atvr (2005) service..
Contents
1. 5 Remove of Engine 6 Cylinder Head Cylinder Piston 7 Starter Driving Disc Clutch Transmission Disc 8 Final Transmission Mechanism 9 Crank case Crank shaft 10 Chassis Front wheel Brake Suspension 1 Rear heel Brake Suspension 12 Electrical devices 13 Wiring diagram 14 Initial Set Up Information Injector Oil Use a good grade of oil that 1s specially formulated for two stroke engines synthetic type 1s recommended HC recommends SAE 30 Transmission Gear Oil Use multi grade motor oil of SAE 90 or 55W 140 Break In Procedure To insure maximum durability and optimal performance and to avoid engine damage please pre mix the first four tanks of fuel with two stroke engine oil at 30 1 ratio Do not operate the ATV at more than half throttle for the first three hours During the break in period the first four tanks of fuel operate the vehicle at various RPM s and do not operate the vehicle above half throttle for extended periods Engine The ATV 50 100 have a two stroke reed induction piston p2. Bolt amp nut of tires locking torque Front wheel 3 0 3 5 kg m Rear wheel 4 5 5 5 kg m Tightness of frontbearing OP Tightness ofrear bearing OP amete ee Buffer device Spring Spring damage 000000000 SSS Spring of shock absorber Suspension arm damage of joint gap amp arm oil damage oil leakageordamage OO 0 00 Tghmessofimsalaion Power transmission device Citn aon OOF o oo GerBox 0 0 SAE 90 0r80W90 Electric device Ignition device Spark pug 0 O Gapof spark plug 0 6 0 7 mm EE Battery connection of terminal Wiring of electrical appliance damage or loose in connection place Engine Body starting amp abnormal noise Low speed amp accelerating exhaust air filter Service Time month Service Items Judgement Standard Remarks Ist Each 12 riding 6 Lubrication device 0 Oil and oit filter O 00 Checktheoillevel Obekag POP OP L 00 Fuel installation Flfl erisdiy Clgged o o s oo o Lekweofful Oj Oj Jo gate amp chke P OP Alterationoftubes OP lights S 202 Ade JOJOLl e 00 dirty damage Exhaust pipe amp muffler 2 Installation loosed ordamage OP Funetionofmuter Frame amp body looseordamage JOll o Each 2 years Cleaning combustion chamber exhaust pipe
3. Clutch Transmission Disc Disassembly of Clutch Transmission Belt Disc Operation Parts name Remark Disassembly Clutch Nut Clutch Weight Set Drive face ass y Axle ring of spring Compression spring Secondary spring seat Guide pin Secondary sliding slot wheel Oil ring 10 Needle bearing 11 Internal circle clip 12 Radial ball bearing 13 Secondary fix slot wheel Operation with sequence in reverse of separating 8 8 Final Transmission Mechanism Attention of Operation This chapter explain that final reduction mechanism maintenance can be operated in the vehicle Use professional tool to change driving shaft Replace Transmission Gear Oil Remove 4 Hex Washer Face Bolt fixed on Floor Panel Move forward the Floor Panel Remove Hex Washer Face Bolt and Copper Plain Washer Leak out oil Transmission Gear Oil Fix Hex Washer Face bolt and Copper Plain Washer Remove Oil Plug and add 80C C new Transmission Gear Oil Fix Oil Plug Recommend use grade SAE 90 55W 140 Gear Oil Diagnosis of Trouble Engine starts but vehicle does not move Transmission gears broken Transmission gears burns out Operate of noise Abrasion wore and teeth hurted of gear Bearing wore and loosened Gear oil leaking Too much gear oil filled Oil seal wear out or damage Reverse Loose or damaged of bolt Bad adjustment or defected of the link Ass y
4. Crank Shaft Case Log qoe duo X 2 5 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for 50 100 2 6 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV 50 100R V 2 7 CHECK AND ADJUST Way of Check amp Adjustment 1 Mark 7716 checking time 2 Mark yx is the regular exchange of service items This exchange time is just for general riding of the majority not for the special use please arrange with this principle according to the difference of the riding condition Service Time month Service Items Before P each 12 riding Operating Device Handle Play loose tight Operation Wheels Right left turn round angle Brake Device 00 Device Brake Play Handle handle front Test Ride 10 20 mm Adjust Wires Loose tightanddamage O O Of LZ Nuvi E DE E Brake Hub Limitation 855 5 Sic Size Tires pressure E pr Front and Rear Cushion Damage aaa V of Bolt Service Time month Service Items Judgement Standard Remarks Ist Each 12 riding 6 Riding Device Tire Check amp of tires Ditch front wheel till 3 mm wheel 7 3mm Abnormal amp ditch in tires amp ditch in tires
5. of Battery Remove seat and battery terminal disassembly connection wires of battery check voltage between battery terminals Charging sufficiently over 12 8 V Charging insufficiently 11 5 12 8V 7 WARNING Must check battery voltage with digital voltmeter Oterminal Check Charging System Power leakage test Disassembly ground guide wire from battery after turning OFF main switch next connect voltmeter to the end between terminal amp ground guide wires Check voltage when main switch 1s OFF terminal 7WARNING Check voltage according to sequence from big to small Voltmeter s fuse will be broke when check voltage over the limitation chose Don t turn ON main switch when check current Current Leakage over mA 13 ELECTRICAL DEVICE Check Charging Status 7WARNING Charging status will change voltage hugely check battery voltage after battery charged completely over 12 8 V Start engine will consume a lot power of battery Assembly voltmeter to terminal of main fuse start engine open light rise running amount and check charging voltage amp current Charging current 1 2 Amp 5000rpm Voltage of charging control 14 15V 5000rpm Check Voltage of Head Light 7WARNING Check head light which wires connecting Start engine turn light switch open high beam Check volt
6. 3 5mm oil seal 7 oil seal 10 5 Front Wheel Attention of Operation Remove the body cover and support the frame body bottom before remove the front wheel don t invert the front wheel when front wheel depart ground Diagnosis of Trouble Steering handle not straight e Loose not correct adjustment or Heavy steering movement damaged right or left link Ass y e Air pressure too low inside of front e Steering shaft bended tire e Suspension arm knuckle damaged e Rim radial ball bearing broken e Rim damaged Brake efficiency abnormal Front wheel shaking or deviation e Brake lining wear out e Front rim defected e Brake pads adjust not correct or e Loose or damaged of front rim wear out bearings e Brake drum wear out e Tire defect e Tire wear out e Bad adjustment or defected of the right or left link Ass y e Bad adjustment or defected of the right or left knuckle FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Front Wheels Operation Parts name Disassembly front wheels L R Rubber cover Cotter pin Scotch nut Plain washer 12 40 4 5 Disassembly front brake drum Hex washer face bolt Front coller Front brake drum Rim Assembly front brake drum Assembling with sequence 85 in reverse of disassembly Assembly wheels 4 gt WARNING Change the R L bearing set if necessary FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Front Br
7. Bad adjustment or defected of the knuckle Final Transmission Mechanism Disassembly of primary drive gear final reduction mechanism Disassembly of Drive Sprocket Ass y Remove 1 Nylon Nut and 1 Plain Washer Disassembly of clutch drive face WARNING First drain the oil of transmission Main axle comp Check the wear amp damage o Middle axle shaft and gear Gear shift arm Gear shift fork guide shaft 10 Gear shift fork Assembly Operation with sequence in 10 gt 1 reverse of disassembly 1 2 3 4 5 6 7 9 9 Final Transmission Mechanism Change the Driving Shaft Remove the driving shaft from mission cover WARNING Don t damage joint face of mission cover Remove the oil seal of primary drive gear Remove the bearing Install the new bearing in the mission cover outer handle A 17 guide rod of puncher jacket puncher of bearing 37 40mm Final Transmission Mechanism Assembly Disassembly of reverse Operation Parts name Disassembly reverse 1 Shift rod 3 washer face bolt 6 22 Assembly Assembly with sequence in reverse of 3 9 disassembly Crank Case Crank Shaft Attention of Operation This chapter explain the necessary procedure of disassembling crank case due to repair amp maintain the crank shaft Before disassembling of crank case must operation with sequence of each chapter to
8. HIGH STARTING AC BATTERY TENSION CARB SWITCH COIL MOTOR GENERATOR PLUNGER
9. Hex bolt 2 i 2 3 Fuel Tube 2 Assembly Operating with sequence in reverse o 39 disassembly FUEL SYSTEM Replace Air filter Disassembly of oil tank Remove 2 Hex Bolt and move to the rear of the Air Cleaner Ass y Remove 3 Tapping Screw Truss Head Phillips Remove Air Cleaner case cap o Replace new Air filter Disassembly of Air Cleaner Ass y Disassembly of handle bar and front cover Disassembly of oil tank Operation Parts Name 1 Air cleaner cover 2 Air cleaner element 3 Cleaner filter net 4 Air cleaner case cap 5 Cleaner guide pipe REMOVE OF ENGINE Attention of Operation Operation after disassembling the engine Crank shaft case Crank shaft Exchange bearing of final transmission mechanisms Disassembly of Engine Disassembly of external cover of body Disassembly of throttle valve and cable REMOVE OF ENGINE 7WARNING The oil over flow when remove the oil tube so use clip or plug stop the seal lt Air Cleaner Ass y Tail of Muffler ACG wire wire of start motor Starter wire of carburetor Vacuum pressure tube Cap of spark plug Oil pump control cable Throttle cable 10 Sprocket Ass y 1 2 3 4 5 6 7 9 9 WARNING Actually for brace the frame avoid body turn inside out 11 washer face bolt of engine a SB NO Assembly WARNING Car
10. M Disassembly of Oil Tank Q Disassembly Hex Bolt 2 x WARNING Oil level gauge Fill motor oil with clean container Joint of oil disassembly oil pipe Oil tank Assembly e Operation with sequence in reverse of 4 1 disassembly WARNING Connect correct oil pipe after assembly release the air in motor oil pump FUEL SYSTEM Attention in Operation Pay attention to the parts which using gasoline Tube amp Cable must be in accordance with the correct location Release air in oil pump when disconnect oil tube Diagnosis of Trouble No starting No gasoline in tank The arrow mark of Fuel valve pointed at OFF position Gasoline blocked Too much fuel in cylinder Air filter is clogged Idle speed unstable of carburetor rotation not smooth Poor idle speed adjustment of carburetor Low compression pressure Poor ignition system Bad adjustment of air adjusting screw on carburetor Air filter is clogged Defect of auto side plunger on carburetor Idle speed nozzle 15 clogged Mixed air too thin Nozzle of carburetor is clogged Gasoline filter 1s clogged Vent of gasoline tank is clogged Gasoline tube cranked broke clogged Poor action of float chamber valve Gasoline level too low Air pipe is clogged Mixed air too rich Poor action of float chamber valve Gasoline level too high Air nozzle 15 clogged Auto side plunger defect FUEL SYSTEM Disas
11. SERVICE MANUAL ATV 50 100 R MARCH 2005 High Power Engine HER CHEE INDUSTRIAL LTD Foreword This service manual contains information on servicing ATV 50 100R This manual is written for use as a guideline only It 1s recommended that any mechanic with or without sufficient experience thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual For fully qualified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manual in full before attempting service on ATV 50 100R All the data and diagrams provided this service manual are valid at the time of publication Information may be updated without notice due to improvements or upgrades No quotation reproduction or reprint of the service manual as a whole or in part will be permitted without the express written consent from ADLY Motor sports INDEX Initial Set Up Information 1 Information for Preparation 2 Check and Adjust 3 Engine Lubrication System 4 Fuel System
12. Use the bearing puller to remove the crankshaft bearing from crank shaft then remove the R L crank case Special tool Bearing puller TLJT 00 WARNING Must remove the oil seal when Assembly of Crank Case separate the crank case and never use the old oil seal crank case puller TH Right crank case Left crank case crank case puller bearing puller Clean the crank case with gasoline and check each part whether damaged or cracked WARNING Smear of oil on sliding surface of each shaft in crank case after checking Cleaning the washer dust of joint face and amend the part damage with oil stone Crank Case Crank Shaft Put new crank shaft into right crankcase Put crank shaft assembly into left crank case WARNING Smear the 2 stroke oil to main bearing and big end of connecting rod Note the position of connecting rod Put left oil seal into L crank shaft case surface depth under 1 0 mm 1 seal Imm guide rod of punch 17 mm outer handle A jacket punch oil seal 10 4 Crank Case Crank Shaft Assembly of Crank Case Install the dowel pins in the joint face of left crank case Install the right crank case Special tool Bearing puller TLJT 00 a ZY Install the new oil seal to crank case Special tool Bearing puller TLJT 00 SS ia 768 12 5 1
13. V OIL Lubrication by designated lubricant _ nme GREASE Lubrication by grease Special Tool Parts on which special tools shall be used Tool General tools shall be used a New Replace by new items after dismounting Attention V Dangerous and important operations 2 2 INFORMATION FOR PREPARATION SPECIFICATION MODEL TYPE TARTING LUBRICATION TRANSMISSION 222 NGKBPR7HS 0 PARK PLUG NGK BPR7HS YTX4L BS 12V Maintenance free OIL CAPACITY 1 0 Liter Liter 0 0 WHEEL BASE REAR BRAKE DRUM RONT SUSPENSION REAR SUSPENSION RONT TIRE x SPECIFICATIONS SUBJECT TO CHANGE WITHOUT ANY NOTICE 2 4 INFORMATION FOR PREPARATION LOCKING TORQUE Adopt the standard torque locking for the item unlisted STANDARD TORQUE Locking Torque kg m 6 mm Hex Washer Face Bolt Nut 8 mm Hex Washer Face Bolt Nut 10 mm Hex Washer Face Bolt Nut CHASSIS RearAxleNut S M 50 Rear Brake Arm Serew 6 12 FronShockAbsober 4 10 40 Rear Shock Absorber 2 10 40 Engine MouningNut Front 1 10 45 Engine Mounting Nut Rear 1 8 30 ENGINE Sewarda a Chuck Cover 3 9 38 EM LL L E m Nut of Primary Fix Sheave Oil check Screw NENNEN Joint Screw of Exhaust Muffler 2 6 n2 t Exhaust Pipe Support Screw of Muffler Spark Plug 1M 14 Bolt of
14. ables and wires properly Install the front cover into the rear cover 5 Pull the seat lock cable and remove the seat Install the battery with the red wire to positive and the black wire to the negative 6 Remove the oil tank cap and fill with 2 stroke SAE 30 of a synthetic and low smoke type and enough unleaded gasoline to operate Be sure the arrow mark on the fuel valve arm petcock is set into the correct position on 7 Install the Front Bumper 8 Turn the main switch and try to start up the engine order to use the electric starter you need to check the following A Turn on the engine operation switch located on left handle bar B Pull the rear brake lever C Push the electric starter bottom to left or right 9 Ifthe vehicle is operating in a very dusty area please add more oil on the air cleaner filter E E pen Ee ai LJ PDI PRE DELIVERY INSPECTION For ATV 50 90 100 1 Record the frame and engine number into the owner s manual 2 Check that all tires have correct pressure specified on the tire or in the owner s manual 3 Engine lubrication oil 2 stroke Grade SAE30 tank 15 filled 4 Battery 1s installed properly 5 All brake cables are adjusted properly 6 Fuel tank has enough gasoline to operate _ 7 Check the suspension and drive chain for proper setup LJ LJ 8 Check that all electrical components and lights are working properly 9 Make sure that the owner s man
15. adjust screw WARNING e No fire Before disassembling loose fuel draining screw draining out the gasoline from carburetor FUEL SYSTEM 2 Auto side plunger Oil ring Float Chamber Pan phillips bolt Drain screw Over flow tube Pan phillips bolt Needle valve Carburetor Ass y Throttle screw set Air adjust screw set WARNING Must confirm rotation Float chamber seal before disassembling Pilot jet Not locking too much avoid to Main jet base hurt seat face Operating with sequence in reverse of Disassembling 12 Air adjust screw set WARNING use high pressure air clean each way of carburetor WARNING must adjust air screw when changing air screw and carburetor ass y FUEL SYSTEM Disassembly of Inlet Valve Disassembly of handle bar amp front cover Disassembly of fuel tank Disassembly of carburetor Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass y Reed valve gasket Assembly Assembling with sequence in reverse 5 gt 1 of disassembly WARNING Using new gasket the Reed valve ass y gasket must aim at hole of reed Reed valve gasket valve WARNING confirm no leaking of the reed valve and manifold 5 7 FUEL SYSTEM Disassembly of Fuel Tank Disassembly of handle bar and front cover WARNING No fire e Shall be wiped off when fuel overflowed Operation Parts Name 1
16. age between green amp black guide wires Control Voltage 11 14 V AC 5000rpm Voltmeter ammeter terminal of main fuse wa main fuse 13 7 ELECTRICAL DEVICE Terminal of connector WARNING Check in range of AC Check Regulator rectifier when voltage 1s not in the range controlling Control voltage 12 14V S000rpm regulator Check the Rectifier gt Check the rectifier e Disassembly connector of rectifier Check the terminal of connector Disassembly of ACG 13 8 ELECTRICAL DEVICE Operation Parts name Disassembly Hexagon socket bolt Plain washer Self tapping screw Generator Cover Hexagon socket bolt Plain washer Fan Hexagon nut Spring washer 10 Plain washer 11 Fly wheel of generator 12 Semi cycle key 13 A C G base 14 Hex socket bolt 1 2 3 4 2 6 7 9 9 7 WARNING Beware not to damage the coil m Lmlls5 ra23s6t6N2 Assembling with sequence in reverse of disassembly ACG Charging Coil Check WARNING Checking in the engine connected With start motor ACG connector Disassembly ACG connection Check resistance of charging wire amp lighting wire Connect Black and Black Red Wire then check resistance Standard Resistance 470 6700 13 9 ELECTRICAL DEVICE Ignition Coil Disassembly Disassembly spark plug cap Separating cable disassembling bo
17. agnosis of Troubles Too much smoke means too much carbon muck piping up the spark plug Poor synchronizing adjust of oil pump too much exhaust gas Bad quality of engine oil Overheating Poor synchronizing adjustment of oil pump too exhaust gas Bad quality of engine oil Piston burnt Short of engine oil or engine oil tube is clogged Poor adjustment of oil pump Airin tube system or in oil pump Bad oil pump Clogging oil from oil tank Vent of oil tank s cap is blocked Oil Filter is clogged Preparation standard Use separating engine oil appointed use for 2 stroke tank capacity 1 1 liter LUBRICANT SYSTEM Disassembly of Motor Oil Pump Remove Generator Cover Remove A C G fly wheel and fly wheel base WARNING Operating after cleaning motor oil pump around and no entering to the crank shaft case LUBRICANT SYSTEM 1 Fuel tube 7WARNING Clogging the tube to avoid fuel flow out 2 Fuel connection tube 3 Pan phillips bolt e Remove from both side of oil pump 4 Control cable e Remove from oil pump 5 Oil pump e Assembly with sequence in reverse of disassembly WARNING Smear oil to new O ring before install the oil pump into crank case The oil pump must correctly installed into crank case 7WARNING Don t loosen adjusted screw on control cable Adyjust the cable if it s loose LUBRICANT SYSTE
18. ake Disassembly brake plate Handle bar Release adjustment screws Release front left or right wheel AsS y Strain spring Front brake shoe Comp Release brake cables Front brake panels Assembly Assembling with sequence in 7 1 reverse of disassembly FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Suspension Arm Operation Parts name Disassembly L R Hex bolt Hex flange nut with serration Release front cushions Hex flange nut with serration Hex washer face bolt Suspension arms Assembly Assembling with sequence in 6 reverse of disassembly FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Steering Shaft Ass y Q ty Disassembly steering shaft Ass y Handle bar A ssy Hex flange nut with serration Steering shaft holder Holder spacer coller Hex flange nut with serration Release Ball joint left right thread Steering shaft Ass y ee mea KJ KO NO LPO Disassembly knuckles Cotter pin Hex flange nut with serration Left amp right link Ass y Scotch flange nut Left amp right knuckle Assembly knuckles Assembling with sequence in reverse of 128 disassembly Aassembly steering shaft Ass y WARNING Adjusting gap of throttle Tcl REAR WHEEL SUSPENSION BRAKE Diagnosis of Troubles Rear wheel shaking or deviation The shape of rear rim damaged Rear wheel axle damaged Swing arm sub Ass y damaged Rear rim b
19. and carbon muck in muffler ieee DRIVE CHAIN gt Tolerance 10 06 0 00 0 Check the tension of drive chain Oo Others greasing of each part BENE Abnormal from previous day confirm normal CHECK AND ADJUST Disassembly of External Parts ATV 50 90 100R IL Remove the external parts for check and adjustment Disassembly the Rear Cover Pull the Seat Releaser Unit and take off Seat Ass y Remove 4 Pan Flat Head Phillips Bolt Remove 2 Ladder Bolt Remove 4 Nylon Nut 2 Plain Washer and 2 Rubber Washer Remove Floor Panel Remove 4 Pan Flat Head Phillips Bolt Disassembly the Handle Bar Release brake throttle and cables Remove 4 Hex Socket Bolt and take off the Handle Bar Release 1 Hex Socket Bolt and take off the R Lever Ass y Disconnect light indicator position light and speedometer Release 2 Pan Flat Head Phillips Bolt and take off the L Handle Switch Ass y Optional Release 1 Hex Socket Bolt and take off the L Lever Ass y Optional Disassembly the Front Cover Disassembly the Handle Bar Remove the Fuel Tank Cap Pull the Seat Releaser Unit and take off Seat Ass y Remove 2 Ladder Bolt and 4 Pan Flat Head Phillips Bolt Remove 2 Hex Washer Face Bolt and l Do not damage amp break the cover 4 Plain Washer And 2 Hex Flange ee Before locking screws please confirm the matchi
20. disassembly Disassembly of oil pump Disassembly of carburetor Disassembly of intake valve Dis mounting of engine Disassembly of cylinder head and cylinder Disassembly of ACG Disassembly drive face ass y Must disassembly of final reduction mechanism when change the left crank case Must use special tool into the inner ring of crank shaft bearing and pull in crank shaft to assembly when assembly crank case amp crank shaft put new bearing into crank case and put into new oil seal after assembling crank case Diagnosis of Troubles Noise of Engine Damage of crankshaft bearing Damage of needle bearing of crankshaft pin Crank Case Crank Shaft Assembly Disassembly of Crank Case Special tool Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing Right Radial ball bearing Left Hex socket bolt 10 Oil seal bracket 11 Right oil seal 12 Left oil seal Radial ball bearing 13 Assembly E 1 2 3 4 5 6 7 9 9 me i NO OO Crank Case Crank Shaft Disassembly of Crank Case Install the puller on right crank case separate the R crank case and L crank case Special teo Crank case puller TLJT 03 Install the puller on left crank case remove the crank shaft from the crank case Special too Crank case puller TLJT 03 WARNING Don t knock the crank shaft when disassembling
21. e white Black 2 2 o Fo Exchange of Bulbs Head light bulb Remove handle bar and front cover Press down the bulb base and turn left to change head light bulb head light cover head light bulb head light wire 13 13 ELECTRICAL DEVICE Rear light bulb Brake light bulb Rear direction light bulb Dus signal lens Remove 2 screws pull out the light duet Tere cover then change bulb Remove R L screw on direction light Cover pull out the cover then replace the bulb P N tail light lens 13 14 AIV ELECIRICAL DIAGRAM DE SWITCH HORN UNIT REGULATOR STARTING SAFETY SWITCH SHIFT GEARS ck Green RECTIFIER MN OPTIONAL CONTACT SWITCH K Black TR dp s mm aR sown CaF 1 Bal Lt db SEP e CHI D BARES E 2ed BR INDICATOR s SIGNAL INDICATOR R Y BR oe HIGH EAMG INDICATOR OIL LEVEL INDICATOR EE REVERSE e EIN INDICATOR sH ee RR TURN SIGNAL NEUTRAL amp R W BR pp INDICATOR Q S 1 1 1 1L 1l DGR f ope INDICATOR Pot 1 o S 7 5 Lj v CELL d GR YL HEAD 6H Eg HUNE Ha TAIL LIGHT LIGHT STOP LIGHT EFT TURN ye ELE E O L 4 rLr tl E CNN m CAP Hebe db d ppue gus FUSE 7 I ML OIL LEVEL GAUGE LEFT HANDLE SWITCH BRAEK
22. earing defected Rear suspension too soft Spring too soft or adjust not correct Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct or wear out Brake drum wear out Tire wear out REAR WHEEL SUSPENSION BRAKE Assembly Disassembly Rear Wheel of BW N Scotch nut Plain washer 14 40 4 5 Take off the wheel Ass y Hex washer face bolt Take off shaft connector Rim Tire NNN OO r2 L2 P2 F2 WN e Assembling with sequence in reverse of disassembly REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Rear wheel axle and Brake panel Operation Parts name Q ty Disassembly Rear Brake Left rear wheel Ass y Left spacer collar Hex washer face bolt Rear drum cover Rear drum cover gasket Rear drum Rear brake shoe Comp Disassembly Rear wheel axle Right rear wheel Ass y Right spacer collar 10 sprocket Ass y 11 off rear wheel axle Disassembly Rear Brake Panel 12 Hex flange nut with serration 13 Rear brake cable 14 Hex washer face bolt 12 27 15 Plain washer 16 Hex washer face bolt 12 22 17 Rear brake panel Assembly Assembly with sequence in reverse Rear break 7 1 of disassembly Rear wheel axle 11 8 8 Rear break panel 17 12 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Rear wheel axle and Brake panel Operation Parts name Q ty R
23. eight roller wear out 8 1 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case Cover Operation Parts name Disassembly Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket Assembly Operation with sequence in reverse 6 of disassembly 8 2 Starter Driving Disc Clutch Transmission Disc Disassembly of Kick Starter Disassembly of left crank case cover Operation Parts name Disassembly Kick pinion spring clip Kick pinion Hex washer face bolt Kick crank External ring clamp Plain washer Starting shaft ass y Starting shaft reset spring Bushing WARNING Rotating pedal kick to crank and remove the case cover assembly O ON WN B WN ee 8 3 Starter Driving Disc Clutch Transmission Disc Operation Parts name PDO Ww BNO WO Starting shaft reset spring Starting shaft ass y Plain washer External ring clamp Kick crank Hex washer face bolt Kick pinion Kick pinion spring clip Installation of Kick Pinion Kick Pinion Spring Clip e Set kick starter shaft first Turning starter hang kick pinion spring clip on crank shaft case convex and assembly of kick pinion to the location of removing Turning starter let starting shaft and kick pinion conjoin Check of Starter Check the wear amp damage of starting shaft or gear Check the
24. emarks Left rear wheel Ass y Left spacer collar Hex washer face bolt Rear drum cover Rear drum cover gasket Rear drum Rear brake shoe Comp Disassembly Rear wheel axle Right rear wheel Ass y Right spacer collar 10 sprocket Ass y 11 Take off rear wheel axle Disassembly Rear Brake Panel 12 Hex flange nut with serration 13 brake cable 14 Hex washer face bolt 12 27 15 Plain washer 16 Hex washer face bolt 12 22 17 Plain washer 18 Rear brake panel Assembly Assembly with sequence in reverse of Rear break 7 1 disassembly Rear wheel axle 11 8 Rear break panel 18 12 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Swing arm sub Ass y Operation Parts name Disassembly Swing arm sub Ass y Rear brake panel Ass y Nut Bush Swing arm spacer Oil ring Swing arm bolt Swing arm sub ass y YAN NB WN e BN Assembly e Assembly with sequence in reverse 7 1 of disassembly REAR WHEEL SUSPENSION BRAKE Assembly Disassembly of Front amp Rear Cushion Operation Parts name Disassembly Front Cushion Hex washer face bolt Hex flange nut with serration Hex bolt Front cushion Disassembly Rear cushion 5 washer face bolt 6 cushion Assembly Assembly with sequence in reverse of Front cushion 4 1 disassembly BR WN Re Rear cushion 6 5 ELECTRICAL DEVICE At
25. ent of Oil Pump x WARNNING Control rod oil pump Going on this operation after adjusting and checking the guide wiring of throttle X M 4 G 3 1 ASN A c AS e The free play within 1 mm of the oil pump control cable is good Starting AR the engine push slightly the throttle to feed oil At same time of rising the engine rotation confirm the function of control rod AN 4 A adjust nut e The condition will be appeared with bad synchronizing as follows Starting difficult and having smoke when opening degree of oil pump s control rod 15 too big Piston will be burnt when the opening degree of pump s control rod is too small Adjustment of Drive Chain Loose 4 Hex Bolts on Rear Brake Panel Adjust the drive chain adjuster to proper chain tolerance 10 20 mm unload Tie up 4 Hex bolt on Rear Brake Panel Lubricate the chain CANTION Beware the direction of chain fix clip if disassembly the chain tum direction fix clip 3 6 LUBRICANT SYSTEM Attention of Operation Pay attention to avoid dust enter to the interior of engine and oil tube when disassembly the oil pump Never disassembly oil pump Must draw out the air in the pump if there have air in the pump when disassembly tube of carburetor After disconnect the oil tube must fulfill the oil in the connection tube before installation Di
26. ge must use the electrical meter 13 1 ELECTRICAL DEVICE Diagnosis of troubles No Electrical Power e Over discharged of the battery e Wire hardness did not connected to the battery e Fuse broken e Main switch defect Low Voltage e Battery charges insufficient e Bad connection e Charge system defect e Regulator rectifier defect No Continues Current Bad contact of battery with main wire hardness Bad connection of charge system Bad contact of the lighting system cause short circuit Charge System no function Bad connection of the wire hardness connectors Main wire hardness broken or short circuit Regulator rectifier defect AC Generator defect Fuse broken 13 ELECTRICAL DEVICE Wiring Diagram II rv ec 7 MAIN SWITCH ASS Y Re SWITCH ASS 4 5 57 SY HEAD LIGHT ASS Y STARTING RELAY REGULATER RECTIFIER a HIGH TENSION COIL ELECTRICAL DEVICE Wiring Diagram MAIN SWITCH ASS Y HEAD LIGHT ASS Y REGULATER RECTIFIER LT E ELECTRICAL DEVICE Disassembly Of Battery Disassembly Release seat Remove rubber cap Battery end WARNING Disassembly battery from Battery end end to end Battery Assembly Assembling with sequence in reverse Dx of disassembly Battery terminal WARNING Connect end first next end both terminals with caps 13 5 ELECTRICAL DEVICE Check Voltage
27. lt pe spark plug s cap and disassembly ignition coil Assembly Assembly with sequence in reverse of disassembly Conduction Test Check first coil resistance of ignition terminal Standard valve 20 0 3 050 WARNING Check ignition status with performance tester due to this test has its own standard Check second coil resistance between spark plug cap amp terminal Standard valve 9 5 11 2 spark plug cap installed Remove spark plug cap from high tension coil Check second coil resistance between high voltage amp terminal Standard valve 5 7 k Q without spark plug cap 13 10 ELECTRICAL DEVICE Assembly Separation of Starting Motor Disassembly of starting motor Remarks Armature rotor Carbon brash Oil ring Oil ring Front fixed seat Assembling with sequence in reverse of disassembly 13 11 ELECTRICAL DEVICE Check Main Switch Remove connector of main switch wire check conductivity between each terminal Remove main switch Disconnect main switch wire Pull the main switch Bracket inside front cover Push the stopper on main switch underneath front cover then push out the main switch Check safety switch Remove the connector of safety switch check conductivity between terminal 13 12 ELECTRICAL DEVICE Switch of Lights Yellow red Blue MEN Start Switch Color blu
28. ng is correct of all parts Disconnect Main Switch Wire and head light wire 3 4 CHECK AND ADJUST Disassembly of External Parts Remove the external parts for check and adjustment Disassembly the Rear Cover Pull the Seat Releaser Unit and take off Seat Ass y Remove 4 Pan Flat Head Phillips Bolt Remove 2 Ladder Bolt Remove 4 Nylon Nut 2 Plain Washer and 2 Rubber Washer Remove Floor Panel Remove 4 Pan Flat Head Phillips Bolt Disassembly the Handle Bar Release brake throttle and cables Remove 4 Hex Socket Bolt and take off the Handle Bar Disconnect light indicator position light and speedometer Release 1 Hex Socket Bolt and take off the R Lever Ass y Release 2 Pan Flat Head Phillips Bolt and take off the L Handle Switch Ass y Release 1 Hex Socket Bolt and take off the L Lever Ass y Disassembly the Front Cover Disassembly the Handle Bar Remove the Fuel Tank Cap Pull the Seat Releaser Unit and take off Seat Ass y Remove 2 Ladder Bolt and 4 Pan Flat Head Phillips Bolt Remove 2 Hex Washer Face Bolt and 4 Plain Washer And 2 Hex Flange Nut With Serration Disconnect Main Switch Wire and head light wire ATV 50 100R V WARNNING Do not damage amp break the cover Before locking screws please confirm the matching is correct of all parts 3 5 e CHECK AND ADJUST Adjustm
29. ort motor It must use two cycle oil and should never be run without oil in the oil tank Rebel the regulation will have extreme damage to the motor will result Ignition System The ignition system installed on ATV 50 100R is the Computerize Digital Ignition CDI type There 1s no maintenance required for this type of system Chassis The chassis is constructed of mild steel tubing If any frame repairs are necessary oxyacetylene welding can be used If wire feed or arc welding 1s used use extreme care and disconnect the battery while welding Set Up Procedure The following instructions provided a general overview of the procedures needed to properly set up and deliver the ATV 50 100R to the retail customer 1 Take out the battery and fill with acid liquid Pre charging the battery will extend its life The preparation and charge procedure is based on the battery s instruction 2 Install the rear wheels and parts in the following order 14x40x4 5mm washer big B 14mm hex bolt torque 450 550kg cm 44 54N m C Cotter pin open up the end after installed D Rubber cap 3 Install the front wheels and parts in the following order 12x40x4 5mm washer big B 12mm hex bolt torque 300 350kg cm 29 5 34N m C Cotter pin open up the end after installed D Rubber cap 4 Set the handle bar into the lock pin of the steering base Tie up the 4 hex socket bolts Install the rear cover into handle bar and adjust the c
30. r damage the cylinder CYLINDER HEAD CYLINDER PISTON Disassembly of Cylinder Head Cylinder Piston e Disassembly of cover e Disassembly of generator cover e Disassembly of muffler e Disassembly of spark plug cap CYLINDER HEAD CYLINDER PISTON Disassembly Cylinder head Nut of cylinder head WARNING Loosing nut 2 3 times Cylinder head Cylinder head gasket WARNING Don t knock cooling fin Cylinder gasket WARNING Clean and not damage cylinder gasket of crank shaft case Piston ring clip Piston pin Piston Piston ring 10 needle bearing Installation of Piston Ring Install top piston ring amp 2 piston ring on piston Do not scratch piston and do not bend piston rings Remove carbon muck inside ring ditch and piston ring when not installed Be sure the rings rotate freely after install into piston WARNING Change whole set of piston ring with genuine parts Starter Driving Disc Clutch Transmission Disc Attention of Operation Don t make greases stick to surface of transmission belt or belt plate Otherwise the efficiency of power transmission will be lowered by skid Diagnosis of Trouble Vehicle does not move after engine start up Drive belt wear out Drive face comp damage Clutch lining wear out Driven Ass y spring defect Power insufficient Drive belt wear out Driven Ass y spring defect Drive face dirty or oily W
31. ry out following adjusting 1221 after installation Cable of throttle valve Oil pump control cable Rear break cable REMOVE OF ENGINE Disassembly of Muffler Hex flange nut with serration Hex washer face bolt Silencer muffler Hex head Phillips bolt Exhaust pipe front Assembly 6 Assembling with sequence in reverse of disassembly CYLINDER HEAD CYLINDER PISTON Attention of Operation Can be operated when engine installed on vehicle Must cleaning before operating avoiding dust enter the engine Remove the gasket dust stay on joint face Avoid to use screw driver harm the joint face when remove the cylinder amp cylinder head Avoid to harm the cylinder inner surface and piston face Cleaning before check parts and smear motor oil appointed in sliding face before installing Diagnosis of Troubles Low compression pressure poor start idle speed not stable Air leakage of cylinder head gasket Wear amp damage the piston ring Wrong installation of spark plug Wear amp damage the cylinder and piston Reed valve defect Compression pressure too high overheating locking Piling up carbon of cylinder head or piston head Piston Noise Wear the cylinder and piston Wear the piston pin hole and piston pin Wear the needle bearing of crank connecting rod small end Piston ring noise Wear or damage the piston ring Wear o
32. sembly Assembly Valve Of Throttle Disassembly carburetor lt Operation Parts Name Q Disassembly Pan phillips bolt Throttle valve Throttle cable Throttle valve spring WARNING Remove from guide wire of throttle Rubber Sealing Washer Needle nozzle valve COON QV Uta BW N 0m mm N 11 Adjust nut FUEL SYSTEM Operation Parts Name Q Assembly 11 Adjusted nut WARNING Assembly of needle nozzle lt Needle nozzle Washer Sealing set of guide wire Assembly of throttle valve Assembly of throttle cable Throttle cover Washer Throttle valve spring Throttle cable Throttle valve R ee oY 9 9 7 6 5 4 3 2 Aim the ditch of throttle valve to chamber then install throttle valve into carburetor Pan phillips bolt Lock the throttle cover FUEL SYSTEM Remove Carburetor Turn the arrow of fuel valve pointed at OFF Disassembly Throttle valve set Gasoline tube Engine oil tube Auto side plunger wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp WARNING Don t let dust enter into carburetor WARNING Release air CON WN BW NO Carburetor Assembly S 1 22 ee Motor oil joint FUEL SYSTEM Disassembly Assembly Carburetor Disassembling of carburetor Adjust the idle speed Adjust the air
33. tention of Operation Battery electrolyte contains sulfuric acid which can cause severe burns Avoid contact of skin eyes or clothing When sulfuric acid water spill into clothing will stick to skin Take off the clothing and flush with water Battery be charged and discharged Without charging the battery will have less lifetime If the battery have short circuit inside both terminal will not have voltage existed Besides the regulator rectifier lost the function and shorter lifetime e If the battery stay too long without use it will lost power and have less capacity The battery need to charge each 2 3 months After fill up the electrolyte the new battery will generate voltage It s necessary to recharge if the voltage 1s low It s necessary to leave the battery for more than 20 minutes before sealing the cap It will increase the lifetime of new battery if recharged before installed Do not unplug the electrical components from wire hardness when the current 15 working This will cause too high of voltage and damage other compounds such as rectifier light bulbs etc Turn off the main switch to OFF before the operation The Maintenance Free battery does not need to refill electrolyte or water All charge system needs to be installed before check Do not use quick charge unless it s in urgent The battery needs to be taking out from vehicle when doing charge work When checking the volta
34. tightness amp damage of starting shaft reset spring Check the wear amp damage of bush R 7 7WARNING Unable to install main shaft fix position when inside and outside reset spring overlap Use flat driver screw start from inside then outside spring and press main shaft small gear of pedal LO Starting shaft ass y Starting shaft reset spring bushion 8 4 Starter Driving Disc Clutch Transmission Disc Check the wear amp damage of kick pinion kick pinion Check the wear amp damage of kick pinion spring clip kick pinion spring clip 8 5 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case Operation Parts name Disassembly Hex washer face bolt Cone spring washer One way clutch gear Clamp washer Primary fixed sheave Bushing V Belt Primary sliding slot wheel Oil ring 10 Hex nut 11 Clutch cover 12 Drive face ass y Assembly Operation with sequence in reverse 2 21 of disassembly 8 6 WARNING Don t damage transmission belt WO ONAN NA hb m e eee Starter Driving Disc Clutch Transmission Disc Disassembly of Sliding Driving Disc Operation Parts name 1 Cam plate 2 plate slider 3 Weight roller 4 Primary sliding slot wheel Assembly Operation with sequence in reverse 4 of separating 8 7 Starter Driving Disc
35. ual and tool bag are installed under the seat If there are any other questions please check the owner s manual for details CAUTION Before install the front rim beware the stopper D of front brake plate assembly must fit into the front knuckle 7 mm plate 2 INFORMATION FOR PREPARATION Attention on Operation All washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted 9 O o Q Locking of all screws nuts cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks e All items must use original parts pure oil and greases 2 All service shall use special tools and general tools to repair All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated 2 1 INFORMATION FOR PREPARATION Attention on Operation Certified lubricants in cans shall be used on all the elements to be lubricated li 5 After assembly performance of all elements shall be duly checked and the locking shall be duly verified Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation
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