cectek Gladiator User manual

GLADIATOR
&
QUADRIFT
SERVICE MANUAL

Ⅰ- Power-train & Control System
Introduction……………………………P1
Ⅱ- 500cc EFI Engine Service Manual…P20
Ⅲ- GLADIATOR & QUADRIFT
Chassis Service Manual…………….P80
Ⅳ- Special Tools………………………….P141
TOPIC

Engine Specification …….…….....……….………
Engine Lubrication System …….………………..
Engine Breather System …………………………
CVT System ………………………..……………….
Start System ………………………..………………
Injection System ……………………………...……
Emission Control System ………………………..
Cylinder Head/Block ………………………………
EMS System ………………………………………..
Electricity wiring Circuit ……….……..………….
▲Power-train & Control
System Introduction
P2
P3
P4
P5
P6
P7
P8
P9
P10
P19

DISMANTLE
CVT Cover Dismantle ………..…..………..………
CVT Belt Dismantle ………………..…………..…..
CVT Driven Pulley Dismantle ……..……………...
CVT Driving Pulley Dismantle …..………………..
Rewind Starter Dismantle ……..……………..…...
Timing Check ……………………..………………...
Accessory Cover Dismantle.……………………..
Start Pressure Release Mechanism Dismantle..
Alternator Rotor Dismantle …………………....…
Cam Shaft Dismantle ……………………..……....
Chain Dismantle ……………………………..…….
Cylinder Head Dismantle ………………………...
Balancer Dismantle ……………………………..…
The Oil Pump Dismantle ……….…………………
The Driveshaft Dismantle ………………………..
The Oil Main Circuit Dismantle ………………….
The Cylinder Block Dismantle …………………..
The Transmission Gear Dismantle ……………..
The Oil Release Valve Dismantle …………….…
The Crankshaft Dismantle ……………………….
The Piston Dismantle ……………………………..
▲500cc EFI Engine
Service Manual
P21
P22
P22
P23
P23
P24
P26
P27
P28
P29
P31
P32
P33
P34
P35
P37
P38
P40
P42
P43
P44

▲500cc EFI Engine
Service Manual
ASSEMBLY
The Piston And Connection Rod Assembly ..…
The Balancer Assembly ..……………………....…
The Balancer Assembly ………………….……….
The Main Shaft Assembly ……………………...…
The Lay Shaft Assembly ……………………….…
The Rear Driveshaft Assembly ………………..…
The Cylinder Head Assembly ………………....…
The Water Pump Assembly …………………..….
The Shift Drum And Fork Assembly ………....…
The Transmission Gear Assembly ………..….…
The Gear Idle Gear Assembly ………………...…
The Crankcase And Cylinder Block Assembly..
The Bearing And Crankshaft Assembly ….….…
P45
P47
P48
P49
P50
P52
P53
P56
P57
P58
P60
P61
P65

SEAT REMOVAL...................................................
INSTRUMENT COVER REMOVAL ......................
SADDLE REAR COVER REMOVAL....................
SIDE SADDLE COVERS REMOVAL ...................
FRONT BUMPER COVER REMOVAL……….…..
MAINTENANCE ACCESS PANEL REMOVAL....
KEY POSITION COVER REMOVAL……………...
FRONT RACK REMOVAL....................................
FRONT COVER REMOVAL……………………….
BATTERY REMOVAL...........................................
DIRECTION INDICATION LIGHTER FLASHER
REMOVAL……………………………………......…
FUSE BOX REMOVAL………………...................
RELAYS REMOVAL……………….......................
REAR RACK REMOVAL………………………….
REAR COVER REMOVAL…………….................
LHS & RHS FOOT REST COVERS REMOVAL..
PROTECTOR REMOVAL…………………...…….
AIR FILTER BOX REMOVAL……………….…….
FUEL TANK REMOVAL……………….................
EXHAUST PIPE REMOVAL……………..............
FRONT &REAR WHEEL REMOVAL..................
FRONT PROPELLER SHAFT REMOVAL………
▲Chassis
Service Manual
P81
P81
P83
P84
P85
P87
P87
P88
P89
P92
P94
P94
P95
P96
P97
P100
P101
P103
P107
P111
P113
P114

LHS & RHS STEERING LINK REMOVAL..........
FRONT LHS & RHS BRAKE CALIPER
REMOVAL.…………………………………….……
FRONT LHS & RHS SHOCK ABSORBER
REMOVAL…………………………………………..
FRONT LHS & RHS HUB REMOVAL.................
FRONT LHS & RHS A-ARM ASSY. REMOVAL..
FRONT DIFFERENTIAL REMOVAL……………..
REAR LHS & RHS BRAKE CALIPER
REMOVAL …………………………………………..
REAR LHS & RHS HUB REMOVAL....................
REAR LHS & RHS SHOCK ABSORBER
REMOVAL……....………………………………..…
REAR LHS & RHS A-ARM ASSY. REMOVAL...
REAR DIFFERENTIAL REMOVAL...…………....
ECU REMOVAL…………………..........................
RADIATOR REMOVAL………………..................
INSTRUMENT REMOVAL…………….................
FRONT BRAKE PAD REMOVAL……………......
REAR BRAKE PAD REMOVAL……………........
FOOT BRAKE PADDLE REMOVAL.…………....
▲Chassis
Service Manual
P115
P118
P119
P120
P121
P124
P126
P127
P128
P129
P131
P133
P134
P136
P137
P138
P139

Power
Power- -Train & Control Train & Control
Introduction
Introduction
1

Engine Specification
Type: 4 Stroke、Single Cylinder
SOHC 、4 Valve
Displacement: 497 ㏄
Bore x Stroke: 90 x 78 mm
Compression Radio: 10.0
Power: 15kW@5000rpm
(homologation)
Max Power: 30kW@7000rpm
Torque: 40Nm@5500rpm
Max. rev.: 7500rpm
Transmission: CVT 、V-belt
Emission: 2002/51/EC
Weight: 67kg
2

Engine Lubrication System
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
Lubrication: Wet Sump
Oil Pump: Rotor Type
Oil Filter: Paper Type
Oil Type: 10W40 SJ
Oil Volume: 3.0 L
3.5 L (Replace Filter)
Pressure Release: 4.5 kg/cm2
Pressure S/W: 0.2 kg/cm2
Oil Inlet:
Oil Return:
Left Side Right Side
3

Engine Breather System
Engine Oil
Exhaust Side
Intake Side
Air Box
Air Filter
Breather Hose
Piston
Con-Rod
Crankshaft
Blow-by gas
Blow-by Gas Spec.: ≦10 L/min
4

CVT System
CVT Belt Type:
- DAYCO P/N:
Off Road: 5324
On Road: 5324
-CVT:
Drive Wheel
Tightening Torque 40~45Nm
Driven Wheel
Tightening Torque 120Nm
Ratio: Min. Max.
0.316 ~ 1.581
Engine Speed Limit: 7500rpm
CVT Belt
Drive Wheel Driven Wheel
5

Start System
Starter Specification:
- CECTEK Type: 40196007
- Output: 0.7 kW
- Operation Voltage: 12 V
- Temperature Range: -10~+120℃
Starter Circuit Diagram :
Rewind Starter Handler
Starter
Spin Nose
Ring Gear
Starter
GND
Battery
GND
GND
Key S/W
Relay
Starter S/W
-+
6

Injection System
Injector
Cylinder Head
Intake Valve
Throttle Body ASM
Idle Air Control Valve
(IACV)
Intake Air Intake Port
Fuel Injection
Air Flow Temperature
air temp.
coolant temp.
…
IACV or TPS
MAP
RPM
ECU
To calculate air flow and
necessary fuel flow
Injector
Fuel injection control
7

Emission Control System
Emission relational part:
-ECU
- Throttle Body ASM
- Injector
- Spark Plug
- Ignition Coil ASM
- O2 Sensor
- Catalyst
Catalyst :
- 100 cells/in2
- Volume: 116 ㏄
Emission:
- Updated 2002/51/EC
Catalyst
Throttle Body ASM
Injector
Ignition Coil ASM
O2 Sensor
8

Cylinder Head/Block
Cylinder Head ASM
- Aluminum Alloy: AC4B+T6
- SOHC (Chain Drive)
-4Valves
- Spark Plug: Champion PRG7C
Cylinder Block ASM
- Liner Material: FC250
- Aluminum Alloy: ADC12
Intake Valve *2
Exhaust Valve
Spark Plug
Cast-in Liner Spark Plug
9

EMS System
Block Diagram
Pin Assignment
10

ECU
Part Introduction
ECU Type: MC21 1030
Assembly:
Electrical Characteristic:
Operation Voltage Range: 9~16V
Storage Temperature Range: -40~70℃
Operation Current: <500mA
ECU Type:
MC21 1030
ECU Pin 28: -
Map Sensor
Connector
ECU
Connector
11

Injector
Part Introduction
Identification Code: 28140652
Injector holes: 4ea
Circuit Diagram :
Measurement
Resistance: 12.0±0.6Ω
ECU Injector
Pin 28
MPR
Main Power Relay
-
+
Identification Code:
28140652
ECU Pin 28: -
MPR: +
12

Throttle Body ASM
Throttle Body
Throttle Position Sensor
(TPS)
Idle Air Control Valve
(IACV)
(Step Motor)
13