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Item 

Cause  

Solution 

Starting transmission gear damaged(with 
abnormal sound) 

Check and replace 

Starting  one  way  clutch  failure (motor 
idling) 

Check and replace 

Starting motor failure 

Replace  

Starting relay failure 

Replace 

Insurance off 

Replace 

Ignition 
system 

Trigger signal connection wires not good  Check connection 

High voltage connecting wire unreliable

Ensure 

high 

voltage 

connect wires reliable 

Spark  plug 

fault 

Spark 

plug 

carbon 

deposition  

Remove  sparkplug  carbon 
deposition 

Spark plug damaged 

Replace new sparkplug 

Spark  plug  clearance  too 
big or too small 

Adjust sparkplug clearance

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/exhaust 
system 

Air filter blocked 

Clean air filter 

Air intake system pipe air leakage 

Ensure  intake  pipe 、 air 
filter  not  damaged , each 
connection  fixed 、 no  air 
leakage 

Exhaust 
clog 

Muffler blocked 

Dredge  

Vent  or  muffler  carbon 
deposited 

Remove carbon 

Valve timing 

Bore  pressure  too  high 、 starting 
resistance too much 

Adjust valve clearance 

Check  pressure  regulator 
and replace camshaft 

Valve not timing 

Check  and  adjust  valve 
timing  

Engine  

Cylinder 
pressure not 
enough 

Cylinder  head  and  body 
connect face leakage 

Replace  sealing  gasket ,
tight cylinder bolt 

Spark plug leakage 

Tight spark plug 

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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