SERVICE MANUAL
Contents
1. Q O e IDE N xd GR f 0 o re a S DIAC a E Bra X A aa l ge Y fellow aoe gt e lt T o o i J LY AM gt Mi a a Am A S De OK Urani CO ELI a LE peze e l Q OO am B Blue gt l a E m kd A aa ll SP C m L So L2. 5 Remove of Engine 6 Cylinder Head Cylinder Piston 7 Starter Driving Disc Clutch Transmission Disc 8 Final Transmission Mechanism 9 Crank case Crank shaft 10 Chassis Front wheel Brake Suspension 11 Rear heel Brake Suspension 12 Electrical devices 13 Wiring diagram 14 Initial Set Up Information Injector Oil Use a good grade of oil that is specially formulated for two stroke engines synthetic type is recommended JEHM recommends SAE 30 Transmission Gear Oil Use multi grade motor oil of SAE 90 or 85W 140 Break In Procedure To insure maximum durability and optimal performance and to avoid engine damage please pre mix the first four tanks of fuel with two stroke engine oil at 30 1 ratio Do not operate the ATV at more than half throttle for the first three hours During the break in period the first four tanks of fuel operate the vehicle at various RPM s and do not operate the vehicle above half throttle for extended periods Engine The ATV 50 90 100 II have a two stroke reed induct
3. LA LA LA LA WL Aassembly steering shaft Ass y x WARNING Adjusting gap of throttle Ts 11 6 REAR WHEEL SUSPENSION BRAKE Diagnosis of Troubles Rear wheel shaking or deviation The shape of rear rim damaged Rear wheel axle damaged Swing arm sub Ass y damaged Rear rim bearing defected Rear suspension too soft Spring too soft or adjust not correct Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct or wear out Brake drum wear out Tire wear out REAR WHEEL SUSPENSION BRAKE Assembly Disassembly Rear Wheel of ATV 50 OoHX x NO E 0 NN e Assembling with sequence in reverse of disassembly i Q ty Disassembly L R Rubber cover 2 Cotter pin 2 Scotch nut 2 Plain washer 14 40 4 5 2 Take off the wheel Ass y 2 Hex washer face bolt 8 Take off shaft connector 2 Rim 2 Tire 2 Assembly g N REAR WHEEL SUSPENSION BRAKE Assembly Disassembly Rear Wheel of ATV 90 100 Operation Parts name Q ty 2 w e Assembling with sequence in reverse of disassembly Rubber cover Plain washer 144044 5 Take off the wheel Ass y Hex washer face bolt Shaft connector Rim Tire O 0 OO E 0 NN a LA HLA LA GO LA LA LA WN WY 2 Assembly 10 1 UY REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Rear wheel axle and Brake panel Remarks Disassembly Rear Brake Left rear wheel Ass
4. x WARNING e No fire e Shall be wiped off when fuel overflowed Operation Parts Name 2 i 3 Fuel Tube Assembly O Operating with sequence in reverse of 31 disassembly FUEL SYSTEM Replace Air filter O Disassembly of oil tank Remove 2 Hex Bolt and move to the rear of the Air Cleaner Ass y Remove 3 Tapping Screw Truss Head Phillips Remove Air Cleaner case cap Replace new Air filter Disassembly of Air Cleaner Ass y O Disassembly of handle bar and front cover O Disassembly of oil tank Disassembly Hex socket bolt Plain washer Self tapping screw Atr cleaner case cap Air filter Atr cleaner case Cleaner guide pipe Grommet 1 8 Assembly O Operating with sequence in reverse of S gt disassembly REMOVE OF ENGINE Attention of Operation e Operation after disassembling the engine Crank shaft case Crank shaft Exchange bearing of final transmission mechanisms Disassembly of Engine e Disassembly of external cover of body e Disassembly of throttle valve and cable REMOVE OF ENGINE 7WARNING The oil over flow when remove the oil tube so use clip or plug stop the seal ACG wire wire of start motor Starter wire of carburetor Vacuum pressure tube Cap of spark plug Oil pump control cable Throttle cable 10 Drive Sprocket Ass y l 2 3 4 5 6 7 8 9 x WARNING O Actually for brace the frame avoid body turn inside out 11 Hex washer face bolt o
5. 6 5 4 3 2 l Installation of Kick Pinion Kick Pinion Spring Clip e Set kick starter shaft first Driving gear Friction spring Turning starter hang kick pinion spring Yon N ds clip on crank shaft case convex and ye N Le e assembly of kick pinion to the location LLEDO LAS of removing J M D aa Turning starter let starting shaft and Si i L kick pinion conjoin o Check of Starter e Check the wear damage of starting main shaft of starter shaft or gear e Check the tightness amp damage of starting shaft reset spring e Check the wear amp damage of bush returning spring bush of main shaft 8 4 Starter Driving Disc Clutch Transmission Disc e Check the wear amp damage of kick kick pinion pinion e Check the wear damage of kick pinion spring clip a kick pinion spring clip 8 2 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case Operation Parts name Disassembly Hex washer face bolt Cone spring washer One way clutch gear Clamp washer Primary fixed sheave Bushing V Belt Primary sliding slot wheel Oil ring x WARNING Don t damage transmission belt VW ooN GN Ln U NN a e e e A A nl pd en pan 11 Clutch cover 12 Drive face ass y l Assembly e Operation with sequence in reverse 12221 of disassembly 8 2 Starter Driving Disc Clutch Transmission Disc Disassembly of Sliding Driv
6. amp operating parts O o o o Brake Hub wo wo 130 7 Device Fi jwa 8 19x7 5 8 19x7 8 16x8 7 Fi PI si psi 3 1 Service Time Service Time month Service Items Judgement Standard Remarks ee Fi each 12 riding Riding Device Tire Check amp II of tires Ditch front wheel till 3 mm Rear wheel T 3 mm Abnormal amp ditehintirs O Ofo ooo Bolt amp nut of tires locking Blocking torque Front wheel 3 0 3 5 kg m Rear wheel 4 5 5 5 kg m Tightness of front beati O pp Tightness of rear henne Buffer device Spring damage PF JOO Spring of shock absorber Suspension arm damage of joint gap amp arm oil leakage or damage Tightness of installation S n a Power transmission device Cluteh acion Jojolo n n GerBox BARRI Electric device E Ignition device Spark plug O O Gapofspark plug 0 6 0 7 mm Battery connection of terminal Battery connection ofterminal O L Wiring of electrical en e temo Engine Engine Body starting amp abnormal noise AF Low speed amp accelerating Idle 1800 100 rpm exhaust air filter O O 3 2 Service Time Service Time month Service Items Judgement Standard Remarks BEL Pi each 12 riding an SSS Oilandoilfiker O JOJO O eekmecillevel Oilleakage Y OPO Fuel installation Fuelfilterisdity Clogeed O S o Leakage Of we OL OF a Throtle gate de choke CO A
7. y Left spacer collar Hex washer face bolt Rear drum cover Rear drum cover gasket Rear drum Rear brake shoe Comp Disassembly Rear wheel axle Right rear wheel Ass y Right spacer collar 10 Rear sprocket Ass y 11 Take off rear wheel axle Disassembly Rear Brake Panel 12 Hex flange nut with serration 13 Rear brake cable 14 Hex washer face bolt 1227 15 Plain washer 16 Hex washer face bolt 1222 17 Plain washer 18 Rear brake panel Assembly O Assembly with sequence in reverse Rear break 7 1 of disassembly Rear wheel axle 118 Rear break panel 18 12 4 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Swing arm sub Ass y Operation Parts name Q ty e Assembly with sequence in reverse Disassembly Swing arm sub Ass y Rear brake panel Ass y Hex flange nut with serration Plain washer Hex washer face bolt 14290 Swing arm sub Ass y Assembly 5 gt 1 NL 0 NN a of disassembly ME 5 REAR WHEEL SUSPENSION BRAKE Assembly Disassembly of Front amp Rear Cushion Operation Parts name Q ty Disassembly Front Cushion Hex washer face bolt Hex flange nut with serration Hex bolt Front cushion Disassembly Rear cushion 5 Hex washer face bolt 6 Rear cushion Assembly e Assembly with sequence in reverse of Front cushion 4 1 disassembly BO Ne Rear cushion 6 5 6 REGULATOR RECTIFIER
8. Bolt Remove 2 Hex Washer Face Bolt and 4 Plain Washer And 2 Hex Flange Nut With Serration Disconnect Main Switch Wire and head light wire WARNNING x Do not damage amp break the cover Before locking screws please confirm the matching is correct of all parts 3 4 e CHECK AND ADJUST Adjustment of Oil Pump x WARNNING Going on this operation after adjusting and checking the guide wiring of throttle e The tolerance within 1 mm of the oil pump control cable is good Starting the engine push slightly the throttle to feed oil At same time of rising the engine rotation confirm the function E of control rod adjust nut a e The condition will be appeared with bad synchronizing as follows x Starting difficult and having smoke when opening degree of oil pump s control rod is too big gt Piston will be burnt when the opening degree of oil pump s control rod is too small Adjustment of Drive Chain Loose 4 Hex Bolts on Rear Brake Panel Adjust the drive chain adjuster to proper chain tolerance 10 20 mm unload Tie up 4 Hex bolt on Rear Brake Panel Lubricate the chain CANTION Beware the direction of chain fix clip if disassembly the chain tum direction fix clip 3 5 LUBRICANT SYSTEM Attention of Operation O Pay attention to avoid dust enter to the interior of engine and oil tube when disassembly the oil pump O Never disassembly oil pump O Must draw out the air i
9. from crank shaft then remove the R L crank case Special tool Bearing puller TLJT OO x WARNING Must remove the oil seal when Assembly of Crank Case separate the crank case and never use the old oil seal crank case puller X w Th Right crank case Left crank case crank case puller bearing puller O Clean the crank case with gasoline and check each part whether damaged or cracked x WARNING Smear of oil on sliding surface of each shaft in crank case after checking O Cleaning the washer dust of joint face and amend the part damage with oil stone 10 3 Crank Case Crank Shaft O Put new crank shaft into right crankcase O Put crank shaft assembly into left crank case x WARNING Smear the 2 stroke oil to main bearing and big end of connecting rod O Note the position of connecting rod O Put left oil seal into L crank shaft case surface depth under 1 0 mm it seal tmm Jacket punch outer handle A 10 4 Crank Case Crank Shaft Assembly of Crank Case O Install the dowel pins in the joint face of left crank case O Install the right crank case Bearing puller TLJT 00 O Install the new R oil seal to crank Case Bearing puller TLJT 00 10 5 Front Wheel Attention of Operation e Remove the body cover and support the frame body bottom before remove the front wheel don t invert the front wheel when f
10. tool bag are installed under the seat If there are any other questions please check the owner s manual for details CAUTION Before install the front rim beware the stoppere of front brake plate assembly must fit into the front knuckle 7 mm platee INFORMATION FOR PREPARATION Attention on Operation O All washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted O O o O O Locking of all screws nuts cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks O All items must use original parts pure oil and greases Qe Oo All service shall use special tools and general tools to repair e All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated 2 1 INFORMATION FOR PREPARATION Attention on Operation O Certified lubricants in cans shall be used on all the elements to be lubricated bn E O After assembly performance of all elements shall be duly checked and the locking shall be duly verified O Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority O Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation Y OIL Lubrication by d
11. valve Gasoline level too low Air pipe is clogged Mixed air too rich Poor action of float chamber valve Gasoline level too high Air nozzle is clogged Auto side plunger defect FUEL SYSTEM Disassembly Assembly Valve Of Throttle Disassembly carburetor E AAA NO Disassembly Pan phillips bolt Throttle valve Throttle cable Throttle valve spring x WARNING Remove from guide wire of throttle Rubber Sealing Washer Needle nozzle valve On ON Aa BPW NY KR NO ked jw jn jn pen jn jn ked pp N 11 Adjust nut FUEL SYSTEM x WARNING Assembly of needle nozzle Assembly of throttle valve Sealing set of guide wire Assembly of throttle cable Throttle cover Washer Throttle valve spring Throttle cable Throttle valve ke k ked ke e k ked d ked d Aim the ditch of throttle valve to chamber then install throttle valve into carburetor Lock the throttle cover Pan phillips bolt FUEL SYSTEM Remove Carburetor Turn the arrow of fuel valve pointed at OFF Disassembly Throttle valve set Gasoline tube Engine oil tube Auto side plunger wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp Carburetor Assembly On ON rN BPW NY WARNING Don t let dust enter into carburetor x WARNING Release air 8 1 a Motor oil joint FUEL SYSTEM Disassembly Assembly Carburetor Disassembling of carburetor A
12. SERVICE MANUAL ATV 50 90 II ANSI September 2005 High Power Engine HER CHEE INDUSTRIAL CO LTD Foreword This service manual contains information on servicing ATV 50 90 100 This manual is written for use as a guideline only It is recommended that any mechanic with or without sufficient experience thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual For fully qualified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manual in full before attempting service on ATV 50 90 100 All the data and diagrams provided in this service manual are valid at the time of publication Information may be updated without notice due to improvements or upgrades No quotation reproduction or reprint of the service manual as a whole or in part will be permitted without the express written consent from ADLY Moto INDEX Initial Set Up Information l Information for Preparation 2 Check and Adjust 3 Engine Lubrication System 4 Fuel System
13. SSIS Locking Place Quantity Locking Torque kg m ENGINE Locking Place Screw of Cylinder Cap Flywheel Nut Clutch Cover Nut Clutch Carrier Nut Joint Screw of Exhaust Muifler 2 4 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV 50 90 100 1D MT KE br p dl oy TET LI DO J Al NU T ki L MAL CL rU 8 wie KA ular N Kaa A A TF a Ti GO LOI Mi mati k 1 if E P Y a EIT A IT mi OIC pr e AAA mg mel Uha atah y Mal Renee fin N SREE y i EA EEE ai l tain GL Train ATT a R dr 4 R ae SSRA ii TL ely 2 5 CHECK AND ADJUST Way of Check amp Adjustment 1 Mark O is checking time 2 Mark yy is the regular exchange of service items This exchange time 1s just for general riding of the majority not for the special use please arrange with this principle according to the difference of the riding condition Service Time month Service Items Judgement Standard Remarks Pere Ist Each each 12 riding 6 Operating Device Device Handle Play loose tight En n po Wheels Wheels Right left turn round angle turn round angle Front and Rear Cushion Damage a of Bolt Brake Device Device Brake Play Handle handle front Test Ride 10 20 mm Adjust Wires Loose tight and damage OOO pp Wore of brake
14. d piston pin O Wear the needle bearing of crank connecting rod small end Piston ring noise O Wear or damage the piston ring O Wear or damage the cylinder CYLINDER HEAD CYLINDER PISTON Disassembly of Cylinder Head Cylinder Piston e Disassembly of cover e Disassembly of generator cover e Disassembly of muffler e Disassembly of spark plug cap l 4kg a CYLINDER HEAD CYLINDER PISTON Disassembly Cylinder head Nut of cylinder head x WARNING Loosing nut 2 3 times Cylinder head Cylinder head gasket WARNING Don t knock cooling fin Cylinder gasket x WARNING Clean and not damage cylinder gasket of crank shaft case Piston ring clip Piston pin Piston Piston ring 10 needle bearing Installation of Piston Ring Install top piston ring amp 2 piston ring on piston e Do not scratch piston and do not bend Piston piston rings up piston ring e Remove carbon muck inside ring ditch and piston ring when not installed Be sure the rings rotate freely after piston ring install into piston x WARNING Change whole set of piston ring with genuine parts Starter Driving Disc Clutch Transmission Disc Attention of Operation O Don t make greases stick to surface of transmission belt or belt plate Otherwise the efficiency of power transmission will be lowered by skid Diagnosis of Trouble Vehicle does not move after engine start up O Drive belt wear out O Dri
15. djust the idle speed Adjust the air adjust screw x WARNING e No fire e Before disassembling loose fuel draining screw draining out the gasoline from carburetor FUEL SYSTEM Disassembly Plunger starter Pan phillips bolt Auto side plunger Oil ring Float Chamber Pan phillips bolt Drain screw Over flow tube Pan phillips bolt O o JJ DD UU ka 10 11 FThrottle screw set 12 Air adjust screw set x WARNING Must confirm rotation 13 Float chamber seal before disassembling 14 Pilot jet Not locking too much avoid to 15 Main jet base hurt seat face 16 e Operating with sequence in reverse of Disassembling 12 Air adjust screw set x WARNING use high pressure air clean each way of carburetor WARNING must adjust air screw when changing air screw and carburetor ass y FUEL SYSTEM Disassembly of Inlet Valve Disassembly of handle bar amp front cover Disassembly of fuel tank Disassembly of carburetor Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass y Reed valve gasket Assembly 5 gt 1 Reed valve ass y Reed valve gasket e Assembling with sequence in reverse of disassembly x WARNING Using new gasket the gasket must aim at hole of reed valve x WARNING confirm no leaking of the reed valve and manifold FUEL SYSTEM Disassembly of Fuel Tank O Disassembly of handle bar and front cover
16. ear oil to new O ring before install the oil pump into crank case The oil pump must correctly installed into crank case 7 WARNING Don t loosen adjusted screw on control cable Adjust the cable if it s loose LUBRICANT SYSTEM Disassembly of Oil Tank 1 Hex Bolt 1 WARNING 2 Joint of oil disassembly oil pipe Fill motor oil with clean container 3 Oil tank oo e Operation with sequence in reverse of disassembly x WARNING Connect correct oil pipe after assembly release the air in motor oil pump FUEL SYSTEM Attention in Operation Pay attention to the parts which using gasoline Tube amp Cable must be in accordance with the correct location Release air in oil pump when disconnect oil tube Diagnosis of Trouble No starting No gasoline in tank The arrow mark of Fuel valve pointed at OFF position Gasoline blocked Too much fuel in cylinder Air filter is clogged Idle speed unstable of carburetor rotation not smooth Poor idle speed adjustment of carburetor Low compression pressure Poor ignition system Bad adjustment of air adjusting screw on carburetor Air filter is clogged Defect of auto side plunger on carburetor Idle speed nozzle is clogged Mixed air too thin Nozzle of carburetor is clogged Gasoline filter is clogged Vent of gasoline tank is clogged Gasoline tube cranked broke clogged Poor action of float chamber
17. esignated lubricant ann GREASE Lubrication by grease Special Tool Parts on which special tools shall be used Tool General tools shall be used ar New Replace by new items after dismounting A Attention W Dangerous and important operations 2 2 INFORMATION FOR PREPARATION SPECIFICATION MODEL ATV 50 ATV 90 TYPE AIR COOLED 2 STROKE SINGLE CYLINDER KICK amp ELECTRIC OIL PUMP SEPARATE SUPPLY AUTOMATIC C V T V BELT NGK BP7HS 12V 4AH 1 LITER 4 5 LITER TARTING LUBRICATION TRANSMISSION PARK PLUG BATTERY A gt Q A Yo O C Q UEL TANK 1270 mm 875 mm 860 mm 660 mm 1540 mm 850 mm 900 mm 700 mm EAT HEIGHT WHEEL BASE 955 mm 100 kg DOUBLE DRUM DRUM OIL DAMPED INDEPENDENT SINGLE A ARM OIL DAMPED SWING SINGLE SHOCK 105 kg RONT BRAKE REAR BRAKE RONT SUSPENSION REAR SUSPENSION RONT TIRE 16x8 7 20 x7 8 19 8 7 REAR TIRE 16x8 7 18 5x9 5 8 19 8 7 SeSPECIFICATIONS SUBJECT TO CHANGE WITHOUT ANY NOTICE TAH AITHIAISIZAIOIOIO MO ma alam E lt lt lt S Z gt esi esi jes Q z SIMI gt gt gt j 4 es a la la l gt O Kal ala Al z alela E lt SIG lt lt oi 9 Es 6 T 4 2 2 INFORMATION FOR PREPARATION LOCKING TORQUE Adopt the standard torque locking for the item unlisted STANDARD TORQUE 5 mm Screw 0 4 6 mm Screw 1 0 6 mm Hex Washer Face Bolt Nut 1 2 mm Hex Washer Face Bolt Nut 2 7 10 mm Hex Washer Face Bolt Nut 4 0 CHA
18. f engine A A ked ked e me e NO me me gt Assembly x WARNING Carry out following adjusting 121 after installation Cable of throttle valve Oil pump control cable Rear break cable REMOVE OF ENGINE Disassembly of Muifler Operation Parts name Qty Remain Disassembly Remove tail of muffler Take off the engine Ass y Hex head phillips bolt Hex washer face bolt Hex washer face bolt Muffler Assembly e Assembling with sequence in reverse 5 gt of disassembly Nn BW NHN a N ked m CYLINDER HEAD CYLINDER PISTON Attention of Operation Can be operated when engine installed on vehicle Must cleaning before operating avoiding dust enter the engine Remove the gasket dust stay on joint face Avoid to use screw driver harm the joint face when remove the cylinder amp cylinder head Avoid to harm the cylinder inner surface and piston face O Cleaning before check parts and smear motor oil appointed in sliding face before installing Diagnosis of Troubles Low compression pressure poor start idle speed not stable O Air leakage of cylinder head gasket Wear amp damage the piston ring Wrong installation of spark plug Wear amp damage the cylinder and piston Reed valve defect Compression pressure too high overheating locking O Piling up carbon of cylinder head or piston head Piston Noise O Wear the cylinder and piston O Wear the piston pin hole an
19. f engine Disassembly of cylinder head and cylinder Disassembly of ACG Disassembly drive face ass y e Must disassembly of final reduction mechanism when change the left crank case O Must use special tool into the inner ring of crank shaft bearing and pull in crank shaft to assembly when assembly crank case amp crank shaft put new bearing into crank case and put into new oil seal after assembling crank case Diagnosis of Troubles Noise of Engine O Damage of crankshaft bearing O Damage of needle bearing of crankshaft pin 10 1 Crank Case Crank Shaft Assembly Disassembly of Crank Case 1 0kg m 2 pecialtodl Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing Right Radial ball bearing Left Hex socket bolt 10 Oil seal bracket 11 Right oil seal 12 Left oil seal 13 Radial ball bearing 2 Assembly 13 gt l 2 3 4 5 6 7 8 9 ked e a NO m N NA 10 2 Crank Case Crank Shaft Disassembly of Crank Case O Install the puller on right crank case separate the R crank case and L crank case Special tool Crank case puller TLJT 03 O Install the puller on left crank case remove the crank shaft from the crank case Special teal Crank case puller TLJT 03 WARNING Don t knock the crank shaft when disassembling O Use the bearing puller to remove the crankshaft bearing
20. ing Disc Operation Parts name 1 Cam plate 2 Cam plate slider 3 Weight roller 4 Primary sliding slot wheel Assembly e Operation with sequence in reverse K of separating 8 3 Starter Driving Disc Clutch Transmission Disc Disassembly of Clutch Transmission Belt Disc 5 5ke m 4 5 PI l Axle ring of spring l Compression spring l Secondary spring seat l Guide pin 2 Secondary sliding slot wheel l Oil ring 2 Oil seal 2 10 Needle bearing l 11 Internal circle clip l 12 Radial ball bearing l 13 Secondary fix slot wheel l Assembly e Operation with sequence in reverse 31 of separating 8 4 Final Transmission Mechanism Attention of Operation e This chapter explain that final reduction mechanism maintenance can be operated in the vehicle Use professional tool to change driving shaft Replace Transmission Gear Oil Remove 4 Hex Washer Face Bolt fixed on Floor Panel Move forward the Floor Panel Remove Hex Washer Face Bolt and Copper Plain Washer Leak out oil Transmission Gear Oil Fix Hex Washer Face bolt and Copper Plain Washer Remove Oil Plug and add 80C C new Transmission Gear Oil Fix Oil Plug Recommend use grade SAE 90 or 85W 140 Gear Oil Diagnosis of Trouble Engine starts but vehicle does not move O Transmission gears broken O Transmission gears burns out Operate of noise O Abrasion wore and teeth hurted of gear O Bearing wore and lo
21. ion piston port motor It requires the use of two cycle oil and should never be run without oil in the oil tank Extreme damage to the motor will result Ignition System The ignition system installed on ATV 50 90 100 II is the Computerize Digital Ignition CDI type There is no maintenance required for this type of system Chassis The chassis is constructed of mild steel tubing If any frame repairs are necessary oxyacetylene welding can be used If wire feed or arc welding is used use extreme care and disconnect the battery while welding Set Up Procedure The following instructions provided a general overview of the procedures needed to properly set up and deliver the ATV 50 90 100 to the retail customer 1 Take out the battery and fill with acid liquid Pre charging the battery will extend its life The preparation and charge procedure is based on the battery s instruction 2 Install the rear wheels and parts in the following order A 14x40x4 5mm washer big B 14mm hex bolt torque 450 550kg cm 44 54N m C Cotter pin open up the end after installed D Rubber cap 3 Install the front wheels and parts in the following order A 12x40x4 5mm washer b1g B 12mm hex bolt torque 300 350kg cm 29 5 34N m C Cotter pin open up the end after installed D Rubber cap 4 Set the handle bar into the lock pin of the steering base Tie up the 4 hex socket bolts Install the rear cover into handle bar and adjust the cab
22. les and wires properly Install the front cover into the rear cover 5 Pull the seat lock cable and remove the seat Install the battery with the red wire to positive and the black wire to the negative 6 Remove the oil tank cap and fill with 2 stroke ou SAE 30 of a synthetic and low smoke type and enough unleaded gasoline to operate Be sure the arrow mark on the fuel valve arm petcock 1s set into the correct position on 7 Install the Front Bumper 8 Turn on the main switch and try to start up the engine In order to use the electric starter you need to check the following A Turn on the engine operation switch located on left handle bar B Pull the rear brake lever C Push the electric starter bottom to left or right 9 Ifthe vehicle is operating in a very dusty area please add more oil on the air cleaner filter O uU u L L E PDI PRE DELIVERY INSPECTION For ATV 50 90 100 1 Record the frame and engine number into the owner s manual 2 Check that all tires have correct pressure specified on the tire or in the owner s manual 3 Engine lubrication oil 2 stroke Grade SAE30 tank 1s filled 4 Battery 1s installed properly 5 All brake cables are adjusted properly 6 Fuel tank has enough gasoline to operate _ 7 Check the suspension and drive chain for proper setup L L 8 Check that all electrical components and lights are working properly 9 Make sure that the owner s manual and
23. ling with sequence in 825 reverse of disassembly LUN e GO N N Ln Assembly wheels A gt x WARNING Change the R L bearing set if necessary 11 3 FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Front Brake Disassembly brake plate Handle bar covers Release adjustment screws Release front left or right wheel Ass y Strain spring Front brake shoe Comp Release brake cables Front brake panels O Assembling with sequence in reverse of disassembly 11 4 FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Suspension Arm Operation Parts name Disassembly L R Hex bolt 2 Hex flange nut with serration 2 Release front cushions 2 Hex flange nut with serration 4 Hex washer face bolt 4 Suspension arms 2 Assembly 6 1 O Assembling with sequence in reverse of disassembly IR 11 5 FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Steering Shait Ass y Operation Parts name Disassembly steering shaft Ass y Handle bar A ssy Hex flange nut with serration Steering shaft holder Holder spacer coller Hex flange nut with serration Release Ball joint left right thread Steering shaft Ass y rere rR NNN NF Disassembly knuckles Cotter pin Hex flange nut with serration 10 Left amp right link Ass y 11 Scotch flange nut 12 Left amp right knuckle Assembly knuckles Assembling with sequence in reverse of 128 disassembly
24. lteran oftubes CO Lights A ptm OP OF O n Onoff normal dirty damage O P A Exhaust pipe amp muffler Installation loosed or damage PO S o Function ofmufler OSO Frame amp body loose or damage Frame amp body loose or damage assis OF re em pipe and carbon muck in muffler DRIVE CHAIN DRIVE CHAN n Check the tension of drive chain O aen 10 20mm Others greasing ofeachpa O OF o o Abnormal from previous day confirm normal 3 3 CHECK AND ADJUST Disassembly of External Parts Remove the external parts for check and adjustment Disassembly the Rear Cover Pull the Seat Releaser Unit and take off Seat Ass y Remove 4 Pan Flat Head Phillips Bolt Remove 2 Ladder Bolt Remove 4 Nylon Nut 2 Plain Washer and 2 Rubber Washer Remove Floor Panel Remove 4 Pan Flat Head Phillips Bolt Disassembly the Handle Bar Remove 2 Tapping Screw Truss Head Phillips and take off Front Handle Bar Cover Remove 2 Handle Grip Remove 4 Hex Socket Bolt and take off the Handle Bar Release 1 Hex Socket Bolt and take off the R Lever Ass y Release 2 Pan Flat Head Phillips Bolt and take off the L Handle Switch Ass y Release 1 Hex Socket Bolt and take off the L Lever Ass y Disassembly the Front Cover Disassembly the Handle Bar Remove the Fuel Tank Cap Pull the Seat Releaser Unit and take off Seat Ass y Remove 2 Ladder Bolt and 4 Pan Flat Head Phillips
25. n the pump if there have air in the pump when disassembly tube of carburetor Oo After disconnect the oil tube must fulfill the oil in the connection tube before installation Diagnosis of Troubles Too much smoke means too much carbon muck piping up the spark plug O Poor synchronizing adjust of oil pump too much exhaust gas O Bad quality of engine oil Overheating e Poor synchronizing adjustment of ou pump too exhaust gas O Bad quality of engine oil Piston burnt O Short of engine oil or engine oil tube is clogged e Poor adjustment of oil pump O Airin tube system or in oil pump O Badoilpump Clogging oil from oil tank e Vent of oil tank s cap is blocked e Oil Filter is clogged Preparation standard Oo Use separating engine oil appointed use for 2 stroke e Oil tank capacity 1 1 liter LUBRICANT SYSTEM Disassembly of Motor Oil Pump O Remove Generator Cover O Remove A C G fly wheel and fly wheel base x WARNING Operating after cleaning motor oil pump around and no entering to the crank shaft Case LUBRICANT SYSTEM Operation Parts Name Qty Remake Parts Name Disassembly 1 Fuel tube 2 Fuel connection tube 3 Pan phillips bolt 4 Control cable 5 Oil pump Q ty Remarks 7WARNING Clogging the tube to avoid fuel flow out e Remove from both side of oil pump e Remove from oil pump e Assembly with sequence in reverse of disassembly x WARNING Sm
26. osened Gear oil leaking e Too much gear oil filled O Oil seal wear out or damage Final Transmission Mechanism Disassembly of primary drive gear final reduction mechanism O Disassembly of Drive Sprocket Ass y Remove 1 Nylon Nut and Plain Washer O Disassembly of clutch drive face 7WARNING First drain the oil of transmission Disassembly Bolt Mission cover Main axle comp Check the wear amp damage of Plain washer shaft and gear Primary drive gear Assembly Operation with sequence 8 21 reverse of disassembly OO eVausvr Final Transmission Mechanism Change the Driving Shaft O Remove the driving shaft from mission cover x WARNING Don t damage joint face of mission cover O Remove the oil seal of primary drive gear O Remove the bearing O Install the new bearing in the mission cover NO Driv ing shaft ES ii dh gt cap of transmission case Oil seal bearing A outer handle A 3 17mm guide rod of puncher y lt EA Jacket puncher NAAA of bearing 37 40mm Crank Case Crank Shaft Attention of Operation e This chapter explain the necessary procedure of disassembling crank case due to repair amp maintain the crank shaft O Before disassembling of crank case must operation with sequence of each chapter to disassembly Disassembly of oil pump Disassembly of carburetor Disassembly of intake valve Dis mounting o
27. ront wheel depart ground Diagnosis of Trouble Steering handle not straight e Loose not correct adjustment or Heavy steering movement damaged right or left link Ass y e Air pressure too low inside of front e Steering shaft bended tire e Suspension arm knuckle damaged e Rim radial ball bearing broken e Rim damaged Brake efficiency abnormal Front wheel shaking or deviation e Brake lining wear out e Front rim defected e Brake pads adjust not correct or e Loose or damaged of front rim wear out bearings e Brake drum wear out e Tire defect e Tire wear out e Bad adjustment or defected of the right or left link Ass y e Bad adjustment or defected of the right or left knuckle 11 1 FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Front Wheels of AT V 50 Disassembly front wheels L R Rubber cover Plain washer 12 40 4 5 Disassembly front brake drum Hex washer face bolt Front coller Front brake drum Rim Assembly front brake drum Oo Assembling with sequence 8 gt 5 in reverse of disassembly Assembly wheels 4 gt WARNING Change the R L bearing set if necessary 11 2 FRONT WHEEL FRONT SUSPENSION FRONT BRAKE Disassembly of Front Wheels of AT V 90 100 Operation Parts name Remarks Disassembly front wheels L R Rubber cover Plain washer 12 40 4 5 Disassembly front brake drum Hex washer face bolt Front coller Front brake drum Rim Assembly front brake drum Assemb
28. ve face comp damage e Clutch lining wear out O Driven Ass y spring defect Power insufficient O Drive belt wear out O Driven Ass y spring defect O Drive face dirty or oily e Weight roller wear out 8 1 Starter Driving Disc Clutch Transmission Disc Disassembly of Left Crank Case Cover Operation Parts name Q n Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket 12 l l l 2 l Assembly e Operation with sequence in reverse 6 of disassembly 8 2 Starter Driving Disc Clutch Transmission Disc Disassembly of Kick Starter O Disassembly of left crank case cover Operation Parts name Disassembly Kick pinion spring clip Kick pinion Hex washer face bolt Kick crank External ring clamp Plain washer Starting shaft ass y Starting shaft reset spring Bushing x WARNING Rotating pedal kick to crank and remove the case cover assembly VW 0 10 O BE Y LA ed a me Ked e e pen pl pl 8 3 Starter Driving Disc Clutch Transmission Disc Operation Parts name x WARNING Unable to install main shaft fix position when inside and outside reset spring overlap Use flat driver screw start from inside then outside spring and press main shaft Starting shaft reset spring Starting shaft ass y Plain washer External ring clamp Kick crank Hex washer face bolt Kick pinion Kick pinion spring clip ke e a ee e d ke d d 9 8 7
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