1

GO-KART [XYKD260] Repair Manual

2

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

3

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

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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

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Standard Torque Rating

SER

NUM Position

XYKD

Diameter of screw

（mm）

Torque（N.m）

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

joint

14 80-100

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,

elevation

8 20-26

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

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 8 30-40

19 Screws of front brake disc and front wheel rim 6 20-26

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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.

Connection part between Steering gear parts and handle ball

Steering wheel nylon bushing

Brake pedal Accelerator pedal Accelerator cable Parking brake cable

Front lower swing arm

Front Wheel Support Part

Front wheel axle

Main seat slide rail

Constant speed

gimbal

Rear wheel rim axle

Rear swing arm axle

Sub seat slide rail

7

Structure Drawing

Pipe of

cooling liquid

kettle

Water tubing

Temperature

Control

Switch

Rear brake oil

tube

Brake cable

8

Fuse 15A

Flash apparatus

Relay

CDI

BATTERY

Ignition coil

rectifier

Electric parts

case

Quadric air-intake

mechanism

Throttle cable

Reverse cableParking

brake cable

9

Troubleshooting

Can not or difficult to start

Main cable Speed Sensor cable

Description Adjustment Reasons

Whether oil run in carburetor. Take down vent bolt to check.

Take off spark plug to check sparkle or not

Yes

● ● No oil in oil tank

● Jam between oil tank and carburetor

● Oil tank hole jammed

● Oil filter jammed

● Oil cleaning net jammed

● Pressure oil switch not work

● Spark plug not work

● CDI parts not work

● Spark plug not clean

● Trigger not work

● Spark plug coil broken or short-circuit

● Ignition coil broken or short circuit

● Igniter switch not work

● Magneto coil not work

● Valve gap not enough

No

Yes No or not enough

Pressure Value

10

Description Routine

Power is not strong, not speed up

● Damage of cylinder, piston rings

● cylinder head gasket works not well

● Valve is damaged

● Mixing air time not good

●EEV of carburetor not work

● Valve socket not good

●Air leakage of minus pressure tube

●Ignition time not good

●Vent bolt of carburetion not work

● 化油器过满溢出

OK No or not enough

Start according right method

No explosion No start with explosion

Take off spark plug again

火花塞是干的 火花塞湿

●Too many oil in carburetor

●EEV of carburetor not work

●Value of throttle is unusual.

Dry Wet

◆

Reasons

Check Ignition time [Ignition led]

● Battery connection badness

● Air filter jammed

● Vent hole of oil tank cover jammed

● CDI parts not work

● Trigger not work Yes No

● Valve gap not good

● Shape of valve changed Yes No

Check Valve Gap

Check Compress pressure Value in Plunger

Yes

●

● oil tube jammed

● minus Pressure line not connected well

● Carburetor jammed

No

Let engine work at high speed

11

Description Routine

◆

● Plunger ring is damaged

● Air leakage from gasket position Yes No or Lower

● Parts of Carburetor jammed No Yes

● Spark plunger polluted/damaged

● Temperature of spark plunger wrong

Clean Dirt

● Valve socket not work well

● Mix air time not good

Check spark plunger

Check Carburetor jammed.

Engine is too hot or not

● Oil is not replaced

● Mix air rare

● Quality of oil bad No Yes

Speed up or work at high speed

Check oil quantity level and quality

OK

●

● Too many oil

● Oil is not enough No

● Plunger or Cylinder damaged

● Too many carbon powers in firebox

● Ignition time wrong

● Mix air rare

● Ignition time wrong

● Quality of oil is bad

● Too many carbon powers in firebox

● Cooling liquid not enough

Reasons

12

Description Routine

Egine works unusually（such as idle and low speed）

No sound Unusual sound

Ignition Time OK?

Yes

●

● CDI parts not good

● Magnetor not good No

● Mixed air is rare[Take screws down]

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

● Carburetor is loosed

● Airproof parts not good No Yes

● “O” gasket not good

● Air leakage in vacuum parts

Vent screw of carburetor OK?

Air leakage in carburetor gasket?

Sparks OK?

Reasons

13

Description Routine

Engine works unusually [High speed]

OK No or less spark ● Ignition coil not good

● Ignition coil is broken or in short

● CDI parts not good

● Spark plunger not good or polluted

● Ignition trigger not good

● Air tube jammed or damaged

Yes

● Cut Air Valve not good

● Vacuum line jammed or damaged No

◆

Cut Air Valve OK?

Ignition time OK?

Yes

●

● CDI parts not good

● Magnetor not good No

● Adjustment not good

● Value socket damaged Yes No

● Oil line or oil filter jammed

● Vent hole is jammed OK Unusual

● Not enough oil in oil tank

● minus Pressure line switch not work

Handspike gap OK?

Check oil automatic screw function?

● Clean carburetor socket No Yes

Carburetor socket jammed?

Reasons

14

Description Routine

Not move with high speed

● Protruding sprocket wheel and magneto

flywheel position not match Yes No

Mixed time right?

● Spring not good Yes No

Spring of valve good？

◆

Engine works at high speed or easy to stop?

Engine works at high speed

●

● Ignition coil wrong connection

● Spark plug bad connection

No high speed or easy to stop

reverse gear OK

Check reverse operation system

●Length of reverse cable is not suitable reverse position wrong

● Connection of battery not good

● Oil line not good

No Yes

Any unusual sound of engine gear case

●Differential gear damaged

●reverse gear damaged

●Connector sheath of reverse gear damaged

●Differential damaged

Reasons

15

Description Adjustment

No power in battery

◆

Open side cover of engine and check clutch strap broken or not

Start engine and check voltage of battery

Battery can not charging

●

●Check battery whether out of usage

●Battery not good Normal

● Connection of line is not good

Normal

● Stator not good

● Yellow line is broken Unusual

Resistance value of coil

Yes ● Blue/yellow or Green line is broken No

Voltage between Blue/yellow and Green li

Yes

● Booster not good

● connection-peg not good No

Whether any looseness of booster and connection-peg？

● Magneto not good

Reasons

16

Description Adjustment

The charge is not good ( Overcharge )

No spark

● 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

No Yes ● connection-peg not

good

● booster not good

Use a new spark plunger then check i

No or less sparks

●

Sparks OK

No

Any looseness between lid of spark and between high-voltage lines

● Lid of spark is loosen Yes

● previous Spark Plunger broken

Connection of CDI parts OK?

Yes No ● Connecter is not good

Check statement and features of connecter of CDI and measure the resistance

Reasons

17

Item

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

Requirements

Km ( remark )

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

OK No

Yes No

Related parts OK?

● 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

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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.

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.

Vent bolt

20~30mm

Adjustment Bolt

19

Parking Brake System

When stop vehicle on 20º-25°ground 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

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

Wheel System

Wheel

Check tire with air pressure gauge.

Standard information：

Spec. of Tire Pressure Value

（off-road）

Pressure Value

（Road）

Front AT21X8-10 28kPa 200kPa Rear AT22X11-10 35kPa 225kPa

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

Cushion System

Brake oil pump

Attention!

When exhaust, you must guarantee that there is

enough brake fluids in brake pump oil cup.

Adjustment bolt of brake

Attention! Please make sure that length of rear wheel

brake line is out about 3-5mm.

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

Metal hexad flange screws

Front/rear axe screws

Brake Handle

Adjustment bolt

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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

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

Replacement of lubricating oil

Take down oil position screw Take down vent bolt and put oil out Put on vent bolt with revolving

Pour oil according to standard value：

Attention! Make sure that ground is plainness.

Oil position screws Air proof gasket

Attention! Make sure that no damage in airproof gasket

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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 Check driving/driven condition

Electronic System

Ignition System

Station of Spark Plug

Take off spark plug Check sparks plug and clean dirt,

carbon with special cleaner or steel wire brush.

Spark Plug：Distance should be 0.6 mm to 0.8 mm

Ignition Timing

Take off ignition screw Check ignition LED to confirm ignition time: When idle speed is 1500±100rpm，it matches “F” well.

Function of Ignition Advance Angle

Driving wheel

Driven wheel

Check gap, whether any dirt and Carbon

Chechecks any broken Checks gasket

Important! When install spark plunger, please tight it by plug socket after hand.

Important! Because of CDI system function, there is no necessary to adjust ignition time. If any problem, please check ignition system.

Ignition Screw

22

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.

Engine

Engine Body

Low speed and speed up condition

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. Standard period of change filter core：per 4000 KM If road condition is not good, you should change filter core early

Lubricating System

Standard Position

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.

Idle Screw

Air filter screws

Clips

Filter Core

Caution: since the filter paper of the filter core contains

oil (viscous); it cannot clean with air.

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Lubricating oil quality and quantity

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.

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

Pour lubricating oil.

Replacement of lubricating oil

Take off filter lid and let oil out Take up filter lid with revolving

Pour in lubricating oil.

Full capacity：0.8 Liter，Type：85W-140 Start engine to make sure no leakage problem Stop engine and check oil 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

Max Position

Min Position

Attention! Open parts of net should be inside.

Filter net lid

Spring Filter net

Air proof gasket

Attention! Put lubricating oil out on warm condition.

Attention! Check air-proof gasket and change it if any broken.

Oil vernier

24

Accelerator operation system

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.

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

hole

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.

Water Leakage

Check cooling line whether any broken, damage or leakage.

Range

Pedal limit screw

Screw

Oiling position

Adjustment bolt

Screw

Adjustment bolt

kettle

Reverse gear handle

25

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.

3 Oil System

Maintenance information Electricity enrichment valve Floater Room

Troubleshooting Cut air valve Oil tank

Carburetor Vacuum room Oil switch

Maintenance Information

.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

Important! No spark when use fuel.

Rear adjustment screw

Front adjustment screw

26

﹒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

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

Oil Line

Clips of Air filter

Clips of engine Pressure three-way line

Plug of electricity enrichment valve

Throttle cable

Oil drain bolt

27

Take off plug of electricity enrichment valve

Take off carburetor

Electricity Enrichment Valve

Inspection

Check connected line of electricity enrichment value. Resistance value: 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. Take down electricity enrichment valve.

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. Connecter

Screws of support part Support part

E.E.V. Pin

E.E.V.

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

28

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.

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

Vaccum Room

Disassembly

Take down two screws and take off vacuum room cover

Cut air valve

Bolt

Cut air valve

“O” gasket

Cover of Vacuum Room

Screw

29

Take off spring and vacuum plunger.

Take off support pats, spring and ejector pin

Inspection of Vacuum Plunger

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

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

Floater Room

Take off four screws and floater room.

Inspection of Pin Valve

Check station of valve socket

Plunger Spring

Important! Please protect septum of vacuum plunger. Vacuum Plunger

Septum Nozzle Pin Spring

Support pats

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

Bolt Floater Room

Bolt

Pin valve

30

Take off main ejector, pin ejector socket, pin ejector, sub ejector and vent screws.

Clean ejector with extractive oil.

Clean carburetor pass way with huffing air.

Installation

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

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

Main Ejector

Sub Ejector

Main Ejector Socket

Vent bolt

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

Attention! Extractive oil should be fresh one.

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

Vent bolt

Sub Ejector Main Ejector Socket

Main Ejector

Oil tank

31

Takes down four screws of oil tank

Take oil line and pressure line part from oil switch.

Take off oil tank

Oil Switch

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

Oil Line

Pressured line

Oil switch

Important! NO SPARK!

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

Radiator Lid

32

Take off radiator lid . Connect Out-water line and fix it tightly In pouring cooling liquid till it is full.

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

Radiator Lid

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

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

NOICE!

Before checking please put some water on lid airproof surface.

Important! Do not use too high pressure; otherwise radiator will be destroyed on condition of high pressure.

Out-water line

Radiator Inspector

Radiator Lid

Sluice bottle

33

Temperature Control Switch

Disassembly

Drain radiator liquid out

Dismantles switch wiring.

Dismantles the switch

5 Engine Disassembly

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; Take down screws and take off rear brake; Take down rear bone [left and right], break connection between rear bone and engine

Take off gimbals [left and right]

Take apart water line and out cooling liquid

Rear Wheel Screw

Support Part

Attention! When 80°C, the fan can automatically

open; if failed, it needs the prompt inspection.

Rear Brake

Rear Bone

34

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

Take off auto-restarted plug Take off transmission line Take off earth line Take off line between engine and battery Take down screws of bumper

Take down screws between air filter, support part and Vehicle body.

Erath Line Power Line

Bumper

Water Line

Air Filter Screw

Muffle Screw

35

Take down screws between engine and rear suspend part

Take down front suspend part of engine

Take down suspend part under engine Take off engine with muffle, air filter and carburetion

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.

Installation

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

Rear Suspend Screw

Front Suspend

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

Muffle Screw

Suspend Part under Engine

36

6 Front Wheels and Steering System

37

Disassenmbly

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

Front wheel rim screws

38

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.

Take down two screws and take off front brake pump assembly.

Take down the cotter pin locked screws of the steering assembly.

Take down the locked screws and take apart front vibration

Damper.

Take down two screws between support parts and vehicle body.

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.

Front Wheel Rim

Brake Disc

Important! It is connected by bearing You should use special tools.

Screws

Front Vibration Damper

Bolt Up Support Part

Down Support Part

Important! It is connected by wimble, please pay attention to bone when knock the assembly.

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Take apart U/D support part and front bone.

It is same to RIGHT WHEEL. Take down three screws and take apart steering support nips.

Take down screws between steering assembly and gimbal.

Take apart steering assembly.

Take down screws between steering bearing and gimbal.

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

Front Bone

U/D Support Part

Fix part of S.S.

Steering assembly Bolt

Gimbal

Fixing parts of S.W.

Bolt

Gimbal

Screw

Steering assembly

Important! It is connected by wimble please knock assembly carefully.

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Take down six screws and gather respective assembly

Installation

Do it as opposite procedure compared with DISASSEMBLY.

7 Seat System Disassembly

Steering Wheel

Screw

Steering Wheel

Screw

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Safety Belt

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

Take off seat.

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

adjustment, back or front.

Bolt

Bolt

Man Handle

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Disassembly setting screws of safety belt on left side of seat

Take off safety belt.

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

8 Rear Drive Line System

Screw

Man handle

Slide Rail

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Disassembly

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

Rea wheel rim screw

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

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

Dismantle two setting screws and take down rear brake pump.

Dismantle four setting screws of rear bone

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

Dismantle four setting screws and take off brake disc.

Take off SPEED SENSER ASS.

Parking Brake

Rear brake pump Screw

Screw

Rear BoneBrake Disc

Rear Wheel Rim

Screw

Important! IT IS CONNECTED WITH AXLTREE;

YOU SHOULD USE PROFESIONAL TOOL.

Parts of speedometer

Parking Brake Screw

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It is same on right side. Take off seat. Take down two setting screws of tranquilization part.

Take off fixed part and rubber sheath.

Disassembly setting screws on left and right tranquilization part. Take of tranquilization part.

Disassembly setting screws of rear vibration damper.[L&R ]

Take off left and right rear vibration damper.

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

Installation

Do it as opposite procedure compared with DISASSEMBLY

Universal Joint

Screw

Rubber sheath Fixed part

Rear Support Part

Screw Tranquilization part

Rear Vibration Damper

Screw

Screw

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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

Battery

Capacity 14AH

Voltage （in full） At least 12.5V

Charge current Standard 1.4A

Charge time Standard 13 hours

Rectifier of Voltage Model Semiconductor switch type

Control voltage 14.0-15.0V

Resistance value of Charge Coil

（20℃）

0.1-1.0Ω

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

Resistance value of

Ignition coil（20℃）

Original coil 0.1-0.2Ω

Sub-coil With spark plug 7.3-11KΩ

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.

ITEM Checking Position Standard Value

Igniter switch Black/White-Green Electric current bleed when

switch is off.

Magnetor coil Black/Red-Green 50—350Ω（20℃）

Trigger Green/White-Blue/Yellow 50—170Ω（20℃）

Igniter coil

Main coil Black/Yellow-Green 3.6—4.6kΩ

Sub-coil with cap of spark

plug Black/Yellow-cap of Spark plug 7.3—11kΩ

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

Igniter.

Igniter