GO-KART [XYKD260] Repair Manual

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
Overall Length...2470
Overall Width....1570
Overall Height1535
Wheelbase..1870
Front Track.1345
Rear Track.1250
Ground Clearance200

KD260-2 KD260-3
2690
2550
1510
1670
1460
1440
1950
2010
1270
1485
1250
1263
220
200

ENGINE
Type...Water cooling, four stroke
Engine capacity.260cc
Bore *Stroke.70mm*66.8mm
Displacement.257cm
Corrected compression ratio91
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-9NGK
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....20-25
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

Front 25
Rear 30

WEIGHT[KG]

KD260-1 KD260-2
Net Weight 355
346
G.W. 380
370

Road Tire
200
225

KD260-3
365
380

Standard Torque Rating

XYKD
SER
NUM

Position

Diameter of screw
mm

TorqueN.m

Screw used between Exhaust pipe and Front Cylinder

20-26

Igniter plug

10

18-20

Screw used between Front wheel hub and front universal

joint

14

80-100

18

120-140

Screw used for Rear wheel hub and Constant-velocity joint

Universal joint fastening bolt

20-26

Bolt of protective parts of steering mechanism

30-40

Screws between handle ball and gimbal

10

50-60

Screws of wheel and wheel rim[Front and rear]

10

50-60

Screws of support parts[Front wheel] and vehicle body

10

50-60

10

Connection of brake pump parking brake and front gimbals,

elevation

20-26

11

Screws of handle adjusting line

10

30-40

12

Screws exhaust pipe and engine rear support part

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

body

16

110-130

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

30-40

19

Screws of front brake disc and front wheel rim

20-26

Lubricating oil and How to do lubrication

1Engine
Position

Description of Lubricating Oil

Remark

Crankcase

Only 15W/40SF

Full capacity1.0L

Gear case

Only 15W/40SF or 85W/140

Full capacity0.22L

Parts of Clutch

Li oil ZL-3HSY 1413

4.5~5.0g

2Vehicle 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

Main seat slide rail

Brake pedal
Accelerator pedal
Accelerator cable
Parking brake cable

Front wheel axle

Front lower swing arm

Rear swing arm axle

Structure Drawing

Pipe
of
cooling liquid
kettle

Water tubing
Temperature
Control
Switch

Brake cable

Rear brake oil

tube

Fuse 15A

Relay

Flash apparatus

CDI

Electric
case

parts

rectifier

Ignition coil
BATTERY
Throttle cable

Quadric air-intake
mechanism

Reverse cable

Parking
brake cable

Speed Sensor cable

Main cable

Troubleshooting
Can not or difficult to start
Adjustment

Description

Reasons

Whether oil run in carburetor. Take

down vent bolt to check.

No oil in oil tank

Jam between oil tank and carburetor

Yes

No

Oil tank hole jammed

Oil filter jammed

Oil cleaning net jammed

Take off spark plug to check

sparkle or not

Yes

No or not enough

Pressure oil switch not work

Spark plug not work

Spark plug not clean

CDI parts not work

Trigger not work

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

OK

No or not enough

Valve socket not good

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

No explosion

Air leakage of minus pressure tube

No start with explosion

Ignition time not good

Take off spark plug again

Vent bolt of carburetion not work

Too
many oil in carburetor

Dry

Wet

EEV of carburetor not work

Value of throttle is unusual.

Power is not strong, not speed up

Description

Reasons

Routine

Let engine work

at high speed

Battery connection badness

Air filter jammed
oil tube jammed

Yes

No

minus Pressure line not connected well

Vent hole of oil tank cover jammed

Check Ignition
time [Ignition led]

Yes

No

Carburetor jammed

CDI parts not work

Trigger not work

Check Valve Gap

Yes

Valve gap not good

No

Shape of valve changed

Check Compress pressure Value in Plunger

10

 Valve socket not work well

Yes

Plunger ring is damaged

No or Lower

Air leakage from gasket position

Mix air time not good

Check Carburetor jammed.

No

Parts of Carburetor jammed

Yes

Check spark plunger

Clean

Spark plunger polluted/damaged

Dirt

Temperature of spark plunger wrong

Description

Reasons

Routine

Check oil quantity

level and quality
OK

No

Too many oil

Oil is not enough

Oil is not replaced

Cooling liquid not enough

Engine is too hot or not

Plunger or Cylinder damaged

No

Yes

Mix air rare

Quality of oil bad

Too many carbon powers in firebox

Ignition time wrong

Speed up or work at high

speed

Too many carbon powers in firebox

11

Quality of oil is bad

Mix air rare

Ignition time wrong

No sound

Unusual
sound

Egine works unusuallysuch as idle and low speed

Description

Reasons

Routine

Ignition Time OK?

Yes

No

CDI parts not good

Magnetor not good

Vent screw of
carburetor OK?

Yes

Mixed air is rare[Take screws down]

No

Mixed air is thick[Take screws up]

Air leakage in
carburetor gasket?
O gasket not good

No

Yes

Carburetor is loosed

Airproof parts not good

Air leakage in vacuum parts

Sparks OK?

12

 Spark plunger not good or polluted

OK

CDI parts not good

Ignition coil not good

No or less spark

Ignition coil is broken or in short

Ignition trigger not good

Cut Air Valve OK?

Yes

Cut Air Valve not good

Vacuum line jammed or damaged

No

Air tube jammed or damaged

Engine works unusually [High speed]

Description

Reasons

Routine

Ignition time OK?

Yes

No

CDI parts not good

Magnetor not good

Adjustment not good

Handspike gap OK?

Yes

No

Value socket damaged

Check oil automatic

screw function?
Not enough oil in oil tank

OK

Oil line or oil filter jammed

Unusual

Vent hole is jammed

minus Pressure line switch not work

Carburetor socket jammed?

No

Clean carburetor socket

Yes
13

Mixed time right?

Yes

Protruding sprocket wheel and magneto

No

flywheel

position not match

Spring of valve good

Yes

No

Spring not good

Not move with high speed

Description

Reasons

Routine

Engine works at high

speed or easy to stop?
Ignition coil wrong connection
Spark plug bad connection

Engine works at
high speed

No high speed or easy to

stop

Connection of battery not good

Oil line not good

Check reverse operation system

reverse gear OK

Length of reverse cable is not suitable

reverse position wrong

Any unusual sound of engine

gear case

reverse gear damaged

No

Connector sheath of reverse gear damaged

Yes

Differential gear damaged

14

Differential damaged

Open side cover of engine and check

clutch strap broken or not

No power in battery
Description

Reasons

Adjustment

Start engine and check

voltage of battery

Battery can not charging

Check battery whether out of usage

Normal

Battery not good

Resistance value
of coil

Normal

Unusual

Stator not good

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

Yes

No
15

Booster not good

connection-peg not good

Magneto not good

The charge is not good ( Overcharge )

Measure of voltage between

rectifier polarities

Voltage is usual when

ignition switch is On

No voltage when ignition

switch is On

black line of main cable

is broken

Any looseness or default of booster connection-peg

connection-peg

Yes

No

No spark
Description

booster not good

Reasons

Adjustment

not

good

Use a new spark plunger then check

i

No or less sparks

previous Spark Plunger broken

Sparks OK

Any looseness between lid of spark and

between high-voltage lines

No

Lid of spark is loosen

Yes

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?

No

Yes

Ignition switch not good

Magneto coil not good

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

Electronic System
Cushion System

Brake System

Wheel System

Engine

Others

Check & Repair method

Maintenance period List
Maintained time

ITEM

Km ( remark )

Item
Requirements

1000Km

4000Km

8000Km

12000Km

Oil System

Carburetion System

Carburetor
Core of air filter

I
often

Spark plug

Lubricating oil in engine

Clean net of lubricating oil

First time1000Km; then per 2000 Km

Per year

Gap of valve

Battery
Brake system

I
17

remark

Brake DISC.

Brake lighter switch

Main lighter

Per month

Clutch

Suspend parts
Support parts
Screw and bolt

Per month

Wheel/spoke

Trimester

Vent hole of crankcase

Idle of carburetor

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.
Ccleaning
Ruse a new part
Amake an adjustment
LLubricating
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
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.

Adjustment Bolt

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

Brake Handle

When stop vehicle on 20-25ground and can not park it.

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

Front
Rear

Pressure Value

Pressure Value

off-road

Road

28kPa
35kPa

200kPa
225kPa

AT21X8-10
AT22X11-10

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 TYPE85W-140 or 15W/35S

Put on oil position screw after checking airproof gasket

Oil position screws

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

Air proof
gasket

Full capacity1.2 Liter

Standard capacity1.1 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
Check driving/driven condition

Driven wheel

Driving wheel

Electronic System
Ignition System
Station of Spark Plug

Check gap, whether

any dirt and Carbon

Take off spark plug

Check sparks plug and clean dirt,
carbon with special cleaner or
steel wire brush.
Checks gasket
Spark PlugDistance 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.
Ignition Screw
Take off ignition screw
Check ignition LED to confirm ignition time:
When idle speed is 1500100rpmit matches F well.

Function of Ignition Advance Angle

21

Chechecks any broken

Same to Ignition system, put on Ignition LED. Then start

engine and make speed up to 7500 to 8000 rpm, system
works well if LED reach at standard position.

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
Open six clips and take off air filter cover.
Take off filter core
Change filter core if it is dirty or damaged.

Clips

Air filter screws

Standard period of change filter coreper 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!
Open parts of net should be inside.

Spring

Filter net

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
gasket
Pourair-proof
in lubricating
oil.and change it if any broken.
Full capacity0.8 LiterType85W-140
Start engine to make sure no leakage problem
Stop engine and check oil quantity.

23

status of accelerator pedal

Accelerator operation system

Oiling position

Pedal limit screw

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

Oil System

Maintenance information Electricity enrichment valve Floater Room

Troubleshooting

Cut air valve

Carburetor

Oil tank

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

No oil flow into
Too much oil in cylinder

septum of vacuum piston is destroyed

Pressure entrance is jammed
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 andOil

Work abnormally

line is not working

Floater is not working

Adjustment of idle is not working

Mixed air is rare
Air filter is jammed

No enough oil

Mixed air is thick

Air in plug

Oil is polluted
EEV is on for long time
Cut air valve is not workingdisc 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

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

Clips of engine

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
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.

Support part

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

E.E.V.

Connecter

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 value400600mmHg
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
with screws

Bolt
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

Important!
Please protect septum of vacuum plunger.

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

Important!

Main
Socket

Ejector

. 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

Installation

Main
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

Ejector

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

Important! NO SPARK!

Pressured line

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
Important! Before take off radiator lid
please make sure that cooling liquid is31
NOT HOT.

Radiator Lid

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.

Function Inspection

Sluice bottle
Radiator Inspector

Radiator Lid
Before take off radiator lid please
make sure that cooling liquid is NOT HOT.

Important!

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 pressure73.5-103 Kpa

Important! Do not use too high pressure;

otherwise radiator will be destroyed
on
32
condition of high pressure.

Temperature Control Switch

Disassembly

Drain radiator liquid out

Dismantles switch wiring.
Dismantles the switch

Attention! When 80C, the fan can automatically

open; if failed, it needs the prompt inspection.

5 Engine
Rear Wheel Screw

Disassembly
Dismantles Earth Line from the battery
Lift back vehicle with Left and Right support parts, and make sure rear
Wheel takes off;

Support Part

Take down screws and take off rear wheel;

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.

35

6 Front Wheels and Steering System

36

Disassenmbly
Support front part of vehicle and make front wheel take off.
Take apart four screws of front wheel[Left wheel for example]
37

Front wheel rim screws

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

attention to bone when knock the
assembly.

Screws

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

Take down two screws between down support part and vehicle body.
Take apart down support part and front bone assembly.
Take down screws between up-down support part and front bone.
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Bolt

Down Support Part

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

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S.W.

Gimbal

Steering Wheel

Take down six screws and gather respective assembly

Installation

Screw

Do it as opposite procedure compared with DISASSEMBLY.

Screw

Seat System

Disassembly
40

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.

41

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.
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Front wheel screw

Dismantles 2 setting screws, and take down the brake to pump.

Parking Brake
Dismantle locking screws, take down the trailing wheel.
Dismantle two setting screws and take down brake pump.

Screw
Rear brake pump

Screw

Dismantle two setting screws and take down rear brake pump.

Parking Brake

Dismantle four setting screws of rear bone

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

Take off SPEED SENSER ASS.

Parts of speedometer

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Screw

Rear Bone

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.

Left is same with Right.

Installation
Do it as opposite procedure compared with DISASSEMBLY
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Screw

9 Electric System
Repair Information
Troubleshooting

Battery
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

Battery

At least 12.5V

Charge current

Standard

1.4A

Charge time

Standard

13 hours

Model

Rectifier of Voltage

Semiconductor switch type

Control voltage

14.0-15.0V

Resistance value of Charge Coil

0.1-1.0

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
Voltage Rectifier not to good

Storage battery leakage

The magnetic stator not good

Voltage Rectifier 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
47

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
Resistance value of
Ignition coil20

Standard Value

Original coil
Sub-coil

0.1-0.2

With spark plug

7.3-11K

Without spark plug

3.6-4.6K

Resistance value of pulse trigger winding coil20

50-170

Resistance value of magneto stator20

50-350

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
48

CDI and Igniter trigger [Black and White]

CDI and Magneto Stator [Black and Red]

Bad connection between lines

CDI is not good.

Sub Ignitions line

CDI and Trigger [Green/WhiteBlue/Yellow]

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

Igniter coil

Checking Position

Standard Value

Igniter switch

Black/White-Green

Electric current bleed when

switch is off.

Magnetor coil

Black/Red-Green

5035020

Trigger

Green/White-Blue/Yellow

5017020

Main coil

Black/Yellow-Green

3.64.6k

Sub-coil with cap of spark

plug

Black/Yellow-cap of Spark plug

7.311k

If no barriers after inspecting as above, you need a application detector to check

Igniter.

49