GAOKIN E02 User manual

第- 1 - 页
E02（GK194MS）
Maintenance Manual
Edited：Li LinJun
Verified：Hu Xianyong
Approved：Li Xuelong

第- 2 - 页
Catalog
1 Overview..................................................................................................................................... - 3 -
1.1 product chracteristic................................................................................................................... - 3 -
1.2 Product application、specification and apllying range.............................................................. - 3 -
1.3 Model meaning .......................................................................................................................... - 3 -
1.4 Applying environment and working condition .......................................................................... - 3 -
1.5 Affect to environment and energy.............................................................................................. - 4 -
1.6 Safety ....................................................................................................................................... - 4 -
2 Product technical charateristic .................................................................................................... - 4 -
2.1 Main performance parameter..................................................................................................... - 4 -
2.2 Main structure parameter ........................................................................................................... - 5 -
2.3 Transmission system parameter ................................................................................................. - 6 -
2.4 Fuel and lubricating oil parameter ............................................................................................. - 7 -
2.5 Coolant parameter...................................................................................................................... - 7 -
3. Engine outline drawing.............................................................................................................. - 7 -
3.1 Engine model and countermark position.................................................................................... - 7 -
3.2 E02 engine outline drawing ....................................................................................................... - 7 -
4．Engine assembly requirement and accessory............................................................................ - 8 -
4.1 Engien assembly ........................................................................................................................ - 8 -
4.2 Inlet and exhaust system ............................................................................................................ - 8 -
4.3 Fuel supply system..................................................................................................................... - 9 -
4.4 Coolant system......................................................................................................................... - 10 -
4.5 Electrical equipment system .................................................................................................... - 10 -
4.6 EFI system.................................................................................................................................- 11 -
5．Engine usage、maintenance and fault solution………………………………………………- 13 -
5.1 Engine using and cautions........................................................................................................ - 14 -
5.2 Maintenace............................................................................................................................... - 16 -
5.3 Common fault check list .......................................................................................................... - 20 -
Annex files…………….................................................................................................................... - 25 -
Annex 1E02 outline drawing...................................................................................................... - 26 -
Annex 2Carburetorwireconnectingdrawing ............................................................................ - 27 -
Annex 3EFI wire connecting drawing........................................................................................ - 28 -
Annex 4Carburetorwiresandconnectormodel ........................................................................ - 29 -
Annex 5EFIwiresandconnectormodel ..................................................................................... - 30 -

第- 3 - 页
1Overview
1.1Enginecharacteristic
GK194MS engine works stable, with high torque, long life, low consumption, can be
used in wide range.
1.2Types、application、Specification
GK194MS engines including two series E02、E03 and 8 models，E02 is the engine with
gears. It is applied to two wheels motorcycles、sports ATV、applicability ATV、UTV。
Details please refer to the following table:
S/N Product
code Model Feature Remark
1 E02C 194MS Carb.、manual clutch、pedal
shifting (5forward shifts)
Used on two wheels
vehicle
2 E02C-2 194MS-A EFI 、 manual clutch 、 pedal
shifting (5forward shifts)
Used on two wheels
vehicle
3 E02F 194MS-2
Carb.、manual clutch、pedal
shifting (4forward shifts+1
reverse)
Used one ATV
4 E02F-2 194MS-2A
EFI 、 manual clutch 、 pedal
shifting(4forward shifts+1
reverse)
Used one ATV
1.3Modelmeaning
1.4Operatingenvironmentandworkingcondition
Working environment temperature，engine with carburetor -10～40°C；engine with

第- 4 - 页
EFI（with battery above 45A.h）-30～40°C。
Apply to sea level elevation，engine with carburetor in 4000m；engine with EFI in 5000m。
Engine must be installed and fixed on vehicle or testing-bed, assembled all
accessories and filled in enough correct lubricating oil and coolant.
1.5Effecttoenvironmentandenergy
Polluted air like COx、CxHy、NOx will be emitted when engine works and consumes
fuel.
1.6Safety
The temperature of working engine is high, people are not allowed to touch engine
to avoid scald.
Engine output shaft is a high speed spinning part, please install protecting plate
or cover to avoid hurt.
2Producttechnicalcharacters
2.1Mainperformanceparameters
S/N Items Parameter/Description Remark
1. Working temperature
range °C
Engine with carb.-10～40
Engine with EFI （ matched with
batter above 45A.h y）-30～40
2. Height applied to m
Engine with carb. in 4000m
Engine with EFI in 5000m
3. Max. net power kW@r/min 27.5@5750 (10h running-in with
hi
g
h shift
)
4. Calibrating power ——
5. Max. net torque N.m@r/min 51.5@4250 (10h running-in with
hi
g
h shift
)
6. Min. fuel consumption
g/
kW.h ≤300 WOT
7. Max. RPM r/min 6500

第- 5 - 页
S/N Items Parameter/Description Remark
8. idling r/min 1500±150
9. Exhaust limited Carb. Euro II，EFI Euro.III Vehicle
calibrating
10. Noise limited Db(A) ≤80 Vehicle
calibrating
2.2Mainstructureparameter
S/N Items Parameter/Description Remark
1 Type Vertical、1 cylinder、SOHC、4 Stroke 、4
valves、water cooling
2 Outline size(L x b x h)mm
E02C E02F
380x420x500
3 Net weight kg 49 50
4 Bore diameter mm 94
5 Piston stroke mm 85
6 displacement ml 589.9
7 compression 9.7：1
8 Ignition mode Storage power supply、ignition coil
i
g
nites
9 Fuel supply Carburetor or EFI
10 Air inlet mode Naturally aspirated
11 Crankshaft rotating
direction Rotate to right
12 Valve transmission type Roller crossed rocker
13 Valve clearance mm Inlet valve 0.09～0.14
Outlet valve 0.17～0.22 Cool state
14 Lubrication mode pressure、splash
15 Starting mode electric

第- 6 - 页
S/N Items Parameter/Description Remark
16 Water pump flow L/min ≥90（runoff type 5000r/min）
17 Water coolant volume ml 200 Water
j
acket
18 Thermostat ℃ open/full open 71/85
19 Fuel pump flow L/min 4.39 (1000r/min)
20 Fuel pressure -
21 Fuel filter Pater-type
22 Fuel volume L 2.3
23 Generator output 14V 330W (5000r/min)
24 Starting generator power 12V 650W
25 Spark plug mm model：NGK CR7E，clearance：0.7～
0.8
2.3transmissionsystemparameter
The follow table shows E02 engine transmission parameter
S/N Items
Parameter/Description
Remark
E02C E02F
1. Clutch type Manual wet-type oil bath multiple
chi
p
s t
yp
e
2. Power output mode Chain wheel、chain link
3. Chain parameter 530type 15teeth
4. Transmission type Mechanical、5shifts
5. Gear shift order 1-N-2-3-4-5 R-N-1-2-3-4 Reverse
limited
6. Each shift transmission
ratio
1shift 6.029 reverse 4.854
Primary
transmissi
on ratio
2．345
2shift 3.846 1 shift 4.983
3shift 2.814 2 shift 3.4
4shift 2.244 3shift 2.558
5shift 1.876 4shift 1.97

第- 7 - 页
2.4Fuelandlubricatingoilparameter
S/N Items Parameter/Description Remark
1. Fuel grade 93#
2. Lubricating oil grade
-10～40°C，API 10W/40-SG or SH Recommend
to Use
mineral
oil
-20～40°C，API 5W/40-SG or SH
3. Lubrication oil consumption ≤5g/(kW.h)
4. Lubricating oil total volume 2．30 L
5. Lubricating oil max.
temperature 120°C
2.5watercoolantparameter
S/N Items Parameter/Description Remark
1. Coolant specification Antifreeze -30℃
2. Coolant volume ml 200 Water
jacket
3. Coolant inlet
temperature °C ≤90
4. Coolant outlet
temperature °C ≤105
5. Thermostat Open /full open 71/85℃，lift 3.5mm
3.Engineoutline
3.1Enginemodelandcountermarklocation
E02engine,please look at engine left side
3.2E02engineoutlinedrawing
See attached file 1 E02outline drawing (EFI)

第- 8 - 页
4．Engineassemblyrequirementandaccessory
Choose and install proper accessory on engine to ensure the engine get best performance. The
followings are engine accessory, we can match for customer, or customer can choose from the table by
themselves.
4.1Engineassembly
S/N Items Parameter/Description Remark
1) Assembly dip angle allowed 15（±0.5）°
Bore center line
and vertical
axis
2) Suspension fixed mode Three-point fixed, hard
connect
3)
E02
Front suspension hole
diameter、coordinate
Φ11(374.5,-23.5)
Φ11(355,-92.5) To main fixed hole
4) Rear suspension hole
diameter、coordinate
Φ11(35.5,116.5)
Φ16(0,0)、
Φ11(30.5,-132.5)
To main fixed hole
5) Top suspension hole
diameter、coordinate Φ9（211.3,248.8） To main fixed hole
4.2Inletandexhaustsystem
S/N Items Parameter/Description Remark
1)
Air filter A
Structure Box type with exhaust gas
connector
2) Model 17100-E02-0000
3) original
resistance Pa 1685
4) Air inlet rate m 3/h 300
5) volume L 4.5
6) Filter element Foam type
7)
Air filter B
Structure Box type with exhaust gas
connector、scaven
g
e
p
ort
8) Model 17100-E02-00A0
9) original
resistance Pa 1685

第- 9 - 页
S/N Items Parameter/Description Remark
10)
Air inlet rate
m3/h 300
11) Connecting tube
Small end internal diameter
(throttle valve) ≥ Φ 40mm ，
length about 140mm
12) volume L 4
13) filter element Paper and foam
14)
muffler
Model 18000-E02B-00C0
15) Exhaust
back
p
ressure - Exit 100mm
16) original
resistance Pa -
17) Pipe diameter mm Inner diameter ≥ Φ34
18) Pipe length mm 625（or 1225）
19) Volume L 4.5
20) accelerant No
4.3fuelsupplysystem
S/N Items Parameter/Description Remark
1)
Carburetor
A
(with air
filter A)
structure Equal vacuum membrane type
2) Model KINZO PD42J
3) Stroke mm 30
4) Oil supply L -
5) Mouth
diameter mm Φ42
6) Oil pipe inner
diameter mm Φ7
7) Accelerating
p
um
p
No
8) Carburetor
B
(with air
Structure plunger type
9) Model Dellorto PZ40

第- 10 - 页
S/N Items Parameter/Description Remark
10)
filter B) Stroke mm 35
11) Oil supply L -
12) Mouth
diameter mm Φ40
13) Oil pipe inner
diameter mm Φ7
14) Accelerating
bum
p
yes
15) Electric injector supply oil See 4.5
4.4Coolantsystem
S/N Items Parameter/Description Remark
1)
radiator
Structure Integration thermo switch、liquid adding
hole、pressure regulating valve
2) Model 19600-E02B-00A0
3) Radiating area -
4) Thermo
switch ℃ starting temperature 65
5) Pressure
control bar Starting pressure 0.9
6) Water tank
volume ≥20% total volume
7)
Inlet/outlet
water
pressure
difference Pa
-
8) Water pipe
inner diameter Φ19
9)
Fan
Model 19100-E02B-00A0
10) Power W ≥80
11) Air volume
m3
/
h -
4.5Electricappliancesystem
S/N Items Parameter/Description Remark