Cectec KINGCOBRA User manual

KINGCOBRA / ESTOC
SERVICE MANUAL V1.3

TOPIC
POWER TRAIN
ENGINE
CHASSIS
SUSPENSION / TRANSMISSION
ELECTRICAL
SPECIAL TOOLS
MAINTENANCE
Ⅰ
Ⅱ
Ⅲ
Ⅳ
Ⅴ
Ⅵ
Ⅶ

POWER TRAIN
Ⅰ
Engine Specification…………………
Engine Lubrication System…………
Engine Breather System…………….
CVT System……………………………
Start System…………………………...
Injection System………………………
Emission Control System…………..
Cylinder Head / Block………………..
EMS System…………………………..
P1
P2
P3
P4
P5
P6
P7
P8
P9

Engine Specification
Ⅰ
Type：4 Stroke / Single Cylinder / SOHC / 4 Valves
Displacement：497cc
Bore x Stroke：ø90mm x 78mm
Compression Ratio：10.0
Max. rev.：7500rpm
Transmission：CVT / V-belt
Emission：2002 / 51 / EC
Weight：67kg
Ⅰ-1

Engine Lubrication System
Ⅰ
Oil Sump
Oil Peak-up
Oil Pump
Oil Filter
Gear Box
Pressure S/W
Balancer
Balancer
Crankshaft
Con-Rod Cylinder
Piston、Liner
Crankshaft
Camshaft
Release Valve
Left Side Right Side
Lubrication：Wet Sump
Oil Pump：Rotor Type
Oil Filter：Paper Type
Oil Type：10w / 40
Oil Volume：3.0L / 3.5L (Replace Filter)
Pressure Release：4.5 kg/cm
Pressure S/W：0,2 kg/cm
Oil Inlet：
Oil Return：
Ⅰ-2
2
2

Engine Breather System
Ⅰ
Engine Oil
Exhaust SideIntake Side
Air Box
Air Filter
Breather Hose
Piston
Con- Rod
Crankshaft
Blow-by Gas
Ⅰ-3

CVT System
Ⅰ
CVT Belt
Drive Wheel Driven Wheel
CVT Belt Type：DAYCO 5324
Drive Wheel Tightening Torque：40~45Nm
Driven Wheel Tightening Torque：120Nm
Ratio：0.316(min)~1.581(max)
Engine Speed Limit：7500rpm
Ⅰ-4

Starter Output：0.7KW
Operation Voltage：12V
Temperature Range：-10 ~ +120 ℃
Starter Circuit Diagram：
Start System
Ⅰ
Rewind Starter Handler
Starter
Spin Nose
Ring Gear
Starter
GND
Battery
GND
GND
Key S/W
Relay
Starter S/W
-+
Ⅰ-5

Injection System
Ⅰ
Injector Cylinder Head
Intake Valve
Throttle Body ASM
Idle Air Control Valve
(IACV)
Intake Air
Intake Port
Fuel Injection
Fuel Injection Control
Air Flow Temperature
IACV or TPS Air Temp
MAP Coolant Temp
RPM …..etc
ECU
To Calculate Air Flow And Necessary Fuel Flow
Injector
Ⅰ-6

Emission Control System
Ⅰ
Catalyst
Throttle Body ASM
Injector
Ignition Coil ASM
O2 Sensor
Emission Relational Part：
ECU / Throttle Body ASM / Spark Plug / Ignition
Coil ASM / O2 Sensor / Catalyst
Catalyst：100 cells/in2
Catalyst Volume：116cc
Emission：Updated 2002 / 51 / EC
Ⅰ-7

Cylinder Head / Block
Ⅰ
Intake Valve
Exhaust Valve
Spark Plug
Cast-in Liner
Spark Plug
Cylinder Head ASM：Aluminum Alloy < AC4B+T6 >
SOHC / Chain Drive / 4 Valves
Spark Plug Type：Champion PRG7C
Cylinder Block ASM：Liner Material < FC250 >
Aluminum Alloy < ADC12 >
Ⅰ-8

EMS System
Ⅰ
Block Diagram
Ⅰ-9

EMS System
Ⅰ
Pin Assignment
Ⅰ-10

ECU
Ⅰ
ECU Type:
MC21 1030 ECU Pin 28: -
Map Sensor
Connector
ECU
Connector
Ⅰ-11

ECU
Ⅰ
Part Introduction
ECU Type：MC21 1030
Assembly：
Electrical Characteristic
Operation Voltage Range：9~16V
Storage Temperature Range：-40~+70℃
Operation Current：＜500mA
Ⅰ-12

Identification Code:
28140652
ECU Pin 28: -
MPR: +
Injector
Ⅰ
Part Introduction
Identification Code：28140652
Injector Holes：4ea
Circuit Diagram：
Measurement Resistance：12.0 ± 0.6Ω
ECU Injector
Pin 28
MPR
Main Power Relay
-
+
Ⅰ-13

Throttle Body ASM
Ⅰ
Throttle Body Throttle Position Sensor
(TPS)
Idle Air Control Valve
< IACV > (Step Motor)
Ⅰ-14

Step Motor
Pin 33
Pin 24
Pin 34
Pin 25
Throttle Body –TPS、Step Motor
Ⅰ
TPS
ECU Pin6 : 5V
GND
ECU Pin 21
ECU
5V
GND
Pin 24
Pin 25
Pin 34
Pin 33
Pin 21
Pin 6
Part Introduction
TPS Circuit Diagram：
Step Motor Circuit Diagram：
Measurement TPS Resistance：
1~2Ω( ECU Pin21 + GND )
ECU
Ⅰ-15

Part Introduction
Sensor Voltage：12V
Sensor Pitch Angle：65°±10°
Sensor Roll Angle：-20°~+20°
Sensor Temperature：-10~+60℃
Circuit Diagram：
Assembly
Bolt：M4 Bolt x 2
Tighten Torque：1.5~2.5Nm
Measurement Resistance：3.9Ω( Vcc + Output )
Vcc
GND
Output
Top ViewLeft View
Rollover (Fuel-Cut) Sensor
Ⅰ
Rollover
Sensor ECU
Pin11
Vcc：12V
GND
OUTPUT
+
-
Ⅰ-16

Part Introduction
Pump Characteristic Voltage：12V
Feed Fuel Pressure：250 ± 10Kpa
Feed Fuel Rate：30.6 L/hr (min)
Circuit Diagram：
Measurement Resistance： 4~ 10Ω( Full Stop )
93~100Ω( Empty Stop )
Fuel Pump
Ⅰ
Fuel Level
Fuel Filter
Fuel Connector
Sensor -
Pump +
Pump -
Fuel
Pump ECU Pin1
12V
GND
meter
Relay
GND
END S/W
Pump +
Pump -
Sensor +
Sensor -
Sensor +
Meter Pin24
Ⅰ-17