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ATV DXR 200 TALLER.indd

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2. LECTRIC DETAILS y W TS A gt X 4 1 LN IS 7 lt P MT gt MT P 7 i Ya 28 t a ier 2 7 ELECTRIC DETAILS 6 4 STARTING SYSTEM BRIEFING 01 starter motor 02 starter relay 03 start button ELECTRIC DETAILS 6 4 STARRING SYSTEM NOTE SERVICE INFORMATION Service Limit mm Item Standard mm Starter motor brush length CAUTION 1 THE REMOVAL OF STARTER MOTOR CAN BE ACCOMPLISHED WITH THE ENGINE INSTALLED 2 WHEN CONNECTING THE STARTING SYSTEM WIRES CONNECT THEM SECURELY TO AVOID HARD STARTING DUE TO POOR CONNECTION 3 TORQUE VALUE 1 STARTER MOTOR BOLT 0 3 0 4 KG M 2 STARTER CLUTCH LOOK NUT 1 2 KG M A SPECIAL TOOLS 1 FLYWHEEL HOLDER 2 FLYWHEEL PULLER 3 COMMON TOOLS NOTE TROUBLESHOOTING lt Q A gt lt Q A gt Starter won t turn Fuse burned out Weak battery Faulty ignition switch Faulty starter clutch Faulty starter relay Loose wire connection Faulty starter motor lt Q A gt Lack of Power Weak battery Loose wire connection Foreign matter stuck in starter gear lt Q A gt Engine does not start but starter rotates Faulty starter clutch Reverse rotation of starter motor Weak battery ELECTRIC DETAILS 6 4 1 Starter motor removal Fig 6 34 6 35 01 remove the starter motor wir
3. BALAS ROJAS ATV DXR 200 INTRODUCTION The work shop or service manual is mainly for NACIANAL MOTOR S A U Area importers and their net work dealers amp service stations to fulfill the necessary maintenance and repairs information 1 Due to continuous launch of new models formation in this manual may be subject to change without notice For any further information regarding this manual or the products please contact the Territorial Distributor or Area Importer 2 All details of this manual are based on the latest product information available at the time of approval for printing Maker reserves the right to make changes at any time without notice and without incurring any obligation 3 This manual has been specially prepared to provide the necessary information for the Area importer dealers and their qualified mechanics of proper maintenance and repair details 4 This manual covers all series of products RAM 125 150 that user has to find out what details belong to By Sales and Service Department NACIANAL MOTOR S A U The images reflected in this manual can vary of the acquired pattern For Area Importer and Territorial Distributor All rights reserved No part of this manual may be reproduced or unauthorized use in any form or by any means without prior permission of the Maker NACIONAL MOTORS S A U http www derbi com NACIONAL MOTOR S A U CONTENTS PART 1 GENERAL INFORMATION 01
4. reference NOTE REFERENCE OF CDI TESTER OPERATE THE CDI TESTER FOLLOWING THE MANUFACTURER S OPERARION MANUAL CONNECT THE SPECIAL CONNECTOR TO THE CDI COUPLER AND CDT TESTER Switch Range C D I Good C D I Faulty 1 OFF No spark 2 P No spark 3 No spark Good spark 4 1 Good spark No spark 5 ON2 Good spark No spark if the CDI unit is faulty replace with a new one 6 2 5 Pulse Coil Inspection Fig 6 27 01 disconnect the pulse coil coupler 02 measure the resistance of the terminals Resistance 50 60 OHM 6 2 6 Exciter Coil Inspection Fig 6 28 01 disconnect the exciter coil wire coupler 02 measure the resistance between the wire terminal and ground Resistance 100 120 OHM LECTRIC DETAILS p v gt E D 24 by L 4 gt MES 1 gt Pa F EN SA a 5 d 1 d e 25810 u f NS 3 Moy d A m i a e ELECTRIC DETAILS 6 3 CHARGING SYSTEM BRIEFING 01 AC generator 02 rectifier amp regulator 03 battery YUASA YTX7A BS ELECTRIC DETAILS 6 3 CHARGING SYSTEM NOTE SERVICE INFORMATION Battery capacity Electrolyte specific gravity Charging current A C Generator Charging RPM Capacit
5. NOTE provides principal information OPTION or APPENDIX provides others specification of product 1 3 IMPORTANT NOTICE The ATV is designed and built for OFF ROAD use only It is illegal and risky to manual this ATV on any public street road or highway Any Working Machine or On Road base usage should follow the area laws and re gulations which all details should be provided and informed by each Area Importer Be sure to check the local area riding laws and regulations before riding this ATV IMPORTANT SAFETY MESSAGE REFO LINN TOO HOLIAS NIVR 192291 136 JENNY 31 pey ueesJ5 4 67 umoag 28 HDI o39 49 12518 moja U09149 M9 054040 o Y A 209 d 3 12018 Pod NH 149919 M D MOA A 8 1 9 10049 67 9718 1 Ir eng MEM 91 2018 g j _ I AVIAN HAHSVI4A Ta S T 0 4 0 IND 9 TIVI 2211 YVA 5 Y UILIROAFA4S WALSAS TVOINLITTA NN2NLLS 021 061 621 LSVId f AS 1 AVES IMPORTANT SAFETY MESSAGE GENERAL INFORMATION 1 1 SERVICE
6. REAR SHOCK ABSORBER AND SWING ARM BRIEFING Shaft pivot 02 Cover thrust Washers 04 Oil seal Bush 06 Bearing needle roller O ring 08 Spacer Seal guard 10 Rear arm Under guard 12 Support chain Shock absorber 14 Bolt Pin clevis 16 Cover thrust CHASIS DETAILS 5 6 REAR SHOCK ABSORBER AND SWING ARM WARNING NORMALLY THE REAR SHOCK ABSORBER JUST REPLACE A NEW ONE WHENEVER ANY WEAR DAMAGE SHOWING UP IT IS RARELY REQUIRE DISASSEMBLY THE REAR SHOCK ABSORBER THE SHOCK ABSORBER CONTAINS HIGHLY COMPRESSED NITROGEN GAS THE MAKER WILL TAKE NO ANY RESPONSIBLE FOR PROPERTY DAMAGE OF PERSONAL INJURY THAT MAY RESULT FROM IMPROPER HANDLING 1 DO NOI TAMPER TO ATTEMPT TO OPEN THE CYLINDER ASSEMBLY 2 DO NOT SUBJECT CHOCK ABSORBER TO AN OPEN FLAME OR OTHER HIGH HEAT THAT MAY CAUSE THE EXPLODE DUE TO EXCESS GAS PRESSURE 3 DO NOT DEFORM OR DAMAGE THE CYLINDER IN ANY WAY CYLINDER DAMAGE WILL RESULT IN POOR DAMPING PERFORMANCE 4 TAKE CARE NOT SCRATCH THE CONTACT SURFACE OF THE PISTON ROD WITH THE CYLINDER OR OIL COULD LEAK OUT 5 WHEN SCRAPPING THE SHOCK ABSORBER FOLLOW THE NOTE ONLY NOTE DISPOSAL REAR ABSORBER STEPS FIG 5 96 GAS PRESSURE MUST BE RELEASED BEFORE DISPOSING OF SHOCK ABSORBER BY DRILLING 1 A 2 3MM 0 08 O L2IN A HOLE THROUGH GAS CHAMBER WALL AT A POINT 25 30MM 1 0 1 2 IN FROM BOTTOM END OF GAS CHAMBER BE SURE TO WEAR EYE PROTECTION TO PREVENT EYE D
7. B Not overheating refer to 7 3 10 7 3 10 Accelerate or run at high speed A Engine knocks 1 Excessive carbon build up in combustion chamber 2 Poor quality fuel 3 Slipping clutch 4 Mixture too lean 5 ignition timing too advanced B Engine does not knock PROBLEMS SHOOTING 7 4 Poor PERFORMANCE AT HIGH SPEED 7 4 1 Check ignition timing A Incorrect 1 Faulty CDI unit 2 Faulty pulse coil B Correct refer to 7 4 2 7 4 2 Check valve clearance adjustment A Incorrect 1 Incorrect adjustment or worn valve seat B Correct refer to 7 4 3 7 4 3 Check fuel filter for fuel supply A Abnormal 1 No fuel in fuel tank 2 Clogged fuel filter 3 Clogged fuel tank cap breather hole B Normal refer to 7 4 4 7 4 4 Check carburettor for clogged jets A Clogged 1 Clean B Not Clogged refer to 7 4 5 7 4 5 Check valve timing adjustment A Incorrect 1 Cam sprocket aligning marks not aligned B Correct refer to 7 4 6 7 4 6 Check valve return spring tension A Broken or weak 1 Faulty spring B Good PROBLEMS SHOOTING 7 5 Poor CHARGING BATTERY OVER DISCHARGE OR OVERCHARGE 7 5 1 Start the engine and measure the limit voltage between the battery terminals A Battery voltage is normal 1 Dead battery 2 Faulty battery B Battery voltage does not increase refer to 7 5 2 7 5 2 Measure the resistance of the A C generator c
8. check for proper routing and free play on throttle brake clutch Clutch check operation Brakes check operation free play fluid level check parking brake operation Drive chain Drive chain check free play Wheels check tire pressure and wheel run out check wheel nut torque Steering check turning operation Suspension check operation Drive lever check operation Fittings check headlight Fasteners check all for loose or missing hardware Electrical check all light and switch operations check safety switches for proper operation Ignition check ignition timing check and correct any damage or missing parts Final re check and tighten all screw nuts bolts Comprobar la manejabilidad y observar cualquier ruido anormal test ride and observe any abnormal noise y owner s manual tools pack low pressure gauge re check end user s information pw APPENDIX Standard Motor Corp Sports Quads 125 150 170 250cc SK 125 150 170 250cc double light STGs 125 150 170 250cc double light separate front fender BL 125 150 170 250cc single light STGb 125 150 170 250cc single light separate front fender APPENDIX 8 2 UPDATE INFORMATION 170 amp BLAST MODEL gt for page 2 1 General Specification Weight 125 150 170 152 Kg 154 Kg 155 Kg Engine 4 Stroke Air Cooled Cylinder Single Forward Inclined Bore Stroke 125 56 5 x 49 5 mm 1
9. incorrect toe in 2 bent Steering shaft 3 improperly installed steering shaft 4 damaged bearing or bearing race 5 deformed steering knuckles 7 9 3 check tire for any 1 uneven tire pressure on L amp R side 2 incorrect tire pressure 3 unevenly worn tires 7 9 4 check wheels for any 1 incorrect wheel balance 2 deformed wheel 3 loose bearing 4 bent or loose wheel axle 5 excessive wheel run out 7 9 5 check frame for any 1 twisted 2 damaged frame 3 improperly installed bearing race 7 9 6 check swing arm for any 1 worn bearing or bush 2 bent or damaged 7 9 7 check rear shock absorber 1 fatigued spring 2 improperly adjusted spring prolate 3 oil leakage 7 9 8 check drive chain for any improperly adjusted chain slack APPENDIX 8 1 Notes Pre DeLiverY INSPECTION The dealer or service station will assemble and inspect the ATV according to the following pre delivery checklist before delivering no the customer ITEMS CONTENTS Appearance check the overall out looking and correct any surface damage or missing parts Battery fill with electrolyte charge battery properly valves check valve clearances check cam chain tension Spark plug check gap Carburettor check idle speed syncronization starter operation Fuel line check fuel hose routing and ensure that clamps are in proper position Engine oil check engine oil 4 stroke level Cables
10. 2 Fig 4 126 4 127 05 drive in new bearing using a bearing driver under squarely 1 Fig 4 127A 06 apply engine oil to the bearings before installation Play Pla 4 125 ENGINE DETAILS 4 8 7 Crankshaft inspection Fig 4 128 4 129 4 130 4 131 01 measure the connecting rod big end side clearance service limit more than 0 80mm replace 02 measure the connecting rod big end radial clearance at points at right angles to the shaft service limit more than 0 05mm replace 03 measure he crankshaft run out service limit more than 0 05mm replace 04 check crankcase bearings 1 for noise or excessive free play 4 8 8 Crankshaft installation The installation should follow the reverse order of removal option install the starter spindle onto the right crankcase 01 assemble the main shaft and countershaft onto right crankcase 02 install the transmission drum 1 Fig 4 132 03 install the R transmission fork to countershaft 4th gear 04 raise the guild pin 2 into the transmission drum groove 05 transmission fork can be installed more easily by tuning on neutral light cooper piece on transmission drum toward cylinder 06 install the mid transmission fork to main shaft 3rd gear 07 install the fork guide pin into the transmission drum groove 08 install the L transmission fork to the countershaft 5th gear 09 install the fork guide pin into the t
11. 2 Fig 5 35 24 remove the chain fensioner assembly 3 Fig 5 35 25 remove rear axle hub 4 Fig 5 35 CHASIS DETAILS CHASIS DETAILS 5 2 2 Inspection 01 02 03 04 05 06 07 08 09 10 11 12 13 inspect wheel refer to part 3 22 measure wheel runout refer to pare 3 23 check wheel hub 1 for any crack or damage replace Fig 5 36 check wheel hub Splines 2 for any wear or damage replace Fig 5 36 check disc hub 1 for any wear or damage replace Fig 5 37 inspect sprocket hub 1 for any crack damage replace Fig 5 38 inspect splines 2 for any wear damage replace Fig 5 38 check rear axles 1 for any scratched or damage replace Fig 5 39 check splines 2 or threads for any wear or damage replace measure rear axle runout a for any damage replace Fig 5 39 service limit 1 5mm 0 06 in inspect rear axle hub 1 for any cracks or bend replace Fig 5 40 inspect bearing 1 for any play in axles hub or turns roughly replace Fig 5 41 inspect oil seats 2 for any wear or damage replace 5 2 3 Rear axle hub bearing and oil seal replacement steps 01 02 clean the outside of the rear axle remove the oil seal 1 by using a flat head screw driver and place a wood block 2 against the outer edge to protect this edge Fig 5 42 03 04 remove the bearing 3 using a
12. 40 Idle speed 125 cc on 1400 100 rpm 150 cc on 1500 50 rpm Throttle grip free play 2 6 mm Air screw opening 125 cc on 1 3 4 150 cc on 1 3 4 1 2 WARNING 1 GASOLINE IS VERY DANGEROUS BE SURE TO KEEP SPARKS AND FLAMES AWAY FROM WORKING AREA AWARENESS 1 Gasoline is poisonous People could be injured SOLUTION 1 1 If people should swamp some gasoline or inhale a lot of gasoline vapor or gasoline in eyes go to doctor immediately 2 If gasoline spills on skin wash with soap and water If gasoline spills on clothing be changed clothes WARNING 2 POTENTIAL HAZARD IMPROPER CARE WHEN REFUELLING AWARENESS 2 Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If fuel tank is overfilled fuel could spill out due to heat from the engine or the sun SOLUTION 2 1 Do not overfill the fuel tank 2 Do not spill fuel especially on the engine or exhaust pipe 3 Wipe up any spilled fuel Be sure to close fuel tank cap 4 Do not refuel right after the engine has been running NOTE PROBLEMS SHOOTING lt Q A gt Lean mixture clogged carburettor fuel jets float level zoo low intake air leak faulty charcoal canister restricted fuel line ENGINE DETAILS lt Q A gt Engine Cranks but do not start no fuel in the tank no fuel in the carburettor cylinder flooded with fuel no spark at plug clogged air cleaner intake air leak improper
13. 6 17 19 wire harnesses routed along the handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions 20 When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Fig 6 18 22 careful not to drop any parts 23 When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Fig 6 19 24 Do not bend or twist the control cables Damaged control cables will not operate smoothly and may stick or bind Fig 6 20 ELECTRIC DETAILS 6 2 IGNITION SYSTEM BRIEFING 01 AC generator 02 C D I 03 Ignition coil 04 plug cap ELECTRIC DETAILS 6 2 IGNITION SYSTEM NOTE SERVICE INFORMATION ITEM STANDARD Spark plug Standard type DR 8EA NGK Hot type DR 7EA NGK Cold type DR 9EA NGK Spark plug gap 0 6 0 7 mm Ignition timing F mark Max aligning angle 15 2 or 1 400 rpm 33 2 3 900 rpm Ignition coil Primary coil 0 2 0 3 Ohm resistance 20 C Secondary with plug cap 7 6 8 6 Coil with plug cap 3 2 4 8 Pulse coil resistance 20c 50 60 Ohm Exciter coil resistance 20c 100 120 Ohm Max voltage at ignition 140 V min 140V Min coil primary side Pulse coil max Voltage 1 5 V 300 rpm min Exciter coil max voltage 300 10 00
14. Service Precautions 1 02 Briefing Service Information 1 03 Cleaning 1 04 Storage PART 2 SPECIFICATION 2 01 General Specification 2 02 Location amp Cable Routing 2 03 Torque Value 2 04 Special Tools OPTION reference PART 3 PERIODIC MAINTENANCE AND ADJUSTMENT 3 01 Caution of periodic maintenance 3 02 Owner s manual and tool kit 3 03 Periodic maintenance table 3 04 Engine oil 4 stroke 3 05 Spark plug inspection 3 06 Air cleaner cleaning 3 07 Idle speed adjustment 3 08 Throttle lever adjustment 3 09 Speed limited adjustment 3 10 Front drum brake inspection 3 11 Rear disc brake fluid inspection 3 12 Front brake lever free play adjustment 3 13 Parking brake adjustment 3 14 Clutch adjustment 3 15 Drive chain slack check and adjustment 3 16 Cable inspection and lubrication 3 17 Upper and lower arm pivot lubrication 3 18 Steering shaft inspection amp lubrication 3 19 Ton in adjustment 3 20 Front shock absorber adjustment P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g P g 9 11 12 13 14 16 19 21 23 23 24 26 28 29 31 31 31 31 31 33 33 35 35 37 37 37 39 39 PI 4 CONTENTS 3 21 Rear shock absorber adjustment option 3 22 Tire inspection 3 23 Tire wear limit 3 24 Wheel removal and installation 3 25 Replacing the headli
15. service limit of true roundness more 0 05mm replace NOTE THE CYLINDRICITY THE DIFFERENCE AMONG THE VALUES MEASURED AT THE 3 LEVELS IN X OR Y DIRECTION IS SUBJECT TO MAX VALUE CALCULATED SERVICE LIMIT OF CYLINDRICITY MORE THAN 0 05MM REPLACE 05 inspect the top of the cylinder for warp Fig 4 66 service limit less than 0 05mm replace 06 measure the connecting rod small end 1 0 Fig 4 67 service limit more than 15 032 replace 07 check the cam follower contact face for ear or electrode position peeling Fig 4 68 08 measure the cam follower shaft 1 0 Fig 4 69 service limit more than 12 05mm replace 09 measure the cam follower shaft O D Fig 4 70 service limit more than 11 95mm replace 10 check the push bar for bending and steel balls for wear or looseness Measure the push bar length service limit less than 141mm replace Fig 4 72 ENGINE DETAILS IN lt EX UP X CENTER DOWN ENGINE DETAILS 4 5 5 Piston installation Fig 4 72 The installation should follow the reverse order of removal 01 install 3rd ring rail onto the piston 02 install oil ring side rail and 2nd ring onto the piston 03 install top ring onto the piston 04 put engine oil on each rings 05 remove the gasket from crankcase surface Be sure to put a towels in crankcase to prevent foreign matters falling into 06 install the piston pis
16. 01 install the slow jet needle jet jet holder and main jet 02 install the air screw referring the number of rotations records as the removal 03 install the float valve float and float pin ENGINE DETAILS 4 1 7 Choke refer to Fig 4 10 4 11 For different requirements the choke position may locate on left handle bard below the start button Fig 4 11 Starting a cold engine requires a richer air fuel mixture 2 on direction 3 to open the choke and 4 to close the choke 4 1 8 Float level inspection Fig 4 08 01 turn the carburettor upside down for float valve touch the float valve seat Then tilt carburettor slowly to check float level with level gauge during float pin touch valve service limit float level 12 5mm 125 or 13mm 150 02 very careful bend the float pin to perform adjustment 03 re check the proper float operation 04 install the float chamber 4 1 8 Carburettor installation Fig 4 05 4 06 01 use slow compressed air through all passages before install 02 tighten the 2 locknuts and air cleaner connector band screw torque 0 8 1 2 kg m 4 1 9 Throttle valve installation Fig 4 1 4 2 4 3 4 4 The procedure reverses the removal steps 01 install the jet needle into the throttle valve and secure with the needle retainer Jet needle notch 4th Notch from top to bottom 02 assemble rubber cover carburettor cap throttle v
17. 12 02mm replace 05 measure the camshaft O D Fig 4 89 service limit less than 11 97 11 98mm replace 06 remove the push rod holder bolt 1 Fig 4 90 07 remove the push rod holder 2 Fig 4 90A 08 check the bearing road for proper operation Fig 4 90B 09 check the bearing push rod and o ring for any damage Fig 4 90B 4 6 6 Camshaft installation Fig 4 91 4 86 The installation should follow the reverse order of removal 01 install the bearing push rod by pressing it in squarely and tighten the bolt Don t forget to install the 2 washers 02 install the cam 1 by aligning the punch mark 2 on the cam with the punch mark on the timing gear 3 03 install the washer camshaft spring and camshaft set plate and tighten the bolt torque 0 8 1 2 kg m 4 6 7 Starter gear installation The installation should follow the reverse order of removal 01 install the generator flywheel by aligning the groove in the flywheel with the key on the crankshaft Do not damage the starter clutch roller during installation 02 hold the flywheel and tighten the flywheel lock bolt torque 4 0 5 2 kg m 4 6 8 L crankcase cover installation The installation should follow the reverse order of removal 01 install the L crankcase cover and tighten the 8 bolts Torque 0 8 1 2 kg m 02 install reduction gear shaft and washers Then install reduction gear shaft by aligning shaft pin with seat groove 03 apply engine oil
18. 2 Fig 4 75 06 remove the reduction gear 1 shaft 2 and washer 3 Fig 4 76 07 inspect the reduction gear for any damage 08 inspect the reduction gear cover o ring 4 for any damage 4 6 2 L crankcase cover removal Fig 4 77 4 78 01 disconnect the neutral light switch wire 02 remove the L crankcase cover bolts 03 remove the L crankcase cover and two dowel pinions 04 clean off all gasket 05 remove the reduction pinion 1 Fig 4 81 4 6 3 Generator removal 01 remove the flywheel lock bolt Fig 4 79 02 remove the flywheel Fig 4 79 4 6 4 Starter clutch removal and inspection 01 remove the bolt 1 on starter gear set 2 Fig 4 80 02 remove the starter gear 03 measure the starter gear I D a Fig 4 82 4 83 service limit more than 22 081mm replace 04 measure the starter gear O D Fig 4 B4 service limit less than 54 135mm replace 05 measure the starter clutch roller O D Fig 4 85 service limit 10 15mm gt e ENGINE DETAILS 4 6 5 Camshaft removal 01 remove the camshaft set plate 1 Fig 4 86 02 remove the spring 1 camshaft 2 washer and cam Fig 4 86A 4 86B 03 inspect the camshaft o ring for wear or damage 04 measure the cam lobe height a Fig 4 87 x service limit less than 32 628mm replace 04 measure the camshaft hole 1 D a Fig 4 88 service limit more than 12 0
19. ARM BOLT 1 5 2 0 ENGINE DETAILS NOTE PROBLEMS SHOOTING lt Q A gt Poor performance at idle speed compression too low incorrect valve clearance too small burned or bend valve incorrect valve timing broken valve spring valve seas not airtight leaking cylinder head gasket warped or cracked cylinder head poorly installed spark plug lt Q A gt Compression to high excessive carbon build up in combustion chamber or on pinion head lt Q A gt White smoke from exhaust muffler worn or damaged valve stem or guide damaged valve stem oil seal Worn piston ring lt Q A gt Abnormal noise Incorrect valve clearance too large Burned valve and rocker arm Worn camshaft or cam follower Worn valve guide 4 4 1 Cylinder head cover removal Fig 4 42 01 remove the 3 bolts attaching on cylinder head cover 02 remove the cylinder head 03 check the cylinder head cover o ring replace it if damage 4 4 2 Rock arm set removal fig 4 42 4 42A 01 remove the 3 bolts 02 remove the rock arm set 03 measure L amp R rocker am clearances a standard 0 05 0 25mm CAUTION TURN THE PISTON ON TOP END BEFORE MOVING THE ROCK ARM SET WHEN REMOVING THE ROCK ARM SET LOOSEN THE CENTER BOLS AND THEN L amp R BOLT 4 4 3 Cylinder head removal Fig 4 43 01 remove the intake and exhaust valve push bars 02 remove the cam follower bolts 1 03 remove cylinder head lock nuts
20. FACING UP AND FLAT RACING DOWN 3 TORQUE VALUE OF CLUTCH CENTER LOCK BOLT 0 8 1 2 Kgm 4 SPECIAL TOOLS UNIVERSAL HOLDER PLIERS NOTE PROBLEMS SHOOTING lt Q A gt Clutch slips during acceleration no free play or worn friction disk or weak spring lt Q A gt Clutch won t operation excessive free play bent clutch plate lt Q A gt Improper shifting improperly adjusted clutch lever free play too large bent gear shift spindle or damaged transmission drum grooves worn or deformed gear shift plate faulty gear shift cam stopper lt Q A gt Clutch won t operate vehicle run slowly excessive free play bent clutch plate lt Q A gt Too much pressure on clutch lever kinked twisted or damaged clutch cable or damaged clutch lifter lt Q A gt Clutch does not operate smoothly improper clutch outer groove lt Q A gt Gear tripping faulty gear shift cam stopper bent gear shift spindle or worn gear teeth ENGINE DETAILS 4 7 1 R crankcase cover removal 01 drain the engine oil out 02 option remove the kick lever 03 disconnect the clutch cable Fig 4 92 04 remove the R crankcase cover bolts 1 Fig 4 92 05 remove the R crankcase cover 06 remove the oil filter rotor 1 Fig 4 93 4 7 2 Clutch removal 01 remove the 4 clutch lifter bolts 1 Fig 4 94 02 remove the clutch lifter Fig 4 55 03 remove the bearing and circlip with a pair of pliers Do not expand it exce
21. FILTER ELEMENT CHECK 1 THE AIR INLET TO THE FILTER CASE FOR ANY OBSTACLE 2 THE AIR CLEANER RUBBER JOINT TO THE CARBURETTOR AND 3 ALL FITTINGS ON AIRTIGHT SEAL 3 TIGHTEN ALL FITTINGS SECURELY TO AVOID THE POSSIBILITY OF UNFILTERED AIR ENTERING THE ENGINE CAUTION NEVER START THE ATV WITHOUT THE AIR FILTER ELEMENT PERIODIC MAINTENANCE PERIODIC MAINTENANCE 3 07 IDLE SPEED ADJUSTMENT Fic 3 13 01 Warm up the engine 02 Turn pilot air screw clockwise until it is lightly seated 03 Loosen pilot air screw by turning it counterclockwise 1 1 2 04 Stop the engine and check the inductive tachometer 05 Start the engine and adjust the throttle stop screw until around 1 500 100 rpm 06 Turn the pilot screw in or out clockwise or counter clockwise to get the highest engine speed 07 Re adjust the idle speed with the throttle stop screw 3 08 THROTTLE LEVER ADJUSTMENT Fic 3 14 Be sure to adjust the engine idling speed before adjusting the throttle lever free play 01 Loosen the locknut 02 Turn the adjusting bolt until the throttle lever free play is 4 6 mm 0 16 0 24 in a 03 Tighter the lockout 3 09 SPEED LIMITED ADJUSTMENT Fic 3 15 The speed limiter keeps the carburettor throttle from becoming full open even when the throttle lever is turned to a maximum Screwing in the adjuster stops the engine speed from increasing 01 Loosen the lockout 02 T
22. PRECAUTIONS 01 Be sure to use the new gaskets o rings ring clamps cotter pins during the re assembly or any service Fig 1 01 02 When tightening bolts screws or nuts should start with large diameter boles to smaller ones Be tighten to the specified torque diagonally Fig 1 02 03 Only use genuine parts and lubricants as Maker s suggestion Fig 1 03 04 On servicing vehicle be sure to use the special or common tools Fig 1 04 05 After disassembly be cleaned all the removed parts Lubricate sliding surfaces with engine oil on engine parts before reassembly Fig 1 05 06 Apply designated greases and lubricants to the specified lubrication points Fig 1 06 07 After reassembly check all parts for proper tightening and operation Fig 1 07 08 Disconnect battery negative terminal before operation Fig 1 08 09 When connecting the battery the positive terminal should be connected first After connection apply grease to battery terminals The terminal caps shall be installed securely Fig 1 09 10 If the fuse is burned out only replace the new fuse with the specified capacity Fig 1 10 11 When using a spanner or other tools make sure not to damage the vehicle s surface 12 After service operation check all connecting points fasteners and lines for proper connection and installation GENERAL INFORMATION 1 2 BRIEFING SER
23. Rear wheel 08 10 1 25 mm 4 5 Kg m Front shield bolt 03 08 1 25 mm 2 6 Kg m Rear shield bolt 03 08 1 25 mm 2 6 Kg m Engine Mounting F engine and frame 01 12 1 25 mm 4 5 Kg m Swing Arm 01 08 1 50 mm 8 5 Kg m Under guard 04 08 1 25 mm 2 3 Kg m Chain supporter 02 08 1 25 mm 1 5 Kg m Tensioner 02 08 1 25 mm 0 9 Kg m Footrest amp 04 08 1 25 5 5 Rear shock absorber upper bolt 01 08 1 25 mm 2 5 Kg m Rear axles hexagon nut IN 02 08 1 50 mm 5 0 Kg m EX 02 08 1 50 mm 19 0 Kg m IN EX 02 08 1 50 mm 24 0 Kg m Sprocket axles 06 08 1 50 mm 2 4 Kg m Rear axles upper and lower 02 08 1 50 mm 5 0 Kg m Disc and brake 04 08 1 25 mm 2 8 Kg m Caliper 02 08 1 25 mm 2 8 Kg m Caliper bracket 02 08 1 25 mm 2 3 Kg m Exhaust pipe holder frame 02 08 1 25 mm 2 3 Kg m Handlebar holder 02 08 1 25 mm 2 0 Kg m SPECIFICATION 2 04 SPECIAL Toots OPTION REFERENCE 01 ignition timing light 02 03 pocket tester 04 05 micrometer 25 50mm 06 07 magnetic stand 08 09 cylinder bore gauge 10 1 impact driver set 12 13 snap ring pliers 14 15 thickness gauge 16 17 bearing installer 18 19 bearing installer 20 21 crankcase installer 22 23 flywheel remover 24 25 bearing remover 26 27 Bond quick gasket NOTE cylinder valve adjuster rpm tester dial gauge 1 100mm micrometer 0 25 mm V block snap ring pliers thickness
24. THE SANE NUMBER OF TURNS SHOULD BE GIVEN TO BOTH TIE RODS 3 LAND R UNTIL SPECIFIED TOE IN IS OBTAINED 4 TIGHTEN THE ROD END LOCKOUTS 2 OF BOTH TIRE RODS TORQUE LOCKNUT 3 0 KG M 3 20 FRONT SHOCK ABSORBER ADJUSTMENT Fic 3 35 01 adjust the spring prelate by turning adjuster increase or decrease 02 the police softer 2 position A standard position B stiffer 3 position C D E WARNING ALWAYS ADJUST BOTH FRONT SHOCK ABSORBER SPRING PROLATE TO THE SAME SETTING UNEVEN ADJUSTMENT CAN CAUSE POOR HANDLING AND LOSS OF STABILITY 3 21 REAR SHOCK ABSORBER ADJUSTMENT Fic 3 37 3 38 Check the rear shock absorbed 1 function for any damage replace NOTE LENGTH OF ABSORBER FREE 380 3MM STROKE 70MM A FIG 3 38 OPTION Adjustable rear absorber with spring prolate OPTION 01 looser the locknut 02 adjust the spring prolate the length of spring install changes 1 5mm 0 06 in per turn of the adjuster 03 turn adjuster clockwise increase the spring prolate turn adjuster counter clockwise decrease the spring prolate Torque locknut 5 5 kg m PERIODIC MAINTENANCE PERIODIC MAINTENANCE 3 22 INSPECTION Fic 3 39 3 40 3 22 1 Tire Deals Be sure to keep the tire pressure Operating this ATV with improper tires or with improper or uneven tire pressure CAUTION USE OF IMPROPER TIRES ON THIS ATV OR OPERATION OF THIS WITH IMPROP
25. and please keep it with the ATV for ready use even when the ATV is resold 1 Owner s manual 2 tool kits NOTE FOLLOWS ITEMS ARE AVAILABLE ON EACH IMPORTER 1 THE REPLACEMENT OWNER S MANUAL AND TOOL KIT 2 THE PARTS LISTS AND SPARE PARTS BE SURE TO USE ONLY GENUINE PARTS FOR REPLACEMENT 3 SERVICE MANUAL IS WRITTEN FOR THE PROFESSIONAL TECHNICIANS PERIODIC MAINTENANCE 3 03 PERIODIC MAINTENANCE Be sure to perform periodic inspections and maintenances as the manual suggestion 1 should be settled by local dealer or service station 2 should be inspect and clean adjust replaced or lubricate when it is necessary 3 clean 4 replace 5 A Adjust 6 L Lubricate PS1 4 Stroke engine oil viscosity SAE 10W 40 a qualified synthetic oil is strongly recommended 4 stroke engine oil is a major factor affecting the engine performance and service life PS2 Air cleaner requires more frequently cleaning or replacement after riding on 1 dusty rain days 2 sand area 3 snow days PS3 Air cleaner tube requires more frequently checking on 1 very wet 2 muddy conditions PS4 Brake fluid replaces every 2 years period PS5 Check battery before riding ATV Re charge battery or replace a new battery if it necessary CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL A QUALIFIED SYNTHETIC 4 STROKE OIL IS STRONGLY RECO
26. check gear shift angles for any wear or damage replace Fig 4 107 04 install the gear shift cam stopper 1 and spring 2 Fig 4 108 05 tighten the 6 mm lock bolt torque 0 8 1 2 kg m 06 install the set pin 1 into the transmission drum hole Fig 4 109 07 install gear shift cam aligning the pin hole in gear shift car with set pin after the gear shift cam is on position put the stopper in the gear shift cam groove and tighter stopper bolt 08 rotate transmission drum to make sure the stopper operation 09 tighten the bolt torque 0 8 1 2 kg m 10 install the gear shift spindle and washer Be sure the return spring aligns with the crankcase tab 11 install the outer clutch and thrust washer Be sure thrust washer chamfered side facing up 12 install the clutch 13 staffer the clutch friction disks and clutch plates and put them on the clutch center 14 install the clutch center together with the well arranged friction disks and plates into the outer clutch 15 install the circlip The circlip chamfered side racing up 16 install the tension spring and clutch lifter 17 install the washer to the bolts and tighten the 4 bolts x torque 0 8 1 2 kg m 18 install the clutch lifter guide pin and oil filter rotor 19 install the washer the make OUTSIDE facing up and lock nut torque 4 0 5 0 kg m 20 install the oil filter rotor cover 21 check the gasket for any wear or damage replace 22 put the 3 oil filter rotor cover
27. collar into front arm and check free play inspect thrust cover 1 and bussing 2 for any wear damage replace Fig 5 90 check ball joint movement for any exits free play replace Fig 5 92 check ball joint movement for any turns roughly replace Fig 5 92 check ball joint surface for any pitting wear damage replace Fig 5 92 CHASIS DETAILS CHASIS DETAILS 5 5 5 Installation reverse the 5 5 1 procedure and follows points as Fig 5 93 01 lubricate bushing 1 inner collar 2 thrust cover 3 use lightweight lithium soap base grease 02 tighten upper front arm nut 4 03 tighten lower front arm nut 5 04 inject grease from the nipples 6 using a grease gun until slight overflow front the thrust cover Fig 5 94 use lightweight lithium soap base grease 05 tighten steering knuckle nuts torque 4 8 kg m 06 tighten knuckle arm bolts torque 3 8 kg m 07 connect tie rod to knuckle arm 08 lubricate front shock absorber bushing 1 Fig 5 95 use lightweight lithium soap base grease 09 tighten front shock absorber nuts 2 torque 4 5 kg m 10 tighten front shock absorber bolts torque 2 6 kg T 11 install front brake assembly 12 install front wheel refer to part 5 1 13 adjust front shock absorber refer to part 5 5 and 3 20 CHASIS DETAILS 5 6 01 03 05 07 09 11 13 15
28. cylinder valve EX ENGINE DETAILS 4 4 HEAD VALVE SERVICE INFORMATION ITEM STANDARD MM SERVICE LIMIT MM 01 Valve clearance cold engine IN 0 05 0 1 EX 0 05 0 1 02 Cylinder compression 10 14 Kg cm2 8 Kg cm2 or less 03 Cylinder head war page 0 05 or less 0 1 or more 04 Rocker arm clearance IN 0 05 0 25 0 4 or more EX 0 05 0 25 0 4 or more 05 Rock arm shaft clearance IN 0 013 0 46 0 126 or more EX 0 13 0 46 0 126 or more 06 Valve seat angle IN 80 90 degree 90 degree or more EX 80 90 degree 90 degree or more 07 valve stem O D IN 5 45 5 465 5 42 or less EX 5 45 5 465 5 42 or less 08 Valve guide I D IN 5 475 5 505 5 505 or more EX 5 475 5 485 5 525 or more 09 Valve stem guide clearance IN 0 01 0 035 0 035 or more EX 0 03 0 055 0 055 or more CAUTION 1 WHEN ASSEMBLING APPLY MOLYBDENUM DISULFIDE OR ENGINE OIL ON THE VALVE GUIDE MOVEABLE PARTS AND VALVE ARM SLIDING FACES FOR LUBRICATION 2 THE VALVE ROCKER ARM SHOULD BE LUBRICATED WITH ENGINE OIL THROUGH THE CYLINDER HEAD OIL PASSAGE CLEAN THE ENGINE OIL PASSAGE BEFORE CYLINDER HEAD ASSEMBLY 3 AFTER DISASSEMBLY CLEAN THE REMOVED PARTS AND CRY THEM WITH COMPRESSED AIR BEFORE CONDUCTING ANY INSPECTION 4 THE TORQUE VALUES 1 CYLINDER HEAD COVER BOLT 0 8 1 2 2 CYLINDER HEAD LOCK NUT 2 3 2 8 3 CAM FOLLOWER BOLT 1 5 2 0 4 ROCKER
29. diagonally 2 04 remove the push bar guide plate 3 05 remove the cylinder head 4 ENGINE DETAILS 4 4 4 Cylinder head disassembly and check Fig 4 44 4 45 01 remove the valve spring cotters by spring compressors 02 remove the retainers springs springs seats washers and valve stem seals 03 remove carbon deposits from the combustion chamber 1 and Nexhaust ports Fig 4 45 04 clean all gasket and cylinder surface 05 check cylinder head for war page for replaced 1 service limit O Imm or more 06 check the free length of the inner and outer springs Fig 4 46 service limit inner spring 33 5mm 1 outer spring 46 9mm 2 07 check valve stem for bending burning or abnormal wear check valve movement and measure each valve stem O D Fig 4 47 service limit IN less than 5 42mm for replace 1 EX less than 5 40mm for replace 2 08 clean any carbon from valve guide and measure the guide 1 0 Fig 4 48 4 49 service limit IN more than 5 505mm for replace EX more than 5 525mm for replace 09 apply engine oil to new o rings and install them into new valve guides Then drive in the new valve guides 10 ream the new valve guides Fig 4 50 11 clean the cylinder head thoroughly to remove any metal particles 12 remove carbon deposits from combustion chamber and valves 13 replace valve if the valve face is rough or worn unevenly 14 check valve seat width if to
30. drain oil 05 Reinstall the drain plug and tighten it 05 Fill 4 stroke engine oil and install the dipstick 07 Re start the engine and warm up for a few minutes While warming up if oil leakage is found stop engine immediately and check cause Be sure no exotic material enters crankcase 08 Check the oil level The oil level should be between the maximum and minimum marks NOTE ENGINE OIL CAPACITY AT CHANGE 1 0L AT DISASSEMBLY 1 1L CAUTION WHEN REPLACING ENGINE OIL IT IS NECESSARY TO CHECK SC CLEAN ENGINE OIL FILTER BE PUT SPRING OF OIL FILTER ON RIGHT POSITION FIG 3 06 E lt gt Maximum N 1 e 4 44 N 9 lt 2 E 4 0 20 50 60 80 100 Fe l 1 1 LI J 20 0 0 9 20 30 40 PERIODIC MAINTENANCE 3 05 SPARK PLUG INSPECTION Fic 3 07 3 08 Standard spark plug DR 8EA D 8EA 0 1 Remove the spark plug 1 Fig 3 07 02 Check the spark plug for wear fouling deposits and cracks 03 Remove the fouling deposits with a wire brush 04 Measure the spark plug gap 0 6 0 7mm 0 024 0 03 in Fig 3 08 Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specification When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten to the specified torque Spark plug gap 0 6 0 7 mm 0 024 0 0
31. frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses Fig 6 08 09 After clamping check each wire to make sure it is secure Fig 6 09 10 Do not squeeze the wire against the weld or its clamp Fig 6 10 LECTRIC DETAILS ELECTRIC DETAILS 11 After clamping check each harness to make sure that it is not interfering with any moving or sliding parts Fig 6 11 12 When fixing the wire harnesses do not make it contact with the parts which generate high heat Fig 6 12 13 Route the wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route the wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Fig 6 13 14 Route the harnesses so they are neither pulled the tight nor have excessive slack Fig 6 14 15 Protect wires and harnesses with electrical tape or tube if they come in contact with a sharp edge or corner Fig 6 15 16 When the rubber protecting covers are used to protect the wire harnesses they shall be installed securely Fig 6 16 17 Do not break the sheath of the wire If a wire or harness has a broken sheath it can be repaired by wrapping it with a protective tape or replacing it 18 After routing check that the wire harnesses are not twisted or kinked Fig
32. general bearing puller Fig 5 43 install the new bearings and oils seal by reversing the previous step It may use a socket 4 matches the outside diameter of the race of the bearing and oil seal Fig 5 44 CAUTION Fig 5 44 DO NOT STRIKE THE CENTER RACE 5 OR BALLS 6 OF THE BEARING CONTACT SHOULD BE MADE ONLY WITH THE OUTER RACE 7 CHASIS DETAILS CHASIS DETAILS 5 2 4 Installation Reverse the 5 1 1 procedure and follows the lubricate as 01 lubricate oil seal lips 02 lubricate bearing use lightweight lithium soap base grease lightly 03 lubricate splines use lightweight lithium soap base grease 04 install rear axles hub On this step the rear axles should not be tighten completely The firm tightening is done after the chain slack adjustment 05 install disc hub to rear axle 06 install rear axle by top the L end axle CAUTION 1 NEVER DIRECTLY TAP THE AXLE END WITH A HAMMER WHICH WILL CAUSES DAMAGE TO THE AXLES THREAD AND SPLINE 2 INSTALL THE WHEEL BOSS AND SUITABLE SOCKET ON THE AXLES END TO PROTECT THE THREAD AND SPLINE FROM DAMAGE 07 install caliper torque 2 8 kg m 08 install sprocket hub 09 install rear axle inner nut 10 install rear axle outer nut 11 drive chain On this step the rear axle nut should not be screwed on 12 install under guard torque 2 3 kg m 13 apply the parking brake 14 install wheel hu
33. less shaft O D 02 Reduction pinion 10 031 10 056 10 096 or more shaft hole I D 03 Reduction gear 9 973 9 984 9 926 or less shaft O D 04 Reduction gear 10 031 10 056 10 096 or more shaft hole I D 05 Roller O D 10 19 10 205 10 15 or less 06 Starter gear I D 22 021 22 042 22 081 or more 07 Starter gear O D 54 175 54 2 54 135 or less CAUTION 1 DO NOT INSTALL THE STARTER CLUTCH BY FORCE 2 INSTALL THE GENERATOR BY ALIGNING THE GROOVE IN THE FLYWHEEL WITH THE KEY ON THE CRANKSHAFT 3 INSTALL THE STARTER MOTOR REDUCTION GEAR SHAFT BY ALIGNING THE SHAFT PIN WITH THE SEAT GROOVE 4 THE TORQUE VALUES OF FLYWHEEL LOCK BOLT 0 8 1 2 KGM 5 THE SPECIAL TOOLS 1 FLYWHEEL HOLDER 2 FLYWHEEL PULLER NOTE PROBLEMS SHOOTING lt Q A gt Poor performance at high speed and starting improperly tightened flywheel lock bolt lt Q A gt Starter clutch slips worn starter clutch roller faulty starter clutch roller or spring worn starter gear shaft O D lt Q A gt Starring noise worn reduction gear worn starter gear worn starter clutch roller faulty reduction pinion shaft bearing ENGINE DETAILS 4 6 1 Starter motor removal 01 remove the 2 starter motor mounting bolts 1 and the motor Fig 4 4 02 inspect the start motor o ring on any damage 03 inspect the start motor pinion on any damage 04 remove the 3 bolts 1 Fig 4 75 05 remove the reduction gear cover
34. limit 3 0mm 05 replace the disc for any wear or damage 06 take out the cotter pin 1 and remove master cylinder Fig 5 53 5 54 07 replace the master cylinder for any wear or damage 5 3 3 Installation brake shoe disc master cylinder Reverse the removal procedure 01 install the brake shoe into caliper 02 install the master cylinder 03 install disc to brake hub torque 2 8 kg m 04 lubricate the rear axles splines lightweight lithium soap base grace O 5 Install under guard torque 2 3 kg m 06 install the caliper new gasket cover 07 install wheel hub 08 install the R wheel 09 adjust the parking brake under apply the rear brake repeatedly by pressing on the rear brake pedal until pedal strokes become constant Be sure that the adjust bolt of adjuster unit is in contact with the pad WARNING AFTER THE ADJUSTMENT OR CHANGE IS PERFORMED BLOCK THE REAR OF ATV OFF THE GROUND AND SPIN THE REAR WHEEL TO MAKE SURE THERE IS NO BRAKE DRAG IF ANY BRAKE DRAG SHOWS UP PERFORM THE ABOVE PROCESS CHASIS DETAILS 5 4 STEELING SYSTEM BRIEFING 01 03 05 07 09 11 blot flange plug taper holder handle lower joint universal bracket tie rod 02 04 06 08 10 holder handle upper steering washer collar washer lock CHASIS DETAILS 5 4 STEELING SYSTEM 5 4 1 Removal 01 remove handlebar cover F
35. new bulb and secure it in place with the bulb holder 04 Reinstall the light cover 3 27 BATTERY CHARGING SYSTEM Fic 3 49 Be sure to keep the battery capacity If not enough capacity please re charge or replace a new battery CAUTION THE BATTERY IS A MF MAINTENANCE FREE TYPE WHICH IS UNNECESSARY TO BE REFILLED DISTILLED WATER DO NOT QUICK CHARGE THE BATTERY ONLY USE A MF BATTERY CHARGER AND BATTERY TEMPERATURE SHOULD NOT EXCEED 45C REMOVE THE BATTERY FROM THE ATV WHEN RE CHARGING PERIODIC MAINTENANCE Erant PERIODIC MAINTENANCE 3 28 Battery REMOVAL Fic 3 49 When recharging or store remove battery from ATV The procedure 01 be sure the ignition main switch is OFF 02 take out the seat 03 disconnect the negative terminal lead from battery 04 disconnect the positive terminal lead from battery 05 take out battery 06 store or re charge battery CAUTION ONLY STORE THE BATTERY ON COOL AND DRY PLACE DO NOT LEAVE OR STORE THE BATTERY IN HOT MORE THAN 30C OR COLD LESS THAN OC AREA 3 29 Fuse 15A Fic 3 49 To replace a fuse 15A be sure to follow 01 be sure the ignition main switch is OFF 02 open fuse holder and take out old fuse 03 install new fuse and close the fuse holder CAUTION BE SURE TO TURN THE IGNITION SWITCH OFF BEFORE CHECKING OR REPLACING THE FUSE TO PREVENT ACCIDENTAL SHORT CIRCUITING ON ELECT
36. on reduction gear cover o ring 04 install the reduction gear cover and tighten the 3 bolts torque 0 8 1 2 kg m 4 6 9 Scarier motor installation The installation should follow the reverse order of removal 01 apply engine oil to the starter motor and o ring 02 install the starter motor 03 tighten the 2 mounting bolts torque 0 8 1 2 kg m ENGINE DETAILS E 7 al A ENGINE DETAILS 4 7 CLUTCH GEAR SHIFT MECHANISM BRIEFING 01 03 05 07 09 11 13 15 outer clutch plate clutch pressure plate clutch circlip plate clutch lifter pin clutch lifter guide spindle gear shift spring shaft drum stop 02 04 06 08 10 washer spline disc clutch friction center clutch spring clutch bearing rod clutch lifter cam gear shift stopper gear shift ENGINE DETAILS 4 7 CLUTCH GEAR SHIFT MECHANISM NOTE SERVICE INFORMATION ITEM STANDARD MM SERVICE LIMIT MM 01 Clutch spring free length 35 5 34 2 or less 02 Reduction friction 2 9 3 0 2 6 or less disk thickness 03 Clutch place bending 0 0 1 0 2 or more 04 Outer clutch I D 111 111 5 112 5 05 Outer clutch guide O D 11 95 11 99 11 91 or less 1 0 5 5 1 5 5 or more CAUTION 1 INSTALL THE CLUTCH PLATES IN THE SAME CHAMFER DIRECTION ONLY 2 INSTALL THE THRUST WASHER WITH THE CHAFER
37. screws torque 0 3 0 4 kg m 4 7 6 R crankcase cover installation The installation should follow the reverse order of removal by installing the dowel pins gasket and install the right crankcase cover and tighten the mounting bolts torque 0 8 1 2 kg r pw ENGINE DETAILS ENGINE DETAILS 4 8 CRANKCASE CRANKSHAFT TRANSMISSION SYSTEM STARTER SPINDLE C l holder clutch wire 03 counter shaft 05 main shaft 06 gear shift fork 07 fork R gear shaft 08 fork center gear shaft 02 R crankcase 09 fork gear shaft 10 drum gear shaft 04 bearing 11 rotor neutral switch 12 crankshaft 13 L crankcase 14 oil filter 15 spring 16 oil filter cap ENGINE DETAILS 4 8 CRANKCASE CRANKSHAFT TRANSMISSION SYSTEM STARTER SPINDLE NOTE SERVICE INFORMATION lt TRANSMISSION FORK gt ITEMS SERVICE LIMIT MM 01 Claw thickness 02 Fork 1 0 03 Fork shaft O D lt TRANSMISSION DRUM gt STANDARD MM 4 93 5 0 12 12 018 11 97 11 984 ESTANDAR MM 4 43 or less 12 058 or more 11 936 or less SERVICE LIMIT MM 12 985 12 965 20 959 20 98 ESTANDAR MM 12 915 or less 20 919 or less SERVICE LIMIT MM 01 Gear 1 0 start ITEMS 01 Left 02 Right lt TRANSMISSION GEAR gt ITEMS M 4th M 5th S start 1st S 2nd S 2nd 02 Main Sha
38. screws Fig 4 18 02 measure the clearance of pump body to outer rotor Fig 4 19 service limit 0 20mm 03 measure the clearance of inner rotor to outer rotor Fig 4 20 service limit 0 02mm 04 Measure the clearance of rotor end to pump body Fig 4 21 service limit 0 15mm 4 2 4 Oil pump reassembly and installation Fig 4 22 The procedure reverses the removal steps 01 install the outer and inner rotors into pump body Fig 4 22 02 put pump shaft by aligning the flat on shaft to inner rotor 03 put the gasket and pump cover 2 Tighten the screw 3 04 install the 2 o rings and tighten the 2 mounting bolts 05 install the oil pump gear and cover 06 tighten the 2 bolts torque 4 0 5 0 kg m 07 install the oil filter rotor 08 install the R crankcase cover CAUTION 1 MAKE SURE TO PUT SOME ENGINE OIL BEFORE INSTALL O RING 2 MAKE SURE THE WASHER WITH THE MARK OUTSIDE FACING UP ENGINE DETAILS ENGINE DETAILS 4 3 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION CAUTION WHEN REMOVING ENGINE A FIRM ENGINE STAND IS REQUIRED TO SUPPORT THE ENGINE BE SURE DO NOT USE HAMMER OR SCREW DRIVER TO STRIKE OR PRY THE ENGINE DO NOT DAMAGE THE CRANKCASE MATTING SURFACES AND CLEAN OFF ALL GASKET MATERIAL FROM THE MATING SURFACES 2 AFTER CRANKCASE ASSEMBLY CHECK TRANSMISSION SYSTEM OPERATION SMOOTHLY AND THEN START ENGINE AND CHECK THE LUBRICATION SYS
39. the boss on the knuckle correctly engages with the locating slot on the brake shoe plate Fig 5 19 05 on Fig 5 20 tighten 1 bolt brake cam lever torque 0 9 kg m 2 nut front wheel hub torque 7 0 kg m 3 nuts front wheel torque 4 5 kg m 06 install the new cotter pin 1 Fig 5 21 CAUTION 1 DO NOT LOOSEN THE WHEEL HUB AFTER TORQUE TIGHTENING 2 IF THE WHEEL HUB NUT GROOVE IS NOT ALIGNED WITH THE COTTER PIN HOLE ALIGN GROOVE WITH THE HOLE BY TIGHTENING UP THE WHEEL HUB NUT 07 adjust front brake cable free play a refer 10 part 3 22 Fig 5 22 HASIS DETAILS LB 4 A y 7 AN L S F 4 A x 4 7 Dm 7 e 2 E ri QT 4 N 7 B t A 7 Ed a Y SS gt I CHASIS DETAILS 5 2 REAR WHEEL AND REAR AXLE BRIEFING 01 axle 02 spacer 03 hub 04 collar sprocket axle 05 sprocket driven 40T 06 chain 07 nut hexagon 08 washer lock 09 collar wheel 10 tire 11 wheel pw CHASIS DETAILS 5 2 REAR WHEEL AND REAR AXLE 5 2 1 Rear wheel removal 0 gt 02 03 04 05 06 07 08 09 10 place the ATV on a level place put the parking brake on 1 Fig 5 23 loosen rear wheel nut 1 Fig 5 24 elevate the rear wheel by p
40. throttle operation lt Q A gt Engine idles roughly stalls or runs poorly excessively used choke ignition malfunction faulty carburettor poor quality fuel lean or rich mixture clogged air cleaner incorrect idle speed faulty charcoal canister lt Q A gt Engine lacks power clogged air cleaner faulty carburettor faulty ignition system lt Q A gt Rich mixture float level too low clogged air jets clogged air cleaner worn throttle needle lt Q A gt Misfiring during acceleration faulty ignition system faulty carburettor faulty accelerating pump faulty charcoal canister lt Q A gt Backfiring carburettor fuel level too low improperly adjusted carburettor faculty exhaust pipe CAUTION 1 BEFORE DISASSEMBLING CARBURETTOR LESSEN THE FLOAT CHAMBER DRAIN SCREW TO DRAIN RESIDUAL GASOLINE OUT 2 THE CARBURETTOR JETS AIR MUST CLEANED WITH COMPRESSED AIR ENGINE DETAILS 4 1 1 Throttle disassembly Fig 4 01 4 02 4 03 4 04 01 remove the carburettor cap 1 Fig 4 01 02 pull out the throttle valve Option disconnect the accelerating pump cable 03 disconnect the choke knob cable 04 disconnect the throttle cable and remove the spring Fig 4 03 05 pry off needle retainer 1 and remove jet needle 2 Fig 4 04 06 check the throttle valve 3 and jet needle for wear or damage NOTE lt OPTION gt FIG 4 12 THE CARBURETTOR WITH ACCELERATING
41. worn main shaft journal bearing or worn crankshaft pin bearing worn transmission system bearing lt Q A gt Transmission gear tripping worn gear teeth or bent transmission fork damaged gear shift cam stopper lt Q A gt Hard shifting clutch improperly adjusted bent or damaged transmission fork or bent gear shift spindle damaged transmission drum grooves 4 8 1 Crankcase removal 01 cylinder head removal refer to pare 4 4 02 cylinder piston removal refer to part 4 5 03 starter motor generator L crankcase refer 10 pare 4 6 04 clutch gear shift mechanism refer to part 4 7 05 remove the 8 L crankcase bolts Fig 4 110 06 use the plastic hammer to sperate L and R crankcase halves be sure do not use the driver pry the crankcase that will damage the mating surfaces Fig 4 222 07 remove the gasket 1 and dowel pins 2 be sure don t lose the gear shift spindle washer Fig 4 222 4 8 2 Transmission system removal and inspection 01 remove the transmission fork shaft and transmission forks 2 Fig 4 113 4 114 02 remove the transmission drum 1 Fig 4 115 03 inspect each transmission fork for bending or damage Fig 4 116 04 measure each transmission fork claw thickness service limit less than 4 43mm replace 05 measure each transmission fork shaft hole 1 D a Fig 4 116 service limit more than 12 058mm replace 06 check the transmission fork shaft for bending or damage 07 measur
42. 0 12 0 20 in at the brake lever pivot If the free play is incorrect adjust as follows Fig 3 19 3 20 3 21 01 Loosen the lockout and fully turn in the adjusting bolt at the front brake lever 02 Make sure the cable joint in the equalizer is straight If not turn the adjusting nuts at the front wheel hubs until the cable joint becomes straight 03 Turn adjusting bolt at the brake lever until specified free play is obtained Specified free play 3 5 mm 0 12 0 20 in a 04 Tighten the lockout WARNING IMPROPERLY SERVICED OR ADJUSTED BRAKES AWARENESS May lose braking ability and could lead to an accident SOLUTION Be sure that the brakes operate smoothly and the free play is correct after serviced Be sure brakes do not restraint 3 13 PARKING BRAKE ADJUSTMENT Fic 3 22 3 13 1 Parking brake adjustment may be required if the parking brake does not function properly 01 Loosen the lockout of the parking brake cable adjuster 02 Turn the adjuster until there is little or no free play 03 Tighten the lockout 3 13 2 Brake lever pedal and cable lubrication Lubricating the pivoting parts of each lever and pedal Recommended lubricant cable lube or SAE 10W30 motor oil WARNING POTENTIAL HAZARD RUNNING IMPROPERLY ADJUSTED BRAKES AWARENESS The brakes could malfunction causing reduced braking performance This could increase the chance of a collision or accident SOLUTION After adjusting the parking brak
43. 0 rpm 400 V max ELECTRIC DETAILS CAUTION 1 THE IGNITION SYSTEM HAS AN ELECTRICAL AUTO ALIGNED IN THE CDI UNIT SO THE IGNITION TIMING IS NOT ADJUSTABLE 2 DO NOT DROP OR IMPACT THE CDI UNIT WITH STRONG FORCE AVOID DAMAGE BE CAREFUL WHEN REMOVING IT 3 LOOSE CONNECTOR IS THE MAIN CAUSE OF FAULTY IGNITION SYSTEM BEFORE OPERATION CHECK EACH CONNECTOR FOR PROPER CONNECTION 4 CHECK THE SPARK PLUG S HEAT RANGE IMPROPER SPARK PLUG WILL CAUSE POOR ENGINE PERFORMANCE OR BURNED ENGINE 5 SPECIAL TOOLS OR TESTING INSTRUMENTS ELECTRIC TESTER TIMING LIGHT AND TACHOMETER NOTE TROUBLESHOOTING lt Q A gt Engine stalls immediately after it starts Weak spark Improper ignition timing Faulty CDI unit lt 0 A gt No spark at plug Faulty ignition switch Poorly connected broken or shorted wire on 1 between pulse coil CDI unit and ignition coil 2 between exciter coil and CDI unit 3 between CDI unit and ignition coil 4 between CDI unit and ignition switch 5 between ignition coil and spark plug lt Q A gt Engine starts but runs poorly Faulty ignition coil Poorly connected wire Faulty spark plug Spark plug cap electricity leakage Faulty A C generator Starter not installed properly Loose Faulty CDI unit ELECTRIC DETAILS 6 2 1 Ignition Coil 01 continuity test Fig 6 21 1 remove the front cover under the fuel tank 2 disconnect the igniti
44. 08 5 1 2 Inspection Fig 5 09 101 check the wheel any cracks bends warpage replace 02 measure the wheel run out replace Fig 5 09 service limit radial 1 2 0 mm 0 08 in lateral 2 2 0 mm 0 08 in WARNING AFTER REPLACING THE TIRE RIDE CONSERVATIVELY TO ALLOW THE TIRE TO BE RSROPERLY SEATED IN THE RIM FAILURE 10 DO SO MAY CAUSE AN ACCIDENT RESULTING IN ATV DAMAGE AND RIDER INJURY 03 inspect the front wheel hub for any crack and damage replace Fig 5 10 CAUTION WHEN TWO PERSONS WORK TOGETHER PAY ATTENTION TO THE MUTUAL WORKING SAFETY ON BOTH SIDE pw CHASIS DETAILS CHASIS DETAILS lt continue 5 1 2 Inspection gt 04 inspect the brake drum inner face to wipe off oil from brake drum with rag sacked in lacquer thinner solvent Fig 5 11 05 inspect the brake drum inner face a to polish brake drum lightly on the scratches place Fig 5 12 06 measure the brake drum inside diameter for any damage replace y service limit more than 111mm 4 37in replace 07 inspect bearing on play on wheel hub or turn roughly replace 08 inspect oil seal on any wear or damage replace 5 1 3 Wheel bearing and oil seal replacement 01 clean the outside of the wheel hub 02 remove the oil seal 1 by using a flat head screw driver 2 and place a wood block against outer edge to protect edge Fig 5 13 03 remove the bearing 3 usi
45. 10 remove the engine from left to right Fig 4 40 4 3 2 Engine Installation Engine installation should follow the reverse order of removal After installation be sure to perform the follows test adjustment 01 throttle operation 02 clutch lever free play adjustment and 03 drive chain adjustment CAUTION WHEN INSTALLING THE ENGINE DO NOT DAMAGE THE BOLT THREAD AND ROUTE THE WIRES AND CABLES PROPERLY WARNING 1 SERVICING AN ENGINE WHILE IT IS RUNNING AWARENESS 1 Hoc surface or moving parts can harm people Electrical components can be damaged SOLUTION 1 Turn off the engine when performing maintenance unless otherwise specified WARNING 2 STARTING OR RUNNING THE ENGINE IN A CLOSED AREA AWARENESS 2 Exhaust smoke is poisonous and may cause loss of consciousness and death within a short time SOLUTIONS 2 Only run ATV in an area with ample atmosphere ENGINE DETAILS 4 4 CYLINDER HEAD VALVE BRIEFING 01 03 05 07 09 11 13 15 17 19 cylinder head spark plug guild push rod screw tapping adjusting retainer valve spring spring valve outer seat valve spring inner insulator carburettor valve IN o ring 10 12 14 16 18 oe ni 02 04 06 08 gasket head cover rocker arm holder nut tapping adjuster cotter spring valve inner seal valve stem seat valve spring outer head
46. 3 in Tightening Torque Spark plug 25 Nm 2 5 m kg 18ft 1b NOTE A PLUG WITH VERY WHITE CENTRE ELECTRODE PORCELAIN COLOUR COULD INDICATE AN INTAKE AIR LEAK OR CARBURET ION PROBLEM PERIODIC MAINTENANCE 3 06 AIR CLEANER CLEANING Fic 3 09 3 10 3 11 3 1 2 NOTE THERE IS A HOLE AT THE BOTTOM OF THE AIR CLEANER CASE ANY DUST OR WATER COLLECTS IN THIS HOLE BE SURE TO EMPTY THE HOLE AND CLEAN THE AIR FILTER ELEMENT AND AIR CLEANER CASE 01 Remove the seat Fig 3 09 02 Remove the air filter cover Fig 3 10 03 Remove the air filter element fig 3 11 04 Wash the element gently but thoroughly in solvent Fig 3 12 WARNING POTENTIAL HAZARD USING LOW FLASH POINT SOLVENTS OR GASOLINE TO CLEAN THE AIR CLEANER ELEMENT AWARENESS Low flash point solvents or gasoline can catch fire or explode SOLUTION Use parts cleaning solvent to clean the air filter element 05 Squeeze the excess solvent out of the filter and let it dry Do not twist the filter element when squeezing it 06 Inspect the element If damaged replace it 07 Apply some motor oil to the element which element should be wet but not dripping 08 Reinstall the element to the element guide 09 Reinstall the element assembly and parts removed for access NOTE 1 CLEAN THE AIR FILTER ELEMENT EVERY 20 40 HOURS RIDING IT SHOULD BE CLEANED AND LUBRICATED MORE OFTEN IF THE ATV IS USING IN EXTREMELY DUSTY AREAS 2 WHEN CLEANING
47. 50 62 x 49 5 mm 170 cc 65 0 mm x 49 5 mm Displacement 124 5 cm3 149 5 cm3 164 5 cm3 Carburettor DTG 017 or PD 19D KEIHIN gt for page 3 22 3 25 Replacing the headlight on BLAST model CAUTION THE ONLY DIFFERENCE ON BLAST BL MODEL IS FRONT LAMP COVER AND FRONT LAMP SET WHERE WITH THE E MARK LAMP REGULATION 01 Remove the front cover as introduction 02 Put new bulb and secure it in place with the bulb holder 03 Reinstall the headlight back lt see the picture attachment procedure gt gt for page 4 4 NOTE Service Information for Fuel System and Carburetion Main Jet 150 102 170 cc en 108 Slow Jet 150 cc en 40 170 cc en 40 for page 4 26 NOTE SERVICE INFORMATION FOR CYLINDER PISTON STANDARD MM SERVICE LIMIT MM lt Cylinder gt 01 Cylinder bore 65 65 1 lt Piston Piston Ring gt 03 Piston O D 170 64 97 64 99 64 8 menos APPENDIX 8 3 UPDATE INFORMATION EEC 92161 The special model for European On Road Homologation will have many different specification than other areas that all details should be refer to the local riding laws and regulations before riding this ATV CAUTION THE ATV FOR OM ROAD USE HAS TO MATCH THE LOCAL RIDING LAWS AND REGULATION ALL DETAILS SHOULD BE PROVIDED BY EACH AREA IMPORTER ONLY Different Portion it will have some difference 01 Speedometer 02 E mark Mirror 03 Integral Bake system one brake f
48. AFTER WASHING APPLY THE BRAKES SEVERAL TIMES AT SLOW SPEEDS TO LET FRICTION DRY OUT THE LININGS WN GENERAL INFORMATION 1 4 STORAGE Before long term storage says 60 days or more be sure to check the ATV for needed repairs and have it corrected 01 Change engine oil and oil filter 02 Drain the fuel from tank and carburettor 03 Clean the spark plug and put about 20 25cc engine oil SAE 10W30 or 20W40 into the cylinder Start engine for a few seconds 04 Spray anti rusty rust inhibiting oil into the inside of fuel tank 05 Clean the drive chain thoroughly and lubricate it 06 Lubricate all control cables 07 Remove the battery Be sure to re charge battery before storage Do not put the battery on hot or cold place 08 Check the tire pressure and block up the frame to raise all wheels off the ground 09 Wash and dry the ATV and wax all painting surfaces 10 Cover a plastic bag over the exhaust pipe 11 Do not apply oil to any rubber parts or the seat cover NOTE MAKE ANY NECESSARY REPAIRS BEFORE STORING THE ATV SPECIFICATION 2 1 GENERAL SPECIFICATION Dimension L W H 1 610 1 35 1 010 mm or 634 40 7 39 7in Seat height 770 mm or 30 3in Wheel base 1 080 mm or 42 5in Min ground clearance 120 mm Min turning radius 3 000 mm Weight 125 50 152 Kg 154 Kg Engine 4 Stroke Air Cooled Cylinder Single Forward Inclined Bore Stroke 125 cc 56 5 x 49 5 mm 150 cc 62 x 49 5 mm Dis
49. AMAGE FROM ESCAPING GAS OR METAL CHIPS 5 6 1 Removal 0 1 place the ATV level place 02 elevate the rear wheel by placing a stand under frame 03 remove the rear wheel 1 Fig 5 97 04 remove the caliper 1 Do not place parking brake lever arse brake pedal when the caliper 1 is take out from disc Fig 5 98 05 remove the under guard 1 Fig 5 99 06 remove the chain assembly 2 and chain guide 3 Fig 5 99 07 remove the rear axle hub 1 with rear axle Fig 5 100 08 remove the tensioner Fig 5 100 09 remove the cotter pin 1 washer 2 shaft 3 Be hold the swing arm 4 during removing the lower shaft Fig 5 101 10 remove the seat 11 remove the shock absorber upper nut 1 Fig 5 102 12 remove the washer 2 Fig 5 102 13 remove the shock absorber upper bolt 3 Fig 5 102 14 remove the shock absorber 4 Fig 5 102 pw CHASIS DETAILS JL OT et p YE RN CHASIS DETAILS 5 6 2 Inspection and remove the swing arm 01 02 03 04 05 06 07 08 09 10 check the swing arm free play under 1 Fig 5 103 1 check the tightening torque of the pivot shaft swing arm securing nut torque 8 5 kg m 2 check the swing arm side play A by moving it from side to side Any noticeable check the inner collar bearing bushing and thrust cover or adjust the shim Fig 5 104 3 check the swing arm vertical move
50. AN BE STARTED AT THIS POSITION AND THE HEADLIGHT AND TAILLIGHT COME ON AT THE SAME TIME 3 OFF ALL ELECTRICAL CIRCUITS ARE SWITCHED OFF THE KEY CAN BE REMOVED IN THIS POSITION 6 5 3 Handlebar switches 1 Fig 6 54 01 check the start button 2 Fig 6 55 02 check the engine stop switch 3 Fig 6 56 03 check the Hi Lo beam switch 4 Fig 6 57 NOTE LO POSITION IS FOR LOW BEAM AND FCAILLIGHT HI POSITION IS FOR HIGH BEAM AND TAILLIGHT CAUTION DO NOT PUSH STARTER BUTTON MORE THAN FOUR SECONDS EACH TIME WHICH WILL CAUSE THE STARTER OVERHEAT AND DAMAGE THE STARTER DURING ENGINE RUNNING DO NOT PRESS STARTER BUTTON TO AVOID STARTER amp ENGINE DAMAGE NOTE OPTION THE STOP LIGHT L amp R SINGLE LIGHT FLASHER ARE THE DEVICES FOR CERTAIN AREA REGULATION DETAILS REFER TO EACH AREA IMPORTER ELECTRIC DETAILS ELECTRIC DETAILS ELECTRICAL SYSTEM RAM 125 150 G n S TR BR vom LI 5 2 it B W B R Ym B W of HE d are qe 6 BR B BLACK 1 FRONT LIGHT L BLUE 2 NEUTRAL LIGHT G GREEN 3 MAIN SWITCH Y YELLOW 4 LEFT HANDLE SWITCH R RED 5 IGN COIL w WHITE 6 SPARK PLUG P PINK 7 STARTER RELAY BR BROWN 8 FUSH L W BLUE WHITE 9 RECT REGU G W GREEN WHITE 10 BATTERY B R BLACK RED 11 STARTER
51. CDI unit wire coupler terminals A Abnormal refer to 7 6 4 Normal refer to 7 6 5 Be Checked related parts A Abnormal 1 Faulty ignition switch 2 Faulty exciter coil 3 Faulty pulse coil A Faulty ignition coil B Normal 1 Broken wire harness 2 Loose coupler connection 7 6 5 Check the CDI unit with a CDI tester A Abnormal 1 Faulty CDI unit B Normal refer to 7 6 5 Check the ignition coil with a CDI tester A Abnormal 1 Faulty ignition coil PROBLEMS SHOOTING 7 7 BRAKE PERFORMANCE POORLY 7 7 1 Drum brake poor Check 1 brake shoe wear out or 2 worn or rusty brake drum or 3 improperly adjusted brake free play or A improper brake cam lever position or 5 improper bake shoe position or 6 fatigue damage return spring or 7 oily or grassy brake shoe or 8 oily or grassy brake drum or 9 brake cable broken 1 brake pad wear out or 2 brake disc bent or wear out or 3 fatigue damage return spring or 4 damage ratchet or 5 oily or grassy brake disc or 6 oily or grassy brake pad or 7 brake horse broken or 8 brake fluid leaking 7 8 ABSORBER MALFUNCTION Check 1 bent or damaged damper rod or 2 damaged oil seal lip or 3 fatigued shock absorber spring PROBLEMS SHOOTING 7 9 INSTABLE HANDLING 7 9 1 check handlebar for any improperly installed or bent 7 9 2 check steering for any 1
52. DETAILS CHASIS DETAILS 5 6 4 installation reverse the 5 6 1 procedure and follows points as Fig 5 110 01 lubricate bearings 1 bushing 2 on inner surface o ring 3 pivot shaft outer surface 4 dust cover lips 5 Fig 5 110 use lightweight lithium soap base grease 02 tighten swing arm pivot shaft nut torque 8 5 kg m 03 check swing arm side play 04 check swing arm vertical movement 05 lubricate shock absorber bushings 1 Fig 5 121 5 122 torque 2 5 kg m 06 install new cotter pin 07 install chain tensioner 08 install rear axle hub with rear axle 09 install chain guide and chain assembly 10 install under guard and caliper 11 install rear wheel 12 adjust drive chain slack refer to pare 3 15 13 adjust rear shock absorber option pw CHASIS DETAILS CHASIS DETAILS 5 7 Drive CHAIN AND SPROCKET 5 7 1 Removal 01 remove the change pedal 02 remove the L crankcase cover 1 Fig 5 113 03 remove the drive sprocket holder 2 Fig 5 114 04 loosen L rear wheel nuts 1 Fig 5 115 05 elevate the rear wheels by placing suitable stand under frame 06 remove the L rear wheel 1 07 remove the under guard 1 Fig 5 116 08 loosen rear ales hub upper nut 1 and then lower hub nut 2 Fig 5 117 09 loosen chain tensioner adjusters 3 Fig 5 117 10 remove clip 1 plate 2 master link 3 and dri
53. ER OR UNEVEN TIRE PRESSURE MAY CAUSE LOSS OF CONTROL AND INCREASE RISK OF ACCIDENT 01 The tires listed below have been approved by maker for this model Other tire combinations are not recommended MANUAFACTURE SIZE TYPE FRONT DURO AT21 7 10 DI2002 CHENG SHIN AT21 7 10 C873N REAR DURO AT21 10 8 012001 CHENG SHIN AT21 10 8 C874N 02 The tires should be set to the recommended pressure SUGGESTION MINIMUM MAXIMUM FRONTAL 30 kPa 27 kPa 33 kPa 0 30 kgf cm2 4 4 psi 0 27 kgf cm2 3 9 psi 0 33 kgf cm2 4 7 psi REAR 25 kPa 22 kPa 28 kPa 0 25 kgf cm2 3 6 psi 0 22 kgf cm2 3 2 psi 0 28 kgf cm2 4 0 psi NOTE CHECK AND ADJUST TIRE PRESSURES WHEN THE TIRES ARE COLD TIRE PRESSURES NUTS BE EQUAL ON BOTH SIDES TIRE PRESSURE ABOVE THE MINIMUM SPECIFIED COULD CAUSE THE TIRE TO DISLODGE FROM ME RIM UNDER SEVERE RIDING CONDITIONS HIGHER PRESSURES MAY CAUSE THE TIRE CO BURSE INFLATE THE TIRES SLOWLY AND CAREFULLY FAST INFLATION COULD CAUSE BURST PERIODIC MAINTENANCE 03 Be sure no more than follows pressures when seating tire Beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi 3 22 2 The low pressure tire gauge Fig 3 35 Keep the low pressure tire gauge with the ATV for ready use all the time Take out dirt or dust the gauge Always make two measurements of tire pressure and take the 2nd reading 01 Set pressure with tires cold 02 Set tire pressures to match the suggested tire pressur
54. G stopper bolt Oil filter screen cap Oil bolt Crankcase assembly bolt L crankcase cover bolt R crankcase cover bolt ACG bolt AGG coil lock bolt Perno del generador A C 05mm screw 06 nim nut SH bolt 06mm flange bolt nut 08mm flange bolt nut 10mm flange bolt nut THREAD DIA 06 1 0 mm 08 1 25 mm 08 1 25 mm 08 1 25 mm 06 1 0 mm 06 1 0 mm 16 1 0 mm 05 0 8 mm 06 1 0 mm 06 1 0 mm 06 1 0 mm 08 1 25 mm 06 0 75 mm 06 1 0 mm 06 1 0 mm 36 1 5 mm 12 1 5 mm 06 1 0 mm 06 1 0 mm 06 1 0 mm 05 0 8 mm 05 0 8 mm 10 1 225 mm 0 45 0 60 1 00 1 40 0 70 1 10 2 00 3 00 3 50 4 50 TORQUE 4 0 5 0 Kg m SPECIFICATION 2 3 3 Chassis Parts Torque Value ITEMS S THREAD DIA TORQUE Steering column holder and frame 02 08 1 25 mm 2 3 Kg m Steering column and handlebar 01 10 1 25 3 0 Kg m F shock absorber upper amp lower 04 10 1 25 mm 4 5 Kg m Front arm upper frame 02 10 1 25 3 0 Kg m Steering Knuckle and upper arm 02 10 1 25 4 8 Kg m Front arm lower frame 02 10 1 25 3 0 Kg m Steering Knuckle and lower arm 02 10 1 25 mm 2 5 Kg m Joint rod L amp R 04 10 1 25 mm 3 8 Kg m Tie rod locknut 04 10 1 25 2 5 Kg m Tire rod end and steering column 04 10 1 25 mm 3 0 Kg m Front hub 02 14 1 50 mm 7 0 Kg m Front wheel 08 10 1 25 mm 4 5 Kg m Rear collar wheel 02 14 1 50 mm 12 0 Kg m
55. MAY CHANGE OR INSTALL EXTRA DEVICE TO MATCH AREA SPECIAL REQUIREMENT SUCH AS WORKING MACHINE OR ON ROAD FOR ANY QUESTIONS REGARDING THE DIFFERENT SPECIFICATION PLEASE CONTACT THE AREA IMPORTER SPECIFICATION 2 2 LOCATION amp CABLE ROUTING 01 02 03 04 05 06 07 08 09 Clutch cable Parking brake cable Front brake cable Throttle switch lead Throttle cable Handlebar switch Voltage regulator lead Main switch Wire harness Ground lead Front brake cable Clutch cable Main switch lead Wire holder Clamp Carburettor overflow hose Flywheel magneto lead Cable guide Rear brake cable Crankcase ventilation hose Spark plug lead Tail brake light lead Rear brake fluid reservoir Master cylinder pw SPECIFICATION SPECIFICATION 2 3 TORQUE VALUE 2 3 1 Standard Torque Value TYPE TORQUE KG M TYPE TORQUE KG M 05mm bolt nut 06mm bolt nut 08mm bolt nut 10mm bolt nut 12mm bolt nut 0 45 0 60 0 80 1 20 1 80 2 00 3 00 4 00 5 00 6 00 2 3 2 Engine Pares Torque Value ITEM Cylinder bolt Cylinder head bolt Cylinder head bolt Cylinder head nut Cylinder head cover bolt Cylinder head oil check bolt Oil filter lock nut Oil Rotor cap nut Oil pump bolt Carburettor lock bolt Exhaust pipe joint lock nut Rock arm lock bolt Valve adjusting lock nut Bearing push bolt SP
56. MMENDED CLEANING ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION PERIODIC INSPECTION ADJUSTMENT AND LUBRICATION WILL KEEP ATV IN THE SAFEST AND BEST OPERATION CONDITION BE SURE TO USE ONLY GENUINE MAKER PARTS FOR REPLACEMENT PERIODIC MAINTENANCE TABLE OF PERIODICAL CHECK amp SERVICE 1000 2000 every 1000 km m every 100 hrs 01 Engine oil 02 engine oil filter 03 Engine idle speed 04 Value clearance 05 Spork plug 06 Air cleaner 07 Air cleaner tube 08 Carburettor amp choke 09 Throttle lever 10 Speed limiter 11 Fuel line 12 Upper A arm 13 Lower A arm 14 Rear brake fluid 15 Steering 16 Brake function 17 Brake shoe 18 Clutch system 19 Suspension 20 Wheel tire 21 Nuts bolts fasteners 22 Drive chain 23 Battery 24 Exhaust 25 Control cable WARNING WITH IMPROPER MODIFICATIONS AWARKNESS Improper installation of accessories or modification of this ATV may change ATV handling condition which could lead to an accident SOLUTION Ol Never modify this ATV through improper installation or use of accessories 02 All parts and accessories added to this ATV should be genuine maker or equivalent components designed for use on this ATV and should be installed and used according to instructions PERIODIC MAINTENANCE 3 04 EPIGONE OIL 4 STROKE ENGINE
57. N FiG 3 30 01 place the vehicle on a level place 02 check the steering column bushings and bearings 03 move the handlebar up and down and or back and forth 04 if excessive play replace the steering column bushings and or bearing 05 check the tie rod ends 06 turn the handlebar to the L and or R until it strips completely than slightly move the handlebar to L to R 07 if tie rod end has any vertical play replace tie rod ends 08 raise the front end of vehicle 09 check ball joints and or wheel bearings 10 move the wheel laterally back and forth 11 if excessive play replace front arm and or wheels bearings 12 use a grease gun to lubricate the pivot points Recommended lubricant Lithium soap base grease PERIODIC MAINTENANCE PERIODIC MAINTENANCE 3 19 ADJUSTMENT FiG 3 32 3 32 3 33 3 34 3 35 01 place the ATV on a level place 02 check the Toe in if out of specification be adjusted NOTE 1 MARK BOTH FRONT TIRE TREAD CENTRES 2 RAISE THE FRONT END OF THE ATV 3 FIX HANDLEBAR STRAIGHT AHEAD 4 MEASURES THE WIDTH A BETWEEN THE MARKS 5 ROTATE THE FRONT TIRE 180 DEGREE THE MARKS 6 MEASURE THE WIDTH BETWEEN THE MARKS 7 CALCULATE THE TOE IN TOE IN B A TOE IN 0 10MM 0 0 39 IN NOTE THE TOE IN ADJUSTMENT STEPS 1 PLACE THE CONFIRMATION MERCIES 1 ON THE BOTH TIE RODS END 2 LOOSEN THE ROD END LOCKOUTS 2 OF BOTH TIE RODS 3
58. OIL ONLY Fic 3 02 3 03 3 04 Maker recommends engine oil viscosity SAE 10W 40 a qualified synthetic oil is strongly recommended Other viscosities shown in Fig 3 05 may be used when the average temperature in your area is within the indicated range NOTE 4 STROKE ENGINE OIL IS A MAJOR FACTOR AFFECTING THE ENGINE PERFORMANCE AND SERVICE LIFE NONE DETERGENT VEGETABLE OR CASTOR BASED RACING OILS ARE NOT RECOMMENDED A QUALIFIED SYNTHETIC OIL IS RECOMMENDED CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL CLEAN ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION 3 04 1 Engine oil measurement 01 Place the ATV upright on a level place 02 Warm up the engine for several minutes and stop it 03 Remove the oil cap dipstick and wipe it off with a clean paper Insert dipstick in filler hole without screwing it in 04 Take dipstick and check the oil level 05 The oil level should be between the maximum and minimum marks If the level is low add oil to the proper level 05 Re start the engine and warm up a few minutes While warming up if oil leakage stop engine immediately and check 07 Check the oil level CAUTION BE SURE NO EXOTIC MATERIAL ENTERS THE CRANKCASE 3 04 2 Engine oil replacement 01 Place the ATV on a level place 02 Warm up the engine for several minutes and stop it 03 Place a container under the engine 04 Remove the oil cap dipstick and drain plug off to
59. ON 1 3 CLEANING Clean ATV regularly to protect the surface finishes and check for the damage wear and oil or brake fluid leakage will enhance ATV overall appearance and general performance 01 Block off the end of the exhaust pipe to preven 1 water entry Next make sure the spark plug and fuel caps are fastened 02 If engine case is greasy apply de greaser with a paint brush Do not apply de greaser to the chain sprockets or wheel axles 03 Use only enough pressure to rinse the dirt CAUTION HIGH PRESSURE WATER OR AIR MAY DAMAGE CERTAIN PARTS SUCH AS WHEEL BEARINGS BRAKES TRANSMISSION SEALS AND ELECTRICAL DEVICES 04 Use the cool water to remove dirt Once the majority of the dirt has been taken off wash all surfaces with warm water and mild detergent type soap 05 Rinse the ATV off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 06 Dry the chain and lubricate it to prevent rust 07 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 08 Automotive wax can be used on all painted and chrome plated surfaces Avoid combination cleaner waxes 09 When finishing start the engine and let it run for several minutes Finally test the brakes WARNING POTENTIAL HAZARD OPERATION WITH WET BRAKES AFTER WASHING AWARENESS WET BRAKES MAY HAVE REDUCED STOPPING ABILITY INCREASING THE CHANCE OF AN ACCIDENT SOLUTION TEST THE BRAKES
60. PUMP 4 1 2 Carburettor removal Fig 4 05 4 06 01 be sure to turn the fuel clock off 02 loosen the drain screw to drain fuel from the float chamber 03 disconnect the fuel inlet tube 04 loosen the air cleaner connector band screw 1 Fig 4 05 05 remove the 2 carburettor lock nuts 2 and remove carburettor Fig 4 05 06 remove the chock cable Fig 4 06 4 1 3 Float float valve inspection Fig 4 7 01 remove the float pin float and float valve Fig 4 7 02 inspect the float valve seat for any wear or damage 03 inspect the float for damage or fuel inside the float 4 1 4 Jets air screw throttle screw removal Fig 4 8 4 9 01 remove the main slow jet 1 and jet holder 2 Fig 4 8 02 remove the air screw 1 and throttle stop screw 2 Fig 4 9 CAUTION 1 BE CAREFUL NOT TO DAMAGE THE JETS AND JET HOLDER DURING THE REMOVAL BEFORE REMOVAL TURN THE THROTTLE STOP AND AIR SCREW CLOCKWISE UNTIL SEAT LIGHTLY AND RECORD NUMBER OF ROTATIONS 2 THE DAMAGED SCREW SEAT DRILL OCCUR IF THE SCREW IS TIGHTENED AGAINST THE SEAT USE SLOW COMPRESSED AIR THROUGH ALL PASSAGES FROM IN OUT DIRECTION NOT OUT IN DIRECTION BEFORE REASSEMBLY 4 1 5 Fuel outlet ball removal and inspection 01 remove the o ring and remove the check valve nut 02 take out the spring and the steel balls 03 inspect the check valve steel balls for any rust and the spring for damage replace 4 1 6 Slow Main jet installation Fig 4 8 4 9
61. RICAL SYSTEM IT A FUSE TAILS FREQUENTLY WHICH MEANS A SHORT CIRCUIT OR AN OVERLOAD IN THE ELECTRICAL SYSTEM BE SURE TO CHECK IT ON ONLY USE THE FUSE SPECIFIED AS 15 3 30 Tank Fic 3 50 3 51 3 52 3 53 3 54 3 54A 3 30 1 Fuel tank arid fuel valve removal 01 lock the fuel cap and fuel clock on OFF Fig 3 50 02 loosen the screw Fig 3 51 03 disconnect the fuel horse Fig 3 52 04 remove the fuel tank Fig 3 54 05 remove the fuel valve 06 disassembly the fuel valve Fig 3 54A 3 30 2 Fuel tank and fuel valve inspection 01 check valve strainer for dirt and clog clean or replace 02 check the o rings for any wear damage replace 03 check the rubber gasket for any wear damage replace 04 check the fuel tank for any wear damage replace 05 check the fuel hose for any wear damage replace 3 30 3 Fuel tanks and fuel valve installation 01 reverse the 3 30 1 procedure 02 check for any fuel leakage 03 check the wire and horse connection y M gt EM ee 3 52 A S 3 D PERIODIC MAINTENANCE 3 31 ENGINE ADJUSTMENT Fic 3 55 3 56 3 57 3 58 3 59 3 60 3 31 1 Valve clearance 01 remove the cylinder head cover Fig 3 55 02 rotate the generator flywheel on camshaft on the top dead centre TDC and align the T mark Fig 3 56 3 57 03 Valve clearance IN 0 05mm 0 05mm Fig 3 58 04 adjust by loosening the lock nut
62. TEM IS WORKING NORMALLY 3 ENGINE OIL CAPACITY 1 1 L AT DISASSEMBLY 1 0 LAT CHANGE 4 THE TORQUE VALUES 1 ENGINE BRACKET BOLT 2 0 2 5 KGM 2 DRIVE GEAR LOCK BOLT 0 8 1 2 3 EXHAUST MUFFLER HANGER LOCK BOLT 2 4 3 0 A EXHAUST PIPE JOINT LOCK NUT 0 8 1 2 4 3 1 Engine removal Be sure to turn off the fuel clock Fig 4 23 01 remove the carburettor Fig 4 24 02 disconnect the clutch cable Fig 4 25 4 26 03 remove the exhaust pipe Fig 4 27 4 28 4 29 4 30 03 remove the spark plug cap Fig 4 31 04 turn the fuel cap off and disconnect the fuel cube 05 disconnect the generator wire connector Fig 4 32 WARNING ATV WITH IMPROPER MODIFICATIONS AWARENESS Improper installation of accessories or modification of this ATV may change ATV handling condition which could lead to an accident SOLUTION 1 Never modify this ATV through improper installation or use of accessories 2 All parts and accessories added to this ATV should be genuine maker or equivalent components designed for use on this ATV and should be installed and used according to instructions ENGINE DETAILS ENGINE DETAILS continue 4 3 1 Engine removal 06 remove the starter motor wire 1 Fig 4 33 07 remove the drive gear and chain Fig 4 34 4 35 08 remove the gear shift lever bolt and gear shift lever Fig 4 36 4 37 09 remove the bolts Fig 4 38 4 39
63. VICE INFORMATION WARNING TO AVOID THE ENGINE RUNNING DURING REPAIR OR SERVICE THE EXHAUST SMOKE CONTAINS POISO NOUS CARBON MONOXIDE GAS WHICH MAY CAUSE SERIOUS INJURY OR DEATH SOLUTION 1 Never run the engine in a close area 2 If need to run the engine be sure the working area is well ventilated and do not allow any flames or spark in working area 1 2 1 Identification numbers Fig 1 11 01 The vehicle identification number VIM marks on the frame 02 Engine number is marked on the engine 1 2 2 Engine details refer to Pare 4 01 Cylinder compression 13 Kg cm2 02 Idle speed 1 500 100 rpm 03 Valve clearance IN 0 05 mm EX 0 05 mm 04 Ignition timing 15 degree 1 500 rpm 05 Engine oil 4 stroke disassembly 1 1L change 1 0 L 1 2 3 Chassis Frame details refer to Part 5 01 Front brake lever free play 10 20mm 02 Rear brake pedal free play 10 20mm 03 Brake fluid DOT 3 or DOT 4 1 2 4 Tire pressure details refer to Part 3 01 Front tire 30 kPa 0 30kgf cm 2 4 4psi 02 Sear tire 25 kPa 0 25kgf cm 2 3 6psi 1 2 5 Lubrication portion refer to Pare 4 amp 5 details The Vehicle Identification Number VIN on Prame as 17 digits RERSMS 0 je 08 Production series 07 9 95 Check Digit 94 vehicle version 03 Vehicle variant 02 Venicle style 91 Country and Manufacture code identifier GENERAL INFORMATI
64. Y R YELLOW RED 12 MAGNETO B Y BLACK YELLOW 13 C D I UNIT B W BLACK WHITE 14 TAIL LIGHT LG R LIGHT GREEN RED PROBLEMS SHOOTING NOTE THE FOLLOWING PROBLEMS SHOOTING DOES NOT COVER ALL THE POSSIBLE CAUSES OF TROUBLE IT SHOULD BE HELPFUL THE GUIDE TO PROBLEMS SHOOTING ON THIS SECTION AND THE OTHERS ON EACH PARTS REFERTO THE RELATIVE PROCEDUREIN THIS MANUAL FORINSPECTION ADJUSTMENT AND REPLACEMENT OF PARTS SUCH AS PART ELECTRIC PART 5 CHASSIS OR PART 4 ENGINE DETAIL ON CASES OF lt Q A gt MAY HELP 7 1 Engine does not start or hard to start 7 2 Poor performance especially at low and idle speed 7 3 Poor performance engine lacks power 7 4 Poor performance at high speed 7 5 Poor charging battery over discharge or overcharge 7 6 Spark plug has no function 7 7 F or R Brake Performance Poorly 7 8 Shock absorber Malfunction 7 9 Instable Handling NOTE STANDARD MOTOR CORP IS CONTINUALLY STRIVING TO IMPROVE BY TAKING MODIFICATION OR SIGNIFICANT CHANGES ON ALL MODELS ALL NECESSARY FURTHER INFORMATION WILL BE AVAILABLE ON EACH AREA IMPORTERS NOTE 1 THE REPLACEMENT OWNER S MANUAL AND TOOL KIT ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 2 THE PARTS LISTS ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 3 BE SURE TO USE ONLY GENUINE MAKER PARTS FOR REPLACEMENT PROBLEMS SHOOTING 7 1 ENGINE DOES NOT START OR HARD TO START 7 1 1 Chec
65. alve spring 03 connect the throttle cable to the valve 04 install the throttle valve into the carburettor Align the groove in the throttle valve with the throttle stop screw 05 tighten the carburettor cap 06 inspect the throttle grip free play and make adjustment throttle grip free play 2 6mm 4 1 10 Fuel tank refer to part 3 30 4 1 11 Air cleaner cleaning refer to part 3 06 ENGINE DETAILS 4 2 LUBRICATION SYSTEM BRIEFING 01 oil filter rotor 02 oil pump 03 primary gear 1ST CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL A QUALIFIED SYNTHETIC A STROKE OIL IS STRONGLY RECOMMENDED CLEANING ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION THE DRAWING OF LUBRICATION SYSTEM FOLLOWS DIRECTION AS ENGINE DETAILS 4 2 LUBRICATION SYSTEM NOTE SERVICE INFORMATION ITEMS STANDARD RAM SERVICE LIMIT MM lt OIL PUMP 01 Inner rotor outer rotor clearance 0 20 mm 02 Outer rotor pump body clearance 0 20 mm 03 Rotor end pump body clearance 0 015 0 1 mm 0 15 mm CAUTION 1 BE VERY CAREFUL ON REMOVING AND INSTALLING THE OIL PUMP 2 BE SURE THAT NO ANY DUST OR FOREIGN MATTERS ENTERS THE ENGINE NOTA TROUBLE SHOOTING lt Q A gt Oil level too low 1 abnormal consumption of oil 2 oil leaks 3 worn or poorly installed piston rings 4 worn valve guide or seal lt Q A gt Engine burns 1 low or no
66. amage replace if necessary 6 4 5 Assembly Fig 6 37 01 remove the brush springs and then install the brushes into the brush holder 02 insert the commutator into the starter motor body Be careful not to damage the mating surfaces of brushes and commutator 03 apply a thin coat of grease to the rear cover bearing and then install the washers and rear cover 04 Install the brush spring and make sure that the brushes can move freely after installation ELECTRIC DETAILS ELECTRIC DETAILS lt continue de 6 4 5 Assembly gt 05 apply a thin coat of grease to the front cover oil seal and bearing 06 install the special washer and the front cover to the motor body and do not damage the oil seal 07 after the front and rear covers are installed the punch marks must aligns each other 08 install and tighten the case bolts Torque 0 8 1 2 kg m 09 after assembly check the starter motor for proper operation 6 4 6 Starter relay inspection Fig 6 41 6 42 01 remove the cover 02 Turn ignition switch ON and then press the starter button 03 The starter relay is normal to hear a clicking sound If there is no clicking sound Fig 6 41 1 Inspect the starter real voltage 2 Inspect the starter relay ground circuit 3 Check for continuity between the starter relay wires Fig 6 42 04 Connect the starter relay wires to a 12V battery Fig 6 42A 05 Connec
67. and turning adjusting bole 05 after adjustment turn the crankshaft several rotations to make sure the valve clearance is correct CAUTION 1 CHECK THE VALVE CLEARANCE WHILE THE ENGINE IS BELOW 35C 2 CHECK THE VALVE CLEARANCE AGAIN AFTER THE LOCK NUT IS LIGHTENED 3 31 2 Ignition timing 15 degree 1 500 rpm 01 remove the ignition timing hole cap on L crankcase Fig 3 57 02 use the ignition timing light to check ignition timing Fig 5 59 03 the correct ignition timing at idle speed mark on F in flywheel CAUTION THE CDI IGNITION TIMING IS NOT ADJUSTABLE IF TIMING IS INCORRECT CHECK THE IGNITION SYSTEM 3 31 3 Cylinder compression Fig 3 60 01 warn up engine few min and then stop engine 02 remove the spark plug and insert the compression gauge 03 open the throttle fully and re start engine 04 measure the compression 1 3kg cm2 Fig 3 60 05 if compression is low be checked 1 leaky valve 2 small valve clearance 3 damaged cylinder head gasket 4 worn piston rings 5 worn cylinder and piston 06 if compression is high be checked 1 carbon deposits have accumulated on combustion chamber 2 carbon deposits have accumulated on the piston head 3 31 4 idle speed adjustment refer to part 3 07 ENGINE DETAILS 4 01 FUEL SYSTEM AND CARBURETION NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt 01 Throttle disassembly 02 Carburetto
68. b 15 install plate washer 16 install wheel hub nut torque 12 kg m 17 install new cotter pin CAUTION 1 DO NOT LOOSEN THE AXLE NUT AFTER TORQUE TIGHTENING 2 IF THE AXLE NUT GROOVE IS NOT ALIGNED WITH THE COTTER PIN HOLE ALIGN GROOVE WITH THE HOLE BY TIGHTENING UP THE AXLE NUT CHASIS DETAILS lt continue 5 2 4 Installation gt Reverse the 5 1 1 procedure and follows the lubricate as 18 tighten rear axle inner nut 1 torque Ist tighten 5 0 kg m final tighten 24 kg m tighten rear axle outer nut 2 torque 19 kg m NOTE REAR AXLES NUT TIGHTEN STEPS RARER 5 2 5 19 install rear wheel 20 install rear wheel nuts under temporary tighten 21 remove the stand and set the ATV on ground securely 22 tighten rear wheel nut torque 4 5 kg m 23 replace the parking brake 24 adjust drive chain slack refer to part 3 25 drive chain slack 30 40mmd l8 1 57 25 tighten rear axle hub upper nut torque 5 0 kg m 26 tighten rear axle hub lower nut torque 5 0 kg m 5 2 5 Rear axles nut tighten steps 01 apply the bone or locking agent on rear axle nuts threads 02 15 tighten the inner rear axles nut on 5 0 kg m 03 2nd tighten the outer rear axles nut while holding the inner rear axle nut on 19 kg m 04 3rd loosen the inner rear axles nut while holding the outer rear axle nut on 24 kg m CHASIS DETAILS 5 3 Rear Disc BRAKE BRIEFING 01 master
69. bsorber 3 Inspection steering knuckle A Inspection front arm 5 Installation 5 06 REAR SHOCK ABSORBER AND SWING ARM 1 Removal R shock 2 Inspection and remove the swing arm 3 Inspection R shock 4 installation 5 07 Drive CHAIN AND SPROCKET 1 Removal 2 Inspection 3 Driven sprocket replacement 4 Installation CHASIS DETAILS 5 1 FROM WHEEL AND FRONT BRAKE BRIEFING 01 lever camshaft 02 plate brake shoe 03 camshaft 04 brake shoe set 05 o ring 06 spacer bearing 07 tire 08 wheel 09 hub 10 collar 11 washer 12 indicator plate 13 seal CHASIS DETAILS 5 1 FRONT WHEEL AND FRONT BRAKE 5 1 1 Removal 01 place the ATV on a level place 02 out parking braked 1 and place a stand under frame Fig 5 01 03 remove the front wheel nuts 1 Fig 5 02 04 remove the cotter pin 1 Fig 5 03 05 remove wheel hub nut 1 and washer 2 Fig 5 04 06 remove wheel hub 3 and collar 4 Fig 5 04 07 remove adjuster 1 and pin 2 Fig 5 05 08 remove spring 3 circlip 4 and brake cable 5 Fig 5 05 09 remove the shoe plate 1 Fig 5 06 10 remove the brake shoe 1 Fig 5 07 11 remove the brake cam lever 1 Fig 5 08 12 remove the wear indicator plate 1 Fig 5 08 13 remove the camshaft 3 Place an aligning mark next to the punched mark on the camshaft lever before remove that it car be reinstalled in the same position Fig 5
70. cylinder 02 brake hose 03 brake pad caliper 04 caliper 05 bracket caliper 06 bracket disc 07 disc 08 brake fluid reservoir 09 hose Co O SS 10 1 9 de 0 21 0 d 2 4 y B lt gt COS 4 22 CHASIS DETAILS 5 3 Rear Disc BRAKE 5 3 1 Brake fluid change refilling 01 remove the brake fluid tank cap 1 be sure to put a towel to prevent the brake fluid dropping Fig 5 45 02 connect with a transparent hose on caliper bleed valve and loosen the lock nut 1 to draw the existing brake fluid out Fig 5 46 03 fill the new brake fluid into tank Be sure no air on hose 1 Fig 5 47 04 use only recommended brake fluid DOT 3 or DOT 4 only Fig 5 48 05 after re fill brake fluid place the brake lever several times and loosen the bleed valve lock nut to bleed air out CAUTION 1 NEVER ALLOW FOREIGN MATERIALS DIRT WATER ENTER THE BRAKE FLUID RESERVOIR 2 BRAKE FLUID CAN DAMAGE ANY PAINTING AND PLASTIC CHASIS DETAILS 5 3 2 Brake shoe lining disc master cylinder inspection 01 remove the brake shoe lining from caliper Fig 5 49 02 inspect the brake shoe lining for any wear or damage replace Fig 5 50 03 be sure to replace the whole set of brake shoe lining 1 Fig 5 51 04 remove the rear disc 05 measure the disc thickness a and run out Fig 5 52 service
71. e 3 23 WEAR LIMIT Fic 3 40 When the tire groove decreases to 3 mm 0 12 in a due to wear be sure to replace the tire PERIODIC MAINTENANCE 3 24 WHEEL REMOVAL AND RE INSTALLATION Fic 3 42 3 42 3 24 1 Removal 01 Elevate the wheel by placing a suitable stand under frame 02 Remove the nuts from the wheel 03 Remove the wheel assembly 3 24 2 Installation When installing the wheels reverse the removal procedure Tighten the wheel nuts to the specified torque Wheel nut torque Front 45 Nm 4 5 Kg m 32 ft lb Rear 45 Nm 4 5 Kg m 32 ft lb 3 25 REPLACING THE HEADLIGHT Fic 3 43 3 44 3 45 3 46 It the headlight bulb burns out be sure to replace the new bulb 01 Remove the front cover 1 Fig 3 44 02 Take out bulb 2 from bulb holder and remove defective bulb 03 Put a new bulb and secure it in place with the bulb holder 34 Reinstall the front cover WARNING POTENTIAL HAZARD THE HEADLIGHT BULB IS HOT WHEN IT IS AND IMEDIATELY AFTER IT IS TURNED OFF AWARENESS People can be burned or a fire could stare if the bulb touches something flammable SOLUTION Wait for the bulb to cool before couching or removing it 3 26 REPLACING THE REAR LIGHT Fic 3 47 3 48 If the rear light bulb burns out be sure co replace the new bulb 01 Remove the rear light cover 1 Fig 3 47 02 Take out bulb 2 from bulb holder and remove defective bulb 03 Put a
72. e lift the rear part of ATV off the ground and spin the rear wheels Check to make sure there is no brake drag If brake drag is noticed perform the adjustment again PERIODIC MAINTENANCE PERIODIC MAINTENANCE 3 14 CLUTCH ADJUSTMENT AND LUBRICATION Fic 3 22 3 24 3 14 1 The clutch cable free play should be 5 8 mm 0 20 0 31in a If the free play is incorrect adjust as follows 01 Loosen the lockout 02 Turn the adjuster clockwise or counter clockwise until proper free play is attained clockwise free play is increased counter clockwise free play is decreased 03 Tighten the lockout 3 14 2 Clutch lever lubrication Lubrication the pivoting parts of clutch lever Recommended lubricant cable lube or SAE 10W30 motor oil 3 15 DRIVE CHAIN SLACK CHECK amp ADJUSTMENT Fic 2 25 3 26 3 27 3 15 1 Inspect the drive chain while all tires are touching the ground Check the slack at the position shown in the Fig 3 25 The normal vertical deflection is approximately 30 40 mm 1 2 1 6in If the deflection exceeds 40 mm I 6 in a adjust the chain slack 3 15 2 Drive chain slack adjustment 01 Loosen the rear wheel hub bolts 1 2 Fig 3 26 02 Loosen the adjuster lockouts on each side To lighter the chain turn the chain adjuster clockwise To loosen chain turn adjuster counterclockwise and push the wheel forward 03 Turn each adjuster exactly the same amount to ma
73. e each transmission fork shaft O D a Fig 4 117 service limit less than 11 936mm replace 08 check the transmission drum for scratches or poor lubrication 09 check the transmission drum groove for damage 10 check the bearing for excessive free play 11 measure the transmission drum O D Fig 4 117 service limit L less than 19 926mm a replace less than 20 919mm b replace 12 check the transmission drum and fork shaft holes in the L and R crankcase halves for wear or damage ENGINE DETAILS 4 8 3 Transmission gears crankshaft removal 01 remove the transmission main shaft and counter shaft from L crankcase when removing gears must remove as a set base Fig 4 119 02 remove crankshaft and disassemble main shaft amp counter shaft 4 8 4 Gear shaft collar inspection 01 check each gear and teeth for any wear and damage replace 02 measure each gear I D Fig 4 120 4 121 service limit main 5th more than 20 61mm replace counter 3rd more than 16 574mm replace counter 2nd more than 22 081mm replace 03 measure each shaft collar I D Fig 4 120 4 121 countershaft starter idle gear more 16 85mm replace countershaft 1st gear more 19 00mm replace 04 measure each shaft collar O D Fig 4 122 countershaft starter idle gear less 19 55mm replace countershaft 1st gear less 19 55mm rep ace 05 ch
74. e lock nut 1 Fig 6 34 02 remove the two starter motor mounting bolts 1 and the motor Fig 6 35 CAUTION BEFORE SERVICING THE STARTER MOTOR TURN OFF THE IGNITION SWITCH AND DISCONNECT THE BATTERY GROUND THEN TURN ON IGNITION SWITCH TU SEE IF THE STARTER MOTOR CAN OPERATE TO ENSURE WORK SAFETY 6 4 2 Disassembly and inspection Fig 6 36 6 37 6 38 01 remove the two starter motor case bolts 1 and remove the front and rear covers commutator housing and other parts Fig 6 36 6 37 02 inspect the removed parts 03 inspect the commutator for any wear damage or discoloration and other visual faults replace if necessary 04 Clean off any metal powder from the commutator segments 05 Check for continuity between pairs of commutator segments There should be continuity Fig 6 38 06 a continuity check between individual commutator segment and armature shaft There should be no continuity 6 4 3 Starter motor housing continuity check Fig 6 39 01 Check and make sure that there is no continuity between the wire terminal and the brushes replace if necessary 6 4 4 Brush inspection Fig 6 40 01 measure the length of each brush Service Limit 8 5mm replace if below 02 check for continuity between the brushes replace if there is continuity 03 check front cover bearing and oil seal for wear looseness or damage replace if necessary 04 check the rear cover bearing for wear looseness or d
75. eck the main shaft and countershaft for any wear and damage 06 measure main shaft and countershaft O D Fig 4 123 4 124 Main shaft starter less than 19 919mm rep ace 5th less than 19 919mm replace Countershaft starter less than 16 05mm replace 15 less than l6 4l mm replace 2nd less than 21 919mm replace 3rd less than 19 919mm replace ENGINE DETAILS 4 8 5 lt OPTION gt Starter spindle removal and inspection this section is only for engine with kick OPTION 01 disassemble the starter spindle 02 check starter ratchet and pinion for any wear or damage 03 check starter spindle return spring any deformation damage 04 measure the starter ratchet 1 0 OPTION service limit more than 20 35mm replace 05 check the starter spindle for any wear or damage 06 measure the starter spindle O D OPTION service limit A less than 15 95mm replace B less than 19 95mm replace C less than 12 85mm replace 4 8 6 Bearing inspection and replacement 01 check the main shaft and countershaft bearings for smooth tuning Fig 4 125 02 replace the bearings with new ones if bearing do not turn smoothly quietly or if they fit loosely in the case 03 if the countershaft needle bearing in the L crankcase is nosy or has excessive free play be sure to change it 04 remove the main shaft and countershaft bearings 1 from L amp R crankcase halves
76. ength and rod end angle under 1 loosen the locknuts 1 Fig 5 72 2 adjust the tie rod length by turning both tie rod ends tie rod length 321mm 12 6 in 3 set rod end 2 on knuckle arm side in an angle where the indentation surface 3 of the tie rod is parallel to the rod end shaft 4 and then tighten the locknut Fig 5 73 torque 3 0 kg m 4 set other rod end 5 on steering column side in an angle as shown in A and B position and tighten locknut The threads C on both rod ends must be of same length rod end angle 164 166 degree torque 3 0 kg m 5 after adjustment on both tie rods mark R 8 L on A Rtie rod L tie rod C to knuckle arm D to steering column 09 inspect busing 1 o ring 2 for any wear damage replace Fig 5 74 CHASIS DETAILS CHASIS DETAILS 5 4 3 Installation reverse the 5 4 1 procedure and follows the points as 01 lubricate steering column bushings 02 lubricate steering column bearings and lip oil seals use lightweight lithium soap base grease 03 install lower bearing 1 Fig 5 75 04 install oil seals 2 collars 3 upper bearing 4 Be sure co do not damage the oil seals during installation 05 install cable holder and new washer 06 install steering column holder bolt torque 2 3 kg m 07 bend the lock washer tab along the bolt flats 08 tighte
77. ft L crank Start 4th 5th 03 Counter R crank Shaft O D L crank 1st gear 2nd gear 3rd gear lt CRANKSHAFT gt ITEMS 20 02 20 041 20 20 021 20 02 20 041 20 01 20 041 19 52 19 541 20 02 20 041 16 516 16 534 14 978 14 989 15 959 19 98 15 959 19 98 14 966 14 989 21 959 21 98 16 466 16 484 21 959 21 98 19 959 19 98 ESTANDAR MM 20 081 or more 20 061 or more 20 081 or more 20 081 or more 19 581 or more 20 081 or more 16 574 or more 14 938 or less 19 919 or less 19 919 or less 14 938 or less 19 919 or less 16 416 or less 21 919 or less 19 919 or less SERVICE LIMIT MM 01 Connecting rod big end clea rance 02 Connection rod big end radial CAUTION 0 1 0 25 0 0 008 0 03 0 8 0 005 0 1 1 DURING DISASSEMBLY CRANKCASE DO SEPARATE THE CRANKCASE HALVES WITH AN IRON HAMMER 2 AFTER SEPARATION BE CAREFUL NOT TO DAMAGE THE RIGHT AND LEFT CRANKCASE MATING SURFACES TO AVOID OIL LEAKAGE 3 BE SURE TO REPLACE NE GASKET DURING REASSEMBLY 4 AFTER TRANSMISSION SYSTEM DISASSEMBLY MAKE SURE THAT THE GEAR SHIFTING OPERATION IS NORMAL BEFORE REASSEMBLY 5 APPLY ENGINE OIL TO THE TRANSMISSION SYSTEM AND CRANKSHAFT 6 SPECIAL TOOLS 1 BEARING REMOVER 2 BEARING REMOVER BLOCK 3 UNIVERSAL BEARING PULLER ENGINE DETAILS NOTE PROBLEMS SHOOTING lt Q A gt Excessive engine noise
78. fuel passage B Engine speed increases refer to 7 3 2 7 3 2 Check ignition timing with a timing light A Incorrect 1 Faulty CDI unit 2 Faulty pulse coil B Correct refer to 7 3 3 PROBLEMS SHOOTING 7 3 3 Check valve clearance A Incorrect 1 Incorrectly adjusted valve clearance 2 Excessively worn valve seat Protruded valve stem 3 Correct refer to 7 3 4 7 3 4 Test cylinder compression A Too low 1 Faulty valve seat 2 Worn cylinder and piston 3 Leaking cylinder head gasket A Incorrect valve timing B Normal refer to 7 3 5 7 3 5 Checking carburettor for clogging A Clogged 1 Clean and unclog B Not clogged refer to 7 3 6 7 3 6 Remove the spark plug for check A Fouled or discolored 1 Fouled spark plug 2 Incorrect valve timing B Not fouled or discolored refer to 7 3 7 7 3 7 Check crankcase for excessive or dirty engine oil A Excessive oil 1 Oil level too high 2 Oil level too low 3 Oil not changed B Normal oil level refer to 7 3 8 PROBLEMS SHOOTING 7 3 8 Check cylinder head for oil lubrication A Abnormal 1 Clogged oil cooler 2 Clogged oil line 3 Faulty oil pump B Normal refer to 7 3 9 7 3 9 Check for engine overheating A Overheating 1 Worn cylinder and piston 2 Mixture too lean 3 Poor quality fuel 4 Excessive carbon build up in combustion chamber 5 Ignition timing too advanced
79. gauge bearing installer piston pin puller bearing installer bearing remover bearing remover attachment 5 mm 1 THE REPLACEMENT OWNER S MANUAL AND TOOL KIT ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 2 THE PARTS LISTS ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 3 BE SURE TO USE ONLY GENUINE MAKER PARTS FOR REPLACEMENT 20 2 19 N Sy 17 18 PECIFICATION SS 1 DIT c 524 2 PERIODIC MAINTENANCE PART 3 PERIODIC MAINTENANCE U 0 0 0 0 0 0 5 3 01 PERIODIC INSPECTION ADJUSTMENT AND LUBRICATION WILL KEEP ATV in the safest and best operation condition Be sure to use only genuine maker parts for replacement WARNING 1 SERVICING AN ENGINE WHILE IT IS RUNNING AWARENESS 1 Hot surface or moving parts can harm people Electrical components can be damaged SOLUTION 1 Turn off the engine when performing maintenance unless otherwise specified WARNING 2 STARTING OR RUNNING THE ENGINE IN A CLOSED AREA AWARENESS 2 Exhaust smoke is poisonous and may cause loss of consciousness and death within a short time SOLUTIONS 2 Only run ATV in an area with ample atmosphere 3 02 OWNER S MANUAL AND TOOL KIT Fic 3 02 Be sure to keep the owner s manual and tool kit which include low pressure tire gauge all the time with ATV The owner s manual and tool kit are part of the ATV
80. ght 3 26 Replacing the rear light 3 27 Battery charging system 3 28 Battery removal 3 29 Fuse 3 30 Fuel tank 3 31 Engine Adjustment PART 4 ENGINE DETAILS 4 01 Fuel System and Carburetion 4 02 Lubrication System 4 03 Engine Removal Installation 4 04 Cylinder Head Valve 4 05 Cylinder Piston 4 06 Starter Generator L Crankcase Start Clutch Camshaft 4 07 Clutch Gear Shift Mechanism 4 08 Crankcase Crankshaft Transmission Starter Spindle PART 5 CHASSIS DETAILS 5 01 Front Wheel Front Brake 5 02 Rear Wheel Rear Axle 5 03 Rear Brake 5 04 Steeling System 5 05 Front Shock Absorber and Front Arm 5 06 Rear Shock Absorber and Swing Arm 5 07 Drive Chain and Sprocket 39 41 42 43 43 43 43 45 45 45 47 52 57 61 65 73 31 87 93 104 111 119 123 130 136 143 CONTENTS PART 6 ELECTRIC DETAILS 6 01 Service Precautions Electric Devices 6 02 Ignition System 6 03 Charging System 6 04 Starting System 6 05 Lights Instruments Switches PART 7 TROUBLE SHOOTING 7 01 Engine does not start or hard to start 7 02 Poor performance especially at low and idle speed 7 03 Poor performance engine lacks power 7 04 Poor performance at high speed 7 05 Poor charging batter
81. ier Faulty A C generator ELECTRIC DETAILS 6 3 1 Battery Removal Fig 6 29 01 remove the seat 02 disconnect the negative cable first then the positive cable 03 remove the battery 1 CAUTION WHEN DISCONNECTING THE POSITIVE CABLE THE TOOL SHOULD NOT TOUCH THE FRAME OTHERWISE IT WILL CAUSE FLAMES TO IGNITE GASOLINE AND DAMAGE THE BATTERY 6 3 2 Installation 01 the installation sequence is the reverse of 6 2 1 02 connect the positive cable first and then the negative cable 6 3 3 Charging inspection open circuit voltage 01 remove the seat 02 disconnect the battery terminal cables 03 measure the voltage between battery charged the terminals Full Charge 13 1V on a voltmeter Undercharged 12 3V on a voltmeter Fig 6 29A 6 3 4 Charging 01 connect the charger positive cable to the battery positive terminal 02 connect the charger negative cable to the battery negative terminal CAUTION KEEP FLAMES AND SPARKS AWAY FROM A CHARGING BATTERY TURN THE POWER ON OFF AT THE CHARGER AT THE BATTERY TERMINALS 10 PREVENT SPARKS NEAR THE BATTERY CELLS CAUSING EXPLOSION CHARGE THE BATTERY ACCORDING TO THE INSTRUCTIONS ON THE BATTERY SURFACE QUICK CHARGING SHOULD ONLY BE DONE IN AN EMERGENCY MEASURE THE VOLTAGE 30 MINUTES AFTER THE BATTERY IS CHARGED Charging current Standard 0 7A Quick 3 Charging Time Standard 5 10 hrs Quick 1 0 hour After Chargi
82. ig 5 55 02 disconnect fuel breather hose 03 remove the L and R lever holder Fig 5 56 5 57 04 remove the front cover 1 Fig 5 58 05 disconnect main switch 1 neutral 2 front lamp leads 3 CHASIS DETAILS lt continue 5 4 1 Removal gt 06 remove the stay 1 Fig 5 61 07 remove the handlebar holders 2 Fig 5 61 08 remove the handler 3 Fig 5 61 09 remove cotter pins 1 nuts 2 and tie rods 3 Fig 5 62 10 remove cotter pins 1 nut steering column 2 and washer 3 Fig 5 63 11 straighten lock washer tabs 1 Fig 5 64 12 remove bolts 2 lock washer 3 cable holder 4 Fig 5 64 13 remove bearing 1 oil seals 2 collars 3 Fig 5 65 14 remove steering column 1 Fig 5 66 CHASIS DETAILS CHASIS DETAILS 5 4 2 Inspection 01 handlebar for any cracks bends damage replace Fig 5 67 02 steering column for any bends damage replace Fig 5 68 WARNING DO NOT ATTEMPT TO STRAIGHTEN A BENT SHAFT WHICH MAY DANGEROUSLY WEAKEN THE SHAFT 03 inspect bearing 1 and oil seals 2 for any wear damage replace Fig 5 69 04 inspect tie rod for any bend damage replace Fig 5 70 05 check tie rod end movement any free play replace Fig 5 71 06 check tie rod end movement any turns roughly replace 07 tapered surface on tie rod end for any pitting wear damage replace Fig 5 71 08 adjust L amp R tie rod l
83. intain correct axle alignment There are marks on each side of the swing arm and on each chain adjuster Use them to check for proper alignment 04 After adjusting alignment be sure to tighten the lockouts and the wheel hub bolts NOTE UPPER WHEEL HUB BOLT 50 NM 5 0 KG M 36 FT LB LOWER WHEEL HUB BOLT 50 NM 5 0 KG M 36 FT LB 3 15 3 Drive chain cleaning and lubrication Use only Kerosene to clean the drive chain Wipe it dry and thoroughly lubricate it with SAE 30 50 motor oil Do not use any other lubricants on the drive chain Recommended lubricant SAE 30 50 motor oil PERIODIC MAINTENANCE PERIODIC MAINTENANCE 3 16 CABLE INSPECTION AND LUBRICATION FiG 3 28 WARNING POTENTIAL HAZARD DAMAGED CONTROL CABLES AWARENESS Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restricted which could cause an accident or injury SOLUTION Inspect cables frequently Replace damaged cables Lubricate the inner cables and the cable ends If the cables do not operate smoothly be sure to replace new Recommended lubricant chain amp cable lube or SAE 10W30 motor oil 3 17 UPPER ARM AND LOWER ARM PIVOT LUBRICATION FiG 3 29A 3 29B Lubricate the upper arm pivot and the lower arm pivot Recommended lubricant Lithium soap base grease 3 18 STEERING SHAFT INSPECTION LUBRICATIO
84. ively open 3 Clogged air cleaner B Dry spark plug 7 2 Poor PERFORMANCE ESPECIALLY AT LOW AND IDLE SPEED 7 2 1 Check ignition timing A Incorrect 1 Faulty GDI unit 2 Faulty pulse coil B Correct refer to 7 2 2 7 2 2 Check carburettor air screw adjustment A Incorrectly adjusted 1 Mixture too lean Turn screw in 2 Mixture too rich Turn screw out B Correctly adjusted refer to 7 2 3 7 2 3 Check carburettor gasket for air leaks A Air leaks 1 Faulty intake manifold gasket 2 Loose carburettor lock nut 3 Broken heat insulator 4 Cracked vacuum tube B No air leaks refer to 7 2 4 PROBLEMS SHOOTING 7 2 4 Remove the spark plug and install it into spark plug cap to test spark by connecting it to the engine ground A Weak or intermittent spark 1 Faulty or fouled spark plug 2 Faulty CDI unit 3 Faulty A C generator A Faulty ignition coil 5 Faulty ignition switch B Good Spark refer to 7 2 5 7 2 5 Check A C generator A Faulty 1 Faulty A C generator 2 Damaged or cracked vacuum tube 3 Clogged air vent hole B Good 7 3 Poor PERFORMANCE ENGINE LACKS POWER 7 3 1 Start the engine and accelerate lightly A Engine speed does not increase sufficiently 1 Clogged air cleaner 2 Restricted fuel flow 3 Clogged fuel tank cap breather hole 4 Clogged exhaust muffler 5 Carburettor fuel level too low 6 Clogged carburettor high speed
85. k if fuel reaches carburettor by loosening drain screw A Fuel does not reach carburettor 1 No fuel in tank 2 Clogged fuel line between fuel tank and carburettor 3 Clogged float chamber passage 4 Clogged fuel filter 5 Clogged charcoal canister 6 Clogged fuel valve strainer 7 Clogged fuel valve passage 8 Clogged carburettor air balance tube 9 Deteriorated fuel or fuel containing water of foreign material B Fuel does reach carburettor refer 7 1 2 7 1 2 Remove the spark plug and install it into spark plug cap to test spark by connecting it to the engine ground A Weak or no spark 1 Faulty spark plug 2 Fouled spark plug 3 Faulty GDI unit 4 Faulty pulse coil 5 Faulty exciter coil 6 Faulty ignition switch 7 Broken or shorted ignition coil B Good spark refer to 7 1 3 7 1 3 Test cylinder compression A Low or no compression 1 Faulty or slipping clutch 2 Valve clearance too small 3 Leaking valve 4 Worn cylinder and piston rings 5 Leaking cylinder head gasket B Normal compression refer to 7 1 4 PROBLEMS SHOOTING 7 1 4 Start engine again A Engine fires but does not start 1 Faulty choke control system 2 Leaking intake manifold 3 Incorrect ignition timing or incorrectly adjusted air screw B Engine does not fire refer to 7 2 5 7 1 5 Remove the spark plug and test it again A Wet spark plug 1 Flooded carburettor 2 Throttle valve excess
86. lacing a stand under frame Fig 5 24 remove rear wheels 2 Fig 5 24 remove cotter pin 1 wheel hub nut 2 Fig 5 25 remove plate washer 3 wheel hub 4 Fig 5 25 loosen rear axle outer nut 1 Fig 5 26 loosen rear axle inner nut 2 Fig 5 26 Tighten rear axle inner nut 1 of 1 8 clockwise turn 2 Fig 5 27 CHASIS DETAILS lt continue 5 2 1 Rear wheel removal gt 11 remove under guard 1 Fig 5 28 12 loosen rear axle hub upper nut 2 Fig 5 28 13 loosen rear axle hub lower nut 3 Fig 5 28 14 loosen chain tensioner adjuster 4 Fig 5 28 15 remove chain assembly 1 Fig 5 29 16 remove rear axle outer nut 1 Fi9 5 30 17 remove rear axle inner nut 2 Fig 5 30 18 remove the drive sprocket hub 3 Fig 5 30 19 release the parking brake Fig 5 31 20 remove brake caliper 1 be sure do not depress parking brake lever or brake pedal when the caliper if out the disc Fig 5 31 21 remove the rear axle Fig 5 32 Fig 5 32a Fig 5 32b CAUTION 1 NEVER DIRECTLY TAP THE AXLE END WITH A HAMMER WHICH WILL CAUSES DAMAGE TO THE AXLES THREAD 1 AND SPLINE 2 FIG 5 33 2 INSTALL THE WHEEL BOSS 3 AND SUITABLE SOCKET 4 ON THE AXLES END TO PROTECT THE THREAD AND SPLINE FROM DAMAGE FIG 5 33 21 take out wire clips and disc hub be sure do not damage disc hub during removal Fig 5 34 22 remove the rear axle hub upper bolt 1 Fig 5 35 23 remove the rear axle hub lower bolt
87. lubrication pressure 2 clogged oil passage 3 not using specified engine oil CAUTION BESURETO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL A QUALIFIED SYNTHETIC 4 STROKE OIL IS STRONGLY RECOMMENDED CLEANING ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION 4 STROKE ENGINE OIL VISCOSITY SAB 10W 40 A QUALIFIED SYNTHETIC OIL IS STRONGLY RECOMMENDED 4 STROKE ENGINE OIL IS A MAJOR FACTOR AFFECTING THE ENGINE PERFORMANCE AND SERVICE LIFE PERIODIC INSPECTION ADJUSTMENT AND LUBRICATION WILL KEEP ATV IN THE SAFEST AND BEST OPERATION CONDITION BE SURE TO USE ONLY GENUINE MAKER PARTS FOR REPLACEMENT ENGINE DETAILS 4 2 1 Engine oil 4 stroke engine oil only refer to part 3 04 4 2 2 Oil Pump Oil Filter Rotor Removal Fig 4 13 option remove the kick lever if this engine has kick 01 disconnect the clutch cable 02 remove the right crankcase cover bolts and crankcase cover 03 check any oil leaks or damage from the cover gasket oil seal and o ring replace the new one if necessary 04 remove the 3 screws on oil filter rotor cover Fig 4 14 05 remove the washer and oil filter rotor Fig 4 15 06 remove the 2 oil pump mounting bolts and oil pump body Fig 4 16 07 remove the 2 o rings Fig 4 17 08 check any deformation or damage on o ring if so replace it CAUTION SURE TO USE THE NEW GASKET WHEN RE ASSEMBLY 4 2 3 Oil pump disassembly and inspection 01 remove the 2
88. ly Starter relay inspection Starter motor installation Q 6 05 LiGHTS IINSTRUMENTS SWITCHES NOTE SERVICE INFORMATION NOTE TROUBLE SHOOTING lt Q A gt 1 Light switch wire inspection 2 Main switch inspection 3 Handlebar switches ELECTRIC DETAILS GENERAL ELECTRIC SYSTEM BRIEFING 01 neutral light 02 wire harness 03 fuse 15 250V 04 battery YUASA YTX7A BS 05 earth cable 06 ignition coil 07 plug cap 08 rectifier amp regulator 09 main switch 10 C D I 11 starter relay ELECTRIC DETAILS 6 1 SERVICE PRECAUTIONS ELECTRIC Devices 01 After operation the terminal caps must be installed securely Fig 6 01 02 When disconnecting the connector the lock on the connector shall be released first Fig 6 02 03 Hold the connector body when connecting or disconnecting it Do not pull the connector wire Fig 6 03 04 Check if any connector terminal is bending protruding or loose Fig 6 04 05 The connector must be inserted completely If the double connector has a lock lock it at the correct position Be checked if there is any loose wire Fig 6 05 06 Before connecting a terminal check for damaged terminal cover or loose negative terminal Fig 6 06 07 insert the terminal completely Check the terminal cover for proper coverage Do not make the terminal cover opening face up Fig 6 07 08 Secure wire harnesses to the
89. ment B by moving it up and down Any movement is tight binding or rough cheek the inner collar bearing bushing check inner collar bearing bushing and thrust cover or adjust the shim Fig 5 105 remove the swing arm pivot shaft nut 1 washer 2 Fig 5 106 remove the swing arm pivot shaft 3 Fig 5 106 remove the swing arm 4 Fig 5 106 remove the thrust covers 1 Fig 5 107 remove the L side washer 2 oil seal 3 Fig 5 107 remove the R and L inner collars 4 spacer 5 Fig 5 107 remove the L thrust cover protector 6 Fig 5 107 inspect the swing arm set 7 for any crack bend damage replace Fig 5 107 inspect the pivot shaft 1 by roll the axle on a flat surface on any bends replace Be sure do not try to straighten a bend axles which will cause a weak pivot shaft 5 6 3 Inspection 01 02 03 04 05 06 07 inspect shock absorber rod 1 for any bends damage replace Fig 5 108 inspect shock absorber for any oil leaks gas leaks replace Fig 5 108 move spring up and down to check any fatigue replace Fig 5 108 any damage on thrust cover inner collar washer replace Fig 5 107 any wear damage on dust cover or protector replace Fig 5 107 inspect o ring 1 for any damage replace Fig 5 109 inspect bearing 2 and dust cover 3 for any scratches or damage replace Fig 5 109 NOTE BE SURE THE POSITION OF FITTING THE BEARING AND BUSHINQS CHASIS
90. n the steering column torque 3 0 kg m 09 install new cotter pin 10 put amp tie rods rod end mark is facing up knuckle arm 11 tight en tie rod nuts torque 2 5 kg m 12 install new cotter pin 13 tighten handlebar holder bolts Be sure the upper handlebar mark 1 face co front Tighten the bolts 2 on the from side of handlebar holder and then tighten the bolts 3 on the rear side Fig 5 76 torque 2 0 kg m 14 install throttle housing and front brake lever torque 1 0 kg m 15 fit the throttle housing projection onto the indent on the front brake lever 16 adjust toe in refer to part 3 19 CHASIS DETAILS 5 5 FRONT SHOCK ABSORBER AND FRONT Arms BRIEFING 01 shaft pivot 02 cover thrust 03 bush solid 04 collar 05 upper arm 06 nipple grease 07 collar lower 08 lower arm 09 shock absorber CHASIS DETAILS 5 5 FRONT SHOCK ABSORBER AND FRONT ARMS 5 5 1 Removal 01 02 03 04 05 06 07 08 09 remove the f wheel hub and brake shoe plate part 5 1 remove the front bumper Fig 5 77 remove the shock absorber Fig 5 78 remove the cotter pin 1 nut 2 tie rod 3 from knuckle arm Fig 5 9 remove the cotter pin 4 bolts 5 knuckle arm 6 Fig 5 79 remove the cotter pin 7 nuts 8 bolts 9 and steering knuckle 10 check front arms free play under Fig 5 80 5 81 5 82 1 check
91. ng open circuit voltage 12 8V min ELECTRIC DETAILS 6 3 5 Performance Test when the battery is fully charged 01 start and warm up the engine for 10 minutes 02 connect battery positive cable to the ammeter positive probe 03 connect the voltmeter across the battery terminals to test the charging voltage Headlight Switch Position Charging rpm 3000 rpm 8000 rpm OFF Day 2 150 rpm max 2A 13V 3A 13 5V ON Night 2 150 rpm max 2A 13V 3A 13 5V 6 3 6 Limit voltage test when the battery is fully charged Start the engine and gradually increase the engine speed to measure the limit voltage Limit Voltage 14 7 0 4V use a tachometer for operation 6 3 7 A C Generator removal and inspection Fig 6 30 01 disconnect the A C generator s wires 02 measure the resistance wires Resistance 0 2 0 3 OHM CAUTION DO NOT CONNECT THE A C GENERATOR S WIRES TO GROUND 6 3 8 Regulator Rectifier Fig 6 31 6 32 6 33 01 remove the front cover 02 remove the regulator rectifier screw 1 and disconnect the regulator rectifier wire coupler 2 03 measure the resistances between the regulator rectifier wire terminals Replace the regulator rectifier if the readings are not within the specification in the table Fig 6 33 CAUTION FOR ACCURATE TESTING IT IS NECESSARY TO USE A SPECIFIED TESTER USING AN IMPROPER TESTER OR MEASUREMENTS IN IMPROPER RANGE MAY GIVE FALSE READINGS
92. ng a general bearing puller Fig 5 12 04 install the new bearing and oil seal by revering the previous steps It may use a socket 4 matches the outside diameter of the race of the bearing and oil seal Fig 5 14 CAUTION DO NOT STRIKE THE CENTER RACE 5 OR BALLS 6 OF BEARING CONTACT SHOULD BE MADE ONLY WITH THE OUTER RACE 7 FIG 5 14 5 1 4 Brake shoe and brake plate inspection 01 sand with coarse and paper on glazed parts Fig 5 15 02 measure the brake shoe thickness a Fig 5 15 service limit less than 2 0mm 0 08 in replace 03 check the spring 1 for any ware and damage replace Fig 5 15 04 check brake shoe plate for any cracks or damage replace Fig 5 16 05 check oil seal 2 and brake shoe pivot 3 pin for any damage replace Fig 5 16 06 check camshaft hole 4 for scratches or excessive wear replace Fig 5 16 CHASIS DETAILS CHASIS DETAILS 5 1 5 Front wheel installation Reverse the 5 1 1 procedure and follows the lubricate as 01 lubricate brake cam 1 brake shoe pivot pin 2 oil seal 3 Fig 5 17 use lightweight lithium soap base grease 02 lubricate oil seal lips and bearing use lightweight lithium soap base grease lightly 03 installing the wear indicator plate 1 to the camshaft 2 align the projection 3 on the wear indicator plate 4 tied the slot on the camshaft Fig 5 18 04 install brake shoe plate and be sure
93. o put the master link clip 1 on the rounded end facing the direction of travel Fig 5 126 04 tighten under guard bolts and rear wheel nuts torque under guard 2 3 kg m rear wheel nuts 4 5 kg m 05 tighten drive sprocket holder screw and change pedal bolts torque crankcase cover 1 0 kg m change pedal 1 4 kg m 06 adjust drive chain slack refer to part 3 15 drive chain slack 30 40mm 1 18 1 57in 07 tighten rear axle hub upper nut torque 5 0 kg m Fig 5 117 08 tighten rear axle hub lower nut torque 5 0 kg m ELECTRIC DETAILS PART 6 ELECTRIC DETAILS 6 01 Service Precautions ELECTRIC Device 6 02 IGNITION SYSTEM NOTE SERVICE INFORMATION NOTE TROUBLE SHOOTING lt Q A gt Ignition Coil CD I unit removal GDI Inspection Test with a CDI tester Pulse Coil Inspection Exciter Coil Inspection Q Q N 6 03 CHARGING SYSTEM NOTE SERVICE INFORMATION NOTE TROUBLE SHOOTING lt Q A gt Battery Removol Installation Charging inspection open circuit voltage Charging Performance test Limit voltage test 7 A C Generator removal and inspection 8 Regulator Rectifier 6 04 STARTING SYSTEM NOTE SERVICE INFORMATION NOTE TROUBLE SHOOTING lt Q A gt Starter motor removal Disassembly and inspection Starter motor housing continuity check Brush inspection Assemb
94. o wide or narrow a Fig 4 51 service limit 1 2 1 5mm or over for grind CAUTION 1 DO NOT DAMAGE THE CYLINDER HEAD MATING SURFACE 2 CHECK FOR DAMAGE AFTER DRIVING IN THE VALVE GUIDES 3 THE NEW VALVE GUIDES MUST HAVE OVERSIZED O D ENGINE DETAILS 4 4 5 Cylinder head assembly and installation The installation should follow the reverse order of removal 01 lubricate each valve stem with engine oil 02 insert the valves into the valve guides 03 apply oil on valve stem seals and install them into guides 04 install the valve spring seat washers inner and outer springs and retainers 05 compress the valve springs using the valve spring compressor and then install the valve cotters 06 tap valve stems gently with a plastic hammer to cotters 1 Fig 4 52 07 install the dowel pins 1 and new gasket 2 onto the cylinder Fig 4 53 08 install the cylinder head 09 install the push bar guide plate and 4 cylinder head lock nut 11 tighten the cylinder head lock nuts diagonally torque 2 3 2 8 kg m 12 install cam follower bolts copper washer then tighten bolt torque 1 8 2 3 kg m 13 install the 2 push bars 14 install the rocker arm set bolts and copper washers 15 tighten the centre bolt and then L amp R boles torque 1 5 2 0 kg m 16 adjust the valve clearance 17 install a new cylinder head cover o ring onto the cylinder head cover Be sure to p
95. oil A High resistance 1 Faulty coil 2 Broken pink and yellow wires 3 Shorted pink and yellow wires B Normal refer to 7 5 3 7 5 3 Connect the regulator rectifier socket red wire to and frame body to Measure the voltage between them A Battery has no voltage 1 Broken red wire B Battery has voltage 7 5 4 Check the regulator rectifier coupler for loose connection A Abnormal 1 Faulty regulator rectifier 2 Poorly connected coupler B Normal 1 Faulty A C Generator 7 5 5 Connect the regulator rectifier black wire to and frame body to Measure the voltage between them A Ignition switch ON battery has no voltage 1 Broken black wire B Ignition switch ON battery has voltage refer to 7 5 amp 7 5 6 Check the regulator rectifier coupler for loose connection A Loose connection 1 Poorly connected coupler B Normal 1 Faulty regulator rectifier PROBLEMS SHOOTING 7 6 SPARK PLUG HAS NO FUNCTION 7 6 1 Replace with a new spark plug and test again A Good spark 1 Faulty spark plug B Weak or no spark refer to 7 6 2 7 6 2 Check spark plug cap and ignition coil wire for looseness A Loose 1 Loose spark plug cap B Not loose refer to 7 6 3 7 6 3 Check the CDI unit wire coupler for looseness A Abnormal 1 Poorly connected coupler Normal refer to 7 6 4 7 6 4 Check for continuity and measure the resistance between the
96. on coil 1 wire coupler and measure resistance between ignition coil primary wire terminals Resistance 0 2 0 3 OHM 02 remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil terminal Fig 6 21A Resistance 3 2 4 8 OHM without plug cap CAUTION THIS TEST IS FOR REFERENCE ONLY ACCURATE TEST SHOULD BE PERFORMED WITH A CDI TESTER 03 measure the spark plug cap s resistance Remove the spark plug cap 1 and measure the spark plug s resistance Fig 6 22 6 23 Resistance 4 2 5 8 OHM 04 performance test with a CDI tester If the spark is weak inspect the spark plug and CDI unit If both of them are normal replace a new ignition coil SQA r ELECTRIC DETAILS 6 2 2 CDI unit removal Fig 6 24 01 remove the front lamp cover 02 disconnect the CDI unit 1 coupler and remove the CDI unit NOTE 0 1 CONDENSER DISCHARGE IGNITION 6 2 3 CDI Inspection Fig 6 25 6 26 01 measure the resistance between the CDI unit terminals 02 replace the CDI unit if the readings are not with in the specifications in the table Fig 6 26 below CAUTION THE CDI UNIT IS FULLY TRANSISTORIZED FOR ACCURATE TESTING IT IS NECESSARY TO USE A SPECIFIED TESTER USING AN IMPROPER TESTER OR MEASUREMENTS IN IMPROPER RANGE MAY GIVE FALSE READINGS USE ELECTRIC TESTER FOR TESTING 6 2 4 lt gt Test with CDI tester
97. or 4 wheeler 04 Tire should have E mark 05 Light or blinker should have E mark 06 Muffler with E mark under Emission control 07 S mark Horn 08 Others steeling lock air tube seat wire system NOTE REFER TO REFERENCE PICTURE SET CAUTION THE ON ROAD ATVS WILL HAVE DIFFERENT TIRE PRESSURE SPECIFICATION THAT SHOULD BE PROVIDED BY EACH AREA IMPORTER ONLY CAUTION THE ON ROAD ATVS WILL HAVE SOME DIFFERENT IDENTIFICATION NUMBER ID PLATE OR WARNING LABEL CAUTION THE ON ROAD ATVS WILL HAVE SOME DIFFERENT PAPER OF DOCUMENTS WITH THE VEHICLE THAT SHOULD BE PROVIDED BY EACH AREA IMPORTER ONLY CAUTION THE ON ROAD ATVS MAYBE ALLOW MORE THAN SINGLE RIDER HOWEVER IT IS NOT RECOMMENDED MAKER FOR MORE THAN SINGLE RIDER TO OPERATE ON ROUGH DRIVING CONDITION CAUTION THE ON ROAD VEHICLE SPECIFICATION WILL BE NOT ALLOWED TO MAKE ANY MODIFICATION FOR MORE SPEED OR OFF ROAD DUTY IF SO THERE WILL BE OUT OF ON ROAD STANDARD THAT MAKER WILL MAKE NO ANY RESPONSIBILITY ON PRODUCTS WARRANTY OR ANY DEFECT MATTER By Sales and Service Department of NACIONAL MOTORS S A U For Territorial Distributor All rights reserved Ho part of this manual may be reproduced or unauthorized use in any form or by any means without prior permission of the Maker http www derbi com NACIONAL MOTOR S A U E 08107 MARTORELLES T 34 93 565 78 78 WWW DERBI COM use recambios RIGINALES use original parts
98. or less 10mm from bottom of piston skirt 0 01 0 075 0 005 0 065 15 002 15 008 STANDARD MM 15 003 15 005 0 005 0 013 15 01 15 02 0 135 or more 0 125 or less 15 012 or more SERVICE LIMIT MM 125 150 15 012 or more 0 015 or more 15 032 or more AFTER DISASSEMBLY CLEAN THE REMOVED PARTS AND CRY THEM WITH THE SLOW COMPRESSED AIR BEFORE CONDUCTING ANY INSPECTION ENGINE DETAILS NOTE PROBLEMS SHOOTING lt Q A gt Compression too low worn stuck or broken piston rings worn or damaged cylinder or piston lt Q A gt Compression too high excessive carbon build up in combustion chamber or on piston head lt Q A gt White smoke from exhaust muffler worn or damaged cylinder or piston worn or damage piston ring lt Q A gt Abnormal noise piston worn or damaged cylinder piston or piston ring worn piston pin or piston pin hole 4 5 1 Cylinder removal Fig 4 54 01 remove the cylinder head 02 remove the cylinder head dowel pins 03 remove the 2 bolts and remove the cylinder 1 4 5 2 Cam follower removal Fig 4 55 01 remove the cam follower shaft 1 02 remove the cam follower 2 and 12mm washer 3 Fig 4 55 03 remove the cylinder gasket 1 and dowel pins 2 Fig S 57 4 5 3 Piston removal and inspection 01 remove the piston pin clip Be sure put a towels under piston to prevent the clip drops 1 into the crankcase Fig 4 56 02 clean any gasket ma
99. ot come on Burnt bulb Faulty ignition or light switch Fuse burned out Dead battery or loose battery wire lt Q A gt Light comes on but dims Weak battery High wire or switch resistance Aged bulb or faulty lighting circuit lt Q A gt Operating the light switch headlight beam does not change Faulty or burnt bulb Faulty light switch Loose wire connection ELECTRIC DETAILS 6 01 02 03 04 05 06 07 08 5 1 Light switch wire inspection removal the front cover Fig 6 43 check front lamp wire Fig 6 44 check the front lamp bulb 1 Fig 6 45 check the neutral position lights 1 Fig 6 46 check the neutral lights AC generator wire Fig 6 47 removal the stop taillight Fig 6 48 replace the bulb Fig 6 49 be follows bulb specification check the stop taillight Fig 6 50 NOTE IN SH THE NEUTRAL POSITION THE GREEN INDICATOR LIGHT WILL GO ON AND THE IGNITION SWITCH OULD BE AT ON 1 OR ON 2 POSITION NOTE O PTION THE SCOP LIGHT L amp R SINGLE LIGHT FLASHER ARE THE DEVICES FOR CERTAIN AREA REGULATION DETAILS REFER 10 EACH AREA IMPORTER ELECTRIC DETAILS 6 5 2 Main switch inspection 01 the main switch 1 Fig 6 51 02 check the ON Fig 6 52 03 check the NO 2 Fig 6 53 NOTE 1 1 ENGINE CAN BE STARTED AT THIS POSITION 2 ON 2 ENGINE C
100. over removal Generator removal Starter clutch removal and inspection Camshaft removal Camshaft installation Starter gear installation L crankcase cover installation Starter motor installation 4 07 GEAR SHIFT MECHANISM NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt R crankcase cover removal Clutch removal Clutch inspection Gear shift mechanism removal Gear shift inspection and installation R crankcase cover installation o 0 RON 4 O8 CRANKCASE CRANKSHAFT TRANSMISSION STARTER SPINDLE NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt Crankcase removal Transmission system removal and inspection Transmission gears crankshaft removal Gear shaft collar inspection Starter spindle removal and inspection Bearing inspection and replacement Crankshaft inspection Crankshaft installation Crankcase installation 1 2 3 A 5 6 7 8 9 ENGINE DETAILS 4 1 SYSTEM AND CARBURETION BRIEFING 01 Dutch 02 Cleaner cover 03 Seal of air cleaner cover 04 Plate of element sec 05 Element of air cleaner 06 Side cover 07 Fuel tank 08 Fuel hose 09 Carburettor 10 Joint of air cleaner ENGINE DETAILS 4 1 Fue SYSTEM AND CARBURETION NOTE SERVICE INFORMATION Carburettor Float level 125 cc on 12 5 mm 150 cc on 13 Main jet 125 cc on 90 150 cc on 102 Slew jet 125 cc on 35 150 cc on
101. placement 124 5 cm3 149 5 cm3 Carburettor DTG 017 o PD 19D KEIHIN Spark DR 8EA NGK Starting Electric Ignition C D I Generator ACG Fly Wheel Magneto Battery YUASA YTX 7A BS Engine Oil 4 Stroke qualified synthetic oil Engine Oil capacity 1 101 Air Filter Wet type element Transmission National 5 speeds Primary reduction Helical gear Primary red Ratio 4 055 73 18T Secondary reduction drive chain Secondary red Ratio 3 333 40 12T Operation Left foot operation Gear ratio 1st 2 769 36 13T 2nd 1 882 32 17T Ird 1 272 28 20T or 1 4 28 20T 4th 1 130 26 23T 5th 0 960 24 257 SPECIFICATION Clutch type Operation Fuel type Fuel tank capacity Reserve fuel Chassis type Caster angle Trail Suspension F R Shock absorber Brake system F R Front drum brake Rear disc brake Rim Front Rear Wheel travel F R Headlight type Front Rear Indicator neutral Fuse NOTE Wet multi blade Left hand operation Unleaded gasoline 8 0 1 76 Imp gal 2 12 US gal 2 0 L 0 44 Imp gal 0 53 US gal Steel tube frame 9 0 degree 40mm 1 57 double A wishbone swing arm coil spring oil damper double drum single disc Right hand operation Right foot operation steel 10 x 5 5 8 x 8 0 AT 180mm 7 09in 180mm 7 09in bulb type 12V 18W 18W x 2 12V 21W x 1 12V 3 4W x 1 15A 250V THE ATV Z S DESIGNED FOR OFF ROAD USE MAINLY TO MATCH DIFFERENT AREA REGULATION ATV
102. r removal 03 Float float inspection 04 Jets air screw throttle screw removal 05 Fuel outlet ball removal and inspection 06 Slow Main jet installation 07 Choke 08 Float level inspection 09 Carburettor installation 10 Throttle valve installation 11 Fuel tank and fuel valve removal 12 Fuel tank and fuel valve inspection 13 Fuel tanks and fuel valve installation 14 Air cleaner cleaning 4 02 LUBRICATION SYSTEM NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt 1 Engine oil 2 Oil pump oil filter rotor removal 3 Oil pump disassembly and inspection 4 Oil pump reassembly and installation 4 03 ENGINE REMOVAL INSTALLATION NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt 1 Engine removal 2 Engine installation 4 04 CYLINDER HEAD VALVE NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt 1 Cylinder head cover removal 2 Rock arm set removal 3 Cylinder head removal 4 Cylinder disassembly and check 5 Cylinder head assembly and inspection ENGINE DETAILS 4 05 CYLINDER PISTON NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt Cylinder removal Cam follower removal Piston removal and inspection Cylinder head inspection Piston installation Cylinder installation Q G N 4 06 STARTER GENERATOR L CRANKCASE START CLUTCH CAMSHAFT NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING lt Q A gt Starter motor removal L crankcase c
103. ransmission drum groove 10 install the transmission fork shaft CAUTION MAKE SURE THE MAIN AND COUNTERSHAFT ARE PARALLEL 4 8 9 Crankcase installation The installation should follow the reverse order of removal 01 install the crankcase squarely and do not strike it in force by installing the crankcase aligning the starter spindle with the L crankcase hole 02 install the dowel pins and gasket be sure the dowel pins and gasket do not till to avoid oil leakage 03 tighten 8 bolts diagonally and evenly torque 0 8 1 2 kgm 04 install the rest all parts starter motor generator refer to part 4 6 clutch gear shift refer to part 4 7 cylinder piston refer to part 4 5 cylinder head refer to part 4 4 CHASIS DETAILS 5 01 WHEEL FRONT BRAKE 1 Removal 2 Inspection 3 Wheel bearing and oil seal replacement 4 Brake shoe and brake plate inspection 5 F wheel installation 5 02 REAR WHEEL REAR AXLE 1 Rear wheel removal 2 Inspection 3 Rear axle hub bearing and oil seals replacement 4 R wheel installation 5 R axle nuts tightening steps 5 03 Rear Disc BRAKE 1 Brake fluid change refilling 2 Brake shoe disc master cylinder inspection 3 Installation brake shoe disc master cylinder 5 04 STEELING SYSTEM 1 Removal 2 Inspection 3 Installation 5 05 Front SHOCK ABsorBER AND FRONT ARM 1 Removal 2 Inspection shock a
104. ssively to avoid deformation Fig 4 96 04 remove the spring clutch anger clutch friction disks and plates Fig 4 57 05 remove the thrust washer 1 outer clutch and outer guide Fig 4 9S 4 7 3 Clutch Inspection 01 check the clutch tension spring to make sure each clutch tension spring free length a Fig 4 99 service limit less than 34 20mm replace 02 check the clutch friction disc to make sure thickness a Fig 4 100 service limit 2 60mm 03 check clutch plate s on bending with a feeler gauge Fig 4 101 service limit 0 20mm 04 check outer clutch groove for scratches from friction disc 05 measure the outer clutch 1 D a Fig 4 202 service limit 112 5 06 measure the outer clutch guide I D and O D service limit I D 5 50mm O D 11 91 ENGINE DETAILS ENGINE DETAILS 4 7 4 Gear shift mechanism removal 01 remove the gear shift pedal 1 Fig 4 103 02 remove the gear shift spindle 2 and washer 3 Fig 4 103 03 remove the stopper 1 and spring 2 Fig 4 104 04 remove the gear shift cam bolt 3 Fig 4 204 05 remove the gear shift cam and set pin 4 7 5 Gear shift inspection and installation The installation should follow the reverse order o removal 01 check gear shift cam stopper for any wear or damage replace Fig 4 105 02 check gear shift plate for any wear or deformation replace Fig 4 106 03
105. t the starter motor terminals to an electric tester and check for continuity between the terminals Fig 6 42A 06 Replace the starter relay with a new one if there is no continuity Fig 6 42A 6 4 7 Starter motor installation 01 apply engine oil to the starter motor O ring and then install the O ring 02 Install and tighten the two mounting bolts 03 install the starter motor wire lock nut and rubber cover ELECTRIC DETAILS 6 5 LiGHTS INSTRUMENTS SWITCHES BRIEFING 01 head light 02 03 neutral light 04 06 05 engine stop switch 74 main switch taillight Hi Lo beam switch ELECTRIC DETAILS 6 5 LiGHTS INSTRUMENTS SWITCHES NOTE SERVICE INFORMATION Headlight 12V 18W 18W 2 Stoplight Taillight 12V 21W 1 Neutral beam indicator 12V 3 4W 1 Fuse 15A General Instructions All plastic plugs have locking tabs that must be released before disconnecting 2 All plastic plugs have locking tabs that must be released before disconnecting 3 An electric tester must be used for checking the continuity between two points 4 The electric tester also contains a voltmeter which can be used to measure the voltage 5 Different bulbs have different specifications When replacing use a new bulb of the same specification 6 The continuity check can be made without removing the switch from vehicle NOTE TROUBLESHOOTING lt Q A gt lt Q A gt Light does n
106. terial from cylinder surface Fig 4 57 03 press the piston pin out of the piston and remove the piston 04 inspect the piston piston pin and piston rings 05 remove piston rings Do not damage rings set Fig 4 53 05 remove carbon deposits in the piston ring grooves 06 install piston rings and measure ring to groove clearance service limit 0 09mxn or more replace 2nd 0 09mm or more replace Fig 4 59 07 remove the piston rings 1 and insert each piston ring into the cylinder bottom And measure the ring end gap Fig 4 60 service limit 0 05 08 measure the piston hole I D a Fig 4 61 service limit 15 012mm 09 measure the piston pin O D a Fig 4 62 service limit 14 96mm or less replace 10 measure the piston O D to take measurement at 10mm from the bottom and 90 degree to the piston pin hole position Fig 4 63 service limit 61 8mm ENGINE DETAILS ENGINE DETAILS 4 5 4 Cylinder inspection 01 inspect the cylinder bore for any wear scratches or damage 02 measure the cylinder bore at 3 levels top middle bottom in X and Y directions 90 degree to the piston pin Fig 4 64 service limit 62 1mm 03 measure the cylinder piston clearance service limit less than O Imm replace 04 each measured value is the true roundness the difference between the values measured in X and Y directions Fig 4 65
107. the front arm brackets 1 of the frame Any bent cracked damage repair or replace 2 check the tightening torque of the front arm upper lower securing nuts 2 torque F arm upper and lower 3 0 kg n 3 check the front arms upper and lower free play A by moving it from side to side Any play noticeable replace the inner collar bushings and thrusts covers as a set 4 check the front arms upper and lower vertical movement B by moving it up and down movement is tight binding rough replace the inner bushings and thrusts covers as a set remove the nut 1 washer 2 bolts 3 upper front arm 4 Fig 5 83 remove the nuts 1 washers 2 bolts 3 lower front arm 4 Fig 84 CHASIS DETAILS 5 5 2 Inspection shock absorber 01 02 03 check shock absorber rod for any bend damage replace Fig 5 85 check shock absorber any oil leaks replace check shock absorber spring fatigue replace 5 5 3 Inspection steering knuckled 1 and joint rod 2 Fig 5 86 5 87 for any cracks pitting damage replace 5 5 4 Inspection front arm upper 1 and lower 2 Fig 5 88 01 02 03 04 05 06 07 08 any cracks bends damage replace do not try to straighten a bent arm that will dangerously weaken the arm check collar free play any loose replace inner collar and bushing as a set Fig 5 89 5 91 insert the inner
108. ton pin and piston pin clip The piston IN mark is located on intake valve side Be sure to put a towels in the crankcase to prevent piston pin clip falling into Fig 4 73 4 5 6 Cylinder installation The installation should follow the reverse order of removal 01 install the 12mm washer wave washer into the groove 02 install the cam follower and cam follower shaft 03 apply engine oil on the cam follower shaft o ring 04 put the cylinder though the piston When installing be carefully that ring end cap should not be 90 degree co piston pin Ring end gaps should align with the 4 cylinder head lock nuts NGINE DETAILS D 4 7 gt AN z AU 4 a d SR 2 ENGINE DETAILS 4 6 STARTER Motor GENERATOR L CRANKCASE COVER STARTER CLUTCH CAMSHAFT BRIEFING 02 stertor 01 starting motor 04 camper wire harness 03 L crankcase 06 shaft reduction gear 05 bearing needle 08 cover reduction gear 07 gear reduction 10 o ring 09 cap L crankcase cover 12 bearing needle 11 camshaft 14 Shaft cam gear 13 shaft starter gear 16 o ring 15 washer 18 flywheel I7 outer starter 19 gear starting clutch ENGINE DETAILS 4 6 STARTER MOTOR GENERATOR L CRANKCASE COVER STARTER CLUTCH CAMSHAFT NOTE SERVICE INFORMATION ITEMS STANDARD MM 125 150 SERVICE LIMIT MM 125 150 01 Reduction pinion 9 972 9 987 9 932 or
109. urn the adjuster clockwise or counter clockwise until proper length is attained Finally Tighten the locknut speed limited length 12mm 0 47 in a 3 10 FRONT DRUM BRAKE INSPECTION Fic 3 16 A wear indicator is provided on the front brake that shows brake shoe wear without disassembling the brake Exercise the front brake and check the position of the indicator If the indicator reaches the wear limit line replace a new set 3 11 REAR DISC BRAKE INSPECTION BRAKE FLU ID Fic 3 27 The ATV has a single disc brake on rear axle Check the operation of rear brake pedal and brake function before each riding Be sure to check periodically the brake shoes during service 3 11 1 Check the brake fluid level Fig 3 18 Whenever the fluid level nears the lower level mark brake fluid has to be added to reservoir Use only DOT 3 or 4 brake fluid pw PERIODIC MAINTENANCE lt continue the 3 11 1 Check the brake fluid level gt CAUTION 1 NEVER ALLOW FOREIGN MATERIALS DIRT WATER ENTER THE BRAKE FLUID RESERVOIR 2 BRAKE FLUID CAN DAMAGE ANY PAINTING AND PLASTIC WARNING BRAKE FLUID CONTACTING THE SKIN AND EYES AWARENESS May cause irritation SOLUTION Avoid contacting brake fluid with the skin or eyes WAS 6 gt PERIODIC MAINTENANCE 3 12 FRONT BRAKE LEVER FREE PLAY ADJUSTMENT The front brake lever free play should be adjusted to 3 5 mm
110. ut the o ring into the groove 18 install the cylinder head cover 19 tighten the 3 cylinder head cover bolts torque 0 8 1 2 kg m ENGINE DETAILS 4 5 CYLINDER PISTON BRIEFING 01 03 05 07 09 gasket cylinder head gasket cylinder follower cam piston ring piston pin 02 cylinder washer wave 12 3 21 0 2 shaft caw follower circlip piston ENGINE DETAILS 4 5 CYLINDER PISTON NOTE SERVICE INFORMATION CYLINDER ITEM 01 Cylinder bore 02 Cylinder war page 03 Cylindricity 04 True roundness PISTON PISTON RING ITEM 01 Ring grove top clearance 2nd 02 Ring end gap top clearance 2nd side rail oil ring 03 Piston O D 125 150 04 Piston O D measure location 05 Piston Cyl 125 clearance 150 06 Pis Pin hole I D lt OTHERS gt ITEM 01 Piston pin O D 02 Piston Pis pin clearance 03 Connecting rod small end 1 D CAUTION STANDARD MM 125 150 56 5 56 6 62 62 1 0 01 or less 0 01 or less STANDARD MM 125 150 0 5 0 75 0 45 0 7 0 5 0 75 0 8 1 05 0 15 0 35 0 1 0 3 0 15 0 35 0 1 0 3 0 2 0 5 0 3 0 9 56 45 56 48 61 97 61 99 SERVICE LIMIT MM 125 150 56 6 62 1 or more 0 05 or more 0 05 or more SERVICE LIMIT MM 125 150 0 85 0 09 or more 0 85 1 05 or more 0 5 or more 0 5 or more 0 5 or more 56 3 or less 61 8
111. ve chain 4 Fig 5 118 11 remove drive sprocket Fig 5 114 12 remove chain guide Fig 5 116 13 remove chain guide roller upper 1 and lower 2 SSS ag lt 9 E CHASIS DETAILS 5 7 2 Inspection 01 measure the 10 link length out of specification for replacement Fig 5 120 10 Link length limit 150 1mm 5 91 in 02 by using finger to check the chain tense the 10 link is a distance between 1 and 11 Every time to check 2 or 3 10 link Fig 5 121 03 clean drive chain by placing it in kerosene and brush off dire Next dry the chain Finally lubricate the chain Fig 5 122 use lubricate SAE 30 50 motor oil drive chain 04 inspect drive chain stiffness for any stiff replace Fig 5 123 05 inspect the drive sprocket if more than 1 4 teeth 1 wear replace Fig 5 124 06 inspect the drive sprocket if bent teeth replace 07 inspect the chain guide Fig 5 116 5 7 3 Driven sprocket replacement steps Fig 5 125 5 125A 01 straighten the lock washer 1 tabs and remove the driven sprocket 2 02 install a new driven sprocket and lock washers torque 2 4 kg m 03 bend the lock washer tabs along the nut flats 5 7 4 Installation reverse the 5 7 1 procedure and follows points as Fig 5 121 01 lubricate Molybdenum disulfide grease inner surface collar 02 tighten chain guide roller bolts torque 0 9 kg m 03 install drive chain Be sure t
112. y Regulator Rectifier Charging coil resistance CAUTION 12V7AH MF 1 320 20 C 3 0A max 2 100 rpm min 2A min 3000 rpm No contact point 0 2 0 3 OHM 1 THE BATTERY IS A MF BATTERY WHICH IS UNNECESSARY TO REFILL WITH DISTILLED WATER 2 DO NOT QUICK CHARGE THE BATTERY USE A MF BATTERY CHARGER AND THE BATTERY TEMPERATURE SHOULD NOT EXCEED 45 C 3 REMOVE THE BATTERY FROM THE VEHICLE FOR CHARGING IF BATTERY MUST BE CHARGED ON THE MOTORCYCLE KEEP SPARKS AND FLAMES AWAY FROM A CHARGING BATTERY 4 WHEN INSPECTING THE A C GENERATOR USE AN ELECTRIC TESTER 5 ROUTE THE CHARGING SYSTEM WIRES PROPERLY TO AVOID SHORTED WIRE DUE TO WIRES BEING TWISTED OR KINKED 6 TORQUE VALUE 1 GENERATOR STARTER 2 GENERATOR ROTOR 7 SPECIAL TOOLS 1 FLYWHEEL HOLDER 2 FLYWHEEL PULLER 8 TESTING INSTRUMENTS ELECTRIC TESTER 0 8 1 2 KG M 5 5 6 5 KG RO ELECTRIC DETAILS NOTE TROUBLESHOOTING lt Q A No power Dead battery Fuse burned out Disconnected battery cable Faulty ignition switch lt Q A gt Low battery Weak battery Loose battery connect ion terminal Charging system failure Faulty regulator rectifier lt Q A gt Intermittent power Loose battery cable connection Loose charging system connection Loose lighting system connection lt Q A gt Charging system failure Loose broken or shorted wire or connector Faulty regulator rectif
113. y over discharge or overcharge 7 06 Spark plug has no function 7 07 F or R Brake Performance Poorly 7 08 Shock Absorber Malfunction 7 09 Instable Handling PART 8 APPENDIX 8 01 Notes of Pre Delivery Inspection 8 02 UPDATE information 170cc amp BLAST model 8 03 UPDATE information EEC 92 61 On Road Model 149 153 159 165 171 179 180 181 184 185 186 187 187 188 IMPORTANT SAFETY MESSAGE 1 1 IMPORTANT SAFETY MESSAGE BE SURE TO INFORM THE END USER FOLLOWS 1 TO READ THE OWNER MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THE ATV MAKE SURE THE END USER UNDERSTAND ALL INSTRUCTIONS 2 PAY ATTENTION TO THE WARNING AND CAUTION LABELS ON THE ATV 3 ANY OVER 90cc SHOULD NOT BE RIDDEN BY ANYONE UNDER 16 YEARS OF or REFER THE LOCAL RIDING LAWS AND REGULATIONS 1 2 IMPORTANT INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THE OWNER MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH The important information shown in this manual in texts or symbols is described as follows Failure to follow 1 WARNING instructions could result in severe injury or death to the ATV rider an on looker or a worker inspecting or repairing the ATV CAUTION marks special precautions that must be taken to avoid damage 10 the

ATV DXR 200 TALLER.indd

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