Doohan iTank User manual

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Preword
This maintenance manual will introduce you the info. On the vehicle specification,
maintenance procedure, adjustment and diagnosis of iTank.
The employee of service provider authorized by Zhejiang Doohan Technology
Co., Ltd. can provide better service to iTank users after having knowledge of this
manual and the maintenance technology report which will be published afterwards.
It is advised that the brand name products or tools for specific use should be
obtained via Zhejiang Doohan Technology Co., Ltd.
Entries must be received by 30 August 2016.
Without the written permission of Zhejiang Doohan Technology Co., Ltd., no one
shall publicize any part of the manual in any form.

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Warning
Warning: To reduce the possibility of personal and/or property damage, the
following instructions must be followed:
The maintenance manual provided by Zhejiang Doohan Technology Co., Ltd. is
compiled for qualified professional technicians. If, any attempt to repair or maintain
the vehicle without proper training and appropriate tools and equipment may lead to
vehicle damage or abnormal operation of the vehicle.
The maintenance procedures recommended and introduced in the manual are
effective methods for maintenance and repair. Of which, some procedures need to use
tools specially designed for them.
Hence, if anyone wants to use replacement, maintenance or tools which are not
recommended or recognized by Zhejiang Doohan Technology Co., Ltd., he/she must
make sure that they are not harmful for the personal safety and safe operation of the
vehicle.

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Contents
Chapter 1.The vehicle information
Chapter 2 Standard component specification and general torque
Chapter 3 Dismantle and replacement of parts of the car
3.1 Disassemble and switch the covering parts
3.1.1 Schematic diagram of the covering parts
3.1.2 Procedure of dismantling and switching the covering pieces and the tools
required
3.2 Disassembling and changing of steering handle
3.2.1 Schematic diagram of the steering handle
3.2.2 Tools required to change and disassembling the steering handle base order
3.2.3 Change the steering handle base
3.3 The front wheel and front disc brake system
3.3.1 The front wheel and front disc brake system map
3.3.2 Tools needed to disassemble and switch the front wheel, front disc brake
system and the order of disassembling and switching
3.3.3 The check of front and back tyres
3.3.4 Disassemble and replace the front disc brake lower pum
3.3.5 Disassemble and change the front wheel and front disc brake plate

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3.4 The rear wheel and rear disc brake system
3.4.1 The rear wheel and back disc brake system map
3.4.2 Tools needed to disassemble and switch the rear wheel, rear disc brake
system and the order of disassembling and switching
3.4.3 Disassemble and replace of the lower pump of the rear disc brake
3.4.4 Disassemble and switch split back splash guard
3.4.5 Disassemble and change the rear wheel and rear disc brake plate
3.5 The seat tank and the rear cushion
3.5.1 Schematic diagram forThe seat tank and the rear cushion
3.5.2 Tools needed to disassemble and switch the sitting tank and rear cushion and
the order of disassembling and switching
3.5.3 Disassemble and changing sitting tank
3.5.4 Disassemble and changing rear cushion
3.6 The front mechanism
3.6.1 The connection of the front mechanism to the frame
3.6.2 Procedure of dismantling and switching the front mechanism and the tools
required
3.6.3 Disassemble and switch the front mechanism (the whole machine)
3.6.4 Front mechanism exploded views (components)
3.6.5 Disassemble and change steering linkage assembly
3.6.6 Disassembly and change the steering base
3.6.7 Dismantling and change knuckle

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Chapter 4 An introduction to electrical parts and their repair
4.1 Electric device
4.2 An introduction of the electrical parts
4.3Electrical principle diagram
4.4 Faulting phenomenon and repair method

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Chapter 1.The vehicleinformation

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Chapter 2 Standard component specification and general torque
This chapter is used to inform the customers the specification of the standard
components the vehicle uses and their corresponding repair tools.
Specify the locking torque force for standard fixtures according to ISO standard screw
thread depth. The manual has already explained the locking torque force of the special
components or assembly in relevant chapters. In order to prevent curling, please lock
the multi-fixture assembly to designated torque force in cross mode and progressive
manner. Unless otherwise prescribed, the locking torque should be based on clear and
dry screw thread; the components should maintain the room temperature standards.
1、The car uses hexagon flange bolt, whose national standard number is GB/T 5789-
2000. For the standard component specification, repair tools specification and general
torque please refer to the following table:

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2. The car uses inner hexagon flange bolt, whose national standard number is
GB/T70.1-2000. For the standard component specification, repair tools specification
and general torque please refer to the following table:
3.The car uses hexagon flange bolt whose national standard number is GB/T 6177.1-
2000, and hexagon locking-nuts with flange, whose national standard number is
GB/T6187.1. For standard component specification, repair tool specification and
general torque please refer to the following table:

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4.The car uses inner hexagon flange bolt, whose national standard number is
GB/T70.2-2000. For the standard component specification, repair tools specification
and general torque please refer to the following table:
5.The car uses cross recessed pan head tapping screws which national standard number
is GB/T 845-1985, GB/T818-2000 cheese head screws with cross recess, the repair
tools are uniformed as cross screwdriver There are no requirements for torque force,
screwing down will be enough.

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Chapter 3 Dismantle and replacement of parts of the car
Preparation for dismantling and replacement
①Before the dismantling or removal, clean the dust, dirt and foreign
matter on the car.
②While dismantling, the paired parts must be put together. The paired
parts must be used repeatedly or switched in pairs
③While dismantling, clean all the parts, and put them on the tray in the
order of dismantling sequence. Doing so will save the time of
assembling and ensure the correct installation of the parts.
④Put all parts in places away from fire and water.

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3.1 Disassemble and switch the covering parts
3.1.1 Schematic diagram of the covering parts

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3.1.2 Procedure of dismantling and switching the covering pieces and the tools
required

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Notes:
●Use appropriate support to support the car, so that the front wheel will hang in the air.
●Dismantle the parts in order. While installing, follow the sequence in an opposite
direction of the dismantling process.
●If the solid wrench is not applicable, you can switch to sleeve or speed wrench of the
same specification.

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3.2 Disassembling and changing of steering handle
3.2.1 Schematic diagram of the steering handle

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3.2.2 Tools required to change and disassembling the steering handle base order
●Use appropriate support to support the car, so that the front wheel will hang in the air.
●Dismantle the parts in order. While installing, follow the sequence in an opposite
direction of the dismantling process.
●If the solid wrench is not applicable, you can switch to sleeve or speed wrench of the
same specification.
3.2.3 Change the steering handle base
① Place iTank on a flat platform ②Dismantling steps:
●Lower part of the front panel
●Front storage box trimming : Clutch on one end of the front storage box trimming, pull it
down with great force.
●Front storage box left trimming: After twisting the screw, Clutch on one end of left trimming
of the front storage box, pull it down with great force.

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●Right trimming of front storage compartment : Same as the above
●Front panel assembly
●Upper cover of front storage compartment
●Refer to "Disassemble the covering pieces".
●Handlebar block
●Handlebar seat
③ After changing the steering handle base, install according to the order opposite to the
disassembly
3.3 The front wheel and front disc brake system
3.3.1 The front wheel and front disc brake system map

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3.3.2 Tools needed to disassemble and switch the front wheel, front disc brake system
and the order of disassembling and switching
Notes:
Use appropriate support to support the car, so that the front wheel will hang in the air.
Dismantle the parts in order. While installing, follow the sequence in an opposite
direction of the dismantling process.
If the solid wrench is not applicable, you can switch to a sleeve or speed wrench of the
same specification.

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3.3.3 The check of front and back tyres
①Tyre inspection
⑴Tire pressure
Exceeded the standard value (225±10KPa), please adjust the tyre pressure.
Warning:
●Please check and adjust the tyre pressure when the exterior tyre temperature equals to
the outdoor temperature.
●Driving an overloaded iTank will lead to the damage of the tyre or accidental injury
●Don't overload the iTank