PowerMax ROUGH-RIDER 700 UTV Maintenance Manual

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700UTV Maintenance Manual

Catalog

General Information

……………………………...5

1 Description

…………………………………………………..5

1.1 Identification code………..……………………………..6

1.1.1. Frame No. …………………………………………………6

1.1.2. Engine No.…………………………………………………7

1.2 Special tools, instruments and meters…………………7

1.3 Periodic maintenance chart……………………………….10

Engine

………………………………………………………….11

2. Inspection and adjustment of engine

…………….11

2.1 Inspection of cylinder head, intake

and exhaust valve………………………………………….11

2.2 Inspection of spark Plug………………………………….14

2.3 Inspection of cylinder, piston and piston ring…….15

2.4 Inspection of crankshaft………………………………….18

2.5 Inspection of clutch……………………………………….19

2.6 Inspection of carburetor………………………………….19

2.7 Inspection of air filter………………………………….20

2.8 Inspection of oil filter………………………………….21

2.9 Inspection of lubrication system……………………….21

2.10 Lubrication of engine…………………………………….22

2.11 Inspection of cylinder head…………………………….22

3.Disassembly of engine

……………………………………27

3.1 Cylinder head and block………………………………….27

3.2 Piston and connecting rod……………………………….32

3.3 starting mechanism………………………………………..33

3.4 Sensor………………………………………………….…….33

3.5 Left crankcase cover……………………………….…….33

3.6 Magneto…………………………………………………..….34

3.7 Oil pump………………………………………….……..….34

3.8 Clutch…………………………………………………...….36

3.9 Carburetor……………………………………………...….36

3.9.1 Structure of carburetor………………………...…..36

3.9.2 Inspection and adjustment of carburetor…....….37

4.Chassis

4.1 Direction system………………………...……………...42

4.2 Brake system…………………………………………...….57

4.3 Wheels and tires……………………………………...….77

4.4 Transmission system…………………………….…...….81

4.5．Reverse mechanism parts…………………………………89

4.6 Suspension…………………………..…………………...91

4.7 Cooling System of Engine..……。。。。………………..97

4.8 Iubrication points………………..………………….102

5. Electrical system………………………..……....….105

5.1 Ignition system…………………………..……....….108

5.2 Magneto and charging system…………..……....….109

5.3 Battery……………………………………..……....….110

5.4 Lighting system…………………………..……....….111

5.5 Meterand signal system…………………………..……112

5.6 Electrical starting system…………….……..…….113

6.Appendix

………………..…………………..……....…115

6.1 Specification………..…………………..……....….115

6.2 Requirements for torque of fastener……………….121

6.3 Electrical circuits……………………………....….122

1.Description

General Information

1.1 Identification code

1.1.1. Frame No.

Frame No. is carved in the lower right side of Figure 1-1

Figure 1-1

1.1.2. Engine NO.

Engine NO. is carved on the right side of the engine, fighre 1-2 fighre 1-2

1.2 Special tools, instruments and meters

1.2.1 Oil filter detacher

To fasten and detach the oil filter

1.2.2 Height gauge

To gauge the height of various components

1.2.3 Vernier

To measure the length of various components

1.2.4 尺 Outside micrometer

To accurately measure external diameter of a column

1.2.5 Inside micrometer

To accurately measure internal diameter of a hole

1.2.6 Dial indicator

To accurately measure a small distance

1.2.7 Torque Spanner

To measure torque force

1.2.8 Feeler gauge

To measure gap-width

1.2.9 Multimeter

To check electrical circuits and parts

1.2.10 Barometer

To measure pressure of the tyre

1.2.11 Magneto drawing device

To detach the magneto

1.2.12 Snap ring clamp

To install and detach snap rings

1．2．13 Steering wheel pull tool

1.3 Maintenance schedule

Maintenance schedule

ITEM

ROUTINE

Whicheve comes first month km

(mi) hours

Valves

● Check valve clearance.

● Adjust if necessary.

Sparkplug

Air fiter element

● Check condition.

● Adjust gap and clean.

● Rep;ace if necessary.

● clean.

● Replace if necessary.

Carburetor*

Crankcase breathersystem*

Exhaust system*

Spark arrester

● Checkandadjustidlespeed/starteroperation.

● Adjust if necessary.

● Check breather hose for cracks of damage.

● Replace if necessary.

● Check for lecakage.

● Tighten if necessany.

● Replace gasket(s) if necessary.

● Clean.

EVERY INITAL

320

3 6 6

1,200 2,400 2,400

4,800

(200) (750) (1,500) (1,500) (3,000)

20 75 150 150 300

○ ○ ○ ○

○ ○ ○ ○ ○

Every20-40hours

（More often in wet of dusty areas.）

○ ○ ○ ○

○ ○

○

Fuel line*

● Check fuel hose for cracks or damage.

● Replace if necessaly.

●Replace.(Wamenginebefore draining.)

○ ○ ○

Engine oil

○ ○ ○ ○

Engine oil filter cartridge

●Replace.

Engine oil strainer*

●Clean.

○ ○ ○

○

Final gear oil

Differential gear oil

● Check for oil leakage.

● Replace eveny 12 months.

Front brake*

Rear brake*

● Check operation/fuid leakage.(See NOTE page 8).

● Correct if necessary.

● Check operation.

● Adjust if necessary.

○ ○

○ ○ ○ ○ ○

Select lever safety system cable

V-belt*

Wheel

Wheel bearing*

Front and rear suspendion*

Steering system*

Drive shaft universal joint*

Axle boots*

Fittings and fasteners*

Lights and switches*

● Check operation.

● Adjust if necessary.

● Check operation.

● Check for cracks or damage.

● Check balance/damage/

● Repair if necessary.

● Check bearing assemblies for lossenss/ damage.

● Replace if necessary.

● Check operation.

● Correct if necessary.

● Checkoperation./Replace if damaged

● Check toe-in./Adjust if necessaly.

● Lubricate with lithium–soap–bassed grease.

● Check operation.

● Replace if damaged.

● Check all chassis fittings and fastenrs.

● Correct if necessary.

● Check operation.

● Adijust headinght beams.

Engine

○ ○ ○

○ ○ ○ ○

○ ○

○ ○ ○ ○ ○

○ ○ ○

○ ○ ○ ○ ○

Inspection of cylinder head, intake and exhaust valve

Preheat the engine ,then misfire and unplug the spark plug.

Fix pressure gauge into the hole, open the choke and throttle handle, and start for 4-6 times.

Note: Giving a leakage check to the pressure gauge.

Rotate the engine until the pressure gauge stop rising.

The maximum reading would be greater than 0.7-0.9Mpa

after starting for 4-6 times.

See figure 2-1.

Figure 2-1 check the valve lash

Note: when adjust valve lash, the engine must be cooled.

(The tempreture should be less than 35℃ )

Remove the seat cushion and fuel tank, unplug the vision hole cover ,round the flywheel of magneto anti-clockwise to aim “T” at the signal of fore cover on the left.

Note: The piston must be fixed to the dead enter.

(Figure

2-2)

Figure 2-2

Remove cylinder valve cover, check the lash between the valve stem by feeler gauge .

Valve clearance: inlet and exhaust valve: 0.05～0.08mm.

See figure 2-3.

Figure 2-3

Loose the lock nut,rotate the adjusting screw until it appears that the feeler gauge be pulled .Then fasten the adjusting screw by valve adjuster,tighten the lock nut and check the valve lash .Afterword install the cylinder valve cover , vision hole cover,the fuel tank and cushion. See figure

2-4.

Figure 2-4

1. Unplug the Spark-Plug cap:remove the spark plug by box key,look over

whether the spark-plug insulator and

electrode is damaged or sooting.

If so ,see figure 2-5. Figure 2-5

2． Check the spark clearance by feeler gauge whether it

is between 0.6～0.7mm.Or adjust the gap,clean incrustation

with spark-plug cleaner and steel

wire brush and check if the spark plug sealing washer(Figure 2-6). Figure 2-6

cylinder

Piston,piston ring and piston pin connecting rod item bore diameter of cylinder taper out of roundness degree of toruosity external diameter of piston bore diameter of piston pin hole gap between piston pin and piston pin hole

Piston ring end Top ring/the clearance gap between second ring oilring piston ring and piston top ring the second groove ring gap between cylinder and piston external diameter of piston pin bore diameter

Gap between small end of connecting rod and piston pin standard value:mm limit value:mm

φ102～φ102.03

0.0040

0.0035

0.04

φ101.95～φ101.97

φ22.002～φ22.010

0.007～0.020

0.25～0.40

0.3～0.9

0.3～0.07

0.02～0.06

0.03～0.08

φ21.995～φ21.990

φ22.016～φ22.027

0.016～0.033

φ102.1

0.005

0.06

φ101.92

φ22.010

0.02

0.5

1.2

0.10

0.09

φ21.96

φ22.03

0.035

3.Swirl the when spark plug and tighten to 18～20N.m by box key ,then fix the spark plug cap when assembling.

Camshaft lube is injected by a hole of engine body into cylinder ,so the hole must not jam.It is necessary to fix the cushion and adjer without dust permeated into the crank case before assembly.

diagnosing and eliminating of malfunction:

●

Emission of black smoke for abrasion of cylinder or piston,

1. Cylinder , piston of piston ring is worn out.

2.The piston ring is not properly assembled.

3. The piston or cylinder wall is scraped.

●

overheated

1、

Excessive incrustation of piston.

2、Blast and abnormal noise.

3、Abrasion of cylinder or piston.

Inspection of cylinder.

1.Check whether the cylinder is damaged.

2.Measure the bore diameter of cylinder at three spots.

3.At the top,the middle and the bottom of the piston stroke .And measure the bore diameter at directions of right-angle intersection. repairing limit value: out of roundness: 0.005 mm

taper ：0.005mm

Inspection of piston and piston ring

Measure the gap between piston ring and piston groove.

1.unplug the piston ring;

Note:It is forbidden to damaging the piston ring when assembling.Check whether the piston and the piston groove is cracked and abraded.See figure 2-7

Figure 2-7

2.Insert piston ring into cylinder,and measure the

end gap.repairing limit value:the first ring/the

second ring: 0.5mm

See figure 2-8. Figure 2-8

Measure the bore diameter of piston pin hole. repairing limit value: see figure 2-9

Figure 2-9

3.Measure the external diameter 10mm

above the bottom of the piston skirt.

Extreme position :The gap between

cylinder and pistonrepairing

limit value: 0.1mm See figure 2-10

Figure 2-10

7 Measure the external diameter of piston pin:

The gap between piston and piston pin:

Repairing limit value: 0.02mm .See figure 2-11

Figure 2-11

2.4 Inspection of crankshaft

check that whether crank and connecting rod can rotate without stuck and whether the clearance between crank and connecting rod is 0.5～0.6mm.The hop of crank shaft should be 0.05mm.If not so,replace it. See figure 2-12-1, figure 2-12-2.

Figure 2-12-1 Figure 2-12-2

Inspection of clutch

The wear condition of shoe block and friction plate: See figure 2-13

Figure 2-13

2.6 Inspection of carburetor

1、Inspect the idle of carburetor

The engine speed should be 1500±150r/min 10 minutes after starting at normal idle and will not misfire when briskly accelerate.If not so, rotate the carburetor idle adjusting screw clockwise to rise the idle , anti- clockwise to lower.When adjusting is unavailable,check

that if there is a jam in

carburetor idle nozzle or a air-leakage of intake pipe.

See figure 2-14

Figure 2-14

1、Disassemble the air cleaner,remove cartridge,clean the cartridge with non-flammable cleaning solvent,and then make it dry.

Note: Petrol is forbidden.

2.Dip the air filter cartridge into 20# oil,then take it out and squeeze the excessive oil,assemble it orderly.Impermeability is necessary.See figure 2-15, figure 2-16.

Figure 2-15 Figure 2-16

22 ． 88

Cleaning of lubricator oil strainer:remove clarifier

(Figure 2-17),clean it to ensure a well work- condition.Then fix it up.

Note: Clean the clarifier

before injecting oil

into crankcase.

Figure 2-17

Lubricant of engine:the vehicle is oiled with lubricant capacity :

1.The capacity is 1.9L after disassembly and assembly.

2、The capacity is 1.8L when fueling up after drain.

Inspection of lubricant:locate the dune buggy on the ground to lookover the capacity with dip stick.If the level is lower than the bottom indicator,fuel up with recommended lubricant to the upper indicator.

Inspection of oil pump:

Flow of oil pump:

r/min

L/min

1000

3.78

2000

7.43

3000

10.89 measure clearance of the top of internal external rotor

Limit value: 0.20mm

Check the oil level,start the engine and let it running for a fow minutes to make it heated and lubricated completely ,then misfire.Unplug the dip stick to do cleaning and dip it into the oil case again.Then unplug the dip stick and look whether oil level is lower than the indicator. See figure 2-18

Note:Ensure that the engine is landed by both four wheel in flat ground.

Indicator of oil level

Figure 2-18

2.

11

1. Check whether the spark plug and valve seat is cracked and whether the cylinder head is out of shape.Examine the flatness of cylinder head by flat or knife edge gauge and clearance gauge .

Repairing limit value:

0.05mm.See figure 2-19

Figure 2-19

2 Remove and examine the width of valve .

Repairing limit value: 2.0mm.

See figure 2-20-1 , 2-20-2, 2-20-3.

If the mating surfaces is coarse,corrode or cannot contact with valve seat normally.repalce it.

Figure 2-20-1 Figure 2-20-2

Figure 2-20-3

Measure the width of mating surfaces of valve repairing limit value: 1.5mm

If the valve seat is to wide or narrow or cracked, grind it to ensure impermeability.

4、Measure bore diameter of valve guide with internal micrometer and special gauge.At last calculate clearance between valve stem and valve guide.

Repairing limit value: intake : 0.12mm exhaust: 0.14mm

Note: Eliminate carbon in the pipe before measuring.If the pipe will be replaced,grind the valve seat again .

5、Inspection of valve and valve pipe:

Check whether the valve is bent, burn or the valve stem is worn out.

Check the motion of valve and measure external diameter.

Repairing limit value: intake : 5.95mm exhaust: 5.95mm

See figure 2-21.

Fix valve into guide and look over the motion.

Figure 2-21

Inspection of valve spring

Measure the free height and squareness

Repairing limit value:(intake and exhaust)

See figure 2-22-1, 2-22－2 free height of inlet valve spring: 32.5mm, squareness:0.10mm free height of exhaust valve spring: 36.2mm squareness:0.10mm

Figure 2-22-1 Figure 2-22-2

6、Examining lifting distance of breaker cam.

Measure the length of fillet with micrometer and check

If it is worn out.

Repairing limit value:inlet lifting distance: 5.73mm

Exhaust lifting distance: 6.53mm.See figure 2-23.

Figure 2-23

7、Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal.

Repairing limit value: φ22.939mm

Inspection of rocker arm.

Check whether the rocker arm is worn out,or damaged and whether the oil hole is blocked.

Note:If there is a rocker arm to be replaced,examine the peak of breaker cam

measure the bore diameter of rocker arm

Repairing limit value: φ12.038mm.See figure 2-24

Figure 2-24

Inspection of rocker arm shaft.

Examine if the rocker arm if worn out or cracked.

Measure the external diameter of rocker arm shaft with micrometer.

Repairing limit value: φ11.96mm

The repairing limit value of clearance between rocker arm shaft and hole : 0.05mm ,See figure 2-25

Figure 2-25

① Unplug the intake pipe and spark plug.( Figure 2-26-1,

Figure 2-26-1

② Remove cylinder valve cover,cam chainwheel cover and

Figure 2-27-1

③remove valve chain wheel Figure 2-27-2

Figure 2-27-1 Figure 2-27-2

④remove lower rocker arm shaft.See figure 2-28

Figure 2-28

⑤Remove vision hole cover of left front cover .See figure 2-29

Figure 2-29

Alignment: asjust these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover. alignmentment of top dead center:

Rorate the crankshaft with “T” sleeve anti-clockwise until these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover .That is to say the piston of cylinder is at the top dead center.

Inspection of compression top dead center:

See figure 2-30-1 and figure 2-30-2. figure 2-30-1 figure 2-30-2.

When inlet valve spring rise,rotate the crankshaft until the “T” indicator on the magneto rotor to be at the same level with the center of vision hole cover of left front cover.That is to say the piston is at the compression top dead center and there are valve clearance in these four rocker arms of cylinder head. See figure 2-31

Figure 2-31

Remove chain tensioner adjuster.See figure 2-32.

Figure 2-32 remove the cylinder head

Loosen the bolt by intersection manner before remove the

bolt.see figure 2-33.

Figure 2-33 remove adjuster cotter sealed ring

of cylinder headtensioner

adjuster guide board

See figure 2-34.

Figure 2-34 remove cylinder block0-seal adjuster cotter sealed ring of cylinder head

See figure 2-35.

Figure 2-35

3. 2 piston and connecting rod

①remove the piston snap ring

Note: block the crankcase breather with a piece of cleaning cloth to avoid the snap ring falling into the case

.See figure 2-36.

Figure 2-36

②remove piston pin and piston

Clean the buckle of piston and piston pin hole to facilitate the removing of piston pin.

Note:it is forbidden to knock the piston pin with a hammer.

See figure 2-37.

Figure 2-37

33 starting mechanism

3.4 sensor

Figure 2-38

3.5 left crankcase cover

See figure 2-39

Figure 2-39

3. 6 magneto

Remove the stator coil

Remove the pluse coil

Remove the stator with rotor

Stripper.See figure 2-40.

Figure 2-40

Remove the whitney key. See figure 2-41

Figure 2-41

3.7 oil pump

Remove the bolt of oil pump cover .See figure 2-42.

Figure 2-42

Remove right cover

.See figure 2-43.

Figure 2-43

Remove the right support frame, clutch pulley disc .See figure

2-44-1, figure 2-44-2, figure 2-44-3.

Figure 2-44-1 Figure 2-44-2

Figure 2-44-3

3.8 clutch

①remove the clutch

Remove bolts. See figure 2-45.

Figure 2-45

Remove the clutch shoe block and clutch cover.

See figure 2-46

Figure 2-46

Check the wear condition of the clutch shoe block and clutch cover.

See figure 2-47. Figure 2-47

3.9 carburetor

3.9.1 structure of carburetor

1．carburetor assembly 2.oil needle component 3.Plunger spring 4. Big diaphragm

5.Plunger 6.Diaphragm circlip7.Screw on upper cover 8.Mixture ratio adjusting screw component。9 .idle metering jet 10.High speed jet 11.Liner 12.Foam pipe

13.0-ring of foam pipe 14.Float 15。Screw M4×816。Float pin 17.Big screw

18.Float seal ring 19.Fuel inlet valve component 20.High speed jet 21.Drain screw

22.idle metering air jet 23.Enriching Plunger component 24.Seal ring of external shaft cover 25.External shaft cover 26.Screw M4×8 27.Suction pipe A

28.T- plastic pipe 29.Suction pipe B 30.ACV valve diaphragm cover 31.Screw

M4×12 32。Suction pipe C 33.ACV valve diaphragm component 34.Fuel inlet pipe 35.Starting jet 36.Dust-proof cover 37.Screw 38.Nut 39.acceelerator pull cablelocating dowel loop 40.adjusting screw component 41.Screw

42．Washer 43.Fixing clamp 44.Washer 45。Screw 46。clip 47.Robber pipe

48.Non-return valve 49.Flood pipe

decomposition

1. Remove the evacuated chamber cover

2. spring

3. piston valve remove permanent seat spring

spring block oil needle remove pilot screw spring washer

Note:the pilot screw is set at maximum performance.Before removing pilot screwd,note the revolutions of screw in order to fix it back. remove float chamber cover washer remove float pin float triangular needle remove the cover nut

0-rings spring starting plunger pilot jet check the carburetor body float bowl oil passage gas-fouling block→cleaning chap/damage→replace the carburetor assembly cleaning steps: check the float damaged→replace check the float triangular needle triangular needle seat

0-rings filter gauze

Damaged/worn out/block→replace check the piston valve crack→replace diaphragm rupture→replace piston valve oil stick

bent/worn out→replace

Note:If the piston valve is damaged,inject the petrol into valve.Replace it when there is oil leakage. check the main jet main jet pilot jet pilot screw

0-scrapers pilot jet bent/worn out/damaged→replace gas-fouling block→blow with compressed air

Chassis

Automobile body fastener locking moment of force

Locking spare part

F/Rrocking shaft and frame

Disk and the wheel hub

Fastener specificat

（N.m） ion

Force

M10 45

Note

M8 23

F disk and the front wheel

M8 steering knuckle

R disk and the rear wheel M10 steering knuckle

F/R wheel and the wheel hub M10

Direction column and direction

M14 stylobate

Inside and outside direction M8 column and direction column

Direction and direction column M8

F/R bridge gear box and frame M10

Front wheel hub and drive shaft M18

Engine and connecting board M6

The setting base of the engine M10 and the frame

The engine and the setting base M10

King pin ball head M10

F/R shock absorberand and M10 frame/rocker shaft

Rear steering knuckle and M10

120

Other uses

Other uses M5 6

(The behind torsion revise follow to this table)

4.1 Direction system

The structure of the steering

1、

Direction column groupware

2、Azimuth training gear drive gear 3、Spring elastic ring 4、Seal packing collar 5、Regulator cover 6、Compression spring 7、

Compressesthe pad 8、gasket 9、gasket 10、The rubber dirt-proof boot holds the band

11、 Left rubber dirt-proof boot 12、Flange bolt M10×30 13、Azimuth training gear ball head 14、tension bar locking nut M10 15、Changes the drive shaft part 16、

Flange bolt M8×20 17、Slot nut M12 18、2 Cotter pin3.2×32

The structure of Steering wheel part

、

Flange bolt M8×16 2、 mast jacket part

3、

Steering wheel part

4、gasket ф12.5 5、Flange self-locking nut M12×1.25 6、

Plastic center lid

Daily inspection

1、Inspect it whether has the crack and the distortion

2、Inspect the ends ball whether becomes less crowded,the dustproof rubber set does appear the aging, bursts.

3、Inspects the steering wheel whether appears the crack, flexible and moves.

4、Checke the steering wheel to rotate whether nimble, do not have stagnation.

5、Inspects the torque of the steering wheel whether obviously increase.

Attention

Thesteering force cutting which exerts to transfers in steering wheel outflow boundary is smaller than 245N.

6、Inspects the reverse running clearance whether does surpass the limited stipulation.

Attention

Tthe reverse running clearance is smaller than30mm .

If find some problems in the daily inspection,it should be service immediately to ensure the normal work of the steering system.

Warning:Any quality flaw of the steering system can cause the serious damage to the driver or send its death.

4.1.1 Dismantle,inspect,maintain and reinstallment the steering system

4.1.1.1 Dismantle the parts of the steering wheel

1、Takes down the plastic center lid

2 、 Takes down the steering wheel fixing nut, the gasket.Attached figure 4-1-1.

Attached figure 4-1-1

gasketф12.5

Flange self-locking nut M12×1.25

3、）Use the special tools(attacheh figure1.2.14)pull out the steering wheel.(attached figure1.2.14)

Attached figure4-1-2

1. Steering wheel

4.1.1.2 Inspect the steering wheel

1、 Inspects the steering wheel whether has the hidden danger which the fissure and possibly breaks, if has, must replace the steering wheel.

Attached figure4-1-3

1. The framework of the steering wheel

2、 Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. (Attached

figure4-1-3)

3、 Inspects the grip part which is covered by the foam whether has damaged, if it is,must replace a new steering wheel

4、Checke the internal spline between the steering wheel and steering column whether have damaged,if the attrition is serious,must replace the steering wheel.

The tolerance clearance between the internal spline on the steering wheel and outer spline on the steering column is smaller than 0.1MM.

4.1.1.3 Dismantle the steering column parts

1、 Takes down the parts of the front panel (engine covers) , the connection covers part, the display board and the steering wheel center covers (attached figure 4-1-4).

Attached figure 4-1-4

1. Front panel

2. Connecting cover parts

steering wheel center covers

4. panel

5. steering wheel

2、 Take down the steering wheel(Attached figure4-1-4)

3、Loose the M bolt which is on the steering drive axle, the top of splinet, draws out the cross gimbal.

4 、 Loose the fastening four piece M8 × 16bolt on the steering column,take down the steering column from the frame.((Attached figure4-1-5)

(Attached figure4-1-5)

1. Flange nut

M8×16

Steering column parts

3、Frame

4.1.1.4 Inspection and maintain the steering column parts(Attached figure4-2-6)

Attached figure4-2-6

steering column tube

Bearing

central axis of the steering shaft

Spline

1 、 Inspect the central axis of the steering shaft whether flexible and moves.If does,dismantle and checke the axis,bearing and retaining ring whether ware or damaged,according to the inspection situation to instead the parts.

2.Checke the two ends of the spline on the central axis whether is wear out,if so,instead the central axis.

3、Checke the spline in the tow ends of the central axis whether have wear,if dose,instead the central axis.

4、Inspect the steering column tube and welding line of the branch whether have crack and corrosion,if it does,instead the steering column tube

4.1.1.5Dismantle the steering drive axle

1、Loose the clamp bolt in the cross gimbal, internal spline on the top of the steering drive axle,pull out the top of

the steering drive axle.(Attached figure4-1-7)

Attached figure4-1-7

the steering drive axle

2. Flange bolt M8×20

2、Loose the clamp bolt in the cross gimbal, spline on the bottom of the steering drive axle,pull out the lower of the steering drive axle.(Attached figure4-1-8)

Attached figure4-1-8

1Flange boltM8×16

2. Flange boltM8×20

4.1.1.6 Inspect and maintain the steering drive axle

1、Inspect the cross gimbal turn agility with no stagnation.

If does,dismantle and checke the cross axis, needle bearing,and the bearing hole on the cross gimbal fork whether have wear and corrosion,to instead the parts basesd on the checke.(Attached figure4-1-9) the cross gimbal

Attached figure4-1-9

Attention Install the cross gimbal,daub the lithium grease on the surface of the bearing.

2 、 Inspect the transmission shaft whether have crack and distortion.If it does,instead the parts.

4.1.1.7 Dismantle the direction machine part

1、Loose the four piece of nolt,dismantle the direction

machine from the frame.(Attached figure4-1-9

Attached figure4-1-9

1. Frame jointing board

2. connecting bolt

3. Direction machine

2 、 Loose the open-groove nut on the L/R turning steering knuckle,take down the steering tension rod from the steering knuckle.(Attached figure

Attached figure4-1-11

1. Cottor pin3.2×32

2. O pen-groove nut

M12

Direction machine ball

Steering knuckle

4.1.1.8 inspect and maintain the direction machine parts

1、Inspect the drive of the gear whether agile.

If it is not agile, dismantle the direction machine to see the gear and rack whether have wear,instead the parts according to the inspection.

2 、 Whether the inspection gear drive reverse gap does surpass the rating

If it does,adjust the gap and the bolt .

If cannot reduce the gap through the adjustment, instead the gear, rack

3、Inspects the dustproof rubber set whether gets older and dehiscence.Replace the olde rand dehiscence rubber wrap

4、Inspect the tow balls on the steering tension rod whether rotates nimbly with no loose. If it is not, replace the ball.

5、Inspects the dustproof rubber set of the ball whether gets older and dehiscence.Replace the olde rand dehiscence rubber wrap.

6、Inspect the steering tension rod whether have crack and distortion.If it does, through the sizing repair

Warnning: Do not use the welding to repair the steering tension rod.

Attention

1、When replace the rubber set of the ball , must enter 1/2 volumein lithium grease in to the rubber.

2、When replace the direction machien,cleaning all the parts,and daub the lithium grease in to the movement.

Attention:continue to ues

the hidden danger Ball

pin may causes the serious accident or the death.

4.1.1.3Reinstalls the steering system parts

1. Connecting the direction machine with four pieces bolt M10

×30 on the frame,then use tow pieces of locknut to connect the direction machine ball and the rod.(Attached figure4-1-12-1) figure4-1-12-2

Attached figure4-1-12-1 figure4-1-12-2

1. direction machine

tension rod

set bolt

locknut

Direction machine ball

M10*30Bolt tight of force,40N.m

M10Nut tight of force,36N.m

2. Connecting the steering transmission shaft and direction machine with one piece of flange boltM8 ×

20.(Attached figure4-1-13)

Attached figure4-1-13

direction machine

Hexagon flange nutM8×20

steering transmission shaft

M8*20 Bolt tight of force,32N.m

3. Connecting the steering transmission shaft and steering column tube with one piece of flange boltM8×20,then use

four pieces of flange nut M8×16 fix the steering column tube on the frame.(Attached figure4-1-14-1 figure4-1-14-2)

Attached figure4-1-14-1 figure4-1-14-2

steering transmission shaft

Hexagon flange nutM8×12

Hexagon flange nutM8×20

steering column tube

3. steering column

M8 Bolt tight of force,32N.m

4. Use one piece of flange self-lock nutM12×1.25 fix the steering wheel on the steering column tube,then cover the direction column plastic center lid.(Attached figure4-1-15)

Attached figure4-1-15

1. flange self-lock nutM12×1.25

2. steering wheel

Steering wheel tight of force,40N.m

4.2 Brake system

Front Disk Brake components

1、

Brake pump assembly

2、flange boltM6×20 3、tape3（L＝150） 4、） tape4 （L＝200） 5、tape3（L＝150） 6、flange boltM6×30 7、flange boltM6

×20 8、band 9、flange boltM6×20 10、brake tube seatI 11、

Brake components

4.2.1 Preparation for inspection before the maintenance of the brake system.

。Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained.

This vehicle uses the double return route hydraulic pressure disc brake system.Please follow the tips of inspection as below. a) To check the amount of liquid in the oil cup.If it is lower than the minimun mark(Attached figure4-2-1),refill the box with the same type of fluid as was recommended by the manufacturer,to ensure the fluid level is higher than the minimum mark.

Lowes tminimun mark

Attached figure4-2-1 b) )The brake pedal should be kept between 20mm-30mm,

Otherwise, please adjust the screw to meet required travel distance.(Attached figure4-2-2)

20~30mm

Attached figure4-2-2

1. Brake pedal

Inspect the brake pedal does maintain the certain counter-tension(Attached figure4-2-2)

When checks disk brake plate, the saved liquid in the oil cup will pour automatically into the pressure pipe and the liquid level along with it to reduce, the periodic inspection the disk brake plate liquid volume will be an important project.

Attention,must use DOT4 Brake Flui

5.Periodical inspection of the wear condition of rear disk brake plate is also necessary.Disk brake plate must be replaced depending on its wear condition.(Attached figure4-2-3)

Attached figure4-2-3

1、Disk Brake

6. Disk brake plate uses hydraulic pressure of the brake fluid. Therefore, fuel pipe must be periodically inspected and replaced.

Inspection method: If the oil tubing has the aging, crack or distortion, must replace the oil tubing.

4.2.2Disassembly, inspection, maintenance and assembly of the hydraulic brake system.

4.2.2.1 Disassembly of front disk brake plate and the brake

plate clip parts.

1. Take down the front wheel parts(Attached figure4-2-4)

Attached figure4-2-4

1. Conical Nuts M10

2、Loose the tow pieces of bolts fixed the brake plate clip and take down it. (Attached figure4-2-5)

Attached figure4-2-5

brake plate clip

2. bolt

3. Sequently remove the cotter pins, open-groove nuts, cushion and front wheel hub from the front wheel shaft.

(Attached figure 4-2-6)

Attached figure 4-2-6

Cotter pins

3.2×32

Open-groove nut

M12

Direction machine ball

Front Sheep horn

Front wheel hub

4、Take down the brake plate from the front wheel hub.(Attached figure4-2-7

Attached figure4-2-7

Front disk brake plate

4.2.2. Dismantle the disk brake pump

1. Dismantle the disk brake pump installment place and take down the disk brake pump unit.(Attached figure4-2-8)

Attached figure4-2-8

The disk brake pump

The disk brake pump installment place

2.Loose the bolt M 6×12 which fixed the tighten disk brake oil cup,and take down it.(Attached figure4-2-9).

Attached figure4-2-9

Hexagon BoltM6×12

Disk brake oil cup

4.2.2.3 Dismantlethe rear brake plate clip and the rear disk brake plate

1 、 Dismantle the rear wheel parts(Attached figure4-2-10)

Attached figure4-2-10

1. Conical Nuts M10

2. Wheel hub

2 、 Remove rear disk brake clip from the rear bridge gearbox.(Attached figure4-2-11)

Attached figure4-2-11

1、Rear Disk Brake Clip

2、

Hexagon BoltM10×30

3. Loose the rear bridge gearbox on the frame,take down the middle transmission shaft parts.(Attached figure4-2-12)

Attached figure4-2-12

Disk Brake Clip

Disk brake plate

Middle transmission shaft

4. Take down the disk brake plate installment place from the rear bridge gearbox.(Attached figure4-2-13)

Attached figure4-2-13

The disk brake plate installment place

The rear disk brake plate

5. Dismantle the disk brake plate from the installment place(Attached figure4-2-14)

Attached figure4-2-14

Rear disk brake plate

4.2.2.4 Dismantle the disk brake vitta

1、Loose the vitta fixed nut on the front arm shaft and take down the front vitta.(Attached figure4-2-15).

Attached figure4-2-15

Hexagon BoltM6×12

2.Loose one piece of Mnut,which fixed the three Contacts tubing,then take down it.(Attached figure4-2-16)

Attached figure4-2-16

Hexagon flange Bolt M6

Three Contacts tubing of the disk brake

3、Loose one piece of Mnut,which fixed the right fuel pipe bracket on the frame and take down the fuel pipe.(Attached figure4-2-17)

Attached figure4-2-17

Connecting bolt

Rear disk brake vitta

4、Loose one piece of M nut which fixed the three contacts tubing of the rear fuel pipe and take it down.(Attached figure4-2-18)

Attached figure4-2-18

Two tubes of the disk brake

Hexagon flange Bolt M6

5、Break out the hydraulic brake system from the bodywork.

4.2.2.3 Inspect and maintain the hydraulic brake system

1.Inspect the brake oil cup whether heve crack and leak oil,if so,replace the brack oil cup.

2、Inspect all fixed nuts on the two ends of the fuel pipe whether become flexible and damaged

Maintain method,fix the flexible nut,instead the damaged nut.

Locking Torque: 30N.m

3、Check all Fuel Pipes for deterioration, distortion, crack, wear and other hidden defects.

Maintain method,instead the fuel pipes with problems.

4、Check the Brake Plate Clip for distortion, crack, rust and stuck.

Maintain method,instead the brake plate with problems.

5、Inspect the Disk Brake Shoe for wear condition. Brake shoe must be replaced when worn out.(Attached figure4-2-19)

Attached figure4-2-19

1、Brake Shoe

Attention: Brake shoe must be replaced when the thickness is less than 1mm

6、Inspect the Brake Shoe for maximum wear, distortion and

crack, in which case it must be replaced.

Attention,1.The standard thickness of the front disk brake plate is 4mm. Brake shoe must be replaced when the thickness is less than

3.5mm.

2.Replace the brake shoe when it is distortion and crack.

Attention:1The standard thickness of disk brake plate is 7.5mm.Disk brake plate must be replaced when the thickness is less than

6.8MM.

2.Replace the disk brake plate when it is distortion and crack.

4.2.2.4 Assembly of front Brake System

Use two nylon tape connect the the fuel pipe clip with both left and right higher front shaft arms.

Attention: Fuel Pipe must avoid physical contact with other components in movement.

Fix the Disk Brake Plate onto the Front Wheel Hub with four pieces of M Bolts.

Attention: grease the bolt with thread glue when fastening.

Fastening Torque of the Bolt: 22 N.m -28N.m

3、Fix the Front wheel Hub onto the Front Wheel Shaft with gasket,open-groove nuts and cotter pins.

(AttachedFigure 4-2-20)

Fastening Torque of the open-groove nut

,50 N.m -60N.m

AttachedFigure 4-2-20

Front Wheel Shaft

gasket

open-groove nut

4. cotter pin3.2×32

Conical NutM10

Front wheel Hub

4.Fix the Plate Clip onto Front Turning Joint with four pieces of M10×22 Bolts.

Fastening Torque: 18 N.m --22N.m

5、Assemble Front Wheel Components onto Front Wheel Hub with four piecesof

Nuts.(AttachedFigure4-2-20)

GB/T802M10 Conical

Fastening Torque of Conical Nut:50 N.m -55N.m

6.Fix Front Disk Brake Pump onto the frame with two pieces of

M M10×55 bolts

Fastening Torque of the bolt ,40N.m

Attention:Do not operate the vehicle immediately after assembling the brake system. Please apply the Brake

Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating before riding the vehicle.

7.。Fix Disk Brake Plate onto the Bottom Seat with six pieces of M8 Bolts.

Attention,Grease the bolt with thread glue when fastening

Fastening Torque of bolt: 22 N.m -28N.m

8.Mount the Bottom Seat of disk brake plate and rear middle transmission shaft and rear bridge onto the rear bridge.(AttachedFigure4-2-12)

9. Mount the Disk Brake Clip onto rear bridge with two pieces of Mbolt.

Fastening Torque,18 N.m -12 N.m

10 、 Sequently fixe the F/R three contacts of front fuel pipe,F/R fuel pipe.

4.2.3 Dismantle,inspect,maintain and instead the Parking system

4.2.3.1 Dismantle the parking system

1、Take down the central lid(AttachedFigure4-2-21)

AttachedFigure4-2-21

The Central lid

2 、 Loose the two pieces Mbolt,take down the parking handle.(AttachedFigure4-2-22)

AttachedFigure4-2-22

Parking handle

3 、 Take down the Parking Cable from the Parking handle(AttachedFigure4-2-23)

AttachedFigure4-2-23

1. Parking Cable

4.Take down the Parking Cable from the rear disk brake clip.(AttachedFigure4-2-24)

AttachedFigure4-2-24

1. Parking Cable

5、Loose two pieces of inner hexagon Mnuts,take down the parking institution from the rear disk brake clip.(AttachedFigure4-2-25)

AttachedFigure4-2-25

Rear disk brake clip

Connecting bolt

Rectangle four-head bolt

4.2.3.2 Inspect and maintain the Parking system

1 、 Inspect whether the Parking handle is loosen or distortion,carries on the adjustment to the loosen and distortion part.Instead the parking handle when the adjustment can not get the request.

2、Inspect the parking Cable

Instead the breaks cable

Replace the crack and loosen protective covering of the cable.

Pours into the few lubricating oil to increase the flexibility of the cable.

3、Inspec the parking institution

After cleaning the parking institution,checke whether the rectangle four-head thread in it is wear out,and instead the it.

4.2.3.3 Reinstall the Parking system

1 、 Grease the Lithium lubricating on the rectangle four-head thread.then load it in the parking bracket.(AttachedFigure4-2-25)

2、Assemble the parking bracke onto the rear disk brake clip with two pieces of inner hexagon M nuts.

3、Assemble the back-end of the parking cable onto the parking bracke.

4、Assemble the parking handle onto the frame with two pieces of M nuts.

5、Assemble the front of the parking cable onto the parking handle.

6、Adjust the inner hexagon nuts until the rear brake shoe exactly contact with the rear disk brake plate,then finish the adjustment with lock the inner hexagon nuts with spanner,

Attention:after the adjustment,the UTV can paking stabilized in the 12 ° pitch with the fully loaded.(The total quality is 920KG)

4.3 Wheel and Tyre parts

4.3.1 Preparation for maintenance of wheel.

1. Inspect the wear condition of the tyre. (Attached Figure

4-2-21)

Attached Figure 4-2-21

Check if the Wheel Hub is worn-out or damaged.(Attached

Figure 4-2-21)

3. Check if the Wheel Hub is rusted or cracked.

Check if the conical nuts of the Wheel Hub are loosen or distorted.

4.3.2 Disassembly, inspection and assembly of wheel components.

4.3.2.1 Disassembly of wheel components

Remove M10 Conical Nuts (4pcs) and detach the tyre.(Attached Figure 4-2-20)

4.3.2.2:Inspection of wheel components

1、Check if the wheel hub has any distortion, rust, crack or other potential defects. If so, please replace the wheel hub.

2、。Check if the tyre has reached its maximum wear condition in which case it should be replaced.

3、Check the joining condition of the tyre and wheel hub.

If the joint of tyre and wheel hub is loose, replace the tyre immediately.

4、Check the vibration of tyre/wheel hub.

Vibration of assembled Tyre must be controlled within 3mm.

Otherwise, please replace with new tyre.

Remove the tyre for vibration test of the wheel hub. Should the vibration exceed 1.2mm, the wheel hub must be replaced.

5、Inspect the four conical bores on the wheel hub. In occasion of angular distortion or wear,the wheel hub must be replaced.

The angle of the conical bores is 60°

4.3.2.3 Assembly of wheel

Attach the wheel hub onto the wheel with four pieces of

M10 Conical Nuts and a dustproof lid.

Caution: assemble the wheel in correct direction (shown as the arrow).

(Attached Figure4-2-22)

4.3.3 Speicification and operation guide of Wheel Hub and

Tyre.

Since wheels and tyres are crucial to the vehicle operation, inspection for tyre pressure and profile depth is necessary.

Specification of Wheel and Tyre

Wheel Hub Dimension

Tyre Dimension

（kPa/PSI）

Tyre Pressure

Front

Wheel

Rear

Wheel

12×6.AT

12×8AT

25×8-12

25×10-12

70/10

35/10

To ensure maximum security and longer life expectancy of the wheel, please periodically inspect the tyre pressure and profile depth. Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle

(such as hard turning). Excessive tyre pressure can also reduce the friction force between the tyre and ground, causing spinning or lose of control. Therefore, please ensure the tyre pressure strictly complies with figures shown in the chart above.

Before operating the vehicle each time, please check if profile depth of the tyre is over worn, which might result in spinning, instability, lose of control and other potential security risk of the vehicle.

Warnning: the profile depth falls below 3mm, pleasereplace the inmediatly.(AttacheFigure4-2-13) tyre

4.4 Transmission System

Front Bridge

front case components

1、front axle differential components 2、2 front retarder shell2 3、retarder shell1 4、initiative gear 5、knot fork Ⅰ 6、M10×1.25

flange surface self-lock Bolt

7、front bridge initiative gasket with jack（0.5T） gasket with jack（1.0T） 11、 hexagon bolt

M8×25 12、driven gear 13、 inner hexagon bolt M8×25 14、 inner hexagon bolt M8×10 15、M10×16 M10

×16 oil change bolt 16、Carry ring with hole 17、ф5×80column pin 18、power divider assembly 19、power divider coupling 20、rack 21、power divider"O"ring 22、 front case cover "O"ring 23、sulcate ball bearing6007R 24、sulcate ball bearing 6912 25、sulcate ball bearing 16007 26、needle bearing15BM2112 27、bolt M14×15 28、copper gasketф14×2 29、 power divider coupling 30、gasket with jackⅡ（0.1T） gasket with jackⅡ（0.2T）gasket with

Ⅱ（1.5T） 31、axes fork 32、front bridge croos gimbal combination 33、boltM14×15 34、 copper gasketф14×2 35、tube (L1700）36、pipe clampⅠ 37、front bridge croos gimbal combination 38、front bridge middle transmission shaft 39、spring flange 40、gasket 41、front bridge middle transmission shaft spring 42、front middle axes front dustproof cover 43、front middle axes rear dustproof cover 44、 gasket ф10 46、flange boltM10×110 47、flange nut M10 48、gasketф10 49、knot fork Ⅱ 50、front

bridge middle transmission shaft cover anchor ear

4.4.1 Disassembly, inspection, assembly of front bridge components(Reference the front bridge assembly,the figure of the front box parts).

4.4.1.1Preparation for disassembly and maintenance of front bridge components.

1.。Check if the connection between wheel hub and conical nuts is reliable wth no loosen.

2、If there is any distortion on the front wheel hub,the wheel hub must be replaced immediately.

3. Whether the spare part does coordinate with the sheep horn,whethe the sheep horn bearing exists stagnation,shake and noise,if bearing is unreliable,must disassemble the front bridge assembly(refer to the front bridge assembly,the figure of the front box parts),then instead the bearing to use.Checke the sheep horn whether have rupture,if so ,instead it.

4.Whether the constant velocity cardan joint does coordinate, to be correct to the position; If is not correct or the coordination is not good causes to the position hits the tooth and the different sound,

must dismantle it, installs and driving agine after the position correct.

5. Check if there exists any slip thread on the open-groove nut.

6. Disassemble the front bridge transmission box parts,checke each joggle whether contraposition and right,the joggle have no intervene.

7. Whether the oil nozzle does stop up, if so, first to use the needle to poke the materia,l If it will not be able to solved, replace the oil nozzle to install the original position of the front box .

8. If there is any problems with the sensor,it must be inspected and maintained by the special serviceman.

9. The gear is easy to wear out,and it is in the transmission system.

4.1.2 Disassemble,inspection and assembly of the front bridge

4.4.2.1 Disassemble the front bridge

1. Take down the left and right front wheel parts.

2. Sequently remove the front disk brake clip,cotter pin,open-groove nut,cushion and front wheel hub.

3、Disassembe the left and right arm rocker and cross steering knuckle.

4. Disassembe the differential device

5. Take down the front bridge from the frame

6. Emit the oil in the differential device

7. Pull out the left and right transmission shaft from the differential device.( Attached Figure 4-4-1)

Attached Figure 4-4-1

The right transmission shaft of front bridge

4.4.2.2 Inspection and maintain the front bridge

1、Check whether the dustproof rubber wrap on the left and right transmission shaft is dilapidation and aging,if so,instead the new one.

2、Checke whether the inner and outer ball cage of the left and right transmission shaft movement is

Smooth,ceaseless.If it is stagnation and obvious becoming less loosen,replace it.

3 、 Disassembe the left and right transmission shaft ,cleaning and assemble it again.

Attention,

1、The dustproof rubber wrap on the ball cage is not allow to contact with the gas and diesel oil.

2 、 The dustproof rubber wrap does not allow to be scratched,a slight scratches can damage the dustproof rubber wrap very quickly.

3、When reassembles the left and right transmission shaft, in the ball cage must sufficiently enter 2/3 volume with the Lithium lubricating.

4、Open the differential device and inspect the damage of the gears,axes adn gasket,instead those parts according to the checke.

4.4.2.3 Assemble the front bridge parts

1、Put the left and right transmission shaft in the front bridge differential device. (Attached Figure4-4-1)

2、Poursin 0.32L SAE 80 API GL-4 the high quality gear grease into the front bridge differential device and screws tight the oil filler bolt

Fastening Torque of Conical Nut,23N.m

3、Install the front bridge differential device onto the frame with two pieces of hexagon boltsM10×110,two pieces of nutsM10 and two pieces of flat gasket.(Attached Figure4-4-2)

Fastening Torque of the Bolt,40-50N.m

Attached Figure4-4-2

Flange boltM10×110

Front bridge differential device

Rear Bridge box parts

1、 rear axle differential

components

2、 retarder shellⅠ 3、

sulcate ball bearing6305 4、

needle bearing55BM6720 5、 initiative gear 6、 sulcate ball bearing6206c3-22 7、 rear disk brake install seat 8、 rear case import axes oil envelop 9、 needle bearing55BM6720 10、 rear case initiative gear "O" ring 11、

Ⅰrear retarder adjustment gasketⅠ 12、flange nut M12 13、rear disk brake leading install plate 14、drive piston gasket（0.25T）drive piston gasket（0.30T）drive piston gasket （0.35T）drive piston gasket（0.40T）drive piston gasket（0.45T） drive piston gasket（0.50T） 15、bolt M8×20 16、gasketф8.5 17、drive piston gasket

（0.25T）drive piston gasket（0.30T）drive piston gasket（0.35T） gasket with jack

（1.8T） gasket with jack（1.8T） 18、rear case oil filler hole bolt 19、oil filler hole "O"ring 20、rear retarder pipe 21、retarder shell Ⅱ22、column axes boltM8 23、 gasketф8.5 24、flange nut M825、1rear case export axes oil envelop1 26、sulcate ball bearing

16017c2 27、 rear case

cover "O"ring 28、circle bearing（0.25T）circle bearing（0.30T） circle bearing（0.40T）29、boltM8×25 30、gasket ф8.5 31、flange nutM10×22 32、 boltM8×30 33、gasket ф8.5 34、compression spring 35、rear bridge middle transmission shaft 36、spring flange 37、rear bridge middle transmission shaft connecting cover

(The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.)

4.5.Reverse mechanism parts

.

R everse mechanism operate parts

4.5

Inspection and maintain of reverse mechanism(refer to the selector mechanism figure)

1、Inspect the reverse mechanism handle whether is nimbly, if ti is not, disassemble the reverse mechanism to checke the inner striking fork is stagnation,the steel ball is locked by something,the spring is natural.If exist the problems all the above, replace the parts,and try again., if still not good to inform the special serviceman to service the reverse mechanism.

2、If the reverse mechanism appears lacks files,adjust the connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again.

3 、 Disassemble the reverse mechanism to checke the connecting rod of the reverse mechanism whether is rupture,if so,instead the connecting rod.

4、Checke the intension of the pull-off spring whether is enough.

5、Checke whether the gear is nicety,whether have jump or

drop. If so, inform the special serviceman to inspect and service

6、To chcke the few aspect if it is not revers, ①wether the clutch is open completely. ② whether the shifts gears to lubricate is reliably(the oil tubing in the reverse mechanism whether is stoped up).③there is any stagnation in the reverse mechanism.If so, inform the special serviceman to service.

4.6.Suspension

4.6.1.Rear Suspension

1、simple rear shock absorber(left/right) 2、 hexagon flange surface bolt

M12×1.25

×70 3、 hexagon flange surface bol

M12×1.25×65 4、self-lock nutM12×1.255、rear balancing pole 6 left ball pull-rod balancing pole 7、 right ball pull-rod balancing pole

8、self-lock nutM8 9、rear balancing pole amortize rubber cover 10、balancing pole board 11、 hexagon flange surface bol

M8×16

Rear arm shaft

1、rear left upper rocker combination 2、rear right lower rocker combination 3、 rear left lower rocker combination 4、rocker rubber middle membrane5、M10×

1.25×70 6、rocker rubber middle membrane 7、rear right upper rocker combination

8、rocker cushion collar gasket

4.6.2.Front Suspension

1、axes using spring flange

2、front right upper rocker combination

3、front ball pin parts

4、axes using spring flange

5、front left lower rocker combination

6、front right lower

rocker combination

7、 rocker rubber middle membrane

8、 hexagon flange surface bol

M10×70

9、 hexagon self-lock

nut

M10×1.25 10、 rocker cushion collar gasket

11、 hexagon self-lock nut

M10×1.25 12、cotter pin 3.2×3213、 simple front shock absorber(left/right)parts

14、 hexagon self-lock nut

M10×1.25 15、 flange surface bolt hexagon flange surface bolt M618、 hexagon flange surface bolt M6×12

4.6.3 Disassembly, Maintenace and Assembly the supporting rocker parts

1、Disassembly and Maintenace

In the suspension,there is easy to appear the problem with bushing, cotter pin and shock absorber.

A、If the left and right rocker rocks fiercely,chcke the few aspect,wether the bushing of the rocker is crushed,the middle rubber separate is aging and chapped.

B、checke whether the cotter pin is credible,if it is not instead the same spec cotter pin.

C 、 The problem with the shock absorbe and maintain method,whether it can returns to the position under the pressur and the torsional spring is rupture.If it is rupture or nearly to rupture,instead the shock absorbe.whether it leak oil,if so instead the same spec shock absorbe.According to the different request,if there is a oil cup on the rocker,must checke it whether complete and refuels.

2、Assembly(See the figure)

1、Use 16pieces of Hexagon Flange BoltM10×70 and 16pieces of

bolt to connect the front upper left and right rocker,front lower L/R rocker,rear upper L/R rocker and rear lower L/R rocker with the frame.To ensure the fastening torque is 40-45Nm.

2、Connect the front shock absorbe,frame and rocker with 4pieces of Hexagon Flange BoltsM10 × 52 and 4pieces of self-lock nutsM10.

3 、 Connect the rear shock absorbe and rear lower rocker combination with 2pieces of Hexagon Flange BoltsM10×65 and

2pieces of self-lock nutsM10.

4、

Connect the rear shock absorbe and frame with 2pieces of Hexagon

Flange BoltsM10×70 and 2pieces of self-lock nutsM10.

Attention:

A、Put on the butter to each part when it is assemble.

B 、 Do not scratches the surface of the spare part surface.

1 2

Hexagon Flange BoltsM10×52

Hexagon Flange BoltsM10×70

1 2

Hexagon Flange BoltsM10×65

Hexagon Flange BoltsM10×70

To checke whether put ont the butter before fix,then fix the upper and lower rockers and L/R front shock absorbe,ect.

4.6.4Inspection and Maintenance of Rear Suspension

1、 It is similar to the front suspension

Check if there exists any distortion or crack on the install axis of the shock absorbe in which case it must be replaced.

2、 nspect the rocker bushing and the middle rubber separate is integrant.( According to the front Suspension)

3、 The cotter pin on the head of the install axis which in the rear shock absorbe whether is credible.

Attention,

After disassemble the rear shock absorbe,check if there exists any distortion or crack on the frame connection hole and the rear shock absorbe,if so,inform the special serviceman to inspect and service first or install the rear shock absorbe

on the frame after instead.(Attention,the bolts must be the special self-lock nut, the fastening torque must be 45-55N.m)

4.7.Cooling System of Engine

4.7.1 Disassembly, Inspection and Assembly of Water Cool System

4.7.1.1 Disassemble the Water Cool System

4、 1. Disassemble the bumper and front faceplate(Attached Figure4-5-1)

Attached Figure4-5-1

Bumper

Front faceplate

2. Take down the water tank bracket combination and slanting

Figure4-5-2) support combination.(Attached

Attached Figure4-5-2

1. Cooling System

Water tank bracket combination

Water tankslanting support combination

3. ake down the rubber water pipe and water tank inductor.(Attached Figure4-5-3)

Attached Figure4-5-3

4. Take off Cooling System.(Attached Figure4-5-2)

4.7.2 Inspection of Water Cooling System

1..Check if the rubber pipe of Water Cooling System is torn or worn out.If so, please replace with new pipe.

2. Check the tightness of the hoop on the rubber pipe connected with Water Cooling System.If loosen, please have the hoop tightened immediately.

3. Inspect if ventilator is damaged.If so, please replace with new ventilator.

4.7.2.1 Assembly of Water Cooling System

1. Mount Water system onto the Frame with buffer cushion

(4pcs), Collar Sheath (4pcs), ф6 Cushion (4pcs) and

Hexagon Flange Bolt M6*20 (4pcs).

2.Connect the water tank bracket combination on the frame with

2pieces of Hexagon Flange BoltsM6×12..

3..Connect the water tankslanting support combination on the frame with 2pieces of Hexagon Flange BoltsM6.

4. Use Hoops (4pcs) and Rubber Pipes (2pcs) to connect

Water Cooling System with Engine.

Pours the high quality refrigerating fluid into the water tank after install.

Recommended antifreeze:

High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.

Antifreeze and water mixing ratio:

1:1

Total amount:

1.8L(1.58 lmp qt,1.90 US qt)

Coolant reservoir capacity

(up to the maximum level mark):

0.3L(0.26lmp qt,0.32 US qt)

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。Start engine when pour full the refrigerating fluid, loose the exhaust nut on the pipe,the water level will get lower at this time,Supply the refrigerating fluid until the water level stop to change,then screw the exhaust nut,cover the water tank lid.The water tank inspection is finished. .

4.7.2.2 Oil Cooling System

Except the Cooling System of the engine,this UTV is also equip the Oil Cooling System.( Figure)

4.7.2.3Disassembly, Inspection and Assembly of Oil Cooling

System

1、Disassemble the oil cooler

2、Disassemble the connecting steel oil pipe

3、Disassemble the connecting pressure resistancerubber pipe

4.2.2.4Inspection and maintain the Oil Cooling System

1、Checke if the oil cooler is distortion and leak oil.To adjust the distortion one,and welding the leak one.If it can not solve,instead the oil cooler

Checke if the steel oil pipe is distortion and leak.To adjust,intead the serious distortion one and leak oil pipe.

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Check if Rubber Pipe is torn, aged, worn out or distorted.

4、Check if the"O"rubber gasket ring which is connect with the teel oil pipe and the the oil cooler is aging and damaged,instead the aging and damaged one.

4.2.2.5Assembly Oil Cooling System

1、To take a pressure resistance inspection to the Oil

Cooling System after maintain,the pressure is 0.3MPA.

2、After take the pressure resistance inspection, pass over 0.03MPA compressed air through the connecting oil cooler,steel oil pipe and Rubber Pipe for 3 minutes,do not leak.

3、According to the disassemblage order, reverse carries on the assembly.

4、When it is finished assembly,pour the" L" engine oil,then start the engine for 10 minutes to checke whether leaks.If it is not ,the Oil Cooling System maintain is finish.

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4.8.Iubrication points

The details of the chassis lubrication is as below

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1、right upper rocking shaft and frame connection(plus engine oil)

2、right upper rocking shaft and Yanggakdoconnection(plus butter)

3、right lower rocking shaft and frame connection(plus engine oil)

4、right lower rocking shaft and Yanggakdoconnection(plus butter)

5、right steering rod and steering vertical column connection(plus butter)

6、right steering rod and

Yanggakdoconnection(plus butter)

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7、 wheel hub connection(plus engine oil)

8、front right half shaft and front case connection(plus engine oil)

9、front right shock absorber and frame connection(plus butter)

10、front right shock absorber and rocker connection(plus butter)

11、steering vertical column and frame connection(plus butter)

12、left upper rocker and frame connection(plus engine oil)

13、left upper rocker and Yanggakdoconnection(plus butter)

14、left lower rocker and frame connection(plus engine oil)

15、left lower rocker and Yanggakdoconnection(plus butter)

16、left steering rod and steering vertical column connection(plus butter)

17、left steering rod and

Yanggakdoconnection(plus butter)

18、front left half shaft and wheel hub connection(plus engine oil)

19、front left half shaft and front case connection(plus engine oil)

20、front left shock absorber and frame connection(plus butter)

21、front left shock absorber and rocker connection(plus butter)

22、rear wheel import axis and the case connection(plus engine oil)

23、rear left shock absorber and frame connection(plus butter)

24、rear left shock absorber and rocker connection(plus butter)

25、rear left upper rocker and frame connection(plus engine oil)

26、 rear left lower rocker and frame connection(plus engine oil)

27、rear left upper rocker and Yanggakdoconnection(plus butter)

28、rear left lower rocker and Yanggakdoconnection(plus butter)

29、rear left half shaft and wheel hub connection(plus engine oil)

30、rear left half shaft and front case connection(plus engine oil)

31、rear right shock absorber and frame connection(plus engine oil)

32、rear right shock absorber and rocker connection(plus butter)

28、33、rear right upper rocker and frame connection(plus engine oil)

35、rear right upper rocker and Yanggakdoconnection(plus butter)

36、rear right lower rocker and Yanggakdoconnection(plus butter)

37、rear right half shaft and wheel hub connection(plus engine oil)

38、rear right half shaft and front case connection(plus engine oil)

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5.Electrical system

Route color indication

1.Black┄┄Ｂ 18.Blue White┄┄L/W

2.Red┄┄Ｒ 19.Blue Black┄┄L/B

3.Yellow┄┄Ｙ 20.Red Black┄┄R/B

4.Green┄┄G 21.Red White┄┄R/W

5.Orange┄┄O 22.Green White┄┄G/W

6.White┄┄Ｗ 23.Brown White┄┄Br/W

7.Gray┄┄Gr 24.Brown Blue┄┄ Br/L

8.Blue┄┄L 25.Red Brown┄┄R/Br

9.Brown┄┄Br 26.Yellow Red┄┄Y/R

10.Dark Green┄┄Dg 27.Green Red┄┄G/R

11.Dark Red┄┄Dr 28.Green Black┄┄G/B

12.White Green┄┄W/G 29.Black White┄┄B/W

13.White Red┄┄W/R 30.White Blue┄┄W/L

14.White Black┄┄W/B 31.Yellow White┄┄Y/W

15.Light Blue┄┄Lb 32.Green Blue┄┄G/L

16.Light Green┄┄Lg 33.Purple┄┄V

17.Black Yellow┄┄B/Y

Troubleshooting and repair

No electrification：1. First, Check the safety.

2. Second, if the safety is good, then check the battery whether it is power on.

3. Finally, check the switch lock and electric route, whether they are bad.

Other troubleshooting and causations as follows

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ignition system phenomena

１,no spark cause

1.switch lock

※ carve out a way or short circuit,connection badness

※ line bonding badness

2.CDI set

※ After electrify no measure

★repair

★replace noise from the CDI

3.high voltage

※ high voltage lead insulated badness

※high voltage lead

carve

★repalce

★repalce out a way or short circuit

4. magneto

※ signal loop and charge ★repalce loop carve out a way or short or sparkove intermittence r electrification system

1, discharge self

2, uncharge or shortage-charge circuit

1. spark plug

※ pollute or wear intermittence

2. high voltage bag

※high voltage lead wire insulated badness

1. cover polluted or drenched by rain

carve out a way or short circuit, caused by connected wire badness

rectifier damaged

3.baterry

★repalce

★replace

★ water-proof,keep clean of the cover and repalce electrolyte

★repair

★repalce

★ entered distilled remark

※lowerelectrolyte water

１． flash not bright or weak

２, horn sound

※ electrode failure

1. the switch of flash lamp or emergency light contacted badness

2. lamp

※ filament of lamp damaged

※ the watt of lamp larger or smaller than regulated number

routing

★replace

★ repair or replace

★replace

107

5.1 ignition system

The key diagram of ignition elements ignition elements:

Ignition pressure provided by magneto ignition coil through diode commutated,by R(red line)input CDI(capacitance discharge ignition),charge to capacitance C.at the same

108

time ,spring coil produce spring signal ,provided to SCR as the turnon spring signal ,when reaching the ignition timing,SCR turnon capacitance began to discharge at the elementary coil

L1 caused instant lower pressure ,while at the secondary coil caused induce pressure.its instant pressure up to

10000V,sparkover at the clearance of sparkplug(0.6mm).so the engine ignited charge system

The key diagram of charge elements

5.2 magneto and charge system

the elements of charge:

When the engine running,driven magnet rotor circumgyrate,so on the stator coil produce alternating current then induce electromotive force come into to being the pressure.Through 3 lines Y(yelloe ) output into the rectifier ,through rectifier into direct current pressure and

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output.through R1 to charge the battery.

5.3 Battery

Under the following problems, please change the battery

1. With long time charge but the pressure do not increase to a set value.

2. At the bottom of case there is something dirty or electrode have become white or the case with a sulfate function

3. Electrode former scratched or scratched by press or insulation without work.

Pay attention when using

1. Long time out of using but without charge is not correct.

2. Too much charge (so long time charge is not correct, generally if battery empty, the normal charge time hours)

3. Do not charge under a much higher pressure or electric current

4. Keep battery at a low temperature and dry place

5. Charge battery before fix it.

If battery without electrolyte, it may cause the

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

If under such accidents, please deal with it as follows or ask for help from the doctors.

1. Exterior, wash lots of cleaning water

2. Interior, drink milk or water and then milk of magnesia or egg or rap oil and hospitalize as soon as possible.

3. Eyes, wash cleaning water at least 15 minutes and hospitalize as soon as possible.

5.4: Lighting system

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white green red2 white red magneto function black blue black yellow

/red red black yellow

/green green blue yellow gray fast and near light swith

OFF switch dark green dark brown green

/red green

/black light green red

/white stating urgnt switgh

OFF turnning switch

OFF horn switch flashing relay green

/black green

/red dark brown dark green gray brown white white white rectification

regulator black red1 blue green

/red dark dark brown green yellow meter indicator light

12V 3W black front brake switch rear brake switch blue/white

M battery

12V 12Ah biue

/black1 black red function red

1 brown

/ blue switch brown

/ red brown brown

/blue red

/white yelow

/red

;5A（2.4

;25A( Ignition ）

;10A( signal

） ;25A（ frontlight

） whole safety box starting button yellow

/green yellow green yellow

/green yellow green blue yellow2 dark green dark brown dark green dark brown black purple oil temperature indicator oil light temperature

12V 1.7W

front

1 switch light

12V 18W front light

12V 18W rearlight

/ brakelight

12V 5W/21W black black black black front left right turn light black rearleft right turn light black left right turn indicator light

12V 10W the key diagram of illumination system

5.5 Meterand signal system

：Operation and working way：

１、 Headlight

Headlight Switch

function

yellow

/ red

yellow green

２、 Emergency light switch ３、Turing light switch

function

green

/red green

/black function gray nigger brown dark green

OFF

112

When using this function, left and right turning lights will shine at the same time. shine)

Meter meet an emergency, the lamp is red (do not

４、Horn Switch

function yellow

/red light green function yellw

/red blue

/white biue

OFF

When press the button, the horn will move. But if without sound or with unclear sound or with little sound please check the problem according to the guide

5.6：Electrical starting system

Starting Circuit

Starting system working process

113

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

Note:

1. When electrical starting, please keep the battery with enough power and the time of pressing button will be within

55 seconds. If longer time more than 5 seconds, it may cause the damange of startor relay and the startor relay motor and may also cause the damage of the battery that it can not be charged or not charge enough.

2. When starting, if heard some noises from the startor relay, the battery must be without enough power. Please stop starting and change a powerful battery or charge for it.

3. If the startor motor can not work normally, please check according to the 2 rule to see if it is not lubricated enough

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6.Appendix

6.1 Specification

6.1.1 Specification of technique a）Specification of vehicle

Overall length

Overall width verall height

Wheel base

3010mm

1460mm

1840mm

1890mm

Wheel gauge F1100mm/ R1150mm

Mini. Clearance to the ground 245mm

Seat height turning radius

Suspension

790mm

2500mm

Front：Hydraulic spring swing arm

Rear：Hydraulic spring swing arm

)Braking pattern

(Normal condition)

Primary Brake（1）：(E-mark) foot/left hand operation

（1）：(E-mark)Braking pattern Front dual disk, Rear single disk/front and rear linkage, right foot/right hand operation

Emergency brake：

Braking

Front dual disk, Rear single disk/front and rear linkage, Right hand operation hand operation

（2）：Primary Brake（2）： Front dual disk, Rear single disk/front and rear linkage, right foot/right hand operation

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Emergency brake：

Parking brake：

Wheel Hub

Engine/ hand operation，Gear shift handle

Front：Alloy/ Steel wheels

Rear：Alloy/ Steel wheels

25x8-12 Front 25x8-12 （Vacuum

Tyre）

Tyre dimension

Tyre pressure

25x10-12 Rear 25x10-12 （Vacuum

Tyre）

70kpa Front 70kpa

70kpa Rear 35kpa

Fuel tank Vol.

Dry weight

29L±0.1L

524kg

Max. loading weight 300kg

Total weight(including

843kg hitch)： b） Specification and modle of engine

Engine Model/Brand HS1102MU-2/ HSUN

Pattern Single cylinder, water cool, dual exhaust, four stroke

Bore×Stroke 102mm×84mm

Compression Ratio 9.2:1

Volume

Max. power

686ml

25kW (5000r/min- 5500r/min)

（E-mark）Max. power

（E-mark）

13kW （5500r/min）

Rated power

Max. Torque

24kW (6000r/min-6500r/min)

49N·m （5000r/min）

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（ E-mark ） Max. 27N·m （4000r/min）

Torque（E-mark）

Mini. Idle speed 1400±100r/min

Fuel type

Lubrication

Starting system

Ignition

Unlead #90

Pressure Splash

Electric Start and hand recoil start

C.D.I

Drive train

Transmission

Axle continuous

Belt drive ratio

5.0695～0.7679

L Drive 5.3595（30/17×41/21× ratio： 24/18）

H Drive 3.2230（26/21×41/21× ratio 24/18）

R Drive 3.8282（25/17×41/21× ratio 24/18）

Clutch

Lubrication

(Crankcase)

Engine Drive ratio

16.339～2.475

Wet automatic centrifugation

Comply with GB11121-1995 standard.

Depending on regional weather condition, choose either SAE 5W-40 or

SAE 10W-30（Cold region）SAE.20W-40

（Warm region）

Oil capacity 1.9L

Engine dry weight 71kg c） Specification and modle of spare parts

Carburetor modle PD42J-A

117

Pattern

Spark plug

Speed meter

Battery

Parallel Vacuum

DR8EA

Electronic

12V 32Ah

Headlight 12V 35W/35W

Front Indicator 12V 3W

Rear Indicator 12V 5W

White light

Red light

Brake light 12V 21W Red light

Rear license plate light

Turning light

12V 5W

12V 10W

Rear reflector

White light

Amber light

Red light d）Specification and modle of other parts and structure

Disk brake hydraulic

DOT4 oil

Turning operation

Hand operating steering bar system

Driving method

Two wheel/ four wheel drive (2W means two wheel drive, 4W means four wheel

Shaft arms

Parking brake

Frame

Magneto drive)

Front and Rear dual shaft arms

Mechanical

Steel pipe

Spark plug gap

Safety fuse

6.2 Performance Requirement

Rotate DC output

0.6-0.7 mm

30A

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6.2.1 Starting Performance

Starting time must be less than 15s

6.2.2 Accelerating Performance

Starting accelerate must less than14s/200m,superpass accelerate must less than 13s/200m.

6.2.3 Max. Speed

65km/h。The Max. Speed is 65km/h(e-mark is 65km/h)

6.2.4 Climbing power

the climbing angle must more than 18°

6.2.5 Lowest fuel oil consumption rate

Lowest fuel oil consumption rate is ≤340g/Kw·h

6.2.6 Reliability

The reliable actual service life is 7000KM. The testing method carries on according to GB/T5374-1995.

6.2.7 Durability

The durability actual service life is 16000KM,The testing method carries on according to GB/T4570-1995.

6.2.8 Exhaustion

The pollutant limiting value should conform to GB 14621-2002, the GB14622-2002 request a） idle speed discharges

CO≤3.8 %，HC≤800 ppm b） The operating mode discharges

CO ≤ 7.0 g/km，HC≤1.5g /km，NOx≤0.4 g/km

6.2.9 Braking performance

a）Braking distance≤27m (Initial speed is 60km/h)

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b） the brake to reduce the speed must more than 5.88m/s

6.2.10 Noise

The acceleration travel noise is not bigger than 79dB

(A),installment noise is 93dB (A),rotate speed is 2750mim

6.2.11 Radio harassment characteristic

The multipurpose vehicle produces the radiated interference permissible value and the ignition system noise remover insertion loss loss value, the radio harassment characteristic should conform to

GB14023-2006

6.2.12 Parking performance

Multipurpose vehicle when neutral position use parking brake of in the vehicle arresting gear should guarantee the vehicles in the slope are 18%, coefficient of adhesion between the tire and the road surface isnot smaller than on 0.7 slopeway, the counter- two directions maintains static fixed is motionless, meantime between many to 5min

6.2.13 The side leans the steady constant angle

The multipurpose vehicle under the idling, the static condition, and right flank inclines the biggest side to left side to lean the steady constant angle not to have to be smaller than 25°.

6.2.14 Front illuminator performance

6.2.14.1 The vehicle should be loaded with conforms to GB 5948-1998 or the GB 4599-94 request front illuminator

6.2.14.2 The high beam of each front light luminous intensity should achieve 8000cd. When test, its electrical power system should be at the charge condition

6.2.14.3 The front light beam shines the position to be supposed to conform to the following stipulation

120

a）Under the regular service condition, the front light beam shines the position to be supposed to maintain stably b）Front is loaded with the illuminator multipurpose vehicle to be supposed to have the low and far beam transducer and when the headlight high beam becomes the headlight low beam, all headlight high beams ought to be able also to extinguish. On the identical vehicle front illuminator does not allow left, right to be far, the low-beam lights. alternately starts brightly; c) When apposed setting the front illuminator far and low-beam lights, the low-beam lights should be located on leans, in other situations the low-beam lights should be located the flank d）The front headlight low beam all does not allow to dazzle. e）The shines position of the frontheadlight low beam light beam, the front illuminator shines when is away from 10m on the screen, the first illuminator headlight low beam light beam light and shade closure line corner or the center point highly should be 0.6H ~0.8H (H is front illuminator datum center highly); f）The front headlight high beam light beam and the headlight high beam single light beam lamp should conform to the GB 7258-20048.4.7.3rd corresponding requirement according to the position.

6.2.15 Light signal installment request

6.2 Requirements for torque of fastener

Tight spot

Column tight torque

Even fork axis nut

Front shock absorber upper nut

Front shock absorber lower nut

（N.m）Torsion value（N.m）

35～45

45～50

35～45

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Rear shock absorber upper nut

Rear shock absorber lower nut left rocker upper nut left rocker lower nut right rocker upper nut right rocker lower nut engine hanging nut

Even fork and cradle connecting nut front wheel nut rear wheel nut

6.3 Electrical circuits

45～55

40～50

35～45

40～50

45～55

45～50 the characteristic of the electrical circuits,

1.Actualize the electrial starting when it is at N,parking and brake.

2.When it is in the H gear,the H gear switch of the engine is on the ground,the H gear is lighting by the CDI inner transistor to control the dash light earth connection.

3.The function of the diode in this circuitry is that after parking and brake to actualize the electrial starting .

4.The relay electrical source,to provide the electricity

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L 2

C DI through the CDI working,it can protect the relay and to extend the useful time.

5.Use the pan- fuse box,each operating circuit is working independence,and easy to service,there is no connect with the inner cable and the functional line,it is hard to emerge the dummy section.

3 0A

OVERRIDE mp h km/h

123

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