...

Page 95: ...CHASSIS Ⅲ LHS COVER DISMANTLE Dismantle the rivets screw then pull out the panel The mudguard panel LH Dismantle the bolt rivet then pull out the left side cover The side panel LH Ⅲ 10 ...

Page 96: ...CHASSIS Ⅲ LHS COVER DISMANTLE Dismantle the screws Release the tenon of left cover Then pull out the cover The side cover LH Ⅲ 11 ...

Page 97: ...CHASSIS Ⅲ LHS COVER DISMANTLE Dismantle the bolts then remove the cover The engine cover LH Ⅲ 12 ...

Page 98: ...CHASSIS Ⅲ RHS COVER DISMANTLE Dismantle the rivet The engine cover RH Release the tenon then pull out the cover Ⅲ 13 ...

Page 99: ...CHASSIS Ⅲ RHS COVER DISMANTLE Dismantle the rivets and screw then remove the panel Dismantle the rivets then remove the cover The upper engine cover RH The mudguard panel RH Ⅲ 14 ...

Page 100: ...CHASSIS Ⅲ RHS COVER DISMANTLE Dismantle the bolt and rivet then remove the panel The panel Push the revolve lever from the cover inside Dismantle the screws Ⅲ 15 ...

Page 101: ...CHASSIS Ⅲ RHS COVER DISMANTLE Revolve lever alignment Opposite side of revolve lever The revolve lever and button Dismantle the center bolt from the revolve lever Ⅲ 16 Torque 10 Nm ...

Page 102: ...CHASSIS Ⅲ RHS COVER DISMANTLE Screw contraclockwise the shift bar 2 4WD of the rod The shift bar 2 4WD Release the tenon then pull out the cover The side cover RH Ⅲ 17 ...

Page 103: ...ASSIS Ⅲ HEAD LAMP DISMANTLE Dismantle the bolts Dismantle the screws from the two sides of the cover Dismantle the screws from the two side of the cover Dismantle the head lamp connector Ⅲ 18 Torque 10 Nm ...

Page 104: ...CHASSIS Ⅲ HEAD LAMP DISMANTLE The front nose Turn it over Press the tenon then remove the grille The grille Ⅲ 19 ...

Page 105: ...HEAD LAMP DISMANTLE Dismantle the screws from the back of the lamp Dismantle the screw from the front of the lamp The head lamp assy The head lamp angle adjustment bolt Upper clockwise Lower counterclockwise Ⅲ 20 ...

Page 106: ...CHASSIS Ⅲ UPPER MUDFLAP DISMANTLE Dismantle the bolt Pull out the tenon then remove the mudflap The upper mudflap R Ⅲ 21 Torque 10 Nm ...

Page 107: ...CHASSIS Ⅲ UPPER MUDFLAP DISMANTLE Dismantle the bolt Pull out the tenon then remove the mudflap Upper mudflap L Ⅲ 22 Torque 10 Nm ...

Page 108: ...CHASSIS Ⅲ PROTECTOR DISMANTLE Dismantle the bolts Then remove the cover The protector cover RHF Dismantle the bolts then remove the cover The protector cover LHF Ⅲ 23 Torque 10 Nm ...

Page 109: ...CHASSIS Ⅲ PROTECTOR DISMANTLE Dismantle the bolts Dismantle the bottom bolt then remove the cover The protector cover RHR Ⅲ 24 Torque 10 Nm Torque 10 Nm ...

Page 110: ...CHASSIS Ⅲ PROTECTOR DISMANTLE Dismantle the bolts Dismantle the bottom bolt then remove the cover The protector cover LHR Ⅲ 25 Torque 10 Nm Torque 10 Nm ...

Page 111: ...CHASSIS Ⅲ PROTECTOR DISMANTLE Dismantle the bolts Then remove the cover The front protector cover Dismantle the bolts then remove the cover The engine protector cover Ⅲ 26 Torque 10 Nm Torque 10 Nm ...

Page 112: ...CHASSIS Ⅲ PROTECTOR DISMANTLE Dismantle the rear bolts Dismantle the bolts from two sides of the cover The rear protector cover Ⅲ 27 Torque 10 Nm Torque 10 Nm ...

Page 113: ... FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the rear Dismantle the bottom bolts Then remove the right foot rest The right foot rest Dismantle the rivets and screw of the front Ⅲ 28 Torque 10 Nm ...

Page 114: ...Ⅲ FOOT REST PEDAL DISMANTLE Dismantle the rivets and screw of the rear Dismantle the bottom bolts then remove the left foot rest The left foot rest Dismantle the rivets and screw of the front Ⅲ 29 Torque 10 Nm ...

Page 115: ...CHASSIS Ⅲ FRONT FENDER DISMANTLE Pull out the tenon Dismantle the upper bolt then remove the fender The front fender RH Ⅲ 30 Torque 10 Nm ...

Page 116: ...CHASSIS Ⅲ FRONT FENDER DISMANTLE The front fender LH Pull out the tenon Dismantle the upper bolt then remove the fender Ⅲ 31 Torque 10 Nm ...

Page 117: ...CHASSIS Ⅲ INNER MUDFLAP DISMANTLE Dismantle the bolt Pull out the tenon then remove the mudflap The inner mudflap RH Ⅲ 32 Torque 10 Nm ...

Page 118: ...CHASSIS Ⅲ INNER MUDFLAP DISMANTLE The inner mudflap RH Dismantle the screws then remove the ventilator The ventilator RH Ⅲ 33 ...

Page 119: ...CHASSIS Ⅲ INNER MUDFLAP DISMANTLE Dismantle the bolt Pull out the tenon then remove the mudflap The inner mudflap LH Ⅲ 34 Torque 10 Nm ...

Page 120: ...CHASSIS Ⅲ INNER MUDFLAP DISMANTLE The inner mudflap LH Dismantle the screws then remove the ventilator The ventilator LH Ⅲ 35 ...

Page 121: ...CHASSIS Ⅲ REAR LAMP DISMANTLE Dismantle the rivet Dismantle the bottom bolts of the bracket Dismantle the connectors The rear lamp housing RH Ⅲ 36 ...

Page 122: ...CHASSIS Ⅲ REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the bolts then remove the cover The rear lamp cover RH The rear lamp RH Ⅲ 37 ...

Page 123: ...CHASSIS Ⅲ REAR LAMP DISMANTLE Dismantle the screw Dismantle the bottom bolts of the bracket Dismantle the connectors The rear lamp housing LH Ⅲ 38 ...

Page 124: ...CHASSIS Ⅲ REAR LAMP DISMANTLE Turn the lamp housing over Dismantle the screws then remove the cover The rear lamp cover LH The rear lamp LH Ⅲ 39 ...

Page 125: ...CHASSIS Ⅲ REAR COVER DISMANTLE Dismantle the bolts then remove the hooks The hook carrier The hook alignment Dismantle the bottom screws from two sides of rear cover Ⅲ 40 Torque 10 Nm ...

Page 126: ...CHASSIS Ⅲ REAR COVER DISMANTLE Dismantle the upper bolts Screw out the fuel cap Avoid any dirt Cover the fuel tank The fuel cap Ⅲ 41 Torque 10 Nm ...

Page 127: ...CHASSIS Ⅲ REAR COVER DISMANTLE Pull up the rear cover Avoid any dirt reinstall the fuel cap The rear cover Ⅲ 42 ...

Page 128: ...CHASSIS Ⅲ REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Push the tenon then remove the cover The rear cover RH Ⅲ 43 ...

Page 129: ...CHASSIS Ⅲ REAR COVER DISMANTLE Turn over the rear cover Dismantle the screws Push the tenon then remove the cover The rear cover LH Ⅲ 44 ...

Page 130: ...CHASSIS Ⅲ REAR COVER DISMANTLE Dismantle the rear cover The mesh Turn over the rear cover then push the tenon The meshes RHS LHS Ⅲ 45 ...

Page 131: ...CHASSIS Ⅲ REAR COVER DISMANTLE Dismantle the rear cover The slipproof on the rear cover Turn over the rear cover then push the tenon to remove the slipproof The slipproof pad Ⅲ 46 ...

Page 132: ...SSIS Ⅲ TAIL LAMP ASSEMBLY DISMANTLE Pull out the wire then remove the seat wire Dismantle the bottom bolt from two sides of bracket Dismantle the connector then remove the tail lamp The tail lamp assy Ⅲ 47 ...

Page 133: ...CHASSIS Ⅲ TAIL LAMP ASSEMBLY DISMANTLE Turn over the tail lamp Pull out the plate of lock When reinstall the wire make sure the wire into the position The lock Ⅲ 48 ...

Page 134: ...CHASSIS Ⅲ TAIL LAMP ASSEMBLY DISMANTLE Turn over the lamp Dismantle the nuts The tail lamp Ⅲ 49 Torque 10 Nm ...

Page 135: ...AL HOUSING DISMANTLE Dismantle the negative wire to protect the electrical parts Dismantle the connector After dismantle all connector Dismantle the nuts then remove the wire of start relay Ⅲ 50 Torque 10 Nm Torque 10 Nm ...

Page 136: ...CHASSIS Ⅲ ELECTRICAL HOUSING DISMANTLE Dismantle the screws of fuse box Remove the small wire harness Lift the rear of electrical housing to remove other wire harness The electrical housing Ⅲ 51 ...

Page 137: ...HROTTLE BODY DISMANTLE Dismantle the bolts of air cleaner Dismantle the connector of sensor Release the screw of clamp Release the screw of clip then remove the hose and pull out the air clenaer Ⅲ 52 Torque 10 Nm ...

Page 138: ...CHASSIS Ⅲ Pull out the air cleaner Ⅲ 53 THROTTLE BODY DISMANTLE The air cleaner ...

Page 139: ...HASSIS Ⅲ Dismantle the connector of IACV and TPS Dismantle the bolts of throttle cable cover The throttle cable cover Ⅲ 54 THROTTLE BODY DISMANTLE Be careful about the O ring of the throttle cable cover ...

Page 140: ...SSIS Ⅲ Release the nuts to loosen the throttle cable then remove the throttle cable Release the screw then remove the throttle The throttle Ⅲ 55 THROTTLE BODY DISMANTLE Avoid any dirt Cover the intake pipe ...

Page 141: ...CHASSIS Ⅲ MUFFLER DISMANTLE Release the bolt of clip Dismantle the bolts of muffler Then remove the muffler The muffler Ⅲ 56 Torque 15 Nm Torque 25 Nm ...

Page 142: ...CHASSIS Ⅲ MUFFLER DISMANTLE Check the gasket of muffler The gasket Dismantle the connector of O2 sensor Dismantle the nuts of exhaust pipe Ⅲ 57 Torque 20 Nm ...

Page 143: ...CHASSIS Ⅲ MUFFLER DISMANTLE Then remove the exhaust pipe The exhaust pipe Ⅲ 58 ...

Page 144: ...CHASSIS Ⅲ FUEL PUMP DISMANTLE Use Spanner Fuel Retainer to dismantle the retainer Then turn counterclockwise Pull out the fuel pump half way Then turn counterclockwise Ⅲ 59 ...

Page 145: ...CHASSIS Ⅲ FUEL PUMP DISMANTLE Pull out the fuel pump 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 Ⅲ FUEL PUMP ASSEMBLY Install the O ring then use oil to lubricate Put in the fuel gage first Then turn counterclockwise Put in the fuel pump half way Ⅲ 61 ...

Page 147: ...CHASSIS Ⅲ FUEL PUMP ASSEMBLY Turn counterclockwise And pull out the fuel pump half way Then put in the fuel pump to end Turn clockwise Ⅲ 62 ...

Page 148: ...CHASSIS Ⅲ FUEL PUMP ASSEMBLY Then install the retainer Use the special tool to tighten the retainer Ⅲ 63 Torque 25 Nm Make sure the mark of fuel tank match the output pipe of fuel pump ...

Page 149: ...E FRONT ABSORBER UPPER ARM DISMANTLE FRONT LOWER ARM DISMANTLE FRONT DIFFERENTIAL DISMANTLE REAR WHEEL DISMANTLE REAR CALIPER DISMANTLE REAR HUB DISMANTLE REAR DISK KNUCKLE DISMANTLE REAR ABSORBER UPPER ARM DISMANTLE REAR LOWER ARM DISMANTLE REAR STABILIZER BAR DISMANTLE REAR GEAR BOX DISMANTLE P1 P2 P3 P5 P6 P9 P10 P11 P16 P17 P18 P20 P21 P22 P23 P24 ...

Page 150: ...DISMANTLE Dismantle the nuts of wheel then remove the wheel The wheel Off Road Remove the wheel cap On Road Push the cap from the back of wheel The wheel cap Ⅳ 1 SUSPENSION TRANSMISSION OFF ROAD ON ROAD Torque 60Nm Ⅳ ...

Page 151: ...e the upper bolt of caliper Dismantle the lower bolt of caliper then remove the caliper Avoid any knock suspend the caliper with cloth Ⅳ 2 SUSPENSION TRANSMISSION Avoid any knock suspend the caliper with cloth Torque 25Nm Torque 25Nm Ⅳ ...

Page 152: ...nut of hub by 1 Reinstall the caliper then use brake to hold the hub Dismantle the nut of hub by 2 Reinstall the nuts of wheel then use big screw driver to hold the hub The pin nut and washer Ⅳ 3 SUSPENSION TRANSMISSION PIN NUT WASHER Torque 100Nm Torque 100Nm Ⅳ ...

Page 153: ...asher is lower when install the washer must in the right direction The flange of washer is lower when install the washer must in the right direction Pull out the hub The hub Ⅳ 4 SUSPENSION TRANSMISSION HUB SIDE NUT SIDE HUB SIDE NUT SIDE Ⅳ ...

Page 154: ...ISK COVER DISMANTLE Turn the hub over dismantle the bolts of disk then remove the disk The disk Dismantle the bolts of cover then remove the cover The cover Ⅳ 5 SUSPENSION TRANSMISSION Torque 20Nm Torque 10Nm Ⅳ ...

Page 155: ... KNUCKLE DISMANTLE Turn the knuckle Then dismantle the pin and nut of knuckle Ⅳ 6 SUSPENSION TRANSMISSION The pin washer and nut Use the tool to dismantle the ball joint of tie rod PIN NUT WASHER Torque 25Nm Ⅳ ...

Page 156: ...ismantle the lower pin and nut of knuckle The pin and nut Use the tool to dismantle the ball joint of lower arm then remove the knuckle Ⅳ 7 SUSPENSION TRANSMISSION LHF RHF KNUCKLE DISMANTLE Torque 50Nm Ⅳ ...

Page 157: ...tle the upper pin and nut of knuckle Use the tool to dismantle the ball joint of upper arm Ⅳ 8 SUSPENSION TRANSMISSION PIN NUT WASHER The pin washer and nut The knuckle LHF RHF KNUCKLE DISMANTLE Torque 30Nm Ⅳ ...

Page 158: ...PPER ARM DISMANTLE Dismantle the nuts and bolts of absorber then remove the absorber The absorber Dismantle the nut and bolt of arm then remove the arm The upper arm Ⅳ 9 SUSPENSION TRANSMISSION Torque 70Nm Torque 70Nm Ⅳ ...

Page 159: ...LHF RHF LOWER ARM DISMANTLE Dismantle the nuts and bolts of arm then remove the arm The lower arm Ⅳ 10 SUSPENSION TRANSMISSION Torque 70Nm Ⅳ ...

Page 160: ...L DISMANTLE Dismantle the bolt of differential to drain the gear oil The bolt and washer By check the gear oil to know the stative of differential Ⅳ 11 SUSPENSION TRANSMISSION Then reinstall the bolt Change new washer Ⅳ ...

Page 161: ...Pull out the CV Joint horizontally Or use the screw driver to open the CV Joint The CV Joint Ⅳ 12 SUSPENSION TRANSMISSION Avoid any dirty cover the differential FRONT DIFFERENTIAL DISMANTLE Ⅳ ...

Page 162: ...crew driver to lock the shaft Dismantle the bolts of shaft 2 By shift the gear position to engage reverse gear and 4 wheel driver Then pull out the shaft Ⅳ 13 SUSPENSION TRANSMISSION The propeller shaft Torque 25Nm FRONT DIFFERENTIAL DISMANTLE Ⅳ ...

Page 163: ...antle the nuts and bolts of differential Lift the differential Ⅳ 14 SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Dismantle the connector of differential Turn the counterclockwise side Torque 40Nm Ⅳ ...

Page 164: ...Remove the differential The differential Ⅳ 15 SUSPENSION TRANSMISSION FRONT DIFFERENTIAL DISMANTLE Ⅳ ...

Page 165: ...ISMANTLE Dismantle the bolts of wheel then remove the wheel The wheel Off Road Remove the wheel cap On Road Push the cap from the back of wheel The wheel cap Ⅳ 16 SUSPENSION TRANSMISSION Torque 60Nm OFF ROAD ON ROAD Ⅳ ...

Page 166: ...e the upper bolt of caliper Dismantle the lower bolt of caliper then remove the caliper Avoid any knock suspend the caliper with cloth Ⅳ 17 SUSPENSION TRANSMISSION Avoid any knock suspend the caliper with cloth Torque 25Nm Torque 25Nm Ⅳ ...

Page 167: ...nut of hub by 1 Reinstall the caliper then use brake to hold the hub Dismantle the nut of hub by 2 Reinstall the nuts of wheel then use big screw driver to hold the hub The pin nut and washer Ⅳ 18 SUSPENSION TRANSMISSION PIN NUT WASHER Torque 100Nm Torque 100Nm Ⅳ ...

Page 168: ...sher is lower when install the washer must in the right direction The flange of washer is lower when install the washer must in the right direction Pull out the hub The hub Ⅳ 19 SUSPENSION TRANSMISSION HUB SIDE NUT SIDE HUB SIDE NUT SIDE Ⅳ ...

Page 169: ... DISMANTLE Turn the hub over and dismantle the bolts of disk then remove the disk The disk Dismantle the nuts and bolts of knuckle then remove the knuckle The knuckle Ⅳ 20 SUSPENSION TRANSMISSION Torque 20Nm Torque 70Nm Ⅳ ...

Page 170: ...PPER ARM DISMANTLE Dismantle the nuts and bolts of absorber then remove the absorber The absorber Dismantle the nut and bolt of arm then remove the arm The upper arm Ⅳ 21 SUSPENSION TRANSMISSION Torque 70Nm Torque 70Nm Ⅳ ...

Page 171: ...R RHR LOWER ARM DISMANTLE Dismantle the nuts and bolts of arm then remove the arm Use the open wrench to lock the ball joint then dismantle the nut The lower arm Ⅳ 22 SUSPENSION TRANSMISSION Torque 70Nm Ⅳ ...

Page 172: ...REAR STABILIZER BAR DISMANTLE Dismantle the bolts of bar from two sides The stabilizer bar Dismantle the nut of ball joint Ⅳ 23 SUSPENSION TRANSMISSION The ball joint Torque 30Nm Torque 70Nm Ⅳ ...

Page 173: ...OX DISMANTLE Dismantle the bolt of gear box to drain the gear oil The bolt and washer By check the gear oil to know the stative of gear box Ⅳ 24 SUSPENSION TRANSMISSION Then reinstall the bolt Change new washer Ⅳ ...

Page 174: ...REAR GEAR BOX DISMANTLE Pull out the CV Joint horizontally Or use the screw driver to open the CV Joint The CV Joint Ⅳ 25 SUSPENSION TRANSMISSION Avoid any dirty cover the differential Ⅳ ...

Page 175: ...le the bolts of shaft 1 By use the screw driver to lock the shaft Dismantle the bolts of shaft 2 By shift the gear position to engage reverse gear Then pull out the shaft Ⅳ 26 SUSPENSION TRANSMISSION The propeller shaft Torque 25Nm Ⅳ ...

Page 176: ... GEAR BOX DISMANTLE Dismantle the upper bolt of gear box Dismantle the lower nuts and bolts of gear box Lift the gear box Ⅳ 27 SUSPENSION TRANSMISSION Turn the contraclockwise side Torque 25Nm Torque 40Nm Ⅳ ...

Page 177: ...REAR GEAR BOX DISMANTLE Then remove the gear box The gear box Ⅳ 28 SUSPENSION TRANSMISSION Ⅳ ...

Page 178: ...LECTRICAL CONNECTOR WIRE CIRCUIT ECU PIN LAMP PIN DIFF PIN OTHER PIN ADJUSTMENT FOR TIRE CIRCUMFERENCE INJECTION PARTS POSITION ELECTRIC PARTS POSITION GROUND WIRE POSITION P1 P2 P3 P4 P5 P6 P7 P9 P11 P12 ...

Page 179: ...Ⅴ Ⅴ 1 ELECTRICAL Connector ...

Page 180: ...Ⅴ Ⅴ 2 ELECTRICAL Wire circuit ...

Page 181: ...Ⅴ Ⅴ 3 ELECTRICAL ECU pin ...

Page 182: ...Ⅴ Ⅴ 4 ELECTRICAL Lamp pin ...

Page 183: ...Ⅴ Ⅴ 5 ELECTRICAL DIFF pin ...

Page 184: ...Ⅴ Ⅴ 6 ELECTRICAL Other pin ...

Page 185: ...Ⅴ Ⅴ 7 Turn off the main switch Dismantle the connector of speedometer Turn on the main switch Press the two buttons at the same time ADJUSTMENT FOR TIRE CIRCUMFERENCE Adjustment Tire Circumference ...

Page 186: ...the connector of speedometer then show the three figure number The Tire Circumference A shift the flashing position of number B increase the flashing number On Road 556 Off Road 646 Press and release the two Buttons at the same time then the speedometer will auto restart to normal function A B 646 646 Adjustment Tire Circumference ...

Page 187: ...Ⅴ Ⅴ 9 Injection Parts Position 1 THROTTLE BODY INJECTOR ECU ECM O2 SENSOR ...

Page 188: ...Ⅴ Ⅴ 10 Injection Parts Position 2 SPARK PLUG IGNITION COIL FUEL CUT SENSOR WATER TEMP SENSOR ...

Page 189: ...Ⅴ Ⅴ 11 Electric Parts Position OIL PRESS SENSOR HORN FUEL PUMP RECTIFIER ...

Page 190: ...Ⅴ 12 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 ...

Page 191: ...E Ⅵ 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 P1 P2 P4 P6 P8 P9 P11 P13 P15 ...

Page 192: ...y Control Switches Lights DRIVE Front Propeller Rear Propeller Steering Differential Oil Wheel Nut BRAKE Brake System Brake Pad BODY A Arms Absorbers 300km 1500km 3000km 6000km R R R R R R R R I I I I R I R C R R I I I I I I R R I I I I I I I I I I I L I L I L I I L I L I L I I I I R I I R I I I I I I I I I I I I L I L I L I I I I Inspect C Clean L Lubricate R Replace Ⅵ 1 ...

Page 193: ...il Capacity with filter 3500cc 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 2 ...

Page 194: ...e Ⅵ 3 Engine Oil Drain Bolt Engine Oil Fill Dipstick Max Min 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: ...riginal Oil Type PENNZOIL 80w 90 The approved oil PENNZOIL 4096 80w 90 Use a SAE 80w 90 hypoid oil on API classification GL 5 to fill the differential SAE GRADE API SERVICE GRAVITY API VISCOSITY 40 cSt VISCOSITY 100 cSt VISCOSITY INDEX POUR POINT FLASH POINT COLOR 80W 90 GL 5 26 150 14 5 95 26 204 5 Ⅵ 4 ...

Page 196: ...Ⅵ 5 Differential Oil Drain Bolt The Differential Oil Drain Bolt Torque 40 Nm Ⅵ Differential Oil Type Differential Oil Fill Plug ...

Page 197: ... NO 1 RADIATOR ASSY 60046001 2 BOLT BFH060200884 3 CAP ASSY 60046002 4 BOLT BFH060120882 5 HOSE RADIATOR OUTLET 60040005 6 CLIP CC02003209 7 HOSE RADIATOR INLET 60040004 8 CLIP CC02504009 B A A B Connect to Thermostat Cover Connect to Water Pump Cover ...

Page 198: ...ifreeze Ⅵ 7 Required engine coolant solution capacity Total capacity 3550c c Engine Coolant 1775c c Water 1775c c Reservoir Tank Level B A A B Radiator Cap Reservoir Tank Cap Make Sure The Coolant Between Max And Min Level Of Reservoir Tank While Engine is Cold ...

Page 199: ...mostat Cylinder Head Cover Spark Plug Alternator Accessary Cover Drive Shaft Seal Cover Drive Yoke Balancer Cover Oil Sump CVT Drive Pulley CVT Driven Pulley CVT Cover TORQUE 250Nm 9Nm 20Nm 10Nm 20Nm 90 90 35Nm 90 20Nm 10Nm 10Nm 10Nm 20Nm 20Nm 10Nm 10Nm 10Nm 35Nm 90 90 10Nm 10Nm 5Nm 10Nm 10Nm 12Nm 200Nm 10Nm 10Nm 20Nm 10Nm 10Nm 120Nm 45Nm 10Nm POSITION Ⅱ 28 Ⅱ 31 Ⅱ 32 Ⅱ 39 Ⅱ 45 Ⅱ 47 Ⅱ 47 Ⅱ 48 Ⅱ 47 ...

Page 200: ...5 LHS Engine Bolts x 2 6 LHS Footrest Bolts x 4 7 Rear Propeller Shaft Bolts x 8 8 LHR Wheel Rim Nuts x 4 9 LHR Caliper Bolts x 2 10 Rear Differential Bolts x 3 11 LHR Suspension Bolts x 2 12 Rear Muffler Bolts x 2 1 2 3 4 5 6 7 8 9 10 11 12 TORQUE 70 N m 25 N m 60 N m 40 N m 45 N m 40 N m 25 N m 60 N m 25 N m 40 N m 70 N m 20 N m Ⅵ 9 ...

Page 201: ... x 2 3 RHR Wheel Rim Nuts x 4 4 RHS Footrest Bolts x 4 5 RHS Engine Bolts x 2 6 Front Propeller Shaft Bolts x 8 7 RHF Wheel Rim Nuts x 4 8 RHF Caliper Bolts x 2 9 RHF Suspension Bolts x 2 10 Front Muffler Bolts x 2 TORQUE 70 N m 25 N m 60 N m 40 N m 45 N m 25 N m 60 N m 25 N m 70 N m 20 N m Ⅵ 10 ...

Page 202: ...he screws and bolt of LHS upper mudflap Then remove the LHS upper mudflap Pull out the spark plug hat Clean up around the spark plug then dismantle the spark plug Ⅵ SPARK PLUG EXCHANGE MAINTENANCE Spark Plug Ⅵ 11 ...

Page 203: ...The spark plug Type Champion PRG7C Gap 0 6 0 7mm Assemble The spark plug Torque 12N m Ⅵ SPARK PLUG EXCHANGE MAINTENANCE Spark Plug Ⅵ 12 ...

Page 204: ...ntle 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 Pull out the oil filter then clean the old oil inside Ⅵ OIL FILTER EXCHANGE MAINTENANCE Oil Filter Ⅵ 13 ...

Page 205: ...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 Tighten the cover to end Ⅵ OIL FILTER EXCHANGE MAINTENANCE Oil Filter Ⅵ 14 ...

Page 206: ...r 2 The front deck 3 The front cover Push the revolve lever from the cover inside Dismantle the center bolt from the revolve lever Screw counterclockwise the shift bar 2 4WD of the rod Ⅵ AIR FILTER EXCHANGE MAINTENANCE Air Filter Ⅵ 15 ...

Page 207: ...Release the RHS tenon Release the LHS tenon Dismantle the LHS bolt of seat holder Dismantle the RHS bolts of seat holder Ⅵ AIR FILTER EXCHANGE MAINTENANCE Air Filter Ⅵ 16 ...

Page 208: ...The seat holder Release the clips of cover then remove the air cleaner cover Pull out to open the clip Change the air filter Ⅵ AIR FILTER EXCHANGE MAINTENANCE Air Filter Ⅵ 17 ...

Page 209: ...OLS Ⅶ 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 1 ...

Page 210: ... 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 M12 1 5 Ⅶ 2 ...

Page 211: ...92000001 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 Brand Loctie Type 272 Volume 250ml Ⅶ 3 ...

Page 212: ...http www cectekpowersports com ...

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