M565li t3 Efi

2020 ATV
SERVICE MANUAL 20.0

PN. F010106A27
M565Li T3 EFI
WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts
have almost same appearance. Always refer to Parts Manual of each ATV model for spare
parts information and service.
※General Information
※Maintenance
※Engine
※Chassis
※Final Drive
※Brakes
※Electrical
ATV SERVICE MANUAL EUROPE 20.0
PN. F010106A27
M565Li T3 EFI 维修手册英文版本 20.0 零件代号 F010106A27

Foreword
This manual is designed primarily for use by the ATV factory certified service technicians in
a properly equipped shop. Persons using this manual should have a sound knowledge of
mechanical theory, tool use, and shop procedures in order to perform the work safely and
correctly. The technician should read the text and be familiar with service procedures
before starting the work. Certain procedures require the use of special tools. Use only the
proper tools, as specified. Cleanliness of parts and tools as well as the work area is of
primary importance.
This manual is divided into sections. Each section covers a specific ATV component or
system and, in addition to the standard service procedures. Keep this manual available for
reference in the shop area. When using this manual as a guide, the technician should use
discretion as to how much disassembly is needed to correct any given condition.
All references to left and right side of the vehicle are from the operator's perspective when
seated in a normal riding position.
At the time of publication all information contained in this manual was technically correct.
Some photographs used in this manual are used for clarity purposes only and are not
designed to depict actual conditions. We constantly refine and improve its products, all
materials and specifications are subject to change without notice.
This ATV’s publications and decals display the words Warning, Caution, Note, and At This
Point to emphasize important information:
WARNING
Indicates a potential hazard which will result in severe injury or death to the operator,
bystander or person inspecting or servicing the ATV..
CAUTION
Indicates a potential hazard which may result in personal injury or death or damage to the
machine.
NOTE
The word “NOTE” in this manual will alert you to key information or instructions.
CONTENTS
CHAPTER1 ………………………………………………General Information↖
CHAPTER2 ………………………………………….……………Maintenance↖
CHAPTER3……………………………………. …. ………………500 Engine↖
CHAPTER4…………………………………………..…………………Chassis↖
CHAPTER5………………………………………………….………Final Drive↖
CHAPTER6………………………………………………………………Brakes↖
CHAPTER7………………………………………………….….………Electrical↖
WARNING
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is
poisonous and can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery
electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with
skin, eyes or clothing. Always keep alert and wear protection.
Exhaust system components are very hot during and after use of ATV. Never service
when the engine is warm or hot. Escaping steam from cooling system or hot oil from the
machine can cause severe burns. The engine must be cool before service.
Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention
and wear protection.
CHAPTER 1 GENERALINFORMATION M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 1 GENERAL INFORMATION
WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have
almost same appearance. Always refer to Parts Manual of each ATV model for spare parts
information and service.
1.1 IMPORTANT INFORMATION
1.2 V.I.N AND ENG INE SERIAL NUMB ER
1.3 VEHICLE DIMENSIONS
CHAPTER 1 GENERAL PAGE. 1- 1

1.1 IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES

1. Remove all dirt, mud, dust and foreign material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. When disassembling the machine, always keep mated parts together. This includes gears,
cylinders, pistons and other parts that have been ”mated ”through normal wear. Mated part must
always be reused or replaced as an assembly.
4. During machine disassembly, clean all parts and place them in trays in the order of disassembly.
This will speed up assembly and allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
REPLACEMENT PARTS
Use only genuine parts for all replacements. Use recommended oil and grease for all lubrication
jobs. Other brands may be similar in function and appearance, but inferior in quality.
GASKETS,OIL SEALS AND O-RINGS

1. Replace all gaskets seals and O-rings when overhauling the engine. All gasket surfaces, oil seal
lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
Replace all lock washers/plates and cotter pins

after removal. Bend lock tabs along the bolt or
nut flats after the bolt or nut has been tightened
to specification.
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating of
lightweight lithium base grease to the seal lips.
Oil bearings liberally when installing, if
appropriate.
① oil seal
CAUTION:
Do not use compressed air to spin the bearings
dry. This will damage the bearing surfaces.
① Bearing

CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip ① , make sure that the sharp-edged
corner ② is positioned opposite the thrust
③ it receives. See sectional view.
④Shaft
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two or
three.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin ①
and reinset the terminal into the connector.
6. Connect:
 Connector
NOTE:
The two connectors ” click ” together.
7. Check for continuity with a tester.

NOTE:
 If there is no continuity, clean the terminals.
 Be sure to perform the steps 1 to 7 listed
above when checking the wire harness.
 Use the tester on the connector as shown.
WARNING
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and
can cause severe injury or death. Always start engines outdoors.
Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is
poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
Always keep alert and wear protection..
Exhaust system components are very hot during and after use of ATV. Never service when
the engine is warm or hot. Escaping steam from cooling system or hot oil from the machine can
cause severe burns. The engine must be cool before service.
Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention and wear
protection.

CONVERSION TABLE
How to use the CONVERSION TABLE
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.
METRIC MULIPLIER IMP
**mm x 0. 3937 = **in
**cm x 0.03937 = **in
CONVERSION TABLE
METRIC TO IMP
Known Multiplier Result
Torque m·kg 7.233 ft·lb
m·kg 86.794 In·lb
cm·kg 0.0723 ft·lb
0.8679
cm·kg In·lb
Weight kg 2.205 lb
g 0.03527 oz
Distance km/h 0.6214 mph
km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3927 in
mm 0.03927 in
3
Volume/ cc(cm ) 0.03527 oz(IMP liq.)
Capacity cc(cm3) 0.06102 cu·in
lit(liter) 0.8799 qt (IMP liq.)
lit(liter) 0.2199 gal(IMP liq.)
Miscellaneous kg/mm 55.997 lb/in
2
kg/cm 14.2234 psi(lb/in2 )
Centigrade 9/5(℃)+32 Fahrenheit(°F)

1.2 V.I.N AND ENGINE SERIAL NUMBER

M565Li
1.3 VEHICLE DIMENSIONS

Note.
The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA.

M565Li

NOTES

CHAPTER 2 MAINTENANCE M565LiT3 EFI SERVICE MANUA 20.0
CHAPTER 2 MAINTENANCE
WARNING
have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts
2.1 PERIODIC MAI NTENANCE
2.2 FUEL SYSTEM
2.3 TOE ALIGNMENT
2.4 BRAKING SYSTEM INSPECTION
2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT
2.6 W HEELS
2.7 TIRE PRESSURE
2.8 FRAME, NUTS, BOLTS, FASTENERS
CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE

GENARAL
CAUTION
Mark on the following chart
DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is
recommended that service be performed by an authorized dealer.
▲： Service/Inspect more frequently when operating in adverse conditions.
PERIODIC MAINTENANCE SCHEDULE

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
Inspection, adjustment and lubrication intervals of important components are explained in the
following chart on the following pages.
Maintenance intervals are based upon average riding conditions and an average vehicle
speed of approximately 16km/h (10 miles per hour). Vehicles subjected to severe use, such
as operation in wet or dusty areas, should be inspected and serviced more frequently.
Inspect, clean, lubricate, adjust or replace parts as necessary.

NOTE: Inspection may reveal the need for replacement parts. Always use genuine parts
available from your dealer.
Service and adjustments are critical. If you are not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T =Tighten to Correct Torque

Item Hours When Remarks

Service (Main) Brake / Pre-ride I
System
Auxiliary (Secondary) Brake / Pre-ride I
Parking Brake / Pre-ride I
Tires / Pre-ride I
Wheels / Pre-ride I
Frame nuts, bolts fasteners / Pre-ride I
Air Filter-Pre-Cleaner / Daily I C
▲
Coolant/Level / Daily I
Coolant 150 Annually R
Coolant strength 25 hrs 3 months I Inspect strength seasonally
▲ Air Box Sediment Tube / Daily D
Headlamp Inspection / Daily C

apply dielectric grease to connector when
replaced
Tail lamp inspection / Daily C
apply dielectric grease to socket when
replaced
▲ Air Filter-Main Element 2 Weekly I C
Replace if necessary
▲ Transmission Oil Level 10 Monthly I
change annually
Battery Terminals 10 Monthly I C
Battery fluid level 10 Monthly I
DL Brake pad wear 2 Weekly I
▲ Gear case Oil 10 Monthly C

150 annually R
Engine Cylinder Head and 25 3 months I
Cylinder Base Fasteners (re-torque required at first service only)
▲ General Lubrication 25 3 months L
all fittings, pivots, cables,
etc.
Engine Oil-Level / Daily I

Engine Oil Change 30 hrs 3 months R

Break-in Service at 1 month. Change oil more
often in cold weather use.
▲ Oil Filter 50 hrs 6 months I C
▲ Engine breather hose 100 hrs 6 months I
Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage
Throttle Cable / Pre-ride I
DL Throttle Cable 50 hrs 6 months A L (Grease M) R if necessary
Shift linkage 50 hrs 6 months I A R if necessary
DL Transmission belt 50 hrs 6 months I

R if necessary
▲ Steering 50 hrs 6 months I L T if necessary
▲ Rear Axle ( and Bearings) 50 hrs 6 months I L
▲ Front Suspension 50 hrs 6 months I L

T if necessary
▲ Rear Suspension 50 hrs 6 months I
T if necessary
Spark Plug 100 hrs 12 months I
R if necessary
DL Ignition Timing 100 hrs 12 months I
Adjust as needed
DL Fuel System 100 hrs 12 months Check for leaks at tank, cap, lines, fuel valve,
filter, and carburetor. Replace lines every 2
years.
DL Fuel Filter 100 hrs 12 months R
Radiator 100 hrs 12 months I R
Cooling System hoses 50 hrs 6 months I

R if necessary
Spark arrestor 10 hrs monthly C
R if necessary
DL Clutches (drive and Driven) 25 hrs 3 months I R
R if necessary
Engine mounts 25 hrs 3 months I T
DL Valve clearance 100 hrs 12 months I A
DL Shift selector box 200 hrs 24 months Change grease every two years

(H/L/R/N)
DL Brake fluid Level / Pre-ride I
Brake fluid 200 hrs 24 months Change every two years
Idle Speed / As A
Required
DL Toe adjustment / As Periodic inspection, adjust when parts are
Required replaced
Headlight Aim / As Adjust if necessary
Required
▲ Front drive chain (and 300 hrs (full time in I, Replace if necessary
DL sprockets) in transmission 4X4), or 1000 hrs ( in

(only SDX300 ); 2X4 alternate 4X4 )
▲ Ball joint (A arm- strut) 10 hrs monthly I, (for damage, wear, and play)
DL R. Replace if necessary
LUBRICANT AND FLUID

Item Lube Rec Method Frequency
1. Engine Oil SAE 15W/40 SE Add to proper Check level daily
level on dipstick
2. Brake Fluid DOT 3 Only Maintain level As require; change
Between fill lines. See every two years or 200
“7.CONTROL” hours
3. Transmission Oil SEA 80W/90GL5 Add to proper Change annually or at
level on dipstick 100 hours
4.Rear Gear case oil SEA 80W/90GL5 Add to proper Change annually or
level at 100 hours
5. Front Gear case SEA 80W/90GL5 Add to proper Change annually or
oil ( SDX30-0 ) level at 100 hours
▲ 6. Front A-arm Grease Locate fitting on pivot shaft Every 3 months or 50
pivot Shaft and grease with grease gun hours
( Except
Maintenance-Free
A-arm pivot )
▲ 7.Steering Grease Locate fitting on Every 3 months or 50
Post Bushings pivot shaft and hours
grease with grease gun
▲ 8.Front Wheel Grease Inspect and replace bearings if Semi-annually
bearings (high temperature necessary
resist)
9.Tie rods Grease Locate fittings and grease Semi-annually
10.Shift Grease Locate fittings and grease Semi-annually
Linkages
▲ 11.Ball joints Inspect Inspect and replace it if Semi-annually
necessary
▲ 12.Rear Axle Grease Locate fittings and grease Every 3 months or 50
Bearing hours
▲ 13.Swing Arm Grease Locate fittings and grease Monthly or 20 hours

Bearing
▲ 14.Throttle Grease M Grease, inspect and replace it Monthly or 20 hours
Cable if necessary
15. Rear prop shaft Grease Locate fittings and grease Every 3 months or 50
U-joint hours
16. Rear prop shaft Grease Locate fittings and grease Every 3 months or 50
yoke hours
17. Front prop shaft Grease Locate fittings and grease Every 3 months or 50
U-joint ( SDX300) hours
18. Front prop shaft Grease Locate fittings and grease Every 3 months or 50
yoke ( SDX300) hours
19. Inner and outer Grease M Grease, inspect and replace it Every 3 months or 50
CV-Joints (SDX300) if necessary hours
▲
21. A-arm pivot Grease Locate fittings and grease Every 3 months or 50
hours
shaft
LUBRICATION RECOMMENDATIONS
NOTE:
1. More often under severe use, such as wet or dusty conditions.
2. Grease: Light weight lithium-soap grease.
3. Grease M：Molybdenum disulfide (MoS 2 ) grease (water resistant).
4. When suspension action becomes stiff or after washing.
5. Hours are based on 10 mph(16Km/h) average.

2.2 FUEL SYSTEM

WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is
performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust
fumes are poisonous and can cause loss of consciousness and death in a short time.
Never drain the float bowl when the engine is hot. Severe burns may result.
FUEL LINES
FUEL FILTER
Check fuel lines for signs of wear, The fuel filter should be replaced in
deterioration, damage or leakage. Replace if accordance with the Periodic Maintenance
necessary. Chart or whenever sediment is visible in the
Be sure fuel lines are routed properly and filter.
secured with cable ties.
CAUTION: Make sure lines are not kinked or
pinched.
Replace all fuel lines every two years.
VENT LINES AND ROLL OVER VALVE* Fuel Pump Module

1. Check fuel tank, oil tank, battery, and
transmission vent lines for signs of wear, Description and Working Principle
deterioration, damage or leakage. Fuel Pump Module supplies fuel to engine at
Replace every two years.
system pressure. Fuel Pump Module is
2. Be sure vent lines and drain lines are
routed properly toward the ground and mounted to fuel tank at bottom and supplies
secured with cable ties. CAUTION: Make fuel to engine through hoses.
sure lines are not kinked or pinched
Fuel Pump module consists of Fuel Pump to
*NOTE. On some models, there is a
Roll-Over Valve on the end of the gas tank generate the fuel flow and pressure
vent line. Make sure the ↑ mark on the regulator to regulate the fuel pressure.
R-O Valve is upwards.
Fuel Pump
When power is supplied to fuel pump, motor in
pump assembly rotates the impeller.
Impeller in turn draws the fuel from strainer and
pumps the flow to generate the system
pressure.
Appearance & Components of Fuel

Module
1. Fuel Pump
2. Strainer
3. Gasket, Fuel Module
4. Module Bracket
5. Module Harness
6. Fuel Tube (out pump)
Dimensions
Fuel Module Cover in elliptical shape with outer
edge dimensions as 115mm x 65mm.
Identification and Markings

Fuel Module, Fuel Pump and Regulator are
marked with batch code in Julian Date Code.
On Fuel Module, batch code in mentioned on

the label available on fuel module cover. disconnecting fuel lines, please follow the “Fuel
On Fuel Pump Batch code is engraved on Pressure Relief Procedure” described
pump body (shell). in this section.
On Fuel Pressure Regulator, batch code is Small amount of fuel may drip after the fuel
engraved on regulator dome area. lines are disconnected. In order to reduce
Operating Conditions the risk of personal injury, cover the pipe/ hose
Fuel Pump Module needs to be mounted on ends with suitable blind with no rust or
Fuel Tank Bottom according to the contamination.
installation instructions. After servicing, make sure that the fuel
Fuel Pump Module is intended to use with hoses and clamps are connected according to
gasoline. However if the fuel contains the hose fitment instructions given in vehicle
ethanol, please contact vehicle manufacture to instruction manual.
check whether the fuel pump module After servicing, please follow the ‘Fuel
itself can survive or not. Leakage Check Procedure’ described in this
Make sure there is at least 3 liters of section.
gasoline in the fuel tank before priming for first After servicing make sure to fill at least 3
time (do not run the pump dry) liters gasoline before pump is primed
Fuel Hose connections needs to be installed (ignition key should be turned on only after
according to the fuel flow diagram shown ensuring there is minimum 3 liters of fuel in
Fuel Flow Description in vehicle fuel system the fuel tank)
Service Procedure
Precautions: Fuel Module Removal:
Before attempting any service on fuel system, Relieve fuel pressure in fuel lines referring
following cautions should be always to the ‘Fuel Pressure Relief Procedure’
provided in this section.
Disconnect negative cable at battery.
Disconnect fuel module wire coupler.
Drain the fuel in fuel tank thru fuel filler with
help of hand pump (siphon). Collect the
fuel in approved container for contamination
and safety.
Disconnect the fuel hoses from fuel module
by using standard tools
Remove the fuel tank from vehicle.
Place the fuel tank with bottom up condition.
Care to be taken not to cause any
followed for personal safety and to avoid scratches/ damages on fuel tank.
system damages. Open the fuel module mounting bolts.
Disconnect negative cable at battery. Take out fuel module assembly from fuel
DO NOT smoke, and place ‘No SMOKING” tank with care
sign near work area Care to be taken not to damage the strainer
Make sure to have fire extinguisher handy. while removing fuel module from tank.
Make sure to perform work in well ventilated Fuel Module Installation:
area and away from any open fire/flames. Replace the fuel module gasket in fuel
Wear Safety glasses module assembly with a new one. Old/ used
To relieve fuel vapor pressure in fuel tank, gaskets can cause leakages.
remove fuel filler cap fuel filler neck and Fold strainer towards fuel pump and insert
then reinstall it. fuel module in tank opening with care. Care
As fuel lines are at high pressures when the should be taken not to cause any damages on
engine is stopped, loosening or strainer.
disconnecting fuel line will cause dangerous
spout of fuel. Before loosening/
Fuel Module Orientation: Fuel module bolts not Connections are now safe for servicing.
symmetrical and can be mounted Upon the completion of servicing, Connect
only in the intended direction. Regulator side Fuel Module Connector to Vehicle Harness
should be facing the Fuel Tank rear
side.
Make sure that the fuel tank surface at module
mounting area is clean and free of
surface defects.
Place the bolts on module cover and tighten
the bolts gradually in star pattern
sequence to apply equal compression on
gasket. It is shown as below.
Bolt Tightening Torque: 4.4 Nm.

Fuel module is installed with special bolts (step
bolts). Use designated bolts only.
Follow the tightening torque and tightening
sequence instruction. Over torque and
miss-sequence can cause unequal
compression of gasket and leakage.
Install the fuel tank to vehicle.
Connect for fuel hoses with suitable hose
clamps.
Connect fuel module coupler
Follow “Fuel Leakage Check Procedure’ to
check any leakage before the engine is
started.
Fuel Pressure Relief Procedure:
Caution: This work must not be done when
engine is hot. If done so, it may cause
adverse effect to catalyst (if equipped)
After making sure that engine is cold, relieve
fuel pressure as follows.
Place vehicle gear in ‘Neutral’.
Disconnect fuel module electrical coupler
from vehicle harness.
Start engine and run till it stops due to lack
of fuel. Repeat ignition key ON and OFF
for 2 ~ 3 times of about 3 seconds each time to
relieve fuel pressure in lines. Fuel
2.3TOE ALIGNMENT
METHOD: STRAIGHTEDGE OR STRING
Be sure to keep handlebars centered
NOTE: String should just touch side surface

of rear tire on each side of the ATV.
Measure from string to rim at front and rear of
rim.
Rear rim measurement (A) should be 1/16" to
1/8" (1.5 to 3 mm) more than front rim
measurement (B).
NOTE: The steering post arm (frog) can be
used as an indicator of whether the
handlebars are straight. The frog should
always point straight back from the steering
post when handlebars are straight.
WARNING: Always pay attention to tie rods

assembly, Both ends must screw in same and
enough threads length.

2.4 BRAKING SYSTEM

INSPECTION
The following checks are recommended to

keep the braking system in good operating
condition. Service life of braking system
components depends on operating conditions.
Inspect brakes in accordance with the
maintenance schedule and before each ride.
Keep fluid level in the master cylinder
reservoir to the indicated level on reservoir.
Use DOT 3 brake fluid.
NOTE: Use new brake fluid or brake fluid

from a sealed container to avoid
contamination to system.
Check brake system for fluid leaks.

Check brake for excessive travel or spongy
feel.
Check friction pads for wear, damage and
looseness.
Check surface condition of the disc.
BRAKE PAD INSPECTION

Pads should be changed when friction
material is worn to 3/64" (1mm).
HOSE/FITTING INSPECTION
Check braking system hoses and fittings for
cracks, deterioration, abrasion, and leaks.
Tighten any loose fittings and replace any
worn or damaged parts.
Adjusting brake pedal
FOOT BRAKE ADJUSTMENT If the push rod joint is reinstalled, adjust the
NOTE push rod length so that the distance between
On European ATV foot brake is the SERVICE the centers of the master cylinder lower
brake (MAIN brake) mounting bolt hole and joint pin hole is
Use the following procedure to inspect the 80±1mm.After adjustment, tighten the joint
hydraulic foot brake system and adjust or nut.
bleed if necessary.

1. First check foot brake effectiveness by

applying a 25 kg (50 lb). (Approx)
downward force on the pedal.
The top of the pedal should be at least 1 CONTROLS
inch, (25 .4m m) above the surface of the Check controls for proper operation,
footrest.
positioning and adjustment.
Brake control and switch must be positioned
to allow brake level to travel throughout entire
If less than one inch, two things must be range without contacting switch body.
examined:
Free Play:
Free play of the brake pedal should be
1/8-1/4 inch (3-6mm).
If free play is excessive, inspect pedal,
linkage, and master cylinder for wear or
damage and replace any worn parts.
Bleeding:
If free play is correct and brake pedal travel is
still excessive, air may be trapped some
where in the system. Bleed the hydraulic
brake system in a conventional manner,
following the procedure outlined in the Brake
chapter.
FOOT BRAKE TESTING

The foot brake should be checked for
proper adjustment.
Support the rear wheels off the ground. While
turning the rear wheels by hand, apply the Note: burnishing procedure is also applicable
auxiliary footbrake. This brake should not for parking brake. See CHAPTER 7
stop the wheels from turning until the lever is BRAKES.
half way between its rest position and
bottoming on the footrest.
MECHANICS PARKING BRAKE FOR

EUROPE ATV
Checking
Although the parking brake has been
adjusted at the factory, the brake should be
checked for proper operation. The
mechanical brake must be maintained to be
full functional.

1. With the engine off, apply the parking

brake lever and attempt to move the ATV.
2. If the rear wheels are locked, it is adjusted
properly.
3. If the wheels are not locked, it must be
adjusted.
To adjust (set up) the mechanical parking

brake, use the following procedure
Note: The adjusting on the caliper is for the
wear out of the pads. ↑ adjust on the lever
1. With the engine off, loosen the adjustor on

the lever.
2. Loosen the jam nut of the adjuster on the Adjusting can also be done to the brake cable
caliper. on the parking lever side by turn the adjuster
3. Turn the adjuster (bolt) CW (clockwise) by (nut) directly.
hand till the pad touch the brake disc, turn the
adjuster bolt CCW (counterclockwise) by 1/4
to one turn for 10 to 20mm free play at the
end of the parking lever.
4. Tighten the jam nuts securely against the
adjusters.
5. Make sure the rear wheels turns freely
without dragging.
6. Turn the adjustor (the one on the lever)
and apply the lever. While adjusting, it is
important you apply the lever back and forth
for operation, free play and the locking of the
parking position. ↑ adjust on the caliper
7. Make sure the rear wheels turns freely
without dragging and parking brake works
properly.
CAUTION Don’t over tighten the adjustor.
Free play of the lever: 20mm.
8. Field test for parking. It must be capable of
holding the laden ATV stationary on an 18%
up and down gradient.
A temporary adjusting can also be done to

the brake cable on the parking lever side by
turn the adjuster (nut) directly. But the adjust
range is limited. Always do the procedure 1
to 8 when necessary.
↑ adjust on the caliper B-type ATV

Adjusting
To adjust (set up) the mechanical drum brake,
use the following procedure.
1. Loosen the jam nuts of the
adjuster on the right hand of
right and left brake cable.
2. Turn the both adjusters keep the rock arm
on the lever balance until 1/8” (2to3mm) free
play is achieved at the brake lever.
rake shoes as a set either is worn to the limit.
NOTE: While adjusting free play, it is

important you apply the lever back and forth.
3. Tighten the jam nuts securely against the
adjusters.
If the right hand adjustment is inadequate
to attain the proper brake free-play gap, make
adjustment at the middle of the cables
adjuster jam nuts.
NOTE: Apply the front brake a number of
times to ensure the wheels lock and the
brake light illuminate properly.
4. Make sure the right and left brake are
balance after the adjustment of the front
brakes by test at low speed. Contact your
dealer for proper diagnosis and repairs.
5. If adjusting the cables does not attain
proper brake performance and free-play, the
brake shoes must be replaced.
Note: After the adjusting, the adjustment
distance of the cables and the angle of the
drum levers between the right and left brake
must be same.

2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT

Operator weight and vehicle loading affect
suspension spring preload requirements. Adjust
as necessary.
FRONT SUSPENSION
Compress and release front suspension.
Damping should be smooth throughout the
range of travel.
Check all front suspension components for
wear or damage.
Inspect from strut cartridges for leakage.
Shock spring preload can not be adjusted,
replace if necessary.
REAR SUSPENSION
Compress and release rear suspension.
Damping should be smooth throughout the
range of travel. Check all rear suspension
components for wear or damage.
Inspect shock for leakage
Shock spring preload can be adjusted using

the shock spanner wrench.

2.6 WHEELS
Inspect all wheels for runout of damage.
Check wheel nuts and ensure they are tight.
Do not over tighten the wheel nuts.
WHEEL, HUB TORQUE TABLE
Front Wheel Nuts 69 Ft.Lbs 96 N.m

Rear Wheel Nuts 69 Ft.Lbs 96 N.m
Front Spindle Nut Refer to FRONT HUB
INSTALLATION
Rear Hub
Retaining Nut 80 Ft.Lbs 110.6 N.m
WHEEL REMOVAL
1. Stop the engine, place the transmission in
gear
And lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing
a suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the
wheel.
WHEEL INSTALLATION
1. With the transmission in gear and the
parking Brake locked, place the wheel in
the correct Position on the wheel hub. Be
sure the valve stem is toward the outside
and rotation arrows on the tire point
toward rotation.
2. Attach the wheel nuts and finger tighten
them.
Install as shown at right for front or rear
wheels.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the
proper Torque listed in the table above.
On rear wheel nuts, Make sure tapered
end of nut goes into taper on wheel.
CAUTION:
If wheels are improperly installed it could
affect Vehicle handling and tire wear

2.7 TIRE PRESSURE

TIRE INSPECTION
CAUTION : Tire Pressure Inspection
 Maintain proper tire pressure. Refer to the
warning tire pressure decal applied to the Front Rear
vehicle.
Improper tire inflation may affect ATV
maneuverability.
When replacing a tire always use original 7PSI 7PSI
equipment size and type and replace in (48±0.5KPa) (48 ±0.5KPa)
pairs, especially in SDX300 model.
 The use of non- standard size or type tires
may affect ATV handling and cause
machine damage, especially in SDX300 WARNING Operating an ATV with worn tires
model. will increase the possibility of the vehicle
TIRE TREAD DEPTH skidding easily with possible loss of control.
Always replace tires when tread depth is Worn tires can cause an accident.
worn to 1/8" (3mm ) or less. Always replace tires when the tread depth
measures 1/8" (3mm ) or less.

2.8 FRAME , NUTS, BOLTS, FASTENERS

Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule.
Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.
Item Torque（Ft-Lb） Torque (Nm) Remarks
EARLY DESIGN* Handlebar Clamp Nut M6 12 16
Handlebar Clamp Nut M8 18 25
Nut M10X1.25 Attaching Tie Rod to Steering column 26-30 35-41
Nut M10X1.25 Attaching Tie Rod to Front Absorber Strut body 26-30 35-41
Tie Rod Jam Nut M12 13 17
MANTENANCE-FREE PIVOT DESIGN Bolt M12 Attaching 37-44
50-60 LT*
A-Arm and Frame
Nut M10X1.25 Attaching A-Arm to Ball Joint Stud 22-25 30-35
Screw M6 Attaching Ball Joint Mounting Bracket to Front 8
11 LT*
Absorber Strut body (MacPherson)
Swing Arm Pivot Left 14 19 Refer to SWING
Swing Arm Pivot Right 120 165 ARM
120 ASSEMBLY
INSTALLATION
，4.2 SWING
Threaded Pivot Nut (for swing arm) 165
ARM，
CHAPTER 4A
CHASSIS
Nut M14X1.5 Attaching Front Absorber to Frame 15-18
21-25 LT*
(MacPherson)
Nut M8 Binding Front Absorber and Front Absorber Strut body 15
21 LT*
(MacPherson)
18
Bolt M8 Attaching Front Caliper to Front Absorber Strut body 25 LT*
Bolt M8 Attaching Upper Steering Clamp to Frame 12 16
12
Nut M8 Attaching Lower Steering Bearing Retainer to Frame 16
20
Nut M10X1.25 Attaching Front Wheel to Front Wheel Hub 27
Front （Drive） Axle Nut Refer to FRONT HUB INSTALLATION
18
Screw M8 Attaching Front Brake Disc to Front Wheel Hub 25 LT*
22-25
Nut M10X1.25 Attaching Rear Brake Disc to Rear Brake 30-35 LT*
Rear Axle Nut M20X2 (for swing arm) 80 110.6
Rear Hub Retaining Nut M20X1 （for IRS） 101 137
Nut M10X1.25 Attaching Rear Caliper to Axle Tube 18 25 LT*
Bolt M12x30 Attaching Axle Tube and Swing arm to Rear 60
80
Gear-box
Bolt M12x35 Attaching Axle Tube to Swing arm 60-66 80-90
LT*---Apply Loctite™ 243

NOTES


CHAPTER 3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 3 ENGINE
3.1 Service information ........................................................................ 1-17
3.2 Inspection and adjustment ............................................................... 18-28
3.3 Engine Removal, Inspection and Installation ................................. 29-89
3.4 Cooling and lubrication system...................................................... 90-100
3.5 Fuel injection system ................................................................... 101-121
3.6 Troubleshooting........................................................................... 122-124

3.1 Service information

Unit conversion table .......................................................................... 3-1
3.1.1 General precautions ................................................................... 3-2
3.1.2 Fuel, oil and engine coolant recommendation ............................ 3-3
3.1.3 Engine running-in ....................................................................... 3-3
3.1.4 Engine shape & location of engine identification number ............... 3-4
3.1.5 Engine general information......................................................... 3-5
3.1.6 Maintenance specifications ......................................................... 3-9
3.1.7 Engine tightening torque list ....................................................... 3-13
3.1.8 Engine service tools ................................................................... 3-15

Unit conversion table
Item Conversion
Pressure 1kgf/cm2=98.0665kPa 1kPa=1000Pa
1mmHg=133.322Pa=0.133322kPa
Torque 1kgf·m=9.80665N·m
Volume 1mL=1cm3=1cc
1L=1000cm3
Force 1kgf=9.80665N
DANGER/WARNING/CAUTION
Please read the following notification carefully which emphasize the special
meaning of DANGER, WARNING and CAUTION. Always pay attention to these
notifications when servicing the engine.
DANGER: indicates a high risk which should be alert to.
WARNING: indicates a moderate risk which should be alert to.
CAUTION: indicates a minor risk which should be paid attention to.
However, DANGER, WARNING and CAUTION notification included in this service

manual don’t cover all the potential risk in the engine operation and repair.
Therefore, mechanics should be equipped with knowledge of basic mechanical
CHAPTER 3 ENGINE PAGE. 3- 1

safety beside the notification of DANGER and WARNING. If you are not confident
to complete the whole repair, please refer to the senior mechanic for support.
3.1.1 General precautions
Warning: Proper service and repair procedures are important for the
safety of the service mechanic and the safety and reliability of the
vehicle.
· When two or more persons working together, pay attention to the safety of each
other.

1
· When it is necessary to run the engine indoors, make sure that exhaust gas is
forced out doors.
· When working with toxic or flammable materials, make sure that the area you
work in is well ventilated and that you follow all of the manufacturer's instruction.
· Never use gasoline as a cleaning solvent.
· To avoid getting burned, do not touch the engine, engine oil, radiator, and
exhaust system until they have cooled.
· After servicing the fuel, oil, engine coolant, exhaust or brake system, check all of
the lines, and fittings related to the system for leaks.
· In order to protect the environment, do not unlawfully dispose of motor oil,

engine coolant or parts no longer used.
Warning：
· If parts replacement is necessary, replace the parts with LINHAI

genuine parts or their equivalent.
· When removing parts that are to be reused, keep them arranged in an

orderly manner so that they may be reinstalled in proper order.
· Be sure to use special tools when instructed.
· Make sure that all parts used in reassembly are clean. Lubricate them
when specified.
· Use the specified lubricate, bonds, or sealants.
· When tightening bolts, screws and nuts, tighten the larger sizes first.
Always tighten the nuts and bolts from the inside working out,
diagonally and to the specified torque.
· Use a torque wrench to tighten fasteners to the specified torque. Wipe off
grease and oil if a thread is smeared with them.
· After removing the parts, need to double check them, cleaning all the
parts before measure

1
3.1.2 FUEL, OIL AND ENGINE

COOLANT RECOMMENDATION
FUEL: Use unleaded gasoline that is

Graded 92 octane or higher.
ENGINE OIL: Use 4-stroke motor oil,

the oil need to meet API service
Classification SG or higher. If engine
oil with a SAE 15W-40 is not
available, choose from the right chart
according to the environmental
temperature.
ENGINE COOLANT: Since antifreeze also has corrosion and rust-

inhibiting properties, engine coolant contains antifreeze, and the freezing
point should below the atmospheric temperature like 5℃.
Recommended coolant type: -35℃ anti-frozen, antisepsis, high-boil

coolant.
Danger: Keep the engine coolant properly and do not drink it
as it is poisonous
Warning: Do not mix other brand engine coolant together.
3.1.3 Engine running-in

As the engine has a lot of relative motions parts, such as pistons, piston
rings, cylinder blocks and inter-meshing gears, thus, good operation at the
beginning is necessary. It helps a good adaptation to each part, adjust
working gap, and make a smooth friction surface to bear heavy load.
Recommended running-in time: 20 hours, see detailed specification

below:
0～10 hours
Avoid continuous operation above half-throttle or vary the speed of the

vehicle from time to time. Do not operate it at one set throttle position.
Allow a cooling-off period of 5 to 10 minutes after every hour of operation.
1
Avoid acceleration heavily. T he accelerator should be changed smoothly,

avoid changing heavily from small to bigger
10～20 hours
Avoid prolonged operation above three-quarter throttle. Allow using freely

but not full throttle.
CAUTION： Maintain and repair as regular procedures during
break-in period;
After break-in, do not forget to check and maintain the engine

before normal use

1
3.1.4 ENGINE SHAPE & LOCATION OF ENGINE IDENTIFICATION NUMBER(EIN)
Location of Engine identification

number

1
Engine left side
Engine Right side
3.1.5 ENGINE GENERAL INFORMATION

1
NO. ITEM TYPE/SPECIFICATION

1
Type Single-cylinder, liquid-cooled, 4-stroke,
SOHC
2 91mm×76.8mm
Bore × Stroke 499.5mL
3 Displacement
Compression ratio 10.3:1
4
Low idling speed(Idling) 1500r/min±100r/min
5 Electric
Starting
6
ignition type/ ECU / BTDC1 0º 1500r/min

ignition timing
Electric
al Spark plug/Electrode DCPR8EA-9 NGK/0.8mm～0.9mm
7 system gap
Magneto type/ Power Permanent Magnet AC Type
Combustion chamber Triangular combustion chamber

Combus
tion Throttle body type D46
8 system
Ai r filter type Sponge, Paper filter
Gasoline RQ-92
Valves
9 Valves type SOHC/ Timing chain drive
system
Lubrication type Pressure and splash

Lubricatio
n System Oil pump type Rotor drive
10
Oil filter type Paper type, replaceable
Engine oil type SAE10W/50/SN
Cooling Cooling type Liquid-cooled/close-loop cooling

11
system
Coolant type —35℃anti-corrosion and anti-freezing
Transmission type CVT+ Gearshift
Reducer gear Two forward gear, one reverse gear, one

1
park
Gearshift methods/ Manual operation/L-H-N-R-P
orders
Drive
12 train CVT ratio range 3.106～0.677
system
Gearshift Final ratio 1.333（24/18，bevel gear）
ratio
Secondary 1.952(41/21)，
ratio
Variable L:2.53(38/15)；
gear
Total ratio H：1.35(27/20) ；R:2.07(29/14)
13 Overall size L:6.595；H：3.514 ；R:5.392
L（mm）×W（mm）×H（mm）：621×515×506
14 Dry weight 62kg
15 Output type Front/Rear shaft drive
16 Rotation of engine output When forward, clockwise(rear view)
Valves & Cylinder Head （ mm）

Item Standard value Service Remarks
limit
Dia. Of valve neck Intake valve Φ33 ——
Exhaust valve Φ 29 ——
Thickness of valve neck Intake/Exhaust 1 0.5
Valve clearance(cold Intake 0.06～ 0. 08 ——

engine)
Exhaust 0.08～ 0. 10 ——
Inner dia. Of valve guide Intake/Exhaust 5.000～ 5.012 5.045
Outer dia. of valve stem Intake 4.96～ 4.975 4.93

Exhaust 4.95～ 4.965 4.93
Gap between valve Intake 0.020～ 0.047
guide and stem Exhaust 0.030～ 0.057

1
Valve stem roundness 0.006 0.06
（diameter difference）
Valve end run-out Intake/Exhaust 0.03 0.05

Cylinder, Piston, Piston Ring & Crankshaft (mm)
Item Standards Service limit Remarks
Cylinder compression 1000kPa
Piston/Cylinder clearance 0.030～0.050 0.10
Dia. of Piston 90.95mm～90.979 mm

down along to the piston 90.85
Inner diameter of cylinder
90～91.015
Flatness of cylinder top
and bottom surface 0.03
1st ring R round 11.7

Free open of piston ring 2nd ring R round 12 0.05
1st ring 0.25 ～0.40 8.9

2nd ring 0.30～0.45 9.5
Oil ring 0.2～0.7
Gap of piston ring 0.15
st
1 ring 0.02 ～0.06
0.15
2nd ring 0.02～0.06
0.15
Oil ring 0.03～0.15
1st ring 1.17 ～ 1.19
2nd ring 1.47～1.49
Height of piston ring
Oil ring 2.37～2.47
st
1 ring 1.21 ～ 1.23
nd
2 ring 1.51～1.53
Oil ring 2.50～2.52
22.004～22.010
Height of piston ring
21.991～22.000
22.01～22.02
0.004～0.015
Width of piston ring
0.010～0.025

1
Inner diameter of piston

pin hole
Diameter of piston pin

0.1～0.45 21.980
Inner diameter of small
end of connecting rod 22.06
Gap of piston/piston pin
Small end hole of 22.95～23.00
connecting rod / gap of 0.08
piston pin 0.08
Side gap of big end of
connecting rod
Thickness of big end of

connecting rod 0.7

1
To Be Continue (mm)
Thickness of big end of
connecting rod 22.95～23.00
Crankshaft beat 0～0.025 0.055
Connecting rod bearing 36.992～36.996 36.068
journal
Connecting rod bearing 37.006～37.028 37.06

bore
Gap of connecting rod 0.01～0.032 0.065
bearing
Main journal 41.955～41.970 41.935
Case main bearing bore 41.980～42.000 42.10
Gap of main bearing 0.045～0.01 0.08
Gap of crankshaft axial 0.05～0.45 0.6

direction

3.1.6 MAINTENANCE SPECIFICATIONS
Lubrication System
Item Standards Service

Limit
－
Oil Change 2600mL （ without oil filter
replacement）
Engine Oil
2700mL（with oil filter replacement）
Oil Change
Capacity
3000mL
Oil Capacity
－
Recommended engine oil （see · Special for four stroke motorcycle
original） Grade/TEMP SAE-15W/40 if it’s not available,
select alternative according to the
following specifications.
· API classifications: SG or higher
· SA E classifications: according
to the left chart.
Clearance Between 0.1mm ～ 0.15mm 0.2mm
Inner and Outer Rotor
Clearance Between 0.08mm ～0.15mm 0.2mm
Outer Rotor and Case


COOLING SYSTEM
Item Standards Service Limit
Opening
temperature 65℃±2℃
Fully opening 85℃

Thermostat
Travel when
fully opening When 85℃,≥5mm
Radiator cap opening

pressure 110 kPa±15kPa(1.1kgf/cm 2 )
Water Resistant of Resistant of
Relations temperature B A,C
between （℃） terminal( Ω) Terminal( kΩ )

water temp
-20 —— 13.71～16.94
and resistant
of water 25 —— 1.825～2.155
temp. sensor
50 176～280 ——
80 63.4～81.4 0.303～0.326
110 24.6～30.6 0.138～0.145
Working OFF-ON Around 89℃

temp. of
thermo
ON-OFF Around 82℃
switch

-35℃ anti-freezing, anti
Coolant type
–corrosive and high boiling
point

Clutch + Transmission mechanism (mm)
Belt width 35.2 33.5
Free length of driven pulley

238.5 214
spring
Hole dia. of driven pulley

38.10～38.14 38.30
collar
Clearance between
gearshift fork and 0.10～0.35 0.45

engagement groove
Thickness of gearshift fork 5.8～5.9 5.7
Groove width of high/low

6.05～6.15 6.25
sliding
Output gear groove width of

6.05～6.15 6.25
driven shaft
Groove width of gearshift

8.05～8.10
drum
Dia. of gearshift pawl pin 7.90～7.95 7．83
Hole dia. of gear box 25～25.021 25.025
Hole dia. of Reverse gear

25～25.021 25.025
transition
Air Intake System
Item Standards

Throttle Body Part NO. 1BK-13520-00
Fuel Injector Part NO. 1BK-13510-00
Idle Speed 1500 r/min ± 100r/min

Electric system
Item Sta n d a rds Remarks
Type DPR8EA-9 (NGK)
Gap of
Sparkplug 0.8mm～0.9mm
sparkplug
Characteristic ＞8mm, u n d e r 0.1MPa
Primary 0.74Ω～0.78Ω
Resistance of
ignition coil
Secondly 10.1Ω～11.1kΩ
Resistance of magneto coil 0.5Ω～1.5Ω
Resistance of sp eed sensor （

900Ω～1 0 0 0 Ω
trigger）
Voltage without lo ad (cold ＞

engine)
50V (AC), 5000r/min
320W, 5000r/min
Max. output power of ma g n e to
460W/5000r/min
Stable voltage 13.5V～15V
Secon dly voltage of ignition coil ≥25kV
Peak voltage ≥3V，

Peak voltage of Trigger coil
200r/min
Resistance of starter relay coil 3Ω ～ 5Ω
Resistance of auxiliary relay

coil 90Ω ～ 1 00Ω

3.1.7 Engine tightening Torque list
Dia. Of Torque
Item Qty Remarks
thread(mm) （N·m）
Oil drain bolt M12×1.5 1 M12×1.5 28～32
OIL PASSAGE BOLT M14×1.5

2 M14×1.5 32～36
(left case)
Plug screw, oil passage Thread

4 M6×12 8~12
pressing plate (left case) locker glue
Thread
Primary screen cover bolt 3 M6×20 8~12
locker glue
Thread
Oil pressure switch 1 M10×1 12~15
locker glue
Apply seal
Screw R21/8 (CVT oil passage) 1 R21/8 18～22 gum
Thread
Bolt, CVT air intake plate 4 M6×12 8~12
locker glue
CVT cover screw Plug

8 M6 6~8
screw(left crankcase cover)
Relief valve(left crankcase

1 M20×1.5 28~32
cover)
Bolt of wiring clamper (left Thread

1 M6×10 8~12
crankcase cover) locker glue
Screw of oil seal plate(left

3 M6×8 8~12
crankcase cover)
Adjust nut, valve clearance 8 M6 8~12

Bolt, timing sprocket 2 M6×10 8~12
Bolt, decompressor, starter 1 M8×32 28~32
Bolt, cylinder 4 M10 40~45
Bolt, cylinder installation 2 M6×132 8~12
Plug, spark 1 M12×1.25 18~20
Sensor, water TEMP 1 M12×1.5 16~20
Thread
Stud bolt M8×42（exhaust port） 2 M8×42 20~25
locker glue
Nut, thrust M8（exhaust port） 2 M8 13

Dia. Of Torque
Item Qty Remarks
thread(mm) （N·m）
Plug, Screw M12×1.5 1 M12×1.5 28~32
Bolt M6×45(thermostat cap) 2 M6×45 6~10
Injector seat installation bolt 2 M8×25 20~25
Bolt COMP. Cylinder head 4

M6 6~8
cover
Thread tension plate pin Thread

1 M8 22~28
locker glue
Bolt, magneto stator Thread

3 M6×30 8~12
locker glue
Bolt, overriding clutch Thread

6 M8×20 28~32
COMP locker glue
Bolt, drive pulley(CVT drive

1 M12×1.5- 55~60
pulley) LH
Screw, CVT driven pulley Thread

1 M20×1.5 110~120
locker glue
Lock nut, drive bevel gear 1 M22×1 140~150
Bolt(bearing seat, drive

4 M8×28 38~42
bevel gear)
Screw （ bearing holder,

4 M8×25 15~20
drive bevel gear）
Stopper nut (driven bevel Thread

1 M65×1.5 100~120
gear) locker glue
Bolt(bearing seat, driven

4 M8×28 38~42

bevel gear)
Nut, Driven Bevel Gear

1 M16×1.5 140~160
Nut, Front output shaft M14×1.5

1 95~100
Bolt, gear orientation 1 M14×1.5 38~42 Thread
locker glue
Bolt, oil pump cover Thread

3 M5×16 6~8
locker glue
Bolt, oil guard Thread

2 M6×12 8~12
locker glue
Magnetor Rotor nut 1 M16×1.5 160~170 Thread
locker glue

3.1.8 Engine Service Tools
Measurement Tools
Measurement Tools
No. Description Specification Purpose
1 Vernier Caliper 0-150mm For measuring the length and thickness
2 Micrometer 0-25mm For measuring outer diameters of rocker arm, valve stem
and camshaft
3 Micrometer 25-50mm For measuring the max. lift of camshaft
4 Micrometer 75-100mm For measuring piston skirt
5 Cylinder Gauge For measuring cylinder bore diameter
6 Small Bore Gauge 10-34mm For measuring inner gauge of rocker arm, piston pin bore,
connecting rod small end bore

7 Dial Indicator 1/100 For measuring the play
8 Straightedge Gauge Plane measuring
9 Feeler Gauge Plane and valve clearance measuring
10 Fuel Level Gauge For measuring the carburetor fuel level
11 Thickness Gauge For measuring the clearance
12 Spring Balance For measuring the spring tension
13 Tachometer For measuring engine speed
14 Oil Pressure Gauge For measuring oil pressure
15 Compression Gauge & For measuring cylinder compression
Adapter
16 Radiator Cap Tester For measuring radiator cap opening pressure
17 Ohmmeter For measuring resistance and voltage
18 Ammeter For measuring current/switches
19 Thermometer For measuring liquid temperature
20 Timing Light For checking the ignition timing
21 Torque Wrench For measuring the tightening torque
General-purpose and Auxiliary Tools
22 Alcohol Burner Heating up
23 Magnetic Stand For micrometer
24 Slab Auxiliary tool for measuring
25 V-block For measuring the play
26 Tweezer For installation of valve cotter
27 Circlip Pliers For removal and installation of circlips
28 Long Nose Pliers For removal and installation of retainers
29 Impact Driver For removal of cross-headed bolts

Special Tools
No. Description Specifications Purpose

1 Rotor assy puller 1BE-85610-00 Remove magneto rotor
2 Bearing retainer, nut wrench LH188MR FZ/24 Removal of Front output shaft Bearing retainer
3 Bearing limit nut,nut wrench LH188MR FZ/25 For removing Bearing limit nut
4 Drive pulley puller 1BX-17653-00 Removal of drive pulley
5 Driven pulley expander 1BX-17654-00 Removal/installation of drive belt
6 Driven pulley spring compressor 1BA-17730-00 FZ/1 Disassemble driven pulley
7 The tool for one way clutch of drive 1BA-17628-00 FZ/1 Assemble one way clutch of drive pulley
pulley

Materials for Operation and Fixing
Materials for engine operation engine oil, grease and coolant. Fixing materials include sealant, thread locker,
etc.
Description Type Application Area Remark

4-stroke motor oil Cylinder rotating parts, capacity
SAE15W-40 Or sliding parts 2600ml

Lubricating
SAE10W-40 Inner crankcase rotating (for changing oil)
Oil/Engine Oil
API : SG or higher parts,sliding parts 2700ml
Cylinder head rotating (for replacing filter)

parts,
3000ml
Molybdenum piston pin、 valve stem、
valve oil seal、 camshaft
lubrication oil
Grease #3 MoS2 Lithium Base Oil seal, O-ring and other
Grease rubber seals.
Sealed bearing
Coolant -35℃ antifreeze, Cooling system、 Water- Capacity according to

seal
corrosion-resistant, high radiator and water
Joint Face Sealant Crankcase splitting hose
surfaces, contact surface
between crankcase and

Thread Locker Thread Parts See 3.1.7

3.2 INSPECTION AND ADJUSTMENT

3.2.1 Period maintenance table ................................................................ 3-18
3.2.2 Procedure of Maintenance & Adjustment ........................................ 3-19
3.2.3 Valve clearance ............................................................................... 3-19
3.2.4 Engine idle speed ............................................................................ 3-20
3.2.5 Spark plug ....................................................................................... 3-20
3.2.6 Air filter ............................................................................................ 3-21
3.2.7 Driving Belt, CVT ............................................................................. 3-22
3.2.8 Inspection of Lubrication System ..................................................... 3-24
3.2.9 Inspection of Cooling System .......................................................... 3-26
3.2.10 Inspection of Cylinder Pressure ..................................................... 3-27

3.2.1 Period maintenance table
Engine maintenance is a periodic job, careful periodic maintenance is very

important, will assure your vehicle having a good performance, reliability, economy
and durability. Details are explained in below 191MR engine periodic maintenance
ATTENTION： Maintenance intervals in the following chart are based upon

average riding conditions. Vehicles subjected to severe use must be
inspected and serviced more frequently
chart.
A: Adjust 10 hours or 300km
C: Clean 20 hours or 750km
I: Inspect Every 50 hours or 1500km

L: Lubricate Every 100 hours or 3000km or 1 year
R: Replace Every 200 hours or 6000km or
2years
Remark
Facilitating
Conditions &
abnormal sound I I I
Engine No black smoke or blue
Exhaust condition I I I
smoke
I， I， In：0.06mm～0.08mm
Valve setting
A A Out：0.08mm～0.10mm
Idle speed I I 1500 r/min±100r/min
No carbon deposition,
electrode gap:
Spark Plug I I R
0.8mm～0.9mm

Air Filter C R
CVT CVT Belt I R Replace every 2000km
system Primary Pulley, I，
Driven pulley C
Engine oil, filter R R
Throttle Body I I，L
Water volume I I
Water pipe I I
Cooling Radiator valve

System I I I 0.75 kg/cm～1.05kg/cm
opening pressure
Replace coolant Replace every 2 years

3.2.2 Procedure of Maintenance &

Adjustment
This section describes the maintenance
procedures for each item mentioned in the
periodic maintenance chart.
Inspect initially at 20-hour break-in and

every 40 hours or every 1000km thereafter.
Inspect the clearance after removing
cylinder head
3.2.3 Valve clearance 1
Excessive valve clearance results in valve
noise and insufficient valve clearance
results in valve damage and reduced
power.
Check the valve clearance at the period

indicated above and adjust the valve
clearance to specification, if necessary.
● Remove CVT case cover (1)；
● Remove RPM sensor(2) of left

crankcase cover ； 3
2
● Remove cylinder head cover (3)；
● Turn the crankshaft until the line( 4) of T.
D.C. on rotor is aligned with mark (5) of

inspection hole on left crankcase..
● Insert feeler gauge to check the

clearance between the valve stem end
and the adjust bolt on the rocker arm. 5
Valve clearance Intake valve
0.06mm～0.08mm 4
（When cold) Exhaust valve

Attention:
● The valve clearance must be adjusted

when the engine is cold.
● Adjust the valve clearance when the

piston is at the Top Dead Center (T.D.C.)

● If the clearance is incorrect, bring it into

the specified range using the special tool.
Loosen valve adjust bolt and nut, insert a 1

feeler gauge between the valve stem end
2
and valve adjusting bolt (0.06mm
thickness for intake valve, 0.08mm
thickness for exhaust valve), tighten valve
4
adjust bolt, make sure it slightly contacts
3
the feeler gauge, tighten bolt and nut.
● Take out the feeler gauge, measure the 1-Valve Adjust Screw
clearance. If the clearance is incorrect, re- 2-Valve clearance
peat the above steps until the proper 3- Valve
clearance is obtained.
Locknut：12 N·m
Tools： Valve adjuster
Feeler gauge Material： Thread Locker
Caution:
Securely tighten the locknut after

completing adjustment
3.2.4 ENGINE IDLE SPEED

Inspect initially at 20 hours run-in and
every 50 hours or 1500km thereafter.
● Install cylinder head, speed sensor
Start the engine and warm it up for

several minutes, measure engine speed
with a tachometer.
Engine idle speed：1500r/min ± 100r/

min
Tool： Tachometer
3.2.5 SPARK PLUG
Inspect initially at 20 hours run-in and

every 100 hours or 3000km thereafter.
● Remove the spark plug(1) with a

special tool；
Specification: DPR8EA-9(NGK)
● Spark plug inspection：If the electrode

is extremely worn or burnt, or spark plug
has a broken insulator, damaged thread, etc, 1
replace the spark plug with a new one
Incase of carbon deposit, clean with a

proper tool.
SPARK PLUG GAP： Measure the

spark plug gap with a feeler gauge.
Out of specification: Adjust
Spark plug gap：0.8mm～0.9mm
Caution:
Check the thread size and reach when
replacing the spark plug. If the reach is
too short, carbon will be deposited on
the screw portion of the spark plug hole
and engine damage may result
● Spark plug installation
Caution:
To avoid damaging the cylinder head

threads; first, tighten the spark plug
with fingers, and then tighten it to the
specified torque using the spark plug
wrench
Tightening Torque：18~20N.m
Tool： Spark Plug Wrench
Feeler Gauge
2
1
Inspect every 20 hours or 750km, clean
it if necessary Change it every 1500km

3.2.6 AIR FILTER
If the air cleaner is clogged with dust, in-
take resistance will be increased, with a
resultant decrease in power output and an
increase in fuel consumption. Check and
clean the air filter as following:
● Remove fixing clamp(2)，and top cover 3

(1) ；
Note： Be careful not to drop the o-ring
into the air filter box that is attached to the
air filter top cover

4
●Loosen screw(3) remove filter element

(4) separate support (5) and sponge( 6)
● Fill a wash pan of a proper size with a

non-flammable cleaning solvent (A)
● Press the filter element between the

palms of both hands to remove the excess 5 6
solvent. Do not twist or wring the element
or it will tear.
●Immerse the element in engine oil( B)

and then squeeze out the excess oil
leaving the element slightly wet
(A)-Non-flammable cleaning solvent

(B)-Engine oil SAE15W/40

Warning: Never use with gasoline or

low flash point solvents to clean the
filter element.
● Inspect the filter element for tears, torn
Note: Make sure that the air filter element

is in good condition at all times. The surest
way to accelerate engine wear is to operate
the engine without the element or with torn 7
element. If driving under dusty conditions,
clean themust
element air filter element more frequently
be replaced.
● Remove the drain plug (7) of air box to

drain out any water.
3.2.7 Drive belt, CVT

Removal
● Remove CVT cover.
●Loosen primary bolt (1) and gasket(2),

take drive disk.
●Loosen / driven pulley nut (3).
● Remove / driven pulley together with

drive belt.
● Remove drive belt (4 ) from / driven

wheel.
3
1
4 2

Inspection
● Inspect CVT friction disk for wear and

damage. If any cracks or damages are
found, replace CVT with a new one.
● Inspect drive belt for wear and damage.

If any cracks or damages are found, replace
drive belt with a new one.
●Inspect drive belt for width, if width is out

of service limit, replace drive belt with a new
one.
Service Limit：33.5mm
Tool: Vernier Caliper
Installation
Reverse the removal procedure for

installation. Pay attention to the following:
● Insert drive belt with a special tool , as

low as possible, between secondary sliding
sheave and primary fixed sheave:
● Hold / driven wheel with a special tool

and tighten the nut to the specified
torque.
Nut, / driven pulley：110~120N.m
● Install d riving pulley and bolt. Hold the

driving pulley with a special tool and tighten
the bolt to the specified torque.

sign
Caution: Fit the drive belt with the

arrow on the drive belt points towards
normal turning direction.
Bolt, drive pulley：55~60N.m
● Screw off Driven pulley Expander, turn

driving pulley, until the drive belt is properly
seated.
Warning：
The drive belt contact surface of the driven face

should be thoroughly cleaned
● Install CVT cover
3.2.8 Inspection of Lubrication

System
Replace engine oil and oil filter initially

at 20 hours or 750km and every 100 hours
or 3000km thereafter.
Check Engine Oil Level
● Keep the engine in a plan position
● Remove oil dip rod (1) 1

●Clean oil dip rod, insert oil dip rod but do

not tighten it.
oil dip rod
1
● Take out oil dip rod and check if oil is
between upper and lower limit.
● If the engine oil is insufficient, fill more

oil until the sufficient oil is obtained.
Engine oil：SAE15W/40 SG or higher MAX

MIN
Note：
Keep the engine in a plan position Do

not tighten oil dip rod when measuring
Replace Engine Oil
● Remove oil dip rod (1), drain bolt (2) 2、3

and washer (3);
●Drain out the engine oil while the engine

is still warm.
● Clean oil dip rod, drain bolt and washer

with solvent.
● Install washer and drain bolt;

Drain Bolt：28~32N.m
● Fill engine oil （about 2700mL）

● Install oil dip rod, start the engine and

allow it to run for several minutes at idling
speed.
● Turn off the engine and wait for about

3 minutes, and then check the oil level
on the dipstick.
Caution：
The engine oil should be changed

when the engine is warm. If the oil filter
should be replaced, replace engine oil
1 2
Replacing Oil Filter
● Remove relative parts (see Replacing

Engine Oil)
● Remove oil filter cover bolt (1) and

filter cover(2)
● Remove O ring (3) , then oil filter (4)
3 4

Oil Filter Element Inspection
Check and clean the engine oil filter inlet

1 and outlet area 2 for dirt and other
contaminations.
1
2
Oil Filter Element Installation 2
Install a NEW o-ring on oil filter cover,

Apply engine oil on o-ring and the end of
filter;
Install the element into oil filter bore;

Install the element into oil filter bore, bolt. 1
Torque screws to: 8~12N.m
1
3.2.9 Inspection of Cooling System
Check initially at 50 hours or

1500km, replace coolant every 2 years
Check radiator, reservoir tank and water

hoses.
Leakage or Damage——Replace
Inspection of engine coolant
Check coolant level by observing the up-

per and the lower limit on the reservoir tank.

If the level is below lower limit, fill coolant
until the level reaches the upper limit.
2
Replacing Coolant
● Remove radiator cap (1) and reservoir

tank cap (2)
● Place a pan below water pump, and

drain coolant by removing drain plug (3)
and water hose (4)
Warning:
Do not open radiator cap when engine is

hot, you may be injured by escaping hot
liquid or vapor.
Engine coolant is harmful. If coolant

splashes in your eyes or clothes,
thoroughly wash it away with water and
consult a doctor. If coolant is swallowed,
induce vomiting and get immediate
medical attention.
●KDrain coolant
l t from freservoir htank.
f
● Clean radiator with fresh water, if

necessary.
● Connect water hose (4)，and tighten

clamp (3) securely
● Fill the fresh specified coolant into the

radiator
● Loosen bleed bolt (5)，on water pump,

when coolant flow from bleed bolt, tighten
the bolt. Install radiator cap (1) securely
4 3 5
after filling coolant.
● Start the engine and keep it running for

several minutes. After warm up and cooling
down the engine, open radiator cap and
check coolant. Fill the specified coolant until
the level is between the upper and lower
lines on the reservoir tank.
Caution：
Repeat the above procedures several

times and make sure the radiator is
filled with coolant and air is
discharged
● Fill coolant into the reservoir tank till

between upper and lower limit. Install
reservoir tank cap.
Warning：Never mix with other brand
Inspection of Radiator Hose
Perform inspection every 40 hours or

3000km
Check radiator hose and clamp, leakage or
damage----- Replace.
3.2.10 Inspection of cylinder

pressure
Cylinder pressure can reflect the inner

cylinder working status. Check cylinder
pressure is necessary.
Cylinder pressure: 1000kPa
A lower cylinder pressure may be caused by:

● Excessive wear of cylinder
● Wear of piston or piston ring
● Piston ring jam in groove
● Poor closure of valve seat
● Damaged cylinder gasket or other

defects
Note：
When cylinder pressure is too low, check

the above items
Testing Cylinder Pressure
Note:
Before testing of cylinder pressure, make

sure that cylinder head bolts are tightened
to the specified torque and valve clearance
has been properly adjusted.
●Warm up the engine before testing 1
●Make sure battery is fully charged

2
●Remove spark plug 1
●Install cylinder pressure gauge 2 in spark
plug hole
●Keep throttle full open
●Press start button crank the engine a few
seconds. Record the maximum reading of
cylinder pressure.

Tools: Cylinder Pressure Gauge

3.3 Engine Removal, Inspection & Installation

3.3.1 Removal/Installation Orders and the Page Numbers table .............. 3-29
3.3.2 Engine Removal .............................................................................. 3-31
3.3.3 Engine Inspection ............................................................................ 3-41
3.3.4 Engine Installation ........................................................................... 3-78

3.3 Engine Removal, Inspection & Installation

3.3.1 Engine Removal/Installation Orders and the Relative Page Numbers
Disassemb Inspection/M Assem Remark

Item Description
ly aintenance bly s
Spark Plug 3-31 3-20 3-88
Cylinder Head Cover 3-31 3-41 3-88
Timing Chain Tensioner 3-31 3-41 3-87
Start decompression
3-31 3-41 3-87
COMP
Engine
Front Side Timing driven sprocket 3-32 3-41 3-87
Camshaft 3-32 3-42 3-86
Cylinder Head 3-32 / 3-86
Rocker arm 3-32 3-43 3-86
Rocker arm shaft / 3-43 3-86
Valve Spring 3-44 3-45 3-51
Valve 3-45 3-46 3-50
Valve Guide 3-47 3-47
Guide chain plate 3-32 3-52 3-84
Cylinder 3-32 3-52 3-84
Piston 3-33 3-53 3-84
CVT Cover 3-33 3-55 3-88
Primary
Sheave/Secondary
Engine 3-33 3-56 3-83
Right Side Sheave/Drive Belt
CVT case 3-34 3-62 3-83
Chain holder, Tension

3-34 3-62 3-83
plate

Timing Chain 3-34 3-62 3-83
Starting Motor 3-34 / 3-83
Sector Gear 3-35 3-62 3-80
Water Pump 3-35 3-63 3-82
Engine Cap 3-36 / 3-82

Left Side
Oil filter 3-36 3-63 3-82
Left Crankcase Cover/

3-36 3-63 3-81
Magneto Stator
Magneto Rotor 3-36 3-63 3-81
Starting Driven Gear 3-37 3-64 3-80
Starting Dual Gear 3-37 3-65 3-80
Oil pump drive gear/Oil

3-37 3-65 3-80
pump dual gear
To be continue
Description Disassemb Inspection/M Assem Remark
Item
ly aintenance bly s
Gear Position Bolt 3-37 / 3-80
Right Crankcase 3-38 3-66 3-79

/Crankcase inspection

Front Output Shaft

Components/
3-38 3-70 3-79
Driven Bevel Gear
Components
Bevel Gear 3-39 3-71 3-79

Components
Engine Transmission Main 3-39 3-72 3-78

Center Shaft
Shift Drum / Shift 3-39 3-73 3-78

Fork COMP
Drive countershaft 3-39 3-73 3-78
Crankshaft 3-40 3-76 3-79
Balance Shaft 3-40 3-77 3-79
Oil Pump 3-40 3-77 3-80
Filter Net 3-40 / 3-80
Left Crankcase / 3-66 /
Notes: Arrowhead direction is for engine removal orders. Reverse the

direction for assembly and installation.

3.3.2 Engine Removal

Preparation before engine removal
● Prepare a proper tray used for load of

components
● Prepare necessary removal and

assembly tools
● Drain up engine oil（see5.2.8）
● Drain up coolant（see5.2.9）
Engine Front Side
Spark Plug
● Remove spark plug with special wrench

(see5.2.5）
Cylinder Head Cover
● Remove 4 bolts of cylinder head cover.

Remove cylinder head cover (1)
Timing Chain Tensioner
● Remove screw plug ①，insert a flat

screwdriver into slot of timing chain
tensioner adjuster , turn it clockwise to lock
tensioner spring;
● Remove tensioner fix bolt

● Remove tensioner and gasket

Start decompression COMP
● Remove bolt (1)，Remove Start

decompression COMP (2)
Timing driven sprocket
● Loosen two bolts (1) of timing

driven sprocket
● Remove timing driven sprocket
Camshaft, rocker arm
● Loosen bolt(1)
● Remove camshaft holder
● Remove rocker arm shaft, Remove

rocker arm
● Remove camshaft
Note: Turn camshaft to Free State.
Cylinder Head, Guide Chain Plate
● Remove 2 bolts (1) of cylinder head
● Remove 4 cylinder head bolts 2

diagonally
● Remove cylinder head
● Remove guide chain plate
● Remove dowel pin and cylinder head
Note: Take care not to drop dowel pin

into crankcase
gasket

Cylinder
● Remove cylinder
Piston
Put a clean rag under piston so as not to

drop piston pin circlip into crankcase.
Warning: Piston pin circlip is spring-

loading
● Remove piston pin circlip (1) and
discard it.
Note: No need to remove two piston pin
circlip
Remove piston pin circlip (1) from piston

pin hole (connecting rod hole)
Remove piston (2) from connecting rod
Engine Right Side
CVT Cover
● Remove CVT cover （see 5.2.7）
Driving pulley / driven pulley /Drive Belt
● Remove drive bolt (1) clockwise and driven

screw (2) anticlockwise

Drive pulley / driven pulley /Drive Belt
● Remove drive pulley with special tools
● Remove drive pulley / driven pulley

/drive belt
Tool: Drive pulley puller (3)
(1BX-17653-00)
CVT Case
● Remove bolt of air intake plate

Remove air intake plate

● Remove bolt of CVT case
● Remove CVT case
● Remove dowel pin
Remove paper gasket and discard it.
Chain holder, Tension plate
● Remove bolt 1 of tension plate

Remove tension plate 2
● Remove bolt 4 of chain holder
Remove chain holder 3
Timing Chain
● Remove timing chain from crankshaft

sprocket
Starting Motor
● Remove 2 bolts of starting motor

● Remove starting motor
Sector Gear
● Remove 4 bolts of sector gear housing

cover
● Remove sector gear housing cover 1
● Remove dowel pin and gasket
● Remove drive sector gear
● Loosen bolt 3, remove driven sector

gear

Water Pump
● Screw out bolt of water pump
● Remove water pump
Side Cover
●Remove 4 bolts, remove Side Cover

Cap
● Remove 3 bolts, remove cap
Oil Filter
●Screw out 3 bolts of filter cover
● Remove filter cover, O ring
● Remove oil filter
Left Crankcase Cover/Magneto Stator

●Remove bolts of left
● Remove left crankcase cover
●Remove dowel pin and gasket
Magneto Rotor
● Remove nut of Magneto Rotor
● Install special tool to rotor thread

Remove rotor and woodruff key
Tool: Rotor assy puller
(1BE-85610-00)
Starting Driven Gear/Starting Dual Gear
● Remove starting driven gear 1 and

needle bearing
● Remove starting dual gear 2 and shaft

Oil pump drive gear/Oil pump dual gear
● Remove oil guard bolt
● Remove oil guard (1)
● Remove two Circlip (2) by circlip plier
● Remove oil pump drive gear (3), oil

pump dual gear (4) and gasket

● Remove needle bearing (5)
● Remove pin shaft (6), gasket
Engine Center
Gear position bolt
● Remove gear position bolt (1)
● Remove spring and steel ball
Right Crankcase
● Remove left crankcase bolts

● Remove right crankcase bolts
● Separate crankcase carefully with

rubber hammer knocking the case
Front Output Shaft, Driven Bevel Gear
● Remove nut of Real output coupler( 1)
● Remove bevel gear cover bolt
● Remove driven bevel gear (2)
Caution:
Do not damage the seal surface of

right/left crankcase when separating
Crankshaft should remain in the left
crankcase half. CHAPTER 3 ENGINE PAGE. 3- 45
● Remove nut 1 , gasket 2 , front output

coupler 3, oil seal 4, front output shaft
bearing ring 5(LH)
● Remove Front Output Shaft 6
Drive Bevel Gear
● Screw out driven bevel gear bearing seat

bolt
● Remove driven bevel gear from left

crankcase

Transmission Main Shaft
● Remove transmission main shaft 7
Shift Drum, Shift Fork, Drive counter-

shaft
● Remove shift drum 8, shift fork 9, and

drive countershaft 10

Note: Shift drum, shift fork and drive

countershaft should be removed together.
Crankshaft
● Remove crankshaft from left crankcase
Balance Shaft
● Remove balancer shaft from left crank-

case
Oil bump
● Screw out oil pump bolt
● Remove oil bump (1)
Note: Oil pump bolt size M5 X 16

Filter Net
● Screw out the bolt
● Remove filter cap (2)
● Remove filter net

3.3.3 Engine Inspection
Cylinder Head Cover

Cylinder Head Cover 2.Cylinder Head Cover Seal Ring
Check if any scratch is on the cap.
Check is any crack, crush or hardening on

the sealer ring. If so, change accordingly.
● Check tensioner for any damage or poor

Function. Damage, poor function: Replace
● Performance stability inspection methods
■ Insert screw driver 3 into the slotted end

of adjusting screw, turn it clockwise to
loosen the tension and release the screw-
driver
■ Move the screw driver and let go of the

arm slowly, ensuring the arm snaps back
smoothly. If not, replace the chain
tensioner with a new one.
Start decompression COMP
● Check if any crack is on the reducer. If

any, change a new one.

● Move pressure reducing arm 4. Check

if pressure-reducing rocker arm and cam-
shaft can move flexibly and return
automatically.
Timing Driven sprocket
● Check any scratch or damage on cam-

shaft timing chain wheel. If the gear is
scratched or damaged, change a new one
completely (including camshaft timing chain
wheel and timing chain).
Camshaft Inspection
● Check any scratch, abrasion, crack or

other damage on each camshaft and journal.
●Check journal dia. and height of camshaft

by micrometer
Camshaft
Cam(intake)
New part 32.985mm～33.025 mm
Maintenance limit 32.865 mm
Cam(exhaust) A. Cam(exhaust valve)

New part 32.971mm～33.011mm
B. Cam(intake valve)
C. Camshaft journal (timing chain side)
Camshaft journal(timing chain side)
Camshaft bearing shaft （ignition plug side

）

●Test tolerant clearance of camshaft sides

and cylinder cap
Camshaft bearing hole(timing chain side)
Camshaft bearing hole(spark plug side)
If parameters are beyond standards, A. Camshaft bearing hole (timing chain side)
change the parts.
B Camshaft bearing hole (spark plug side)
Cylinder head cover Remove rocker arm
● Remove rocker arm shaft(1)
●Remove rocker arm(intake and exhaust)

Including adjusting screw and nut.
1. Rocker shaft
2.Exhaust rocker arm
3.Intake rocker arm
4.Adjusting screw
5.Nut
● Remove washer(1).
CAUTION: Pay attention not to lose CHAPTER 3 ENGINE PAGE. 3- 53
washers or drop them into the

crankcase.
Rocker Arm Inspection
● Inspect each rocker arm for cracks and 1. Washers

scored friction surfaces. If any, replace 2. Rocker Arm, Exhaust
rocker arm assembly. 3. Cylinder Head Spark Plug Side
● Check the rocker arm rollers for free 4.Big Taper to Spark Plug Side
movement, wear and excessive radial

play. Replace rocker arm assembly if
necessary.
● Check rocker arm bore diameter. If
diameter is out of specification, change
rocker arm assembly.
Rocker Arm Bore Diameter
12.000mm～12.018mm
New
(0.4724in～0.4731in)
1. Rocker Arm, Exhaust
2.Roller
A.Bore for Rocker Arm
● Check adjustment screws for free
movement, cracks and/or excessive play.
Rocker Arm Shaft

1. Free Movement of Adjustment
● Check for scored friction surfaces; if any,

replace parts.
● Measure rocker arm shaft diameter.
Rocker Arm Shaft Diameter
New 11.973mm～11.984mm
Service Limit 11.960mm
Any area worn excessively will require

A. Measure rocker arm shaft diameter here
parts replacement.
Valve Spring Removal
● Use valve spring compressor clamp to

compress valve spring
WARNING
Always wear safety glasses when

disassembling valve springs. Be careful
when unlocking valves. Components
could fly away because of the strong
spring preload
Valve Spring Compressor Clamp
Valve Spring Compressor Cup

Align valve spring compressor clamp with

the center of Valve
● Remove valve lock clips.
●Withdraw valve spring compressor, valve

spring retainer and valve spring.
1. Valve Spring Compressor Clamp

2.Valve Spring Compressor Cup
3.Valve lock clip
CHAPTER 3 ENGINE PAGE. 3-

45
Valve Spring Inspection
● Check valve spring for visible damages,

If any, replace valve spring.
● Check valve spring for free length and

straightness.
Valve Spring Free Length
Normal New 40 mm
Service Limit 38.2 mm
Replace valves springs if not within A.Valve Spring Length
specifications.
Valve Removal
●Push valve stem, then pull valves

(intake and exhaust) out of valve guide.
1. Intake Valve 33mm
2 Exhaust Valve 29mm

● Remove valve stem seal with Snap-on

plier and discard it.
Plier
1. Plier
2. Valve Stem Seal
Valve Inspection
Valve Stem Seal
Always install new seals whenever valves

are removed
Valve
● Inspect valve surface, check for

abnormal stem wear and bending. If out
of specification, replace by a new one.

Valve Out of Round
(Intake and Exhaust Valves)
New 0.005 mm
Service limit 0.06 mm
Valve Stem and Valve Guide Clearance
● Measure valve stem and valve guide in

three places using a micrometer and a
small bore gauge.
NOTE: Clean valve guide to remove
carbon deposit before measuring.
Change valve if valve stem is out of

A. Valve Stem Diameter
specification or has other damages such
as wear or friction surface.
Valve Stem Diameter
Exhaust Valve
New 4.95mm～4.965 mm
Intake Valve
New 4.96mm～4.975 mm
Replace valve guide if valve guide is out

of Specification or has other damages,
such as wear or friction surface
Valve Guide Diameter
New 5.000mm～5.012 mm

1. Valve Seat Area 3.Valve Face(Contact Surface to

Valve Seat)
2. Exhaust Valve Contaminated
If valve seat contact width is too wide or has

dark spots, replace the cylinder head.
Valve Face and Seat
● Check valve face and seat for burning or

pitting and replace valve or cylinder head
if there are signs of damage.
● Ensure to seat valves properly. Apply

some lapping compound to valve face and
work valve on its seat with a lapping tool
(see Valve Guide Procedure below).
● Measure valve face contact width.

NOTE: The location of contact area
should be in center of valve seat.
● Measure valve seat width using a caliper.
Valve Seat Contact Width
Exhaust Valve
NEW 1.20mm ～ 1.40 mm
Intake Valve
New 1.10mm ～ 1.30 mm

A. Valve Contact Surface Width

B. Valve Seat Contact Width
NOTE: Clean valve guide area from

contamination before removal.
Valve Guide Removal
● Use valve guide remover and a

hammer, drive the valve guide out of
cylinder head. Valve Guide Remover
Valve Guide Inspection
Always replace valve stem seals when-

ever valve guides are removed.
Clean the valve guide bore before rein-

1. Valve Guide Remover

stalling the valve guide into cylinder head.
Injector Seat
● Unscrew the set bolt and remove the

injector seat (1)
Injector Seat Inspection
● Inspect Injector Seat for cracks or other

damage.
Check the seal for wear or excessive

using. Replace it if necessary.
Water Temperature Sensor and

Thermostat
●Unscrew the Thermostat bolt, remove

the Thermostat Cover, Thermostat,
Thermostat Seat and Water Temperature

Sensor.
● Water Temperature Sensor Inspection

(Check 5. 4. 6)
● Thermostat Inspection (Check 3.4.7)

Cylinder Head Installation
Valve Guide Installation
For installation, reverse the removal

procedure. Pay attention to the following
details.
● Use valve guide installer to install valve

guide.
NOTE: Apply loctite (antiseize lubricant)

on valve guide prior to install it into the
cylinder head. Valve Guide Installer
● Push valve guide in the cold cylinder

head as per following illustration.
Valve Guide
(Measurement “A”)
NEW 14.70mm～15.30 mm
1. Valve Guide Installer
2. Valve Guide

1. Thrust Surface of Cylinder Head

2.Valve Guide
A. Measurement from Thrust Surface

to Valve Guide Top

● Valve guide to be adjusted in diameter

by using a reamer.
Valve Guide Diameter
New 5.000mm～5.012 mm
Valve Installation
For installation, reverse the removal procedure

(Check 5-45).Pay attention to the following
details.
● Apply some lapping compound to valve
●Install a NEW valve stem seal. Make sure thrust
face and work valve on its seat with a lap-
washer is installed before installing seal.
ping tool.
● Apply engine oil on valve stem and install it.
NOTE: Ensure to seat valves properly.
Apply marking paste to ease checking
contact pattern.
● Repeat procedure until valve seat/valve

face fits together.
Note: Clear up the abradant.
50
NOTE: Ensure
CHAPTER to turn reamer in the right
3 ENGINE M565Li T3 EFI SERVICE MANUAL 20.0
direction. Use cutting oil and make
brakes to clean reamer/valve guide from
1. Valve Guide
metal shavings.
A. Valve Guide Diameter
1. Valve Seat
2. Valve Face(contact surface to valve

seat)
3. Turn valve while pushing against

cylinder head
A. Valve Seat Angle 45
CAUTION: Be careful when valve stem

is passed through sealing lips of valve
1. Valve Spring Lower Seat
stem seal.
2.Sealing Lips of Valve Stem Seal
place while releasing the spring.
NOTE: Valve cotter must be properly

engaged in valve stem grooves.
● After spring is installed, ensure it is

properly locked by tapping on valve stem
end with a soft hammer so that valve opens
Valve Spring Installation and closes a few times.
For installation,
CAUTION: Anreverse the locked
improper removalvalve
procedure (Check
spring will cause5-45). Paydamage.
engine attention to
the following details.
Rocker Arm Installation
● Colored area of the valve spring must be
NOTE:onUse
placed top.the same procedure for
● To ease installation of cotters, apply oil

or grease on them so that they remain in
51
1. Position of the Valve Spring

2.Valve Cotter
● Apply engine oil on rocker arm shaft.
●Install the rocker arm shaft with the

chamfered edge first and use following
procedure.
1、Insert a rocker arm pin through rocker

arm pin bore.
2 、 Install a thrust washer then proper

rocker arm (exhaust side) or (intake side).
3、Push in rocker arm shaft until its

chamfer reaches the end of rocker arm
bore.
● Place the other thrust washer and push 1. Rocker Arm

rocker arm shaft to end position.
2. Thrust Washer(Timing Chain Side)
3.Thrust Washer(Spark Plug Side)
52
Thermostat Installation
● Install the Thermostat seat ( 1),

Thermostat(2),Thermostat cover (3) and
two bolts (4)
Note: Don’t miss to install the “O” seal ring
Injector Seat Installation
● For installation, reverse the removal

procedure (Check 3-48).
Note: Don’t miss to install the seal ring.
1 .Injector Seat
Upper Guide Chain Inspection
● Inspect Upper guide chain, check for

abnormal wear, cracks and rubber fall off. If
out of specification, replace by a new one.
Cylinder Body Inspection
Cylinder Body Distortion
53
● Check the planeness of gasket surface,

total 7 point to inspect with a straight edge
and thickness gauge. Take clearance
readings from several places. If any
clearance reading is out of the service
limit, replace with a new cylinder body.
Cylinder Body Distortion Service Limit:

0.05mm
Tool: Thickness Gauge, straight edge
Cylinder Body Inner Diameter

Inspection
● Check the scoring or other damages in
the inner wall of Cylinder Body, Replace it
if necessary.
● Measure the diameter of bore by Inner

diameter gauge from upper, middle and
lower places of cylinder inner diameter to
check with two mutual vertical directions.
Standard Cylinder Bore: 91.0-91.015mm
Tool: Inner diameter gauge
54
Pistion
Pistion Diameter
● Inspect pistion for cracks or other

damage. Replace pistion and pistion ring if
necessary.
●Vertical measure the pistion on the 8mm

direction between pistion pin by
micrometer
Replace pistion if out of service limit.
Pistion Parameter
New 90.950mm～90.970 mm
Service Limit 90.85 mm
Pistion Ring Groove Clearance
● Measure the one-sided clearance of

pistion 1 and 2 by Straight edge, if out of
service limit, replace pistion and pistion ring.
Service limit (Clearance)
Pistion ring1: 0.15mm
Pistion ring 2: 0.15mm
55
Service limit (Width)
Pistion ring 1: 1.21mm~1.23mm
Oil ring: 2.50mm~2.52mm
Service limit (Thickness)

Tool: Straight edge
Micrometer (0~25mm)
Pistion ring free gap and pistion ring

end gap
● Using a feeler gauge measure each ring

free gap, place the ring in the cylinder To
measure the ring end gap, If the clearance
is too large, the piston and piston rings
should be replaced.
Pistion ring free gap (service limit)

Pistion ring end gap (service limit)

Tool: Vernier caliper. Feeler gauge
56
Pistion Pin and Pin Bore
● To measure the inner diameter of Pistion

pin bore by Bore dial indicator.
To measure the outer diameter of Pistion

pin by micrometer
If out of service limit, replace Pistion and

Pistion pin
Pistion Pin Bore (service limit): 22.02mm
●To measure the outer diameter of Pistion

Pin in three difference positions by
micrometer.
Pistion Pin outer diameter (service limit):

21.980mm
Tool: Inner diameter gauge

(18mm~35mm) Micrometer
(0~25mm)
CVT Cover
● Inspect CVT Cover for cracks. Replace

a new CVT Case if necessary
57
● Inspect seal ring of CVT Cover for

ageing, damage. Replace a new one if
necessary
58
Drive Pulley, Driven Pulley, Drive Belt
59
1 、Drive Pulley Fixed Sheave 10 、Driven Pulley Fixed Sheave
2 、Drive Belt 11 、Driven Pulley Sliding Sheave
3、Ajusting Washer 12 、Spring holder
4、Spring, Drive Pulley 13 、Locating pin
5、Drive Pulley Sliding Sheave 14 、Circlip
6、Centrifugal weight 15 、Spring
7 、C am 16 、Washer
8 、Nut
9 、Washer
60
Drive Pulley
● Loosen Drive Pulley Nut, remove,

CVT, Drive pulley fixed And Sliding
Sheave
● Remove the Cam (1) an d Centrifugal

Weight (2)
Centrifugal Weight Inspection
● Inspect Centrifugal Weight and Sliding

surface for wear or damage, Replace a
set of centrifugal weight if abnormal
Note: Centrifugal Weight should be

replaced by complete set.
Drive Pulley Fixed and Sliding Sheave

Inspection
61
● Inspect the abnormal conditions of drive

surface for multistep wear or other damage.
Replace it if abnormal
● Inspect one-way clutch if equipped.

Replace it if abnormal
Drive Pulley Installation
To install it as contrary process of removal
Note: The nut washer should be

stucked in the hexagon shaft to stand-
still locking.
Driven Pulley
Disassembly
NOTE: Before disassembly, mark on

the spring installation holes and cam
feet to sliders positions.
1. Cam and slider marks
2. Spring Installation Holes Marks
● As the illustration shows, place driven

pulley on the special tool base.
62
Special tool: Driven pulley spring
compressor
(1BA-17730-00 FZ/1)
1. Driven Pulley Spring Compressor
2. Driven Pulley
● Turn special tool handle to compress the

cam and spring. Using a circlip remover
(a plier), remove circlip.
Note: Use special tool to remove circlip

in order to avoid any wounding if spring
seat flying up.
1. Driven Pulley Spring Compressor
2. Circlip
63
3. Circlip Remover
64
● Slowly loosen tool handle to release the

spring tension and remove the special
tool;
Remove cam;
Remove guide pin;
Remove spring and sliding sheave of

driven pulley.
1. Cam
2.Guide Pin
3.Spring
4. Sliding Sheave of Driven Pulley
Driven Pulley Inspection
Driven Pulley Fixed Sheave Inspection
● Check driven pulley faces for any

abnormal conditions, such as heavy wear
65
or visible damage. Replace if necessary.
NOTE: Clean fixed sheave of driven

pulley before inspection.
1. Drive Face of Fixed Sheave

NOTE: Driven pulley assembly is
precisely matched. If only fixed sheave or
sliding sheave is replaced, the vibration
may increase. It’s recommended to
replace both when necessary.
66
Driven Pulley Sliding Sheave Inspection
● Inspect the drive face of sliding sheave

for heavy wear and damage. Replace it if
necessary.
NOTE: Driven pulley assembly is

precisely matched. If only fixed sheave or
sliding sheave is replaced, the vibration
may increase. It’s recommended to
replace both when necessary.
1. Drive Face of Sliding Sheave
● Inspect the 3 sliders on driven

pulley for wear and other damages. If the
worn thickness is over the measurement
illustrated in the following figure, replace
all 4 sliders at the same time.
NOTE: Clean the sliding sheave before

inspection
1. Slider
2. Sliding Sleeve
67
A ≥ 1.5mm
Cam Inspection
● Check spring cam sliding face for wear

and other damages. Replace if
necessary.
68
1. Cam
2.Sliding Face
Driven Pulley Spring Inspection
● Check spring free length. If it is shorter

than limit length, replace it.
Spring free limit length A: 214.0mm.
Driven Pulley Assembly
Reverse the disassembly procedure for 1.Spring
driven pulley assembly.
NOTE: Special tool is also required in

driven pulley assembly.
Drive Belt
● To inspect Belt for greasy dirt
● To inspect Belt for cracks and damage
● To measure width of belt by vernier caliper

Replace a new one if any damage or out of service limit
Drive Belt service limit: 33.5mm

Tools: Vernier Caliper
69
Caution: Clean the Drive belt if any

greasy dirt or lubricating oil.
CVT Case Inspection
● Inspect Bearing Sleeve (1) and Oil seal

(2).Replace it if necessary
Lower Timing Chain Guide Inspection
● To inspect the lower timing chain guide

for damage or ageing Replace it if
necessary
Tensioner Plate Inspection
● To inspect tensioner plate for damage or

70
ageing. Replace it if necessary.
Timing Chain Inspection
● To inspect the radial clearance of timing

Chain.
● To inspect timing chain for excessive wear

Replace timing chain and timing chain
sprocket if excessive wear or damage
Gearshift Sector Gear Inspection
Gearshift, Drive Sector Gear
● To inspect drive sector gear for cracks or

other defects. Replace it if necessary.
● To measure Gear shaft diameter (A) for

cracks or other defects. Replace it if out of
service limit.
Service limit: 14.976mm~14.994mm
Gearshift driven sector gear inspection
● To inspect driven sector gear for dam-

age or abnormal Replace it if necessary.
Oil filter
● To replace a new oil filter

Note: Replace a new oil filter after
71
Disassemble each time.
●Periodic replacement oil filter base on

requirements of Maintenance period.
Crankcase (LH) Cover
● To inspect magneto coil (2) for

damage or Short circuit, Replace it if
abnormal.
●Smear Thread-locking Adhesives on

bolts and fasten base on standard torque
while assembling.
Torque: 10N.m
Magneto rotor
●Remove the set bolt of overrun clutch by

wrench
72
● To inspect the overrun clutch roller and

Cam for wear or damage. Replace it if
defected.
● To install the overrun clutch as right
Note:To confirm the direction is right while

Assemble the overrun clutch into magneto
rotor.
direction.
■ Smear lubricating oil on the overrun

clutch
■Tighten the bolt after smear thread-

locking adhesives by Wrench as standard
torque.
Bolt Torque：30N·m
Accessory： Thread-locking adhesives
● Install driven gear
● Driven gear will be locked if turn it as the

direction of arrow by “B” indicated.
Otherwise, it is smooth running.
● Turning the driven gear bearing. Replace

it if not well running.
● Remove driven gear bearing by special

tools
73
● Install the driven gear bearing by special

tools
Tool： Bearing installation & removal tool
Dual Gear
● To inspect the dual gear surface for

scratch or bump against. Replace it if
abnormal.
Oil Pump Transmission Gear
74
● To inspect the gear surface for scratch,

bump against or plastic ageing. Replace it
if abnormal
Oil Pump Dual Gear
● To inspect the gear surface for scratch,

bump against or plastic ageing. Replace it
if abnormal
75
76
1. Crankcase(Right) 10.Crankcase(Left) 19.Bearing
2. Oil seal 11“

. O” ring seal 20.Bearing
3. Bearing 12.Speed sensor 21.Bearing bush
4. Bearing 13.Bearing bush
5. Bearing 14.Oil strainer 22.Lower timing chain guide
6.Bearing 15“
.O” ring seal 23“
.O” ring seal
7.Bearing 16. Oil strainer cover 24.Gearshift sensor

8.Copper spacer 17.Copper spacer 25.Spacer
9. Bolt 18.Drain Bolt 26.Oil pressure sensor
Crankcase inspection
● Check crankcase halves for cracks or

other damage. Replace if necessary.
● Measure plain bearing inside diameter

and compare to magneto and CVT side
journal diameter of crankshaft ( refer to
CRANKSHAFT). Replace if the
measurements are out of specification.
Plain bearing inside diameter
Service limit 42.100mm
77
1、Plain bearing bore diameter
Plain Bearing Replacement

Plain Bearing Removal
Caution: Always support crankcase

halves properly when ball bearings or
plain bearings are removed .Damages
to crankcase halves may occur if this
procedure is not performed correctly.
NOTE: Always use a press for removal of
plain bearing. Remove plain bearing with
the proper plain bearing remove/installer.
● Carefully push the plain bearings out

from the crankcase half inside towards the
2.Plain bearing remover/installer
outside.
NOTE: Place the proper crankcase sup-
port sleeve under crankcase halves
before removing plain bearing
NOTE: During disassembly ,do not dam-

age the sealing surface of the crankcase
halves.
NOTE: Crankcase and plain bearing must

be installed as a pair as shown in the
following table:
Plain Bearing Installation
Crankcase Plain Bearing
A Red
B Blue
78
CAUTION: Unless otherwise

instructed, never use hammer to
install ball bearings or plain bearing
Install plain bearings with the proper

plain bearing remover/installer in a cool
crankcase. Do not lubricate plain
bearing and /or crankcase for
installation.
NOTE: Place proper crankcase support

sleeve under the crankcase before 1. Oil bore
installing the plain bearings (refer to 2. The partition of the plain bearing
bearing
● Carefully press-in the plain bearings in

the same direction as during installation,
from then crankcase inside towards the
outside.
During installation, make sure not to

damage the 3 sealing surface of the
CAUTION: Mark position of oil bore on

crankcase and on plain bearing re-
mover/installer .Align mark on plain
bearing remover/installer with mark on
crankcase. Wrong oil bore will stop
supply to plain bearing and will cause
engine damaged.
crankcase.
Ball Bearing and oil sealing Inspection
● To inspect the ball bearing for oil

clearance, sound or turning stationarity
79
after Cleaned and lubricated the ball

bearing. Replace it if abnormal by special
tools.
● To inspect all oil sealing for wear,

cracks. Replace it if abnormal by special
tool
● To remove and inspect the gearshift

sensor (24) for break over performance
by multimeter. Replace it if abnormal
● To remove and clean the drain bolt(18) and Oil

strainer(14)
● To install bearing, oil seal by special tools.

Bearing with lubricating oil, Oil seal lips with
lubricating grease
Note: To inspect running performance

after bearing has been installed
● Install new“ O” ring “O” ring

with lubricating grease
● Install gearshift sensor (24)and speed

sensor(12).
● Install spacer (17) and drain bolt (18),

tighten it as standard torque.
Torque (Drain Bolt): 30N·m
Tool: Bearing remover and installer

Multimeter
80
Drive Bevel Gear
● To protect the drive bevel gear shaft by

one clean duster cloth and clamp by vise
● Loosen the Drive Bevel Gear Nut (3),re-

move Drive Bevel Gear(4) and Adjusting
spacer(5).
● To inspect Drive Bevel Gear (4) and

Out- put Driven Gear (2) for rust, cracks,
wear. Replace it if necessary.
●To inspect Bearing (8) for turning.

Replace it if abnormal.
● To adjust Adjusting Spacer (5) if replace

any one of Crankcase (Right), Drive
Bevel Gear (4), Drive Bevel Gear cover
(1). Detail to check Bevel Gear adjusting
method
●To tighten tight Nut (3) by standard

torque and with lubricating oil on bearing
(8) before install.
1- Drive Bevel Gear Cover

2- Output Driven Gear Bear
Service Limit (Drive Bevel Gear Tight
3- Drive Bevel Gear Nut
Nut): 140~150N.m
4- Drive Bevel Gear
5- Adjusting spacer
6- Drive Bevel Gear Shaft

7- Bearing Plate
81
Note: Drive Bevel Gear (4) and Driven

Bevel Gear should be together replaced.
Front Output Shaft
● To inspect Bearing (7) for wear or well

running. To inspect Oil seal (5) for
damage. Replace if abnormal.
● To inspect Bearing(7) for lubrication oil

and Oil seal (5)lips for grease before install
output shaft
● To tighten Bearing Stop Nut(6) with

thread glue as standard torque
Bearing Stop Nut Torque:78~82N·m
Front Output Shaft Nut Torque:95~100N·m
Driven Bevel Gear
● To remove Nut(4),Gasket (19),Coupler

（16）and Oil seal(17)
● To proper protect the thread of Driven
Bevel gear by protector, fixed bevel gear

cover (15), Push out the Driven bevel gear.
● Put one clean duster cloth ①，under the

bevel gear cover, to remove the Bearing stop
nut(11) and Bearing By special wrench ②
● To inspect Driven Bevel Gear(9) for

crack, wear. Replace it if necessary.
● To inspect bearing (10) and (12) for well

running. Replace it If not
82
● To install by use new oil seal(17) and
“O” ring seal (13)
● To adjust Adjusting Spacer (14) if

replace any one of Crankcase (Right),
Driven Bevel Gear (9), Driven Bevel
Gear cover (15). Detail to check Bevel
Gear adjusting method
● To tighten stop Nut(11) with thread glue

by standard torque and with lubricating oil
on Bearing (10) ,Bearing (12),Oil seal(17)
and “O” ring seal before install.
Bearing Stop Nut Torque：100~120N.m
Driven Bevel Gear Nut Torque：140~160N.m
Bevel Gear Spacer Adjusting Method
● To adjust spacer ① and ② if replace any one of

Crankcase, Bevel gear or Bevel Gear Cover.
Caution: Keep the Gear backlash and

contact surface within the proper
scope in order to best match the bevel
gear mesh
Bevel Gear Adjustment
Measure Bevel Gear Backlash
● To install Drive and Driven Bevel Gear

on the Crankcase.
To tighten the Drive Bevel Gear by straight

Screwdriver ③ with duster cloth ② into
the Speed sensor hole ①
●To install special tool ③ and dial indicator
④
83
Tool: Bevel Gear backlash measuring

tool Dial indicator
a=46mm
● To measure backlash by running the
Note: Four points to measure on the

mutual vertical direction.
Driven Bevel Gear shaft.
● To adjust spacer thickness if out of ser-

vice limit. Remeasure the backlash of
Bevel Gear till to accord with service limit.
Bevel Gear backlash service limit：

0.1mm～0.2mm
Adjustment Method：
Measured Washer Thickness

Backlash
＜0.1mm Reduce Adj t thickness
washer t
0.1~0.2m Correct
＞0.2mm Increase washer thickness
84
Gear Surface Contact Inspection
To inspect Gear surface contact after back-

lash adjusted. Detail as follows：
● Remove Drive and Driven Bevel Gear

Shaft from Crankcase.
● Clean splodge and grease for each gears

of Drive and Driven Bevel Gear.
● With dyestuff for each gears surface of

Driven Bevel gear
● To install Drive and Driven Bevel Gear
● Running the Driven Bevel Gear from front

and back direction.
● To inspect dyestuff of Bevel Gears after
① Top contacted on the

Incorrect
Gear Surface
② Middle contacted on the correct

Gear Surface
③ B tt t t d
removed Drive and Driven Bevel Gear.
● If it is proper gear contact surface ②，

move to next Step.
● If it is improper gear contact surface ①

and ③, adjust spacer thickness of Bevel
Gear and recheck till to accord with
Adjusting Method
Gear Contact Surface Adjusting
spacer thickness
Gear Contact Reduce spacer
Surface ① thickness
Gear Contact Increase spacer

Surface ③ thickness
85
standard requirement.
Drive Shaft Inspection
● To inspect gear surface for hard spot,

damage, excessive wear. Replace it if
necessary.
Drive layshaft Combination
● To remove the layshaft as picture
● To inspect gear surface for hard spot,

damage, excessive wear.
To inspect bearing and bush for damage
Note: Rear Retainer couldn’t reuse after

removed. Must to be replaced by new one
or wear. Replace it if necessary.
Shift Drum, Shifting Fork
86
●To inspect shifting fork clearance as pic-

ture indication: Check fit clearance by feeler
gauge. Replace shifting fork ,or gears, or
together replacement if clearance out of
service limit
Shifting fork standard gap:
0.10mm～0.35mm
Service limit: 0.45mm
● To measure the width of shifting fork slot

by vernier caliper
87
Standard values: 6.05mm～6.15mm
● To measure the thickness of shifting fork

by vernier caliper
Standard values: 5.80mm～5.90mm
● To inspect shifting fork ① and ② for

damage, curve. Replace it if with defects.
● Install shift fork on the shift fork rod to

move it by left and right. If not smooth.
Replace it.
88
● To roll the shift fork rod on the slab. Re-

place it if curve
Caution: Don’t try to straightening the

Shift fork rod.
●To inspect the shift fork spring for

broken, damage. Replace it if any defects.
● To inspect Shift Drum Cam for crack,

wear. Replace it if any defects.
89
Installation
Reverse process for installation and

removal. Attention as follows:
Note:
With right installation process to install

the new retainer
To install it base on picture indication

Gears or shaft should be installed with
Caution:
Retainer ring couldn’t reuse if removed

it from shaft Install a new one.
Don’t too wide open when install

retainer ring.
To confirm the retainer ring has been
● Don’t reverse install the shift fork and

spring when assemble the shift fork.
1. Shift fork, shaft. 2. Parking Arm;
3. Retainer ring 4.shift fork

5.Thin shift fork spring
6 Thick shift fork spring

7.Spring seat
90
NOTE: Check each bearing journal of

crankshaft for scoring, scuffing, cracks
and other signs of wear.
NOTE: Replace the crankshaft if the

gears are worn or otherwise damaged.
CAUTION: Components with less than

the service limit always have to be
replaced. Otherwise severe damage
Crankshaft Inspection
Connecting Rod Small End Inner Diam-

eter
● To measure connecting rod small end

inner Diameter by bore dial indicator. Re-
place it if out of service limit
Service limit：22.060mm
Tool: Bore dial indicator (18mm～35mm)
NOTE: Axial play of crankshaft needs to

be measured before splitting the
crankcase.
Crankshaft Axial Play
● Use dial gauge to measure crankshaft

axial play at MAG side.
Crankshaft Axial Play
New 0.050mm～0.450mm
Service Limit 0.6mm
If play is out of specification, replace

crankcase and/ or crankshaft.
Connecting Rod Big End Axial Play

● Using a feeler gauge, measure the
distance between butting face of
91
connecting rods and crankshaft

counterweight.
Connecting Rod Big End Axial Play
New 0.130mm～0.350mm 1. Crankshaft

2.Connecting Rod
3.Gauge
Balance Shaft
● To inspect balance shaft and balance

shaft gear Replace it if damage.
● To inspect balance shaft gears for crack,

scratch or others. Replace it if damage
Oil Pump Inspection
●To inspect all parts of Oil Pump. Replace

it if any defects.
● To measure bottom clearance

( a )(clearance between inner and outer
rotor) and backlash(b) (clearance
between outer rotor and crankcase),
92
Replace oil pump if out of service limit
Bottom Clearance standard value:
0.1mm～0.15mm
Limit value: 0.2mm
Backlash Standard value：
0.08mm～0.15m
Limit value：0.2mm
3.3.4 Engine Installation

The installation essentially the reverse of
93
Note: Clean all parts before install.
Without any cracks for all parts before
the removal procedure, special attention

as follows:
Caution: Without any grease in belt,

drive and driven pulley
Middle parts of Engine Installation

Crankcase (right), Front output shaft,
Shifting Drum, Shifting fork, Drive layshaft
Driven Bevel Gear
● Insert the shifting fork into the sliding sleeve,
● To install Crankcase(right),Front output then install the drive layshaft, shifting fork,
shaft, Driven Bevel Gear and fasten bolt shifting drum into crankcase(left)
as standard torque, Detail as picture
indication.
Front output shaft nut(1) Main Shaft
standard torque ：95~100N .m ● Install the Mail Shaft
Driven Bevel Gear Seat erection bolt

(8)standard torque:40N.m
94
1. Nut 5.Adjusting Spacer
2. Land 6.Driven
Bevel Gear 3.front output shaft
7. Coupler 4.Crankcase(right)
8.Bolt
9. Washer 10.Nut
11. Washer
95
Drive Bevel Gear
● Install Drive Bevel (2) and tighten 4

bolts (1)
Erection Bolt torque (M8X 28):40N.m
Balance Shaft, Crankshaft, Connection

rod
Install balance shaft
● Turn the balance shaft into proper

position (as picture indication),install into
crankshaft
●Keep a strip of straight line for marks on

crankshaft, oil bore of balance shaft neck
Running the crankshaft and balance shaft

to inspect whether match for balance
shaft bore and gap of crankshaft. If not,
reinstall
Crankcase (right)
● Wipe Sealant on the crankcase(left)

junction surface
1. Balance shaft bore 2.Crankshaft gap
Note: Sealant should be uniformity and

continuous threadiness
● Install three locating pin and “O” ring seal

as picture indicated
96
● Mould assembling, light touch to well

done by rubber hammer
● Tighten the bolt as standard torque

Torque: M6:10N·m
Note: opposite angles cross and grading

to tighten the bolt.
M8:25N·m
97
Gears Set Bolt
● Put in steel ball, install the set bolt(1),

tighten It as standard torque
Standard torque: 40N·m
Primary Strainer
● Install primary strainer and cover( 2)
● Tighten bolt as standard torque
Standard torque:8N·m
Shift Sector Gear
● Install shift sector gear, tighten bolt
● Install locating pin and gasket
● Close the shift cover. Tighten bolt
●To inspect gears for smooth changing or

others. If not, recheck all parts and install
again.
1 .Bolt
2 .Shifting Drive Sector Gear

3 .Shifting Driven Sector Fear
98
Engine (left parts) Installation
Oil Pump
● Install oil pump as right picture indica-tion
● Tighten bolt
●Inspect oil pump for smooth running that
hold by pliers. Replace and reinstall it if not
Standard Torque ： 7N·m
1. Outer rotor, Oil pump 4.Oil Pump
2. Roller pin 5.Oil pump shaft
3. Inner rotor, Oil pump 6.Bolt
Oil Pump driving gear, Oil pump dual

gear
● Install dual gear and driving gear.
● Install circlip by circlip plier
Note: Don’t open when install, and

the new circlip have to be used.
●Install oil baffle plate, tighten bolt as

standard torque.
Torque: 8N·m
99
Dual gear
● Install dual gear(1) and dual gear shaft

(2)
Driven gear
● Install driven gear(3)
Magnetor Rotor Combination
● Install woodruff key into crankshaft key

groove
● Install Magnetor Rotor Combination

● Install Nut (1)and Washer (2)
Standard Torque :160~170N·m
Caution: Clean out grease on the sur-

face of Magnetor Rotor and Crank-
shaft Conical surface by noncombus-
tible materials and keep drying.
Left Crankcase
● Install Locating Pin(1) and sealing gasket( 2)
Note: Use new sealing gasket
100
● Install left crankcase
● Install left crankcase fastening bolt
Shaft Sleeve, Blanking Cap
● Install shaft sleeve
● Install blanking cap and tighten bolt.
Installation keeps the Reverse procedure

with removal
101
Oil filter
● Install new oil filter and O ring seal,

tighten bolt.
Water Pump
●Install water pump and tighten bolt.
Starting motor
● Install starting motor, tighten fixed bolt
Engine right side

102
Upper guide chain
● Install upper guide chain
NOTE: Hook up timing chain to prevent It

from falling into crankcase
Lower timing chain guide
Install Lower timing chain guide
Tensioner plate 1. Upper Guide Chain

● Install tensioner plate, tighten 2. Lower Timing Chain Guide
bolt
3. Tensioner plate
CVT case
●Install dowel pin 6, gasket 3 and gasket

9, install CVT case to the right crankcase.
● Install bolt 2, bolt 7 and bolt 10
● Install guide 13 and screw 4
Drive pulley, driven pulley, drive belt
● Use special tool to open fixed plate and

sliding plate
● Install drive belt on drive pulley and

driven pulley
WARNING:
Drive belt contact surface should be

free from any grease or oil.
103
1. driven pulley expander

2. driven pulley
3. Drive belt
Tool: Driven pulley expander
( 1BX-17654-00)
104
● Install CVT assy and tighten bolt and nut

to the specified torque
NOTE: Install bolt of drive pulley

anticlockwise. Install nut of driven pulley
clockwise.
Drive pulley bolt tightening torque:

55~60N.m
Driven pulley nut tightening torque:

1. CVT assy 2. Bolt
110~120N .m
3. Nut
Engine top side
Piston
●Install the piston rings in the order of oil

ring, ② ring, ① ring.
●the first member to go to the oil ring

groove is spacer ①, after placing the spacer
fit the two side rails ②.
WARNING: When installing the spacer
① do not overlap its two ends in the groove
●Install the second ring A and the first ring

B.
NOTE:
Ring A and ring B differ in shape.

Ring A marks “D" and ring B marks
"DY”. The marks should be face up
when installing
●After installing, inspect the smoothness
105
of piston ring moving.
●The gaps of three rings should tagger

120°,
and the gaps should not face the axial

direction
of piston pin or the main push surface of

piston.
1. Do not face to the main push surface of

piston.
2. Do not face to the axial direction of

piston pin.
106
●Apply a light coat of moly oil to the piston pin.
●Install piston pin into holes of piston and

connecting rod small end
NOTE: Piston and cylinder should be

installed according to grouping pairing,
PistonⅠwith cylinder 1 and PistonⅡwith
cylinder 2.
NOTE: When installing the piston, the
“ ▲ ” mark on piston top is located to the

intake side
● place a clean rag beneath piston and in-

stall piston pin circlip ①；
NOTE: While rotating crankshaft, pull the

cam chain upward, or the chain will be
caught between sprocket and crankcase
● Install the dowel pins and the new cylin-

der gasket.
WARNING: Use a new cylinder gasket to
prevent oil leakage

Cylinder
● Apply engine oil to piston skirt and cylin-

der wall.
● Hold each piston ring with proper
NOTE: Pull timing chain from chain cavity,

and then install cylinder properly.
position, insert piston into the cylinder.
107
Chain Guide
● Install upper guide chain( 2)
● Install dowel pin (1) and new cylinder

gasket (3)
WARNING: Use new cylinder gasket to

prevent oil leakage.
● Rotating crankshaft, and rotate the
piston to top dead center of crankshaft
1. Dowel pin 2. Chain guide

3 Cylinder gasket
Cylinder head
● Install cylinder head, tighten bolts

diagonally to the specified torque.
Cylinder head cover bolt tightening

torque:
Initial: 20N.m
Final: 40~45N.m
● Install bolt M6
1. Cylinder head cover bolt M10
2. Nut M6
108
Camshaft, Rocker Arm
● Install camshaft
● Install rocker arm
● Install rocker shaft
1. Rocker arm 4. Adjusting screw
2. Exhaust rocker 5. Nut
3. Intake rocker 6. Camshaft
●Install camshaft holder into the groove of

camshaft.
● Tighten bolt
1. The position of camshaft holder
2. The locating groove of camshaft
3. The moving direction
109
Timing Driven Sprocket
● Remove speed sensor and align the

carved line of magneto and mark of left
cover. If not alignment, rotate camshaft and
make them be aligned.
1 .carved line of magneto
● Install timing driven sprocket, make the

carved line of sprocket and the contact sur-
face of cylinder head cover be parallel
● Hitch timing chain
● Tighten the fastening bolt to the

specified torque
● Tighten the bolt to the specified torque
Decompressor starter bolt specified

torque: 30N.m
Specified torque: 15N.m
NOTE: make sure to apply screw locker

on the fastening bolt of chain sprocket
Decompressor Starter
● Install decompressor starter

110
1 .chain sprocket fastening bolt
2 .carved of timing chain sprocket
3 .the contact surface of cylinder

head cov
111
● Insert flat head screw driver into the end

of tensioner groove, rotate clockwise and
lock tensioner spring
● Install timing chain tensioner and new

seal gasket (1)
● Install fixed bolt (2) and fasten it to the

specified torque
Chain tensioner bolt specified torque:

10N.m
● after installing tensioner, use flat head

screw driver to rotate it anticlockwise and
make the spring press the tensioner adjuster
to compress timing chain.
● Install new gasket 3
● Install tensioner screw to the specified

torque；
Tensioner screw specified torque:

112
8N.m
Cylinder Head Cover
● Put rubber ring on cylinder head cover
● install cylinder head cover
● tighten bolt
Spark plug
● install and tighten spark plug (3)
CVT cover
● install CVT cover and tighten bolt
113
Blank page for technology improvement
114
115
3.4 Cooling and lubrication system

3.4.1 Engine cooling system chart
3.4.2 Engine coolant
3.4.3 Inspection of cooling circuit
3.4.4 Inspection & cooling of Radiator & Water Hoses Radiator Cap
3.4.5 Inspection of Fan Motor
3.4.6 Inspection of Water Temperature Sensor
3.4.7 Inspection of Thermostat
3.4.8 Water pump
3.4.9 Inspection of Engine Lubrication System
3.4.10 Inspection of Lubrication system
3.4.11 Inspection of engine oil pump

3.4.1Engine cooling system chart

3.4.2 Engine Coolant

The cooling used in cooling system is
mixture of 50% distilled water and 50%
ethylene glycol antifreeze. This 50:50
mixture provides the optimized corrosion
resistance and the fine heat protection.
The coolant will protect the cooling sys-
tem from freezing at temperature above -
30℃, the mixing ratio of coolant should
be increased to 55% or 60% according to
the figure on the right.

WARNING:
Use high quality ethylene glycol base
antifreeze and mixed with distilled water.
Never mix alcohol base antifreeze and
different brands of antifreeze
The ratio of antifreeze should not be

more than 60% or less than 50%
DANGER:
DO NOT open radiator cap when the

engine is still hot. Or you may be injured
by scalding fluid or steam;
Coolant is harmful. DO NOT swallow or

stain your skin or eyes with coolant. In
case of accidental swallow or stain, flush
with plenty of water and consult the
doctor immediately;
K l t f h f
3.4.3 Inspection of cooling circuit
● Remove radiator ① and connect tester
②
DANGER: DO NOT open the radiator
when the engine is still hot, or you may be
injured by scalding fluid steam.
● Give a pressure of 105kPa, and check if

the cap hold the pressure for at least 10

seconds
WARNING: When removing the

radiator cap tester put a rag on the filler
to prevent splash of coolant DO NOT
allow a pressure to exceed the radiator
cap release pressure.
WARNING: When removing the

radiator cap tester put a rag on the filler
to prevent splash of coolant DO NOT
allow a pressure to exceed the radiator
cap release pressure.
● If the pressure drops during 10 seconds,

it indicates that there is leakage with the
cooling system. In this case, check the com-
plete system and replace the leaking parts
or components.
3.4.4 Inspection and

cooling of Radiator and
Water Hoses Radia-tor
Cap
● Remover radiator cap ①
● Install radiator cap to cap tester ②
● slowly increase pressure to 108kPa and

if the cap hold the pressure for at least 10
seconds
● If the cap cannot meet the pressure

requirement, replace it.
Radiator Cap Valve Opening Pressure

Standard: 108kPa

Tool: Radiator Cap Tester
Radiator Inspection and Cleaning
● Remove dirt or trash from radiator with

compressed air
● Correct the radiator fins with a small

screwdriver

motor will run at full speed while the ammeter will
indicate the ampere not more than 5A. If the
motor does not work or the ampere exceeds the
limit, replace the motor
●Installation: Apply a little thread locker to the

Radiator Hose Inspection
bolts and tighten to the specified torque.
Fan Motor Bolt Tightening Torque:

● Check radiator hoses leakage or
10N·m
damage. If the hoses are leakage and
damaged, replace them
●Check tightening of clamps. Replace the

clamps if necessary
● After inspection and cleaning of radiator

and hoses, check coolant level. Fill coolant
if necessary
3.4.5 Inspection of Fan Motor
● Remove fan motor from radiator
● Turn the vanes and check if they can

turn smoothly
●Check fan motor. Make sure that the bat-

tery applies 12 volts to the motor and the
1. Radiator; 2. Radiator Cap;
3. Fan Motor; 4.Mounting Nut;
5. Thermo switch

Inspection of Thermo switch
● Remove thermo switch
● Check the thermo switch for closing or

opening by testing it at the bench as
illustrated. Connect the thermo switch ¢Ù
to the circuit tester, place it in a vessel with
engine oil. Place the vessel above a stove.
● Heat the oil to raise the temperature

slowly and take the reading thermostat ②,
when the thermo switch closes and opens.
Tool: ammeter Thermo

switch Operating Temperature:
Standard: (OFF-ON): Approx. 88℃
WARNING:
Avoid sharp impact on thermo switch.

Avoid contact of thermo switch with
th t l
(ON-OFF): Approx. 82℃
● Installation: Use a new O-ring ③ and

tighten the thermo switch to the specified
torque;
Thermo switch Tightening Torque: 17N·m
● Check coolant level after installation of

thermo switch. Fill coolant if necessary
3.4.6 Inspection of Water Tem-

perature Sensor
● Place a rag under water temperature

sensor 1 and remove it from cylinder head
● Check the resistance of water tempera-

ture sensor as illustrated on the right. Con-

nect the temperature sensor 2 to the circuit
tester, place it in a vessel with engine oil.
Place the vessel above a stove
Tool: ohmmeter, thermometer

● Heat the oil raise the temperature slowly

and take the reading from ohmmeter ④and
thermometer ③
Resistance and Water
Temperature
Temperature
（℃） 50 80 1 00 120
Resistance
（Ω） 154±16 52±4 27±3 16±2
● Installation: Apply a little thread locker

and install it to the cylinder head by tighten-
ing to the specified torque
Water temperature Sensor Tightening
WARNING:
Avoid sharp impact on temperature

sensor; Avoid contact of temperature
sensor with thermometer or vessel
Torque: 16N·m
● After installation, check the coolant level.

Fill coolant if necessary
3.4.7 Inspection of Thermostat

● Remove thermostat housing
● Remove thermostat
● Check thermostat pellet for cracks. If

necessary, replace it.
● Test the thermostat according to the fol-

lowing steps:
☆Pass a string between thermostat flange

as illustrated on the right

☆ Immerse the thermostat in a beaker

with water. Make sure the thermostat is in
the suspended position without contact to
the vessel. Heat the water by placing the
beaker above a stove and observe the
temperature rise on a thermometer
① Thermostat
☆ Take the temperature reading from
② String
thermometer when the thermostat valve
opens.
Thermostat Valve Opening
Temperature: 71℃± 3℃ Wate
Tool: Thermometer
☆ Keep heating the water to raise the wa-

ter temperature. When the water tempera- ③ Stove ④ Thermostat
ture reaches the specified valve, the ther-
mostat valve should have been lifted by 3.
Lift valve
5-4.5mm
☆ If thermostat valve opening temperature

or thermostat valve lift does not reach the
standards, replace it.
● Install thermostat: reserve the removal

procedure for installation Apply coolant
☆ Apply coolant to the rubber seal of

ther-mostat
☆ Install thermostat housing. Tighten to

the specified torque:
Tightening Torques: 10N·m
3.4.8 Water Pump
Water pump cover

Water pump is on engine left crankshaft

cover
WARNING:
When engine is hot, do not remove

radiator cap or loose coolant discharge
plug screw to prevent from injury.
Removal and Disassembly

● Drain coolant
● Remove radiator water outlet from wa-

ter pump cover
●Remove mounting bolt from water pump

cover
● Remove water pump
Illustration
1. coolant drain plug screw
2. Seal gasket
3. bolt
4. water pump cover
Inspection of water pump cover
● Check water pump cover seal gasket, if

necessary, replace it
Installation of water pump cover
● Install water pump cover reverse the re-

moval procedure for installation
Water Pump Cover Bolts Tightening Torque:

6N.m
WARNING:
Install seal gasket in the groove of water

pump cover correctly to prevent from
leakage.
● Tighten mounting bolts diagonal cross.


● Check impeller for smooth turning
● install the new O-ring
Use the new O-ring to prevent leakage;
Apply grease to O-ring
● Install water pump and tighten the

bolts and bleed bolt
Water pump bolts tightening torque:
10N·m

● Connect water tubes
● Inject coolant

3.4.9 Inspection of Engine Lubrication System

Add oil to the engine parts (piston, cylin-

der body, camshaft and so on) which run
at high speed.
Engine lubrication should be special oil.

Engine oil is not only used as lubrication,
but also used to wash, rustproof, seal and
cool.
3.4.10 Inspection of Lubrication

system
(Refer to 5.2.8 inspection of lubrication

system)
3.4.11 Inspection of engine oil

pump
(Refer to 3-77)

3.5 FUEL INJECTION SYSTEM

3.5.1 ECU
3.3.2 INJECTOR
3.3.3 Throttle Body Assembly (with stepper motor)
3.3.4 Engine Cool ant Temperature Sensor
3.3.3 Intake Air Pressure and Temperature Sensor (MAP&MAT)
3.3.6 Oxygen Sensor
3.3.7 Ignition Coil
3.3.8 Diagnostic Tools
3.3.9. Preparations Connection
3.3.10. Functions
Below shows the layout of typical EMS for engine. The solid lines in the figure 1 below
indicate the output signals from the Engine Controller and the dotted lines indicate the
input signals to the controller from various sensors and switches.
3.5.1 ECU
3.5.1.1 Description & Working Principle
The ECU continuously monitors the operating conditions of the engine through the
system sensors. It also provides the necessary computation, adaptability, and output
control in order to minimize the tailpipe emissions and fuel consumption, while optimizing
vehicle drivability for all operating conditions. The ECU also provides diagnosis when
system malfunctions occur.
3.5.1.2 Appearance
The MT05 ECU has a polyester header, with an aluminum base plate. below shows
the top and bottom view of the MT05 ECU.

3.5.1.3 Handling – DOs & DONTs
ACTION REASON
DO NOT: Place the ECU close to the High temperature might reduce the life of
exhaust pipe or Engine when removed
the ECU and also can damage the ECU
DO NOT: Place the ECU close to or pour ECU is susceptible to water and liquids
water, oil or any other liquids.
DO NOT: Allow mud or other debris to Having mud or debris accumulated on

accumulate on the surface of the ECU the
ECU casing reduces its heat dissipation
efficiency.
DO NOT: Apply any voltage relative to Drastically affects the performance of the
any point to the ECU
ECU and may lead to ECU damage
DO NOT: Clean ECU with any solvent or Can damage the housing of the ECU
any corrosive liquid
DO: Take extreme care that water ECU connectors can get short and may
droplets or excess moisture should not
fall on ECU connectors lead to ECU damage
DO: Clean the ECU with a moist cloth Prevents ECU damage

and keep it dry
3.5.1.4 Installation requirements
The ECU shall be mounted using M5 machined screws with a torque of 3.9Nm ±10%.
The mounting surface should also be flat to avoid subjecting the base plate to
unnecessary force and warping the PCB.
3.5.1.5 Power Requirements
Power Supply: The controller’s power supply module will power up the
microprocessor if the battery voltage is greater than 6.3 Volts. The power on is controlled
by the controller hardware only.
Operating Range: All planned functions are executed in this range. Battery and / or
Ignition voltage: 9.0 to 16V DC
Power Off: The controller will turn its power off when the ignition voltage: < 6.2
VDC. The controller prepares for entry into Power Down mode. The preparation involves
storing important information into EEPROM.
Reset: During reset, all outputs shall be set to a predefined state. The controller shall
monitor itself for proper operation and enter reset should any internal errors be detected.
The controller shall then restart normal operations after the computer has properly reset
Over Voltage: the controller will survive no permanent damage if the ignition voltage
does not exceed 26V for more than 1 minute
Reverse Voltage: The controller will survive with no permanent damage: Battery and/or
Ignition voltage < -13V DC for 1 minute
3.5.1.6 Temperature Requirements
Storage: The controller shall suffer no damage as a result of being stored at

temperatures of -40 C or
usly for+105
168 C continuo
hours. If the storage
temperature is not as extremely high as +105 C or as extremely
-40 C, thelow as
ECU could be stored for longer time without damage.
Operating: The controller shall operate in the ambient temperature from -20 C to
+85 C.
5.5.1.7 Maintenance service and Repair
ECU is a non-serviceable part. Once there are problems, it’s important to first determine

if the problem is caused by software/calibration. If it is caused by software/calibration,

please refer to software/calibration reflashing procedure. In the event of ECU hardware
failure or malfunction (during warranty period only) the ECU should be sent back to the
vehicle manufacturer giving complete details of the ECU Part No, Serial number, Vehicle
Model & Make, manufacturing Date, Total kms run on the vehicle, Location of use,
Vehicle No, Date of return.
3.5.2 INJECTOR
3.5.2.1 Appearance
The figure below shows the standard Multec 3 Fuel Injector appearance
3.5.2.2 Seal rings
Seal rings for injectors (refer to Figure 12) are made to withstand temperatures
ranging from -40℃to 150℃(-40 to 302℉) without leakage or seeping. They must also be
resistant to varying amounts of fuel additives to fuel (i.e., ethanol, etc.). The following are
currently available seal rings designs. Please contact a Delphi representative if the
specific sealing requirements are not met by these designs:
Injector to fuel rail seal ring
• Dimensions:
• ID. : 6.35 mm
• OD. : 14.85 mm
• Cross-section: 4.25 mm
• Materials
• Viton GLT (blue color). For low temperature applications

• Viton A (black). All other applications.
Injector to manifold
• Dimensions:
• ID: 9.61 mm
• OD: 14.49 mm
• Cross-section: 2.44 mm
• Materials:
• Viton A (black or brown other applications.)
3.5.2.3 Seal rings replacement
Lubricate the seal rings with an approved lubricant or equivalent. The lubricant
application process must prevent lubricant from contacting the director plate, which could
possibly restrict the injector flow.
It is preferred to not reuse the seal rings when re-installing an injector. If re-use is
necessary, carefully inspect each seal ring for any signs of damage, as even minor
defects can lead to fuel / vacuum leakage. Always install injectors and seal rings using
the recommended service procedures to avoid the possibility of a safety hazard.
When installing seal rings to the injector inlet, take extra care not to damage the seal
on the injector top flange.
3.5.2.4 Lubricant Recommendation
Lubrication should be applied to the O-rings only for ease of injector installation.
The table 4 is a list of lubricant oils that were tested and approved for O-ring lubrication.
These lubricants have shown to have no effect on injector performance (plugging,
sticking).

3.5.2.5 Over-Voltage
The Multec 3 injectors and the Multec 3.5 injectors can withstand a voltage of 26v for a
maximum of one minute at a duty cycle of 100 ms pulse width and 200 ms period. The
injector will be pressurized with calibration test fluid at normal operating pressure during
the test. This will not result in any permanent physical damage to the injector or coil
assembly, or any degradation in electrical performance.
3.5.2.6 Temperature Requirements:
Typical injector temperature environments are defined below. The Multec 3 injectors and
the Multec 3.5 injectors will not experience any loss of the ability to comply with the flow
tolerance requirements after exposure to the following temperature environments. Also,
they will not experience unacceptable external leakage, any type of physical degradation,
or loss of service life during or after being exposed to these ambient conditions.
Normal Operating Temperature Range: - 30 to 125C
Extreme Operating Temperature Range (some performance degradation): - 40 to

150C
Storage Temperature Range: -60 to 60C
3.5.2.7 Fuel Contamination
The injector fuel inlet filter protects the fuel injector from initial build fuel contamination as
well as from fuel system assembly contamination. Filtration is extremely important
because particle contaminants can cause an injector to stick open, flow shift or tip leak.
The injector inlet filter is not a serviceable component and is designed only to trap
potential built-in contamination between the chassis fuel filter and injector.
3.5.2.8 Wire Routing

Electrical wiring to the injector should be routed so that conductors are protected from
excessive heat, damage, and wear.
Avoid unnecessary handling (disconnecting and connecting) of the electrical

connector.
3.5.2.9 Handling - DOs & DONTs
ACTION REASON
DO NOT: Re-use injector seal rings if at all Leakage.

possible. If no other choice exists, take extra
care in inspecting the seal rings for damage.
DO NOT: Dip injector tips into lubricants. Can plug injector spray orifices.
DO NOT: Cycle injector repeatedly without fuel Damage to internal mechanical components.
pressure.
DO NOT: Pulse (actuate) a suspected high leak Can dislodge internal contamination if
rate injector (leak >50 sccm air)
DO NOT: Allow water to enter fuel system from Can damage injectors.
air lines, etc. during leak checks.
DO NOT: Contact or apply load to the injector Apply load to 45 deg angle on nylon over mold
tip for installation. see
DO NOT: Pound injectors into manifold during Can damage injectors or seal rings.
assembly to engine.
DO NOT: Apply excessive side loads to May cause loss of electrical continuity.
electrical connectors.
DO NOT: Use any dropped unit. Internal damage may have occurred.
DO NOT: Store injectors, rails, or External contamination can damage the injector
subassemblies including engines on which the electrically and/or mechanically.
injectors have been installed in an unprotected
environment.
DO NOT: Use the injector as a handle. Do not use the injector to lift assemblies
DO NOT: Rack, stage, or handle parts in a Damage will occur.

manner that allows contact between parts.
DO NOT: Remove packing in a way that allows Damage could occur due to contact
contact between parts.
between parts
DO NOT: Tap on fuel injectors to correct any Can damage injector.

malfunction..
DO NOT: Replace the injector with other part Will severely affect the performance of the
number not recommended for this injector

application
DO: Take extra care when installing new fuel Prevent tearing seal ring during installation
seal ring over injector inlet flange.
DO: Use proper lubricants on seal ring surfaces Avoid damage to seal ring during installation.
to install injector in engine. Minimize time Avoid contamination at seal.

between applying lubricant and inserting
injector /rail.
DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure
suspected injector (Actuate consists of one
pulse<5 sec duration at 9 to 15V).
DO: Pulse (actuate) injectors prior to a dry fuel Injector valves may not reseat without fuel
system leak test at engine/vehicle assembly to after shipping and handling resulting in false
reseat injector valves. leakage.
DO: Avoid any liquid contamination in the Coil could short circuit.
injector area.
DO: Use care during connection of harness to Avoid terminal damage.

injector.
DO: Use recommended terminal lubricant on Minimize potential for terminal fretting corrosion.
mating connector.
DO: Return any dropped, damaged, or suspect Ensure fast and correct diagnosis of root cause.
material with a tag that describes the problem.
3.5.2.10 Installation guide lines
Follow these guidelines to prevent damage to the injector and it’s electrical interface
during the replacement or re-installation process.
Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO
10 light mineral oil or equivalent is recommended.
The preferred technique is to apply the lubricant to the sockets the injectors are being
installed into, rather than directly to the seal ring itself. This will help minimize the
possibility of injector contamination.
Avoid applying lubricant over the director plate holes – this may restrict injector flow.
Do not dip the injector tip in lubricant.
All Multec 3 and Multec 3.5 injectors come from the factory with the seal rings
attached. The re-use of seal rings is not preferred when replacing an injector. If an
injector is to be re-used, and no new seal rings are available, take care to inspect each
seal ring for signs of damage. Even minor defects in the seal ring can lead to leakage.
Take extra care in installing seal ring over flange of injector inlet.
Carefully installing the harness connector will prevent terminal damage. Listen for a
positive audible click from the connector retention device — this ensures that it is fully
engaged.
Avoid unnecessarily disconnecting/reconnecting the harness connector.
Wires routed in a manner that can allow them to become pinched between
components can result in a short circuit and a stuck open injector.
For injectors that require orientation for spray pattern, do not rotate the injector in the
fuel rail assembly to install the injector electrical connector. This may dislodge the
retaining clip, and result in improper spray orientation
3.5.2.11 Replacement Techniques
The following procedure outlines standard Multec 3 and Multec 3.5 Fuel Injectors
removal and replacement.
Warning: The injector and all associated hardware may be extremely hot.
Shut off ignition.
Disconnect negative battery cable to avoid possible fuel discharge if an accidental

attempt is made to start the engine.
Disconnect the electrical connector from the injector wiring harness.
Relieve fuel pressure
Remove the retaining clip from the fuel injector.
Remove the fuel line connection from the injector
Carefully clean debris from the interface surfaces. Do not damage seal mating
surfaces.
Remove the injector from the manifold
Apply a light coating of a lubricant to both the upper and lower injector seal ring of the
replacement injector.
Install the new injector into the manifold. Check that the injector is installed in the
original orientation to maintain proper spray targeting, and that the retaining clip is
properly seated on the injector and the fuel line
Install the retaining clip after connecting the fuel line
Tighten the injector mounting to the desired torque as mentioned in the manufacturer
manual
Tighten the fuel line
Re-install the injector electrical connector

Check for fuel leaks with the key “on” and the engine “off”
Start engine and verify proper operation
3.5.2.12 Interchange ability
The injector should be replaced in service only with an equivalent injector of the same
part number. On occasion, a new part number may supersede part numbers. Consult the
appropriate vehicle service manual and part number guide for the latest replacement
injector part number information.
5.5.2.13 Plugging
Fuel deposits cause plugging resulting in flow shifts over the life of the injector.
Fuel varnish or gumming, a type of injector deposit, is created when certain types of fuel
are heated by high injector tip temperatures at soak (no fuel flow). Deposit build up in the
director holes causes the flow shifts
Plugging can cause flow restrictions, frictional changes and the collection of other
particles attracted by the tacky surface. The flow restrictions can degrade emissions and
drivability.
Other fuel and environmental conditions may cause crystal or corrosion growth in the
injector and cause a flow shift.
Oxidation stability of the gasoline affects the potential for deposit formation and must
be controlled by the fuel supplier.
Increased levels of detergent additives reduce the rate of injector plugging.
In case of plugging of injector follow the injector cleaning procedure mentioned in the
section below
3.5.2.14 Cleaning Procedure
Electrically disable the fuel pump by removing the fuel pump connection.
Relieve the fuel pressure in the system and disconnect the fuel connection at the
injector. Plug the fuel feed line.
Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed in the
Injector cleaning tank.
Connect the injector-cleaning tank to injector in the vehicle.
Pressurize the injector-cleaning tank to system pressure.
Start and idle the engine for 15- 20 minutes.

Disconnect the injector-cleaning tank from the system and install the fuel pump
connections. Connect the fuel feed line to injector.
Start and idle the vehicle for an additional 2 minutes to ensure the residual injector
cleaner is flushed from system.
3.5.3 Throttle Body Assembly (with stepper motor)
3.5.3.1 Description and Working Principle
The Throttle Body Assembly is an interactive system comprised of the following

subsystems: the main casting body, bearing system, shaft and valve system, return
spring system, cable interface system, throttle position sensing system, and the bypass
air control system. The subsystems interact and support each other to provide all the
functional requirements, which are mentioned below -
Control intake air flow
Control idle air flow
Sense throttle position - Provide position feedback to Engine Controller
Provide reactionary force to the throttle
3.5.3.2 Appearance
Intake AirPresssure and Temperature Sensor
Idle stepper motor
To engine
To air cleaner assy
Throttle Position Sensor
3.5.3.3 Technical Parameters

Throttle Position Sensor:
Reference voltage: 5±0.1VDC
Resistance between T1 and T2: 3k~12kΩ
Idle Air Control Valve:
Operating voltage: 7.5~14.2 VDC
Solenoid resistance: 53Ω±10%
Solenoid inductance: 33mH±20%
3.5.3.4 Operating Conditions
Normal Operating Temperature: -30~120°C
3.5.3.5 Throttle Body Removal
Disconnect negative terminal of the battery
Disconnect electric lead wire of throttle position sensor coupler, stepper motor coupler
and MAP/MAT sensor coupler ( if this sensor is mounted on the throttle body)
Disconnect accelerator cable from throttle body
Remove air cleaner outlet hose and throttle body outlet hose
3.5.3.6 Cleaning Procedure
If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner
(3M make recommended). Once the throttle body cover is removed, spray the throttle-
body cleaner inside the shipping air passage, and use the brushes to gently dislodge the
dirt, gum and varnish that are present. Do not let the bye pass holes be blocked by dirt or
foreign particles.
3.5.3.7 Throttle Body Installation

Reverse the procedure for installation noting the following:
Adjust accelerator cable play
Check to ensure that all removed parts are back in place.
Reinstall any necessary part which have not been reinstalled
3.5.3.8 Precautions
Do not submerge TPS in any cleaning fluid.
Always open the throttle valve using the throttle cable or lever.
Do not hold the valve at opening position by inserting tools or any sticks into the bore.
The valve may be warped and the bore may be scratched. This type of damage may
keep the throttle from opening easily or fully closing.
3.5.3.9 Handling - DOs & DONTs
ACTION REASON
DO: Use care during assembly of harness to Avoid terminal damage.

throttle body.
DO: Avoid any liquid contamination in the Ensure proper operation.

throttle body area.
DO: Unload and install units one at a time from Damage may be done to critical components.
packing trays.
DO: Return any dropped, damaged, or suspect Ensure fast and correct diagnosis of root cause.
material with a tag that describes the problem.
(Only warranty cases)
DO: Remove and discard protective caps just Protects system from contamination, which can
before assembling mating components. prevent proper operation.
DO: clean the by pass passage after removing To ensure good idle stability
bottom cover
DO NOT: Use any dropped or impacted unit. Internal damage may have occurred or
emissions settings may have been upset.
DO NOT: Store units without protective caps in Contamination may impair correct operation.
place.
DO NOT: Ship or store near saltwater without Corrosion buildup may impact proper
protection.
operation.
DO NOT: Exposed to environmental conditions Corrosion buildup may impact proper

(Moisture) prior to complete vehicle installation.
operation.

DO NOT: Apply any voltage other than system Damage could occur
voltage for testing.
DO NOT: Apply excessive band clamp loading Damage could occur.
DO NOT: Remove packing in a way that allows Minimum air leakage could be affected and/or
contact between parts.
other damage could occur.
DO NOT: Release the throttle cam abruptly Damage could occur.

from any position without the throttle linkage
attached.
DO NOT: Let the by pass holes be blocked by This could effect idle stability
dirt or foreign particles.
DO NOT: Rake, stage, or handle parts in a Damage will occur.

manner that allows contact between parts.
3.5.4 Engine Cool ant Temperature Sensor
This sensor is used in water cooled engines. It provides a resistance that varies as a
function of temperature within prescribed tolerance limits. The sensor has a
negative temperature coefficient of resistance. This is a non-serviceable part.
3.5.4.2 Appearance
3.5.4.3 Installation Requirements

Dynamic Torque Requirement: The sensor shall be hand into the application and then
driven by a driver with a maximum no load speed of 400 rpm or installed to the desired
torque by a hand torque wrench (5/8” hex). The recommended installation torque is:
Minimum: 20 N·m
Maximum: 25 N·m
Static Torque Requirement: The torque required to remove the sensor from the
mating hole shall be within 200% of the installation torque mentioned above.
3.5.4.4 Operating Environment
This device is intended for use in engine coolant and air cooled applications and shall
withstand such an under hood environment.
Normal Operating Temperature: -40°C ~ 135°C (continuously).
Relative Humidity: 0 to 100% RH.
Typical Pressure: When installed at the minimum torque the sensor shall be capable
of sealing engine coolant with a positive pressure of 206.8 kPa (30 psi) at 135°C applied
to the probe tip end of the sensor.
Extreme Operating Environment: Maximum temperature excursion to 150°C for
1 hour.
3.5.4.5 Storage Environment
Storage temperature: -40°C to 120°C for an indefinite duration
Transport at altitudes to: 13,700 m for an indefinite duration Electrical Environment
Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ±
0.1 VDC.
Maximum Excitation Current: The sensor calibration shall not be affected by a current
source of less than 1 mA at all temperatures.
3.5.4.6 Sample Cleaning
When necessary the samples may be cleaned in isopropyl alcohol for one
minute with mating connectors in place and then air-dried
3.5.5 Intake Air Pressure and Temperature Sensor (MAP&MAT)

This sensor has two functions. The first is the intake manifold air temperature, it provides
a resistance that varies as a function of temperature within prescribed tolerance limits.
The second is the intake manifold air pressure; it provides a voltage varies as the intake
air pressure.
3.5.5.2 Appearance
The appearance of the MAP&MAT Sensor is shown as above.
3.5.5.3 Operating Environment
This device is intended for use in inlet manifold for sensing air temperature and
pressure which shall withstand such an under hood environment.
Pressure Range: 20~102kPa
Temperature Range: -40~105°C
Relative Humidity: 0 to 100% RH.
Extreme Operating Environment: Maximum temperature excursion to 125°C for
2 hours.
3.5.5.4 Storage Environment
Storage temperature: -50°C to 150°C for an indefinite duration
3.5.5.5 Electrical Environment

Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ±
0.1 VDC.
3.5.5.6 Sample Cleaning
When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one
minute with mating connectors in place and then air-dried
3.5.6 Oxygen Sensor
This sensor is a device for monitoring the residual oxygen in the exhaust of an internal
combustion engine. It consists of the wide range sensor and stoichiometric sensor.
Usually we use stoichiometric sensor on the small engine. It is the feedback element for
engine closed loop control.
3.5.6.2 Appearance
The appearance of the Engine Oxygen Sensor is shown as below
A/F ratio rich threshold: ＞750 mVDC
A/F ratio lean threshold:＜120 mVDC
Heater power: 7.0W
(These parameters as above are measured basing on 450°C (engine dyno), typically on
70% duty at 10Hz and under 13.5V)

Heater part resistance: 9.6±1.5Ω
(This parameter is measured basing on 21°C)
Operating temperature range: 260-850 °C
3.5.6.4 Fuel Quality Requirements
Pb≤0.005g/L
P≤0.0002g/L
S≤0.04% (weight proportion)x
MMT≤0.0085g/L
Si≤4ppm
3.5.7 Ignition Coil
This coil provides energy to the spark plug in the combustion chamber. The coil itself
doesn’t have a driver. The high voltage tower of the coil is connected to the spark plug
using a high voltage cable assembly. This is a non-serviceable component.
3.5.7.2 Appearance
The appearance of the Ignition coil is shown as below.
Input voltage: 9~14VDC

Output voltage: ~25~30KV
Operating temperature: -30 ~110 °C
Storage temperature: -40~155°C
Mounting Torque: 8.8~11.8Nm
3.5.7.4 Installation requirements
The vehicle frame provides the mounting surface and mounting holes.
Mount coil close to the spark plug and keep the plug wire length very short (less than
6 “).
Mount coil away from any pick coil device. Especially, a VR type Crank / Cam sensor.
Keep a Min distance of 150 mm (around 6”) between coil and any VR sensor device.
Never route the coil C- wire with the same bundle as the Crank sensor wires.
There is around 200 V peak potential between C- wire and engine ground. This voltage
potential could cause a noise on sensor cables.
3.5.7.5 DOs and DONTs
ACTION REASON
DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing,
the power applied possibly leading to personal injury
DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in such a
secondary boots from the secondary tower. Use
tools designed for secondary removal. manner that creates an electrical path to outside the
system permitting improper system operation misfire,

or even possible personal injury if arcing occurs.
DO NOT: Use parts that have been dropped or Damaged components can lead to premature failure.
display physical damage
DO NOT: Scratch or apply any non approved This can jeopardize the seal integrity of the mating
material to the surface of the high voltage tower surfaces which in turn can create a secondary high
which mates with the high voltage secondary voltage leak path.
leads.
DO NOT: Strike any part of the ignition system This can lead to physical damage which can cause a
with a tool or other object. system malfunction or failure.
DO NOT: Permit paint or other sprayed materials Insulating type sprays can create a high resistance
to be sprayed onto the electrical connectors. or open connection. And, a conductive type spray

can create an electrical short condition.
DO NOT: Support the ignition system by the wiring These leads are not designed to support the weight
harness or plug wire. of the ignition system. It can create a poor electrical
connection Or become disconnected allowing the
system to fall and be subjected to physical damage
DO NOT: Pierce or probe the secondary leads. This creates an electrical path to outside the system
permitting improper system operation, misfire, or
even possible personal injury if arcing occurs.
DO NOT: Operate without the spark plug attached If a technician or mechanic comes in contact with the
high voltage generated during operation, personal
injury may occur. Or, if the engine is operated under
this condition, unburned fuel may fill the converter
area creating a potential hazard
DO NOT: Share ignition component wiring with This prevents electrical cross talking between
other components, Dedicated wiring is required. components which can lead to component
malfunction.
DO NOT: Apply voltage to the ignition system This can cause reduced performance or an electrical
other than vehicle system voltage for testing
purposes. malfunction of the ignition system
DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or mating
plug boot to the ignition secondary towers. connection surfaces might occur.
Installation of the high voltage secondary leads by

hand is preferred.
DO: Install the secondary leads before connecting In the event the low voltage connection has been
the primary leads.
made and the power applied, unwanted secondary
output might occur possibly resulting in injury,

damage
the ignition component, and test equipment
DO: Take care when working around the ignition The high voltage produced by the coil secondary
system.
circuit can cause personal injury and/or damage test
equipment
DO: Proper handling and shipping methods need Damaged components can lead to premature failure.
to
be in place to reduce the risk of damage due to

impact, moisture, or contamination
DO: Avoid unnecessary disconnecting and The electrical connections are not designed for
connecting of the electrical components. repeated connection and disconnection.
DO: Insure the low voltage connectors are entirely This prevents intermittent electrical connections
seated and the locking mechanism is engaged. leading to an improper ignition system operation.
DO: Use approved connector breakouts when Connector and/or component damage may occur.
testing the ignition system.
DO: Insure the appropriate seals are included in Liquid intrusion into the terminal connection area
the connector system. might occur causing an electrical intermittent or short
condition. In the event of severe terminal corrosion,
an open condition might occur.
DO: Operate with gasoline based internal Other fuels or combustion designs may require
combustion engines.
additional design considerations
DO: The power feed line should be fused. This could protect the system in the event of an
electrical short
DO: The module heat sink and back plate must not The high level of voltage and current which the
module could be subjected to, could cause module
be used as a connection point when jump starting performance degradation or failure.
the engine
DO: Connection of the module back plate to This greatly reduce potential ground loops and acts
vehicle ground is desirable whenever possible as a heat transfer source from the module.
DO: The ignition system ground wire should be This would greatly reduce the possible of unwanted
kept as short as possible. And, when permissible, electrical ground loops.
should be grounded at the same engine block
position as the engine controller
DO: The electrical wiring to the ignition system Helps prevent electrical intermittent, open or shorted
operating conditions.
should be routed so that the conductors are
protected from excessive heat, damage, and wear.
DO: Ignition secondary leads should not be routed Voltage spikes can be transmitted from the
secondary cables into other leads which are in close.
with the ignition primary harness or any other This could
electrical harness.
create a component performance degradation or
failure condition
DO: Spark plug wires(secondary leads) & primary - Spark plug wires carry very high voltage (30,000
wiring: volt). If the secondary lead loses its dielectric
- must not contact sharp surface characteristics thru being nicked, cut , chaffed, then
an arc thru to a nearby ground could take place. This
- must not be under tension between fixed points
kind of condition could lead to misfire, no start, or

- must be clear of moving parts (belts, fan, etc…) premature failure of ignition system.
- must be protected from or kept at least 125 mm
away from radiant heat source exceeding 400 F.
- must be protected from environmental damage
(dirt, splash, oils, fluids, etc….)
- must be retained, secured or insulated to prevent
pinching, mis-routing, rattles, and squeaks
DO: Not all fasteners are designed for repeat use. Adequate retention force might not be achieved if the
fastener is not designed to be reused. Mating
Beware of fastener specifications. All harnesses
should be supported within 6" of a mating connections are not designed to support the weight
connection. of the harness assembly
DO: For removing spark plugs follow the following To remove spark plugs from Aluminum heads, allow
the engine to cool. The heat of the engine, in
steps:
combination with a spark plug that is still hot, may
1- Grasp the spark plug boot and gently rotate
cause the spark plug threads to strip the cylinder
90 ; and the head
cable away from the spark plug upon removal
2- Before removing spark plug, brush or air blast Use goggles to protect eyes from dirt when applying
dirt away from the well areas compressed air to spark plug wells
3- Use correct size deep socket wrench to loosen
each spark plug one or two turns
DO: Cleaning a spark plug could be done as - Cleaning a spark plug will reduce the voltage
follow:
required for an electrical arc(spark) across the
1- wipe all spark plug surfaces clean….remove oil,
water, dirt and moist residues. electrodes
2- If the firing end of spark plug has oily or wet - Cleaning & re-gapping will not restore a used spark
plug to a new condition. It may be more economical
deposit, brush the spark plug in an approved, non- and efficient to replace used spark plugs with new
flammable and non-toxic solvent. Then plugs instead of cleaning.
dry the spark plug thoroughly with compressed - Sooted plugs should be replaced
air - Do not cool by using water or any liquid
3- Use a propane torch to dry wet-fuel fouled - Clean threads permit easier installation and
plugs. Allow the torch flame to enter up the center
electrode insulator. Allow plug to cool down proper seating which will maximize transfer heat
away from the plug
4- If the spark plug threads have carbon & scale
deposits, clean with wire brush, taking care not

to injure the electrode or the insulator tip
DO: Regap spark plugs to the exact measurement - Too wide a gap could cause the plug to misfire
(higher required ignition voltage).
specified by the engine manufacturer to keep the
- Too narrow of a gap could affect idle stability
best fuel economy and proper engine performance
- A flat gauge can’t accurately measure the spark
- Use round wire-type gauge for an accurate
plug on used plugs
measure of gap on all used spark plugs
- when gapping a spark plug only the side

electrode is moved. The center electrode must not
be moved
DO: When replacing spark plugs with new ones, - Higher heat range plug(hotter plug) could lead to
always use equivalent plugs with same heat
range, thread, size, etc…. pre-ignition & possible piston damage
- Lower heat range (colder plug) could lead to cold
fouling & emission problem
DO: For installing spark plugs follow the - If the thread is damage, it prevents a good heat
following
transform from the shell to the cylinder head
steps:
- Do not use any type of anti-seize compound on
1- make sure the cylinder head threads and spark spark plug threads. Doing this will decrease the
plug threads are clean. Make sure the spark plug amount of friction between the threads. The result
thread is free of dings and burrs. If necessary, use
a thread chaser and seat cleaning tool. of the lowered friction is that when the spark plug
2- Make sure the spark plug gasket seat is clean, is torqued to the proper specification, the spark plug
then thread the gasket to fit flush against the is turned too far into the cylinder head. This
gasket seat. Tapered seat plugs do not require
increases the likelihood of pulling or stripping the
gaskets
threads in the cylinder head
3- Screw the spark plugs finger-tight into the
- Over-tightening of a spark plug can cause
cylinder head. Then, use a torque wrench to
stretching of the spark plug shell and could allow
tighten spark plugs following manufacturer’s
recommendation).
blow by to pass thru the gasket seal between the
Torque is different for various plug type & cylinder
shell and insulator. Over-tightening also results in
head material
extremely difficult removal
3.5.8 Diagnostic Tools
3.5.8.1 Motor Scanner (for MT05 EMS)
3.5.8.2 Precautions

Motor-Scanner is a precision instrument and should be protected from vibration and

impact.
If the unit does not run correctly or the screen is unstable when first turned on,
disconnect it from the main lead and try again.
Make sure the DLC is always firmly inserted into the diagnostic socket.
Never test electrical signals that exceed the limit of specifications.
Test cannot be performed by the person who is driving the car.
This unit should be used and stored in the following conditions:
Ambient temperature: 0~50℃
Relative humidity: <90%
3.5.8.3 Configurations
Delphi Motor scanner consists of 2 main part: the main units (with diagnostic main cable)
and diagnostic connector link (one end is 6PIN connector; the other is the interface for
connecting diagnostic main cable). They are shown in figure 34 as below.
Outline of Main Unit

The 6 PIN diagnostic connector link cable and USB type main unit’s software update
cable are in the delivered package.
Screen:
128×64 array high definition screen with back light for displaying all the information
during testing.
Keyboard:
There are 5 keys (one is reserved) on the main unit for selecting and controlling test
steps.
3.5.9. Preparations Connection
Find the 6PIN diagnostic socket on the motor.
Connect one end of the diagnostic main cable to the main unit, and the other
end to diagnostic socket on the motor, tighten the screws.
Normal Power – on Display
When power is on normally, the unit will display:

Seconds later, the unit will display:
3.5.10. Functions
Delphi Motor-Scanner can be used to diagnose Delphi Engine Management
System with functions: Read DTC, Clear DTC, Data Stream, Status Stream, and Record
Data.
Operations
When the unit is powered up, the screen will display the interface as below.
Here, we take diagnostic function for demonstration.
Select 1 and press key, it will display an interface for language selection, as
shown below:

Select ‘English’ and press key, it will display information about the diagnostic
software version, press to continue, the interface will display as below:
Diagnostic Function
Here, we take ‘diagnostic function’ for demonstration.
Select ‘diagnostic function’ and press , the screen will display an interface to
indicate ‘Delphi-3’ diagnostic connector should be used.
Press , the screen will display engine information as below:
Press , with ‘accessing system’ fleeting on the screen, then, it will display as below:

Available functions are as follows:
Read DTC
Clear DTC
Data Stream
Status Stream
Record Data
Press or key to select function you needed.
1. Read DTC
Select ‘Read DTC’, and press , it will display fault code as below:
Press or key to move ‘.’ icon, and select fault code, take ‘P0118’ for example, it’s
selected when there is ‘.’ in front of it, press , the screen will display detailed
information of the code, as below:

2. Clear DTC
Select ‘Clear DTC’ and press, it will display as below:
3. Data Stream
Select ‘Data Stream’ and press , it will display as below:
Press or key for page up/down to view more. Press key to exit.
4. Status Stream
Select ‘Status Stream’ and press , the interface will display as below:
Press or key for page up/down to view more. Press key to exit.
5. Record Data
Select ‘Record Data’ and press , it will display:

Press or key to enter code, when the first number of the code was set, press
to confirm and continue to input the sequent numbers, till all the 7 numbers were input.
When all the 7 numbers were set, press , the screen will display a message for
confirmation of the Plate Number input. Press to return to the previous interface to
input the code again or press to confirm the code.
Press , another interface will be displayed for you to input date, as below:
It’s the same way to enter month as vehicle code input.
Month was input, then enter date, as below:
Then, ‘Enter Year’ continues, as below:

After that, ‘Enter Week’ follows, as below:
Till now, the ‘date input’ was completed, and it starts to record data, press to stop
recording.
Check malf code meaning by reading the below table.
Fault code Description
P0107 MAP Circuit Low Voltage or Open
P0108 MAP Circuit High Voltage
P0112 IAT Circuit Low Voltage
P0113 IAT Circuit High Voltage or Open
P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage
P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open
P0122 TPS Circuit Low Voltage or Open
P0123 TPS Circuit High Voltage
P0131 O2S 1 Circuit Low Voltage
P0132 O2S 1 Circuit High Voltage

P0032 O2S Heater Circuit High Voltage
P0031 O2S Heater Circuit Low Voltage
P0201 Injector 1 Circuit Malfunction
P0202 Injector 2 Circuit Malfunction
P0230 FPR Coil Circuit Low Voltage or Open
P0232 FPR Coil Circuit High Voltage
P0336 CKP Sensor Noisy Signal
P0337 CKP Sensor No Signal
P0351 Cylinder 1 Ignition Coil Malfunction
P0352 Cylinder 2 Ignition Coil Malfunction
P0505 Idle Speed Control Error
P0562 System Voltage Low
P0563 System Voltage High
P0650 MIL Circuit Malfunction
P1693 Tachometer Circuit Low Voltage
P1694 Tachometer Circuit High Voltage
P0137 O2S 2 Circuit Low Voltage
P0138 O2S 2 Circuit High Voltage
P0038 O2S Heater 2 Circuit High Voltage
P0037 O2S Heater 2 Circuit Low Voltage
P0500 VSS No Signal
P0850 Park Neutral Switch Error
P0445 CCP short to high
P0444 CCP short to low/open
P0601 ECU EEPROM fault detection

3.6 Troubleshooting
Complaint Symptom and Possible Causes Remedy
Compression is Too Low
1. Worn cylinder Replace

2. Worn piston ring Replace
Replace
3. Leakage with cylinder gasket
Replace or repair
4. Wear valve guide or improper
valve seating
5. Loose spark plug

Tighten
Engine will not start
6. Slow cranking of starting motor
or is hard to start Check electrical part
7. Faulty valve timing Adjust
8. Improper valve clearance Adjust
No Sparking from Spark Plug
1. Fouled spark plug

Clean or Replace
2. Wet spark plug Clean and dry or
replace
Replace
3. Defective ignition coil Replace
4. Open or short circuit with pickup
coil
Replace
5. Faulty generator
No Fuel Reach Into Carburetor

Clean or Replace
1. Clogged fuel tank vent tube
Clean or Replace
2. Clogged or faulty fuel valve Replace
3. Faulty carburetor needle valve Replace
4. Clogged fuel hose
Clean or Replace
5. Clogged fuel filter Set to Neutral
position
Transfer is not in Neutral position

1.Improper valve clearance Adjust
2.Improper valve seating Replace or Correct

Replace
3.Faulty valve guide
4.Worn rocker arm or rocker Replace

arm shaft
5.Fouled spark plug

Engine stalls easily Replace
or has unstable 6.Improper spark plug gap
Replace or Adjust
idle speed
7.Faulty ignition coil Replace
8. Clogged idle-vale inlet & exhaust Adjust Fuel level

pipe
9.Faulty magneto
Replace

1. Weak valve spring Replace

Replace
2. Worn camshaft
3. Fouled spark plug Clean or replace

Adjust or replace
4. Insufficient spark plug gap Adjust
5. Improper valve timing
Replace
Poor engine 6. Faulty ignition coil
Adjust or replace
running in high-
7. Weak high pressure oil pump,
speed range
resulting in poor fuel supply
8. Dirty air filter Clean or replace
1. Excessive engine oil Check oil level and drain

Replace
2. Worn piston ring
3. Worn valve guide Replace

Exhaust smoke is Replace
dirty or thick 4. Scored or scuffed cylinder wall Replace
5. Worn valve stem
Replace
6. Worn valve stem oil seal

1. Improper valve clearance Adjust

Replace
2. Weak valve spring
Adjust
3. Improper valve timing Replace
5. Worn piston ring Replace or Correct

Clean or replace
6. Improper valve seating
Clean or replace
7. Fouled spark plug Clean or replace
Adjust fuel level
8. Improper spark plug gap
Clean or replace
9. Clogged carburetor jet Replace
Engine lacks power
10. Improper fuel level in fuel chamber
11. Dirty air filter

Tighten or replace
12. Worn rocker arm or rocker Check oil level and drain
arm shaft
13. Air leakage from air intake pipe
14. Excessive engine oil
1. Carbon deposit on piston top Clean
2. Insufficient or excessive engine oil Check level, add or drain

Replace
3. Faulty oil pump
Engine overheats Clean
4. Clogged oil passage
5. Air leakage from air intake pipe Tighten or replace

Change engine oil
6. Incorrect engine oil
7. Faulty cooling system(see 5.2.9)

Valve Chatter
1. Excessive valve clearance Adjust

Replace
2. Worn or broken valve spring Replace
3. Worn rocker arm or camshaft
Noise from Piston
1. Worn piston Replace

Clean
3. Carbon deposit in combustion
Replace
4. Worn piston pin or pin hole Replace
5. Worn piston ring or piston ring
groove
Noise from Timing chain
1. Stretched chain
Replace chain & sprocket
2. Worn sprocket wheel Replace chain & sprocket
3. Faulty chain tensioner Repair or replace
Noise from Clutch

Replace
1.Worn or damaged crankshaft
spline
Replace
2.Worn inner race spline
Engine is noisy Noise from Crankshaft
1. Worn or burnt crank pin bearing Replace

Replace
2. Excessive thrust clearance
Noise from CVT
1. Worn or slipping drive belt Replace

2. Worn rollers in primary sheave Replace
Noise from Transmission
1. Worn or damaged gear Replace

Replace
2. Worn or damaged input or output
shafts
3. Worn bearing Replace
1. Worn or damaged clutch shoes Replace

Replace
2. Weakened clutch shoe spring
Replace
Slipping Clutch 3. Worn clutch housing Replace
4. Worn or slipping drive belt

CHAPTER 4 CHASSIS M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 4 CHASSIS
M565Li T3 EFI
WARNING
4.1 A-RM REPLACEMENT
4.2 SW ING ARM
4.3 FRONT STRUT REPLACEMENT
4.4 FRONT STRUT BALL JOINT REPLACEMENT
4.5 STEERING POST ASSEMBLY
CHAPTER 4 CHASSIS PAGE. 4- 1

4.1 A-RM REPLACEMENT (MacPherson)
MANTENANCE-FREE PIVOT DESIGN
1. Elevate and safely support vehicle

2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is
flush with end of cup.
3. Using a soft face hammer, tap nut to loosen A- arm from bolt. Remove nut and A-arm
from hub strut assembly.
4. Loosen and remove two bolts on A-arm, and remove A-arm.
5. Examine bushing. Replace if worn or tore. Discard hardware.
6. Install new A-arm assembly onto vehicle frame. Install new bolts and new nuts.
NOTE. Tighten the nuts only finger-tighten at this time. They will be tightened to the final
torque after the front wheels are installed and the vehicle is on the ground.
WARNING
DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during
operation.
7. Attach A-arm to strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin
holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends
toward rear of machine. Bend both ends in opposite directions around nut.
8. Install hubs, calipers and wheels, lower the vehicle to the ground. Apply Loctite™ 242 to
screw threads of the A arm bolts and torque bolts to 37-44 ft. lbs. (50-60 Nm ).
WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular
service.
4.3 FRONT STRUT REPLACEMENT ATV500

1. Hold strut rod with
wrench and remove top
nut
2. Compress spring.
3. Remove upper strut pivot
assembly.
4. Remove coil spring and
collapse strut body.
5. Remove two pinch bolts
from strut body.
6. Remove strut body.
7. Install front shock
cartridge until bottomed
in strut casting.
8. Install pinch bolts with
clamp(s).
Torque pinch bolts to
15ft.lbs.(21Nm).
9. Reassemble spring and
top pivot assembly. Be
sure all parts are
installed properly and
seated fully.
10. Torque strut rod nut to
specification. Do not
over torque nut.
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)

4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV500

1. Loosen front wheel nuts.
2. Elevate and safely support ATV under
footrest/frame area. .
CAUTION: Serious injury may result if
ATV tips or falls. Be sure ATV is secure
before beginning this service procedure.
3. Remove wheel nuts and wheels.
4. Remove cotter pin from ball joint
5. Remove castle nut and separate A-
arm from ball joint stud.
6. Remove screws and ball joint mounting
bracket.
7. Using ball joint cup removal/installation
toolkit, remove ball joint cup from strut
housing. Refer to photos at right.
Install puller guide (1) .
Thread bolt (2) with nut (3) onto bal
joint stud as shown .
Hold bolt (2) and turn nut (3)
clockwise until ball joint is removed
from strut housing.
8. To install new ball joint cup.
Insert new ball joint into driver
(installation toolkit).
Drive new bal joint cup into strut
housing until fully seated.
9. Apply Loctite 242 (blue) to threads of
mounting bracket new screws.
Torque screw s to 8 ft.lbs. (11 Nm).
10. Install A- arm on bal joint cup and
torque castle nut to 25 ft. lbs. (35
Nm ).
11. Reinstall cotter pin with open ends
toward rear of machine.

4.5 STEERING POST ASSEMBLY
Note:
1, Hand tighten the crown nut of the steering post.
2, Align cotter pin hole.
3, Install cotter pin. Bend both ends of cotter pin around nut in opposite directions.
4, Check steering, must move freely and easily from full left to full right without binding.

NOTES

CHAPTER 5 FINAL DRIVE M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 5 FINAL DRIVE

M565Li T3 EFI
WARNING
5.1 W HEEL, HUB, AND SPINDLE TORQUE TABLE

5.2 FRONT HUB DI SASSEMBLY/INSPECTION
5.3 FRONT HUB REMOVAL/INSPECTION 4x4(ATV500)
5.3 b. FRONT HUB INSTALLATION 4X4 (ATV500)
5.4 FRONT HUB BEARING REPLACEMENT 4X4
5.5 FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/
INSPECTION (4X4 )
5.6 FRONT DRIVE AXLE Installation (4X4)
5.7 FRONT DRIVE AXLE Disassembly/ Inspection (4X4)
5.8 FRONT DRIVE AXLE Assembly (4 X4)
5.9 REAR HUB INSPECTION
5.10 REAR GEAR CASE COMPONENT IDENTIFICATION
5.11 REAR GEAR CASE DISASSEMBL
5.12 REAR GEAR CASE ASSEMBLY
5.13 FRONT GEAR CASE DISASSEMBLY
5.14 FRONT GEARCASE DISASSEMBLY
5.15 FRONT GEARCASE ASSEMBLY
CHAPTER 5 FINAL DRIVE M565Li SERVICE MANUAL 2019.0
5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE
Item Specification
Front W heel Nuts 69 Ft.Lbs 96 N.m
Rear Wheel Nuts 69 Ft.Lbs 96 N.m
Front Hub Nut on Spindle/ outer CV joint Refer to FRONT HUB INSTALLATION
Rear Hub Retaining Nut 101Ft.Lbs 137N.m
CAUTION: Locking nuts, and bolts with pre-applied locking agent should be replaced if
removed. The self- locking properties of the nut or bolt are reduced or destroyed during removal.
5.2 FRONT HUB DISASSEMBLY/INSPECTION
1. Elevate front end and safely support

machine under footrest/frame area.
CAUTION
Serious injury may result if machine tips
or falls. Be sure machine is secure
before beginning this service procedure.
Wear eye protection when removing
bearings and seals.
2. Check bearings for side play by grasping
tire/wheel firmly and checking for
movement. It should rotate smoothly
without binding or rough spots.
3. Remove wheel nuts and wheel.
4. Remove brake caliper
5. Remove hub cap, cotter pin, front
spindle nut, and washer.
6. Rotate each bearing by hand and check for
smooth rotation. Visually inspect bearing
for moisture, dirt, or corrosion. Replace
bearing if moisture, dirt, corrosion, or
roughness is evident.
CHAPTER 5 FINAL DRIVE. 5- 2

7. Place a shop towel on hub to protect

surface. Carefully pry seal out of hub. Do
not damage the surface of the seal. Clean
the hub.
8. Drive bearing out through opposite side of
hub and discard.
9. Drive other bearing out and discard.
10. Clean hub and spacer thoroughly.
5.3 FRONT HUB REMOVAL/INSPECTION 4x4
1. Elevate front end and safely support

machine Under footrest/frame area.
CAUTION:
Serious injury may result if machine tips or
falls, Be sure machine is secure before
beginning this service procedure. Wear
eye protection when removing bearings
and seals.
2. Check bearings for side play by grasping
the tire/Wheel firmly and checking for
movement. Grasp The top and bottom of
the tire. The tire should rotate smoothly
without binding or rough spots.
3. Remove wheel nuts and wheel.
4. Remove the two brake caliper attaching
bolts.
CAUTION:
Do not hang the caliper by the brake
Line. Use wire to hang the caliper to
prevent. Possible damage to the brake
line.
5. Remove hub cap, cotter pin, front spindle
nut, and Washer.
6. Rotate each bearing by hand and check
for smooth rotation. Visually inspect
bearing for moisture, dirt, or corrosion, or

roughness is evident.
5.3 b. FRONT HUB INSTALLATION 4X4
1. Inspect the hub strut bearing surface for

wear or damage.
2. Apply grease to drive axle spindle.
3. Install spindle through the backside of the
hub strut. Install the hub onto the spindle.
4. Install spindle nut and tighten to
specification.
5. Install a new cotter pin. Tighten nut slightly
if necessary to align cotter pin holes.
6. Rotate wheel and check for smooth
operation. Bend both ends of cotter pin
around end of Spindle in different
directions.
7. Install hub cap.
8. Rotate hub. It should rotate smoothly
without binding or rough spots or side play.
9. Install brake caliper using new bolts.
Tighten bolts to specified torque.
CAUTION: New bolts have a pre-applied

locking. agent which is destroyed upon
removal. Always use new brake caliper
mounting bolts upon assembly.
10. Install wheel and wheel nuts and tighten
evenly in a cross pattern to specified
torque.
5.4 FRONT HUB BEARING REPLACEMENT 4X4

1. Remove outer snap ring.
2. Form the back side, tap on the outer
bearing race with a drift punch in the relief
as shown.
3. Drive bearing out evenly by tapping on
outer race only. Once bearing is at bottom
of casting, support casting on outer edges
so bearing can be removed.
4. Inspect bearing.
NOTE: Due to extremely close tolerances

and minimal wear, the bearings must be
inspected visually, and by feel. inspect for
rough spots, discoloration, The bearings
should turn smoothly and quietly, no
detectable up and down movement and
minimal movement sideways between inner
and outer race.
5. Inspect bearing housing for scratches,
wear or damage. Replace housing if
damaged.

5.5 FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/
INSPECTION (4X4)
NOTE
The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle
assembly must be replace.
1. Drive axle/ outer CV joint assembly.
2. Boot band “A”.
3. Outer board boot.
4. Boot band “B”.
5. Stopper ring
6. Outer CV joint *
7. Circlip
8. Bearing *
9. stopper ring
10. Inboard boot.
NOTE: Always order and replace 6 and 8 together.
REMOVAL
1. Place the vehicle on level ground and set
the parking brake, Block the rear wheels so
the vehicle will not roll in either direction.
2. Remove the front wheels, steering tie rods,
disconnect the A arm on the ball joint end
as described in this Chapter and Chapter
4.
CAUTION
To avoid damage to the front differential
oil seal, hold the front drive shaft

horizontal and straight out from the front

differential during removal.
3. Hold the drive shaft straight out.
4. Place a tire lever between the inner CV
joint and the differential housing, with a
small piece of wood against the housing to
help get "leverage" and protect the casting.
"pop" the in inner CV joint out from the front
differential.
INSPECTION
NOTE The boots are subjected to a lot of
abuse if the vehicle is ridden in rough
terrain. If the boots are damage and left
un-repaired, the driveshaft joints will fair
prematurely by allowing the joint to be
exposed to dirt, mud and moisture. This
also allow the loss of critical lubrication.
1. Check the rubber boots for wear, cuts or
damage and replace if necessary as
described under the Disassembly /
Assembly procedure in this chapter.
2. Move each end of the drive shaft in a
circular motion (and also a reciprocate for
inner one) and check the drive shaft joints
for excessive wear or play.
3. This inner CV joint (inboard pivot joint) can
be serviced if there is wear or play. The
outer CV joint (outboard pivot joint) cannot
be serviced if worn or damage and if
necessary, the drive shaft assembly must
be replaced.

5.6 FRONT DRIVE AXLE INSTALLATION (4X4)
CAUTION
To avoid damage to the front differential
oil seal and the strut oil seal, hold the
front drive shaft horizontal and straight
into the strut during installation.
1. Hold the drive shaft straight in from the
front differential.
2. Push the drive shaft straight into the front
differential and push it in all the way until it
bottoms out. If necessary, carefully tap on
the outer end of the drive shaft with a
rubber mallet or soft-faced mallet.
3. After the drive shaft is installed, pull the
inner CV joint a little to make sure the
drive shaft stopper ring has locked into the
front differential side gear groove.
4. Carefully install the outer CV joint
(spindle) into the strut，install the front hub
and wheel.
5. Install the ball joint on the A arm, the
steering tie rods, the hubs and the wheels
as described in this Chapter and Chapter
4.
5.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION (4X4)

INNER CV JOINT DISASSEMBLY
NOTE
The outer CV joint cannot be
disassembled or repaired, if damage
or faulty the drive axle assembly must
be replace.
1. Open the clamps on both boot band“A”
and“B”on the inner CV joint, then remove
boot band“B”.Discard the boot band, it
cannot be reused.
2. Carefully slide the boot (A) onto the drive
axle and off the inboard joint.
3. Wipe out all of the molybdenum disulfide
grease within the inboard joint cavity.
4. Remove the stopper ring from the inboard
joint. Remove the stopper ring

5. Remove the inner CV joint.

6. Remove the circlip and slide off the
bearing assembly. Be careful not to drop Inspect groove
any of the steel balls from the bearing
cage.
7. slide the inner CV off the drive axle and
discard the boot band“A”，it cannot be
reused.
8. If the outboard boot requires replacement,
perform the following:
a. Open the clamps on both boot bands
“A”and“B” on the outer CV joint,
then remove boot band“B”.Discard
the boot band, it cannot be reused.
b. Slide the outboard boot off the drive
axle and discard the boot band“A”, it
cannot be reused.
9. Inspect the drive axle as described in this
chapter.
INNER CV JOINT INSPECTION
1. Clean the bearing assembly in solvent
and thoroughly dry.
2. Inspect the steel balls, bearing case and
the bearing race for wear or damage.
3. Check for wear or damage to the inner
splines of the bearing race.
4. If necessary, disassembly the bearing
assembly for further inspection. Carefully
remove the steel balls from the bearing
cage then remove the bearing race from
the bearing cage.
5. If any of the components of the bearing
assembly are damaged, replace the entire
assembly as no replacement parts are
available.
6. Clean the inner CV joint in solvent and
thoroughly dry.
7. Inspect the interior of the inboard joint
where the steel balls ride. Check for wear
or damage and replace the joint if
necessary.
8. Inspect the snap ring groove on the
inboard joint for wear or damage.
9. Inspect the splines on the inner CV joint

for wear or damage. Check the movement of the joint

10. Check the stopper ring in the end of the
inboard joint. Make sure it seats in the
groove correctly, if damage the ring must
be replaced.
11. Inspect the exterior of the inner CV joint
for cracks or damage, replace if
necessary. Check the movement of the
joint for excessive play or noise by moving
the drive axle in a circular and reciprocate
direction.
12. Inspect the drive axle for bending, wear or
damage.
13. Inspect the inner end splines, the outer
end splines and the front hub cotter pin
hole for wear or damage. If any of these
areas are worn or damaged, replace the
drive axle. NOTE. Inner CV joint must be replaced with the
bearing as an assembly.
5.8 FRONT DRIVE AXLE ASSEMBLY (4X4)
1. The rubber boots are not identical and

must be installed on the correct joint. The
boots are marked as follows:
a. Inner CV joint boot : “inner”,
b. Outer CV joint boot: “outer”.
2. IF the outboard boot was removed, install
a new boot onto the drive axle at this time.
NOTE
Position the new boot bands with their
tabs facing toward the rear of the
vehicle.
3. Install 2 new small boot bands onto the
drive axle.
4. Install the inboard boot and move the
small boot band onto the boot. Bend down
the tab on the boot band and secure the
tab with the locking clips and tap them
with a plastic hammer. Make sure they are
locked in place.
5. If the bearing assembly was
disassembled, assemble the bearing as

follows:
a. Position the bearing race and install
the race into the bearing case. Align
the steel ball receptacles in both
parts.
b. Install the steel balls into their
receptacles in the bearing case.
c. Pack the bearing assembly with
molybdenum disulfide grease. This will
help hold the steel balls in place.
6. Position the bearing assembly with the
small end of the bearing going on first and
install the bearing onto the drive axle.
7. Push the bearing assembly on until it
stops, then install the circlip, Make sure
the circlip seats correctly in the drive axle
groove.
8. Apply a liberal amount of molybdenum
disulfide grease to the bearing assembly.
Work the grease in between the balls, the
race and the case. Make sure all voids are
filled with grease.
9. Apply a liberal amount of molybdenum
disulfide grease to the inner surfaces of
the inboard joint.
10. Install the inboard joint over the bearing
assembly and install the stopper ring.
Make sure it is seated correctly in the
inboard joint groove.
11. After the stopper ring is in place, fill the
inboard joint cavity behind the bearing
assembly with additional molybdenum
disulfide grease.
12. Pack each boot with the following
amounts of molybdenum disulfide grease:
a. Inboard boot:35-55grams(1.2-1.9oz.).
b. Outboard
boot:30-50grams(1.1-1.8oz.).
13. Move the inboard boot onto the inner CV
joint.
14. Move the inboard joint on the drive axle.
NOTE
Position the new boot bands with their

tabs facing toward the rear of the

vehicle .
15. Move the small boot band onto the boot.
Bend down the tab on the boot band and
secure the tab with the locking clips and
tap them with a plastic hammer. Make
sure they are locked in place.
16. Install the large boot bands onto each
boot.
CAUTION
It is critical to avoid undue stress on the
rubber boots after the drive axle is
installed and the vehicle is run. Don’t
twist the boot, and always set the both
ends in designed position.
17. Secure all large boot bands. Bend down
the tab on the boot band and secure the
tab with the locking clip and tap them with
a plastic hammer. Make sure they are
locked in place.
18. If removed, install the stopper ring and
make sure it is seated correctly in the
drive axle groove.
19. Apply molybdenum disulfide grease to the
end splines.

5.9 RE AR HUB INSPECTION
1. Remove rear wheel.

2. Remove the cotter pin on the rear wheel driving shaft nut, than remove the nut.
3. Remove the rear disc brake caliper.
4. Remove the link, RR. Stabilizer.
5. Remove the mounting bolt of rear shock absorber and upper and lower A-arm. Takedown the
A-arm components.
6. Remove the mounting bolt of the rear hub, after that inspect bushes, A-arms and collar.
Replace if worn. Discard hardware.

7. Using hub extractor to take down the rear hub.

8. Remove oil seal.
9. Remove the snap spring of the rear hub.
10. Using bearing extractor to take down the hub bearing.
Notice: when reassembling hub bearing that were removed and rear hub, which are need
replaced. (The method is in accordance with removing steering knuckle.)

5.10 REAR GEAR CASE COMPONENT IDENTIFICATION
REAR GEARCASE EXPLODED VIEW
1 NUT M12×1.25 24 DRIVE BEVEL GEAR ASSEMBLY

2 WASHER 12.5×30×4 25 ADJUST SHIM60.5x50.3
3 COUPLER, REAR AXLE 26 BEARING 6010
4 BOLT M8×30 27 O-RING 151×3
5 BEVEL GEAR BEARING HOUSING 28 REAR GEAR BEARING HOUSING
6 OIL SEAL Φ35×Φ61×9 29 OIL SEAL 30x50x13.5
7 ADJUST SHIM 30 BOLT M8×25
8 O-RING 69×3 31 BOLT M10x25
9 BEARING 6305 32 NUT M8
10 BEARING RETAINERM64x1.5x10 33 HE× SCREW M8×45
11 ACTIVE BEVEL GEAR ASSEMBLY 34 WASHER 8
12 NEEDLE BEARING 35 REAR AXLE ASSEMBLY
13 VENT NOZZLE
14 CLAMPS
15 VENT PIPE
16 BOLT M18x1.25
17 WASHER 18
18 OIL SEAL30x60x15
19 WASHER
20 HEXAGON HEAD BOLT
21 REAR GEAR CASE
22 BEARING 6008
23 ADJUST SHIM48x40.3

5.11 REAR GEAR CASE

Important: Before staring any operation
On the gearbox， make sure that never clean
the gearbox with a high pressure water jet.
1. Remove the oil drain plug A and let the oil

drain from the gearbox.
Important: Clean the plug carefully.
Replace the sealing washer B before it’s
assembled. →Fig 1
Fig 1
2. Remove the nut M12×1.25 C，the washer

12.5×30×4 D and the coupler of the rear
axle E. Fig 2
→Fig 2 3. Remove the four bolts M8×35 F ，the drive
bevel gear assembly G and the adjust shim
H. →Fig 3

Fig 4
5. Remove the six bolts M8×25 Q and the two
bolts M10×1.25×25 R.
Remove the ring gear bearing housing T from
the rear gear case S.
→Fig 5
Fig 3
4. Remove the bevel gear-driving Ⅰ，the adjust
shim J and the O-ring K.
Remove the bearing retainer L with the
special tool.
Remove the bearing M and the oil seal P
from the bevel gear bearing housing N.
→Fig 4
Fig 5
6. Remove the oil seal 65×90×9 U from the rear

gear case S.
Remove the needle bearing V from the rear
gear case S.
→Fig 6

Fig 6
7. Remove the adjust shim W from the bevel
gear comp.-driven X.
Remove the bevel gear comp.-driven X from
the ring gear bearing housing T.
Remove the adjust shim Y from the bevel
gear comp.-driven X.
→Fig 7
Fig 8
5.12 REAR GEAR CASE ASSEMBLY

Important: Before staring any operation
on the gearbox，to ensure that the surface of
all parts is clean.
1. Mount the bearing A in the ring gear bearing

housing C.
Mount the O-ring B into the groove of the
ring gear bearing housing C.
→Fig 1
Fig 7
8. Remove the O-ring Z，the oil seal 65×90×9 a
and the bearing b from the ring gear bearing
housing T.
→Fig 8

3. Mount the needle bearing H and the

needle bearing Ⅰ into the suited hole of
the rear gear case G.
→Fig 3
Fig 1
2. Mount the adjust shim D in the shaft neck of
the bevel gear comp.-driven E.
Mount the bevel gear comp.-driven E in the
bore of bearing A.
Mount the adjust shim F in the other neck of
the bevel gear comp.-driven E.
→Fig 2
Fig 3
4. Apply some Loctite 510 silicone sealant on

the screw thread. Mount the drain plug
M14×1.25×12 L with the washer M, tight
securely (35~40N.m).
→Fig 4
Fig 2

Fig 4
5. Apply some Loctite 510 silicone sealant on Fig 6
the shaft neck of pipe joint N for the 7. Tighten the six bolts M8×25 Q to a torque of
installation. 20~25N.m.
Mount the pipe joint N on the suited hole of Tighten the two bolts M10×1.25×25 P to a
the rear gear case G. torque of 35~40N.m.
→Fig 5 Tighten the HE× screw T，the gasket| S and
the nut M8 R to a torque of 20~25N.m .
→Fig 7
Fig 5
6. Mount the shaft neck of the bevel gear

comp.-driven E in the suited hole of the
needle bearing H.
Make the ring gear bearing housing C and
the rear gear case G together
→Fig 6

Fig 7 Mount the bevel gear-driving V into the hole

8. Mount the axle sleeve U of the inner & outer of the bearing W.
race in the neck of the bevel gear-driving V. →Fig 10
→Fig 8
Fig 10
11. Mount the adjust shim d in the shaft neck of
Fig 8 the bevel gear bearing housing Z.
9. Mount the bearing W into the suited hole of Make the rear gear case G and the bevel
the bevel gear bearing housing Z. gear bearing housing Z together.
Mount the bearing retainer X in the bevel →Fig 11
gear bearing housing Z with the special
tool，tight securely (90~100N.m).
Mount the O-ring a into the groove of the
ring gear bearing housing Z.
Mount the oil seal Y into the suited hole of the
bevel gear bearing housing Z.
→Fig 9
Fig 11
12. Apply some Loctite 242 threadlocker on
screw thread.
Tighten the four bolts M8×35 e to a torque of
20~25N.m.
→Fig 12
Fig 9
10. Mount the adjust shim b in the shaft neck of
the bevel gear-driving V. Fig 12

Fig 13
13. Mount the coupler of the rear axle f with 14. Mount the oil seal 65×90×9 j in the ring
the bevel gear-driving V. gear bearing housing C on the right.
Mount the washer 12.5×30×4 g. →Fig 14
Apply some Loctite 242 threadlocker on
screw thread.
Tighten the nut M12×1.25 h to a torque of
50~60N.m.
→Fig 13
Fig 14
15. Mount the oil seal k in the ring gear bearing

housing G on the left.
Make the O-ring m on the fill plug n .
Tighten the fill plug n to a torque of
35~40N.m.
→Fig 15
Fig 15

5.13 FRONT GEAR CASE DISASSEMBLY

FRONT GEARCASE EXPLODED VIEW

1 Screw 27 Bearing Retainer

2 Gear Motor 28 Bevel Gear -Driving
3 O-Ring φ81.2×1.9 29 Oil Seal
4 Bolt 30 Coupler
5 Screw 31 O-Ring
6 Pin Shaft 32 Nut Washer
7 Shift Fork 33 Nut
8 Drive Clutch 34 Bearing 61912
9 O-Ring φ141×2.4 35 Drive Gear
10 Adjust Shim(83×71) 36 Bolt
11 Adjust Shim(61×48) 37 Bracket,Differential
12 Oil Seal 38 Shim
13 Bearing 16007 39 Washer
14 Retainer 62 40 Top Bracket,Differential Gear
15 Drive Clutch Cover 41 Bearing 6007
16 Case Cover, Front Axle 42 Wearing Ring
17 Drain Bolt 43 Gear Shaft(Center), Differential
18 Washer 10 44 Gear(Center), Differential
19 O-Ring φ30.5×3 45 Driven Gear
20 Fill Plug 46 Pin
21 Gear Case, Front Axle 47 Bevel Gear -Driven
22 Breather Pipe
23 Clip
24 Hose Fitting
25 Needle Bearing
26 Bearing 6007

5.14 FRONT GEARCASE DISASSEMBLY 2. Remove the COUPLER A.

Important: Before staring any operation →Fig 2.
On the gearbox make sure GEAR MOTOR A is
protected (if mounted). Never clean the gearbox
with a high pressure water jet.
→Fig 0.
Fig 2
3. Remove the O-RING A .
→Fig 3.
Fig 0
1. Remove the DRAIN BOLT A and let the oil
drain from the gearbox.
Important: Clean the plug carefully and
Replace WASHER 10 B before
Its assembled. →Fig 1.
Fig 3
Fig 1

4. Remove the COUPLER A. 6. Remove the four SCREW A.

→Fig 4. →Fig 6.
Fig 6
Fig 4 7. Remove the GEAR MOTOR A.
5. Remove the OIL SEAL A. →Fig 7.
→Fig 5.
Fig 5 Fig 7

8. Remove the six bolts H（M8 L28）. 11. Remove ADJUST SHIM A
→Fig 8. →Fig 11.
Fig 8
9. Remove the GEAR CASE ASSY, FRONT Fig 11
AXLE A and CASE COVER ASSY, 12. Remove the SCREW A.
FRONT AXLE B . →Fig 12.
→Fig 9.
Fig 9
10. Remove the DIFFERENTIAL GEAR ASSY
A. Fig 12
→Fig 10 13. Remove the PIN SHAFT A, SHIFT FORK B.
→Fig 13.
Fig 10 Fig 13

14．Remove the DRIVE CLUTCH A. 16．Remove the DRIVE CLUTCH COVER A.

→Fig 14. →Fig 16.
Fig 16
Fig 14 17．Remove the ADJUST SHIM A.
15．Remove the RETAINER 62 B . →Fig 17..
→Fig 15.
Fig 17
18．Remove the OIL SEAL A.
→Fig 18.
Fig 15 Fig 18

19．Remove the BEARING RETAINER A with 21. Remove the BEARING 61912 A .
tool B. →Fig 21.
→Fig 19.
Fig 21
22. Remove the six BOLTS A.
→Fig 22.
Fig 19
20. Remove the DRIVE PINION GEAR A.

→Fig 20.
Fig 22
Fig 20

23. Remove the PIN A. 25. Remove the DRIVEN GEAR A and washer
→Fig 23. B and SHIM C and ADJUST SHIM D and
DIFFERENTIAL GEAR E.
→Fig 25.
Fig 25
Fig 23
24. Remove the DRIVE GEAR A
and WEARING RING B
and GEAR(CENTER), DIFFERENTIAL C
and GEAR SHAFT(CENTER),
DIFFERENTIAL D
and PIN E
and BRACKET,DIFFERENTIAL F.
→Fig 24.
Fig 24

2. Put driven gear A and washer B and shim C

5.15 FRONT GEARCASE ASSEMBLY
and adjust shim D and differential gear E as
shown.
1. Mount the the drive gear A and wearing ring →Fig 2.
B and gear(center), differential C and gear
shaft(center), differential D and pin E and
bracket,differential F,then mount pin T
→Fig 1
Fig 2
3. Mount the differential gear assy, then apply
Loctite 263 evenly on the screw thread.Tighten
the six bolts A with the spring lock washer and
the washer to a torque of 90~100Nm.
→Fig 3
Fig 3
Fig 1 4. Mount the drive clutch cover A.

→Fig 4 6. Mount the drive clutch A.

→Fig 6.
Fig 4
5. Mount the retainer 62 A .
→Fig 5. Fig 6
7.Mount the pin shaft A and the shift fork B .
→Fig 7.
Fig 7
Fig 5

8.Mount the screw A .

→Fig 8.
Fig 8
9. Mount the adjust shim A.
→Fig 9.
Fig 9
10. Mount the differential gear assy A to the

gear case assy C ,do not forget put adjust
shim I to the case cover assy B, then make Fig 10
B and C together
→Fig 10

11. Mount the six bolts to a torque of 20~25Nm 13. Mount the four screws A .
→Fig 11. →Fig 13.
Fig 11 Fig 13
12. Mount the gear motor A. 14. Mount the oil seal A.
Important: Before assemble the gear motor, →Fig 14.
make sure that the shift fork S is in their correct
position as shown.
→Fig 12.
Fig 14
15. Mount the coupler A .

→Fig 15
Fig 12 Fig 15

16. Mount the O-ring A.

→Fig 16.
Fig 16
17. Apply some Loctite 263 thread locker on Fig 18
screw thread, mount the nut A, tighten it to a
torque of 50~60Nm.
→Fig 17.
Fig 17
18. Mount the oil seal A and oil seal B,
mount the drain bolt X and washer 10
Y ,tighten it to a torque of 35~40Nm.
→Fig 18

CHAPTER 5 FINAL DRIVE LH500ATV-D SERVICE MANUAL 14.0
NOTES

CHAPTER 6 BRAKES M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 6 BRAKES
NOTE
Also See Chapter 2 for Maintenance Information.
6.1 SPECIFICATIONS
6.2 TORQUE
6.3 BRAKE SYSTEM SERVICE NOTES
6.4 BURNISHING PROCEDURE
6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE
6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION
6.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION
6.8 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT
6.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION
6.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION
6.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION
6.12 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT
CHAPTER 6 BRAKES PAGE. 6- 1

6.1 SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit
Brake Pad Friction material
0.157"/ 4mm 0.04"/ 1mm
Thickness
0.150- 0.164"/3.810- 4.166m
B rake Disc Thickness 0.140"/3 .556m m
m
Brake Disc Thickness Variance
- 0.002 "/ .051m m
Between Measurements
Brake Disc Runout - 0.005 "/ .12 7m m
Rear Brake Caliper
Item Standard Service Limit
Brake Pad hydraulic 0.157"/ 4mm
Friction Hydraulic with
0.236"/ 6mm 0.04"/ 1mm
material mechanics park
Thickness mechanics park 0.197"/ 5mm
Brake Disc Thickness 0.177-0.187"/4.496-4.750m m 0.167"/4.242mm
Brake Disc Thickness
Variance - 0.002 "/ 0.051m m
Between Measurements
Brake Disc Run out - 0.005 "/ 0.12 7m m
6.2 TORQUE
Torque Torque
Item
(ft. lbs. except where noted*) (Nm )
Front Caliper Mounting Bolts 18.0 25
Rear Caliper Mounting Bolts 18 .0 25
Master Cylinder Mounting Bolts *55 in. lbs 6.0
Master Cylinder Reservoir Cover Bolts *5 in. lbs .6
Hand Brake Hose Banjo Bolt 15 .0 21
Front Brake Disc 18 .0 25
Front Wheel Mounting Nuts 20 .0 27
6.3 BRAKE SYSTEM SERVICE NOTES

It is strongly recommended always change the caliper and (or) the master cylinder as an
assembly. The parts inside maybe not interchangeable due to different brake manufactures
and (or) different brake type.
Do not over – fill the master cylinder fluid reservoir.
Make sure the brake lever and pedal returns freely and completely.

Check and adjust master cylinder reservoir fluid level after pad service.
Make sure atmospheric vent on reservoir is unobstructed.
Adjust foot brake after pad service.
Test for brake drag after any brake system service and investigate cause if brake drag is
evident.
Make sure caliper moves freely on guide pins (where applicable) .
Inspect caliper piston seals for foreign material that could prevent caliper pistons from
returning freely.
Perform a brake burnishing procedure after install new pads to maximize service life.
6.4 BURNISHING PROCEDURE

Brake pads (both hydraulic and mechanical) must be burnished to achieve full braking
effectiveness. Braking distance will be extended until brake pads are properly burnished. To
properly burnish the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate the ATV to 50 km/h (30 mph ) and to brake
to a stop.
2. Using hi gear, accelerate to 50 km/h (30 mph); then compress brake lever (pedal) to
decelerate to 0-8km/h (5 mph).
3. Repeat procedure on each brake system 20 times until brake pads are burnished.
(4. Adjust the mechanical parking brake (if necessary).)
5. Verify that the brake light illuminates when the hand lever is compressed or the brake pedal is
depressed.
WARNING
Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
Brake loss can result in severe injury.

6.5 FLUID REPLACEMENT/BLEEDING PROCEDURE

NOTE : When bleeding the brakes or
replacing the fluid always start with the caliper
farthest from the master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid is highly corrosive. Do not spill
brake fluid on any surface of the ATV.
BRAKE BLEEDING-FLUID CHANGE
This procedure should be used to change fluid

or bleed brakes during regular maintenance.
1. Clean reservoir cover thoroughly.
2. Remove screws, cover and diaphragm
from reservoir.
3. Inspect vent slots in cover and remove any
debris or blockage.
4. If changing fluid, remove old fluid from
reservoir with a brake fluid pump or
similar tool.
NOTE: Do not remove brake lever when
reservoir fluid level is low.
5. Add brake fluid up to the indicated MAX
level on the reservoir.
6. Begin bleeding procedure with the caliper
that is farthest from the m aster cylinder.
Install a box end wrench on the caliper
bleeder screw. Attach a clean, clear hose
to the fitting and place the other end in a
clean container. Be sure the hose fits
tightly on the fitting.
NOTE: Fluid may be forced from supply port
when brake lever is pumped. Place
diaphragm in reservoir to prevent spills. Do
not install cover.
DOT 3 Brake Fluid
Reservoir Cover Torque

5 in. lbs. (.6 Nm )
7. Slowly pump brake lever (D) until
pressure builds and holds.
8. While maintaining lever pressure, open
bleeder screw. Close bleeder screw and
release brake lever.
NOTE: Do not release lever before bleeder
screw is tight or air m ay be draw n into
caliper.
NOTE: In some versions of brake, there are 2
hydraulic circulates in one caliper for foot
brake and hand brake. Make sure you bleed
the right circulate.
9. Repeat procedure until clean fluid
appears in bleeder hose and al air has
been purged. Add fluid as necessary to
maintain level in reservoir.
CAUTION:
Maintain at least 1/2 " (13mm of brake fluid in
the reservoir to prevent air from entering the
master cylinder.
10. Tighten bleeder screw securely and
remove bleeder hose.
11. Repeat procedure steps 5- 9 for the
remaining caliper (s).
12. Add brake fluid to MAX level on reservoir.
Master Cylinder Fluid Level:
MAX level or
Sight glass must look dark, if sight glass
is clear, fluid level is too low.
13. Install diaphragm, cover and screws.
Tighten screws to specification.
14. Field test machine at low speed before
putting into service. Check for proper
braking action and lever reserve. With
lever firmly applied, lever reserve should
be no less than 1/2 " (13mm ) from
handlebar.
15. Check brake system for fluid leaks and
inspect al hoses and lines for wear or
abrasion. Replace hose if w ear or
abrasion is found.
6.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION
/INSTALLATION
CAUTION: The master cylinder is a non-serviceable Component; it must be replaced as an
assembly.
NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts
and special instruction.
REMOVAL
1. Clean master cylinder and reservoir
assembly. Make sure you have a clean work
area to disassemble brake components.
2. Place a shop towel under brake hose
connection at m aster cylinder. Loosen bolt,
remove bolt and sealing washers.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
3. Remove master cylinder from handlebars.
INSPECTION
Inspect parking brake for wear. If teeth or
locking cam are worn, replace lever and test
the parking performance, if any locking
problem exists, Replace the master cylinder
as an assembly. NOTE: Mechanics parking
brake is equipped for new Europe model.
INSTALLATION
1. Install master cylinder on handlebars.
Torque mounting bolts to 55 in. lbs. (6 N m).
NOTE: To speed up the brake bleeding
procedure the m aster cylinder can be
purged of air before brake hose is attached.
Fill with DOT3 brake fluid and pump lever
slowly two to three times with finger over the
outlet end to purge master cylinder of air.
2. Place new sealing washers on each side
of hand brake hose and torque bolt to
specification.

Master Cylinder Mounting

Bolt Torque 55 in. lbs . (6 N m)
Brake Line Banjo Bolt Torque
15 ft. lbs. (21 Nm )
3. Fill reservoir with DOT 3 fluid.
4. Follow bleeding procedure, Check all
connections for leaks and repair if necessary.
6.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set.
REMOVAL
1. Elevate and support front of ATV safely.
CAUT ION: Use care w hen supporting vehicle

so that it does not tip or fall. Severe injury m ay
occur if machine tips or falls.
2. Remove the front wheel.
3. Remove caliper from mounting bracket.
4. Push caliper piston into caliper bore slowly
using a C-clamp or locking pliers with pads
installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into
caliper. Remove excess fluid from reservoir as
required.
5. Push mounting bracket inward and slip
outer brake pad past edge. Remove inner pad.
6. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
INSPECTION
Measure the thickness of the pad friction
material. Replace pads if worn beyond the
service limit.
Service Limit 0.3/64"(1 mm)

INSTALLATION
1. Lubricate mounting bracket pins with a light
film of All Season Grease, and install rubber
dust boots.
2. Compress mounting bracket and make sure
dust boots are fully seated. Install pads with
friction material facing each other. Be sure
pads and disc are free of dirt or grease.
Front Caliper Mounting Bolts Torque 18 ft. lbs.
(25 Nm )
3. Install caliper on hub strut, and torque
mounting bolts.
4. Slowly pump the brake lever until pressure
has been built up. Maintain at least 1/2 ". (13
mm) of brake fluid in the reservoir to prevent
air from entering the brake system.
5. Install the adjuster screw and turn clockwise
until stationary pad contacts disc, then back off
1/2 turn (counter clockwise).
6. Install reservoir cap.
Hand and (or) Foot Brake Master
Cylinder(s) Fluid Level:
Between MIN and MAX lines
7. Install wheels and torque wheel nuts, test
and burnish.
See BURNISHING PROCEDURE
6.8 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different
points around the pad contact surface using a
0-1" micrometer and a dial indicator. Replace
disc if worn beyond service limit.
New0.150-0.164"(3.810-4.166mm)
Service Lim it 0.140"/3 .556 mm
Service Limit 0.002 " (0.051mm)
difference between measurements
Brake Disc Runout
Service Limit 0.005" (0.127 mm)

REMOVAL/ REPLACEMENT
1. Removal caliper and hub. Apply heat to the
hub in the area of the brake disc mounting
bolts to soften the bolt locking agent.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install new disc on hub.
5. and tighten to specified.
CAUTION: Always use new brake disc
mounting bolts.
Front Brake Disc Mounting Bolt Torque :
18 ft. lbs. (25 Nm )
6.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION

CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly.
REMOVAL
1. Remove wheel, remove caliper from the
strut.
2. Loosen and remove brake hose(s) to
caliper. Place a container under caliper to
catch fluid draining.
INSPECTION
Inspect caliper body for nicks, scratches or
worn. Replace caliper as an assembly if any
problem exists.
INSTALLATION
1. Install caliper on hub strut, Apply Loctite™
242 to screw threads and Install new bolts.
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm )
2. Install brake hose and tighten securely.
hydraulic circulates (for foot brake and hand
brake) in one caliper. Make sure you install
the right hose.
3. Bleeding and Install wheels, If new brake
pads are installed, burnishing procedure
should be performed. See BURNISHING

PROCEDURE, And field test unit for proper

braking action before putting into service.
Inspect for fluid leaks and firm brakes. Make
sure the brake is not dragging when lever is
released. If the brake drags, recheck
assembly and installation.
6.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set.
REMOVAL and INSPECTION

1. Remove caliper mounting bolts and lift
caliper off of disc.
NOTE. When removing caliper, be careful not
to damage brake hose . Support caliper so as
not to kink or bend brake hose.
2. Push caliper pistons into caliper bore slowly
with pads installed.
NOTE: Brake fluid will be forced through
compensating port into m aster cylinder fluid
reservoir when piston is pushed back into
caliper. Remove excess fluid from reservoir as
required.
3. Remove brake pad retaining pin, and pad
spacer.
NOTE: Do not over spread this spring pin a-
part farther than necessary to remove it.
4. Clean.
5. Measure the thickness of the pad friction
material. Replace pads if worn beyond the
service limit.
Rear Brake Pad Service Limit 0.3/64"(1 mm)
INSTALLATION
1. Install new pads in caliper body. Be sure to
put spacer between pads.
2. Install caliper and torque mounting bolts.
Brake Caliper Torque: 18 ft. lbs. (25 Nm )
3. Slowly pump the brake lever until pressure
has been built up. Maintain at least 1/2 " (13
mm) of brake fluid in the reservoir to prevent
air from entering the master cylinder.

Hand and (or) Foot Brake Master

Cylinder(s) Fluid Level:
Between MIN and MAX lines
4. Install wheels, burnishing procedure should
be performed. See BURNISHING
PROCEDURE, And field test unit for proper
braking action before putting into service.
Inspect for fluid leaks and firm brakes. Make
sure the brake is not dragging when lever is
released. If the brake drags, recheck
assembly and installation.
6.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION

CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly.
1．Clean caliper area.
2．Using a flare nut wrench, remove hose(s).
Place a container to catch brake fluid draining
from brake hose.
3. Remove caliper.
4. Remove brake pad as described above.
5. Inspect surface of caliper for nicks,
scratches or damage and replace if necessary.
6. Install brake pads in caliper body with
friction material facing each other, with the
spacer between the pads. Install retaining pin
through outer pad, pad spacer and inner pad.
7. Install caliper and torque mounting bolts.
Caliper Mounting Bolt/ Caliper body Bolt
Torque:
18 ft. lbs. (25 Nm)
8. Install brake hose and tighten to specified
torque.
Banjo Bolt Torque: 15 ft. lbs. (21 Nm)
hydraulic circulates (for foot brake and hand
brake) in one caliper. Make sure you install the
right hose.
9. Bleed.
10. Field test unit for proper braking action
before putting into service. Inspect for fluid
leaks and firm brakes. Make sure the brake is
not dragging when lever is released. If the

brake drags, recheck assembly and

installation.
6.12 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION
1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different
points around the pad contact surface using a
0-1" micrometer and a dial indicator. Replace
disc if worn beyond service limit.
New0.177-0.187"(4.496-4.750mm)
Service Lim it 0.167"(4.242 mm)
Service Limit 0.002 " (0.051mm)
difference between measurements
Brake Disc Runout
Service Lim it 0.005" (0.127 mm)
REMOVAL/ REPLACEMENT
1. Removal wheel/ hub and caliper.
2. Remove bolts and disc from the flange.
3. Clean mating surface of disc and hub.
4. Install new disc on flange.
5. Tighten to specified.
CAUTION: Always use new brake disc
mounting bolts.
Rear Brake Disc Mounting Bolt Torque :
18 ft. lbs. (25 Nm )

6.13 FOOT BRAKE PEDAL FOR B-TYPE

ADJUSTING
If the push rod joint is reinstalled, adjust the
push rod length so that the distance between
the centers of the master cylinder lower
mounting bolt hole and joint pin hole is
80±1mm.After adjustment, tighten the joint
nut.

NOTES

CHAPTER 7 ELECTRICAL M565Li T3 EFI SERVICE MANUAL 20.0
CHAPTER 7 ELECTRICAL
7.1 PARTS INSPECTION AND SERVICE
7.2 BATTERY
7.3 IGNITION SYSTEM
7.4 CHARGING SYSTEM
7.5 ELECTRICS STARTING SYSTEM
7.6 COOLING SYSTEM
7.7 LIGHTING SYSTEM
7.8 GEAR SHIFT SWITCH TEST
7.9 SPEEDOMETER SYSTEM
7.10 MAIN SWITCH AND HANDLE SWITCH
7.11 FUEL GAUGE/ FUEL LEVEL SENSOR
7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
7.13 WIRING DIAGRAM
CHAPTER 7 ELECTRICAL PAGE.7- 1

7.1 PARTS INSPECTION AND SERVICE

HEADLIGHT LAMP REPLACEMENT
1. . ‘Use bulb 12V 35W/35W.
2. Pull the cable plug off the conducting
strip in the socket, remove the clip①
before
dismounting the bulb.
3. Fit a new bulb into the socket, sitting
properly in the three slots, install the
clip as shown in the fig. and connect
the cable plug to the conducting
strip.
4. Change the bulb.
HEADLIGHT ADJUSTMENT
1. The headlight beam can be adjusted vertically (all models) and horizontally (except the light on
handlebar).
2. Place the vehicle on a level surface with the headlight approximately 25’(7.6m) from a wall.
3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at
the same height.
4. Start the engine and turn the headlight switch to high beam.
5. Observe headlight aim. The most intense part of the headlight beam should be aimed 2’ (51mm)
below the mark placed on the wall in step 2. NOTE : Riding weight must be included on the
seat.
6. Loosen but not remove pivot bolt/ screw and adjust beam to desired position.
7. Tighten nut and bolt / screw.

7.2 BATTERY
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with
skin, eyes or clothing Antidote:
External: Flush with water.
lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always shield eyes when working near batteries.
KEER OUT OF REACH OF CHILDREN
WARNING: The gases given off by a battery are explosive. Any spark or open flame near a battery
can cause an explosion which will spray battery acid on anyone close to it. If battery acid gets on
anyone, wash the affected area with large quantities of cool water and seek immediate medical
attention.
To ensure maximum service life and performance from a new battery, perform the following steps.
NOTE: Do not service the battery unless it will be put into regular service within 30 days. After initial
service, add only distilled water to the battery. Never add electrolyte after a battery has been in
service.
NOTE: New Battery must be fully charged before use.
1. Remove vent plug from vent fitting.
2. Fill battery with electrolyte to upper level marks on case.
3. Set battery aside and allow it to cool and stabilize for 30 minutes.
4. Add electrolyte to bring level back to upper level mark on case.
NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point,
add only distilled water.
5. Charge battery at 1 /10 of its amp /hour rating. Examples: 1 /10 of 14 amp battery = 1.4 amp;
1/10 of 7 amp battery = 0.7 amp (recommended charging rates).
6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or
higher.
BATTERY INSPECTION / REMOVAL

The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid
nears the lower level, the battery should be removed and distilled water should be added to the
upper level line. To remove the battery:
1. Disconnect holder strap and remove cover.
2. Disconnect battery negative (-) (black) cable
first,
followed by the positive (+) (red) cable.
CAUTION
Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and
reinstall the negative cable last!
3. Disconnect the vent hose.
4. Remove the battery.

5. Remove the filler caps and add distilled water only as needed to bring each cell to the proper
level.
Do not overfill the battery.
To refill use only distilled water. Tap water contains minerals which are harmful to a battery.
Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the
battery.
5. Reinstall the battery caps.
BATTERY INSTALLATION
1. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a
solution of one cup water and one tablespoon baking soda. Rinse with clean water and dry
thoroughly.
2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (- ) (black) cable.
3. Install clear battery vent tube from vehicle to battery vent.
WARNING:Vent tube must be free from obstructions and kinks and securely installed. If not, battery
gases could accumulate and cause an explosion. Vent should be routed away from frame and body
to prevent contact with electrolyte. Avoid frame, corrosion will occur.
4. Route cables so they are tucked away in front and behind battery.
5. Reinstall battery cover and holder strap.
Do not start the engine with the battery disconnected. Vehicle lamps will burn out if battery is
disconnected during vehicle operation. Also, the reverse speed limiter can be damaged.
BATTERY TESTING
Whenever a service complaint is related to either the starting or charging systems, the battery
should be checked first.
Following are three tests which can easily be made on a battery to determine its condition: OCV
Test, Specific Gravity Test and Load Test.
MF (Maintenance Free) battery does not require the Specific Gravity Test and Refill
Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require
further battery testing and charging.
NOTE: Lead acid batteries should be kept at or near a full charge as possible.
Load test
CAUTION: Remove spark plug high tension leads and connect securely to engine ground before
proceeding.
NOTE: This test can only be performed on machines with electric starters. This test cannot be
performed with an engine or starting system that is not working properly.
A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still
may not have the storage capacity necessary to properly function in the electrical system. For this
reason, a battery capacity or load test should be conducted whenever poor battery performance is
encountered. To perform this test, hook a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and
view the registered battery voltage while cranking the engine. Continue the test for 15 seconds.
During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning
voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the
battery.

7.3 IGNITION SYSTEM
IGNITION SYSTEM TROUBLESHOOTING

No Spark, Weak or Intermittent Spark
 Spark plug gap incorrect
 Fouled spark plug
 Faulty spark plug cap or poor connection to high tension lead
 Related wiring loose, disconnected, shorted, or corroded
Engine stop switch or ignition switch faulty
 Terminal board or connections wet, corroded
 Poor ignition coil ground (e.g. coil mount loose or corroded)
 Faulty stator (measure resistance of all ignition related windings)
Incorrect wiring (inspect color coding in connectors etc. )
 Faulty ignition coil winding (measure resistance of primary and secondary)
 Worn magneto (RH) end crankshaft bearings
 Sheared flywheel key
 Flywheel loose or damaged
 Trigger coil air gap too wide (where applicable) should be 0.030-0 .050" (0. 75-1.25 mm)
 Excessive crankshaft run out on magneto (RH) end should not exceed 0.005"
(0.13mm)
 Faulty ECU module
CIRCUIT DIAGRAM

IF THE IGNITION SYSTEM FAILS TO OPERATE
Procedure
Check:
1. Fuse (Main) 7.Pickup coil resistance
2. Battery 8.Main switch
3. Spark plug 9.Engine stop switch
4. lgnition spark gap 10.Wiring connection
5. Spark plug cap resistance (entire ignition system)
6. Ignition coil
1.Fuse NO CONTINUITY
Check switches
Replace the fuse.
CONTINUITY
2. Battery INCORRECT
 Check the battery condition.  Clean battery terminals.
Refer to "BATTERY  Recharge or replace the battery.
INSPECTION"
CORRECT Standard spark plug: DPR7EA 9 /
NGK
3.Spark plug
OUT OF SPECIFICATION
 Check the spark plug
condition.
 Check the spark plug
type. Repair or replace the spark plug
 Check the spark plug gap.
Spark plug gap: 0.6 ～

0.7mm

4.lgnition spark gap

 Disconnect the spark plug cap from the
spark plug
Connect the ignition tester 1 as shown.
2 Spark plug
Turn the main switch to "ON".
Check the ignition spark gap .
Check the spark by pushing the
MEETS SPECIFICATION
starter switch, and increase the spark
gap until a misfire occurs.
The ignition system is not faulty.
Minimum spark gap:
6mm (0.24 in)
OUT OF
SPECIFICATION Tester (+) lead →
OR Spark plug side
NO SPARK Tester (—) lead→
5.Spark plug cap resistance High tension cord side 
Remover the spark plug cap.
Connect the pocket tester (ΩX1 k) to
the spark plug cap.
NOTE:
 When removing the spark plug cap.
do not pull the spark plug cap from
high tension cord.
Remove→Turning
counterclockwise
Connect→Turning clockwise.
Check the high tension cord
when connecting the spark
plug cap.
 When connecting the spark plug cap,
cut the high tension cord about 5mm.
Spark plug cap
resistance:
Replace the spark plug cap
10KΩ(20 ℃)
CORRECT

* Tester (+) lead

B/Y Terminal
Tester ( -) lead Green
6. Ignition coil resistance Terminal
Disconnect the ignition coil
connector from the wire
harness.
Connect the pocket tester
(1) to the ignition coil.
 Check if the primary coil
has the specified resistance.
Primary coil resistance:

3.6-4.8Ω (20 ℃)
Tester (+) lead
Spark plug lead
Tester (— ) lead
Green Terminal

(Ω×1k ) to the ignition coil.
Check the secondary has the
specified resistance
Secondary coil resistance: OUT OF SPECIFICATION
3.5kΩ±10％ (20℃)
BOTH MEET
SPECIFICATION
Replace the ignition coil.
*

7. Pickup coil resistance

 Disconnect the pickup coil coupler
from the wire harness.
Connect the pocket tester (Ω 100) to
the pickup coil coupler.
Tester (+) lead →

BI/Y Terminal 
Tester (- ) lead→
B/R Terminal 
 Check the pickup coil has the
specified resistance.
Replace the pickup coil.
Primary coil resistance:

115 -145Ω (20℃)
MEETS
SPECIFICATION
NO CONTINUITY
8.Main switch
CHECK SWITCHES
Replace the main switch
CONTINIUTY
NO CONTINUITY
9.Engine stop switch ( for USA

model)
Replace the handlebar switch.
CONTINIUTY
10.Wiring connection
Check the connection of the POOR CONNECTIONS
entire ignition system
Refer to “CIRCUIT DIAGRAM”.
Correct
CORRECT
Replace the igniter unit.

CHAPTER 8 ELECTRICAL M550 SERVICE MANUAL 16.0
7.4 CHARGING SYSTEM
CHARGING SYSTEM CIRCUIT DIAGRAM
CURRENT DRAW - KEY OFF
CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running.
Damage will occur to light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable. Check for current draw with the key off,
if the draw is excessive, loads should be disconnected from the system one by one until the draw is
eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate
the draw.
Current draw key off:

Maximum of 0.01DCA(10mA)

CHARGING SYSTEM
Procedure
Check:
1. Fuse (Main) 4.Stator coil resistance
2. Battery 5.Wiring system (entire charging system)
3.Charging voltage
1. fuse NO CONTINUITY
Replace the fuse

2. Battery
Check the battery condition. INCORRECT

Refer to "BATTERY INSPECTION"
Clean battery terminals

Recharge or replace the battery
3.Charging voltage
Connect the engine tachometer
to the spark plug lead.
(DC20V) to the battery
Test (+) lead→
Battery (+) terminal 
Tester (-) lead→
Battery (-) terminal 
Measure the battery terminal
voltage.
start the engine and accelerate to
about 5,000rpm
check the terminal voltage
Measured voltage-terminal MEETS SPECITICATION
Voltage:
0.2-2.5V up
NOTE: Use a fully changed battery.
The charging circuit is not faulty

Replace the battery
OUT OF SPECICATION

4. Starter coil resistance
Remove the A.C. magneto coupler from
wire harness
Connect the pocket tester (ΩX1) to
the stator coil
Tester (+) lead –yellow terminal
Tester (-) lead –yellow terminal OUT OF SPECITICATION
Measure the stator coil resistance
Stator coil resistance 0.5-0.8Ω（20 ℃
）
Replace the stator coil
MEETS SPECIFICATION
5.Wiring connection
check the entire charging system for
connections
Refer to “CIRCUIT DIAGRAM” POOR CONNECTION
correct
CORRECT
Replace the rectifier/regulator

7.5 ELECTRICS STARTING SYSTEM

DI AG R AM

TROUBLESHOOTING
THE STARTER MOTOR OPERATES WHEN GEAR SHIFT SWITCH IS IN NEUTRAL OR THE
FRONT/REAR SWITCH IS ON
IF THE STARTER MOTOR FAILS TO OPERATE
Procedure
Check:
1. Fuse (Main) 7. gear shift switch
2. Battery 8. front/rear brake switch
3. starter motor 9. starter switch
4. starter relay 10. wiring connection (entire starting system)
5. aux relay
6. main switch
1. fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section
Replace the fuse
2. Battery
Refer to "BATTERY INSPECTION" section
in CHAPTER 3

3. Starter motor DOES NOT MOVE

Connect the battery positive terminal
and starter motor cable using a jumper
lead.
Check the starter motor operation
Repair or replace the starter

motor

WARNING
4.Starter relay
A wire used as a jumper lead
Disconnect the relay unit coupler from must have the equivalent
the wire harness. capacity as that of the battery
Connect the pocket tester (Ωx1) and lead or more, otherwise it
battery (12V) to the relay unit coupler may burn.
terminals. This check is likely to
Battery (+) lead→ produce sparks, so be sure
Green/Yellow terminal  that no flammable gas or fluid
Battery (-) lead→ is in the vicinity
Yellow/Red terminal 
Check the starter relay for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal
CONTINUITY
Replace the starter replay
5. .Aux relay
Disconnect the aux relay coupler from
the wire harness.
Connect the pocket tester (Ωx1) and
battery (12V) to the aux relay coupler
terminals.
Battery (+) lead→ terminal 
Battery (-) lead→ terminal 
Check the aux relay for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal
Replace the aux relay

6. Main switch
CHECK SWITCHES NO CONTINUITY

7.Gear shift switch
CHECK SWITCHES
NO CONTINUITY
Replace the handlebar switch
8 Front /rear brake switch

NO CONTINUITY
CHECKING SWITCHES
Replace the brake switch
9. Starter switch
NO CONTINUITY
CHECKING SWITCHES
Replace the handlebar switch
10. Wiring connection

POOR CONNECTION
Check the connections of the entire
starting system.
Refer to “CIRCUIT DIAGRAM
Correct

7.6 COOLING SYSTEM
IF THE FAN MOTOR FAILS TO TURN

Procedure
Check:
1. Fuse (Main, Fan)
2. Battery 4. Fan motor (inspection)
3. Main switch 5. Thermo switch
6. relay
7. Wiring connection (entire cooling system)

1. fuse
Replace the fuse

2. Battery
Refer to "BATTERY INSPECTION" section

3 Main switch
4.1 Fan motor(inspection 1)

Connect the battery to the fan motor.
Battery (+) lead→Green/Blue terminal DOES NOT MOVE

Battery (-) lead→Green ground 
Check the fan motor operation
Replace fan motor
1.2 Fan motor (inspection 2)

Turn the main switch to off.
Remove the thermo switch lead from DOES NOT MOVE
thermo switch.
Connect jumper lead to thermo switch
leads.
Turn the main switch to on
The wiring circuit from battery to

fan motor is faulty. Repair

5. Thermo switch
Remove the thermo switch from the
radiator.
Connect the pocket tester (ΩX1) to the
thermo switch.
Immerse the thermo switch in the
water 
Check the thermo switch for continuity.
NOTE:
Measure temperatures while heating the
coolant with the temperature gauge
WARNING
Handle the thermo switch with special
care.
Never subject it to strong shocks or
allow it to be dropped. Should it be
dropped, it must be replaced.
Do not touch the thermo switch to the
bottom of the heated vessel.
88±3 ℃
Thermo switch “ON”
80 ℃Thermo switch “OFF”
Replace the thermo switch
6.Relay
Disconnect the starting circuit cut-off
relay coupler from the wireharness.
Connect the pocket tester (Ωx1) and
battery (12V) to the starting circuit cut-off
relay coupler terminals.
Battery (+) lead→ terminal 
Battery (-) lead→ terminal 
Check the starting circuit cut-off relay
for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal

7. Wring connection UPPER CONNECTION

Check the connection of the entire
cooling system.
Refer to “CIRCUIT DIAGRAM”
Correct
IF THE HEAT ALARM UNIT WORKING

When the main switch is turned on, the temperature of the engine begins to go up. As it
comes to 88±3℃ the therm osta t is connected a nd the fa n sta rts to work, cooling the coola nt, if
the thermostat or the fan, fails to work; the coolant temperature will keep rising. The heat alarm
unit operates the moment the temperature reaches 115±5 ℃a n
engine now to have the circuit fixed.
Procedure
Check:
1 .Fuse(Main, Fan) 4. Thermo unit
2. Battery 5. Voltage
3.Main switch 6. Wiring connection (entire cooling system)
1. fuse
CHECKING SWITCHES NO CONTINUITY
Replace the fuse

2. Battery
Refer to "BATTERY INSPECTION"

3.Main switch
CHECKING SWITCHES NO CONTINUITY

Handle the thermo unit with

4.Thermo unit
special care.
Drain the coolant and remove the
Never subject it to strong
thermo unit from the cylinder head.
shocks or allow it to be
Immerse the thermo unit in the
coolant . dropped.
Should it be dropped, it must be
Thermometer.
replaced.
Do not touch the thermo unit to
the bottom of the heated vessel.
Coolant Resistance
temperature
47.5~56.8Ω
80 ℃
100 26.2~29.3Ω
Replace the thermo unit
MEETS SPECIFICATION
8. Voltage
Connect the pocket tester (DC20V) to
the
Temperature gauge couple.
Tester (+) lead→Green/Blue terminal
Tester (-) lead→Green ground
Turn the main switch to on. OUT OF SPECIFICATION
Check for voltage (12V) on the
temperature gauge lead.
The wiring circuit from main

switch to temperature gauge
is faulty. Repair.
8. Wiring connection check the POOR CONNECTION

connections of the entire cooling
system.
Refer to “CIRCUIT DIAGRAM”
CORRECT
Replace the temperature gauge

7.7 LIGHTING SYSTEM

TROUBLESHOOTING
Procedure
Check:
1. Fuse (Main) 4.Lights switch
2. Battery 5.Dimmer switch
3. Main switch 6. Wiring connection (entire lighting system)
1.fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section
Replace the fuse

2. Battery
Refer to “BATTERY INSPECTION” section
in CHAPTER 3

3. Main switch
NO CONTINUITY
CHECK SWITCHES
4. Light switch
NO CONTINUITY
CHECK SWITCHES
Replace the right handlebar

switch
5. Dimmer sw
NO CONTINUITY
CHECK SWITCHES
Replace the left handlebar

switch

POOR CONNECTIONS
6. Wiring connection
Check the connection of the entire
lighting system
correct
7. check the condition of each of the

lighting system’s circuits
Refer to “LIGHTING SYSTEM CHECK”
LIGHT SYSTEM CHECK

1. If the headlight and the high beam indicator light fail to come on
1.Blub and bulb socket NO CONTINUITY
CHECK SWITCHES
Replace the bulb and/ or bulb

socket
2. Voltage
Connect the pocket tester (DC20V) to
the headlight and high beam indicator
light couplers.
A When the dimmer switch is on low

beam.
B When dimmer switch is on high
beam
Headlight::
Tester (+) lead →White or Blue lead
Tester negative (-) lead →Green lead
Turn the main switch to on.

Turn the light switch to on position.
Turn the dimmer switch to low beam or
high beam.
Check for voltage (12V) on the lead at
bulb socket connectors OUT OF SPECIFICATION
The wiring circuit from the main

switch to
This circuit is not faulty bulb socket connector is faulty.
Repair

2. the taillight fails to come on
1. Bulb and bulb socket NO CONTINUITY
CHECK SWITCHES
Replace the bulb and /or bulb

socket
CONTINUITY
2. Voltage
Connect the pocket tester (DC20V) to
the bulb
socket connector.
Tester (+) lead→
Black terminal 
Tester (-) lead→
Green terminal 
Turn the main switch to on. OUT OF SPECIFICATION
Turn the lights switch to on pilot position.
Check the voltage (12V) on the bulb
socket connector
The wiring circuit from main

switch to
bulb connector of faulty.
Repair
This circuit is not faulty

7.8 GEAR SHIFT SWITCH TEST

DI AG R AM

Switch table

7.9 SPEEDMETER SYSTEM
OPERATION OF SPPED SENSOR

Speed Sensor is on the engine
Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter
and Speed Sensor
A. Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by
means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear
rack.
B. Main Technical Parameter for sensor：
Item Code Vol value Unit
Operating voltage Vcc 5-20 V
Operating current Icc ≤15 mA
Operating distance D 1mm ≤ D ≤ 2.5mm mm
C. The following is the graphic illustration for sensor installation, Wire 1 (red) is positive and wire 2
(black) negative, Wire 3 (yellow) works as the one to output signals.
The following is the graphic illustration for sensor installation。

METER
Dial Meter
Item Vol value Unit

Operating voltage 10V~18V V
Operating current ≤ 500mA A
Operating Environmental temperature -10 ℃~ 65℃℃
Battery warning voltage ≤11.5V V
LCD Meter For M565 T3 EFI
1. Neutral indicator light 11. 4WD and front difflock indicator

2. High beam indicator light 12. Fuel gauge Indicator
3. Turn indicator light 13. EFI Malfunction indicator
4. Reverse indicator light 14. Mileage
5. Speedometer 15. Parking Indicator
6. Coolant temperature meter 16. Oil alarm indicator
7. Engine rpm meter 17. Present time
8.Low speed indicator 18.EPS indicator
9.High speed indicator
10.Position indicator

7.10 MAIN SWITCH AND HANDLE SWITCH
HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL

7.11 FUEL GAUGE/ FUEL LEVEL SENSOR
1. Remove the fuel level sensor

from the fuel tank.
2. Measure the resistance with
an ohmmeter across the sensor
terminal and its body.
3. If the reference values are not
indicated, the sensor is faulty
Resistance Reference Float at

(Sensor value upper-most 6-12Ω
terminal – position A
its body) Float at
lower-most 114-119
position B Ω
A: Float at upper most position B: Float at lower most position

7.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
(Fig 1)
1, The rider shifts 2WD to 4WD by the Switch on handlebar.

2. When shift 2WD/ 4WD or Diff Lock, the mechanics in the front gear box maybe still engaged/
disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or
rides in reverse.
3. Always shift as the vehicle stop.

7.13 WIRING DIAGR

CHAPTER 7 ELECTRICAL CTRICAL PAGE 8- 34

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2020 ATV

SERVICE MANUAL 20.0

M565Li T3 EFI 维修手册英文 版本 20.0 零件代号 F010106A27

CHAPTER1 ………………………………………………General Information↖

CHAPTER3……………………………………. …. ………………500 Engine↖

CHAPTER 1 GENERAL INFORMATION

1.1 IMPORTANT INFORMATION

1.2 V.I.N AND ENG INE SERIAL NUMB ER

1.3 VEHICLE DIMENSIONS

CHAPTER 1 GENERAL PAGE. 1- 1

1.1 IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

GASKETS,OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER PINS

Replace all lock washers/plates and cotter pins

BEARINGS AND OIL SEALS

CHAPTER 1 GENERAL PAGE. 1- 2

7. Check for continuity with a tester.

CHAPTER 1 GENERAL PAGE. 1- 3

How to use the CONVERSION TABLE

CHAPTER 1 GENERAL PAGE. 1- 4

CHAPTER 1 GENERAL PAGE. 1- 5

1.3 VEHICLE DIMENSIONS

CHAPTER 1 GENERAL PAGE. 1- 6

CHAPTER 1 GENERAL PAGE. 1- 7

CHAPTER 1 GENERAL PAGE. 1- 8

2.1 PERIODIC MAI NTENANCE

2.2 FUEL SYSTEM

2.3 TOE ALIGNMENT

2.4 BRAKING SYSTEM INSPECTION

2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT

2.7 TIRE PRESSURE

2.8 FRAME, NUTS, BOLTS, FASTENERS

CHAPTER 2 MAINTENANCE PAGE. 2- 1

2.1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Inspect, clean, lubricate, adjust or replace parts as necessary.

CHAPTER 2 MAINTENANCE PAGE. 2- 2

Item Hours When Remarks

Coolant strength 25 hrs 3 months I Inspect strength seasonally

▲ Air Box Sediment Tube / Daily D

Headlamp Inspection / Daily C

Battery fluid level 10 Monthly I

DL Brake pad wear 2 Weekly I

▲ Gear case Oil 10 Monthly C

CHAPTER 2 MAINTENANCE PAGE. 2- 3

Engine Oil Change 30 hrs 3 months R

▲ Engine breather hose 100 hrs 6 months I

Throttle Cable / Pre-ride I

DL Throttle Cable 50 hrs 6 months A L (Grease M) R if necessary

Shift linkage 50 hrs 6 months I A R if necessary

DL Transmission belt 50 hrs 6 months I

▲ Rear Axle ( and Bearings) 50 hrs 6 months I L

▲ Front Suspension 50 hrs 6 months I L

Radiator 100 hrs 12 months I R

Cooling System hoses 50 hrs 6 months I

DL Valve clearance 100 hrs 12 months I A

CHAPTER 2 MAINTENANCE PAGE. 2- 4

Brake fluid 200 hrs 24 months Change every two years

M565Li T3 EFI 维修手册英文版本 20.0 零件代号 F010106A27