GAOKIN E02 Maintenance Manual Download | Manualshive

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E02

（

GK194MS

）

Maintenance Manual

Edited

：

Li LinJun

Verified

：

Hu Xianyong

Approved

：

Li Xuelong

1
2
3
...
»

Summary of Contents for E02

Page 1: ...1 E02 GK194MS Maintenance Manual Edited Li LinJun Verified Hu Xianyong Approved Li Xuelong...

Page 2: ...utline drawing 7 3 1 Engine model and countermark position 7 3 2 E02 engine outline drawing 7 4 Engine assembly requirement and accessory 8 4 1 Engien assembly 8 4 2 Inlet and exhaust system 8 4 3 Fue...

Page 3: ...he following table S N Product code Model Feature Remark 1 E02C 194MS Carb manual clutch pedal shifting 5forward shifts Used on two wheels vehicle 2 E02C 2 194MS A EFI manual clutch pedal shifting 5fo...

Page 4: ...are not allowed to touch engine to avoid scald Engine output shaft is a high speed spinning part please install protecting plate or cover to avoid hurt 2 Product technical characters 2 1Main performa...

Page 5: ...size L x b x h mm E02C E02F 380x420x500 3 Net weight kg 49 50 4 Bore diameter mm 94 5 Piston stroke mm 85 6 displacement ml 589 9 7 compression 9 7 1 8 Ignition mode Storage power supply ignition coil...

Page 6: ...arance 0 7 0 8 2 3 transmission system parameter The follow table shows E02 engine transmission parameter S N Items Parameter Description Remark E02C E02F 1 Clutch type Manual wet type oil bath multip...

Page 7: ...30 L 5 Lubricating oil max temperature 120 C 2 5 water coolant parameter S N Items Parameter Description Remark 1 Coolant specification Antifreeze 30 2 Coolant volume ml 200 Water jacket 3 Coolant in...

Page 8: ...Front suspension hole diameter coordinate 11 374 5 23 5 11 355 92 5 To main fixed hole 4 Rear suspension hole diameter coordinate 11 35 5 116 5 16 0 0 11 30 5 132 5 To main fixed hole 5 Top suspensio...

Page 9: ...t 100mm 16 original resistance Pa 17 Pipe diameter mm Inner diameter 34 18 Pipe length mm 625 or 1225 19 Volume L 4 5 20 accelerant No 4 3 fuel supply system S N Items Parameter Description Remark 1 C...

Page 10: ...k 1 radiator Structure Integration thermo switch liquid adding hole pressure regulating valve 2 Model 19600 E02B 00A0 3 Radiating area 4 Thermo switch starting temperature 65 5 Pressure control bar St...

Page 11: ...5 8 High voltage wire mm 450 with shielding line 9 Spark plug K Damping electric resistance 5 10 rectifier Structure Three phase full wave rectifier 11 Model 32100 E02B 0000 12 Install requiremnet fix...

Page 12: ...roke about 27 4mm 7 Valve diameter mm 40 8 Intake pipe Structure Integration fuel injector intake air temperature pressure sensor 9 Fuel injector Install requirement Follow intake tube assembly angle...

Page 13: ...0mm straight reach upward water level included angle 15 Refer to 4 6 01 20 Fault indicating lamp Wire K output 12V to driving indicator light current less than 1A 21 Diagnostic apparatus connector 6p...

Page 14: ...d shift gear often if running in not good more faults will be increased Maintain the engine after driving 300km and 1000km improve the engine working condition to ensure good engine performance Mainta...

Page 15: ...speed avoiding to work in high RPM with high load Note The electric control system of the engine must work with engine against reverse ignition function Or it might cause starting system damaged such...

Page 16: ...utral position Nis between shift 1 and shift 2 it only takes half shift If reverse shift is set reverse shift R will occupy shift 1 2 to 5 will be changed as shift 1 to shift 4 the order will be chang...

Page 17: ...5000 Every 5000 Every 10000 Lubricating oil G G G G G Oil filter element G G G G thick filter screen Q Q Q Q Q Magnet ring Q Q Q Q Q Note G replace Q Clean Remark replace oil filter element can t be u...

Page 18: ...should be water overflow Refer to picture 2 Cooling water mix ratio table Lowest temperature Antifreeze agent V Distilled water V 9 20 80 16 30 70 25 40 60 37 50 50 44 5 55 45 Cooling water should mix...

Page 19: ...nge nut M6 10 2 All 6 GB T6177 1 2000 Hexagon flange nut M8 20 3 All 7 GB T70 1 2000 Hexagon socket head cap screws M6 x25 M6 10 2 Tightener 8 90302 E02 0000 Valve clearance adjusting nut M5 7 1 Inlet...

Page 20: ...fuel pump Fuel injector blocked EFI Wash or replace Fuel pressure low EFI Check fuel pipe connection Check pressure replace fuel pump Fuel quality contain moisture Use new fuel Fuel deposited for too...

Page 21: ...nce Ignition coil damaged Replace ignition coil Igniter damaged carburetor Replace igniter Crankshaft sensor failure trigger Clean scrap iron or replace EMS EFI system fault Diagnostic with EMS Intake...

Page 22: ...eposition in spark plug electrode Remove carbon deposition Intake exhaust system Air filter blocked Clean or replace filter element Exhaust clog Muffler blocked dredge Vent or muffler carbon deposited...

Page 23: ...reset Check and replace Carburetor adjustment improper Readjust idling adjusting screw Pump pressure regulator fault EFI Replace oil pump pressure regulator air intake temperature sensor fault EFI Re...

Page 24: ...arburetor adjustment improper Adjust carburetor EFI idling control relative parts failure connect failure Check connection fault diagnosis Exhaust system Muffler blocked Dredge clean carbon Electric s...

Page 25: ...et spring slip off Check and replace Gearshift difficulty Clutch separated not completely Solve per clutch trouble removal Operation improper Improve operation Variable shaft deformation Check and rep...

Page 26: ...26 Annex 1 E02 Outline drawing...

Page 27: ...27 Annex 2 Carburetor wires connection schematic Diagram...

Page 28: ...28 Annex 3 EFI wires connection schematic Diagram...

Page 29: ...29 Annex 4 Carburetor wires and connectors model...

Page 30: ...30 Annex 5 EFI wires and connectors model...

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