E02F

GK194MS-2 Engine Spare Parts Catalog

2009. 4

I

Preface

All the document in the accessory catalog is the new product of Chongqing Gaokin industry co., ltd, who have

right to change or emend this accessory catalog or atlas at any time while not inform in advance or undertake any

resposibility. The revision of this accessory catalog and atlas is belong to the Chongqing Gaokin industry co., ltd, any

company or person can not copy any part of this accessory catalog and atlas unless got our written approval.

Chongqing Gaokin industry co., ltd

April of 2009

II

Accessory Catalog and Atlas Instruction

This accessory catalog and atlas is collecting all the parts, accessory of engine--GK194MS-2（E02F）and mark the part code、name and unit set quantity user can work out the order for the parts according to the parts code、name in the accessory catalog and atlas . 1Ordering Precaution：

（1.1）The user should describe clearly the part code, name and ordering quantity, while working out the ordering plan and accessory parts. （1.2）Colored parts should indicate the color on the order sheet. （1.3）Accessory parts in the real line circle is considered as a component, which can not split for sale. （1.4）Some parts had to be matched for sale, such as left and right box body、cylinder head and its cowl hood, because they are machined after assembly.

Details consult sales engineer.

2、Abbreviation： All used abbreviation in the accessory and atlas as below: W--------watt mm--------millimeter L--------left V--------volt A--------ampere R--------right

3、Dimension: all the dimension are used mm as unit.

parts example instruction Screw(bolt) forelock oil seal O-type seal ring

M6×12 2×12 14×24×5 9.5×1.6

dia.6mm，length12mm specification 2mm，length 12mm Inner dia.14mm，external dia.24mm，thickness 5mm dia.9.5mm，section dia. 1.6mm

III

Catalog

E－1、Right crankcase assembly ..........................................................1 E－8、Tensioner section, timing

gear.....................................................................................................10 E－2、Left crankcase assembly.....................................................................................2 E－9、Shift drum, shifting gear fork, shift

shaft....................................................................................................11 E－3-1、Transmission....-1.........................................................3 E－10、Clutch...................................................................................12

E－3-2、Transmission-2.............................................................4 E－11、Oil pump part......................................................................................................13

E－4、Crank connecting rod, balance shaft, piston assembly.....................................................................................5 E－12、Water pump

part......................................................................................................14 E－5、Cylinder body part..............................................................................................6 E－13、Right crankcase cover

assembly.............................................................................................15 E－6-1、cylinder heat part, camshaft assembly ....................................................................................7 E－14、Starting motor, rotor

assembly.............................................................................................16 E－6-2、cylinder heat part, camshaft assembly ....................................................................................8 E－15、Left front, back cover

assembly………………………………………….………………………..17 E－7、Cylinder head cover, rocker arm..............................................................................................9

-1-

E-1Right crankcase assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1110A-E02-0200 Right crankcase assembly 1

2 GB/T276-1994 Bearing 63/22 C3P6 2 3 GB/T276-1994 Bearing 6208 C3P6 1 4 GB/T276-1994 Bearing 6004-RS 1 5 GB/T276-1994 Bearing 61905 C3P6 1 6 11001-E02-0000 Monitor cover 1 7 91205-E02-0000 O –type seal ring 40x2.5 1 8 15301-E02-0000 Locate spring 1 9 1531A-E02-0000 Oil filter screen 1 10 Q/QD924.1-2003 Locate pin 92401-08020 2 11 GB/T290-1998 Needle bearing HK1516 1 12 GB/T77-2000 Screw M8x10 2 13 15108-E02-0000 Pin shaft 12 1 14 GB/T894.1-1986 Snap ring 12 1 15 Q/QD921.2-2002 Stud bolt 92120-06030 2 16 GB/T77-2000 Bolt M12x16 1 17 11006-E02-0000 Suspension sleeve 1 18 Q/QD924.1-2003 Locate pin 92401-13018 2

-1-

E-2Left crankcase assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1120A-E02-0200 Left crankcase assembly 1

2 GB/T290-1998 Needle bearing HK1210 1 3 GB/T276-1994 Bearing 6305 C3P6 1 4 GB/T276-1994 Bearing 6204-RS 1 5 GB/T290-1998 Needle bearing HK2516 1 6 GB/T276-1994 Bearing 6307E C3P6 1 7 GB/T276-1994 Bearing 63/22 C3P6 1 8 91105-E02-0000 Oil seal 19.8 x 30 x 7 1 9 23110-E02-0000 Reverse limiting stopper 1

10 32900-E02-0200 Gear shift switch assembly 1 11 91101-E02-0000 countershaft oil seal 25 1 12 GB/T893.1-1986 Retaining for hole 62 1 13 91102-E02-0000 Oil seal 12x22x7.5 1 14 11006-E02-0000 Suspension sleeve 1 15 11102-E02-0000 Vent joint 1 16 Q/QD924.1-2003 Locate pin 92401-13018 2 17 Q/QD924.1-2003 Locate pin 92401-08020 2 18 Q/QD920-2002 Bolt with plate M6X75 1 19 Q/QD920-2002 Bolt with plate M6X70 3 20 Q/QD920-2002 Bolt with plate M6X40 11 21 Q/QD920-2002 Bolt with plate M6X50 1 22 Q/QD921.4-2002 Bolt with plate 92140-06045 2

-1-

E-3-1Transmission-1

No. Code No./Drawing No. Description Unit

quantity Diagram

1 22201-E02-0000 In-put shaft 1

2 22203-E02-0000 Oil plug φ1.0 1 3 22204-E02-0000 Oil plug φ2.0 2 4 22202-E02-0100 Out-put shaft 1 5 22501-E02-0200 Reverse idle shaft 1 6 22503-E02-0200 Reverse idle gear 1 7 22502-E02-0200 Reverse idle shaft sleeve 1 8 22302-E02-0200 Reverse out-put gear 1 9 22209-E02-0000 Shaft sleeve 22x26x12 1

10 22311-E02-0200 1st speed driving gear 1 11 22312-E02-0200 1st speed driven gear 1 12 22208-E02-0000 Shaft sleeve 1 13 22321-E02-0200 2nd speed driving gear 1 14 22322-E02-0200 2nd speed driven gear 1 15 22207-E02-0000 Spline sleeve 1 16 22331-E02-0200 3rd speed driving gear 1 17 22332-E02-0200 3rd speed driven gear 1 18 22206-E02-0000 Shaft sleeve 1 19 22341-E02-0200 4st speed driving gear 1 20 22342-E02-0200 4st speed driven gear 1 21 22205-E02-0000 Spline sleeve 1 22 GB/T894.1-1986 Retaining ring for shaft 22 1 23 90703-E02-0000 Retaining ring for shaft 22 2 24 GB/T894.1-1986 Retaining ring for shaft 22 2 25 GB/T894.1-1986 Retaining ring for shaft 22 1 26 90614-E02-0000 washer 22 2 27 90608-E02-0000 washer 28 2

-1-

E-3-2 Transmission-2

No. Code No./Drawing No. Description Unit

quantity Diagram

28 90607-E02-0000 Spline washer 28 1

29 90609-E02-0000 Flange spline washer 1 30 90613-E02-0000 Washer 25 2 31 90623-E02-0000 Spline Washer 25 1 32 90611-E02-0000 Washer 20 3 33 22401-E02-0000 Driving pulley (z=15) 1 34 22403-E02-0000 Cushion blocking 1 35 22402-E02-0000 Driving pulley locate plate 1 36 90108-E02-0000 Stepped bolt M6×12 3

-1-

E-4Crank connecting rod, balance shaft, piston assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1320A-E02-0000 Crank con-rod assy. 1

2 90801-E02-0000 Woodruff key 1 3 GB/T1096-2003 Flat key （C-type ） 5x5x12 1 4 22101-E02-0000 Primary input gear (Z=29) 1 5 90621-E02-0000 Washer 18 1 6 90301-E02-0000 Hexagon nut M18 1 7 13301-E02-0000 Balance shaft 1 8

13310-E02-0000 balance shaft output gear assembly

1

9 90701-E02-0000 Circle ring for piston 2 10 13101-E02-0000 Piston 1 11 13102-E02-0000 Piston pin 1 12 13112-E02-0000 Piston ring B 1 13 13111-E02-0000 Piston ring A 1 14 13122-E02-0000 Oil-ring 2 15 13121-E02-0000 Segment 1

-1-

E-5Cylinder body part

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1211B-E02-0000 Cylinder block 1

2 12113-E02-0000 plug 2 3 12112-E02-0000 Water pipe joint 1 4 Q/QD921.2-2002 Stud M6X38 2 5 12001-E02-0000 Cylinder block seal gasket 1 6 1201A-E02-0000 cylinder head seal gasket 1 7

Q/QD924.1-2003 locating pin 92401-13018

2

8 GB/T6177.1-2000

Hexagon flange face nut M6

4

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E-6-1cylinder head assy. ,camshaft assy.

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1220A-E02-0000 Cylinder head assembly 1

2 1220A-E02-00A0

Cylinder head assembly（second intake air）

1

3 12205-E02-0000 Second intake pipe 1 4 91215-E02-0000 O-ring seal ring9.5×2 1 5 Q/QD921.4-2002 Bolt with plate 92140-06012 1 6 12413-E02-0000 Vacuum tube 1 7 14706-E02-0000 Intake valve 2 8 14707-E02-0000 Exhaust valve 2 9 14702-E02-0000 Spring Retainer 4 10 14701-E02-0000 Valve collet 8 11 14704-E02-0000 External spring of valve 4 12 14703-E02-0000 Inner spring of valve 4 13 91104-E02-0000 Valve oil sealing 4 14 14705-E02-0000 Valve spring seat 4 15 Q/QD921.2-2002 Stud 92120-08035 2 16 Q/QD921.2-2002 Stud 92120-06055 2 17 Q/QD921.2-2002 Stud 92120-08060 1 18 19410-E02-0000 Thermostat assembly 1 19 19401-E02-0000 Thermostat cover 1 20 Q/QD920-2002 Bolt with plate M6X22 2 21 90601-E02-0000 Gasket 8 1 22 Q/QD920-2002 Bolt with plate M8X12 1 23 1481A-E02-0000 Intake pipe 1 24 Q/QD920-2002 Bolt with plate M8X20 4 25 36540-E02-0000 Water temperature sensor 1 26 3330A-E02-0000 Spark plug B7RC 1

-2-

27 90102-E02-0000 Cylinder bolt A（M10x203） 2

E-6-2cylinder head part, camshaft assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

28 90101-E02-0000 Cylinder bolt B（M10x190） 2

29 90619-E02-0000 Washer 10 4 30 Q/QD924.1-2003 Locate pin 92401-08012 2 31 1411A-E02-0010 Camshaft assembly 1 32 14113-E02-0000 Camshaft stop plate 1 33 14303-E02-0000 Timing driven pulley 1 34 14304-E02-0000 Timing driven pulley plate 1 35 GB/T5783-2000 Bolt M6X10 2 36 GB/T6177.1-2000 Hexagon flange face nut M6 2 37 GB/T6177.1-2000 Hexagon flange face nut M8 1

-3-

E-7Cylinder head cover, rocker arm

No. Code No./Drawing No. Description Unit

quantity Diagram

1 12301-E02-0010 Cylinder head cover 1 2 91202-E02-0000 Cylinder cover O-ring sealing 2 3 12302-E02-0000 Valve cover 2 4 14401-E02-0000 Rocker pin 2 5 14420-E02-0010 Exhaust rocker assembly 1 6 90618-E02-0000 Waved washer 2 7 90605-E02-0000 Seal gasket 3 8 14402-E02-0000 Rocker arm shaft cover bolt 3 9 14410-E02-0010 Intake rocker arm assembly 1 10 Q/QD921.4-2002 Bolt with plate 92140-06020 4 11 Q/QD921.4-2002 Bolt with plate 92140-06055 4 12 Q/QD921.4-2002 Bolt with plate 92140-06035 2 13 Q/QD921.4-2002 Bolt with plate 92140-06030 6 14 90615-E02-0000 Seal gasket 6 4 15 14421-E02-0010 Exhaust rocker arm 1 16 14411-E02-0010 Intake rocker arm 1 17 90501-E02-0000 Valve adjust bolt 4 18 90302-E02-0000 Valve adjust nut 4 19 14114-E02-0000 Camshaft seal cover 1

-4-

E-8Tensioner section, timing gear

No. Code No./Drawing No. Description Unit

quantity Diagram

1 1452A-E02-0000 Chain guide plate 1

2 14302-E02-0000 Timing Chain 1 3 1451A-E02-0000 Chain adjusting plate 1 4 90601-E02-0000 Gasket 8 1 5 90104-E02-0000 Adjust plate pin bolt 1 6 14539-E02-0000 Tensioner seal gasket 1 7 14530-E02-0000 Tensioner assembly 1 8 90615-E02-0000 Seal gasket 6 2 9

GB/T70.1-2000 Hexagonal socket head boltM6X25

2

10 90616-E02-0000 Washer 6 1 11 90106-E02-0000 Bolt M6X9.5 1

-5-

E-9 Shift drum, shift fork, shift shaft

No. Code No./Drawing No. Description Unit

quantity Diagram

1 23300-E02-0000 Gear shift lever assy. 1

2 23302-E02-0000 Compress spring 2 3 23301-E02-0000 Return spring 1 4 23303-E02-0000 Sleeve 1 5 GB894.1-1986 Retaining ring for shaft 14 1 6

2331A-E02-0000 Gear-shift shaft and lever welded assembly

1

7 90105-E02-0000 Pin shaft bolt M6x20 1 8 2351A-E02-0000 Locating plate assembly 1 9 23501-E02-0000 Return spring 1 10

GB/T70.1-2000 Hexagonal socket head bolt M6x25

1

11 23221-E02-0000 Dividing board 1 12 GB/T119.2-2000 pin 4x12 1 13 23201-E02-0200 Gear shift drum 1 14 32901-E02-0000 Tension spring 1 15 32902-E02-0000 Moving contactor 1 16 23101-E02-0000 Fork I 2 17 23105-E02-0000 Fork pin II 1 18 23102-E02-0000 Fork II 1 19 23104-E02-0000 Fork pin I 1 20 91207-E02-0000 O-ring sealing 10X2 2

-6-

E-10 Clutch

No. Code No./Drawing No. Description Unit

quantity Diagram

1 2130A-E02-0000 Clutch outer cover assembly 1

2 21001-E02-0000 Clutch sleeve 1 3 21200-E02B-0000 Clutch core assembly 1 4 21202-E02-0000 Clutch compress disk 1 5 2122A-E02-0000 Clutch input disk 7 6 21201-E02-0000 Clutch output disk 7 7 21208-E02-0000 Butterfly spring 1 8 21207-E02-0000 Butterfly spring seat 1 9 2123A-E02-0000 Clutch input diskⅡ 1 10 2121A-E02-0000 Clutch centre sleeve 1 11 21203-E02-0000 Clutch spring 4 12 21204-E02-0000 Clutch lift disk 1 13 90107-E02-0000 Hexagon bolt of flange face 4 14 90606-E02-0000 Washer 18 1 15 90301-E02-0000 Hexagon nut M18 1 16 2142A-E02-0000 Clutch push rod assembly 1 17 GB/T894.1-1986 Check ring 25 1 18 GB/T276-1994 Bearing 61905 C3P6 1 19 21421-E02-0000 Clutch push rod 1 20 90604-E02-0000 Washer 22 1

-7-

E-11Oil pump part

No. Code No./Drawing No. Description Unit

quantity Diagram

1 15110-E02-0000 Pump assy. 1

2 15101-E02-0000 Pump body 1 3 15104-E02-0000 Inner rotor 1 4 15103-E02-0000 Outer rotor 1 5 15105-E02-0000 Driving shaft 1 6 15102-E02-0000 Cover-pump 1 7 GB/T818-2000 Bolt M4X10 1 8 GB/T119.2-2000 Pin 4x16 1 9 15001-E02-0000 Gasket-pump 1 10 GB/T119.2-2000 Pin 4x16 1 11 15106-E02-0000 Pump gear 1 12 90617-E02-0000 Washer 10 2 13 GB/T894.1-1986 Retainer ring for shaft 10 1 14

Q/QD921.4-2002 Bolt with plate 92140-06025

3

15 15107-E02-0000 Gear-driven pump 1 16 90622-E02-0000 Washer 12 2 17 GB/T894.1-1986 Retainer ring for shaft 12 1

-8-

E-12Cooling system

No. Code No./Drawing No. Description Unit

quantity Diagram

1 19700-E02-0000 Water pump 1

2 91403-E02-0000 Adjustable clamper 25-40 1 3 19001-E02-0000 Water pipe A 1 4 91402-E02-0000 Adjustable clamper 20-32 1 5 90601-E02-0000 Washer 8 2 6 90109-E02-0000 Water pipe bolt 1 7

1902A-E02-0000 Pass- by water pipe jointing assembly

1

8 19004-E02-0000 Water pipe D（pass- by） 1 9 91205-E02-0000 O-ring sealing 40x2.5 1

10 90615-E02-0000 Gasket sealing 6 1 11 Q/QD920-2002 Bolt with plate M6X65 2 12 Q/QD921.4-2002 Bolt with plate 92140-06065 1 13 91404-E02-0000 Adjustable clamper 8-16 2 1 1 1 1 2 1 1

-9-

1

E-13Right crankcase cover assembly

No. Code No./Drawing No. Description

Unit quantity

Diagram

1 11301-E02-0000 Right crankshaft cover 1

2 91106-E02-0000

Monitor window for oil level（visible oil seal）

1

3 GB/T77-2000 Bolt M12x16 1 4 GB/T77-2000 Bolt M10x10 1 5 GB/T77-2000 Bolt M8x10 1 6 11311-E02-0000 Oil filter plug 1 7 91203-E02-0000 O-Ring sealing17x3.0 1 8 21411-E02-0000 Shaft-clutch disengage gear 1 9 91103-E02-0000 Oil seal 12x18x5 1

10 GB/T290-1998 Needle bearing HK1210 1 11 90705-E02-0000 Retaining ring for shaft 7 1 12 91102-E02-0000 Oil seal 12x22x7.5 1 13 11303-E02-0000 Oil seal retainer 1 14

GB/T818-2000 Cross recess pan head Bolt M5x12

2

15 91208-E02-0000 O-ring sealing 58X2.5 1 16 15202-E02-0000 Filter cover 1 17 Q/QD920-2002 Bolt with plate M6X22 4 18 1520A-E02-0000 Oil filter 1 19 Q/QD920-2002 Bolt with plate M6X30 11 20 21412-E02-0000 Clutch disengage lever 1 21 Q/QD920-2002 Bolt with plate M6X40 2 22 11302-E02-0000 Gasket -right crankcase cover 1

-10-

E-14Starting motor, rotor assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

1 3110A-E02-0010 Rotor assembly 1

2 24401-E02-0010 Gear driven-starting 1 3 92902-E02-0000 Needle bearing TA3220Z 1 4 90612-E02-0000 Thrust washer35 1 5 24403-E02-0000 Gear idle-staring 1 6 24412-E02-0000 Pin-starting II 1 7 24402-E02-0000 Duplicate gears 1 8 24411-E02-0000 Pin-starting I 1 9 3120A-E02-0000 Starting motor part 1 10 90301-E02-0000 Hexagon nut M18 1 11 90621-E02-0000 Washer 18 1 12 Q/QD920-2002 Bolt with plate M6X30 2 13 3110A-E02-0000 Rotor assembly 1 14

GB/T70.1-2000 Hexagonal socket head boltM8x16

6

15 3111B-E02-0000 Rotor assembly 1 16 2431A-E02-0000 One-way clutch assembly 1 17 24301-E02-0000 One-way clutch body 1

-11-

E-15Left front, back cover assembly

No. Code No./Drawing No. Description Unit

quantity Diagram

1 11401-E02-0010 Left front cover 1

2 31120-E02-0000 Stator assembly（carburetor） 1 3 3114A-E02-0000 Flip flop 1 4 11402-E02-0000 Left front cover seal gasket 1 5 31141-E02-0000 Wire protective sleeve 1 6 11001-E02-0000 Monitor cover 1 7 11002-E02-0000 Upper monitor cover 1 8 91205-E02-0000 O-ring sealing 40x2.5 1 9 91211-E02-0000 O-ring sealing 12.5x1.8 1

10 Q/QD920-2002 Bolt with plate M6X40 10 11 Q/QD920-2002 Bolt with plate M6X120 1 12 Q/QD920-2002 Bolt with plate M6X50 1 13 Q/QD920-2002 Bolt with plate M6X60 1 14

GB/T818-2000 Cross recess pan head bolt M5x12

2

15 Q/QD921.4-2002 Bolt with plate 92140-06035 3 16 11411-E02-0010 Cover (driving pulley ) 1 17

GB/T5789-1986 Hexagon flange face bolt M8×25

3