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250cc Sand Viper Owners/Parts Manual

Contents

1. 166 8 MAGNETOR ASSY 167 9 ADMISSION MACHANISM 168 10 CRANK LINK LEVER amp PISTON 169 11 SPEED CHANGER 170 12 CLUTCH ASSY 171 13 GEARBOX COVER ASSY 172 14 TRANSMISSION GEAR ASSY 173 15 GEAR SHIFT MACHANISM 175 16 ENGINE OIL PUMP ASSY 176 17 COOLANT PUMP ASSY 177 18 ELECTRIC STARTER ASSY
2. Dual 4 point Harness Final Drive Chain 10Ax62 TIRE PRESSURE Front 42kpa 6 1psi Rear 56kpa 8 1psi WEIGHT Net Weight 350kg 771lbs WARRANTY Parts and workmanship 90 Days 25 OPERATION A Operation controls WARNING Do not attempts to start or operate the engine until completely familiar with the location and use of each control necessary to operate this vehicle The operator must know how to stop this machine before starting and driving it a Throttle The right foot pedal is the throttle that controls the off highway recreational vehicle speed As the engine speed increased above idle the clutch automatically engages and moves the vehicle forward Allow the throttle to return to the idle position at any time and the clutch disengages See Fig 1 Each time prior to starting the engine
3. 0 6 0 7mm Fuel type RQ90 unleaded Lubricate oil SAE 10W 30 CAPACITIES Maximum load 400Ibs Fuel tank 16 0L Engine oil 1000ml Gear oil 1000ml Coolant 1800ml Starting lt 5s Climbing 20 25 Battery
4. 178 19 CARBURETOR ASSY 179 2 20 FRAME amp FUEL TANK amp RADIATOR 180 21 FRONT SUSPENSION 184 22 STEERING amp THROTTLE amp BRAKE amp SHIFT 188 23 ENGINE RACK amp TRANSMISSION 192 24 ENGINE ASSEMBLY 194 25 EXHAUST SHIFT amp BRAKE 196 26 REAR SUSPENSION 200 27 ELECTRICAL PARTS 202 28 OTHER PARTS 204 PREPARATION ATTACH INSTRUCTION
5. 12V 9Ah Head Light 12V 15W Tail Light 12V 5W 10W 21W Fuse 10A Brake Track lt 7m 20miles h Top speed 40 miles h or limited as customers require CHASSIS Front Rear brake Hydraulic disc right foot control Front tire 21 8 10 Rear tire 22 10 10 Front Suspension Independent Dual A Arm Rear Suspension Trailing Arm Double Oil amp Damped Shock Restraint System
6. 108 GEARBOX GEAR SHIFT MECHANISM 125 MAGNETO STARTER CLUTCH AND OIL PUMP 141 CHASSIS REPAIR 154 WIRING DIAGRAM 155 PARTS MANUAL 156 1 CRANKCASE ASSY 156 2 SIDE COVER ASSY L 158 3 RIGHT COVER ASSY 159 4 CYLINGDER HEAD CASEING ASSY 161 5 CYLINGDER HEAD ASSY 163 6 CYLINGER BODY ASSY 165 7 TIMING CHAIN
7. 72mm 60mm Displacement 244 cc Corrected compression ratio 10 1 Carburetor KEI HIN No VE 14CEQKY Output Power 14 7hp 7000rpm Maximum Torque 17 6 Nm 5500r min Starting Electric Ignition C D I Lubrication Force amp Splash Transmission Automatic C V T system Spark Plug DPR7EA 9 NGK Plug gap
8. 208 ATTACH BATTERY 208 ATTACH PROTECTIVE BARS 209 ATTACH REAR SHOCK 210 ATTACH TRAILING ARM 210 ATTACH FRONT SHOCK 211 ATTACH FRONT TIRE 212 ATTACH SEAT AND SAFT BELT 213 ATTACH THE RADIATOR 213 ATTACH SILENCER 214 DEALER PRE DELIVERY INSPECTION 215 3 WARRANTY POLICY 4 5 6 7 8 9 10 11 12 13 14 OWNER S MANUAL FOREWORD Thank
9. Make sure all the O ring and seal washer are not damaged Driving belt pulley and driven belt pulley 1 Take of left side cover 2 Check the wear condition on the driving belt pulley and driven belt pulley 3 If wore out measure the depth of wearing Refer to related instruction Oil filling bolt Oil draining bolt Oil draining washer Oil ring Oil draining washer Oil draining bolt Oil filling bolt 54 Spark plug 1 Removing the spark plug 2 Check the spark plug if damage dirty or sediment 3 If dirt or sediment clean with spark plug cleaning tool or cleaning brush Adjust the gap of spark plug if necessary Specified gap of spark plug DPR7EA 9NGK 0 8 0 9 To install spark plugs rotate the spark plug with hand until can t rotate anymore Then fasten the spark plug with spark plug sleeve Torque 18N m Idle adjustment Adjust the idle speed after the engine warm up if the carburetor was repaired adjust the idle speed after adjust air regulating screw According the related requirement do the following operation Worm up engine Connect RPM indicator Rotate valve stopping screw clockwise or count clockwise until the RPM indicator display 1500 150rpm If the idle speed is not steady or the RPM change after operate the throttle pedal just adjust air regulating screw according third chapter Valve stopping screw 55 The maintenance for air filter 1 Take off the air filte
10. 02 DI250 07 01 0001 DI250 07 01 00 01 BRIDLE BOOT 4 3 02 DLJ BT 2075 BT 2075 OUTER BOOT 2 4 02 DI250 07 01 0003 DI250 07 01 00 03 BRIDLE BOOT 4 5 02 DLJ BT 2075 BT 2075 INNER BOOT 2 6 02 DLJ MQC4 2303016 MQC4 2303016 STEEL THREAD CIRCLIP 2 7 03 09 894 2 26 894 2 26 CIRCLIP FOR AXIS 26 2 8 03 01 77 M5X6 09 77 M5X6 HOLDING SCREW M5x6 2 9 02 DN250 07 000003 DN250 07 00 00 03 SPROCKET SHAFT SLEEVE 2 10 03 06 13871 FB38X62X8 13871 FB38x62x8 GEASE SEAL FB 38x62x8 2 11 03 09 893 2 62 893 2 62 CIRCLIP FOR HOLE 62 2 12 03 05 281 1206 281 1206 BALL BEARING 1206 2 13 03 01 5787 M12X1 5X45 05 5787 M12X1 5X45 FLANGE BOLT M12x1 5x45 4 14 02 DI250 07 000006 DI250 07 00 00 06 BEARING SEAT CAST STEEL 2 15 03 06 13871 FB35X55X8 13871 FB35x55x8 GEASE SEAL FB 35x55x8 2 16 03 02 2842 M10X1 25 05 SJ2842 M10x1 25 FLANGE NUT M12x1 5 2 17 03 01 5787 M8X30 05 5787 M8x30 FLANGE BOLT M8x30 6 18 02 DN250 07 000004 DN250 07 00 00 04 CHAIN PULLEY 43 TOOTH 1 19 02 DN250 07 03A DN250 07 03 00 00A 10A CHAIN 66 1 20 02 DN250 07 0200 DN250 07 02 00 00 MID AXIS 1 21 03 02 6187 1 M8 05 6187 1 M8 FLANGE LOCK NUT M8 6 22 03 02 2842 M10X1 25 05 SJ2842 M10x1 25 FLANGE NUT M10x1 25 6 23 02 DS250 08 000003 DS250 08 00 00 03 ENGINE BUMPER 4 24 03 01 5787 M12X1 5X115 05 5787 M12X1 5X115 FLANGE BOLT M12x1 5x115 1 25 03 01 70 1 M10X100 05 70 1 M10
11. 02 DLJ 152MI 023300 152MI 023300 TENSIONER UNIT 1 4 02 DLJ 152MI 023307 152MI 023307 SPRING SEAT BOLT 1 5 02 DLJ 152MI 023306 152MI 023306 TENSIONER SPRING 1 6 02 DLJ 152MI 023004 152MI 023004 TENSIONER SEAL WASHER 1 7 02 DLJ 172MM 023007 172MM 023007 WATER INLET RUBBER PIPE 1 8 02 DLJ 172MM 023009 172MM 023009 WATER PIPE JACKET 1 9 02 DLJ QC T621 1999 B24 QC T621 1999 B24 STEEL BAND CLAMP 2 10 02 DLJ 152MI 023305 152MI 023305 WASHER 8 5 1 11 02 DLJ GB T848 85 6 D ZN GB T848 85 6 D ZN SMALL WASHER 1 12 02 DLJ 152MI 021005 152MI 021005 LOCATION PIN 10X14 2 13 02 DLJ 152MI 023008 152MI 023008 BOLT M6X18 2 14 02 DLJ 152MI 080013 152MI 080013 BOLT M6X22 1 166 7 TIMING CHAIN No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 022200 172MM 022200 CHAIN UNIT 1 2 02 DLJ 172MM 023200 172MM 023200 TENSION PLATE 1 3 02 DLJ 172MM 023001 172MM 023001 CHAIN GUIDE PLATE 1 4 02 DLJ GB96 85 6 D Zn GB96 85 6 D Zn BIG WASHER 1 5 02 DLJ GB T5781 2000 M6X12 D Zn GB T5781 2000 M6X12 D Zn BOLT 1 167 8 MAGNETOR ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 094000 172MM 094000 FREE WHEELING CLUTCH 1 2 02 DLJ 172MM 033000 172MM 033000 TRIGGER COIL 1 3 02 DLJ 172MM 013008 172MM 013008 CABLE PRESS BAND 1 4 02 DLJ 172MM 031000 172MM 031000 FREE WHEELING 1 5 02 DLJ 172MM 032000 172M
12. 0 Owner s Manual Parts Manual READ THIS MANUAL CAREFULLY IT CONTAINS IMPORTANT SAFETY INFORMATION MINIMUM RECOMMENDED OPERATOR AGE JNSZ250DN FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only USA only It does not confirm to federal motor vehicle safety standards and operation on Public streets roads or highways is illegal 16 1 CONTENTS WARRANTY POLICY 3 OWNER S MANUAL 14 FOREWORD 14 A FEW WORDS ABOUT SAFETY 14 IMPORTANT SAFETY INFORMATION 15 SAFETY LABELS 16 ARE YOU READY TO DRIVE 18 IS YOUR VEHICLE READY TO DRIVE
13. 0002 DN250 04 01 00 02 BRAKE CALIPER 2 2 2 02 DN250 09 02 DN250 09 02 00 00 RIGHT TRAILING ARM 1 3 03 04 93 8 05 93 8 SPRING WASHER 8 4 4 03 03 95 8X16X1 5 95 8x16x1 5 PLAIN WASHER 8 4 5 03 01 5787 M8X20 05 5787 M8X20 FLANGE BOLT M8X15 4 6 03 02 6183 1 M10X1 25 6183 1 M10X1 25 FLANGE NUT M10X1 25 4 7 02 D650 02 01 0002 D650 02 01 00 02 TRAILING ARM STEEL BUSHING 4 8 02 D650 02 01 0001 D650 02 01 00 01 TRAILING ARM RUBBER BUSHING 8 9 03 01 5787 M10X1 25X7 5787 M10X1 25X70 FLANGE BOLT M10X1 25X70 4 10 02 DN250 09 0100 DN250 09 01 00 00 LEFT TRAILING ARM 1 11 03 01 5787 M12X1 5X45 5787 M12X1 5X45 FLANGE BOLT M12X1 5X45 4 12 02 DN250 09 000007 DN250 09 00 00 07 SHOCK ABSORBER SPACER 8 13 02 DN250 09 03 DN250 09 03 00 00 SHOCK ABSORBER 2 14 03 02 6183 1 M12X1 5 0 6183 1 M12X1 5 FLANGE NUT M12X1 5 4 15 02 DN250 04 01 0001 DN250 04 01 00 01 BRAKE CALIPER 1 1 16 03 01 70 3 M8X20 05 70 3 M8x20 INNER HEXAGON SUNK SCREW M8X20 4 17 02 DI250 04 01 0004A DI250 04 01 00 04A REAR BRAKE DISC 2 18 03 06 13871 FB32X47X8 13871 FB32X47X8 GREASE SEAL FB 32X47X8 4 19 03 05 276 6005 276 6005 BALL BEARING 6005 4 20 02 DI250 09 000001 DI250 09 00 00 01 REAR WHEEL SPACER 1 2 21 02 DI250 09 000006 DI250 09 00 00 06 REAR WHEEL SPACER 2 2 22 02 DI250 02 000002 DI250 02 00 00 02 KNURLED BOLT 8 23 02 DI250 09 000005 DI250 09 00 00 05 BRAKE DIS
14. 01 02 00 02 UPPER SPORT WING OPTION 1 7 03 01 5787 M12X1 25X65 05 5787 M12x1 25x65 FLANGE BOLT M12X1 25X55 6 8 02 D250 11771 D250 11 771 NYLON BUSHING 6 9 03 02 2842 M12X1 5 05 SJ2842 M12x1 5 FLANGE NUT M12 6 10 02 DN250 01 02 08A DN250 01 02 08 00A RIGHT PROTECTIVE BAR 1 11 03 01 5787 M10X1 25X20 05 5787 M10X1 25X20 FLANGE BOLT M10X1 25X20 1 12 03 02 2842 M10X1 25 05 SJ2842 M10x1 25 FLANGE NUT M10 2 13 03 01 5787 M10X1 25X65 05 5787 M10X1 25X65 FLANGE BOLT M10X1 25X65 2 14 02 DN250 01 02 0001 DN250 01 02 00 01 ARC CUSHION U 220532 12 15 02 DN250 01 02 03 DN250 01 02 03 00 REINFORCED BAR 2 16 03 01 5787 M8X20 05 5787 M8X20 FLANGE BOLT M8X20 2 17 02 D800 04 02 0200 D800 04 02 02 00 WATER TANK GK800 1 18 02 D800 04 02 02 01 D800 04 02 02 01 WATER TANK CAP GK800 1 19 03 02 6187 1 M8 05 6187 1 M8 FLANGE LOCK NUT M8 2 20 02 DN250 01 02 02 DN250 01 02 02 00 TOP PROTECTIVE BAR1 1 21 02 DN250 01 02 05 DN250 01 02 05 00 TOP PROTECTIVE BAR2 1 22 02 DI250 05 01 01 DI250 05 01 01 00 RADIATOR SAFETY COVER 1 23 03 01 5787 M8X30 05 5787 M8X30 FLANGE BOLT M8X30 2 24 02 DN250 01 02 06 DN250 01 02 06 00 RADIATOR SUPPORT 1 25 02 JD 1910003 JD1910003 RADIATOR RUBBER BUSHING 2 26 02 D250 09904 D250 09 904 RADIATOR CAPRADIATOR 1 27 02 DI250 05 01 01 DI250 05 01 01 00 RADIATOR 1 28 02 D650 04 06 01 D650 04 06 01 00 ACT ACTIVATED CARBON 1 2
15. 04 02 02 01 WATER TANK CAP 1 8 03 02 6187 1 M8 05 6187 1 M8 FLANGE LOCK NUT M8 6 9 02 DN250 05 01 0005 DN250 05 01 00 05 OVERFLOWING PIPE 1 10 02 DN250 05 01 0001 DN250 05 01 00 01 ENGINE OUTLET WATER PIPE 1 11 02 DN250 05 01 0002 DN250 05 01 00 02 ENGINE INLET WATER PIPE 1 12 03 01 5787 M6X20 05 5787 M6x20 FLANGE BOLT M6X20 3 13 02 D650 04 06 0001 D650 04 06 00 01 SUPPORT ACT 1 14 02 D650 04 06 0002 D650 04 06 00 02 ACT STOP 1 15 03 02 6187 1 M6 05 6187 1 M6 FLANGE LOCK NUT M6 3 16 02 D650 04 06 01 D650 04 06 01 00 ACT 1 17 02 DN250 05 05 0001 DN250 05 05 00 01 INLET PIPE ACC 1 18 02 JD 1135000 JD1135000 FUEL TANK CAP 1 19 03 01 5787 M8X25 05 5787 M8x25 FLANGE BOLT M8X25 4 20 02 D250 11804 D250 11 804 FUEL TANK 1 21 02 JD 1138000 JD1138000 FUEL SWITCH 1 22 02 DN250 05 02 0002 DN250 05 02 00 02 GAS PIPE1 1 23 02 DS250 11 01 0009 DS250 11 01 00 09 GAS FILTER 1 24 02 DN250 05 02 0003 DN250 05 02 00 03 GAS PIPE2 1 25 02 DN250 11 01 07 DN250 11 01 07 00 OUTLET CVT AIR FILTER 1 26 03 01 823 M5X30 05 823 M5x30 CROSS PANHEAD SCREW M5X30 2 27 02 DN250 11 01 13 DN250 11 01 13 00 CVT WRAP HOOP 2 28 02 DI250 07 0400 DI250 07 04 00 00 ENGINE ASSY 2 29 02 DN250 05 05 0002 DN250 05 05 00 02 OUTLET PIPE ACC 1 30 02 DS250 11 01 0020 DS250 11 01 00 20 AIR BOX 1 31 02 DLJ CF250T 430500 CF250T 430500 AIR FILTER WRAP HOOP 2
16. 17 Figure 16 155 WIRING DIAGRAM G Thermometer swich 88o C Alternator R e ve rse se nsor Start motor 12V 600W Battery 12V 9Ah Speed sensor Flasher 12V 45W Brakes light switch Horn Horn button Turning signal before R 12V 10W Turning signal before L 12V 10W Headlight 12V 35 35W Turning signal Rear L 12V 10W Tail lamp the brake light 12V 5 21W water temp erature sensor Rectifier regulator Fuse box G 3 M Ignition switch OFF Start 1 2 3 Ignition coil t v C tC n v High beam switch ON blue Dipped beam switch green Turn signal switch R L yellow red Reverse indication Charge indication OFF H tC BP ON Radiator fan 12V 10A Turning signal Rear R 12V 10W Thermometer swich 102 o C 5A 5A 10A 15A 5A R L R L 12V ON Start relay ON L N R N ge ar se nsor L g ear se nsor H ge ar se nsor v Spot light 3x 12V 21W 10A 5A Spot light switch Speed meter Rev meter water temp erature meter Voltage meter Wire s colour symbol RS red grey B black R red U blue RU red blue P purple S grey W white YG yellow green L Cambridge blue N brown K pink NB brown black NR brown red UW blue white RB red black GY green yellow SB grey black BR black red Y yellow WG white green GB green blac
17. 172MM 013100 RIGHT SIDE COVER BREATH PIPE 1 3 02 DLJ 172MM 013015 172MM 013015 AIR FILTER BREATH PIPE 1 4 02 DLJ 172MM 013016 172MM 013016 BREATH PIPE CLAMP 1 5 02 DLJ 172MM 013002 172MM 013002 RIGHT SIDE COVER 1 6 02 DLJ 172MM 013008 172MM 013008 CABLE PRESS PLATE 1 7 02 DLJ 172MM 013012 172MM 013012 RIGHT SIDE COVER SEAL WASHER 1 8 02 DLJ 172MM 013007 172MM 013007 OIL FILTER CAP 1 9 02 DLJ 152MI 013100 152MI 013100 OIL FILTER CORE 1 10 02 DLJ 172MM 013006 172MM 013006 SPRING 1 11 02 DLJ 172MM 013001 172MM 013001 ENGINE OIL METER 1 12 02 DLJ 172MM 013019 172MM 013019 3 WAY 1 13 02 DLJ 152MI 021008 152MI 021008 UPPER OBSERVATION HOLE CAP 1 14 02 DLJ 172MM 013031 172MM 013031 BOLT 1 15 02 DLJ 172MM 013028 172MM 013028 O RING 30X3 35 1 16 02 DLJ 152MI 021009 152MI 021009 SEAL RING CAP 1 17 02 DLJ 172MM 013030 172MM 013030 O RING 18X3 35 1 18 02 DLJ 172MM 013005 172MM 013005 OUTLET BOLT 1 19 02 DLJ 152MI 021014 152MI 021014 WASHER 12 1 160 3 RIGHT COVER ASSY No ERP CODE P N ENGLISH Qty 20 02 DLJ 152MI 08008 152MI 08008 LOCATING PIN 8x14 2 21 02 DLJ QC T621 1999 A10 QC T621 1999 A10 CLAMP 12 2 22 02 DLJ QC T621 1999 A12 QC T621 1999 A12 CLAMP 10 4 23 02 DLJ 172MM 013010 172MM 013010 BREATH FAUCET 1 24 02 DLJ 172MM 013009 172MM 013009 WATER OUTLET FAUCET 1 25 02 DLJ 152MI 013009 152MI 013009
18. BOLT M6X40 3 26 02 DLJ 172MM 013026 172MM 013026 PROTECTION PIPE 1 27 02 DLJ 152MI 071007 152MI 071007 BOLT M6X28 1 28 02 DLJ 1P52MI 011018 1P52MI 011018 BOLT M6X70 3 161 4 CYLINGDER HEAD CASEING ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 021009 172MM 021009 OIL PIPE CLAMP 1 2 02 DLJ 172MM 021001 172MM 021001 CYLINDER HEAD COVER 1 3 02 DLJ 172MM 021006 172MM 021006 STOP PLATE 1 4 02 DLJ 152MI 021011 152MI 021011 SEAL WASHER 1 5 02 DLJ 172MM 021100 172MM 021100 SWING ARM INLET AXIS 1 6 02 DLJ 172MM 021200 172MM 021200 SWING ARM OUTLET AXIS 1 7 02 DLJ 172MM 021400 172MM 021400 OUTER ENGINE OIL PIPE 1 8 02 DLJ 152MI 021001 152MI 021001 OIL PIPE RUBBER RING 1 9 02 DLJ 172MM 021431 172MM 021431 OIL PIPE MOUNT 1 10 02 DLJ 152MI 021003 152MI 021003 SHOCK ABSORBER RUBBER STRIP 1 11 02 DLJ 152MI 021004 152MI 021004 REAMED BOLT A M8X25 1 12 02 DLJ 152MI 021015 152MI 021015 REAMED BOLT M12X1 25 1 13 02 DLJ 152MI 021013 152MI 021013 REAMED BOLT M8X25 1 14 02 DLJ 152MI 021008 152MI 021008 UPPER OBSERVATION HOLE CAP 1 15 02 DLJ 152MI 021016 152MI 021016 WASHER 8 3 16 02 DLJ 152MI 021012 152MI 021012 EAR WASHER 1 17 02 DLJ 152MI 021014 152MI 021014 WASHER 12 2 18 02 DLJ 152MI 021009 152MI 021009 UPPER OBSERVATION HOLE SEAL 1 19 02 DLJ 152MI 021010 152MI 021010 SWING ARM AXIS SEAL RING 2 20 02 DLJ GB T
19. air valve and air valve seat Failure of valve gas Damage of cylinder cover seal washer Wearing out of piston rings Wearing of piston and cylinder If the pressure is higher check the following items Accumulating carbon on both the top of piston and cylinder cover Don t hold the start key more than 5 seconds the battery will run out Inspection of oil quantity 1 Put the engine on a level ground 2 Keep the engine running for 2 3 minutes 2 3 minutes later after stopping the engine and check the oil lever 3 Insert the oil dipstick if the oil lever is below the lower limit Fill in the specified oil until the lever catch up upper limit 4 Replace the oil if the oil is polluted heavy Replacement of oil and oil filter cleaning 1 After warm up the engine take off dipstick and unbolt oil draining bolt drain the oil 2 Take off the spring and filter screen 3 Clean the filter screen Torque 20N m The open of the filter screen should head toward inside 4 Clean the oil draining bolt and washer and put them back with the standard torque Torque 20N m Change the O ring or the washer if damaged Oil draining bolt Oil dipstick Filter cover Oil dipstick Upper limitation Lower limitation Oil dipstick O ring Filter net Filter cover Spring O ring Washer Oil draining Right side cover 57 5 fill in the specified oil Oil capacity 0 8 L Recommended oil SAE10W 40 or SAE
20. always keep all four wheels on the ground Attempting wheelies and other stunts increases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off 24 SPECIFICATIONS DIMENSIONS Overall Length 98 in 2500mm Overall Width 60 in 1520mm Overall Height 62 in 1570mm Wheelbase 77 5 in 1970mm Front Track 51in 1300mm Rear Track 50 8in 1290mm Ground Clearance 11 8 in 300mm ENGINE Type liquid cooled 4 Stroke Bore x Stroke
21. approved motorcycle helmet eye protection boots gloves long pants and long sleeved shirt or jacket whenever you drive Although complete protection is not possible wearing proper gear can reduce the chance of injury when you drive The following suggestions will help you choose the proper driving gear Helmets and Eyes Protection Your helmet is your most important piece of driving gear because it offers the best protection against head injuries A helmet should fit your head comfortably and securely An open face helmet offers some protection but a full face helmet offers more Regardless of the style look for a DOT Department of Transportation sticker in any helmet you buy Always wear a face shield or goggles to protect your eyes and help your vision 19 Operating this Off highway recreational vehicle without wearing an approved motorcycle helmet eye protection and protective clothing could increase your chances of head and or eye injury possibly death in the event of severe accident Always wear approved motorcycle helmet that fits properly and wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Additional Driving Gear In addition to a helmet and eye protection we also recommend Sturdy off road motorcycle boots to help protect your feet ankles and lower legs Off road motorcycle gloves to help protect your hands Driving pants with knee and hip pad
22. bearing remover when replacing bearing Bearing remover Bearing remover unit 15 Bearing remover 15 Bearing remover handle Balance block of Bearing remover Bearing remover unit 17 Bearing remover 17 Bearing remover handle Balance block of Bearing remover 132 Bearing remover unit 20 Bearing remover 20 Bearing remover handle Balance block of Bearing remover Bearing remover unit 12 Bearing remover 12 Bearing remover handle Balance block of Bearing remover Check the bearings on the left case of gearbox 1 Check the bearing to see if it works well if not replace with a new one 2 Always use a bearing remover when replacing bearing Bearing remover Bearing remover unit 15 Bearing remover 15 Bearing remover handle Balance block of Bearing remover Bearing remover unit 22 Bearing remover 22 Bearing remover handle Balance block of Bearing remover Bearing remover unit 20 Bearing remover 20 Bearing remover handle Balance block of Bearing remover Bearing remover unit 12 Bearing remover 12 Bearing remover handle Balance block of Bearing remover Inspection on output shaft Comp 1 Break down the output shaft Comp as the right figure 2 Check to see if turning blue pitting damage wearing out if that replaces the part with a new one 133 Assembly 1 The order of the assembly is contrary to the disassembly Pay attention to the following tips 1 Clean parts before installment 2 Co
23. check the throttle assembly to ensure that when pedal is pushed all the way forward the assembly is working smoothly and returns to idle when released Do not operate if pedal or engine throttles linkage fail to return to idle If unable to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance b Brake The brake is located on the left side of the off highway recreational vehicle See Fig 1 Applying pressure to the pedal draws the brake caliper around the brake pump at the 4 wheels and slows or stops the off highway recreational vehicle c Start engine Insert the key into key switch turn the key clockwise and release the key when the engine starts The engine will warm up for 5 minutes and the engine choke will close automatically and run at normal RPM Warning Don t crank starter more than 5 seconds at one time See Figure 2 d Run you Off highway recreational vehicle Press the shift lever forwards to L position the cart will move forwards at low speed H position high speed N position no speed and R position the cart will move backwards Note if the shift can t engage give a slight throttle and then try it again BRAKE PEDAL THROTTLE PEDAL HORN BUTTON ODOMETE WATER TEMPERATURE INDICATOR IGNITION START SWITCH VOLTAGE METER Figure 2 Figure 1 RPM INDICATOR 26 If the shift engages press down the t
24. fuel lever wrong position of enriching valve plate groove 59 Disassembly carburetor 1 Take off all the related parts 2 Loosen the air filter clip 3 Loosen the screw take off the air filter Do not take off screws 4 Pull off the heating tube from carburetor 5 Pull off the vacuum tube from air cut valve Loosen the clip fixing carburetor take off the carburetor from engine Insure the carburetor clean all the time Heating pipe Air shut off valve Fuel pipe Vacuum tube Caliper for air filter 60 6 Remove the 2 screws which fix enriching mechanism take off the enriching mechanism Pay attention to protect the valve anytime Inspection on fuel enriching mechanism Check the fuel enriching mechanism to see conduction resistance 10 the engine stopped for more than10 minutes if failure of conduction replace with a new fuel enriching mechanism Connect a PE tube to the enriching jet hole and connect the yellow cable on the enriching mechanism to the positive pole of battery green cable to the negative pole And keep it for 5 minutes Then breathe the PE tube going through means good Cut the cables you connected just now do the breathing work again after 30 minutes of cutting going through means good Check the valve and enriching needle on the enriching mechanism to see if scratched wore out and damaged if one of them happen change the fuel enriching mechanism Small
25. of alcohol can impair your ability to operate the off highway recreational vehicle safely Likewise drugs even if prescribed by a physician can be dangerous while operating the off highway recreational vehicle Consult your doctor to be sure it is safe to operate a vehicle after taking medication Operating this Off highway recreational vehicle after alcohol or drugs can seriously impaired your judgment balance perception and judgment This can result in serious injury or death Never consume alcohol or drugs before or while operating this Off highway recreational vehicle IS YOUR VEHICLE READY TO DRIVE Before each drive it s important to inspect your Off highway recreational vehicle and make sure any problems are corrected A pre drive inspection is necessary not only for safety but also for comfort Because having a breakdown or even a flat tire can be a major inconvenience If your off highway recreational vehicle has overturned or has been involved in a collision do not drive it until your dealer has inspected your off highway recreational vehicle There may be damages or other problems you cannot see Improperly maintaining this Off highway recreational vehicle or failing to correct a problem before driving can cause a crash in which you can be seriously hurt even die Always perform a pre drive inspection before every drive and correct each problem Pre drive Inspection Check the following items before riding the off high
26. speed I I I 1500 150RPM spark plug I I I No carbon gas between poles 0 8 0 9mm Replace every 6000km Air filter C C C Fuel pipes on carburetor Replace every 4 years Driving belt I R Lubrication Dirty quantity I I I leakage I I I oil filter I I oil replacement R R Cooling Coolant quantity I I I Coolant pipe I I I Opening pressure of radiator valve I I I Coolant replacement every 2 years transmission leakage quantity I replace every one year Clutch If work I I inspection C clean R replacement The period in the table above is for normal condition shorten the period if the using condition is dirtier 53 Check the quantity of gearbox oil To check the oil level Put the engine or vehicle on a flat floor turn off the engine and take off the oil filling bolt fill the specified oil until the oil lever get up to the lip If lack of oil fill the specified oil with the same way Specified oil SAE10W 40 SE API Before put the oil filling bolt back make Sure the seal washer is not damaged Replace the oil in gearbox 1 Remove the oil filling bolt 2 To drain oil in the gearbox Remove the oil draining bolt 3 Put back the oil draining bolt 4 Fill in the gear box with specified oil Specified oil SAE10W 40 SE API Oil capacity 0 75L 5 Install the oil filling bolt back 6 Start engine check if leak and quantity
27. tool 9 17 hook wrench 34 36mm Round nut 9 18 Punch Riveting 9 19 Water Seal removed tool Water Seal static ring 4 20 Bearing tools 28 30mm pushing oil seal on water pump 4 21 Valve Guide Reamer Processing valve guide 6 22 Valve Guide removed tool Removing valve guide 6 23 Belt wheel support Stopping belt to run 8 24 Clutch spring compressor Assembling or disassembling driven pulley 8 25 Flywheel removed tool Disassembling flywheel 10 26 Fixing nut wrench Assembling or disassembling driven pulley 8 46 Grease seal glue threads glue Appling point Attention type coolant temperature sensor threads of timing sprocket fixing screw threads locking glue Driven wheel ball bearings 690IUU Driven wheel needle roller bearings Driven round of movable round action driven groove 5 0 5 5g don t smear to the driven belt working surface Multi purpose grease O ring sealing surface seal lip Combination of speed reducer Plane sealant 47 Engine oil pathway Outer oil pipe unit Oil Pump Oil outlet bolts Oil filter net 48 49 50 51 52 INSPECTION ADJUSTMENT AND MAINTENANCE Period Item Hour 20h running in Every 40h Every 80h Remark Month 1 3 6 Engine body Match condition non normal sound I I I exhaust condition I I I no blue or black gas valve gap I I I In 0 08 0 12 Out 0 08 0 12 idle
28. you for choosing our Off highway recreational vehicle We hope you will have fun with it Before you start operate the Off highway recreational vehicle please read through this Owner s Manual carefully as it contains important safety and maintenance information Failure to follow the warnings contained in this manual can result in serious injuries Be sure to follow the recommended maintenance schedule and service your Off highway recreational vehicle accordingly Preventive maintenance is extremely important to the longevity of your Off highway recreational vehicle We hope you will have a pleasant experience with our products and thanks again for choosing US A FEW WORDS ABOUT SAFETY In order to keep everyone safe you must take responsibility for the safe operation of your Off highway recreational vehicle To help you make informed decisions about safety we have provided operating procedures and other information on labels and in this manual This information alerts you to potential hazards that could hurt you or others It is not practical or possible to warn you about all hazards associated with operating or maintaining a Off highway recreational vehicle You must use your own good judgment You will find important safety information in a variety of forms including Safety Labels On the Off highway recreational vehicle Safety Messages Preceded by a safety alert symbol and one of two signal words WARNING or CUATIO
29. 01 JD1082101 SHIFT RUBBER BUSHING 1 54 02 DI250 05 05 03 DI250 05 05 03 00 SHIFT LEVER 1 55 02 D250 08004 D250 08 004 SHIFT SPRING 1 56 02 D250 08005 D250 08 005 STOP RING 1 57 02 D250 08009 D250 08 009 SHIFT LEVER COVER 1 58 03 03 95 8X16X1 5 95 8x16x1 5 PLAIN WASHER 8 1 59 03 08 91 3X30 05 91 3x30 COTTER PIN 3x30 1 60 02 DN250 05 06 01A DN250 05 06 01 00A SHIFT CABLE 1 61 03 01 5787 M10X1 25X30 05 5787 M10X1 25X30 FLANGE BOLT M10x1 25x30 2 62 03 02 2842 M10X1 25 05 SJ2842 M10x1 25 FLANGE NUT M10x1 25 2 63 03 02 6183 1 M6 05 6183 1 M6 FLANGE LOCK NUT M6 1 65 02 DN250 04 000001 DN250 04 00 00 01 FOOT BRAKE SPRING DN250 2 66 03 03 95 6X12X1 05 95 6x12x1 PLAIN WASHER 6 2 67 03 02 6183 1 M6 05 6183 1 M6 SPRING WASHER 6 2 68 03 01 5787 M6X10 05 5787 M6x10 FLANGE BOLT M6X10 2 69 03 05 304 1 GE12C 304 1 GE12C JOINT BEARING GE12C 1 70 03 03 95 8X16X1 5 95 8x16x1 5 PLAIN WASHER 6 1 71 03 08 91 2X25 05 91 2x25 COTTER PIN 2x20 1 192 23 ENGINE RACK amp TRANSMISSION 34 35 2 3 4 6 7 8 9 10 11 12 13 15 16 17 18 5 20 21 14 22 23 24 25 26 27 28 30 31 29 32 33 1 23 ENGINE RACK amp TRANSMISSION 19 193 23 ENGINE RACK amp TRANSMISSION No ERP CODE PART NO DESCRIPTION Q TY 1 02 DN250 07 0100 DN250 07 01 00 00 CV AXLE ASSY 2 2
30. 02 DLJ 172MM B 066000 172MM B 066000 SHIFT DRUM ASSY 1 2 02 DLJ 172MM B 066002 172MM B 066002 SHIFT YOKE 2 3 02 DLJ 172MM B 066003 172MM B 066003 SHIFT YOKE PIN 2 4 02 DLJ 172MM B 066004 172MM B 066004 SHIFT YOKE PIN SNAP RING 2 5 02 DLJ 172MM B 066001 172MM B 066001 SHIFT DRUM 1 6 02 DLJ 172MM B 066005 172MM B 066005 SPEED DISPLAY TOUCH CHIP 1 7 02 DLJ CF188 065201 CF188 065201 DRIVEN SECTOR GEAR WASHER 1 8 02 DLJ CF188 065203 CF188 065203 DRIVING SHIFT SECTION GEAR 1 9 02 DLJ CF188 065204 CF188 065204 WASHER 13 5X22X1 1 10 02 DLJ CF188 065202 CF188 065202 DRIVING SHIFT SECTOR GEAR AXIS 1 11 02 DLJ CF188 065204 CF188 065204 DRIVEN SECTOR GEAR SPRING 1 12 02 DLJ CF188 065206 CF188 065206 WASHER 6 6X20X2 2 13 02 DLJ 151MI 013008 151MI 013008 BOLT M6X35 1 14 02 DLJ 151MI 023010 151MI 023010 BOLT M6X20 1 16 02 DLJ 172MM C 065100 172MM C 065100 DRIVE SHIFT SECTOR GEAR COMP 1 17 02 DLJ 172MM B 066007 172MM B 066007 SHIFT AXIS 1 18 02 DLJ 172MM B 066009 172MM B 066009 SHIFT PRESS SPRING 1 19 02 DLJ 172MM B 066008 172MM B 066008 SHIFT PRESS BUSHING 1 176 16 ENGINE OIL PUMP ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 151MI 071000 151MI 071000 OIL PUMP ASSY 1 2 02 DLJ 151MI 071002 151MI 071002 OIL PUMP BODY 1 3 02 DLJ 151MI 071003 151MI 071003 OIL PUMP COVER 1 4 02 DLJ 151MI 071001 151MI 071001 OIL PUMP
31. 04 01 01 DN250 04 01 01 00 MAIN BRAKE PISTON 1 39 03 02 6187 1 M8 05 6187 1 M8 FLANGE LOCK NUT M8 2 40 02 DN250 04 01 0005 DN250 04 01 00 05 BRAKE PUSH POLE 2 41 03 02 6172 1 M8 R 05 6172 1 M8 R THIN NUT M8 2 42 03 01 5787 M8X30 05 5787 M8X30 FLANGE BOLT M8x30 2 43 02 D250 10005 D250 10 005 T BLOCK 1 44 03 08 91 3X30 05 91 3x30 COTTER PIN 3x30 3 45 03 03 95 10X20X2 05 95 10X20X2 PLAIN WASHER 10 3 46 02 DN250 04 000002 DN250 04 00 00 02 BRAKE BOARD FOOT PIN 1 190 22 STEERING THROTTLE BRAKE amp SHIFT 70 71 48 53 54 55 56 57 58 59 60 66 67 68 69 22 STEERING amp THROTTLE amp BRAKE amp SHIFT 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 44 45 46 47 49 43 42 41 40 39 38 37 36 50 51 52 61 62 63 191 22 STEERING amp THROTTLE amp BRAKE amp SHIFT No ERP CODE PART NO DESCRIPTION Q TY 47 02 D250 04002 D250 04 002 BUFFER BUSHING LINK ROD 4 48 03 07 882 6X25 05 882 6x25 PIN B M6x30 2 49 02 DN250 04 02A DN250 04 02 00 00A BRAKE BOARD 2 50 02 DN250 05 02 01A DN250 05 02 01 00A THROTTLE PIN 2 51 02 DN250 05 02 0001 DN250 05 02 00 01 THROTTLE BOARD 1 52 02 DN250 05 02 02A DN250 05 02 02 00A THROTTLE CABLE 1 53 02 JD 10821
32. 05 DN250 02 00 00 05 SPACER GE20C 8 10 03 02 2842 M14 05 SJ2842 M14 FLANGE NUT M14x1 5 12 11 03 01 5787 M14X1 5X60 05 5787 M14X1 5X60 FLANGE BOLT M14X1 5X60 8 12 03 05 304 1 POSA14X2 0 304 1 POSA14x2 0 ROD END BEARING 14 8 13 02 DN250 02 000004 DN250 02 00 00 04 ROD END BEARING SPACER 14 16 14 03 02 6172 1 M14X1 5 R 05 6172 1 M14x1 5 R THIN NUT M14 8 15 02 DN250 02 02 DN250 02 02 00 00 LEFT UPPER A ARM 1 16 03 02 2842 M12X1 5 05 SJ2842 M12X1 5 FLANGE NUT M12X1 5 6 17 02 DN250 09 000007 DN250 09 00 00 07 SHOCK ABSORBOR SPACER 8 18 03 01 5787 M12X1 5X170 05 5787 M12X1 5X170 FLANGE BOLT M12X1 5X170 2 19 02 DN250 02 07 DN250 02 07 00 00 FR SHOCK ABSORBOR 2 20 03 01 5787 M12X1 5X60 05 5787 M12X1 5X60 FLANGE BOLT M14X1 5X60 8 21 03 01 5787 M14X1 5X80 05 5787 M14X1 5X80 FLANGE BOLT M14X1 5X80 2 22 02 DN250 02 05 DN250 02 05 00 00 LEFT KNUCKLE 1 23 03 01 5787 M8X20 05 5787 M8x20 FLANGE BOLT M8X15 4 24 02 DN250 04 01 0002 DN250 04 01 00 02 BRAKE CLIPPER 2 1 25 02 DN250 02 000003 DN250 02 00 00 03 FRONT WHEEL BUSHING 33 8 2 26 03 06 13871 FB28X47X7 13871 FB28x47x7 GREASE SEAL FB47X28X7 2 27 03 05 276 6204 276 6204 BALL BEARING 6204 2 28 02 JD 0360007 JD0360007 FRONT WHEEL BUSHING 22 2 29 02 JD 0360150 JD0360150 FRONT BRAKE DISC 2 30 02 DS250 02 000002 DS250 02 00 00 02 FRONT WHEEL KNURLED BOLT 8 31 02 JD 0360200 EU JD0360200 EU BEAR
33. 06 000301 D650 06 00 03 01 HENDLIGHT BULB 2 1 29 02 D650 06 000501 D650 06 00 05 01 FRONT TURNING SIGNLE BULB 2 30 02 D650 06 000401 D650 06 00 04 02 TAILLIGHT BULB 4 31 02 D650 06 000403 D650 06 00 04 03 BRAKE LIGHT BULB 2 32 02 DLJ M FUSE 5A M FUSE 5A FUSE 5A 3 33 02 DLJ M FUSE 10A M FUSE 10A FUSE 10A 4 34 02 DLJ M FUSE 20A M FUSE 20A FUSE 20A 1 35 02 D250 04901A D250 04 901A ELECTRIC COVER 1 204 28 OTHER PARTS 28 OTHER PARTS 2 4 5 6 3 1 J O Y N E R J O Y N E R J O Y N E R 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 23 15 24 205 28 OTHER PARTS No ERP CODE PART NO DESCRIPTION Q TY 1 02 DN250 11 01 1500 DN250 11 01 15 00 RIGHT SEAT COMP 1 2 02 DN250 11 01 1400 DN250 11 01 14 00 LEFT SEAT COMP 1 3 03 02 6183 1 M10X1 25 05 6183 1 M10X1 25 FLANGE NUT M10X1 25 8 4 02 D250 11005A D250 11 005A SAFTY BELT 2 5 02 DI250 11 01 0007 DI250 11 01 00 07 RIGHT SEAT ADJUSTER 1 6 02 DI250 11 01 0006 DI250 11 01 00 06 LEFT SEAT ADJUSTER 1 7 02 DN250 01 02 0007 DN250 01 02 00 07 ROOF RACK 1 8 02 D1600 08 01 0006 D1600 08 01 00 06 LOOP M10x1 25 4 9 02 D1600 01 02 0007 D1600 01 02 00 07 SPACER 1 10 03 02 6183 1 M10X1 25 05 6183 1 M10x1 25 FLANGE NUT M10x1 25 4 11 02 DN250 05 04 0001B DN250 05 04 00 01B EXHAUST PIPE FOR AU 1 12 02 JD 1118009 JD111800
34. 0x14 137 9 Put on gasket 10 Assemble the gear box cover Comp install the parts 5 6 7 in to the related holes respectively Torque 22 N m 11 Install output sprocket pressing plate bolts Torque 10N m 12 Turn the gear shifting drum to the natural position put on driving sector gear Comp driven sector gear Comp and sprocket Align the marks on both driving sector gear and driven sector gear 13 Install sprocket pin and sprocket cover a Put the knock pin 11 2pcs in to the holes in the sprocket cover b Put on sprocket and sprocket cover c Put the parts 14 15 into the related holes Torque 10N m d Install the part 16 use a special tool to push the seal down and smear some grease on the lip of seal 14 Put the draining bolt 4 with washer 3 into the related hole Torque 20N m 15 Install seal sector gear house cover gear shifting arm Comp Torque for bolt of M6 10N m Smear some grease on the lip of seal 138 16 Install seal of main shaft transmission clutch and belt Torque Nut of clutch 49N m Nut of transmission 78N m 17 Install left cover 18 Fill oil through the fill bolt hole and then screw the filling bolt Put the engine into a horizontal position Fill in the oil specified for 4 strokes motor Fill in the oil to the neck of filling bolt hole After fill in oil install O ring and screw the filling bolt 139 Gear box cover Gear shifting mechani
35. 1 9 02 DLJ GB T896 1986 9 GB T896 1986 9 SPLIT WASHER 3 10 02 DLJ 172MM 052310 172MM 052310 NEEDLE BEARING 1 11 02 DLJ GB T893 1 1986 28 GB T893 1 1986 28 HOLE RETAINER RING 1 12 02 DLJ GB T278 1989 1060902 GB T278 1989 1060902 BEARING 1 13 02 DLJ 172MM A 052300 172MM A 052300 DRIVEN PAN UNIT 1 14 02 DLJ 172MM A 052001 172MM A 052001 GALLOWS ROLL 4 15 02 DLJ 172MM A 052104 172MM A 052104 DRIVEN PAN GREASE SEAL 2 16 02 DLJ 172MM A 052100 172MM A 052100 MOVABLE DRIVEN PAN 1 17 02 DLJ GB T3452 1 1992 46 2X1 8 GB T3452 1 1992 46 2X1 8 O SEAL RING 2 18 02 DLJ 172MM A 052007 172MM A 052007 SEAL BUSHING 1 19 02 DLJ 172MM A 052004 172MM A 052004 CLUTCH SPING 1 20 02 DLJ 172MM A 052009 172MM A 052009 SLEEVE 1 21 02 DLJ 172MM A 052002 172MM A 052002 GUIDE PIN 4 22 02 DLJ 172MM B 053000 172MM B 053000 COG BELT 1 172 13 GEARBOX COVER ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM C 060001 172MM C 060001 GEARBOX COVER 1 2 02 DLJ 172MM C 060002 172MM C 060002 GEAR BOX PAPER WASHER 1 3 02 DLJ 172MM 013005 172MM 013005 BOLT M12X1 5 OIL OUTLET 1 4 02 DLJ 152MI 021014 152MI 021014 WASHER12 1 5 02 DLJ 172MM B 069000 172MM B 069000 SHIFT DISPLAY SWITCH 1 6 02 DLJ GB T 276 1994 6202 RS GB T 276 1994 6202 RS BALL BEARING 1 7 02 DLJ GB T 276 1994 6201 GB T 276 1994 6201 BALL BEARING 1 8 02 DLJ GB T 276 1994 6203 GB T 276 1
36. 1 00 00 MAIN FRAME 1 2 02 DNB250 01 02 0011 DNB250 01 02 00 11 LEFT SIDE BAFFLE 1 3 02 DNB250 01 02 0010 DNB250 01 02 00 10 BAFFLE UNDER SEATS 1 4 02 DNB250 01 02 0009 DNB250 01 02 00 09 BAFFLE UNDER FOOT 1 5 02 DNB250 01 02 0008 DNB250 01 02 00 08 FRONT LOWER BAFFLE 1 6 02 DNB250 01 02 0012 DNB250 01 02 00 12 RIGHT SIDE BAFFLE 1 7 02 DNB250 01 02 0003 DNB250 01 02 00 03 CONSOLE PLATE 1 8 02 DNB250 01 02 0900 DNB250 01 02 09 00 WING BOX 1 9 02 LS2 01 02 01 06 LS2 01 02 01 06 LOCK ON WING BOX 1 184 21 FRONT SUSPENSION 1 2 4 6 5 7 8 9 10 11 13 14 12 15 18 17 19 20 16 21 22 23 24 44 45 46 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 3 40 21 FRONT SUSPENSION 47 48 49 50 51 185 21 FRONT SUSPENSION NO ERP CODE PART NO DESCRIPTION Q TY 1 02 DN250 02 03 DN250 02 03 00 00 RIGHT LOWER A ARM 1 2 02 DN250 02 06 DN250 02 06 00 00 RIGHT KNUCKLE 1 3 02 DN250 04 01 0001 DN250 04 01 00 01 BRAKE CLIPPER 1 1 4 02 DN250 02 01 DN250 02 01 00 00 RIGHT UPPER A ARM 1 5 03 01 5787 M14X1 5X90 05 5787 M14X1 5X90 FLANGE BOLT M14X1 5X90 2 6 02 DN250 02 04 DN250 02 04 00 00 LEFT UPPER A ARM 1 7 03 05 304 1 GE20C 304 1 GE20C JOINT BEARING GE20C 4 8 03 09 893 2 35 893 2 35 HOLE RETAINOR RING 35 4 9 02 DN250 02 0000
37. 19 02 DLJ GB T 9877 1988 FB33X35X5 GB T 9877 1988 FB33X35X5 OIL SEAL FB 33X35X5 1 20 02 DLJ GB T 276 1994 6201 GB T 276 1994 6201 BEARING 6201 1 21 02 DLJ GB T 276 1994 6202 RS GB T 276 1994 6202 RS BEARING 6202 RS 1 22 02 DLJ 172MM B 068001 172MM B 068001 HOLLOW BOLT M14X1 5 1 23 02 DLJ CF188 068002 CF188 068002 WASHER 14 4X22X1 1 24 02 DLJ CF188 068003 CF188 068003 SPACER SPRING 1 25 02 DLJ GB T308 1989 3 8 GB T308 1989 3 8 STEEL BALL 1 26 02 DLJ 152MI 130004 152MI 130004 O RING FOR SEAL13 5X1 4 1 02 DLJ 172MM B 011300 172MM B 011300 ODOMETER SENSOR 1 27 02 DLJ 172MM B 011400 172MM B 011400 SEAL CAP 1 28 02 DLJ 152MI 023010 152MI 023010 BOLT M6X20 1 158 2 SIDE COVER ASSY L No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM B 012001 172MM B 012001 LEFT SIDE COVER 1 2 02 DLJ 172MM B 012002 172MM B 012002 AIR DAMPER 1 3 02 DLJ GB T818 2000 M6X12 GB T818 2000 M6X12 SCREW 3 4 02 DLJ 172MM B 012005 172MM B 012005 BOLT 7 5 02 DLJ 152MI 013008 152MI 013008 BOLT 2 6 02 DLJ 152MI 021005 152MI 021005 LOCATING PIN 10x14 2 7 02 DLJ 172MM B 012003 172MM B 012003 LEFT SIDE COVER SEAL WASHER 1 8 02 DLJ 152MI 021018 152MI 021018 BOLT 1 159 3 RIGHT COVER ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 013013 172MM 013013 CYLINDER HEAD COVER AIR PIPE 1 2 02 DLJ 172MM 013100
38. 20 SAFE DRIVING PRECAUTIONS 21 OPERATION 25 SERVICE INSTRUCTION 31 REPAIR 36 ENGINE REPAIR 36 INFORMATION ABOUT REPAIR 37 INSPECTION ADJUSTMENT AND MAINTENANCE 52 COOLING SYSTEM 67 CRANK CASE 78 CYLINDER AND CYLINDER VALVE 85 CYLINDER PISTON 100 CTV
39. 20W 50 API SE or SF or pick one type of oil from right illustration according the weather temperature Temperature 58 Fuel system When using gasoline must be careful to fire Pay attention to the working position of O ring replace with a new one when put back Drain all the fuel in the floating house by loosening the fuel draining screw before operation Don t disassembly the enriching device To close the enriching valve earlier after the engine already warming up a heating tube is put on the carburetor to heat enriching mechanism Specifications Chock diameter 30mm Model CV30 Reversing rounds of the air adjusting screw 2 5 rounds Idle Speed 1500 150rpm Tools General tool Float ruler Trouble shooting Can t start No fuel in fuel tank Fuel path is blocked Too much fuel in cylinder Air filter is blocked Fuel is dirty Open the throttle fully no output engine stop Vacuum diaphragm broken Suction pressure channel blocked Failure of fuel pump Idle speed not steady Failure of adjustment Too thick gas mixture Too thin gas mixture Air filter blocked air leakage on carburetor support failure of air cutting valve suction pressure tube broken Thin gas mixture fuel holes blocked vent hole on the fuel tank blocked fuel filter blocked fuel tube broken damaged blocked failure of float valve action low fuel lever Thick gas mixture enriching valve keep open failure of float valve action high
40. 3 03 95 8X16X1 5 95 8x16x1 5 PLAIN WASHER 8 1 28 03 08 91 3X30 05 91 3x30 COTTER PIN 3x30 1 29 02 DI250 05 05 04 DI250 05 05 04 00 SHIFT CABLE 1 30 03 03 95 6X12X1 05 95 6x12x1 PLAIN WASHER 6 2 31 03 04 93 6 05 93 6 SPRING WASHER 6 2 32 03 01 5787 M6X10 05 5787 M6x10 FLANGE BOLT M6X10 2 33 03 05 304 1 GE12C 304 1 GE12C JOINT BEARING GE12C 1 34 03 07 882 8X25 882 8x25 B PIN 8x24 1 35 03 08 91 3X30 05 91 3x30 COTTER PIN 3X30 1 36 02 D650 07 02 0100 D650 07 02 01 00 PARKING MACHANISM 1 37 02 D650 07 02 0004 D650 07 02 00 04 PARKING STEEL BUSHING 1 38 02 D650 07 02 0001 D650 07 02 00 01 PARKING BRAKE JOINT 1 39 03 08 91 3X30 05 91 3x30 COTTER PIN 3x30 1 40 02 D650 07 02 02 D650 07 02 02 00 PARKING BRAKE CABLE 1 41 02 DI250 04 03 0003 DI250 04 03 00 03 GUARD SPRING 1 42 02 DN250 04 03 0002 DN250 04 03 00 02 PARKING BRAKE OIL TUBE 1 43 02 DI250 04 03 0001 DI250 04 03 00 01 PARKING BRAKE OIL CUP 1 44 02 DN250 04 01 0002 DN250 04 01 00 02 BRAKE CALIPER 2 1 198 25 EXHAUST SHIFT amp BRAKE 1 2 3 4 5 6 7 8 9 10 11 12 14 22 23 24 25 26 27 28 29 30 31 32 33 36 37 35 34 38 39 40 45 46 44 41 42 43 19 13 16 17 47 48 49 50 51 52 53 10 54 56 55 57 58 59 60 25 EXHAUST amp SHIFT am
41. 32 03 01 823 M5X30 05 823 M5x30 CROSS PANHEAD SCREW M5X30 2 33 02 DN250 05 03 0001 DN250 05 03 00 01 AIR FILTER SUPPORT EAR1 1 34 03 01 D818 M6X20 D818 M6x20 CROSS PANHEAD SCREW M6X20 1 35 02 DI250 05 03 0002 DI250 05 03 00 02 AIR FILTER SHELL 1 36 02 DI250 05 03 0002 DI250 05 03 00 02 AIR FILTER SUPPORT EAR2 1 37 03 01 5787 M8X20 05 5787 M8x20 FLANGE BOLT M8X20 1 38 02 DN250 05 03 0103 DN250 05 03 01 03 AIR FILTER CORE 1 39 02 DN250 05 03 0102 DN250 05 03 01 02 AIR FILTER COVER BOX 1 40 02 DN250 05 03 0105 DN250 05 03 01 05 AIR amp OIL SEPARATOR FILTER SPONGE 1 41 02 DN250 05 03 0104 DN250 05 03 01 04 AIR amp OIL SEPARATOR COVER 1 42 03 01 823 M5X30 05 823 M5x30 CROSS PANHEAD SCREW M5X30 7 43 02 DN250 11 01 06 DN250 11 01 06 00 CVT INLET AIR FILTER 1 44 02 JD 1135001 JD1135001 RUBBER SEAL WASHER 1 45 02 DLJ REV 22A REV 22A AIR INTLET 1 196 25 EXHAUST SHIFT amp BRAKE 1 2 3 4 5 6 7 8 9 10 11 12 14 22 23 24 25 26 27 28 29 30 31 32 33 36 37 35 34 38 39 40 45 46 44 41 42 43 19 13 16 17 47 48 49 50 51 52 53 10 54 56 55 57 58 59 60 25 EXHAUST amp SHIFT amp PARKING BRAKE 197 25 EXHAUST amp SHIFT amp PARKING BRAKE No ERP CODE PART NO DESCRIPTION Q TY 1 02 DI250 07 0400 DI250 07 04 00 00 ENGINE AS
42. 4 02 DLJ 172MM 040007 172MM 040007 PISTON PIN 1 5 02 DLJ 152MI 040011 152MI 040011 OIL CHANNEL JOINT 1 6 02 DLJ 152MI 040010 152MI 040010 JOINT SPRING 1 7 02 DLJ 152MI 040006 152MI 040006 WOODRUFF KEY 1 8 02 DLJ 172MM 040006 172MM 040006 PISTON PIN STOP RING 2 9 02 DLJ GB T119 2000 2X14 GB T119 2000 2X14 PIN 1 170 11 SPEED CHANGER No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 021007 172MM 021007 NUT M14X1 5 1 2 02 DLJ 172MM 021006 172MM 021006 WASHER14 5X30 2 1 3 02 DLJ 172MM A 051005 172MM A 051005 DRIVE WHEEL PAN 1 4 02 DLJ 172MM A 051003 172MM A 051003 DRIVE WHEEL PAN SLEEVE 1 5 02 DLJ 172MM A 051100 172MM A 051100 MOVABLE DRIVE PAN 1 6 02 DLJ 172MM A 051200 172MM A 051200 OFFCENTER ROLLER 6 7 02 DLJ 172MM A 051004 172MM A 051004 SLIDING BLOCK 3 8 02 DLJ 172MM A 051002 172MM A 051002 PUSH PAN 1 171 12 CLUTCH ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 052008 172MM 052008 BOLT M12X1 25 1 2 02 DLJ 172MM A 052500 172MM A 052500 OUTTER WHEEL DISC 1 3 02 DLJ 172MM 052005 172MM 052005 THIN NUT M30X1 1 4 02 DLJ 172MM A 052400 172MM A 052400 DRIVE PAN UNIT 1 5 02 DLJ 172MM A 052200 172MM A 052200 DAMPING RUBBER BLOCK 3 6 02 DLJ 172MM A 052600 172MM A 052600 CLUTCH BLOCK 3 7 02 DLJ 172MM A 052006 172MM A 052006 RELEASE SPRING 3 8 02 DLJ 172MM A 052003 172MM A 052003 SIDE PAN
43. 80665N Explanation for symbols in manual That dangerous items need to pay special attention Or it will cause accident even death Important item need to pay some attention otherwise the engine will be damaged and stop running General notes and tips 37 INFORMATION ABOUT REPAIR Engine number location Specification table No Item specification 1 Engine Model 172MM C 2 Displacement 244 3CM3 3 Types of fuel RQ 90 4 Starting electric 5 Type Single cylinder four stroke water cooled vertical 6 Bore Stroke 72mm 60mm 7 Compression pressure 1470kpa 600rpm 8 The maximum power 11kw 7000rpm 9 Maximum torque 17 6N m 5500rpm 10 Distribution phase Intake valve Open BTDC0 1mm Closed ABDC30 1mm Exhaust Valve Open BBDC35 1mm Closed BTDC5 1mm 11 Unladen stability minimum rpm 1500 150rpm 12 Lubrication system Lubrication type Pressure Splashing Pump type Rotor Lubricating oil filter type Metal strainer full flow filtration Engine number 38 Lubrication capacity 1 0L 13 Cooling Compulsory 14 Fuel system Air Filters Foam plastic fitter core Carburetor KEIHNCV30 15 Electric System al Ignition way C D I Electronic ignition Ignition time 10 BTDC 1500rpm Spark Plug DPR7EA 9 NGK Electrode gap 0 8 0 9mm 16 Power transmission system Clutch type Dry foot block a
44. 818 2000 M5X16 D Cr GB T818 2000 M 5X16 D Cr CRUCIFORM SLOT SCREW 1 21 02 DLJ GB T848 85 6 D Cr GB T848 85 6 D Cr SMALL WASHER 2 22 02 DLJ 152MI 021005 152MI 021005 LOCATION PIN 10X14 2 23 02 DLJ GB T9074 17 1988 M6X12 GB T9074 17 198 8 BOLT M6X12 3 162 4 CYLINGDER HEAD CASEING ASSY No ERP CODE P N ENGLISH Qty 24 02 DLJ BOLTM6X25 BOLTM6X25 BOLT M6X25 1 25 02 DLJ 152MI 013010 152MI 013010 BOLT M6X50 3 26 02 DLJ 152MI 021018 152MI 021018 BOLT M6X55 1 27 02 DLJ 172MM 021404 172MM 021404 SHOCK ABSORBER SLEEVE 1 28 02 DLJ 172MM 021002 172MM 021002 BREATH PIPE FAUCET 1 29 02 DLJ 172MM 021300 172MM 021300 AIR FILTER MOUNT 1 30 02 DLJ 172MM 021008 172MM 021008 BLOCKING 1 163 5 CYLINGDER HEAD ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 022100 172MM 022100 CYLINDER HEAD 1 2 02 DLJ 172MM 022700 172MM 022700 EXHAUST FLANGE 1 3 02 DLJ 152MI 022014 152MI 022014 BEARING COVE CAM AXIS 1 4 02 DLJ 172MM 022008 172MM 022008 EXHAUST NUT 2 5 02 DLJ 172MM 022010 172MM 022010 CYLINDER HEAD SEAL WASHER 1 6 02 DLJ 172MM 022900 172MM 022900 CARBURETOR SEAT UNIT 1 7 02 DLJ 172MM 022500 172MM 022500 AIR INLET PIPE CLAMP UNIT 1 8 02 DLJ 152MI 022810 152MI 022810 THERMOSTAT 1 9 02 DLJ 152MI 022803 152MI 022803 UPPER THERMOSTAT SHELL 1 10 02 DLJ 152MI 022021 152MI 022021 CARBURETOR RUBBER P
45. 8x12 1 13 02 D800 05 01 03 03 D800 05 01 03 03 STEERING BOX COVER PLATE 1 14 02 D800 05 01 03 02 D800 05 01 03 02 STEERING GEAR SHAFT 1 15 02 D800 05 01 03 09 D800 05 01 03 09 BALL BEARING 20x42x12 1 16 03 01 5787 M10X30 05 5787 M10X30 FLANGE BOLT M10x30 2 17 02 D800 05 01 03 05 D800 05 01 03 05 BEARING STOP PLATE 1 18 03 01 5787 M6X25 05 5787 M6x25 FLANGE BOLT M6x25 4 19 03 01 5782 M8X30 05 5782 M8x30 BOLT M8X30 2 20 03 04 93 8 05 93 8 SPRING WASHER 8 2 21 02 DN250 03 04 0001 DN250 03 04 00 01 SLIP UNIVERSAL JOINT SHAFT 1 22 02 DN250 03 04 0003 DN250 03 04 00 03 SPRING PLATE 1 23 02 DN250 03 04 0002 DN250 03 04 00 02 SLIP UNIVERSAL JOINT SLEEVE 1 24 03 09 893 2 26 893 2 26 CIRCLIP FOR HOLE 26 1 25 03 05 276 61803 276 61803 BALL BEARING 61803 1 26 02 DN250 03 03 02 DN250 03 03 02 00 STEERING COLUMN SLEEVE 1 27 03 05 276 61902 276 61902 BALL BEARING 61902 1 28 03 09 893 2 28 893 2 28 CIRCLIP FOR HOLE 28 1 29 02 DN250 03 03 01 DN250 03 03 01 00 STEERING COLUMN SHAFT 1 30 03 02 6187 1 M8 05 6187 1 M8 FLANGE LOCK NUT M8 6 31 02 TR1100 05 01 0002 TR1100 05 01 00 02 STEERING WHEEL 1 32 03 01 70 2 M6X25 05 70 2 M6x25 INNER SUNK SCREW M6x25 6 34 2 TR1100 05 01 0002 3 TR1100 05 01 00 02 3 PLASTIC COVER 1 36 03 02 41 M4 05 41 M4 CROSS PANHEAD SCREW M4x5 2 37 03 04 93 4 05 93 4 SPRING WASHER 4 2 38 02 DN250
46. 9 02 D650 04 06 0002 D650 04 06 00 02 BLOCK SHEET ACT 1 30 02 D650 04 06 0001 D650 04 06 00 01 SUPPORT ACT 1 31 03 02 6187 1 M6 05 6187 1 M6 FLANGE LOCK NUT M6 3 32 03 01 5787 M6X20 05 5787 M6X20 FLANGE BOLT M6X15 3 33 02 DN250 01 02 01A DN250 01 02 01 00A LEFT PROTECTIVE BAR 1 34 02 DN250 05 02 0004 DN250 05 02 00 04 INLET PIPE ACT 1 35 02 JD 1135000 JD1135000 FUEL TANK CAP 1 36 02 DN250 05 02 03 01 DN250 05 02 03 01 FUEL TANK 1 37 03 01 5787 M8X20 05 5787 M8X20 FLANGE BOLT M8X20F 4 38 03 02 2842 M8 05 SJ2842 M8 FLANGE NUT M8F 4 39 02 JD 1138000 JD1138000 FUEL SWITCHF 1 40 02 DN250 05 02 0004 DN250 05 02 00 04 FUEL PIPE 1 1 41 02 DS250 11 01 0009 DS250 11 01 00 09 GAS FILTER 1 42 02 DN250 05 02 0005 DN250 05 02 00 05 FUEL PIPE 2 1 43 02 DN250 01 02 07A DN250 01 02 07 00A SHIFT COVER 1 44 02 D800 04 02 02 02 D800 04 02 02 02 SEAL CUSHING WATER TANK 1 45 02 JD 1135001 JD1135001 RUBBER WASHER 1 46 02 DN250 05 02 0002 DN250 05 02 00 02 CLAMP 1 FUEL FILTER 1 47 02 DN250 05 02 0006 DN250 05 02 00 06 PROTECTIVE SPRING1 FUEL 1 48 02 DN250 05 02 0003 DN250 05 02 00 03 CLAMP 2 FUEL FILTER 1 49 02 DN250 05 02 0007 DN250 05 02 00 07 PROTECTIVE SPRING 2 FUEL 1 182 9 20 ALUMINIUM BAFFLE 1 2 3 4 5 6 7 8 183 20 ALUMINIUM BAFFLE NO ERP CODE PART NO DESCRIPTION Q TY 1 02 DNB250 01 0100 DNB250 01 0
47. 9 SEAL SLEEVE 1 13 02 JD 0118006 JD0118006 SMALL CLAMP 1 14 02 DN250 05 04 0002B DN250 05 04 00 02B MUFFLER 1 15 02 DLJ JN0400020 EU JN0400020 EU LEFT BACK VIEW MIRROR 1 16 02 DLJ JN0400030 EU JN0400030 EU RIGHT BACK VIEW MIRROR 1 17 02 DN250 11 01 09 DN250 11 01 09 00 CANVAS ROOF 1 18 02 D650 08 01 0013 D650 08 01 00 13 SAFTY BELT TUBE 4 19 02 D800 08 01 0003 D800 08 01 00 03 CLOTH COVER FOR ENTIRE KART 1 20 02 D250 11770B D250 11 770B FOAM COVER 1 21 02 D250 11770B D250 11 770B ENVELOPMENT 1 22 02 DN250 11 01 11 01 DN250 11 01 11 01 FRONT SHOCK ABSORBER COAT 2 23 02 DN250 11 01 11 02 DN250 11 01 11 02 REAR SHOCK ABSORBER COAT 2 24 02 DN250 11 01 0001 DN250 11 01 00 01 JOYNER PLATE 1 206 42 43 42 41 42 41 42 41 42 41 42 41 42 41 42 41 41 37 38 39 36 40 38 25 26 27 28 29 30 31 32 34 33 35 36 28 OTHER PARTS 207 28 OTHER PARTS No ERP CODE PART NO DESCRIPTION Q TY 25 03 01 D818 M6X20 D818 M6x20 PHILIPS HEAD SCREW M6X20 12 26 02 D250 11005A D250 11 005A RUBBER WASHER 6 12 27 03 02 6183 1 M6 05 6183 1 M6 LOCK FLANGE NUT M6 12 28 02 D250 11005A D250 11 005A MUD GUARD 4 29 02 DN250 11 01 02 DN250 11 01 02 00 FR R MUD GUARD SUPPORT 1 30 02 DN250 11 01 03 DN250 11 01 03 00 FR L MUD GUARD SUPPORT 1 31 02 DN250 11 01 04 DN250 11 01 04 00 RL M
48. 994 6203 BALL BEARING 1 9 02 DLJ GB T 276 1994 6305 RS GB T 276 1994 6305 RS BALL BEARING 1 10 02 DLJ 172MM B 011107 172MM B 011107 BOLT M8X48 3 11 02 DLJ 172MM B 011111 172MM B 011111 BOLT M8X30 5 12 02 DLJ 1P52MI A 011007 1P52MI A 011007 BOLT M8X55 2 13 02 DLJ CF188 332004 CF188 332004 O RING 19X2 5 1 14 02 DLJ CF188 332003 CF188 332003 OIL INLET BOLT 1 15 02 DLJ 172MM C 060003 172MM C 060003 OIL SEAL 32X62X7 1 16 02 DLJ CF188 310028 CF188 310028 AIR PIPE JOINT 1 17 02 DLJ 152MI 080008 152MI 080008 LOCATION PIN 8X14 2 18 02 DLJ 172MM C 060007 172MM C 060007 PAPER WASHER 1 19 02 DLJ 172MM C 060006 172MM C 060006 CHAIN PULLY COVER 1 20 02 DLJ GB5787 86 M6X40 D Cr GB5787 86 M6X40 D Cr BOLT 3 21 02 DLJ 152MI 080012 152MI 080012 BOLT M6X32 3 22 02 DLJ CF188 065002 CF188 065002 OIL SEAL SD 15X25X5 1 23 02 DLJ 172MM B 011113 172MM B 011113 OIL STOP CHIP 1 24 02 DLJ GB T 819 2000 GB T 819 2000 SCREW M4X12 2 173 14 TRANSMISSION GEAR ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM B 067000 172MM B 067000 TRANSITION GEARS ASSY 1 2 02 DLJ GB T894 1 1986 20 GB T894 1 1986 20 RETAINER RING 2 3 02 DLJ 172MM B 067000 172MM B 067000 TRANSITION GEAR 1 4 02 DLJ 172MM B 067001 172MM B 067001 TRANSITON GEAR AXIS 1 5 02 DLJ 172MM B 060001 172MM B 060001 MAIN AXIS 1 6 02 DLJ 172MM B 062000 172MM B 062000 SECONDARY A
49. AL 10X20X5 1 13 02 DLJ 152MI 080008 152MI 080008 LOCATION PIN 8X14 2 178 18 ELECTRIC STARTER ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 090001 172MM 090001 DUPLICATE GEAR AXIS 1 2 02 DLJ 172MM 092000 172MM 092000 DRIVEN GEAR COMP 1 3 02 DLJ 172MM 091000 172MM 091000 DUPLICATE GEAR COMP 1 4 02 DLJ 172MM 090007 172MM 090007 MOUNTING PLATE 1 5 02 DLJ 172MM 093000 172MM 093000 STARTER COMP 1 6 02 DLJ 152MI 080013 152MI 080013 BOLT M6X22 2 7 02 DLJ 172MM 090008 172MM 090008 BOLT M6X14 1 179 19 CARBURETOR ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 100000 172MM 100000 CARBURETOR ASSY 1 180 20 FRAME amp FUEL TANK amp RADIATOR 47 46 48 49 45 20 FRAME amp FUEL TANK amp RADIATOR 1 43 2 3 4 6 7 8 9 10 13 14 11 12 15 16 17 18 19 21 20 33 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 41 40 42 44 181 20 FRAME amp FUEL TANK amp RADIATOR NO ERP CODE PART NO DESCRIPTION Q TY 1 02 DN250 01 0100 DN250 01 01 00 00 MAIN FRAM OPTION 1 2 02 DN250 01 02 0006 DN250 01 02 00 06 COVER FR 1 3 02 DN250 01 02 0004 DN250 01 02 00 04 LEFT SPORT WING OPTION 2 4 02 DN250 01 02 0004 DN250 01 02 00 04 LOWER SPORT WING OPTION 1 6 02 DN250 01 02 0002 DN250
50. AXIS 1 5 02 DLJ 151MI 071001 151MI 071001 OIL PUMP CHAIN PULLEY 1 6 02 DLJ 151MI 073000 151MI 073000 CHAIN OIL PUMP 1 7 02 DLJ 151MI 071004 151MI 071004 INNER ROTOR OIL PUMP 1 8 02 DLJ 151MI 071005 151MI 071005 OUTTER ROTOR OIL PUMP 1 9 02 DLJ 151MI 070002 151MI 070002 OIL PUMP SPACER PLATE A 1 10 02 DLJ 151MI 072000 151MI 072000 OIL PUMP SPACER PLATE B 1 11 02 DLJ GB878 85 M3X12 GB878 85 M3X12 SCREW 1 12 02 DLJ 151MI 071006 151MI 071006 LOCATION PIN 4X6 5 1 13 02 DLJ GB894 1 86 10 GB894 1 86 10 RETAINER RING AXIS 1 14 02 DLJ 151MI 021019 151MI 021019 BOLT M6X12 1 15 02 DLJ 151MI 070003 151MI 070003 BOLT M6X28 2 177 17 COOLANT PUMP ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 080004 172MM 080004 WATER PUMP IMPELLER 1 2 02 DLJ 152MI 081000 152MI 081000 WATER SEAL ASSY 1 3 02 DLJ 172MM 080003 172MM 080003 WATER PUMP COVER 1 4 02 DLJ 172MM 080002 172MM 080002 COVER SEAL WASHER 1 5 02 DLJ 172MM 080001 172MM 080001 WATER PUMP AXIS 1 6 02 DLJ 152MI 013009 152MI 013009 BOLT M6X40 2 7 02 DLJ 152MI 021017 152MI 021017 BOLT M6X25 2 8 02 DLJ GB T893 1 1986 19 GB T893 1 1986 19 HOLE RETAINER RING 1 9 02 DLJ 152MI 080007 152MI 080007 WASHER 7 5X13X1 2 1 10 02 DLJ 152MI 080011 152MI 080011 WASHER 6X12X1 1 11 02 DLJ NTN 6800 NTN 6800 NEEDLE BEARING 2 12 02 DLJ 172MM 080005 172MM 080005 GREASE SE
51. C HUB 2 24 02 DN250 09 01 0001 DN250 09 01 00 01 REAR TIRE 22X10 10 2 25 02 D250 00037 D250 00 037 REAR RIM 2 26 03 03 95 10X20X2 05 95 10X20X2 PLAIN WASHER 10 8 27 03 02 923 M10X1 25 923 M10x1 25 CAPPED NUT M10X1 25 8 28 03 04 93 10 05 93 10 SPRING WAHSER 10 8 29 02 D250 06011 D250 06 011 REAR WHEEL AXLE WASHER 2 30 02 DI250 07 04 0001 DI250 07 04 00 01 HALF AXLE SLOTTED NUT 2 31 03 08 91 4X40 05 91 4x40 COTTER PIN 4X30 2 32 02 JD 0360010 JD0360010 FRONT WHEEL HUB COVER 2 33 02 DLJ BT 2075 BT 2075 INNER BOOT 2 34 02 DI250 07 01 0003 DI250 07 01 00 03 SMALL BRIDLE BOOT 4 35 02 DLJ BT 2075 BT 2075 OUTER BOOT 2 36 02 DI250 07 01 0001 DI250 07 01 00 01 BIG BRIDLE BOOT 4 37 02 DN250 07 0100 DN250 07 01 00 00 CV AXLE ASSY 2 38 02 DN250 04 01 0003 DN250 04 01 00 03 FRACTION PLATE 1 2 39 02 DN250 04 01 0004 DN250 04 01 00 04 FRACTION PLATE 2 2 40 02 DN250 04 01 0006 DN250 04 01 00 06 BRAKE CLIPPER SPRING PLATE 2 1 41 02 DN250 04 01 0005 DN250 04 01 00 05 BRAKE CLIPPER SPRING PLATE 1 2 202 27 ELECTRICAL PARTS 27 ELECTRICAL PARTS 1 2 3 4 5 6 7 10 11 30 13 14 15 16 17 18 19 20 9 21 23 22 24 25 26 27 28 3 29 31 12 29 32 33 34 35 203 27 ELECTRICAL PARTS No ERP CODE PART NO DESCRIPTION Q TY 1 02 D650 06 0012B D650 06 00 12 00B SPOT
52. CTION A Air Filter Clean every 80 running hours If the vehicle is operated under extremely dusty condition we suggest cleaning after every use and replace more often a Remove cleaner cover 1 b Remove air cleaner filter core See Fig 9 c Check the filter paper if the filter paper is dusty please clean with pressure air or replace with a new one B Engine Lubrication You must change the oil in the crankcase after the first 5 hours of operating of your new engine and after 10 hours of use thereafter That will insure proper lubrication of internal parts and prevent costly repairs due to excessive wear a Remove fill plug located on bottom of engine See Fig 10 Tip Off highway recreational vehicle backwards slightly by blocking up the front end and drain oil into suitable container b Replace fill plug and tighten securely Place Off highway recreational vehicle in a level position c Refill crankcase approximately 1000 ml 1qt to top of filler neck with SAE 10W 30 oil Use same grade of oil as used originally d Check oil level before each use of dart or after each 10 hours of operation Add oil to bring up to proper lever Do not mix various grades of oil C Engine Coolant You should check the coolant for lack If lack you should refill coolant approximately 1800 ml into the radiator or reserve coolant The lack of coolant will cause engine overheat This can cause engine damage D Spark Plug a Remove the s
53. ING HUB 2 32 03 05 276 6203 276 6203 BALL BEARING 6203 2 33 03 06 13871 FB25X40X6 13871 FB25x40x6 GREASE SEAL FB40X25X6 2 34 02 JD 0360006 JD0360006 SMALL SPACER 8 2 35 02 D250 06011 D250 06 011 REAR WHEEL AXLE WASHER 2 36 03 04 93 16 05 93 16 SPRING WASHER 16 2 37 03 02 6178 M16 05 6178 M16 SLOTTED NUT M16 2 38 03 08 91 4X40 05 91 4x40 COTTER PIN 4x40 2 39 02 DN250 02 08 0001 DN250 02 08 00 01 TYRE 21X8 10 2 40 02 JD 0760800 JD0760800 RIM 10X5 5 2 186 1 2 4 6 5 7 8 9 10 11 13 14 12 15 18 17 19 20 16 21 22 23 24 44 45 46 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 3 40 21 FRONT SUSPENSION 47 48 49 50 51 187 21 FRONT SUSPENSION NO ERP CODE PART NO DESCRIPTION Q TY 41 03 04 93 10 05 93 10 SPRING WASHER 10 8 42 03 03 95 10X20X2 05 95 10x20x2 PLAIN WASHER 10 8 43 03 02 923 M10X1 25 923 M10x1 25 CAPPED NUT M10X1 25 8 44 03 01 5787 M12X1 5X80 05 5787 M12X1 5X80 FLANGE BOLT M12X1 5X80 8 45 02 D800 05 01 0002 D800 05 01 00 02 ROD END BEARING 12 8 46 02 D800 05 01 0003 D800 05 01 00 03 SPACER 12 TIE ROD 8 47 02 DN250 04 01 0003 DN250 04 01 00 03 FRACTION PLATE 1 2 48 02 DN250 04 01 0004 DN250 04 01 00 04 FRACTION PLATE 2 2 49 02 DN250 04 01 0005 DN250 04 01 00 05 BRAKE CLIPPE
54. IPE1 1 11 02 DLJ 172MM 022601 172MM 022601 LOWER THERMOSTAT SHELL 1 12 02 DLJ 172MM 022400 172MM 022400 SPARK PLUG 1 13 02 DLJ 152MI 021017 152MI 021017 BOLT M6X25 2 14 02 DLJ 172MM 022800 172MM 022800 BREATH SEAL WASHER 1 15 02 DLJ 152MI 022600 152MI 022600 WATER TEMP SENSOR 1 16 02 DLJ GB T6191 1986 M6X18 D Cr GB T6191 1986 M6X18 D Cr SOCKET HEAD SCREW 2 17 02 DLJ 172MM 022007 172MM 022007 DOUBLE SCREW BOLT 2 18 02 DLJ 152MI 022012 152MI 022012 WASHER 8 4 19 02 DLJ 152MI 022013 152MI 022013 CAP NUT M8 4 20 02 DLJ 152MI 022804 152MI 022804 O RING 14 8X1 9 1 21 02 DLJ 172MM 022009 172MM 022009 O RING 31X2 1 22 02 DLJ 152MI 022020 152MI 022020 BOLT M6X22 2 23 02 DLJ 152MI 021005 152MI 021005 LOCATION PIN 10X14 2 164 5 CYLINGDER HEAD ASSY No ERP CODE P N ENGLISH Qty 24 02 DLJ QC T621 1999 A6 5 QC T621 1999 A6 5 STEEL RING CLAMP 2 25 02 DLJ 152MI 090005 152MI 090005 BOLT M6X16 2 26 02 DLJ 152MI 023008 152MI 023008 BOLT M6X18 1 27 02 DLJ 152MI 022017 152MI 022017 CARBURETORS BREATHE PIPE 1 28 02 DLJ GB T848 85 6 D Cr GB T848 85 6 D Cr SMALL WASHER 1 29 02 DLJ 152MI 022021 152MI 022021 SCREW BLOCKAGE 1 165 6 CYLINGER BODY ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM 023100 172MM 023100 CYLINDER 1 2 02 DLJ 172MM 023002 172MM 023002 CYLINDER SEAL WASHER 1 3
55. LIGHT 3 2 02 D650 06 0003 D650 06 00 03 00 HEAD LIGHT 2 3 02 DN250 10 01 02 DN250 10 01 02 00 TURNING SIGNLE 2 4 02 D250 07915 D250 07 915 VOLTAGE REGULATOR 1 5 02 DI250 10 05 DI250 10 05 00 00 IGNITION COIL 1 6 02 DLJ CF250T 461000 cF250T 461000 CDI 1 7 02 D250 07912 D250 07 912 STARTER RELAY 1 9 02 DN250 10 01 02 DN250 10 01 02 00 FUSE BOX 1 10 02 D250 07913 D250 07 913 HORN 1 11 02 D250 07802 D250 07 802 BATTERY 1 12 02 D800 06 000012 D800 06 00 00 12 TAILLIGHT ASSEMBLY 2 13 02 DN250 10 01 01 DN250 10 01 01 00 HARNESS 1 14 02 D250 07909A D250 07 909A IGNITION SWITCH 1 15 02 D650 06 0013 D650 06 00 13 00 HORN BUTTON 1 16 02 DN250 10 02 DN250 10 02 00 00 SPEED METER 250 1 17 02 DN250 10 03 DN250 10 03 00 00 TACHO METER 250 1 18 02 N650 06 05 N650 06 05 00 00 WATER TEMPERATURE INDICATOR N650 1 19 02 D1600 06 05 D1600 06 05 00 00 VOLTAGE METER D1600 1 20 02 DN250 10 06A DN250 10 06 00 00A PANEL SWITCH DN250 1 21 02 DN250 10 0100 DN250 10 01 00 00 BATTERY RUBBER COVER 1 22 03 01 5782 M6X110 05 5782 M6x110 BOLT M6X110 2 23 02 DN250 10 000001 DN250 10 00 00 01 BATTERY STOP BAND 1 24 02 D250 07924A D250 07 924A FLASHER COAT 1 25 02 D250 07914A D250 07 914A FLASHER APPARATUS 1 26 02 D1600 06 10 0002 D1600 06 10 00 02 SPOT LIGHT BULB 3 27 02 D650 06 000301 D650 06 00 03 01 HENDLIGHT BULB 1 1 28 02 D650
56. M 032000 STATOR UNIT 1 6 02 DLJ GB T70 1 2000 M8X18 GB T70 1 2000 M8X18 SOCKET HEAD SCREW 3 7 02 DLJ 172MM 040001 172MM 040001 NUT M16X1 1 8 02 DLJ 172MM 040002 172MM 040002 WASHER16 3X30X2 1 9 02 DLJ 152MI 030002 152MI 030002 BOLT M5X16 2 10 02 DLJ 152MI 060002 152MI 060002 BOLT M6X30 3 168 9 ADMISSION MACHANISM No ERP CODE P N ENGLISH Qty 1 152MI 022500 152MI 022500 VALVE ROD SEAL 2 2 172MM 022300 172MM 022300 CAM UNIT 1 3 152MI 021007 152MI 021007 SWING ARM 2 4 172MM 022001 172MM 022001 INTAKE VALVE 1 5 172MM 022005 172MM 022005 EXHAUST VALVE 1 6 172MM 022002 172MM 022002 OUTTER VALVE SPRING 2 7 172MM 022003 172MM 022003 INNER VALVE SPRING 2 8 152MI 022005 152MI 022005 VALVE SPRING PAN 2 9 152MI 022001 152MI 022001 VALVE SPRING SEAT 2 10 152MI 022006 152MI 022006 VALVE CLAMP 4 11 NTN 16002 NTN 16002 BALL BEARING 2 12 GB894 A 1 86 15 GB894 A 1 86 15 RETAINER RING AXIS 1 13 172MM 022310 172MM 022310 CHAIN PULLY 1 14 152MI 022500 172MM 022301 CAM AXIS 1 169 10 CRANK LINK LEVER amp PISTON No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM A 041000 172MM A 041000 CRANK LINK UNIT 1 2 02 DLJ 172MM 040008 172MM 040008 PISTON RING 1 02 DLJ 172MM 040009 172MM 040009 PISTON RING 1 02 DLJ 172MM 042000 172MM 042000 OIL RING 1 3 02 DLJ 172MM 040005 172MM 040005 PISTON 1
57. N These signal words mean 15 Physical harm may result from failure to adhere to the instructions that are described within the WARNING labels Safety Headings It means Important Safety Reminders or Important Safety Precautions Safety Section It means Go Off highway recreational vehicle Safety Instructions how to use this Go Off highway recreational vehicle correctly and safely This entire manual is filled with important safety information please read it carefully IMPORTANT SAFETY INFORMATION Your off highway recreational vehicle will provide you with many years of service and pleasure Providing you take responsibility for your own safety and understand the challenges you can meet while driving There is much that you can do to protect yourself when you drive You ll find many helpful recommendations throughout this manual The following are a few that we consider most important Follow the Age Recommendation It is strongly recommended that no one under the age of 16 be permitted to drive this off highway recreational vehicle without adult supervision Always Wear a Helmet It s a proven fact helmets significantly reduce the number and severity of head injuries Always wear an approved motorcycle helmet We also recommend that you wear eye protection sturdy boots gloves and other protective gear Drive Off Road Only Your off highway recreational vehicle is designed and manufactured for off road use only The t
58. R SPRING PLATE 2 1 50 02 DN250 04 01 0006 DN250 04 01 00 06 BRAKE CLIPPER SPRING PLATE 1 1 51 02 JD 0360010 JD0360010 FRONT WHEEL HUB COVER 2 188 22 STEERING amp THROTTLE amp BRAKE amp SHIFT 70 71 48 53 54 55 56 57 58 59 60 66 67 68 69 22 STEERING amp THROTTLE amp BRAKE amp SHIFT 1 2 3 4 5 6 7 8 10 9 11 12 13 14 15 17 16 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 34 44 45 46 47 49 43 42 41 40 39 38 37 36 50 51 52 61 62 63 189 22 STEERING amp THROTTLE amp BRAKE amp SHIFT No ERP CODE PART NO DESCRIPTION Q TY 1 02 D800 05 01 0001 D800 05 01 00 01 ROD END BEARING POSA12L 2 2 03 02 6172 1 M12 L 05 6172 1 M12 L THIN NUT M12L 2 3 02 DN250 03 02 DN250 03 02 00 00 TIE ROD 2 4 03 01 70 1 M12X80 05 70 1 M12x80 BOLT M12X80 2 5 02 D800 05 01 0004 D800 05 01 00 04 REINFORCED SHEET TIE ROD 1 6 02 D800 05 01 0003 D800 05 01 00 03 TIE ROD SPACER 8 7 02 D800 05 01 03 07 D800 05 01 03 07 DUST GUARD PLATE 1 8 02 D800 05 01 03 06 D800 05 01 03 06 TIE ROD SUPPORT 1 9 03 11 7940 1 M8 7940 1 M8 GREASE CUP M8X1 1 10 02 D800 05 01 03 01 D800 05 01 03 01 STEERING BOX CASE 1 11 02 D800 05 01 03 04 D800 05 01 03 04 STEERING RACK 1 12 02 D800 05 01 03 10 D800 05 01 03 10 BUSH BEARING14c7x1
59. SEMBLY 1 2 02 DI250 05 05 05 DI250 05 05 05 00 GEAR SHIFT ARM 1 3 02 DI250 05 03 0005A DI250 05 03 00 05A FIXED MOUNT OF SHIFT CABLE 3 1 1 4 02 DI250 05 03 0003A DI250 05 03 00 03A FIXED MOUNT OF SHIFT CABLE 1 1 1 5 03 01 5787 M6X10 05 5787 M6x10 HEXAGON HEADED FLANGE BOLT 2 6 02 DN250 05 06 01A DN250 05 06 01 00A SHIFT CABLE 1 7 03 03 95 8X16X1 5 95 8x16x1 5 PLAIN WASHER 8 1 8 03 08 91 2X25 05 91 2x25 COTTER PIN 2X25 1 9 03 01 5787 M8X20 05 5787 M8x20 HEXAGON HEADED FLANGE BOLT 1 10 02 D250 11037 D250 11 037 ASBESTOS MUFFLER GASKET 1 11 02 DN250 05 04 0001 DN250 05 04 00 01 MUFFLER ELBOW PIPE 1 12 02 DI250 05 04 0002 DI250 05 04 00 02 INTAKE MUFFLER CLAMP 1 13 03 01 5787 M8X25 05 5787 M8x25 FLANGE BOLT M8X25 2 14 02 DN250 05 04 0002B DN250 05 04 00 02B SHORTER MUFFLER 250 1 15 03 01 5787 M8X30 05 5787 M8x30 HEXAGON HEADED FLANGE BOLT 2 16 02 DN250 05 02 0003 DN250 05 02 00 03 MUFFLER MOUNT 1 17 02 JD 1910003A JD1910003A RUBBER MUFFLER BUSHING 2 18 02 DN250 01 02 0005 DN250 01 02 00 05 RIGHT TAIL SIDE BOARD 1 19 03 02 2842 M8 05 SJ2842 M8 SELF LOCKING HEXAGON HEADED 4 22 02 JD 1082101 JD1082101 SHIFT RUBBER BUSHING 1 23 02 DI250 05 05 03 DI250 05 05 03 00 SHIFT LEVER 1 24 02 D250 08004 D250 08 004 SHIFT SPRING 1 25 02 D250 08005 D250 08 005 STOP RING 1 26 02 D250 08009 D250 08 009 SHIFT LEVER COVER 1 27 0
60. SYSTEM 68 69 70 71 72 73 74 75 76 77 Left rotation 12N m Water pump 78 CRANK CASE 79 80 81 82 83 84 85 CYLINDER AND CYLINDER VALVE 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 CYLINDER PISTON 101 102 103 104 105 106 107 108 CTV 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 GEARBOX GEAR SHIFT MECHANISM Precaution Recommended oil 4 Stroke motorcycle SAE10W 30 or 4 trip motorcycle SAE20W 50 API classification SE or SF class engine oil chose the type of oil according the figure on page Oil capacity 0 85 L when disassembly 0 70 L when replacement Torque Gearbox bolts M5 5 N m M6 10 N m M 8 22 N m Draining bolt 20 N m Filling bolt 20 N m Round bolt fixing driving angel gear 85 N m Round bolt fixing driven angel gear 40 N m Tools No Tool specification use Remarks 1 Bearing remover 12mm Remove bearing 6201 Work with 8 9 2 Bearing remover 15mm Remove bearing 6202 Work with 8 9 4 Bearing remover 17mm Remove bearing 6303 Work with 8 9 5 Bearing remover 20mm Remove bearing 6304 Work with 8 9 6 Bearing remover 22mm Remove the bearing on the left of main shaft Work with 8 9 7 Bearing remover 25mm Remove bearin
61. UD GUARD SUPPORT 1 32 02 DN250 11 01 05 DN250 11 01 05 00 RR MUD GUARD SUPPORT 1 33 03 02 6183 1 M8 05 6183 1 M8 FLANGE NUT M8 4 34 03 01 5787 M8X20 05 5787 M8X20 FLANGE BOLT M8X20 4 35 02 DN250 12 03 03 01 DN250 12 03 03 01 REAR TIRE 22X10 10 2 36 02 JD 0780800 JD0780800 REAR RIM 10X8 2 37 02 DN250 12 03 01 01 DN250 12 03 01 01 FRONT TIRE 21X8 10 2 38 02 JD 0760800 JD0760800 FRONT RIM 10X5 5 2 39 02 DN250 12 02 03 01 DN250 12 02 03 01 REAR DESERTR TIRE 22X10 10 2 40 02 DN250 12 02 01 01 DN250 12 02 01 01 FRONT DESERT TIRE 21X8 10 2 41 03 01 5787 M12X1 5X30 05 5787 M12X1 5X30 bolt washer M12 1 5 25 10 42 03 02 6183 1 M12X1 5 05 6183 1 M12x1 5 nut washer M12 1 5 10 43 02 SV1100 08 01 18 SV1100 08 01 18 00 safety belt 1 208 PREPARATION ATTACH INSTRUCTION2 ATTACH BATTERY STEP 1 FILL THE ELECTROLYTE AS BELOW a Pull the seal cap out of the plastic bottle b Turn over the seal cap 180 degree fix it on the outlet of plastic bottle a Cut the inlet of plastic bottle b Fill the battery with electrolyte to upper lever by inserting every inlet of the battery STEP 2 Put the battery into the box on Off highway recreational vehicle STEP 3 Connect the wire to battery red to black to STEP 4 Fix the RUBBER COVE STOP BAND and tighten both bolts and nuts Notice Before use new battery it needs to notice follows 209 1 After the battery is fil
62. XIS ASSY 1 7 02 DLJ 172MM B 062006 172MM B 062006 WASHER 15X28X2 2 8 02 DLJ 172MM B 062002 172MM B 062002 HIGH SPEED DRIVING GEAR 1 9 02 DLJ NTN K16X20X10 NTN K16X20X10 NEEDLE BEARING 2 10 02 DLJ 172MM B 062009 172MM B 062009 SHIFT SLIDING SLEEVE 1 11 02 DLJ 172MM B 062001 172MM B 062001 SECONDARY AXIS 1 12 02 DLJ 172MM B 062007 172MM B 062007 WASHER 24X33X2 2 13 02 DLJ GB T894 1 86 24 GB T894 1 86 24 CIRCLIP AXIS 1 14 02 DLJ K24X28X10 K24X28X10 NEEDLE BEARING 1 15 02 DLJ 172MM B 062003 172MM B 062003 REVERSE DRIVEN GEAR 1 16 02 DLJ 172MM B 062005 172MM B 062005 OUTPUT DRIVEN GEAR 1 17 02 DLJ 172MM B 062004 172MM B 062004 LOW SPEED DRIVEN GEAR 1 18 02 DLJ 172MM C 063000 172MM C 063000 OUTPUT AXIS ASSY 1 19 02 DLJ 172MM C 063002 172MM C 063002 WASHER 20X32X2 5 1 20 02 DLJ 172MM C 063005 172MM C 063005 OUTPUT DRIVEN GEAR 1 174 14 TRANSMISSION GEAR ASSY No ERP CODE P N ENGLISH Qty 21 02 DLJ CF188 061007 CF188 061007 RETAINER RING AXIS 25 1 22 02 DLJ 172MM C 063001 172MM C 063001 OUTPUT AXIS 1 23 02 DN250 07 000005A DN250 07 00 00 05A CHAIN PULLEY 2 24 02 DN250 07 000006 DN250 07 00 00 06 CHAIN PULLEY PRESS PLATE 1 25 02 DLJ 172MM C 063009 172MM C 063009 BOTL M6X12 1 26 02 DLJ 172MM B 062008 172MM B 062008 WASHER 16X28X2 1 175 15 GEAR SHIFT MACHANISM No ERP CODE P N ENGLISH Qty 1
63. aft and valve guide sleeve IN 0 010 0 037mm 0 08mm EX 0 030 0 057mm 0 10mm Depth of the hole in valve guide sleeve seat IN EX 12 12mm Valve seat width in contact IN EX 1 1mm 1 8mm Valve Spring Free length outer spring Inner spring IN EX 40 0 30 5mm 36 0 27 5mm 40 CVT Item Standard Limit Transmission driving pulley Transmission mobile disc unite hole inner diameter 27 000 27 033mm 27 06mm Driving wheel disc sleeve outer diameter 26 959 26 980mm 26 94mm Centrifugal roller unite outer diameter 22 94 23mm 22 4mm Belt width 24 2 0 5mm 22 5mm Clutch Driven pulley Friction plate thickness 1 5mm inner diameter of clutch outer wheel disc 153 153 15mm 153 8mm free length of clutch spring 135 0mm 127 0mm Outer diameter of driven wheel disc bushing 39 95 39 975mm 39 94mm Inner diameter of mobile driven wheel disc 40 0 40 025mm 40 06mm Speech reducing mechanism Item Standards Volume of oil When replacing 0 75l fill to neck When disassembling 0 85l fill to neck Recommended oil SAE10W 40 SF Grade Starting motor Item Standards Limit the use of Starting motors Brush length 10mm 7mm Crankshaft Pistons Cylinder Item Standards Units mm Limit Units mm Crankshaft Connecting rod tip Axial clearance 0 10 0 35 0 6mm Radial clearance 0 013 0 025mm 0 05mm Crankshaft run out tolerance 0 02mm 0 10mm Pistons Pistons i
64. and take off the air cutting valve 4 Take off the O ring 5 Put a new O ring back and then install the valve to the carburetor then fasten the small screws 6 Tighten the clip fixing air cleaner Do the following adjustment Throttle adjustment idle speed adjustment Scre Airway 65 Adjustment of Air regulating screw for idle speed Make the adjustments after the engine warm up 1 Disassemble the related parts 2 Connect a RPM meter 3 Screw the air regulating screw to the end and reverse 2 5 rounds Standard reversing round 2 5 rounds 4 After the engine warm up adjust the idle speed adjusting screw to get the standard RPM Standard RPM 1500 100rpm 5 Accelerate from idle speed to make sure if the acceleration is steady On the other hand make sure the deceleration is steady by decelerating to the idle speed after return to the idle speed check if the RPM change If necessary adjust the air regulating screw as following steps 1 Rotate the adjusting screw clockwise or count clockwise until find a point near the standard reversing rounds where the idle speed is highest 2 Rotate the idle speed adjusting screw to find a required RPM 3 Repeat step 1 and 2 4 Accelerate slowly make sure the speed changes smoothly and the idle speed doesn t fluctuate 5 If the idle speed fluctuate repeat steps1 4 Air adjusting screw for idle Air adjusting screw for idle 66 Carburetor 67 COOLING
65. e all protective roll cage bar are in place before operating the off highway recreational vehicle j Check Brake Light Check for proper operation k Check Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins HIGHT BEAM HEADLIGHT DIPPED BEAM HEADLIGHT SPOT LAMP SHIFTER INDICATOR TURNNING LIGHT SHIFTER INDICATOR Figure 4 Figure 3 SHIFTER LEVER 27 l Check Steering Check for free operation for any unusual looseness in any area Always follow rules for safe operation and wear a helmet 28 RADIATOR SAFETY BELT SPOT LIGHT m Component locations C Passengers STEERING WHEEL FUEL TANK MUFFLER BATTERY RESERVE TANK AXLE NUTS WHEEL NUTS FRONT ARM FRONT SHOCK FRONT TURN SIGNAL HEAD LIGHT RADIATOR RADIATOR CAP BATTERY BRAKE LIGHT REAR SHOCK REAR TIRE ROLL BAR CV SHAFT 29 ADJUSTMENT NUTS The vehicle allows for two riders only Combine maximum weight of driver and the passenger should not exceed 180kg 400Ibs D Seat Adjustment The seat must always be securely fastened in the position which best affords the operator control of the foot pedals steering wheel and the remote stop button a Pull seat adjustment handle upward to disengage seat slide b Move seat to desired position c Be sure seat adjustment handle snaps back into place and that seat is locked into position Before attempt
66. g 6305 Work with 8 9 8 Bearing remover handle 9 Balance block of Bearing remover 10 Guide for press bearing 12mm Assembly bearing 6201 Work with 16 11 Guide for pressing bearing 15mm Assembly bearing 6202 Work with 16 12 Guide for pressing bearing 17mm Assembly bearing 6303 Work with 16 13 Guide for pressing bearing 20mm Assembly bearing 6304 Work with 16 14 Guide for pressing bearing 22mm assembly the bearing on the left of main shaft Work with 16 15 Guide for press bearing 25mm Assembly bearing 6305 Work with 16 16 Handle for pressing bearing 17 Hook wrench 34mm 36mm Remove or assembly round nut 18 Punch Riveting 126 Trouble shooting Engine can run vehicle can t move Damage of gearbox Failure of gear shifting mechamism Gear position display don t work gear jump Failure of connector to gear position display Failure of connection between chip and display Failure of gear shifting limitation Abnormal sound when moving Wearing sintering on gears damage on the surface of gears Wearing loosening on bearings Wrong clearance of angel gears Leaking of oil Over quantity of oil Wearing or damage of oil seal 127 Disassembly 1 Remove left side cover 2 Remove transmission clutch belt 3 Unscrew the draining bolt to drain the oil 4 Remove gear shifting arm 5 Unscrew the gear shift limiting bolt 6 Unscrew the bolt fixing sprocke
67. he steering wheel Cable Check the cable housing for wear Check the fittings for looseness Replace or tighten as needed Tie rod Check the tie rod housing for wear Check the fittings for looseness Replace or tighten as needed SAFE DRIVING PRECAUTIONS Off Road Use Only You off highway recreational vehicle and its tires are designed and manufactured for off road use only not for pavement Driving on pavement can affect handling and control You should not drive your off highway recreational vehicle on pavement Operating this Off highway recreational vehicle on paved surfaces may seriously affect handling and control of the Off highway recreational vehicle and may cause the vehicle to go out of control Never operate the Off highway recreational vehicle on any paved surfaces including sidewalks driveways parking lots and streets When driving off road also remember to always obey local off road driving laws and regulations Obtain permission to drive on private property Avoid posted areas and obey no trespassing signs You should never drive your off highway recreational vehicle on public streets roads or highways even if they are not paved Drivers of street vehicles may have difficulty seeing and avoiding you which could lead to a collision In many states it is illegal to operate off highway recreational vehicles on public streets roads and highways Operating this Off highway recreational vehicle on public
68. hrottle pedal slowly the cart will accelerate See Figure 2 e Operate lights See figure 4 press down the button the corresponding light will run And if move the shift lever to L position the L light will shine H position the H light N position the N light and R position the R light B Pre Drive Inspection Perform this pre drive inspection every day before driving vehicle If not performed serious damage to the vehicle or personal injury may result a Check for Engine Oil Level Check for leaks add oil if required b Check for Fuel Level Add fuel as necessary and do not overfill Check for leaks c Check for Brakes Depress the rear brake pedal several times and then check for proper brake pedal free play Make sure there is no brake fluid leakage Adjust if necessary d Check Tires Check tires condition and pressure The pressure on both Front and Rear tire is 42kpa 6 1PSI and 56kpa 8 1PSI e Check Drive Chain Check for drive chain s condition and tension Lubricate if necessary f Check Throttle Check for smooth operation Assure throttle snaps back to idle g Check Engine Stop Button Perform engine stop button test Repair as necessary h Check all Nuts Bolts and fasteners Check wheels to see that all axle nuts and lug nuts are tightened properly Check and tighten as necessary all other fasteners to specified condition i Check Roll Cage Bar Ensur
69. increase as you screw to left decrease as you screw to the right There is screw on the rear shock use shock wrench as you adjust the rear shock the tension of shock spring will increase as you screw to right decrease as you screw to left See Fig 15 K Storage Instruction In the event you re off highway recreational vehicle is not to be operated for periods in excess of 30 days or at the end of each driving season prepare for storage as follows a Drain fuel tank and carburetor by allowing engine to run out of fuel or use a fuel stabilizer b Lubricate engine cylinder by removing the spark plug and pour one ounce of clean lubricating oil through the spark plug hole into the cylinder Crank the engine slowly to spread oil and replace spark plug c Do not save or store gasoline over winter Using old gasoline which has deteriorated from storage will cause hard starting and affect engine performance Do not drain fuel while engine is hot Be sure to move Off highway recreational vehicle outside before draining fuel Figure 15 LEFT ROTATE RIGHT ROTATE SPRING ADJUSTMENT CAM Figure 14 RIGHT ROTATE LEFT ROTATE 36 REPAIR ENGINE REPAIR Units translation form Item Example Unit conversion Pressure 200kpa 2 00kgf cm2 33kpa 250mmHg 1kgf cm2 98 0665kpa 1kpa 1000pa 1mmHg 133 322pa 0 133322kpa Torque 18N m 1 8kga m 1kgf m 9 80665N M Volume 419ml 1ml 1cm3 1cc 1L 1000cm3 Force 12N 1 2kgf 1kgf 9
70. ing to adjust the seat ensures that engine of the Off highway recreational vehicle is stopped Never operate this Off highway recreational vehicle when the provided seat is not securely fastened to do so could result in a strong possibility of severe personal injury or loss of life Before attempting to adjust the seat ensure the engine of the Off highway recreational vehicle is stopped E Shift Adjustment a Press down the shift lever to the L position so that the unit can move forward at low speed press the lever to H position so that the unit can move forward at high speed Pull back the shift to N position so that the unit can t move pull back the lever to R so that the unit can move backward See Fig 6 b Loosen lock nut and remove the cotter pin and the plain washer Rotate the joint the shifter lever will rotate clockwise or counter clockwise so you can adjust the lever in proper position LOCK NUT Figure 6 Seat adjustment handle JOINT Figure 5 30 Never engage the shift lever when the Off highway recreational vehicle is in motion Only engage the shift lever when the off highway recreational vehicle is at a full stop Give a slight throttle and loosen throttle then engage shift from neutral to shift The shift lever must be on neutral and pull parking lever when leave the Off highway recreational vehicle F Parking Adjustment Press down the reverse lever to the F position so
71. ires are not made for pavement and the off highway recreational vehicle does not have some features required for use on public roads Take Time to Learn amp Practice Even if you have derived other off highway recreational vehicle take time to become familiar with how this off highway recreational vehicle works and handles Practice in a safe area until you build your skills and get accustomed to this off highway recreational vehicle s size and weight Because many accidents involve inexperienced or untrained drives we urge all drivers to take a training course approved by the off highway recreational vehicle Safety Institute Check with your dealer for more information on training courses Be Alert for Off Road Hazards The terrain can present a variety of challenges when you drive off road Continually read the terrain for unexpected turns drop offs rocks ruts and other hazards Always keep your speed low enough to allow time to see and react to hazards Drive within Your Limits Pushing limits is another major cause of off highway recreational vehicle accidents Never drive beyond your personal abilities or faster than conditions warrant Remember that alcohol drugs fatigue and inattention can significantly reduce your ability to make good judgments and driver safely Don t Drink and drive 16 Alcohol and driving don t mix Even one drink can reduce your ability to respond to changing conditions and your reaction time gets wo
72. k WR white red BW black white O Orange BR K NR UW P k NR RY NB NB RB UR RW UW UY PY RW Speed sensor sw R U S U O RW RG RY Y 156 PARTS MANUAL 1 CRANKCASE ASSY No ERP CODE P N ENGLISH Qty 1 02 DLJ 172MM C 011100 172MM C 011100 LEFT CRANK CASE ASSY 1 2 02 DLJ 172MM C 011200 172MM C 011200 RIGHT CRANK CASE ASSY 1 3 02 DLJ 172MM 011001 172MM 011001 SEAL 28X40X8 1 4 02 DLJ 172MM 011002 172MM 011002 INNER OIL PIPE SEAL RING 2 5 02 DLJ 172MM 011004 172MM 011004 CYLINGDER STUD A 3 6 02 DLJ 152MI 021005 152MI 021005 LOCATING PIN 10x14 4 7 02 DLJ 172MM 011005 172MM 011005 CYLINGDER STUD B 1 8 02 DLJ 172MM B 011006 172MM B 011006 CRANK CASE SEAL WASHER 1 9 02 DLJ 172MM 011400 172MM 011400 INNER OIL PIPE 1 10 02 DLJ 152MI 021019 152MI 021019 BOLT M6X12 1 11 02 DLJ 152MI 011017 152MI 011017 BOLT M6X60 5 12 02 DLJ 1P52MI 011018 1P52MI 011018 BOLT M6X70 3 13 02 DLJ 1P52MI A 011006 1P52MI A 011006 BOLT M6X105 1 14 02 DLJ 152MI 011010 152MI 011010 OUTER SLEEVE EAR 2 15 02 DLJ 152MI 011008 152MI 011008 O RING FOR SEAL 4 16 02 DLJ 152MI 011009 152MI 011009 INNER SLEEVE EAR 2 17 02 DLJ GB T 276 1994 6304 GB T 276 1994 6304 BEARING 6304 1 157 1 CRANKCASE ASSY No ERP CODE P N ENGLISH Qty 18 02 DLJ 172MM 060002 172MM 060002 BALL BEARING 22X50X14 1
73. led electrolyte the new battery need to recharge as the Owner s manual said Otherwise the new battery will be damaged and can t recharge 2 The new battery can t overload in use otherwise it damage forever 3 The new battery need to maintenance with recharge as the Owner s manual said ATTACH PROTECTIVE BARS M12x1 75 Torque 70 5 N M M10x1 5 Torque 40 5 N M 1 2 3 4 1 2 3 4 210 ATTACH REAR SHOCK a Remove the bolt and the nut b Attach the rear shock as below picture Torque 70 5 N M ATTACH TRAILING ARM Torque 40 5 N M SPACER SPACER 211 ATTACH FRONT SHOCK Torque 70 5 N M 1 2 1 2 3 212 3 ATTACH FRONT TIRE The hub to fix the front tire is packed as below 1 Remove four nuts four spring washers and four plain washers on the hub 2 Fix the rim on the hub 3 Insert the washers spring washers through bolt on the hub Tighten four nuts Torque 70 5 N M Notice Direction marked on the tire must correspond to the vehicle forward 213 ATTACH SEAT AND SAFT BELT Torque 70 5 N M ATTACH THE RADIATOR 1 Attach the radiator as below pictures 2 Connect wire from fan motor to main wire 3 Arrange the main and reserve coolant rubber tube as below picture FIX SAFTY BELT 214 ATTACH SILENCER Attach the SILENCER as below pictures 215 DEALER PRE DELIVERY INSPECTION
74. nfirm there are no scratches on the surface of part 3 Apply the engine oil to the movable parts 4 Apply the grease to the sealing parts such as seals O rings 5 Replace with a new one after the pats like oil seal O ring are removed 2 If the bearings in the left case and gearbox cover need to be replaced Pay attention to the following cautions 1 Apply engine oil to the cylinders of bearing and case hole 2 Always use a special tool to push down the bearing Special tools Guide for press bearing 25mm Guide for pressing bearing 15mm Guide for pressing bearing 12mm Guide for pressing bearing 22mm Guide for press bearing 17mm Handle for pressing bearing 3 Install main shaft 1 Apply engine oil on the surfaces which main shaft and bearing contact in 2 Put the main shaft on to the left case 134 4 Assembly output shaft Comp 1 Put the gear 2 on to the output shaft after put the circlip 3 on to the output shaft 4 and put the washer 1 on to the output shaft 4 2 Put the parts 5 6 and 7 on to the output shaft after the gear box cover is put back General tool Shaft circlip pliers 135 5 Assembly counter shaft Comp 1 Put all the parts on to the counter shaft in a contrary order of disassembly 2 Apply engine oil on every needle bearing 3 After assembly check to see if the driven gear reverse driven gear low speed driven gear can run freely General tool Shaf
75. nstallation direction IN point to intake valve Pistons diameter 71 96 71 98mm 71 9mm Pistons pin hole diameter 17 002 17 008mm 17 03mm Piston Pin diameter 16 994 17mm 16 98mm Clearance between cylinder and piston 17 006 17 024mm 17 04mm Clearance between piston and piston pin 0 03 0 05mm 0 15mm Clearance between piston pin and connecting rod 0 002 0 014mm 0 04mm 41 Piston pin and linkage between the gap 0 006 0 030mm 0 06mm Clearance between Piston Ring and piston ring groove Piston Ring 1 0 015 005mm 0 09mm Piston Ring 2 0 015 005mm 0 09mm Piston Ring cut gap Piston Ring 1 0 15 0 30mm 0 05mm Piston Ring 2 0 10 0 25mm 0 05mm Oil ring 0 2 0 7mm Piston Ring installation direction mark upward Cylinder Diameter 72 72 019mm 72 1mm Planeness of upper surface 0 05mm Roundness 0 002mm 0 05mm Cylindricity 0 005mm 0 05mm Battery charge devices Item Standards AC Magneto Type Permanent Magnet AC Output Three phase AC Charging coil resistance 20 02 03 Rectifier type Three phase ring rectifying SCR 42 Attention Washer O ring cotter pin and spring washer need to be replaced with a new on after disassembly before tightening bolt nut and screw rotate the hardware several rounds and make sure screws can match well then tighten the hardware from big to small from inside to outside and with the specified to
76. ons and your experience Use Care on Unfamiliar or Rough Terrain Before driving in a new area always check the terrain thoroughly Don t drive fast on unfamiliar terrain or when visibility is limited It s sometimes difficult to see obstructions like hidden rocks bumps or holes in time to react 23 Failure to use extra care when Operating this Off highway recreational vehicle on unfamiliar terrain could result in the Off highway recreational vehicle overturning or going out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the Off highway recreational vehicle Never drive past the limit of visibility Maintain a safe distance between your off highway recreational vehicle and other off road vehicles Always exercise caution and use extra care on rough slippery and loose terrain Failure to use extra care when operating on excessively rough slippery or loose terrain could cause loss of traction or vehicle control which could result in an accident including an overturn Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the Off highway recreational vehicle on such terrain Always be especially cautious on these kinds of terrain Do Not Perform Stunts You should always operate your off highway recreational vehicle in a safe and reasonable manner When driving
77. out If that replace with a new one 3 Check to see if contacting chip deform lack of the elastic force if that replace with a new one 4 Measure the thickness of the shifting fork the standard thickness 5 90 6 00mm 5 Check these areas pointed by 1 and 2 to see if damage bend If that replace with a new one 131 Check the transition shaft to see if wearing out damaged 1 Break down the output driving shaft Comp 2 Check to see if turning blue pitting damage wearing out if that replace the part with a new one Tool circlip pliers Inspection on gear shifting limiting bolt 1 Break down the limiting bolt Comp 2 Check the wearing and damage on the ball if any of them happen replace a new ball Check the wearing and damage on gear shifting sector gear Comp 1 Break down the Comp as the right figure 2 Whenever remove the seal and the gasket replace with a new one when put them back at the same time clean the surfaces going to be in contact To be careful not to damage or scratch the surfaces 3 Check the surfaces on gears and shaft to see if pitting damage wearing out Replace with a new one if any of them is found Check the gearbox cover to see if damaged wearing out 1 Check the bearing to see if it works well if not replace with a new one 2 Check the points of contact on gears display to see if rust if that polish the surface with sandpapering 3 Always use a
78. ow bolt M14 1 5 18N M Fix gear shift stopping ball Torque table for the other bolts and nuts specification Torque N m k g f m specification Torque N m k g f m 5mm Bolt Nut 6mm Bolt Nut 8mm Bolt Nut 10mm Bolt Nut 12mm Bolt Nut 5 0 5 10 1 0 22 2 2 34 3 5 54 5 5 5mm Screw 6mm Screw 6mm SH Flanged bolts 6mm Flanged bolts nuts 8mm Flanged bolts nuts 10mm Flanged bolts nuts 4 0 4 9 0 9 10 1 0 12 1 2 26 2 7 39 4 0 45 172MM B 172MM c Special tools No Tools name Specification Used for Remarks chapter 1 Bearing removed tool 12mm Bearing 6201 Work with8 9 9 2 Bearing removed tool 15mm Bearing 6202 Work with8 9 4 9 4 Bearing removed tool 17mm Bearing 6303 Work with8 9 9 5 Bearing removed tool 20mm Bearing 6304 Work with8 9 9 6 Bearing removed tool 22mm bearing on the left of main shaft Work with8 9 9 7 Bearing removed tool 25mm Bearing 6305 Work with8 9 9 8 Handle for bearing removed tool 4 9 9 Balance block for bearing removed tool 4 9 10 Bearing guide 12mm Bearing 6201 Work with16 9 11 Bearing guide 15mm Bearing 6202 Work with16 9 12 Bearing guide 17mm Bearing 6303 Work with16 9 13 Bearing guide 20mm Bearing 6304 Work with16 9 14 Bearing guide 22mm bearing on the left of main shaft Work with16 9 15 Bearing guide 25mm Bearing 6305 Work with16 9 16 Handle for bearing pushed
79. p PARKING BRAKE 199 25 EXHAUST amp SHIFT amp PARKING BRAKE No ERP CODE PART NO DESCRIPTION Q TY 45 02 DN250 04 01 01 DN250 04 01 01 00 PARKING BRAKE MAIN PISTON 1 46 02 DN250 04 0300 DN250 04 03 00 00 PARKING BRAKE ASSY 1 47 02 JD 1910002 JD1910002 RADIATOR SLEEVE 2 48 02 D650 04 04 0005 D650 04 04 00 05 GRAPHITE WASHER 1 49 02 E650 04 04 05 E650 04 04 05 00 ONE WAY VALVE 1 50 02 JD 0820004 JD0820004 AIR INLET PIPE 1 51 02 SV800 04 07 0001 SV800 04 07 00 01 CLAMP 1 52 02 E650 04 04 04 E650 04 04 04 00 AIR FILTER 1 53 02 E650 04 04 0010 E650 04 04 00 10 AIR FILTER SUPPORT 1 54 02 DN250 05 04 0001 DN250 05 04 00 01 MUFFLER ELBOW PIPE 1 55 03 02 2842 M6 05 SJ2842 M6 FLANGE NUT M6 2 56 02 S650 04 04 03 01 S650 04 04 03 01 HEAT SHIELD 1 57 02 DN250 05 04 0001A DN250 05 04 00 01A MUFFLER ELBOW PIPE 1 58 02 DI250 05 02 0004 DI250 05 02 00 04 MUFFLER RUBBER BUMPER 1 59 02 DI250 05 04 0003 DI250 05 04 00 03 MUFFLER BRACKET 1 60 02 DN250 05 02 0003 DN250 05 02 00 03 MUFFLER MOUNT 1 200 26 REAR SUSPENSION 26 REAR SUSPENSION 1 2 5 4 3 9 8 7 6 10 11 12 14 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 37 36 35 34 33 38 39 40 41 201 26 REAR SUSPENSIONG No ERP CODE PART NO DESCRIPTION Q TY 1 02 DN250 04 01
80. park plug and inspect it Use a spark plug wrench The electrodes should be kept clean and free of carbon The presence of carbon or excess oil Never operate this Off highway recreational vehicle when the provided seat is not securely fastened to do so could result in a strong possibility of severe personal injury or loss of life Figure 9 Figure 10 Figure 11 Cover 1 Filter core OIL INLET OIL INLET 32 will greatly reduce proper engine performance If possible check the spark plug gap area between electrodes using a wire feeler gauge This specification is 0 025 0 030 See Fig 11 b Before installing spark plug coat threads lightly with graphite grease if possible to ensure easy removal next time the spark plug needs inspection c It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance E Carburetor Adjustment Never make unnecessary adjustments The factory recommended settings are correct for most applications It s not necessary to disassemble the screw unless the carburetor needs to be replaced Prepare a 50r w tachometer before adjustment a Warm up the engine 5 10min b Tighten the airscrew gentle Back out 2 3 8 turns counter clockwise c Connect the tachometer adjust the throttle to limit the idle speed The standard value is 1500RPM d Turn the airscrew slowly and observe the RPM of the engine stop adjusting as the RPM reaches the top
81. r unite 2 Disassembly 5 self taping screws from air filter unite and take off the left cover 3 Remove cleaner cover 4 Remove air cleaner filter core 5 Check the filter paper if the filter paper is dusty please clean with compressed air or replace with a new one If the vehicle is operated under extremely dusty condition we suggest cleaning after every use and replace more often Valve clearance inspecting and adjustment Do this operation when the engine temperature is under 35 1 Take off left side cover assy 2 Take off inspecting cover from right cover 3 Turn the belt pulley from right to left until align the top dead center mark on the magneto with the mark beside inspecting hole so the piston stay on the top dead center 4 Loosen the bolts fixing adjusting disc 5 Turn the adjusting disc with the marks IN and EX respectively make rockers contact with valve rod then reverse one scale 6 Tighten the bolts to fix adjusting disc tightly and put all the parts back Cylinder pressure inspection 1 Pull off the high voltage cap 2 Unbolt spark plug 3 Connect the pressure indicator to the screw hole which holding spark plug 4 Open throttle fully 5 Start the engine and read the display on the pressure indicator Standard pressure 1470kpa 600rpm Special tool pressure indicator If the pressure is lower check the following items Fixing bolt Adjusting disc 56 Air leakage between
82. recreational vehicle is at a full stop Give a slight throttle and release throttle then engage shift Only shift from neutral The shift lever must be in neutral and parking lever pulled when leaving the off highway recreational vehicle WARNING Do not shift when pushing throttle Gear damage can occur Gears are not warranted from shifting in motion or over running while shifting ARE YOU READY TO DRIVE Before each drive you need to make sure you and your off highway recreational vehicle are both ready to drive To help get you prepared this section discusses how to evaluate your driving readiness what items you should check on your Off highway recreational vehicle and adjustments to make for your comfort convenience or safety Before you drive your off highway recreational vehicle for the first time we urge you to Read this owner s manual and the labels on your off highway recreational vehicle carefully Make sure you understand all the safety messages Know how to operate all the controls Have adult present if under 16 years old Before each drive be sure You feel well and are in good physical and mental condition You are wearing an approved motorcycle helmet with chin strap tightened securely eye protection and other protective clothing You don t have any alcohol or drugs in your system Protective Apparel For your safety we strongly recommend that you always wear an
83. rque only CF parts or recommended part grease and oil always use special tools and general tools when necessary before measure and check the parts taken off make sure it is clean and apply some oil before install back 43 must smear or inject specified grease or oil on the special points check every tightened points and all the mobile parts after assembly 44 Engine torque table Hardware specification Torque required Where is the hard ware Nut M14 1 5 78N M Fixing transmission Nut M12 1 25 49N M Fixing clutch Nut M16 1 103N M Fixing flywheel Cap Nut M8 30N M Matching the stud fastening cylinder Cylinder stud 30N M Fixing crankcase assembly Filter net cover 20N M Right covered Lvyou Bolt M5 16 10N M Right case filter hole Inner hex bolt M8 18 30N M Fixing clutch Reamed boltsM12 1 25 20N M Fixing oil pipe M7 1 left 12N M Coolant pump impeller Bolt M8 10N M Oil pipe reamed bolt Bolt M8 10N M Exhaust pipe bolt M8 1 10N M Tension spring seat bolt M12 1 5 18N M Spark Plug Bolt M12 1 5 20N M Oil outlet bolt Screw M4 12 5N M Oil stop plate on gearbox cover Bolt M5 10 8N M Seal pressure plate on gearbox Bolt M12 1 5 20N M oil outlet plug bolt on gearbox M20 1 5 20N M Oil inlet plug bolt on gearbox Round Nut M22 1 85N M Fix driving bevel gear BoltM12 20 40N M Fix driven bevel gear Holl
84. rse with every additional drink So don t drink and drive and don t let your friends drink and drive either Never run your Go Off highway recreational vehicle indoors The exhaust from the engine contains a tasteless odorless and poisonous gas called carbon monoxide Keep away from moving parts of the off highway recreational vehicle The operator of the off highway recreational vehicle should never place their hands or other parts of their body near any moving part of the off highway recreational vehicle Failure to adhere to this warning will cause physical harm to your body Skidding or Sliding The terrain surface can be a major factor affecting turns Skidding a turn is more likely to occur on slippery surfaces such as snow ice mud and loose gravel If you skid on ice you may lose all directional control To avoid skidding on slippery terrain keep you speed low and drive carefully SAFETY LABELS This section presents some of the most important information and recommendations to help you drive your off highway recreational vehicle safely Please a few moments to read these pages The labels are considered permanent parts of the off highway recreational vehicle If a label comes off or becomes hard to read contact your dealer for warning labels replacements 17 WARNING 18 Never shift or engage the reverse lever when the off highway recreational vehicle is in motion Only engage the shift lever when the off highway
85. s a driving jersey with padded elbows and chest shoulder protector Drive Training Developing your driving skills is an on going process Even if you have driven other off highway recreational vehicles take time to become familiar with how this off highway recreational vehicle works and handles To build skills Practice driving the off highway recreational vehicle in a safe area do not drive in rough terrain until you get accustomed to the off highway recreational vehicle s controls and feel comfortable with its size and weight Operating Off highway recreational vehicle without proper instruction could increase your risk of an accident which could lead to serious injury or death Attempt supporting with your hands to the ground when the Off highway recreational vehicle turning over could lead to serious injury or death Never support with your hands to ground when the Off highway recreational vehicle will turn over Age Recommendation It is strongly recommended that no one under the age of 16 be permitted this off highway recreational vehicle without adult supervision A child driving an Off highway recreational vehicle that is not recommended for his her age could lose Off highway recreational vehicle control and result in severe injury or death A child under 16 should have adult supervision when operate on the Off highway recreational vehicle 20 No Alcohol or Drugs Alcohol drugs and driving don t mix Even a small amount
86. screw Adjusting plate PE pipe Needle Valve 61 Vacuum chamber Disassembly Loosen the fuel draining bolt drain the fuel in the vacuum chamber Remove the 2 small screws open the cover of vacuum chamber Take off spring and vacuum piston Take off the fuel controlling needle seat Take off the spring and needle Pay attention to protect the vacuum diaphragm Inspection on vacuum piston Check the needle to see if worn out damaged Check the vacuum diaphragm to see if damaged aged cracked Fuel draining screw Small screws Spring Diaphragm Vacuum cylinder Spring Diaphragm Fixing plug Needle 62 Assembly Assemble all the parts by reversing the steps of disassembly Support the bottom of vacuum piston to keep it fully open make sure the vacuum diaphragm go in to the groove of carburetor Then put back the spring following the right figure Protect the vacuum diaphragm from damage Support the vacuum piston until fasten the 2 screws on cover Float chamber Remove the 4 screws take off the float chamber Take out of float pin remove float and float valve Check float valve Check the contact plane of float valve to see if wore Groove Scre Float Float valve Float Vacuum cylinder Groove Bulge Screws Float Float valve Float pin Float valve Float 63 Take off the main jet idling jet air regulating screw Don t damage jets screws Remember the rounds
87. sm 140 Speed reducing gear 141 MAGNETO STARTER CLUTCH AND OIL PUMP 142 143 144 145 146 147 148 149 150 151 152 153 154 CHASSIS REPAIR A Front Wheel Replacement Do not disassemble the castle nuts when you replace the front wheels It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play See Fig 16 Tighten the nuts after replacing the wheels Castle nuts Torque 180 5 N M Wheel nuts Torque 70 5 N M B Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum endplay See Fig 17 Tighten the nuts and put on the cotter Pin after replacing the wheels Castle nuts Torque 180 5 N M Wheel nuts Torque 70 5 N M C Front Wheel Alignment a The front wheels should be toe in from 1 8 to 1 4 To check for alignment measure distance A and B between the centerline CL of the wheels The proper toe in dimension A should be 1 8 1 4 greater than dimension B b To adjust the alignments loose the lock nuts on both sides of Front Tie Rods To make Dimension B smaller scare the rod to the left Adjust the rod to right direction to make Dimension B larger After adjusted to desired length tighten the lock nut against the rod end Recheck the dimensions for proper alignment Figure
88. speed e Adjust the screw and adjust the idle speed to an ideal value f Repeat step d and e until the rotate speed of engine stables F Cleaning Instructions Keep your off highway recreational vehicle clean With a clean rag wipe off and dirt and oil from around controls Wipe off any spilled fuel and oil Keep the engine clean off foreign object and be sure to check that air intake fan is free off debris for proper cooling G Off highway recreational vehicle Lubrication Lubricate vehicle every 90 days of use Apply several drops of lithium grease in arrow pointed points in the following picture Figure 12 33 Front arm Rear arm Tie rod Steering shaft amp Arm 34 H Chain Lubrication I To increase chain life it should be Lubricated with a spray or Chain lubricant J Chain Adjustment Check the chain adjustment after first two hours of use Readjust if it has more than 1 2 flex See figure 13 a Loosen NUT 1 and NUT 2 b Rotate BOLT 1 the BEARING BLOCK will move forwards or backwards so the chain will become loose and tight Repeat this procedure until chain is at proper tension c Tighten all of the nuts J Adjustment of Front and Rear Shock Figure 13 NUT 1 NUT 2 BOLT 1 35 There are five adjustable positions on each Front shock The default position is in the first set by manufacture See Fig 14 Use a round nut wrench as you adjust the front shock the tension of shock spring will
89. streets roads or highways can cause collision with other vehicle Never operate this Off highway recreational vehicle on any public streets roads or highways even dirt or gravel one 22 Keep Hands and Feet on Controls Always keep both hands on the steering wheel and both feet on the foot controls When driving your off highway recreational vehicle It is important to maintain your balance and to control of the off highway recreational vehicle Removing hands or foot away from the controls can reduce your ability to react control of the off highway recreational vehicle Removing hand from Steering wheel or feet from foot controls during operation can reduce your ability to control the Off highway recreational vehicle Always keep both hand on the steering wheel and both feet on the foot controls of you re Off highway recreational vehicle during operation Control Speed Driving at excessive speed increases the chance of an accident In choosing a proper speed you need to consider the capability of your Off highway recreational vehicle the terrain visibility and other operating conditions plus your own skills and experience Operating this Off highway recreational vehicle at excessive speeds increases your changes of losing control of the Off highway recreational vehicle which can result in an accident Always drive at a speed that is proper for you re Off highway recreational vehicle the terrain visibility and other operating conditi
90. t circlip pliers 6 Assembly gear shift drum unit 1 Put all the parts on to gear shift drum with contrary order of disassembly 2 Apply engine oil in the holes in shift forks and pin holes 3 If the touch chip of gear position display or the circlips of shift forks deform replace with a new one 4 After assembly turn the forks to make sure that they can run smoothly General tool Nipper pliers flat screwdriver 7 8 Assembly transition shaft Comp Assemblies the transition shaft comp with reversing the order of disassembly General tool Shaft circlip pliers 136 9 Assembly 1 Apply engine oil on the matching surfaces on both main shaft and bearing then install the main shaft in to left case 2 Assemble counter shaft Comp and gear shift drum Comp well Make sure the gear shifting forks go into the groove on slide bushing on counter shaft 3 Put the assembly assembled by last step in to the related holes in left case 4 Put the output driving shaft Comp and transition shaft Comp in to the related holes in the left case 5 Apply engine oil on the gear s surfaces matching surfaces and bearing 6 Turn the output shaft with your left hand while turn the gear shift drum with your right hand check to see if shift gears easily and smoothly and the gears can engage each other fully 7 Smear the seal glue on to the surfaces is going to be touched with gasket uniformly 8 Knock down pins 2pieces 1
91. t cover and remove the sprocket cover driving sector gear and driven sector gear and so on 7 Unscrew the bolt fixing the pressing sprocket plate and take off sprocket 8 Unscrew the bolt fixing gear box cover and take off the gear box cover 9 Take off the main shaft comp counter shaft comp transition shaft comp output shaft comp and gear moved drum assy 128 129 Inspection Check the surface of input main shaft to see if turn to blue pitting damage wearing Replace with a new one if any of the situations happen Replace the seals with a new one after being removed anyway Check if wearing or damage on counter shaft 1 Beak down the counter shaft according the right figure 2 Measure the run out tolerance of the counter shaft with a dial indicator replace with a new on if the tolerance is more than 0 03mm 3 Check the surfaces of the gears to see if turn to blue pitting damage over wearing replace with a new one if any of them happen 4 Check the clearance between shifting fork and gear as the right figure measure the clearance with a feeler Replace shifting fork or gear if the clearance is more than 0 05mm Standard clearance 0 1 0 3mm 5 Measure the width of the groove for shifting fork with a slide caliper 130 Inspection on gear shift drum assembly 1 Break down the assembly according the right figure 2 Check the drum forks fork pins to see if pitting damage wearing
92. that the unit can move forwards pull back the lever to P so that the unit can park See Fig 7 Adjust Nut 1 Make sure cable is not too tight or too loose Adjust Nut 2 accordingly to adjustment of Nut 1 See Figure 7 G Starting And Operating Instructions a Before starting the engine be sure that the driver is seated properly in the off highway recreational vehicle and tighten the seat belt b Testing the Off highway recreational vehicle in an open place at the beginning to learn how to start turn and stop c Operate the Off highway recreational vehicle slowly until you are familiar with it d The turning radius of this off highway recreational vehicle is small and agile so the centrifugal force is very high when turning at high speed Slow down to a more controllable speed when turning to prevent the off highway recreational vehicle from rolling over e To prevent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed Heel on the ramp of the main board when turning Keep your leg rely on the foot pedal you can feel the off highway recreational vehicle is stable because of the gravity is adjusted and won t roll over H Foot brake adjustment a Loosen the thin nut M8 b Rotate the pushing bar to make space proper c Tighten thin nut M8 d With the same way to adjust another pair NUT 2 NUT 1 Figure 7 THIN NUT M8 PUSHING BAR Figure 8 31 SERVICE INSTRU
93. utomatic centrifugal Transmission Type CVT Gearbox Continuously variable rate 0 9 2 2 Gears High Low reverse Gear box rate Primary 1 57 3 15 2 2 secondary 2 25 2 25 2 25 17 Power output Sprocket output Inspection parameters table Lubrication device Item Standards Limit Engine oil capacity When the replace oil 0 8l Full capacity 1 0l Recommended engine oil Temperature 4 stroke motorcycle specified oil AE 10W 40 20W 50d to use a substitute oil follow the following items API classification SF SE SAE specification Choose one from the left illustration according temperature oil pump rotor Gap between rotors of Inside and outside 0 15mm 0 20mm Oil pump Gap 0 15 0 23mm 0 25mm Face Gap 0 05 0 10mm 0 12mm 39 Cylinder Head Valve Item Standards Limit Cylinder compression pressure 1470kpa 600rpm Valve Clearance IN 0 10mm EX 0 10mm Planeness of the surface Cylinder Head connect 0 02mm 0 05mm Camshaft Height of cam top IN 31 60 31 72mm 31 52mm EX 31 60 31 72mm 31 52mm Valve Rocker Rocker inner diameter IN EX 12 000 12 018mm 12 1mm Rocker outer diameter IN EX 11 973 11 984mm 11 91mm Valve Valve guide sleeve Valve shaft diameter IN 4 975 4 990mm 4 90mm EX 4 955 4 970mm 4 90mm Valve guide sleeve inner diameter IN 5 000 5 012mm 5 03mm EX 5 000 5 012mm 5 03mm Gap between valve sh
94. way recreational vehicle Engine Oil Check the oil level add oil if needed Check for leaks Fuel Check the fuel level add fuel if needed Also make sure the fuel fill cap is securely fastened Check for leaks Tires Use a tire gauge to check the air pressure Adjust if needed Also look for signs of damages or excessive wear Nuts amp Bolts Check the wheels to see that the axle nuts are tightened Use a wrench to make sure all accessible nuts bolts and fasteners are tight Under body amp Exhaust System Check for and remove any dirt vegetation or other debris that could be fire hazard or interfere with the proper operation of the off highway recreational vehicle Air Cleaner Housing Drain Tube 21 Check for deposits in the drain tube If necessary clean the tube and check the air cleaner housing Leaks Loose Parts Walk around you off highway recreational vehicle and look for anything that appears unusual such as a leak or loose cable Lights Make sure the headlight brake light and taillight are working properly Throttle Check the free play and adjust if needed Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released Brakes Press the brake pedal several times check for proper brake pedal free play Make sure there is no brake fluid leakage Steering Wheel Check that the wheels turn properly as you turn t
95. x100 SOCKET HEAD BOLT M10x100 2 26 03 02 6172 1 M10 R 05 6172 1 M10 R THIN NUT M10 2 27 02 DN250 08 02A DN250 08 02 00 00A ENGINE RACK 1 28 03 01 5782 M12X1 25X80 05 5782 M12x1 25x80 BOLT M12x1 5x100 1 29 03 01 5787 M10X1 25X25 05 5787 M10X1 25X25 FLANGE BOLT M12x1 5x25 2 30 03 01 5787 M12X1 5X115 05 5787 M12x1 5x115 FLANGE BOLT M12x1 5x115 1 31 02 DN250 08 01A DN250 08 01 00 00A ENGINE STAY REAR 1 32 02 DI250 07 0400 DI250 07 04 00 00 ENGINE ASSY 1 33 02 DI250 08 000001 DI250 08 00 00 01 ENGINE STAY SPACER 1 34 02 D650 01 02 0002 D650 01 02 00 02 ENGINE RACK CUSHION 2 35 03 02 2842 M12X1 25 05 SJ2842 M12x1 25 NUT M12x1 5 2 194 24 ENGINE ASSEMBLY 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 39 10 11 24 9 43 44 45 CONNECT TO ACT 24 ENGINE ASSEMBLY 195 24 ENGINE ASSEMBLY No ERP CODE PART NO DESCRIPTION Q TY 1 02 DI250 05 01 01 DI250 05 01 01 00 RADIATOR 1 2 02 DI250 05 01 0102 DI250 05 01 01 02 RADIATOR VALVE 1 3 02 DN250 05 01 0004 DN250 05 01 00 04 SUCTION PIPE 1 4 03 01 5787 M8X20 05 5787 M8x20 FLANGE BOLT M8X20 2 5 02 D800 04 02 0200 D800 04 02 02 00 WATER TANK GK800 1 6 02 D800 04 02 02 02 D800 04 02 02 02 SEAL CUSHION 1 7 02 D800 04 02 02 01 D800
96. you rotate the screws to take off If fasten the screws too much then contacting plane maybe damaged Clean the jets in fresh washing liquid Blow the pathway of the fuel with compressed air Do cleaning after the disassembly of vacuum chamber Assembly Put back main jet idling jet air controlling screws for idle speed Put back float needle valve float float pin then install carburetor heating tube Idle jet Main jet Air adjusting screw Float needle valve seat Idle jet Main jet Main jet holder Main jet Air adjusting screw Float Float pin Heating tube 64 Check fuel lever Check the oil lever near the main jet By seeing the height of float Oil lever 18 5 1 0mm General tools Float ruler Confirm the action of float is normal and then install the float chamber If the fuel lever is out of the limitation replace with a new float Ari cutting valve The valve can be checked on the vehicle 1 Pull off the suction tube and vent tube 2 Connect the vacuum pump to the hole connect to suction tube 3 Connect the pressure pump to the hole connected to the vent tube 4 Turn on the suction pump Standard pressure 380mmHg If there is no air going through the vent tube under suction pressure and air going through after taking off the suction pressure that means the valve is normal Replace O ring 1 Take off the carburetor 2 Pull the vent tube from air cutting valve 3 Remove the 2 screws

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