ATV Body - Genero Motors
Contents
1. V OW HORE FOTRE SR DC PONER OUTLET START MICR CDI UNIT START MAC SW l B B exu 00 S 1 POSTIOVBLLB amp 5 a8 zc k VSW 2n a c mE L E E 9 gn i oag BE ESTE 5 a aS a dE 5 HEADLIGT BULB F5 amp V35 35W T d G E ji n a B FHH MR WKRBULB eV2W DG HOF B aY YB LGR E fo R B 3 TALSTOP LIGHT BULB TMENUE GW AM EV5WE WY s HR RE L me MEIER B m F ame LH FR VWERBLLB m EV OW INR G G SSBR B B 45V IB oO AO d a Bu INR Ei B um2. Flexible Length Balance Weight Spring 20 0mm 6 Inspect Clutch Block Movement Replace it in case of any unsmooth ness Main Grooved Wheel 1 Inspect Main Sliding Grooved WheelC Main Fixing Grooved Wheel Shaft Sleeves of Sliding Grooved Wheel Shaft Ring Replace it in case of any abrasion crack scratch or damage 40 Inspection and Repair 2 Inspect Free Movement Put the shaft ring into the main sliding grooved wheel to test the free movement Replace the grooved wheel or the shaft ring in case of getting stuck or loosen 3 Inspect Ball Bearings Replace them in case of any damage 4 Inspect ED of Ball Bearings Replace them in case of any inconformity ED of Balance Weight 15 0mm Limit 14 5mm A Worn Parts B Measurement Points 5 Inspect Cam of Main Grooved Wheel Sliding Fittings 6 Inspect Cam Movement Situation Repair in case of any unsmoothness 41 Inspection and Repair V Belt 1 Inspect V Belt Replace it in case of any crack abrasion off line and gap Replace it in case of any oil remains 2 Measure Width of V Belt Replace it in case of any inconformity Width of V Belt 16 6mm Limit 14 6mm Notes Measure each poison of the V belt Counter Grooved Wheel 1 Inspect Counter Grooved Wheel Fixed Counter Grooved Wheel Movable Oil Seal Replace the set in case of any scratch crack or
3. Replace if it looses the springiness or is crack Steps Check the leaf valve by eyes Notes The leaf should contact the valve seat closely or slightly under a normal situation Suck the leaf in order to test the tightness beside the carburetor The leakage should be stable and unsharp 2 Measure Height of the leaf valve stopper Replace it in case of any inconformity Height of Leaf Valve Stopper 6 0 6 4mm 84 Assembly and Adjustment of the Engine 3 Measure Bend Limit of the Leaf Valve Replace it in case of any inconformity Bend Limit of Leaf Valve 1 0mm Installation Pay attention to the following items in addition to make an assembly as a converse order as the dismantlement 1 Install Gasket Leaf Valve Intake Manifold Notes Unused gaskets are required 85 Assembly and Adjustment of the Engine Removal of Troubles in Carburetor Phenomenon The mix ratio is too thin The engine idle speed is too fast or blow out Bad acceleration CO Low HC High Inspect if the intake guide tube of the air Yes l filter is off or not _ Deen if the intake manifold is cracked or not Dismantle the connector of the air pipe near the carburetor block the opening of the connector and unlock the air guide bolt for 3 4 circle Restart the eneine Check the operation of the throttle Wire rope Check the carburetor Others Such as air filter NG Repair
4. Inspect and repair the starting motor by removing the following parts without dismantling the engine Exhaust Pipe Assembly Rear Wheel 1 Dismantle Starting Motor Crankcase Right 1 Dismantle Screws M6x35 Oil Seal Blocking Sheet 2 Dismantle Crankcase Right Notes Loosen each nut by circle and take down after loosing all nuts Process of Crankcase Dismantlement Install crankcase dismantlement tools 3 Notes Lock the screws of the tool and make it paralleled to the crankcase Loosen slightly one fixing screw when necessary in order to adjust the tool to parallel 3l Dismantlement of Engine Constantly tap each installation base of the engine in turn during dismantlement operation and then remove the right crankcase Tap each strengthening part of the crankcase with a plastic hammer Don t tap the gasket of the crankcase Pay attention to the dismantlement Remove the right as well as the left crankcases completely Take down the dismantlement tool and reinstall it if the right or the left crankcase doesn t have been removed completely Don t dismantle the crankcases by force but check if screws haven t been unfastened 3 Dismantle Crank Shaft Notes Remove the crank shaft with the crankcase dismantlement tool Lock the screws of the tool and make it paralleled to the crankcase Loosen slightly one fixing screw when necessary in order to adjust the tool to
5. Quickcharging should be limited to an emergency normal charging is preferred 114 ATV Body 8 ELECTRIC STARTER Information A weak battery may be unable run the starter motor quickly enough If the battery voltage is enough while the engine is not cranking the starter motor may be damaged Troubleshooting Starter motor turns slowly Weak battery Poorly connected starter motor cable Faulty starter motor Poorly connected battery ground cable Starter motor will not turn Engine stop switch at left or right position Gearshift bar 1s not at neutral position Check for a blown fuse near battery Make sure that the battery 1s fully charged and in good condition 115 ATV Body 9 LIGHT BULBS REPLACEMENT Remove the front fender cover Remove the rubber boot from the headlight case Disconnect the headlight wire connector Relax the lock clips to remove the bulb and replace with a new one Install the bulb aligning the bulb socket groove with the bulb tab and set the lock clips Connect headlight were connector Install the rubber boot Install the front fender cover in the reverse order of removal POSITION LIGHT Remove the bulb socket by pulling it out Remove the bulb Install the bulb in the reverse order of Removal 116 ATV Body TAIL BRAKE LIGHT Remove two screws and brake light cover Remove the bulb socket by turning it counterclockwise Remove the bulb Inst
6. 2 Dismantle Lubricating Pipe Carburetor Assembly 16 Dismantlement of Engine Pipes Wire Ropes and Wires Uint 1 Dismantle Lubricating Pipe beside the lubricating box High Voltage Wires 2 Power Line of Thermal Switch Notes Clog the lubricating pipe and the openness of the lubricating box in order to prevent lubricants from flowing 2 Dismantle Cooling Water Pipes Connecting Water Tank to Engine Generator Housing 3 Dismantle Lubrication Pump Housing 4 Dismantle Lubrication Pump Wire Rope 17 Dismantlement of Engine 5 Dismantle CDI Generator Wires Unit Starting Motor Wires Unit 6 Dismantle Fixing Screws of Exhaust Pipe Fixing Screws behind Exhaust Pipe Notes Pay attention to the temperature of the exhaust pipe 7 Dismantle Engine 09 18 Dismantlement of Engine Cylinder Head Cylinder and Piston Notes Inspect and repair the cylinder head cylinder and piston by removing the following parts without dismantling the engine Covers Food Pedal Carburetor 1 Dismantle Engine Mount 2 Dismantle Intake Manifold Leaf Valve Gaskets 3 Dismantle Spark Plug Cylinder Head Gaskets Notes Loosen the nuts across Loosen each nut by circle and take down after loosing all nuts 19 Dismantlement of Engine 4 Dismantle Cylinder Gaskets of Cylinder 5 D
7. Clean or Replace 86 Assembly and Adjustment of the Engine Removal of Troubles in Carburetor Phenomenon 2 The mix ratio is too thick The engine idle speed is unstable or blow out Bad Acceleration CO and HC values are high Check es If the filter pulp of the air filter is Clean Replace blocked by dirt or not Dismantle the connector of the air pipe near the carburetor block the opening of the connector and unlock the air guide bolt for 3 4 circle that 1s the original circles and the 3 4 circle Restart the engine Check the operation of the throttle Wire rope Check the carburetor Others Such as air filter NG Repair Clean or Replace 87 ATV Body FRONT WHEEL SUPENSION AND STEERING 1 PARTS DRAWING 2 TROUBLESHOOTING 3 HANDLEBAR 4 THROTTLE HOUSING 5 FRONT WHEEL 6 FRONT BRAKES 7 STEERING SYSTEM 1 PARTS DRAWING 88 ATV Body 89 ATV Body 2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing FRONT WHEEL WOBBLING Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly BRAKE DRAG Incorrect brake adjustment Sticking brake cable STEERS TO ONE SIDE Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushing Incorrect wheel alignment POOR BRAKE PERFORMANCE Brake sh
8. a ES 1 Y m Q m COMB METER ASSY T 7 a ua amp KG mam 8 d 4 gt 6 oma z LU L c a 1 m REST EN aE D p Bed a co gi Ss U gt O N allt 5 A 60 AC nine FLUSHER HON EARTH FEGFEC ST SGHOACC RVRL ACH LO FELAY START WAKER DMVER W Ei W W OMB SW LEFT SWICH HON WNEH s DMR 2V 10Wy B P BV DBR DG L o TY Di L BK LH FR WVERELLB a UE eee tie x bs FREE z SH o E l B L LIV Br W DBR DG Ss PUSH A FREE 120 ATV Body 11 TROUBLE SHOOTING 1 Engine does not start 2 Poor Performance at low and idle speed 3 Poor Performance at high speed 4 Loss of power 5 Poor handling 11 1 Engine does not start Check fuel flow to Carburetor N G Spark Test Weak or No Spark OK Cylinder Compression Test N G Low Compression OK N G Start the Engine Engine starts Stops OK Remove spark Plug N G And Inspect Wet plug 121 Possible Causes No fuel in fuel tank Clogged float valve Clogged fuel tank cap breather hole Clogged fuel line or filter Faulty Spark Plug Fouled spark Plug Faulty CDI unit Faulty Alternator Faulty engine stop switch Poor connection Broken or shorted wires Broken or shorted ignition coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and or piston rings Damaged cylinder head gasket Auto choke off or damaged Auto cho
9. and band ends of cotter pins Notes Always use a new cotter pin 100 Indentation Suface pee P Fal r4 i3 M NM ul To amp K uckle Arm To Steering Column ATV Body REAR WHEEL SYSTEM 1 PARTS DRAWING 2 TROUBLESHOOTING 3 REMOVE REAR WHEEL AND REAR BRAKE 4 REAR BRAKE AND WHEEL INSTALLATION 5 SHOCK ABSORBER 6 SWING ARM 1 PARTS DRAWING 101 ATV Body 102 ATV Body 2 TROUBLESHOOTING Bad Brake Performance Brake shoes are worn Bad brake adjustment Brake lining are oily greasy or dirty Brake drums are worn Brake arm setting is improperly engage Vibration or wobble Axle is not tightened well Bent rim Axle bearings are worn Faulty tires Rear axle bearing holder is faulty Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bushing Soft Suspension Wear shock absorber damper Wear shock absorber spring 103 ATV Body 3 REMOVE REAR WHEEL AND REAR BRAKE Remove 4 bolts Wheel Nuts Remove Cotter pin and Cross thread nut Remove the 2 caliper ass y bolt 104 ATV Body Pressure downward to remove the brake pads Check the brake pad if the thickness is under the change to new pads 4 REAR BRAKE AND WHEEL INSTALLATION Install the brake pad as the reverse process 105 ATV Body 5 SHOCK ABSORBER Remove shock link rear bolt Remove shock lin
10. automobile to avoid it to be interfused in the engine or other parts 2 Special tools appropriate instrument and correct operation should be applied to special places in efforts not to damage the special parts e g double open box wrench set and socket wrench shall be used instead of spanner 3 Itis noticeable for dismantlement and assembly Measure and record the dismantlement as reference for the assembly Keep the dismantled parts by classification in order to avoid mixing and loss Clean the engine gears and other parts with kerosene and diesel oil and have them dried with air after being dismantled Compare the repaired and maintained parts to that before being dismantled and then assemble them Parts for assembly must be kept from any foreign matter All bumpers must be operated before assembly All movable parts must be supplied with lubricants or greases Lock screws with the designed torque Closely coordinate with each other in order to avoid loss or disoperation 4 No fire 1s permitted during the maintenance and in the maintenance place B Gasket Oil Seal and O typed Oil Ring 1 Gaskets asbestos gaskets oil rings bolts and small clips shall not be reused after being dismantled C Special Tools Special tools shall be applied to special places in efforts not to damage the special parts during dismantlement and assembly Adjustment and Measurement 1 Engine Speed Meter to test the engine speed 2 Gage To
11. damage 2 Inspect Torque Guide Channel Guide Pin Replace the set in case of any abrasion or damage 3 Inspect Movement of the Sliding Grooved Wheel Replace the set in case of any unsmoothness 4 Measure Spring Flexible Length Counter Grooved Wheel 42 DU Replace it in case of any inconformity Flexible Length Counter Grooved Wheel 94 0mm Limit 91 0mm 43 Inspection and Repair Starting Clutch Gear 1 Inspect Starting Clutch Insert the anchor pin into the groove and turn it counterclockwise Replace the starting clutch assembly in case of unsuccessful operation 2 Inspect Starting Gear Teeth Gear Idle Teeth 2 Replace them in case of any burn deformation abrasion or gap 3 Inspect Contact Surface Starting Wheel Contact Surface Bearing Gasket 39 Replace them in case of any falling or damage 4 Inspect Operation of the Starting Clutch KEKE KE KE E KE E E KE K KE K EK KE K KE K KE K KE K CE KE K KE ECKE CE K K K K K K K K K K K GE Steps Install the starting wheel on the starting clutch and then make the clutch not to move Turn the starting wheel counter clockwise to where marked A and the wheel and the clutch get stuck Their failure to get stuck indicates the clutch is damaged so replace it Turn the starting wheel clockwise to where marked B and the wheel and the clutch can move individually The failure indicates t
12. Brief Introduction Notices This User Manual compiled by ACCESS MOTOR is especially for the distributors and service personnel of ACCESS MOTOR Impossibility of covering all knowledge related to ATV defines the User Manual to be used by the mechanic who can further develop a good sense of theory of engine procedure of maintenance and skills of maintenance in only maintaining and repairing ACCESS MOTOR ATV In the event of lacking such know how either inappropriate fitting or danger upon assembly in the process of repairing ATV will occur ACCESS MOTOR will try hart to improve all types and inform the distributors in advance in case of any modification or alteration of the specifications and make it incorporated into the revised User Manual It is important to notice The following three words always appear in the Manual and are outlined below WARNINGS it indicates some procedures must be abide by otherwise may cause damages to the operator other persons or vehicles and even cause death NOTICES it indicates some procedures must be abided by so as to avoid damages upon vehicles NOTE it indicates some procedures are detailed in the note 1 Identification of the ATV Body and Engine 1 1 Stenciling Position of VIN Number 2 European Code SOCC RK3SP10037A000001 1 2 Stenciling Position of Engine Number SOCC EO03R000001 2 Important Notes A Preparations 1 Assuredly clear up dirt and dust on the engine of
13. Measure the height of the oil level with a easoline gauge Check if the needle vale its seat and the float chamber are worn or torn or not Replace them in case of any abrasion the needle valve and its seat must be replaced together Adjust the chamber tongue if they are in good situation Install the carburetor 81 Re measure the height of the oil level 82 Assembly and Adjustment of the Engine Manual Choke Inspection 1 Dismantle Front and Rear Covers 2 Inspect Operation of the Manual Choker Steps Step 1 Connect an proper tube to the starting air inlet Blow the air into the tube to check if the tube 1s through or not Through operation of the starting piston is normal Not operation of the starting piston 1s abnormal Replace the manual choker assembly in case of abnormality Step 2 Pull upward the manual choker wire to the utmost Blow the air into the tube to check if the tube is through or not Through operation of the starting piston is normal Not operation of the starting piston 1s abnormal Replace the manual choker assembly in case of abnormality Step 3 Q Push back the choker seat and repeat stepl 83 Assembly and Adjustment of the Engine Leaf Valve Dismantlement 1 Dismantle Carburetor 2 Dismantle Intake Manifold Leaf Valve Gasket Inspection 1 Inspect Intake Manifold Replace it in case of any damage or crack Leaf Valve
14. NG 8 ELECTRIC STARTER 9 LIGHT BULBS REPLACEMENT 10 WIRING DIAGRAMS 111 1 TROUBLESHOOTING ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG NO SPARK AT PLUG ENGINE STARTS BUT RUNS POORLY CHARGING SYSTEM FAILURE ENGINE STOP SWITCH AT LEFT OR RIGHT POSITION GEARSHIFT BAR IS NOT AT NEUTRAL POSITION FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POORLY CONNECTED Between CDI and ignition coil Between alternator and CDI unit Between CDI and engine stop switch Between ignition coil and spark plug Between generator and CDI unit IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit LOOSE BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH 112 ATV Body 2 IGNITION COIL Remove the spark plug cap from the spark plug Disconnect the ignition coil primary wire Measure the primary coil resistance STANDARD 1 1 20 Measure the secondary coil resistance with the spark plug cap in place STANDARD 6 61 K 20 3 IGNITION TIMING The ignition advance is 18 1 5000rpm The capacitive discharge ignition CDI system is factory pre set and does not require adjustment 4 ALTERNATOR EXCITER COIL Remove the seat rear fender and front fender disconnect the exciter coil
15. Total Piston Displacement 49cm Bore Stroke 40 0mm 39 2mm 9 5 1 Compression Ratio Electric Foot Kick Types of Start Method of Lubricating Separate Lubrication Brands of Lubricants For Engine 2 Stroke SAE 20 For Gears SAE 40 Amount of Lubricants 110 10cc Engine Oil Gear Oil Amount Changed Total Amount Air Filter Wet Materials Fuel Type Amount in Gasoline Tank Carburetor TK VM16SS Brands and Types Spark Plug BPR7HS Types and Brands NGK Gap 0 9 1 0mm Types of Clutch Dried Inward Direct Loaded unleaded gasoline Only 14 8L Cylinder Head Torque Limit Cylinder Inside Diameter Upper Limit Taper Limit Out of Round Limit Piston Size of Piston Measurement Position Piston Clearance Piston Ring Sectional Drawing Top Ring 2 Ring Depth of Ring Groove Top Ring 2 Ring Close Gap Top Ring 2 Ring 0 03mm Check according to the six directions 39 993 40 012mm 0 1mm 0 05 100mm 0 006mm 39 958 39 972mm 5mm 0 035 0 040mm BxT 1 2x1 6 mm BxT 1 2x1 6 mm 0 15 0 35 mm 0 15 0 35 mm 0 03 0 05 mm 0 03 0 05 mm Width A for Crank Shaft Assembly Width C for Crank Shaft Assembly Gap D for Big End of Connecting Rod Oscillation Amplitude E for Bid End of Connecting Rod Gap F for Small End of Connecting Rod Clutch Thickness of Clutch Upper Limit Length of Pressure Spring External Diameter of Balancin
16. all the bulb in the reverse order of removal Screws Bulb Rubber Boot Bulb Socket SIGAL LIGHT ON ROAD FRONT Remove the rubber boot from the turn signal light case Remove the bulb socket by turning it counterclockwise Bulb Remove the bulb Install the bulb in the reverse order of removal 117 ATV Body REAR Remove the nut Remove rear signal light cover It is install without screw Remove the bulb socket by turning it counterclockwise Remove the bulb Install the bulb in the reverse order of removal 118 Signal light cover ATV Body 10 WIRING DIAGRAMS Color Blue Yellow Brown Black Blue Red Brown White Dark Green Dark Brown YellowAvhite Black Orange Pink White Black Gray 17 BL Black Blue o 18 BAY jBac Yelow 1 BG Bacd Gen 119 ATV Body 1 TROUBLESHOOTING
17. ase of any deformation or damage Leaf Valve 1 Inspect Leaf Valve Leaf Valve Stopper Replace it in case of any crack or damage 38 Inspection and Repair Foot Shaft 1 Inspect Foot Shaft Replace it in case of any abrasion or damage Return Spring Replace it in case of any crack or damage Nail Groove Foot Small Gear Gear Teeth of Foot Shaft Foot Small Gear Teeth Toothed Fact of One Way Clutch 9 Replace it in case of any abrasion or damage 2 Measure Clamp Tension Foot Small Gear Replace it in case of any inconformity Measure it with a spring balancer Clamp Tension 150 250g Clutch 1 Inspect Inside walls of the clutch hub Replace it in case of any scratch or rust Polish the inside walls with emery clothes in case of any scratch 2 Measure ID of the clutch hub 9 Replace the hub in case of any inconformity ID Clutch Hub 112 0mm Abrasion Limit 112 3mm 39 Inspection and Repair 3 Inspect Clutch Block Polishing Parts rub it with rough sand papers Notes Wipe the clutch up with a clean textile after rubbing 4 Measure Thickness of of the clutch block Replace it in case of inconformity Thickness of Clutch Block 2mm Abrasion Limit 1mm 5 Measure Flexible Length of the Clutch Balance A Weight Spring Balance Weight Spring 9 Replace it in case of any inconformity
18. at and the float chamber in case of inconsistent height of the float chamber Replace it in case of any abrasion Assembly Pay attention to the following items in addition to make an assembly as a converse order as the dismantlement Notes Clean all parts with unused gasoline before assembly All O type oil rings and sealing oil rings to be installed into the carburetor must be unused 1 Install Float Chamber Cover 2 Install Throttle Valve Notes Insert the groove of the throttle valve into the convex part of the carburetor completely 80 Assembly and Adjustment of the Engine Assembly Pay attention to the following items in addition to make an assembly as a converse order as the dismantlement 1 Install Carburetor Body Notes Insert the convex part of the carburetor into the concave part of the intake manifold completely 2 Adjust Guide Screw Throttle Set Screw Circles of Unlocking the Guide Screw 4 4Circle Engine Idle Speed 1800 1900r min Adjustment Measure Height of the Oil Level Adjust 1n case of any inconformity Height of Oil Level 3 3 4 3mm Steps for Measuring and Adjusting the Oil Level Place the engine on a flat surface Support the engine from its bottom in order to keep the carburetor vertical Connect the gasoline gauge to the discharge pipe as shown in the picture Unlock the discharge screws and heat the engine for several minutes
19. ation Pump 40K g cm 54 Assembly and Adjustment of the Engine CDI Generator 1 Install Gasket D Semicircular Key Warnings New gaskets are required 2 Install Oil Seal Notes Smear the oil seal lip with the lithium soap greases Inspect the oil seal and replace it in case of any damage 3 Install Grommet Armature Assembly Screws Armature Assembly 80kg cm Notes Put CDI generator wires unit through the crankcase hole Install the grommet as shown in the picture 4 Install Rotor D Plain Washer Nut 3 Notes Clean the conical parts of the crack shaft and the rotor 55 Insert completely the semicircular key into the groove of the crank key when installing the rotor Screws Rotor 380Kg cm 56 Assembly and Adjustment of the Engine Starting Clutch Starting Clutch Electric Starting Clutch Gear Needle Bearing Gear Drum Plain Washer Spacer Pipe Gear Idle Plate Gear Idle Shaft Plain Washer 10 Gear Idle E ee aes ee 380kg cm 57 Assembly and Adjustment of the Engine V Belt and Main and Counter Grooved Wheels 1 Oil Ring 11 2 Clutch Cover PA 3 Clutch Twister 13 4 Return Spring for Clutch 14 5 Pressure Spring 15 6 Spring Seat 16 7 Oil Ring 17 8 Counter Grooved Wheel 18 9 V Belt 19 10 Guide Pin 20 Guide Pin Counter Grooved Wheel 21 Sliding Key of the Plate Cam Conical Spring Gasket One Way Clutch Pl
20. clearance between piston and cylinder according to the following formula Clearance to Cylinder C value of Piston to Cylinder P value of skirt section of the clutch Hone or replace the cylinder the piston and the piston ring in case of any inconformity Clearance between Piston and Cylinder 0 035 0 040mm Upper Limit 0 1mm KKK K KE EOK KE K K K K K K K K K K K K K K K K K K K K KK K K K K K K K Piston Ring 1 Measure Side Clearance Replace the piston in case of any inconformity or and measure it with a thickness gauge Side Clearance Top Ring 0 03 0 05mm 2 Ring 0 03 0 05mm 2 Install Piston into the cylinder Notes Put the piston ring into the cylinder and press it down with the piston crown in order to make it vertical to the cylinder walls 3 Measure Tip Clearance Replace it in case of any inconformity Measure it with a thickness gauge D Tip Clearance Top Ring 0 15 0 35mm 2 Ring 0 15 0 35mm 37 Inspection and Repair Piston Pin and Bearing 1 Inspect Piston Pin Replace it in case of any burn or scratch and examine the lubricating system 2 Measure External Diameter of the Piston Pin Replace it in case of any inconformity ED Piston Pin 9 996 10 000mm 3 Measure Clearance between Piston Pin and Piston Replace it in case of any inconformity Clearance between Piston Pin and Piston 0 008 0 015mm 4 Inspect Bearing of the Piston Pin Replace it in c
21. e in order to prevent the clamp 3 from slipping into the crankcase Notes An unused clamp is required 4 Install Gasket Cylinder Cylinder Notes Unused gaskets are required Notes G E 70 Install the piston ring as shown in the right picture before the installation of the cylinder Hold the cylinder body with one hand and press the piston ring with another hand Top Ring Second Ring 71 Assembly and Adjustment of the Engine 5 Install Gasket Cylinder Cylinder Spark Plug Notes Use an unused gasket Have the convex face of the gasket toward the cylinder head Notes Lock the nuts across Nuts Cylinder Head 140kg cm Spark Plug 180kg cm 6 Install Gasket Leaf Valve Intake Manifold D Notes An unused gasket is required 7 Install Gasket Exhaust Pipe Exhaust Pipe Assemble Bolt Exhaust Pipe 110Kg cm Bolt Silencer Q 260Kg cm 72 Assembly and Adjustment of the Engine Installation of the Engine Notes Pay attention to the following items in addition to install the engine as a converse order as the dismantlement 1 Install Bolt Stand Bolt Engine Body 2 Install Carburetor Notes Insert the convex part of the carburetor into the groove of the manifold 3 nstall Air Filter Notes Insert the concave part of the carburetor into the connecting groove of the air filter 4 Add Gear Oil 5 D
22. g Weight Upper Limit V Belt Width of Belt Upper Limit Foot Pedal Type Designed Value of Spring Pressure Leaf Valve Thickness Obstruct Height 37 90 37 95mm 0 03mm 0 2 0 5mm 0 004 0 017mm 0 4 0 8mm 0 4 0 8mm 2mm Imm 29 9mm 15 0mm 14 5mm Gear Idle 0 15 0 25Kg 0 150 0 154mm 6 0 6 4mm Engine Fastening Torque Cyin Mmio oao 4 Double Headed Bolis for Cylinder Mmi MO 4 Bons for Water Pamp Cover Mmea T 2 BowfoDwtCp mos oso 2 l bkwnghun Mos 3 39 2 Llabvae Melo oo 4 ArHe Meo ooo 2 Baas Melo T o 2 exhaust Tapie Mmi25 19 39 1 CwkweRL Melo oo 6 CukcweCoe M amp 10 T p 8 GearBox Cover Melo Jono 6 EE NN NINI AINININIJI HRI FA 10 Front Damper Stroke Length of Springs Upper Limit Rear Damper Stroke Length of Springs Upper Limit Wheel Types of front wheel Types of rear wheel Size and materials of front disc Size and materials of rear disc Brake Type Inside Diameter of the brake drum Upper Limit Thickness of the brake block Upper Limit Rear Brake Type Thickness of the Brake Sheet Upper Limit Type of Brake Fluid 21x7 10 20x 11 9 Disc 85mm 85 5mm 3mm 1 5mm Single Disc 4mm 0 8mm DOT 4 l1 Body Locking Torque Thread Dia Torque Kg cm Bolts for Holders above Handles M8 150250 150 250 Nuts for Steering Linkage Ax
23. he clutch is damaged so replace it KEKE KE E KE K K KE KE K E K KE K E K K K KE K K K K K K K K K K K K K K K K K K K K K K K K K K 44 Inspection and Repair Lubrication Pump Its abrasion and inside troubles may make the lubricant output inconsistent to the designed figure Though this case 1s rare inspect the following items in case of abnormal lubricant output 1 Inspect Lubricating Pipel 20 Blow it through or replace it in case of block or crack O type Oil Ring Replace it in case of any abrasion or damage 2 Inspect Driving Gear for the Lubrication Pump Driven Gear for the Lubrication Pump Replace it in case of any falling abrasion and damage 45 Inspection and Repair Crank Shaft 1 Measure Out Of Round C Side Clearance D of the big end of the connecting rod Free clearance limit F of the small end of the connecting rod Replace it in case of any inconformity Measure the values above with V type bearing seat micrometer and thickness gauge Limit of Out of Round C 0 03mm Side Clearance D 0 2 0 5mm Free clearance limit F 0 4 0 8mm Crankcase 1 Clean the crankcases with neutral solvent 2 Clean all contact surfaces on the crankcases including the gasket contact surface and the surfaces of the right and left crankcases 3 Inspect Crankcase Rep
24. he brake disk run out Service Limit 0 3 mm 0 012 in INSTALLATION Reverse the BRAKE PADS REMOVAL procedures 95 ATV Body 7 STEERING SYSTEM REMOVAL AND INSPECTION Remove handlebar Remove the two bolts and remove the cable holder steering brackets and dust seal 96 Steering Bracket Dust Seal ATV Body Remove the cotter pins and nuts attaching the tie rods then disconnect the tie rods from the steering column Remove the cotter pin and nut attaching the steering column under the frame body then remove steering column Inspect the steering column Bends damage Replace Notes Do not attempt to straighten a bent shaft this may dangerously weaken the shaft Thiar holder surface Inspect the steering brackets and oil seal Wear damage Replace 97 ATV Body INSTALLATION Reverse the REMOVAL procedures Install the steering column then tighten the nut under the frame body Torque 700 kgf cm 70 Nm 50 Ibf ft Install the cotter pin and band ends of cotter pin Notes Always use a new cotter pin Assembly the steering column and tighten the two bolts Torque 220 kgf cm 22 Nm 16 Ibf ft Install the tie rods then tighten the nut Torque 350 kgf cm 35 Nm 25 Ibf ft Install the cotter pins and band ends of cotter pins Notes Always use a new cotter pin Refer to the TOE IN ADJUSTMENT section in the CHAPTER 3 to adjust toe in Remove
25. iers Gasket Main Fixing Grooved Wheel Axle Collar of Clutch Main Sliding Grooved Wheel Heavy Roller Cam Plate P abso Linitof Cuch Sno dmm CD cum Spring Lene o Ceh 299mm chang new parts 3 500kg cm A00kg cm chang new parts chang new parts 400kg cm 58 Assembly and Adjustment of the Engine Foot Shaft l po Seb ON AC Ir DAC i Starting Return Spring Starting Shaft Gear Spring of Foot Small Gear Foot Small Gear Left Crankcase Cover Starting Shaft Sleeves Plain Washer for Starting Shaft Foot Starting Rod 90kg cm 7 59 AN L sc N TEN l4 oe pu th PTRYRS jx qo X N Wok 7i Tension of the Food Small Gear 150g 250g 90kg cm 5 90kg cm 9 8 chang new parts Assembly and Adjustment of the Engine Starting Clutch 1 Install Gasket Bearing Notes Lay the MOS2 engine oil on the gear casing 2 Install Gasket Gear Idle Gasket 3 Starting Wheel Axle Collar amp 3 Install Starting Clutch Gear Idle Plate Notes Lay the greases on the gear idle Lay the MOS2 engine oil on the inside roller of the clutch Screws Gear Idle Plate 90kg cm V Belt Main and Counter Grooved Wheels and Foot Shaft 1 Clean Sliding Surface Counter Grooved Wheel 2 Lay The lithium soap greases on the sliding surface of the sliding grooved wheel 3 Install 60 Notes Sliding Grooved Wheel int
26. in Sliding Grooved Wheel Notes Hold the cam and sliding grooved wheel by hands in order to prevent the balance weight from falling 63 Assembly and Adjustment of the Engine 16 Install Plain Washer One Way Clutch Gasket 3 Main Fixing Grooved Wheel Plain Washer Nut Notes Lock them with a pneumatic tool 17 Install Gasket V Belt Counter Grooved Wheel Assembly Clutch Casing Wind the V belt onto the grooved wheels and press the spring of the counter grooved wheel in order to make the belt into the wheel Notes Make the arrow sign on the belt forward Get rid of the remained grease or lubricant from the contact surface between the main and counter grooved wheel and the belt before installing the belt 18 Install Nut O type Oil Ring 64 Notes Lock them with a pneumatic tool Warnings An unused O type oil ring is required 65 Assembly and Adjustment of the Engine 19 Install Generator s Housing 20 Install Foot Shaft Assembly Return Spring Sleeves Plain Washer Clamp Ring 21 Hook Return Spring Notes A y amine Y Hook the end of the spring to the convex part eme T and hook another end to the groove of the foot shaft as showed in the right picture b 22 Install Stop Clamp Foot Small Gear 2 Notes Install the stop clamp as shown in the right picture 66 67 Assembly and Ad
27. ischarge Air in the lubrication pump 6 Adjust Wire rope of the lubrication pump 7 Adjust Engine Idle Idle Speed 1800 1900r p m min 73 Assembly and Adjustment of the Engine Carburetor Disassembly 1 Dismantle Air Filter 2 Dismantle Carburetor Lubricating Pipe Carburetor Cover 3 Screws Carburetor Body Notes Block the opening of the lubricating pipe two in order to prevent the lubricant from leaking 3 Dismantle Choke Wire Unit 4 Dismantle Carburetor Assemble Notes 74 Unlock the screws before dismantling the carburetor in order to discharge the gasoline in the carburetor 75 Assembly and Adjustment of the Engine Disassembly 1 Dismantle Float Chamber Cover Sealing Oil Ring 2 Dismantle Float Chamber Pin C Float Chamber Needle Valve 3 3 Dismantle Fixing Seat Needle Valve Seat Main Oil Jet 3 Main Oil Jet Tube Guide Oil Nozzle 4 Dismantle Throttle Set Screw D Spring O type Oil Ring 76 5 Dismantle Guide Screw Spring Notes Count the number of circles as dismantling the guide SCICW TI Assembly and Adjustment of the Engine Inspection 1 Inspect Carburetor Body Clean it in case of block Notes Clean it with paraffinic solvents and blow all oil nozzles with compressed air 2 Inspect Float Chamber Cover Replace it in case of any damage Seali
28. ismantle Rotor Notes Remove the rotor with a flywheel drawer 3 Dismantle Armature Assembly Semi Round Key Gasket 26 Dismantlement of Engine Lubrication Pump Notes Inspect and repair the lubrication pump by removing the following parts without dismantling the engine Covers Foot Pedal Air Filter Inlet Eye of Cylinder Wire Rope of Lubrication Pump 1 Dismantle Lubrication Pump 2 Dismantle Clip Link Drive Gear 3 Dismantle Anchor Pin Clip Link 21 Dismantlement of Engine Driving Mechanism Notes Inspect and repair the driving mechanism by removing the following parts without dismantling the engine Left Crankcase Cover Main and Counter Grooved Wheel V Belt Remove the 9 bolts Remove gear shift drum Gear shift fork guide shaft Gear shift guide shaft Remove shift fork 28 Dismantlement of Engine Remove washer plate main axle comp main axle Remove drive gear primary Drive Gear Primary Check all the bearing are normal if not change to new parts Bearing l dene Bearings a 29 Dismantlement of Engine Check all the gear operation are normal if not change to the new parts Install the brake pad as the reverse process NOTS Install gear shift fork guide shaft gear shift drum need to line up to the 3 tooth of the gear 30 Dismantlement of Engine Starting Motor Notes
29. ismantle Grip Ring for Piston Pin Notes Clog the opening of the crankcase with dried textile to prevent the grip ring from slipping into the case 6 Dismantle Piston Pin Piston Bearings on Small End Notes Remove the collected carbons from the grip ring groove and the pin hole before dismantling the piston pin to make the operation easy Notes A hammer is prohibited for dismantlement of the piston pin 20 Dismantlement of Engine Foot Shaft Main and Counter Grooved Wheel and V Belt Notes Inspect and repair the foot shaft main and counter grooved wheel and V belt without dismantling the engine and any part 1 Discharge the gear oil 2 Dismantle Foot Lever D Crankcase Cover Left Anchor Pin 3 Dismantle Foot Small Gears Clamp 4 Take down Extension Springs 5 Dismantle Grip Ring Plain Washer Sleeves 3 Foot Shaft Assembly Plain Washer 6 Dismantle O Type Oil Ring Nuts for Clutch Hub Notes Use Pneumatic tools to dismantle 21 22 Dismantlement of Engine 7 Dismantle Counter Grooved Wheel Assembly V Belt Gaskets 3 Notes As shown in the picture push with hands the counter grooved wheel assembly to remove the wheel assembly and the V belt together 8 Dismantle Nuts for Main Grooved Wheel Notes Use Pneumatic tools to dismantle 9 Dismantle Fastigiate Spring Gasket One Way C
30. ive wheel bearing play Bent swing arm Bent frame Excessive wear of swing arm bushing OK Bent Axle Vehicle pulls to one side Be Bent tie rod Incorrect tie rod adjustment Rear tire pressure incorrect Improper wheel alignment Bent frame 125
31. justment of the Engine 23 Install Anchor Pin Left Crankcase Cover Screws Left Crankcase Cover 90kg cm Notes Lock them across 24 Install Food Lever Notes Parallel the arm to the edge of the crankcase 68 Assembly and Adjustment of the Engine Cylinder Head Cylinder and Piston 1 Gassing Bolt 11 Piston Clamp Ring 2 Gassing Bolt Cover 12 Piston 3 Spark Plug 13 Piston 4 Temperature Switch 14 Small Roller Bearing 5 Cylinder Head 15 Intake Manifold 6 Head Waterproof Oil Ring 16 Check Valve Assembly 7 Head Oil Ring 17 Check Valve Gasket 8 Cylinder 9 Cylinder Gasket 10 Piston Ring A Clearance between Piston and Cylinder 0 035 0 040mm B Warpage Limit of Cylinder Head 0 03mm C Piston Side Clearance 0 03 0 05mm D Tip Clearance of Piston Ring 0 15 0 35mm E Spark Plug BPSHSA R NGK Clearance 0 9 1 0mm 90kg cm pm 16 1055 17 chang new parts 10 13 12 11 69 Assembly and Adjustment of the Engine Cylinder Head Cylinder and Piston 1 Install Piston Top and Second Ring Notes Have the signed face of the piston ring upward 2 Lay Two stroke lubricant on the bearing crankshaft and the piston groove the pin and the skirt 3 Install Bearing of the Small End Piston Piston Pin Piston Pin Clamp Notes Have the piston top with the arrow 9 downwards Block the opening of the crankcase with a clean textil
32. k rear Remove shock absorber bolt Remove shock absorber super bolt Install the parts as the reverse process 106 ATV Body FENDER AND EXHAUST PIPE 1 FRONT FENDER REMOVAL 2 REAR FENDER REMOVAL 3 EXHAUST PIPE REMOVAL 4 EXHAUST PIPE INSTALLATION 1 FRONT FENDER REMOVAL Remove the four plastic rivets and headlight connector Remove the bolts from the support bracket and remove the right amp left Signal Light connector main switch connector Bolt 107 ATV Body Remove the screws from the two side fenders Screw Screw 2 REAR FENDER REMOVAL Remove the two bolts Bolts 108 Remove the plastic rivet from the rear fender Plastic Rivet Remove the 2 bolts from support under rear Fender and right amp left signal light tail light connector Bolts Bolts Fuse Box Relay Remove the battery wire Remove the two screws from rear cover fender Screws 109 ATV Body 3 EXHAUST PIPE REMOVAL Remove exhaust muffler 2PCS bolt Remove exhaust muffler 2PCS bracket bolt 4 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal Torque Exhaust muffler bolts 300K g cm NOTE After installation check entire system to make sure that there are no exhaust leaks 110 ATV Body ELECTRICAL SYSTEM 1 TROUBLESHOOTING 2 IGNITION COIL 3 IGNITION TIMING 4 ALTERNATOR EXCITER COIL 5 BATTERY CAUTION 6 BATTERY VOLTAGE 7 CHARGI
33. ke power wire disconnected Improper adjustment of air screw Improper ignition timing Fuel Air mixture ratio to lean Carburetor flooded Improper adjustment of air screw Fuel Air mixture ratio to rich Auto choke stuck or damaged Air cleaner dirty ATV Body 11 2 Poor Performance at Low Idle Speed Possible Causes N G Check Ignition Timing Faulty CDI Unit or Pulse generator Check Carburetor and NG l Improper Air Screw adjustment Air Screw Adjustment Preform Spark N G Loose or disconnected ignition system wires waa Fall k pl fouled t Pug Tes a a an Intermittent Spark Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch 122 ATV Body 11 3 Poor performance at high speed Possible cause Check Ignition Timing ee NN Faulty CDI unit or Pulse generator N G Check Fuel Flow to Carburetor Lack of fuel in tank Fuel Flow Clogged fuel line Restricted Clogged fuel valve Clogged fuel filter Clogged fuel tank breather hose Remove Carburetor check N G l l l l for clogged jets m ei T Clean jets with high pressure air gun OK Check Air N G y Clean or Replace air clean element Clean Element Dirty 123 11 4 Loose of power Raise wheels off of ground and Spin by hand Check Tire Pressure K Accelerate Lightly Check Ignition Timing Check Spark Pl
34. kshaft contacts the bearing 48 Assembly and Adjustment of the Engine 5 Lay Binding agent on the contact surface of the left and right crankcases 6 Install Anchor Pin 7 Install Crankcase Right 8 Install Crank Assembly Tools Crank Assembly Tube Crank Assembly Bolt Crank Assembly Connecting Tube Notes Make the connecting rod stay at the top stuck point and turn the assembly tool till the lower part of the crankshaft contacts the bearing 9 Lock Screws Crankcase Notes ae Lock it across SED Pac E MEN Screws Crankcase 90Kg cm N C COH ft ty LEURS D I A ZZ JI 5 7 fa LO p al be A rr SET B TR uo N U OT E ENS ata on ee en 4 49 Assembly and Adjustment of the Engine 10 Install Oil Seal Unused Into the Left Crankcase Notes With a oil seal assemble tool Smear the oil seal lip with lithium soap greases Notes An unused oil seal is required 11 Install Oil Seal Unused Into the Left Crankcase Notes Smear the oil seal lip with lithium soap greases Notes An unused oil seal is required 12 Inspect Operation of the crank shaft Tap with a plastic hammer the crankcase till return to the original point Notes Do not knock the crack shaft 13 Install Oil Seal StopperC Screws Oil Seal Stopper 90Kg cm 50 Assembly and Adjust
35. lace it in case of any crack or damage Bearing and Oil Seal 1 Inspect Bearing for Engine Rotate the inside edge by hands after being cleaned and lubricated Replace it in case of bad performance 2 Inspect Bearing for Engine Replace it in case of any abrasion or damage 46 Assembly and Adjustment of the Engine Crankcase and Crankshaft Oil Seal Stopper Oil Seal Right Crankcase Anchor in Bearing6204C3 C 0 08mm Engine Damper Cover Starting Motor D 00 2 0 5mm Left Crankcase O 00 1 Q9 Nn BW NY Needle Bearing 10 Crank Pin 11 Connecting Rod 12 Left Crankcase 13 Left Crankcase 14 Oil Seal 47 Assembly and Adjustment of the Engine Crankshaft and Crankcase Notes Lay the lithium soap greases on the oil seal lip in order to make the installation of the crankshaft easy and prevent it from being scratched and lubricate the bearings with engine oils 1 Install Bearing Notes Make the signed surface 9 of the bearing facing the crankshaft and give a pressure from the exposed part of the bearing to assemble it 2 Lay Engine oil on the crank bearing 3 Install Crankshaft to the left crankcase 4 Install Crank Assembly Tools Crank Assembly Tube Crank Assembly Bolt Crank Assembly Connecting Tube Notes Make the connecting rod stay at the top stuck point and turn the assembly tool till the lower part of the cran
36. le Seat M8x1 25 200 300 Cover Se e e pes 3 Self Lock Nuts for Front Brake Drum Fixing NusforA Arm Mg 459 80 Upper and Lower Bolts and Nuts for Front un M10x1 25 450 600 4 Shock Eliminator Self Lock Nuts for Steering System Bolts tor Engine Fixer ms 33 30 6 Bolts for Rear Brake Caliper M12125 659 00 4 Bolts for Holders of Rear Brake Dise M8125 30 30 2 Rear Shock Eliminator mios 48 80 4 Self Lock Nuts for Rear Disc Holder MIOXI25 1450 600 i 2 Rear Nuts for Front Die mis 139 D30 2 Bolts for Rear Chain Wheel Base mio asoso s 0000 mas 200 300 o o 5 a 12 Voltage Ignition System Ignition Timing 18 5 000rpm Type of Advance Angle Electrical CDI Type of Generator Ripple Coil Resistance Inside Color 20 W R B Charging Choke Resistance Inside Color 20 B R B Ignition Coil Type 3XG Primary Winding Resistance 1 1 20 Secondary Winding Resistance 6 6K 20 Minimal Spark Lug Gap Spark Plug Lid Type Resistance Types of Charge Flywheel Generator Model Brand 3XG Charging Choke Resistance 0 6 Ignition Coil Resistance 0 5 Voltage Regulator Selenium Rectifier Type SH614 12 Capacity SA Storage Batteries Capacity 12V 5AH Specific Gravity 1 32 Starting Motor Breaker Total Torque Specification Standard Bolt This table is conformable to the Bolt Locking Specifications released by the International Standard A
37. lutch Gasket 3 Main Fixing Grooved Wheel Plain Washer 10 Dismantle Axle Collar Main Sliding Grooved Wheel Notes Hold the cam and grooved wheel together to prevent the counter weight balls from dropping 23 Dismantlement of Engine 11 Loosen Nuts Clutch Spring Compressor Warnings Nuts shall not be dismantled unless the counter grooved wheel is compressed and fixed to prevent the grooved wheel from springing out 12 Dismantle Nuts for Clutch Carrier Notes Compress and fix the counter grooved wheel with a torque tool 13 Dismantle Clutch Carrier Pressure Spring Counter Grooved Wheel Spring Seat 14 Dismantle Guide Pin O Type Oil Ring Counter Sliding Grooved Wheel 24 Dismantlement of Engine Starting Clutch Notes Inspect and repair the starting clutch by removing the following parts without dismantling the engine Left Crankcase Cover V Belt Main and Minor Grooved Wheels 1 Dismantle Gear Idle Plate Starting Clutch 2 Dismantle Axle Collar Starting Wheel Washer Gear Idle 3 Dismantle Bearing Gasket 25 Dismantlement of Engine CDI Generator Notes Inspect and repair the CDI generator by removing the following parts without dismantling the engine Covers Foot Pedal Inlet eye of Cylinder 1 Dismantle Nuts for Rotor Plain Washer Notes Use Pneumatic tools to dismantle 2 D
38. measure the gasoline level of the floating chamber 3 Torque Wrench To lock screw caps and bolts and measure the torque 4 Avometer To test the voltage current and resistance 5 Vernier Scale To measure the depth inside diameter and diameter etc 6 High Voltage Coil Meter To detect the gap of the spark plug Engine 1 Crankcase Tools To dismantle the crank shaft and the crank case 2 Rotating Part Fixer To unfasten and fasten the screw caps and fix the clutch assembly and generator 3 Generator Flyer Drawer To dismantle the generator 4 Clutch Twister To remove the clutch springs 5 Oil Seal Assembly Tools Oil Seal Leading Tools Oil Seal Assembly Tools To be used to assemble the oil seal of the crank shaft 6 Oil Seal Leading Tools To be used to assemble the oil seal of the clutch 7 Clutch Cover Scotch To fix the clutch disk 8 Wrench To fasten or unfasten the caps on the clutch 9 Crank Assembly Tools Crank Assembly Tube Crank Assembly Bolt Crank Assembly Connecting Tube To be used to assemble the crank shaft and the crankcase 10 Shock Eliminator Adjustable Wrench To adjust the shock eliminator s springs 11 Tyre Pressure Gauge To be used to detect the tyre pressure Data Sheet Specifications Length 1825 mm Width 1230 mm Height 1140 mm Distance between shafts 1270 mm Engine Original Type Air Injection Crankcase for Two Stroke Engine Layout of Cylinders Single Cylinder
39. ment of the Engine 14 Install Starting Motor Bolts Starting Motor 130Kg cm 51 Assembly and Adjustment of the Engine Driving Mechanism 1 Bearing 10 Conical Spring Gasket 2 Oil Seal 11 Oil Seal 3 Oil Filter Plug 12 External Clamp 4 O type Oil Ring 13 Gear Box Cover 5 Copper Plain Washer 14 Gasket for Gear Box Cover 6 Bolt for Discharging Oil 15 Anchor Pin 7 Driven Shaft 16 Bearing 8 Bearing 17 Main Driving Gear 9 Gear Idle 18 Gasket for Left Crankcase Cover chang new parts chang new parts A 17 18 chang new parts 52 Assembly and Adjustment of the Engine Lubrication Pump and CDI Generator l X Room c er Water Pump Assembly 11 Magneto Assembly Bearing Spacer Tube Anchor Pin Pump Actuator Disc External Clamp Pump Actuator Bolt Nut Plain Washer 10 Fly Wheel 7 chang new parts 15 12 A C G Gasket 13 Oil Pump Assembly 14 Anchor Pin 15 External Clamp 16 Drive Gear Oil Pump 100kg cm 380kg cm ls chang new parts 14 d l 12 80kg cm chang new parts S M 40kg cm A 53 Assembly and Adjustment of the Engine Lubrication Pump 1 Install Clamping Ring Anchor Pin 2 Install Driving Gear 3 Smear The O type Oil Ring with the lithium soap greases 4 Smear additionally The lubrication pump gear 15cc with the lithium soap greases 5 Install Lubrication Pump Screws Lubric
40. ndlebar and then tighten the two SCreWS 92 ATV Body UP Mark Place the right and left brake master cylinder on the handlebar and install the master cylinder holder with the UP mark facing up First tighten the upper bolt and then tighten the lower blot Torque 100 kg cm 10 Nm 7 2 Ibf ft Install the throttle unit in the handlebar and then install the lower holder and tighten the screw 93 ATV Body 4 THROTTLE HOUSING Disassembly Unscrew the screws on the throttle housing cover Remove throttle housing cover and gasket Disconnect throttle cable from the throttle arm and remove from the throttle housing Assembly is in the reverse order of disassembly 5 FRONT WHEEL FRONT WHEEL REMOVAL AND INSPECTION Place the machine on a level place Remove four nuts attaching the front wheel hub and front wheel Elevate the front wheels by placing a suitable stand under the frame Notes Support the machine securely so there is no danger of it falling over 6 FRONT BRAKES BRAKE PADS REMOVAL Remove the front wheel chapter 14 Remove the two bolts and then remove brake caliper 94 ATV Body Compress the brake caliper holder and remove brake pads A wear indicator is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator FRONT BRAKE DISK Measure the brake disk thickness Service Limit 2 7 0 0106 Measure t
41. ng Gasket Replace it in case of any damage 3 Inspect Needle Valve Needle Valve Seat Float Chamber Replace if in case of any damage 4 Inspect Throttle Valve Replace it in case of any abrasion or damage 78 5 Inspect 6 Inspect 7 Inspect Assembly and Adjustment of the Engine Movement Replace in case of bad performance Insert the throttle valve into the carburetor body to test the movement status Needle Valve Replace it in case of any bend or abrasion Main Oil Jet Guide Oil Nozzle 3 Replace them in case of block Throttle Set Screw Guide Screw Replace them in case of any abrasion or damage 8 Inspect O type Oil Ring Replace it in case of any damage 9 Inspect Chocker Piston Replace it in case of any abrasion or damage 10 Measure Height of the Float Chamber Check the needle valve float chamber and needle valve seat in case of any inconformity Height of Float Chamber 18 5mm 79 Assembly and Adjustment of the Engine Steps for Measuring the Height of the Float Chamber Install the needle valve float chamber and float pin into the carburetor body Turn the carburetor upside down as shown in the picture Measure the clearance between the chamber top to the contact surface of the float chamber that has its sealing oil ring dismantled Notes Make the chamber arm just contact the needle valve only Check the needle valve its se
42. o the Sliding Grooved Wheel Wrap with adhesive tapes the part marked 8 of the fixing grooved wheel and flat the pointed part in order to prevent the oil seal from being damaged as the sliding grooved wheel moves No rotation of the oil seal lip is permitted during the assembly process 61 Assembly and Adjustment of the Engine 4 Install Guide Pin O type Oil Ring Warnings An unused O type oil ring is required 5 Lay The lithium soap greases on the torque cam groove D and O type oil ringQ 6 Inspect Operation of the Sliding Grooved Wheel Repair it in case of bad performance 7 Install Spring Seat Counter Grooved Wheel Pressure Spring Clutch Twister Notes Get rid of the overmuch grease 8 Clean Contact surface between the nut and the clutch twister 9 Install Nut Clutch Twister Notes Compress and fix the counter grooved wheel with a clutch twister in order to install the nut 62 Assembly and Adjustment of the Engine 10 Lock Nut Clutch Twister Notes Install the counter grooved wheel onto the main driving shaft and lock it with a pneumatic tool 11 Clean Sliding Surface Balance Weight 12 Install Balance Weight to the sliding groove 13 Install Cam Main Grooved Wheel Slip Fitting Main Grooved Wheel 14 Inspect Operation of the Cam Main Grooved Wheel Repair it in case of bad performance 15 Install Axle Collar Set of the Ma
43. oes worn Worn brake drum Brake lining oily greasy or dirty Improper brake adjustment FRONT SUSPENSION Loose front suspension fastener Binding suspension link HARD SUSPENSION Faulty front swing arm bushing Improperly installed front swing arms Bent front shock absorber swing rod SOFT SUSPENSION Wear front shock absorber springs Worn or damage front swing arm bushing 90 ATV Body 3 HANDLEBAR Remove the following parts Seat cover Fender front fender and handlebar cover Remove the right and left master cylinder and remove bands then disconnect the rear and front fluid tube from the handlebar Remove the two screws and remove the handlebar switch Remove the screw and remove throttle unit Screw Bolts Remove the handlebar cover then remove four handlebar holder bolts and handlebar holder Handlebar Holder INSPECTION Inspect the handlebar Cracks bends damage Replace 9 ATV Body INSTALLATION Install handlebar and handlebar holder then _ tighten the four bolts Torque 220 kgf cm 22Nm 16 Ibf ft Notes Align the mark on the handlebar with the lower handlebar holder surface Notes Be sure the upper handlebar holder mark face to front eFirst tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side Install the handlebar switch by aligning the pin on the handlebar switch with the hole in the ha
44. parallel 32 Inspection and Repair Cylinder Head 1 Remove Collected carbon from the combustion chamber with a scraper Notes Don t use pointed tools in order to prevent the spark plug installation teeth from being damaged or scratched 2 Inspect Cylinder Head Replace it in case of any scratch or damage 3 Measure Warpage Adjust it in case of any inconformity Warpage Limit 0 03mm KKK K KE KE KE E K K K K K K K K K K K K K K K K K K K KK K K OK K K K K Measuring Steps Put an angle square on the cylinder head and measure the Warpage with a thickness gauge Adjust the cylinder head in case of inappropriate Warpage K KK K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K 4 Finish Cylinder Head KK K K KE KE K K K K K K K K K K K K K K K K K K K K K K KK K K K K K K K Repair Steps Put a sand paper 400 600 on a flat face and finish the cylinder head on it at an order like 8 Notes Rotate the cylinder head to finish it in order to avoid much abrasion of one edge of the cylinder head OK OK 2K K OS KE K OS OK K K K K K K K K OS K K K K K K K K K K KK K K K K K K K 33 Inspection and Repair Cylinder and Piston 1 Remove Collected carbon with round headed scrapper Notes Don t use pointed tools in order to prevent damage or scratch 2 Inspect Cylinder Wall Hone or replace it in case of any abrasion or scratch 3 Remove Collected carbon from the pi
45. ssociation Lock bolts across or subject to the designed order in order to avoid any torsion or unbalance x Use a torque wrench to test the torque X lkef cm 0 098066N m Total Torque A Through Space B External Diameter of Screw Thread A B 14 Inspection amp Adjustment Section The maintenance intervals in the follow table are based upon average riding and condition Riding in usually dusty areas requires more frequent servicing Periodic Maintenance Lubricating Table Gaso r R mus R Rame 1 amp cR a R Sek 1 1 1 Gmuan a 1 Throttle Valve Operation Tf sw T me T Steering Linkage Operation Bakeca Driving System 1 Suspension Stem Bude S DRVEBATTERY Sid Wheel Bearing Cum Tote Cable A Adjust C Clean I Inspection R Replace T Tighten L Lubricate 15 Dismantlement of Engine Notes The engine shall not be dismantled in case of removal of the following parts Main and Counter Grooved Wheel Carburetor CDI Generator Starting Motor Lubrication Pump Cylinder Head Cylinder Piston Cushion Covers Storage Batteries Boxes and Foot Pedal 1 Dismantle Cushion Covers Storage Batteries Carburetor 1 Dismantle Ventilating Tube beside the carburetor Air Filter D
46. ston crown and the ring grooves Piston Crown Replace it in case of any scratch or damage 5 Remove scratch or collected carbon from the piston walls with sand paper 600 800 Notes Remove it across and avoid over attrition 6 Inspect Piston Walls Replace it in case of any abrasion scratch or damage 34 Inspection and Repair 7 Measure Clearance between piston and cylinder KKK KE KE KEKE KE K K K K K K K K K K K K K K K K K K K K KK K K K K K K K K K K Measuring Steps Step 1 Measure the C value of the cylinder with a cylinder gauge Notes Parallel the cylinder gauge to the crank shaft at a right angle and then measure the average value OOOO Reenevaus Wear Limit O 5993 82 112mn 52 98 52012mm 45993 80 12m s093 50 002mm 39993 40 12mn 4093 4002mm mee Soom owotRomdd 06mm If C D the max T max of D1 or D2 max of D5 or D6 R max of D1 D3 or D5 max of D2 D4 or D6 Hone or replace the cylinder the piston and the piston ring in case of any inconformity Step 2 Measure the P value of the skirt section of the piston with a micrometer caliper a 5mm shall be started from the bottom of the piston Piston Size P Standard Size 53 958 53 972mm 51 958 51 972mm 49 958 49 972mm 39 958 39 972mm 35 Replace the piston and the piston ring in case of any inconformity 36 Inspection and Repair Steps 3 Calculate the
47. the cotter pin and nut attaching the tie rod and steering column Remove the cotter pin and nut attaching the tie rod and steering knuckle Then remove tie rod 98 Cotter pin Cotter pin ATV Body Inspect the tie rod Bend damage Replace Cheek the tie rod end movement Tie rod end exists free play or turns roughly Replace Check the tapered surface of the tie rod end Pitting wear damage Replace Adjust the tie rod length Adjustment steps The following procedures are done on both tie rods right and left Loosen the tock nuts Adjust the tie rod length by tuning both tie rod ends Tie rod length 430 1 mm Indentation 99 ATV Body Set the rod end steering column side in an angle where the indentation surface of the toe rod is parallel to the rod end shaft and then tighten the lock nut Torque 300 kgf cm 30 Nm 22Ibf ft Notes After making adjustment on both tie rods be sure to mark them R and L for identification Notes The threads on both rod end must be of the same length INSTALLATION Reverse the REMOVAL INSPECTION procedures Install the tie rod onto the steering knuckle and steering column then tighten the nuts Torque Steering knuckle side 210 kgf cm 21Nm 15 Ibf ft Steering column side 350 kgf cm 35Nm 25Ibft ft Notes Be sure that the rod end on the indentation surface side 1s connected to the steering knuckle Install the all cotter pins
48. ug K Check for Engine Overheating O K Accelerate or Run at High Speed ATV Body N G Does not spin freely N G 2 i Low tire pressure N G o gt Engine speed does Not increase N G _ N G Low pressure N G Clogged N G Fouled or Discolored N G Overheating N G i Knocks 124 Brake dragging Adjust brake Drive chain too tight Damaged wheel bearing Wheel bearings need lubricated Punctured tire Faulty tire pressure value Fuel Air mixture ratio to rich or lean Clogged air cleaner element Clogged exhaust muffler Fuel flow restriction Lack of fuel in tank Clogged fuel valve Clogged fuel filter Clogged fuel tank breather hose Faulty CDI unit Faulty pulse generator Leaking head gasket Worn Cylinder and or piston rings Clean fuel jets Clean float valve Clean Re gap spark plug Faulty spark plug Spark plug is incorrect heat range Wrong fuel type Fuel Air Ratio mixture to lean Use of poor quality or old fuel Excessive carbon deposits in combustion chamber Worn piston and or cylinder Fuel Air Mixture ratio to lean Wrong fuel type Ignition timing to advanced Excessive carbon deposits in combustion chamber ATV Body 11 5 Poor Handing Possible Causes Steering feels heavy NBS Damaged steering bearing Damaged steering shaft bushing Bent steering shaft OK One wheel is wobbling ARS Bent rim Improperly installed wheel hub Excess
49. wire Measure the resistance between the yellow or white or green wire and ground STANDARD 467 700 Electrolyte is poisonous Drink large quantities of water or milk and call a physician if swallowed 5 BATTERY CAUTION The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging or using the battery in an open area The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous Drink large quantities of water or milk and call a physician if swallowed 113 ATV Body 6 BATTERY VOLTAGE Battery is under the seat you can see this battery after removing the seat Measure the battery voltage using a voltmeter VOLTAGE Fully charged 13 1 V Undercharged Below 12 0 V BATTERY REMOVAL Remove the seat then you can see the battery Disconnect the negative cable and then the position cable and remove the battery BATTERY INSTALLATION Install the battery in the reverse order of removal After installing the battery terminals with clean grease 7 CHARGING Connect the charge positive cable to the attery positive terminal Connect the charge egative cable to the battery negative terminal Using 9A charging current about 5 hours Normal charging Or using 4A charging current about 1 hour Quick charging Keep flames and spark away from a battery being charged
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