Hsun hs700atv Maintenance Manual
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Hsun hs700atv Maintenance Manual

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700ATV Maintenance Manual
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Summary of Contents for Hsun hs700atv

  • Page 1 700ATV Maintenance Manual...

  • Page 2: Table Of Contents

    Catalogue General Information ……………………………...5 1 Description …………………………………………………..5 1.1 Identification code………..……………………………..6 1.1.1. Frame No. …………………………………………………6 1.1.2. Engine No.…………………………………………………7 1.2 Special tools, instruments and meters…………………7 1.3 Periodic maintenance chart……………………………….9 Engine ………………………………………………………….11 2. Inspection and adjustment of engine …………….11 2.1 Inspection of cylinder head, intake and exhaust valve………………………………………….11 2.2 Inspection of spark Plug………………………………….12 2.3 Inspection of cylinder, piston and piston ring…….14...
  • Page 3 3.Disassembly of engine ……………………………………27 3.1 Cylinder head and block………………………………….27 3.2 Piston and connecting rod……………………………….31 3.3 Manual starting mechanism……………………………….32 3.4 Sensor………………………………………………….…….32 3.5 Left crankcase cover……………………………….…….33 3.6 Magneto…………………………………………………..….33 3.7 Oil pump………………………………………….……..….34 3.8 Clutch…………………………………………………...….35 3.9 Carburetor……………………………………………...….36 3.9.1 Structure of carburetor………………………...…..36 3.9.2 Inspection and adjustment of carburetor…..….37 4.Chassis 4.1 Steering operation system………………………...…..39 4.2 Brake system…………………………………………...….51...
  • Page 4 5.1 Ignition system…………………………..……..….87 5.2 Magneto and charging system…………..……..….88 5.3 Battery……………………………………..……..….88 5.4 Lighting system…………………………..……..….90 5.5 Meterand signal system…………………………..……91 5.6 Electrical starting system…………….……..…….92 6.Appendix ………………..…………………..……..…93 6.1 Specification………..…………………..……..….93 6.2 Requirements for torque of fastener……………….99 6.3 Electrical circuits……………………………..….100...

  • Page 5: General Information

    General Information 1. Description...

  • Page 6: Identification Code

    1.1 Identification code 1.1.1. Frame No. The frame No. is engraved in the right bottom of the supporting frame. See Figure 1-1. Figure 1-1...

  • Page 7: Engine No

    1.1.2.Engine No. The engine No. is engraved in the right side of the engine. See figure 1-2 Figure 1-2 1.2 Special tools, instruments and meters 1.2.1 Oil filter detacher To fasten and detach the oil filter 1.2.2 Height gauge To gauge the height of various components 1.2.3 Vernier To measure the length of various components 1.2.4 Outside micrometer...
  • Page 8 To accurately measure external diameter of a column 1.2.5 Inside micrometer To accurately measure internal diameter of a hole 1.2.6 Dial indicator To accurately measure a small distance 1.2.7 Torque Spanner To measure torque force 1.2.8 Feeler gauge To measure gap-width 1.2.9 Multimeter To check electrical circuits and parts...

  • Page 9: Periodic Maintenance Chart

    1.2.10 Barometer To measure pressure of the tire 1.2.11 Magneto drawing device To detach the magneto 1.2.12 Snap ring clampTo install and detach snap rings 1.3 Pe riodic maintenance chart EVERY INITAL month Whicheve ITEM 1,200 2,400 2,400 4,800 ROUTINE comes first (mi) (200)
  • Page 10 damage. ● Replace if necessary. ● Check for lecakage. ○ ○ ○ Exhaust system* ● Tighten if necessany. ● Replace gasket(s) if necessary. Spark arrester ○ ○ ○ ● Clean. ● Check fuel hose for cracks or damage. ○ ○ ○...
  • Page 11 ● Repair if necessary. ● Check bearing assemblies for lossenss/ ○ ○ ○ ○ Wheel bearing* damage. ● Replace if necessary. ● Check operation. Front and rear ○ ○ suspendion* ● Correct if necessary. ● Checkoperation./Replace if damaged ○ ○ ○...

  • Page 12: Engine

    Engine 2. Inspection and adjustment of engine Inspection of cylinder head, intake and exhaust valve Preheat the engine ,then misfire and unplug the spark plug.Fix pressure gauge into the hole, open the choke and throttle handle,and start for 4-6 times. Note: Giving a leakage check to the pressure gauge.Rotate the engine until the pressure gauge stop rising.The maximum reading would be greater than 0.7-0.9Mpa after starting...
  • Page 13 cover ,round the flywheel of magneto anti-clockwise to aim “T”at the signal of fore cover on the left. Note: The piston must be fixed to the dead enter. (Figure 2-2) Figure 2-2 Remove cylinder valve cover,check the lash between the valve stem by feeler gauge .

  • Page 14: Inspection Of Spark Plug

    See figure 2-4. Figure 2-4 2.2 Inspection of spark Plug 1. Unplug the Spark-Plug cap:remove the spark plug by box key,look over whether the spark-plug insulator and electrode is damaged or sooting. If so ,see figure 2-5. Figure 2-5 2． Check the spark clearance by feeler gauge whether it is between 0.6～0.7mm.Or adjust the gap,clean incrustation...

  • Page 15: Inspection Of Cylinder, Piston And Piston Ring

    standard value:mm limit value:mm item cylinder bore diameter of cylinder 102～102.03 102.1 taper 0.0040 0.005 out of roundness 0.0035 0.005 degree of toruosity 0.04 0.06 Piston,piston external diameter of piston 101.92 101.95～101.97 ring and piston pin bore diameter of piston pin 22.010 22.002～22.010 hole...
  • Page 16 diagnosing and eliminating of malfunction: Emission of black smoke for abrasion of cylinder or ● piston, 1. Cylinder , piston of piston ring is worn out. 2.The piston ring is not properly assembled. 3. The piston or cylinder wall is scraped. overheated ●...
  • Page 17 Note:It forbidden damaging piston ring when assembling.Check whether the piston and the piston groove is cracked and abraded.See figure 2-7 Figure 2-7 2.Insert piston ring into cylinder,and measure the end gap.repairing limit value:the first ring/the second ring: 0.5mm See figure 2-8. Figure 2-8 Measure the bore diameter of piston pin hole.

  • Page 18: Inspection Of Crankshaft

    3.Measure the external diameter 10mm above the bottom of the piston skirt. Extreme position :the gap between cylinder and pistonrepairing limit value: 0.1mm See figure 2-10 Figure 2-10 Measure the external diameter of piston pin: the gap between piston and piston pin: repairing limit value: 0.02mm .See figure 2-11 Figure 2-11 2.4 Inspection of crankshaft...

  • Page 19: Inspection Of Clutch

    Figure 2-12-1 Figure 2-12-2 Inspection of clutch The wear condition of shoe block and friction plate:See figure 2-13 Figure 2-13 2.6 Inspection of carburetor 1、Inspect the idle of carburetor The engine speed should be 1500±150r/min 10 minutes after starting at normal idle and will not misfire when briskly accelerate.If not so, rotate the carburetor idle adjusting screw clockwise to rise the idle ,anti- clockwise to lower.When adjusting is unavailable,check that if there is a jam in...

  • Page 20: Inspection Of Air Filter

    See figure 2-14 Figure 2-14 2.7 Inspection of air filter 1、Disassemble the air cleaner,remove cartridge,clean the cartridge with non-flammable cleaning solvent,and then make it dry. Note: Petrol is forbidden. 2.Dip the air filter cartridge into 20# oil,then take it out and squeeze excessive oil,assemble orderly.Impermeability...

  • Page 21: Inspection Of Lubrication System

    into crankcase. Figure 2-17 2.9 Inspection of lubrication system Lubricant of engine:the vehicle is oiled with lubricant of APISGSAE10W/40. Others are forbidden. capacity : The capacity is 1.9L after disassembly and assembly. 2、The capacity is 1.8L when fueling up after drain. Inspection of lubricant:locate the dune buggy on the ground to lookover the capacity with dip stick.If the level is lower than the...

  • Page 22: Inspection Of Cylinder Head

    the dip stick and look whether oil level is lower than the indicator. See figure 2-18 Note:Ensure that the engine is landed by both four wheel in flat ground. Indicator of oil level Figure 2-18 2.11 Inspection of cylinder head 1.Check whether the spark plug and valve seat is cracked and whether the cylinder head is out of shape.Examine the flatness of cylinder head by flat or knife edge gauge and clearance gauge .
  • Page 23 If the mating surfaces is coarse,corrode or cannot contact with valve seat normally.repalce it. Figure 2-20-1 Figure 2-20-2 Figure 2-20-3 Measure the width of mating surfaces of valve repairing limit value: 1.5mm If the valve seat is to wide or narrow or cracked,grind it to ensure impermeability.
  • Page 24 guide. Repairing limit value: intake : 0.12mm exhaust: 0.14mm Note :Eliminate carbon in the pipe before measuring.If the pipe will be replaced,grind the valve seat again . 5、Inspection of valve and valve pipe: Check whether the valve is bent,burn or the valve stem is worn out. Check the motion of valve and measure external diameter.
  • Page 25 Figure 2-22-1 Figure 2-22-2 6、Examining lifting distance of breaker cam. Measure the length of fillet with micrometer and check If it is worn out. Repairing limit value:inlet lifting distance: 5.73mm Exhaust lifting distance: 6.53mm.See figure 2-23. Figure 2-23 7、Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal.
  • Page 26 Note:If there is a rocker arm to be replaced,examine the peak of breaker cam measure the bore diameter of rocker arm Repairing limit value: 12.038mm.See figure 2-24 Figure 2-24 Inspection of rocker arm shaft. Examine if the rocker arm if worn out or cracked. Measure the external diameter of rocker arm shaft with micrometer.

  • Page 27: Disassembly Of Engine

    Figure 2-25 3. disassembly of engine 3.1 cylinder head and block Unplug the intake pipe and spark plug.( Figure 2-26-1, 2-26-2) Figure 2-26-1 Figure 2-26-2 Remove cylinder valve cover,cam chainwheel cover and Figure 2-27-1 remove valve chain wheel Figure 2-27-2 Figure 2-27-1 Figure 2-27-2...
  • Page 28 remove lower rocker arm shaft.See figure 2-28 Figure 2-28 Remove vision hole cover of left front cover .See figure 2-29 Figure 2-29 Alignment: asjust these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover. alignmentment of top dead center: Rorate the crankshaft with “T”...
  • Page 29 Inspection of compression top dead center: See figure 2-30-1 and figure 2-30-2. figure 2-30-1 figure 2-30-2. When inlet valve spring rise,rotate the crankshaft until the “T” indicator on the magneto rotor to be at the same level with the center of vision hole cover of left front cover.That is to say the piston is at the compression top dead center and there are valve clearance in these four rocker arms of cylinder head.
  • Page 30 Figure 2-32 remove the cylinder head Loosen the bolt by intersection manner before remove the bolt.see figure 2-33. Figure 2-33 remove adjuster cotter sealed ring of cylinder headtensioner adjuster guide board See figure 2-34. Figure 2-34 remove cylinder block0-seal adjuster cotter sealed ring of cylinder head...

  • Page 31: Piston And Connecting Rod

    See figure 2-35. Figure 2-35 3. 2 piston and connecting rod remove the piston snap ring Note:block the crankcase breather with a piece of cleaning cloth to avoid the snap ring falling into the case .See figure 2-36. Figure 2-36 remove piston pin and piston Clean the buckle of piston and piston pin hole to facilitate the removing of piston pin.

  • Page 32: Manual Starting Mechanism

    3.3 Manual starting mechanism See figure 2-38. Figure 2-38 3.4 sensor Figure 2-39 3. 5 left crankcase cover See figure 2-40. Figure 2-40 3. 6 magneto remove the stator coil...

  • Page 33: Oil Pump

    remove the pluse coil Remove the stator with rotor stripper.See figure 2-41. Figure 2-41 Remove the whitney key. See figure 2-42. Figure 2-42 3.7 oil pump remove the bolt of oil pump cover .See figure 2-43. Figure 2-43 remove right cover .See figure 2-44.

  • Page 34: Clutch

    Figure 2-44 Remove the right support frame,clutch pulley disc .See figure 2-45-1, figure 2-45-2, figure 2-45-3. Figure 2-45-1 Figure 2-45-2 Figure 2-45-3 3.8 clutch remove the clutch Remove bolts. See figure 2-46. Figure 2-46...

  • Page 35: Carburetor

    Remove the clutch shoe block and clutch cover. See figure 2-47. Figure 2-47 Check the wear condition of the clutch shoe block and clutch cover. See figure 2-48. Figure 2-48 3.9 carburetor 3.9.1 structure of carburetor...
  • Page 36 1．carburetor assembly 2.oil needle component 3.Plunger spring 4. Big diaphragm 5.Plunger 6.Diaphragm circlip7.Screw on upper cover 8.Mixture ratio adjusting screw component。9 .idle metering jet 10.High speed jet 11.Liner 12.Foam pipe 13.0-ring of foam pipe 14.Float 15。 Screw M4×816。 Float pin 17.Big screw 18.Float seal ring 19.Fuel inlet valve component 20.High speed jet 21.Drain screw...
  • Page 37 spring spring block oil needle remove pilot screw spring washer Note:the pilot screw is set at maximum performance.Before removing pilot screwd,note the revolutions of screw in order fix it back. remove float chamber cover washer remove float pin float triangular needle remove the cover 0-rings spring...
  • Page 38 float bowl oil passage gas-fouling block→cleaning chap/damage→replace the carburetor assembly cleaning steps: check the float damaged→replace check the float triangular needle triangular needle seat 0-rings filter gauze Damaged/worn out/block→replace check the piston valve crack→replace diaphragm rupture→replace piston valve oil stick bent/worn out→replace Note:If the piston valve is damaged,inject the petrol into valve.Replace it when there is oil leakage.

  • Page 39: Chassis

    pilot jet pilot screw 0-scrapers pilot jet bent/worn out/damaged→replace gas-fouling block→blow with compressed air 4.Chassis 4.1 Steering operation system Structure of Steering Vertical Column...
  • Page 40 1、steering vertical column components 2、turning rocker arm components 3、Steering Bar Clip 4、hexagon flange bolt M8×35 5、inner and external bearing of steering vertical column 6. supporting seal ring of steering vertical column 7、Supporting stent 8、hex bolt M8×60 9、stop reverse piece 10、Supporting Collar Sheath 11、cushionф14×ф32×4 12、Hexagon open-groove nut M14...
  • Page 41 Components of Steering Bar 1、Steering Bar 2、steering Rubber Sheath 3、air duct door pull cable 4、oiler components 5、acceelerator pull cable components...
  • Page 42 6、left switch components 4.1.1Disassembly, inspection and assembly of Steering Vertical Column 4.1.1.1Disassembly of Steering Vertical Column 1.Remove all of the Plastic cover and Plastic oranments on Steering Bar (Figure 4-1-1 1）. Front Mud Shield 2）.Plastic Ornament 3）.Rear Mud Shield 2.Remove Steering Bar Holder (Figure 4-1-2) Figure 4-1-1 1）.
  • Page 43 3）Front Brake Cable 4）Steering Bar 4.Remove the cotter pin, Figure 4-1-3) open-groove nut and cushion at the bottom of the Steering Vertical Column. (Figure 4-1-4) 1）.cotter pin 3.2×32 2）.cushionф14×ф32×4 3）.Hexagon open-groove nut M14 5、Remove the supporting brackets of the steering vertical column Figure 4-1-4 (Figure 4-1-5)
  • Page 44 (Figure 4-1-6) Figure 4-1-6 1)Tension rod 2)front right Differential 3)cotter pin 3.2*32 4)Hexagon open-groove nut M10 7.Pull out the components of the steering vertical column from the bottom seat. ( Figure 4-1-7) Figure 4-1-7 1、 Steering Vertical Column 2、 Bottom Seat 4.1.1.2 Inspection of steering vertical column components: 1.Check whether the nut between the inner ball pin of tension...
  • Page 45 tighten it with proper tools or replace with identical nuts. Figure 4-1-8 Torque: 32-36N.m 1)Steering drop arm assembly 2)Hexagon open-groove nutM10 3)cotter pin 3.2*32 4)Tension rod 2.Check whether the inner and outter ball pin of the tension rod is loosen or got stuck.
  • Page 46 vertical column. Figure 4-1-5 Inspection method: Assemble the steering vertical column to the main frame with supporting bracket and M8 bolts etc. and rotate the steering bar to ensure the column is not stuck or swinging. In occasion of above problems, the supporting bracket must be replaced.
  • Page 47 Figure 4-1-9 1)、Steering bottom seat 2)、Cushion 3)、Hexagon open-groove nut M14 4)、Cotter pin 3.2×32 2.Fix the steering vertical column onto the frame with hexagon flange bolt M8*60 (2pcs), supporting stent (1pcs), inner and outer supporting bracket (2pcs), stop reverse piece (1pcs) and collar pipes (2pcs). (Figure 4-1-10) Fastening Torque of M8*60 Bolt: 26-30N.m Caution: inner surface of the supporting brackets must be...
  • Page 48 Figure 4-1-10 1)、 hexagon flange bolt M8*6 2)、Inner and outer supporting bracket 3)、stop reverse piece 4)、Supporting stent 5)、Supporting Collar Sheath 6)、Supporting ferrel 4.Fix the tension rod into the conical bore of the steering vertical column with tension rod components (2sets), cushion12 (2pcs), M10 hexagon open-groove nuts (2pcs) and cotter pins 3.2×32 (2pcs).
  • Page 49 2)Cushion ф10 3)Hexagon open-groove nut M12 4)Cotter pin 3.2×32 4.1.2 Disassembly, inspeciton and assembly of steering bar 4.1.2.1 Disassembly of steering bar 1.Remove all of the Plastic cover and Plastic oranments on Steering Bar (Figure 4-1-1) 2.Remove steering bar clip（附图4-1-2） 3.Unplug all cables and wires and remove the steering bar (Figure 4-1-3) 4.1.2.2 Inspection of steering bar...

  • Page 50: Brake System

    than 3mm, otherwise replace the steering bar. Figure 4-1-12 3.Check if there exists any slip thread, crack or other defects on the fastening bolts, in which case the bolts must be replaced. 4.Check whether the steering bar clip is damaged(Figure 4-1-12).(Radial runout and wear condition of the inner surface must be less than 0.8mm) Otherwise, replace the steering bar clip.
  • Page 51 1、disk brake pump assembly 2、disk brake compressed bearing 3、disk brake oil bowl sealing washer 4、disk brake oil bowl cover 5、cross recess half-countersunk head screw M5×12 6、disk brake pump seat 7、cross recess pan head screw M5×60 8、disk brake handle 9、hexagonal locknut M8 10、disk brake switch 11、disk brake handle bolt 12、disk brake oil pipe branch seat 栓...
  • Page 52 Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. The vehicle uses brake plate. Please follow the tips of inspection as below: a)Inspect the brake fluid box level on the right handlebar. Should the fluid level falls under the minimum mark, please refill the box with the same type...
  • Page 53 1、Adjusting Screw c) Inspect the elasticity of the brake handlebar. d))Brake fluid will be automatically injected into the brake fuel pipe in the process of abrading brake pad reducing the fluid level in the box. Therefore, periodical inspection of the fluid level is necessary.
  • Page 54 Figure 4-2-3 1)Brake plate clip 2)Hexagon self-lock nut M8 f)Disk brake plate uses hydraulic pressure of the brake fluid. Therefore, fuel pipe must be periodically inspected and replaced. Inspection Method: Fuel pipe must be replace when worn out, cracked or distorted. 4.2.1.1 Disassembly, inspection, maintenance and assembly of Front Disk Brake System.
  • Page 55 (Figure 4-2-5) 1)disk brake plate 2)Rront brake plate clip 4.2.1.3 Disassembly of the Front Disk Brake system: 1.Remove the bottom seat of Disk Brake Pump and then remove the whole unity. Figure 4-2-6 Figure 4-2-6 1)bottom seat of Disk Brake Pump 2)Disk Brake Pump unity 2、Remove the Front Fuel Pipe Brackets(Figure4-2-7) Figure4-2-7...
  • Page 56 4.2.1.4Inspection of the Front Brake System 1.Check the Brake Fluid Box for crack, leakage and other potential defects. 2.Check Fastening Bolts of all Fuel Pipes for possible looseness or damage. 3.Check all Fuel Pipes for deterioration, distortion, crack, wear and other hidden defects. 4.Check the Brake Plate Clip for distortion, crack, rust and stuck.
  • Page 57 1.5mm 4.2.1.5 Assembly of Front Brake System 1.Use Fuel Pipe Brackets (2pcs) and Hexagon Flange Bolts M8*16 (2pcs) to connect the Fuel Pipe Clip with both left and right Lower Front L/R rocker armss. Caution: Fuel Pipe must avoid physical contact with other components in movement.
  • Page 58 4-2-15) stening Torque of Conical Nut: 55 N.m -40N.m 6、Fix Front Disk Brake Pump onto the Right Handlebar with M5*60 hexagon bolts (2pcs) (Figure 4-2-16) astening Torque of the bolt is: 10 --14 Caution: Do not operate the vehicle immediately after assembling the brake system.
  • Page 59 Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. b)Rear wheels of the vehicle use brake plates mechanized by a rear brake pedal. Please follow the tips of inspection as below.
  • Page 60 e)Inspect the elasticity of the brake handlebar. f)Brake fluid will be automatically injected into the fuel pipe in Figure 4-2-10 1、Rear Brake Pedal the process of abrading brake pad reducing the fluid level in the box. Therefore, periodical inspection of the fluid level is necessary. Caution: must use DOT4 Brake Fluid 。...
  • Page 61 Figure 4-2-11 1、Disk Brake Plate Caution: 1. If the thickness of the disk brake plate is less than 2.5mm, it must be replace. 2. In occasion of crack or distortion, the disk brake plate must be replaced. h)Disk brake plate uses hydraulic pressure of the brake fluid. Therefore, fuel pipe must be periodically inspected and replaced.
  • Page 62 3.Release assembling Bolt（M8*14） and detach the Rear Disk Brake Clip. (Figure 4-2-12) Figure 4-2-12 1)Rear Disk Brake Clip 2)hexagon flange bolt M18×14 4、Remove Rear Disk Brake System 4.2.2.4. Disassembly of Rear Disk Brake Plate 1.remove rear wheel components(Figure 4-2-13) 2、Release the transmission case components of rear bridge from the main frame.Remove rear central transmission shaftv...
  • Page 63 Figure 4-2-14 1)hexagon flange bolt M10×115 2)rear transmission case 3)rear central transmission shaft 3.Remove the Rear Disk Brake Plate from Bottom Seat See Figure 4-2-15 Figure 4-2-15 1).Bottom Seat of Rear Disk Brake Plate 2)Rear Disk Brake Plate 4.2.2.5Inspection of Rear Brake System: 1、Check the Brake Fluid Box for crack, leakage and other potential defects.
  • Page 64 5、Inspect the Disk Brake Shoe for wear condition. Brake shoe must be replaced when worn out. 1、Brake Shoe 6、Inspect the Brake Shoe for maximum wear, distortion and crack, in which case it must be replaced. Maximum wear of Rear Disk Brake Plate is less than 2.5mm 4.2.2.6 Assembly of Rear Brake System 1Fix Disk Brake Plate onto the Bottom Seat with Special M8 Bolts...
  • Page 65 transmission case .Then configure the rear central transmission shaft, rear transmission case in turn. See Figure 4-2-15 3、 Mount the Disk Brake Clip onto rear transmission case with M10×30 Bolts (2pcs) Fastening Torque: 18 N.m--22 N.m 4、 Mount Fluid Box of Rear Disk Brake onto the Frame with M Bolt (1pcs).

  • Page 66: Wheels And Tires

    circulating before riding the vehicle. 4.3 Wheel and Tire 4.3.1：Preparation for maintenance of wheel: 1.Inspect wear condition of the tire. (Figure 4-2-16) 2.Check if the Wheel Hub is worn-out or damaged. (Figure 4-2-13) 3.Check if the Wheel Hub is rusted or cracked. Figure 4-2-16 4、Check if the conical nuts of the Wheel Hub...
  • Page 67 2、Check if the tire has reached its maximum wear condition in which case it should be replaced. 3、Check the joining condition of the tire and wheel hub. If the joint of tire and wheel hub is loose, replace the tire immediately. 4、Check the vibration of tire/wheel hub.
  • Page 68 4.3.2 Specification and operation guide of Wheel Hub and Tire. Since wheels and tires are crucial to the Figure 4-2-17 vehicle operation, periodical inspection for tire pressure and profile depth is necessary. Specification of Wheel and Tire Wheel Hub （kPa）Tire Pressure Tire Dimension Dimension Front...

  • Page 69: Transmission System

    depth of the tire is over worn, which might result in spinning, instability, lose of control and other potential security risk of the vehicle. Caution: Should the profile depth falls below 3mm, please replace the tire immediately.( Figure 4-2-18) Figure 4-2-18 Figure 4-2-18) .4 Transmission System Fore Bridge...
  • Page 70 5、L/R turning joint front tank components 1、 gear-box assembly of front bridge 2、 the right cover 3、 the left case 4、 cushion 10.5 5、drive gear of front bridge 6、 front driving axis pin sleeve 7、 M10X1.25 flange locknut 8、 0-ring of front bridge drive gear f9、65X48oil seal 10、oil seal of rear constant velocity joint assembly 11、differential –adjusted washer 12、...
  • Page 71 28、 needle bearing15BM2112 29、 M10X16 oil-change bolt 30、 10X1.5 cooper gasket 31、 power divider coupling 32、differential-adjusted washer 33、bolt M14X15 34、copper gasket 14X2 35、vent pipe of drive case 36、clip of oil pipe 37、fore transmission shaft 38、weak spring of fore transmission shaft 39、dust-proof cover of fore transmission shaft 4.4.1 Disassembly,...
  • Page 72 4.Check if there exists any slip thread or flaw on the open-groove nut . 5..Disassemble the front tank and check whether the gears Is engaged properly. 6..In case the choke is jammed,it must be dredged with a needle.If the problem is not solved, replaced it. 7.If there are defects on sensors ,it must be checked and maintained by a professional.
  • Page 73 4.4.1.3 Inspection and Maintenance of fore bridge: 1. If the dust-proof Rubber Sheath of the transmission shaft is worn out or cracked, please have it replaced immediately. 2、 Check whether the ball is running smoothly. If found loosen or stunk, replace the transmission shaft. 3、...
  • Page 74 Torque of the bolt: 23N.m 3、Fix the fore bridge differential onto the frame with hexagon flange bolt M10×110 (2pcs), M10 nuts (2pcs), cushion 10 (2pcs) ( Figure 4-2-21). Fastening Torque of the Bolt is 40～45N.m. ( Figure 4-2-21) 1、 hexagon flange bolt M10×110 2、...
  • Page 75 needle bearing needle 1、 rear bridge transmission case assembly 2、 the left case 3、 22BM3010 4、 bearing 55BM6720A needle bearing 5、 cluster gear of rear bridge 6、 7、 rear disk brake seat 8、 Oil seal 9、 clamp sheath 0-ring of rear drive gear rear drive gea 10、...

  • Page 76: Gearshiftmechanism

    oil-change Copper gasket Weak spring of rear bridge 34、rear bridge plug M14X15 35. 14 36. transmission shaft rear bridge transmission shaft 38. external clip18 immision shaft dust-proof cover 39. sheath of rear bridge trans 40. external clip1818 41.clip 42. fore of rear bridge transimmision shaft .
  • Page 77 12、waste oil pipe robber plug of gear shift mechanism 13、hex nut (upright)M8 14、connecting rod of gear shift mechanism 15、hex nut (anti)M8 16. gear shift controling 17. cushion6 18. hex nut M6×36 4.5.1Inspection and Maintenance of gear shift Mechanism(refer to the picture of gear shift Mechanism) 1.Check the mobility of gear shift handle.

  • Page 78: Suspension

    situation happens, maintanance staff would come to test and repair it. 4.6 Suspension 4.6.1components of rear Suspension 1、rear damper components 2、hexagon flange bolt M10×50 3、locknutM10×1.25 4、 horizontal rear-fin components 5、 the right horizontal rear-fin velocity joint 6、the left horizontal rear-fin velocity joint 7、locknutM12×1.25 8.
  • Page 79 1、rear left-upper rocker arm assembly 2、middle spacer sleeve of fore L/R rocker arm 3、 hexagon flange bolt M10×65 4、 dust-proof cover of rear rocker arm 5、 rear left-upper rocker arm assembly 6、 middle spacer sleeve of fore L/R rocker arm 7、 hexagon flange bolt M10×65 8、ust-proof cover of rear rocker arm 9、rear left-bottom rocker arm assembly 10、middle spacer sleeve of fore L/R...

  • Page 80: Front Suspension

    4.6.3.front Suspension 1、fore upper-left rocker arm 2、middle spacer sleeve of fore L/R 3、fore rocker arm upper-right rocker arm assembly 4、middle spacer sleeve of rocker arm 5、open-groove nut M10 6、cotter pin 3.2×32 7、fore bottom-left rocker arm assembly 8、fore bottom velocity joint assembly...
  • Page 81 9、stopper elastic ring for shaft 10、middle spacer sleeve of fore L/R 11、fore rocker arm bottom-right rocker arm 12、fore bottom velocity joint assembly 13、 stopper elastic ring for shaft 14、 middle spacer sleeve for security 15、 hexagon flange bolt M10×40 16、hex locknut 17、elastic cushion 18、...
  • Page 82 frame with Hexagon Flange Bolt M10×65 (8pcs), M10 nuts (8pcs), Hexagon Flange Bolt M10×50 (4pcs)and M10locknuts(4pcs)to ensure a torque of 40～45Nm. Caution:A:These components should be greased with butter before assembly. B:The surface of components can not be cracked. Check whether these components are greased with butter and then tighten the up-and-down rocker arm assembly and L/R fore dampers and ther components.Fix the L/R tension rods into hole by way of the trough of open-groove nut with cotter pin(4 pcs),and make these...

  • Page 83: Electrical System

    4.6.5.Inspection and Maintenance of rear Suspension 1.Inspection and Maintenance are similar to the fore Suspension 2.Check whether the assemble shaft of the rear damper is deformed in which case it must bu changed. 3.Check the Collar Sheath and Rubber Sheath 4.Check if the cotter pin on the assembly shaft of the rear damper is reliable.
  • Page 84 Ｂ 1.Black 18.Blue White Ｒ 2.Red 19.Blue Black Ｙ 3.Yellow 20.Red Black 4.Green 21.Red White 5.Orange 22.Green White Ｗ 6.White 23.Brown White Br/W 7.Gray 24.Brown Blue Br/L 8.Blue 25.Red Brown R/Br 9.Brown 26.Yellow Red 10.Dark Green 27.Green Red 11.Dark Red 28.Green Black 12.White Green 29.Black White...
  • Page 86 phenomena cause measure remark ignition system 1.switch lock carve out a way or short repair １,no spark circuit,connection badness line bonding badness 2.CDI set repair After electrify no noise from the CDI 3.high voltage replace high voltage lead insulated badness high voltage lead carve repalce out a way or short circuit...

  • Page 87: Ignition System

    5.1 ignition system The key diagram of ignition elements ignition elements: Ignition pressure provided by magneto ignition coil through diode commutated,by R(red line)input CDI(capacitance discharge ignition),charge to capacitance C.at the same time ,spring coil produce spring signal ,provided to SCR as the turnon spring signal ,when reaching the ignition timing,SCR turnon capacitance began to discharge at the elementary coil L1 caused instant lower pressure ,while at the secondary coil caused induce pressure.its instant pressure up to 10000V,sparkover...

  • Page 88: Magneto And Charging System

    The key diagram of charge elements 5.2 magneto and charge system the elements of charge: When the engine running,driven magnet rotor circumgyrate,so on the stator coil produce alternating current then induce electromotive force come into to being the pressure.Through 3 lines Y(yelloe ) output into the rectifier ,through rectifier into direct current pressure and output.through R1 to charge the battery.
  • Page 89 1. Long time out of using but without charge is not correct. 2. Too much charge (so long time charge is not correct, generally if battery empty, the normal charge time hours) 3. Do not charge under a much higher pressure or electric current 4.

  • Page 90: Lighting System

    5.4: Lighting system function blue yellow yellow black green blue yellow gray dark dark green green light flashing /red /green black green brown green black /red /black /white fast relay near light O FF swith switch green white white green dark dark gray brown...

  • Page 91: Electrical Starting System

    ２、 Emergency light switch ３、Turing light switch green green gray nigger dark function function /red /black brown green O FF When using this function, left and right turning lights will shine at the same time. Meter meet an emergency, the lamp is red (do not shine) ４、Horn Switch function yellw blue...
  • Page 92 Starting system working process Turn on the start switch on the left handlebar, the battery can supply power for the CDI. Then the CDI supply power for the startor relay, then the power from the battery can be sent to the startor motor through the startor relay and the startor motor works help the engine to work.

  • Page 93: Appendix

    6.Appendix Specification 6.1.1 Table of specification a）Specification of vehicle Overall length 2250mm Overall width 1210mm Overall height 1225mm Wheel base 1365mm Wheel gauge 900mm Ground clearance 260mm Seat height 930mm Mini. turning radius 2000mm Suspension Front：Hydraulic spring swing arm Rear：Hydraulic spring swing arm Front dual disk, Rear single disk/front Braking pattern and rear linkage, Right foot/left hand...
  • Page 94 Max. loading weight 180kg G.V.W.R 509kg Max. loading weight 100kg(EMARK) (Hitch)： Total weight(including 609kg(EMARK) hitch)： b）Engine specification Engine Model/Brand HS1102MU/ HSUN Pattern Single cylinder, water cool, dual exhaust, four stroke Bore×Stroke 102mm×84mm Compression Ratio 9.2:1 Volume 686ml Max. power 25kW (5000r/min- 5500r/min) Max.
  • Page 95 Transmission Belt drive rati 5.0695～0.7679 o： L Drive 5.3595（30/17×41/21×24/18） ratio： H Drive 3.2230（26/21×41/21×24/18） ratio： R Drive 3.8282（25/17×41/21×24/18） ratio： Engine Drive 16.339～2.475 ratio： Clutch Wet automatic centrifugation Lubrication (Crankcase) Comply with GB11121-1995 standard. Depending on regional weather condition, choose either SAE 5W-40 or SAE 10W-30 （Cold region）SAE.20W-40（Warm region）...
  • Page 96 Brake light 12V 21W Red light Rear license plate light 12V 5W White light Turning light 12V 10W Amber light Rear reflector Red light d）Other specification Turning operation Hand operating steering bar system Two wheel/ four wheel drive (2W means Driving method two wheel drive, 4W means four wheel drive)
  • Page 97 d) grade climbing Climbing cpacity must be greater than 30° e) minimum specific fuel consumption minimum specific fuel consumption should be less than 340g/Kw·h f) reliability The reliable travelled distance is 6000km.It may be tested by GB/T 5374-1995 g) durability The durability distance travelled distis 16000km, It may be tested by GB/T 5374-1995 h) emission...

  • Page 98: Requirements For Torque Of Fastener

    which the grade of slope is 18% and the adhesion coefficient between tire and road must be greater than 0.7. m) antisway angle 。 The greatest antisway angle to the left and right at unladen or motionless must bu greater than 25°. distance headlamp performance: The dune buggy must be equipmented with distance headlamps that...

  • Page 99: Electrical Circuits

    rignt Nut on bottomr rocker arm of the 40～50 rignt Suspension nut 35～45 Nut connecting chain stay and 40～50 rocker support Nut on fore wheel 45～55 Nut on rear wheel 45～50 6.3 Electrical circuits the characteristic of the electrical circuits, 1.Actualize the electrial starting when it is at N,parking and brake.
  • Page 100 O V E R R I D E C D I m mi n 100 0 FU E L...

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