GO-KART [XYKD260] Repair Manual

1
 1 Service Notice

Position of Identification Number Lubrication diagram

Main Features Structure Drawing

Standard Torque Rating Troubleshooting

Position of Identification Number

Vehicle Identification Number Engine Identification Number

2
 Main features
Vehicle Dimensions [mm] KD260-1 KD260-2 KD260-3
Overall Length………………………….………………………………………………..2470 2690 2550
Overall Width……………………………………………..……………………………..1570 1510 1670
Overall Height……………………………………………………………………………1535 1460 1440
Wheelbase………………………………………………………………………………..1870 1950 2010
Front Track……………………………………………………………………………….1345 1270 1485
Rear Track……………………………………………………………………………….1250 1250 1263
Ground Clearance…………………………………………………………………………200 220 200

ENGINE
Type…………………………………………………………………….……………..Water cooling, four stroke
Engine capacity……………………………………………………………………….260cc
Bore *Stroke………………………………………………………………………….70mm*66.8mm
Displacement………………………………………………………………………….257cm³
Corrected compression ratio…………………………………………………………9：1
Max output power…………………………………………………………………..11kw/7000rpm
Max Torque…………………………………………………………………………..17Nm/5000N.m/r/min
Starting………………………………………………………………………………..Electric Start
Ignition………………………………………………………………………………..C.D.I
Lubrication…………………………..………………………………………………..pressure splash
Transmission…………………………..………………………………………………. Automatic C.V.T System
Spark plug…………………………..……………………………………………….DPR5EA-9（NGK）
Plug gap…………………………..……………………………………………….0.6-0.8mm
Fuel type…………………………..……………………………………………….RQ90 (leadless)
Lubricate oil…………………………..……………………………………………….SAE15W-40/SF

Capacities
Maximum load…………………………..……………………………………………….Two seats/200Kg
Fuel tank…………………………..……………………………………………………...9.5L
Engine oil…………………………..……………………………………………………..1180mL
Starting Time…………………………..……………………………………………………..<10s
Climbing…………………………..……………………………………………………..20º-25°
Battery…………………………..……………………………………………………..12V 14Ah
Head Light…………………………..……………………………………………………..12V 35W
Tail Light…………………………..……………………………………………………..12V 21W/5W
Fuse…………………………..……………………………………………………..10A
Brake Track…………………………..……………………………………………………..7m at 30KM/h
Top speed…………………………..…………………………………..75KM/h (Or as customer requirement)

CHASSIS
Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control
Front tire ……………………………………………… AT21X8-10
Rear tire ………………………………………………AT22X11-10
Front Suspension ………………………………………… Independent dual-A arm
Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock

3
Restraint System ……………………………………… Double quincunx safety belts
Final Drive ………………………………………………… shaft drive

TIRE PRESSURE[kPa] off-road Tire Road Tire

Front …………………………………………………… 25 200

Rear …………………………………………………… 30 225

WEIGHT[KG] KD260-1 KD260-2 KD260-3

Net Weight …………………………………355 346 365
G.W. …………………………………… 380 370 380

4
 Standard Torque Rating
XYKD
SER
Position
NUM Diameter of screw Torque（N.m）
（mm）
1 Screw used between Exhaust pipe and Front Cylinder 8 20-26
2 Igniter plug 10 18-20
3 Screw used between Front wheel hub and front universal 14 80-100
joint
4 Screw used for Rear wheel hub and Constant-velocity joint 18 120-140
5 Universal joint fastening bolt 8 20-26
6 Bolt of protective parts of steering mechanism 8 30-40
7 Screws between handle ball and gimbal 10 50-60
8 Screws of wheel and wheel rim[Front and rear] 10 50-60
9 Screws of support parts[Front wheel] and vehicle body 10 50-60
10 Connection of brake pump parking brake and front gimbals, 8 20-26
elevation
11 Screws of handle adjusting line 10 30-40
12 Screws exhaust pipe and engine rear support part 8 20-26
13 Screw used on Front Vibration Damper 10 30-40
14 Screw used on Rear Vibration Damper 12 50-60
15 Connecting screws between rear support part and vehicle 16 110-130
body
16 Screws of rear support parts of engine 10 30-40
17 Screws of front support parts of engine 10 30-40
18 Screws of back brake disc and back wheel rim 8 30-40
19 Screws of front brake disc and front wheel rim 6 20-26

5
 Lubricating oil and How to do lubrication

1、Engine

Position Description of Lubricating Oil Remark

Crankcase Only 15W/40SF Full capacity：1.0L
Gear case Only 15W/40SF or 85W/140 Full capacity：0.22L
Parts of Clutch Li oil ZL-3H（SY 1413） 4.5~5.0g

2、Vehicle Body
The parts, described [not limited] as following, should be added lubricating oil.

If no special requirement, please use the multiple functions lubricating oil.

In order to prevent the unusual sound and improve the durability, lubricating oil also should be used in
other transmission parts.

Steering wheel nylon bushing

Sub seat slide rail

Constant speed
gimbal
Front Wheel Support Part

Connection part
between Steering gear
parts and handle ball
Rear wheel rim axle

Rear swing arm axle

Main seat slide rail

Brake pedal
Accelerator pedal
Accelerator cable Front wheel axle
Front lower swing arm
Parking brake cable

6
 Structure Drawing

Pipe of
cooling liquid
kettle

Water tubing

Temperature
Control
Switch

Brake cable

Rear brake oil

tube

7
 Fuse 15A Relay

Flash apparatus CDI

Electric parts
case

rectifier

Ignition coil
BATTERY

Throttle cable

Quadric air-intake
mechanism

Parking Reverse cable

brake cable

8
Main cable Speed Sensor cable

Troubleshooting
Can not or difficult to start
Description Adjustment Reasons

Whether oil run in carburetor. Take ● No oil in oil tank

● down vent bolt to check.
● Jam between oil tank and carburetor

● Oil tank hole jammed

● Oil filter jammed

Yes No
● Oil cleaning net jammed

● Pressure oil switch not work

Take off spark plug to check

sparkle or not
● Spark plug not work
● Spark plug not clean
● CDI parts not work
● Trigger not work
Yes No or not enough
● Spark plug coil broken or short-circuit

● Ignition coil broken or short circuit

● Igniter switch not work

● Magneto coil not work
Pressure Value

● Valve gap not enough

9
 ● Valve socket not good
OK No or not enough
● Damage of cylinder, piston rings
● cylinder head gasket works not well

● Valve is damaged
Start according right method
● Mixing air time not good

●EEV of carburetor not work

●Air leakage of minus pressure tube

No explosion No start with explosion
●Ignition time not good
Take off spark plug again
●Vent bolt of carburetion not work

● 化油器过满溢出
●Too many oil in carburetor
火花塞是干的
Dry 火花塞湿
Wet
●EEV of carburetor not work

◆ ●Value of throttle is unusual.

Power is not strong, not speed up
Description Routine Reasons

●
Let engine work ● Battery connection badness
at high speed
● Air filter jammed

● oil tube jammed

Yes No
● minus Pressure line not connected well

● Vent hole of oil tank cover jammed

● Carburetor jammed
Check Ignition
time [Ignition led]

● CDI parts not work

Yes No
● Trigger not work

Check Valve Gap

● Valve gap not good

Yes No
● Shape of valve changed

Check Compress pressure Value in Plunger

10
 ● Valve socket not work well

● Plunger ring is damaged

Yes No or Lower
● Air leakage from gasket position

● Mix air time not good

Check Carburetor jammed.

No Yes ● Parts of Carburetor jammed

Check spark plunger

Clean Dirt ● Spark plunger polluted/damaged

● Temperature of spark plunger wrong

◆

Description Routine Reasons

●
Check oil quantity
level and quality
● Too many oil
OK No ● Oil is not enough
● Oil is not replaced

Engine is too hot or not

● Cooling liquid not enough

● Plunger or Cylinder damaged

● Mix air rare

● Quality of oil bad
No Yes
● Too many carbon powers in firebox

● Ignition time wrong

Speed up or work at high

speed

● Too many carbon powers in firebox

● Quality of oil is bad

11
● Mix air rare
● Ignition time wrong
No sound Unusual
sound

Egine works unusually（such as idle and low speed）

Description Routine Reasons

●
Ignition Time OK?

● CDI parts not good

Yes No
● Magnetor not good

Vent screw of
carburetor OK?

● Mixed air is rare[Take screws down]

Yes No
● Mixed air is thick[Take screws up]

Air leakage in
carburetor gasket?

● “O” gasket not good

● Carburetor is loosed
No Yes
● Airproof parts not good
● Air leakage in vacuum parts
Sparks OK?

12
 ● Spark plunger not good or polluted

● CDI parts not good

● Ignition coil not good
OK No or less spark
● Ignition coil is broken or in short

● Ignition trigger not good

Cut Air Valve OK?

● Cut Air Valve not good

Yes No ● Vacuum line jammed or damaged

● Air tube jammed or damaged

◆
Engine works unusually [High speed]
Description Routine Reasons

●
Ignition time OK?

● CDI parts not good

Yes No
● Magnetor not good

Handspike gap OK?

● Adjustment not good

Yes No
● Value socket damaged

Check oil automatic

screw function?

● Not enough oil in oil tank

● Oil line or oil filter jammed

OK Unusual
● Vent hole is jammed

● minus Pressure line switch not work

Carburetor socket jammed?

No Yes ● Clean carburetor socket

13
 Mixed time right?

Yes No ● Protruding sprocket wheel and magneto

flywheel position not match

Spring of valve good？

Yes No ● Spring not good

Not move with high speed

Description Routine Reasons

●
Engine works at high
speed or easy to stop?

● Ignition coil wrong connection

● Spark plug bad connection

Engine works at No high speed or easy to
● Connection of battery not good
high speed stop
● Oil line not good

Check reverse operation system

reverse gear OK reverse position wrong ●Length of reverse cable is not suitable

Any unusual sound of engine

gear case

●reverse gear damaged

●Connector sheath of reverse gear damaged

No Yes
●Differential gear damaged

14 ●Differential damaged
 Open side cover of engine and check
clutch strap broken or not

No power in battery
Description Adjustment Reasons

●
Start engine and check
voltage of battery

●Check battery whether out of usage

Battery can not charging Normal
●Battery not good

Resistance value
of coil
● Stator not good

Normal Unusual ● Yellow line is broken

● Connection of line is not good

Voltage between Blue/yellow and Green

li

Yes No ● Blue/yellow or Green line is broken

Whether any looseness of booster and connection-peg？

● Booster not good

Yes No
● connection-peg not good
15
● Magneto not good
The charge is not good ( Overcharge )
●
Measure of voltage between
rectifier polarities

Voltage is usual when No voltage when ignition

● black line of main cable
ignition switch is “On” switch is “On”
is broken

Any looseness or default of booster connection-peg

● connection-peg not
No Yes good

● booster not good

No spark
Description
Adjustment Reasons
●
Use a new spark plunger then check
i

● previous Spark Plunger broken

No or less sparks Sparks OK

Any looseness between lid of spark and

between high-voltage lines

No Yes ● Lid of spark is loosen

Connection of CDI parts

OK?

Yes No ● Connecter is not good

Check statement and features of connecter of CDI and measure

the resistance
16
 OK No

Related parts OK?

● Ignition switch not good

● Magneto coil not good

Yes No
● Trigger not good

● Ignition coil not good

● cable is broken
● Connection of coupling parts not good

● CDI not good

2 Inspections and Adjustment

Check & Repair method Transmission System Brake System
Electronic System Wheel System Engine
Cushion System Others
Check & Repair method
Maintenance period List
Maintained time ITEM Km ( remark )
Item
Requirements 1000Km 4000Km 8000Km 12000Km remark

Oil System I I I

Carburetion System I I I

Carburetor I I I I

Core of air filter often R

Spark plug I R I

Lubricating oil in engine First time1000Km; then per 2000 Km

Clean net of lubricating oil Per year R C C C

Gap of valve I I I I

Battery I I I

Brake system I I I I

17
 Brake DISC. I I I

Brake lighter switch I I I

Main lighter Per month I I I I

Clutch I

Suspend parts I I I

Support parts I I I

Screw and bolt Per month I I

Wheel/spoke Trimester I I I

Vent hole of crankcase C C C

Idle of carburetor I I I I
The vehicle should carry on the periodic maintenance according to the stipulation time.
Before the maintenance the vehicle should be cleaned thoroughly.
Definition of Letters：
I: to check, clean, adjust lubricate or change apart.
C：cleaning
R：use a new part
A：make an adjustment
L：Lubricating
Note: When the odometer reading surpasses the maximum features listed in the table,
the maintenance should be done repeatedly according to the table.

Brake System
Adjustment
Check pedal free travel:
20~30 mm
If it is beyond of this distance, please take down/up
adjustment screw.
20~30mm

When air enters the brake cylinder piston or the brake oil pipe, resulting in
brake failure, it is necessary to discharge the air in the brake in the following
manner: first step on the brake pedal with foot, loosen the exhaust screw Adjustment Bolt
of the brake cylinder, open the brake cylinder oil cup, screw up the exhaust
screw until there is no brake liquid and air outflowing, release the accelerator
pedal and repeat the procedures until there is no air out-flowing.

Vent bolt

18
 Attention!
When exhaust, you must guarantee that there is
enough brake fluids in brake pump oil cup.
Brake oil pump

Parking Brake System

When stop vehicle on 20º-25°ground and can not park it. Brake Handle
Please check parking brake system for safety:
1 Take down/up adjustment bolt near by brake handle

2 Take down/up adjustment bolt near by brake caliper

Attention! Please make sure that length of rear wheel

brake line is out about 3-5mm. Adjustment bolt

Parking Brake system is complexes; adjust parts in a whole system to
Make PB system work well.

Adjustment bolt of brake

Wheel System
Wheel
Check tire with air pressure gauge.

Attention! Please make sure that tire is cold before checking.

Standard information：

Spec. of Tire Pressure Value Pressure Value

（off-road） （Road）
Front AT21X8-10 28kPa 200kPa
Rear AT22X11-10 35kPa 225kPa

Metal hexad flange screws

Check mental hexad flange screws of front wheel and axle.
tight them as per required torque.

Cushion System
19 Front/rear axe screws
Leakage or Damage of Vibration Damper
Steps on with foot to the vehicle forehead, compress several times, inspect
its movement, and whether or not any oil leak, damage, loose or unusual sound;
Steps on with foot to the vehicle back position, compress several times, inspect its
its movement, and whether or not any oil leak, damage, loose or unusual sound

Transmission System
Transmission case leakage and capacity

Attention! Make sure that ground is plainness.

Stop the engine and take down oil position screw. If oil level reach at standard position it is OK;
otherwise pour in oil.

OIL TYPE：85W-140 or 15W/35S

Put on oil position screw after checking airproof gasket

Oil position screws Air proof

gasket
Replacement of lubricating oil
Take down oil position screw
Take down vent bolt and put oil out
Put on vent bolt with revolving

Attention! Make sure that no damage in airproof gasket

Pour oil according to standard value：

20
 Full capacity：1.2 Liter
Standard capacity：1.1 Liter
Put on oil position screw with revolving
Try running and confirm no oil leakage
Check oil level

Driving/Driven Wheel
Take off left cover Driven wheel
Check driving/driven condition

Driving wheel

Electronic System
Ignition System
Check gap, whether
Station of Spark Plug any dirt and Carbon
Take off spark plug
Check sparks plug and clean dirt,
carbon with special cleaner or
steel wire brush.
Checks gasket Chechecks any broken

Spark Plug：Distance should be 0.6 mm to 0.8 mm

Important! When install spark plunger, please tight

it by plug socket after hand.

Ignition Timing
Important! Because of CDI system function, there is
no necessary to adjust ignition time. If any problem,
please check ignition system.
Take off ignition screw Ignition Screw
Check ignition LED to confirm ignition time:
When idle speed is 1500±100rpm，it matches “F” well.

Function of Ignition Advance Angle

21
 Same to Ignition system, put on Ignition LED. Then start Standard Position
engine and make speed up to 7500 to 8000 rpm, system
works well if LED reach at standard position.

Engine
Engine Body

Low speed and speed up condition

Idle Screw
Note: idle speed adjustment shall be made when the engine is
warmed up. And Carburetor adjustment following inspection
shall be made after adjustment of the airscrew.

Start engine without transmission [Warm condition]

Adjust idle screw and set idle speed according standard value:
1600 ± 10％
If idle condition is not steady, please adjust vent screw.
Replacement of air filter core Clips
Open six clips and take off air filter cover.
Take off filter core
Change filter core if it is dirty or damaged.

Air filter screws

Standard period of change filter core：per 4000 KM

If road condition is not good, you should change filter core early

Filter Core

Caution: since the filter paper of the filter core contains

oil (viscous); it cannot clean with air.

Lubricating System
22
 Lubricating oil quality and quantity
Attention!
During check oil quantity, you should guarantee the vehicle is in the
horizontal position. Let the engine works 2-3 minutes, then stops the
engine. After 2-3 minutes, then check oil quantity.
Oil vernier

Do not revolve in the vernier when checking it.

If the oil level below the lower limit line, you must supplement the lubricating oil from the note
entrance to the upper limit line.

Max Position

Min Position
If lubricating oil is dirty, please change it.

Oil filter Jammed

Take off spring, filter net.

Clean it
Put filter net, spring, and filter net lid and revolve tight

Filter net lid

Attention! Spring Filter net
Open parts of net should be inside.

Pour lubricating oil.

Replacement of lubricating oil Air proof gasket

Attention! Put lubricating oil out on warm
condition.

Take off filter lid and let oil out

Take up filter lid with revolving

Attention!
Check
Pourair-proof gasket
in lubricating oil.and change it if any broken.
Full capacity：0.8 Liter，Type：85W-140
Start engine to make sure no leakage problem
Stop engine and check oil quantity.

23
 Accelerator operation system
Oiling position Pedal limit screw
status of accelerator pedal
Check free pedal travel of the accelerator pedal.
Free travel: 30~40 mm
When the free travel is outside the specified, range, the requirement may be
met by adjusting the adjustment nut or checking whether the accelerator pedal
stopper is correct or not.

Screw Adjustment bolt Range

Adjustment bolt

If footplate is not working fluently, please add lubricating oil from the Oiling
hole

Screw

Cooling System

Water Level
Guarantee the vehicle is in the horizontal position.
Inspect kettle liquid surface whether between upper limit and lower limit. On the kettle has two across, above is the
upper limit, and under is the lower limit. If the radiator liquid is insufficient, must pour the kettle liquid to upper limit.
The coolant liquid should fit the engine.

kettle

Water Leakage

Check cooling line whether any broken, damage or leakage.

Reverse gear handle

24
 Reverse System
After days of running, it is possible that reverse or other transmissions are not
good because: reverse line is changed in length or shape. Herewith you need
to make screw adjustments.

Front adjustment screw

Rear adjustment screw

3 Oil System

Maintenance information Electricity enrichment valve Floater Room

Troubleshooting Cut air valve Oil tank

Carburetor Vacuum room Oil switch

Maintenance Information

Important! No spark when use fuel.

.Remember position of “O” gasket and use a new one in installation.

.Take down vent screws of floater room; clean carburetor before disassembly.
.Do not take off auto double starter valve.

Troubleshooting

Can not start engine No power and engine stops when accelerate max
﹒No fuel in oil tank ﹒septum of vacuum piston is destroyed
﹒No oil flow into ﹒Pressure entrance is jammed
﹒Too much oil in cylinder ﹒Oil switch is not working

﹒Air filter is jammed Mixed air is little

﹒Oil is not clean ﹒Ejector parts are jammed

25
 ﹒Oil switch is not working ﹒Vent hole of tank cap is jammed

Engine Idle is not steady and﹒Oil line is not working

Work abnormally ﹒Floater is not working

﹒Adjustment of idle is not working ﹒No enough oil

﹒Mixed air is rare
﹒Air filter is jammed

﹒Air in plug Mixed air is thick

﹒Oil is polluted ﹒EEV is on for long time
﹒Cut air valve is not working，disc valve is not working ﹒Floater is not working
﹒Vacuum lines or connecter are jammed ﹒Oil is too many

Accelerator is heavy ﹒Air filter is jammed

﹒Installation of carburetor is not good ﹒Wrong installation of support

part in EEV.
﹒Switch of carburetor destroys cam-drum wheel

Disassembly of Carburetor
Plug of electricity enrichment valve

Clips of Air filter

Throttle cable

Oil drain bolt

Oil Line

Pressure three-way line Clips of engine

Take off oil line

Take off pressure three-way line

Take down Oil drain bolt and drain oil out from Carburetor

Take off carburetor line

Take off clips of air filter

Take off clips of engine

26
 Take off plug of electricity enrichment valve

Take off carburetor

Electricity Enrichment Valve

Inspection
Check connected line of electricity enrichment value.
Resistance value: Screws of support part Support part
Stop the engine and after 10 minutes then test resistance. Value
should not higher than 10 omegas. If no connection or resistance
value is deviated 10 omegas, you must use a new electricity
enrichment valve.

Disassembly
Take down screws of support pats and take down support part. Connecter E.E.V.
Take down electricity enrichment valve.

E.E.V. Pin

Inspection of Valve
Check any damage on electricity enrichment valve and pin
of EEV. If any, please use a new EEV.

Installation
Do installation in oppositive turn in disassembly.
E.E.V.

Attention!
Press EEV at bottom and fix its channel outside with support part.

27
 Cut Air Valve

Inspection
Take off cut air valve from Pressure line and vent line
Connect pressure line and vacuum pump
Connect vent line and vacuum pump
Add air by vacuum pump:
Minus pressure value：400～600mmHg

With pressure no air in vent line and without pressure air

in vent line, valve is ok.

Cut air valve

Replacement
Take down two screws and take off cut air valve
Take off “O” gasket
Use a new “O” gasket and fix valve on carburetor Bolt
with screws
Cut air valve

“O” gasket

Vaccum Room Cover of Vacuum Room

Disassembly

Take down two screws and take off vacuum room cover
28
Screw
Take off spring and vacuum plunger.

Take off support pats, spring and ejector pin

Spring Plunger
Important!
Please protect septum of vacuum plunger. Vacuum Plunger Support pats

Inspection of Vacuum Plunger

Check carburetor valve, ejector pin, no any destroyed and broken
Check septum without scar, olden and broken

Septum Nozzle Pin Spring

Installation of Vacuum Plunger
Do installation in oppositive turn.
Support bottom of vacuum plunger, make sure that it is open and put septum to chimp position of
carburetor completely
Put on spring
Match septum hole with cover and fix cover

Important!
Support vacuum plunger till fix all screw of cover.

Floater Room
Bolt Floater Room

Take off four screws and floater room.

Bolt
Inspection of Pin Valve

Pin valve
Check station of valve socket
29
Take off main ejector, pin ejector socket, pin ejector, sub ejector and vent screws.

Main Ejector Main Ejector

Socket
Important!
. To protect ejector and screws
.Note down zip number when take down screws. If
drives vent-screws strongly, it would be destroyed.

Clean ejector with extractive oil.

Vent bolt Sub Ejector

Vent bolt Main Ejector

Attention!
Extractive oil should be fresh one.

Clean carburetor pass way with huffing air.

Sub Ejector Main Ejector

Installation Socket

Install pin ejector, pin ejector socket, main ejector, sub ejector and vent screws.

Attention!
Please install vent screws according to zip number noted down when
disassembly.

Install pin valve, floater and pin.

Install carburetor in oppositive turn in disassembly.
Do adjustment as following：

．Accelerator line adjustment

．Idle adjustment

Oil Tank

Disassembly
Oil tank

30
 Takes down four screws of oil tank

Take oil line and pressure line part from oil switch.
Oil Line Oil switch
Take off oil tank

Oil Switch

Pressured line
Important! NO SPARK!
1 Stops the engine, dismantles the oil line from the carburetor and check whether the oil stream to leave. After oil
switch and line is clean, there should be no oil leakage. Otherwise you should clean pressure line.

2 Dismantles the pressure line from the carburetor. With pressure oil leakage and without pressure no oil leakage,
then the switch is normal.

3 Switch negative pressure value: Above 130kpa.

4 Cooling System
Replacement of cooling liquid in Radiator
Radiator Lid
Important! Before take off radiator lid
please make sure that cooling liquid is31
NOT HOT.
Take off radiator lid .
Connect Out-water line and fix it tightly
In pouring cooling liquid till it is full.
Out-water line
Carries on pumping air according to the following main point:
1 starts the vehicle, carries on high speed on the smooth road, at least 200 meters.
2 stops and checks foam whether vanishes, as well as liquid surface water level is
whether steady,
3 do the vehicle the system closure, pours into the radiator liquid, until
the radiator this note population border is Stops.
4 fix radiator lid
5 checks enough water in sluice bottle.

Sluice bottle
Function Inspection Radiator Inspector

Radiator Lid

Before take off radiator lid please

Important!
make sure that cooling liquid is NOT HOT.
Radiator Lid

Put lid on is inspector and it is good that keep on SIX seconds under standard pressure.

NOICE!
Before checking please put some water on lid
airproof surface.
Standard pressure of Radiator lid valve:
73.5-103Kpa

Radiator Inspection
Connect Inspector and radiator, add air and it is good that keep on SIX seconds under standard
pressure.
Standard pressure：73.5-103 Kpa

Important! Do not use too high pressure;

otherwise radiator will be destroyed
32 on
condition of high pressure.
Temperature Control Switch
Disassembly
Drain radiator liquid out
Dismantles switch wiring.
Dismantles the switch

Attention! When 80°C, the fan can automatically

open; if failed, it needs the prompt inspection.

5 Engine
Disassembly Rear Wheel Screw

Dismantles Earth Line from the battery

Lift back vehicle with Left and Right support parts, and make sure rear
Wheel takes off;

Take down screws and take off rear wheel; Support Part

Take down screws and take off rear brake;

Rear Brake

Take down rear bone [left and right], break connection between rear bone
and engine
Rear Bone

Take off gimbals [left and right]

Take apart water line and out cooling liquid

33
Take off spark plug cap
Take off Temperature Control Sensor
Take off lines of carburetion

Water Line

Take off auto-restarted plug

Take off transmission line

Take off earth line

Take off line between engine and battery

Power Line Erath Line
Take down screws of bumper

Take down screws between air filter, support part and

Vehicle body.

Bumper

Air Filter Screw

34
Muffle Screw
 Take down screws between engine and rear suspend part

Rear Suspend Screw

Take down front suspend part of engine

Front Suspend

Take down suspend part under engine

Take off engine with muffle, air filter and carburetion

ATTENTION!
The engine is heavy, so multi-people coordination is import to disassemble,
in order to avoid offends somebody or the damage engine.
Suspend Part under Engine

Take down screws of muffle and take it from engine

Take down screws of muffle and take it part from engine
Take down clips of carburetion, take carburetion, exhaust line,
and air filter.

Muffle Screw

Installation
Installation is in oppositive turn and please makes sure that screws are fixed according to standard
strength.

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6 Front Wheels and Steering System

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Disassenmbly
Front wheel rim screws
Support front part of vehicle and make front wheel take off.
Take apart four screws of front wheel[Left wheel for example]

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Take down the cotter pin locked screws of the front wheel hub.
Take down two screws and take off front brake pump assembly.

Take off assembly of front wheel hub and brake disc.

Front Wheel Rim

Important! It is connected by bearing

You should use special tools.
Brake Disc

Take down two screws and take off front brake pump assembly.
Take down the cotter pin locked screws of the steering assembly.
Important! It is connected by wimble, please pay Screws
attention to bone when knock the
assembly.

Take down the locked screws and take apart front vibration
Damper.

Front Vibration Damper

Take down two screws between support parts and vehicle body.

Up Support Part Bolt

Take down two screws between down support part and vehicle body.
Take apart down support part and front bone assembly. Down Support Part
Take down screws between up-down support part and front bone.
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Take apart U/D support part and front bone.

Important! It is connected by wimble

please knock assembly carefully.

Front Bone

It is same to RIGHT WHEEL.

Take down three screws and take apart steering support nips.
Fix part of S.S.

U/D Support Part

Take down screws between steering assembly and gimbal. Steering assembly

Gimbal
Take apart steering assembly.

Take down screws between steering bearing and gimbal.

Steering assembly Bolt

Screw Bolt

Take off gimbals.

Take down screws between steering bearing and vehicle body.
Take apart steering assembly.

Fixing parts of S.W. Gimbal

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 Steering Wheel
Take down six screws and gather respective assembly

Installation
Screw
Do it as opposite procedure compared with DISASSEMBLY.

Screw

7 Seat System
Disassembly
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 Safety Belt

Man Handle

Disassembly safety bolt on seat right.

Disassembly safety bolt on seat back.
Disassembly safety bolt on vehicle body. Bolt

Bolt

Take off seat.

Handle counter-clock wise rotation, may carry on to the seat

adjustment, back or front.

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 Man handle

Slide Rail

Disassembly setting screws of safety belt on left side of seat

Take off safety belt.

Screw

It is same to take off left seat and safety belt.

8 Rear Drive Line System

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Disassembly
Rea wheel rim screw

To support behind the entire vehicle, and make the trailing wheel to take off.
Dismantles 4 front wheels fixing g screws. (Left side Wheel )
Take down the cotter pin of the front wheel hub locking screws.
Front wheel screw
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 Dismantles 2 setting screws, and take down the brake to pump.

Parking Brake Screw

Dismantle locking screws, take down the trailing wheel. Rear brake pump
Dismantle two setting screws and take down brake pump. Screw

Dismantle two setting screws and take down rear brake pump.

Dismantle four setting screws of rear bone Parking Brake Screw

Take down rear bone, rear wheel rim and brake disc assembly.
Take down rear bone off rear wheel rim

Important!
IT IS CONNECTED WITH AXLTREE;
YOU SHOULD USE PROFESIONAL TOOL.
Rear Wheel Rim

Dismantle four setting screws and take off brake disc.

Brake Disc Screw Rear Bone

Take off SPEED SENSER ASS.

Parts of speedometer

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 Universal Joint

It is same on right side.

Take off seat.

Take down two setting screws of tranquilization part.

Fixed part
Rubber sheath

Take off fixed part and rubber sheath.

Disassembly setting screws on left and right tranquilization part.

Screw

Take of tranquilization part.

Rear Support Part

Screw Tranquilization part

Rear Vibration Damper

Disassembly setting screws of rear vibration damper.[L&R ]
Take off left and right rear vibration damper.

Screw

Disassembly setting screws and take off rear support part. Screw
Left is same with Right.

Installation
Do it as opposite procedure compared with DISASSEMBLY
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 9 Electric System
Repair Information Battery
Troubleshooting Charge System

Repair Information
IMPORTANT!

．Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the
connection, you must pay attention to the color of the line cables. The coupling must meet on the
same coupling.

．The test condition may usually lead to differences between observed data and standard features.

．Magneto installment and disassemble.

．As to other problems, please view more information in CHARTER 1.

Battery
．Do periodic inspection electrolyte the capacity, make sure line is between the scale division line, if
lower than the scale division, please supplement the distilled water.

．When charging the battery, you must dismantle the battery from the vehicle, but do not take off the
liquid lid.

．Expect for in emergency cases, do not carry on the rapid charge rate to the storage battery.

．When charging battery, please do it according to standard datum.

．During voltage inspection, you must uses the digital multitester.

．When battery is out of usage, you must use a new one.

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Specification
Item Standard Value
Capacity 14AH
Voltage （in full） At least 12.5V
Battery
Charge current Standard 1.4A
Charge time Standard 13 hours
Model Semiconductor switch type
Rectifier of Voltage
Control voltage 14.0-15.0V
Resistance value of Charge Coil 0.1-1.0Ω
（20℃）

Troubleshooting

No Power(Ignition trigger is “OFF”) Voltage is lower

－The battery is at the electric discharge condition ．The battery charge is not good or at the electric
discharge condition
－Storage battery leakage ．Voltage Rectifier not to good

－Voltage Rectifier not good ．The magnetic stator not good

－The magnetic stator not good ．Coupling connection is not good

－Battery not good

．Battery line cable connection falls off Electric current not steady-going on

．Fuse in short ．Line cable connection not good

．Line cable in short ．Charge system not good

．Ignition trigger not good ．Ignition system not good or in short

．Coupling connection is not good or short

Charge system
Leakage examination
Put ignition switch to OFF, and take out positive or cathode electrode line of battery. Take out your
digital multitester and put switch to “mA” position, connect battery line and battery to examine its
leakage flow value. If value is bigger than 15mA that means that the entire vehicle has the leakage
problem, you should promptly arrange looks up.

Control voltage inspection

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Carries on the warm start and make sure that other electricity components are at the off-position. (For
instance lights, speaker).
The engine control in Idle speed the condition, the digital multitester twists to the DC voltage files and
then connect in parallel fashion to the storage battery beginnings and ends. The storage battery must be
in fills the electricity in the situation, gradually speeds up the engine speed, biggest charging voltage
should be 14 to 15V.

10 Ignition System
Maintenance Information Troubleshooting Features of Igniter

Maintenance Information
IMPORTANT!
Because of CDI ignition system, you can not make an adjustment at the ignition time. If something
occurs during the ignition exceptionally, you should inspect the connect line, the CDI part, the trigger,
protruding parts of the flying wheel whether some of them has the distortion or the damage. If any you
must carry on the replacement.

．Maintains of Igniter。

．Maintains of Spark Plug。

．Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the
connection, you must pay attention to the color of the line cables. The coupling must meet on the same
coupling.

．The test condition may usually lead to differences between observed data and standard features.

Features of Igniter
Item Standard Value
Original coil 0.1-0.2Ω
Resistance value of
With spark plug 7.3-11KΩ
Ignition coil（20℃） Sub-coil
Without spark plug 3.6-4.6KΩ
Resistance value of pulse trigger winding coil（20℃） 50-170Ω
Resistance value of magneto stator（20℃） 50-350Ω

Troubleshooting

No spark or not enough The revolution is unusual.

．The line connection is bad, broken line or in short.

－CDI and Igniter coil[Black and Yellow ] －Ignition coil
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－CDI and Igniter trigger [Black and White] －Bad connection between lines
－CDI and Magneto Stator [Black and Red] －CDI is not good.

－CDI and Trigger [Green/White，Blue/Yellow] ．Sub Ignitions line

－CDI and Grounding line [Green] －Spark plug is not good

．Ignition Switch is not good －Trigger is not good

．CDI is not good －Spark coil is not good

．Trigger is not good Ignition

－CDI is not good.
－Trigger is not good
－Magneto Stator is not good
Main features of Igniter

Dismantles the accumulator cell fixed belt;

Dismantles the electric appliance lid.
Igniter

ITEM Checking Position Standard Value

Electric current bleed when
Igniter switch Black/White-Green
switch is off.
Magnetor coil Black/Red-Green 50—350Ω（20℃）
Trigger Green/White-Blue/Yellow 50—170Ω（20℃）
Main coil Black/Yellow-Green 3.6—4.6kΩ
Igniter coil Sub-coil with cap of spark
Black/Yellow-cap of Spark plug 7.3—11kΩ
plug
If no barriers after inspecting as above, you need a application detector to check
Igniter.

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