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GO-KART (XYKD260) Repair Manual: Downloaded From Manuals Search Engine
GO-KART (XYKD260) Repair Manual: Downloaded From Manuals Search Engine
ENGINE
Type…………………………………………………………………….……………..Water cooling, four stroke
Engine capacity……………………………………………………………………….260cc
Bore *Stroke………………………………………………………………………….70mm*66.8mm
Displacement………………………………………………………………………….257cm³
Corrected compression ratio…………………………………………………………9:1
Max output power…………………………………………………………………..11kw/7000rpm
Max Torque…………………………………………………………………………..17Nm/5000N.m/r/min
Starting………………………………………………………………………………..Electric Start
Ignition………………………………………………………………………………..C.D.I
Lubrication…………………………..………………………………………………..pressure splash
Transmission…………………………..………………………………………………. Automatic C.V.T System
Spark plug…………………………..……………………………………………….DPR5EA-9(NGK)
Plug gap…………………………..……………………………………………….0.6-0.8mm
Fuel type…………………………..……………………………………………….RQ90 (leadless)
Lubricate oil…………………………..……………………………………………….SAE15W-40/SF
Capacities
Maximum load…………………………..……………………………………………….Two seats/200Kg
Fuel tank…………………………..……………………………………………………...9.5L
Engine oil…………………………..……………………………………………………..1180mL
Starting Time…………………………..……………………………………………………..<10s
Climbing…………………………..……………………………………………………..20º-25°
Battery…………………………..……………………………………………………..12V 14Ah
Head Light…………………………..……………………………………………………..12V 35W
Tail Light…………………………..……………………………………………………..12V 21W/5W
Fuse…………………………..……………………………………………………..10A
Brake Track…………………………..……………………………………………………..7m at 30KM/h
Top speed…………………………..…………………………………..75KM/h (Or as customer requirement)
CHASSIS
Front/Rear brake ………………………………Hydraulic disc brake/ Left leg control
Front tire ……………………………………………… AT21X8-10
Rear tire ………………………………………………AT22X11-10
Front Suspension ………………………………………… Independent dual-A arm
Rear Suspension …………………………………Independent swing arm/ Double hydraulic shock
1、Engine
2、Vehicle Body
The parts, described [not limited] as following, should be added lubricating oil.
Connection part
between Steering gear
parts and handle ball
Rear wheel rim axle
Brake pedal
Accelerator pedal
Accelerator cable Front wheel axle
Front lower swing arm
Parking brake cable
Pipe of
cooling liquid
kettle
Water tubing
Temperature
Control
Switch
Brake cable
Electric parts
case
rectifier
Ignition coil
BATTERY
Throttle cable
Quadric air-intake
mechanism
Troubleshooting
Can not or difficult to start
Description Adjustment Reasons
● Valve is damaged
Start according right method
● Mixing air time not good
● 化油器过满溢出
●Too many oil in carburetor
火花塞是干的
Dry 火花塞湿
Wet
●EEV of carburetor not work
●
Let engine work ● Battery connection badness
at high speed
● Air filter jammed
● Carburetor jammed
Check Ignition
time [Ignition led]
10
●
Check oil quantity
level and quality
● Too many oil
OK No ● Oil is not enough
● Oil is not replaced
●
Ignition Time OK?
Vent screw of
carburetor OK?
Air leakage in
carburetor gasket?
● Carburetor is loosed
No Yes
● Airproof parts not good
● Air leakage in vacuum parts
Sparks OK?
12
◆
Engine works unusually [High speed]
Description Routine Reasons
●
Ignition time OK?
●
Engine works at high
speed or easy to stop?
reverse gear OK reverse position wrong ●Length of reverse cable is not suitable
14 ●Differential damaged
No power in battery
Description Adjustment Reasons
●
Start engine and check
voltage of battery
Resistance value
of coil
● Stator not good
● connection-peg not
No Yes good
● cable is broken
● Connection of coupling parts not good
Oil System I I I
Carburetion System I I I
Carburetor I I I I
Spark plug I R I
Gap of valve I I I I
Battery I I I
Brake system I I I I
17
Clutch I
Suspend parts I I I
Support parts I I I
Wheel/spoke Trimester I I I
Idle of carburetor I I I I
The vehicle should carry on the periodic maintenance according to the stipulation time.
Before the maintenance the vehicle should be cleaned thoroughly.
Definition of Letters:
I: to check, clean, adjust lubricate or change apart.
C:cleaning
R:use a new part
A:make an adjustment
L:Lubricating
Note: When the odometer reading surpasses the maximum features listed in the table,
the maintenance should be done repeatedly according to the table.
Brake System
Adjustment
Check pedal free travel:
20~30 mm
If it is beyond of this distance, please take down/up
adjustment screw.
20~30mm
When air enters the brake cylinder piston or the brake oil pipe, resulting in
brake failure, it is necessary to discharge the air in the brake in the following
manner: first step on the brake pedal with foot, loosen the exhaust screw Adjustment Bolt
of the brake cylinder, open the brake cylinder oil cup, screw up the exhaust
screw until there is no brake liquid and air outflowing, release the accelerator
pedal and repeat the procedures until there is no air out-flowing.
Vent bolt
18
Standard information:
(off-road) (Road)
Front AT21X8-10 28kPa 200kPa
Rear AT22X11-10 35kPa 225kPa
Cushion System
19 Front/rear axe screws
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Leakage or Damage of Vibration Damper
Steps on with foot to the vehicle forehead, compress several times, inspect
its movement, and whether or not any oil leak, damage, loose or unusual sound;
Steps on with foot to the vehicle back position, compress several times, inspect its
its movement, and whether or not any oil leak, damage, loose or unusual sound
Transmission System
Transmission case leakage and capacity
Driving/Driven Wheel
Take off left cover Driven wheel
Check driving/driven condition
Driving wheel
Electronic System
Ignition System
Check gap, whether
Station of Spark Plug any dirt and Carbon
Take off spark plug
Check sparks plug and clean dirt,
carbon with special cleaner or
steel wire brush.
Checks gasket Chechecks any broken
Ignition Timing
Important! Because of CDI system function, there is
no necessary to adjust ignition time. If any problem,
please check ignition system.
Take off ignition screw Ignition Screw
Check ignition LED to confirm ignition time:
When idle speed is 1500±100rpm,it matches “F” well.
Engine
Engine Body
Filter Core
Lubricating System
22
Max Position
Min Position
If lubricating oil is dirty, please change it.
Attention!
Check
Pourair-proof gasket
in lubricating oil.and change it if any broken.
Full capacity:0.8 Liter,Type:85W-140
Start engine to make sure no leakage problem
Stop engine and check oil quantity.
23
If footplate is not working fluently, please add lubricating oil from the Oiling
hole
Screw
Cooling System
Water Level
Guarantee the vehicle is in the horizontal position.
Inspect kettle liquid surface whether between upper limit and lower limit. On the kettle has two across, above is the
upper limit, and under is the lower limit. If the radiator liquid is insufficient, must pour the kettle liquid to upper limit.
The coolant liquid should fit the engine.
kettle
Water Leakage
3 Oil System
Maintenance Information
Troubleshooting
Can not start engine No power and engine stops when accelerate max
﹒No fuel in oil tank ﹒septum of vacuum piston is destroyed
﹒No oil flow into ﹒Pressure entrance is jammed
﹒Too much oil in cylinder ﹒Oil switch is not working
25
Disassembly of Carburetor
Plug of electricity enrichment valve
Throttle cable
Take down Oil drain bolt and drain oil out from Carburetor
26
Disassembly
Take down screws of support pats and take down support part. Connecter E.E.V.
Take down electricity enrichment valve.
E.E.V. Pin
Inspection of Valve
Check any damage on electricity enrichment valve and pin
of EEV. If any, please use a new EEV.
Installation
Do installation in oppositive turn in disassembly.
E.E.V.
Attention!
Press EEV at bottom and fix its channel outside with support part.
27
Inspection
Take off cut air valve from Pressure line and vent line
Connect pressure line and vacuum pump
Connect vent line and vacuum pump
Add air by vacuum pump:
Minus pressure value:400~600mmHg
Replacement
Take down two screws and take off cut air valve
Take off “O” gasket
Use a new “O” gasket and fix valve on carburetor Bolt
with screws
Cut air valve
“O” gasket
Disassembly
Take down two screws and take off vacuum room cover
28
Screw
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Take off spring and vacuum plunger.
Important!
Support vacuum plunger till fix all screw of cover.
Floater Room
Bolt Floater Room
Bolt
Inspection of Pin Valve
Pin valve
Check station of valve socket
29
Attention!
Extractive oil should be fresh one.
Install pin ejector, pin ejector socket, main ejector, sub ejector and vent screws.
Attention!
Please install vent screws according to zip number noted down when
disassembly.
.Idle adjustment
Oil Tank
Disassembly
Oil tank
30
Take oil line and pressure line part from oil switch.
Oil Line Oil switch
Take off oil tank
Oil Switch
Pressured line
Important! NO SPARK!
1 Stops the engine, dismantles the oil line from the carburetor and check whether the oil stream to leave. After oil
switch and line is clean, there should be no oil leakage. Otherwise you should clean pressure line.
2 Dismantles the pressure line from the carburetor. With pressure oil leakage and without pressure no oil leakage,
then the switch is normal.
4 Cooling System
Replacement of cooling liquid in Radiator
Radiator Lid
Important! Before take off radiator lid
please make sure that cooling liquid is31
NOT HOT.
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Take off radiator lid .
Connect Out-water line and fix it tightly
In pouring cooling liquid till it is full.
Out-water line
Carries on pumping air according to the following main point:
1 starts the vehicle, carries on high speed on the smooth road, at least 200 meters.
2 stops and checks foam whether vanishes, as well as liquid surface water level is
whether steady,
3 do the vehicle the system closure, pours into the radiator liquid, until
the radiator this note population border is Stops.
4 fix radiator lid
5 checks enough water in sluice bottle.
Sluice bottle
Function Inspection Radiator Inspector
Radiator Lid
Put lid on is inspector and it is good that keep on SIX seconds under standard pressure.
NOICE!
Before checking please put some water on lid
airproof surface.
Standard pressure of Radiator lid valve:
73.5-103Kpa
Radiator Inspection
Connect Inspector and radiator, add air and it is good that keep on SIX seconds under standard
pressure.
Standard pressure:73.5-103 Kpa
5 Engine
Disassembly Rear Wheel Screw
Lift back vehicle with Left and Right support parts, and make sure rear
Wheel takes off;
Take down screws and take off rear wheel; Support Part
Rear Brake
Take down rear bone [left and right], break connection between rear bone
and engine
Rear Bone
33
Water Line
Bumper
34
Muffle Screw
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Take down screws between engine and rear suspend part
Front Suspend
ATTENTION!
The engine is heavy, so multi-people coordination is import to disassemble,
in order to avoid offends somebody or the damage engine.
Suspend Part under Engine
Muffle Screw
Installation
Installation is in oppositive turn and please makes sure that screws are fixed according to standard
strength.
35
36
37
Take down two screws and take off front brake pump assembly.
Take down the cotter pin locked screws of the steering assembly.
Important! It is connected by wimble, please pay Screws
attention to bone when knock the
assembly.
Take down the locked screws and take apart front vibration
Damper.
Take down two screws between support parts and vehicle body.
Take down two screws between down support part and vehicle body.
Take apart down support part and front bone assembly. Down Support Part
Take down screws between up-down support part and front bone.
38
Front Bone
Take down screws between steering assembly and gimbal. Steering assembly
Gimbal
Take apart steering assembly.
Screw Bolt
39
Installation
Screw
Do it as opposite procedure compared with DISASSEMBLY.
Screw
7 Seat System
Disassembly
40
Man Handle
Bolt
41
Slide Rail
Screw
To support behind the entire vehicle, and make the trailing wheel to take off.
Dismantles 4 front wheels fixing g screws. (Left side Wheel )
Take down the cotter pin of the front wheel hub locking screws.
Front wheel screw
43
Dismantle two setting screws and take down rear brake pump.
Take down rear bone, rear wheel rim and brake disc assembly.
Take down rear bone off rear wheel rim
Important!
IT IS CONNECTED WITH AXLTREE;
YOU SHOULD USE PROFESIONAL TOOL.
Rear Wheel Rim
44
Screw
Disassembly setting screws and take off rear support part. Screw
Left is same with Right.
Installation
Do it as opposite procedure compared with DISASSEMBLY
45
Repair Information
IMPORTANT!
.Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the
connection, you must pay attention to the color of the line cables. The coupling must meet on the
same coupling.
.The test condition may usually lead to differences between observed data and standard features.
Battery
.Do periodic inspection electrolyte the capacity, make sure line is between the scale division line, if
lower than the scale division, please supplement the distilled water.
.When charging the battery, you must dismantle the battery from the vehicle, but do not take off the
liquid lid.
.Expect for in emergency cases, do not carry on the rapid charge rate to the storage battery.
46
Troubleshooting
.Battery line cable connection falls off Electric current not steady-going on
Charge system
Leakage examination
Put ignition switch to OFF, and take out positive or cathode electrode line of battery. Take out your
digital multitester and put switch to “mA” position, connect battery line and battery to examine its
leakage flow value. If value is bigger than 15mA that means that the entire vehicle has the leakage
problem, you should promptly arrange looks up.
10 Ignition System
Maintenance Information Troubleshooting Features of Igniter
Maintenance Information
IMPORTANT!
Because of CDI ignition system, you can not make an adjustment at the ignition time. If something
occurs during the ignition exceptionally, you should inspect the connect line, the CDI part, the trigger,
protruding parts of the flying wheel whether some of them has the distortion or the damage. If any you
must carry on the replacement.
.Maintains of Igniter。
.Various cables must carry on the connection by the same color one. The different color line cable
must be same with one kind of color. The colored throat is closed to the connect part. When doing the
connection, you must pay attention to the color of the line cables. The coupling must meet on the same
coupling.
.The test condition may usually lead to differences between observed data and standard features.
Features of Igniter
Item Standard Value
Original coil 0.1-0.2Ω
Resistance value of
With spark plug 7.3-11KΩ
Ignition coil(20℃) Sub-coil
Without spark plug 3.6-4.6KΩ
Resistance value of pulse trigger winding coil(20℃) 50-170Ω
Resistance value of magneto stator(20℃) 50-350Ω
Troubleshooting
49