SMC Networks ATV50 Service Manual
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SMC Networks ATV50 Service Manual

Cf5 series; cf0 series; ur5 series; ur0 series; atv with f/n/r 3 in 1 engine
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Standard Motor Corporation
SERVICE MANUAL
CF5/UR5/UR0
ATV 50/100 ATV with F/N/R
3 in 1 engine

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Summary of Contents for SMC Networks ATV50

  • Page 1 Standard Motor Corporation SERVICE MANUAL CF5/UR5/UR0 ATV 50/100 ATV with F/N/R 3 in 1 engine...
  • Page 2 Renew eplace wit h a new pa art before i installation Brake fl se recomm mended bra ake fluid D DOT4. Special to ools pecial tools - 1 - MC ATV50 0/100 Se Service M Manual...
  • Page 3  Keep electrolyte e beyond re each of ch ildren. - 2 - MC ATV50 0/100 Se Service M Manual...
  • Page 4 Pay s special atte ention to O O-rings or o seals beca ause most cleaning a agents hav ve an adve rse effect on them. - 3 - MC ATV50 0/100 Se Service M Manual...
  • Page 5 Bolts and f fasteners s should be kept clean n and dry. D Do not app ply oil to the thre ads. - 4 - MC ATV50 0/100 Se Service M Manual...
  • Page 6 T To avoid d amaging th bearing, us se equal fo orce on bo th races. oth of thes se example es can res sult in bear ring damag - 5 - MC ATV50 0/100 Se Service M Manual...
  • Page 7 , sparks or r open flam mes (e.g., w welding eq quipment, l ighted SMOKE w when charg ging or han ndling batte eries. - 6 - MC ATV50 0/100 Se Service M Manual...
  • Page 8 Check if any wire loose. E. Check if the conn nector is co overed by t the twin connec ctor boot co ompletely and secure ed properly - 7 - MC ATV50 0/100 Se Service M Manual...
  • Page 9 Route wire e harnesse es to avoid sharp edg ges or corners an nd also avo oid the proj jected end ds of bolts and screw - 8 - MC ATV50 0/100 Se Service M Manual...
  • Page 10 40. W With sand paper to c clean rust o on connect tor pins/ter rminals if found. And d then con duct conne ection ope ration later - 9 - MC ATV50 0/100 Se Service M Manual...
  • Page 11 0 or others R) AT 21x10 0-8 or other ad Light (typ pe 1): 12V 3 35W/35W*1 (Hi/Low-Be eam) ar Light: 12V V 5W* 1 (LE Flas sher Light : 12V 10W* 4 10 - MC ATV50 0/100 Se Service M Manual...
  • Page 12 0 or others R) AT 21x10 0-8 or other ad Light (typ pe 1): 12V 3 35W/35W*1 (Hi/Low-Be eam) ar Light: 12V V 5W* 1 (LE Flas sher Light: 1 12V 10W* 4 11 - MC ATV50 0/100 Se Service M Manual...
  • Page 13 8*1.25 2.2~ ~3.0 otector, mu uffler 6*1.00 0.7~ ~1.0 C. Generato or nut (flyw wheel/rotor 0*1.25 3.8~ ~4.2 gnet (A.C. G. coil) sc 6*1.00 1.0~ ~1.6 ar shifting lever nut 6*1.00 12 - MC ATV50 0/100 Se Service M Manual...
  • Page 14 (EX) 8*1.50 0/16 ar Brake H ub Bolt 0*1.25 ot brake bo 0*1.25 0/6.0 ot brake bo 8*1.25 0/1.6 haust Pipe holder (fra ame) 8*1.25 8/2.8 ndlebar Ho older 8*1.25 0/1.5 13 - MC ATV50 0/100 Se Service M Manual...
  • Page 15 Chapte e r 1 Gen eral Inform mation 06.Troub bles Diag nosis A. E Engine do oes not sta 14 - MC ATV50 0 /100 Se Service M M anual...
  • Page 16 Chapte e r 1 Gen eral Inform mation B. E Engine po oor perform mance at low and id dle speed C. E Engine po oor perform mance at high spee 15 - MC ATV50 0/100 Se Service M M anual...
  • Page 17 Chapte e r 1 Gen eral Inform mation D. P Poor Perfo o rmance 16 - MC ATV50 0 /100 Se Service M M anual...
  • Page 18 Chapte e r 1 Gen eral Inform mation A. P Poor Steer r ing 17 - MC ATV50 0 /100 Se Service M M anual...
  • Page 19 Chapter 2 Maintenan nce Informa ation 01. Techn nical Dat 02. Period dical Ma intenanc ce Sched dule 03. Fuel H Hoses 04. Thrott tle Cable 05. Air Cl leaner 06. Spark k Plug 07. Idle S Speed Ad djustmen 08.
  • Page 20 Chapter 2 Maintenan nce Informa ation 02 Period dical Ma intenanc ce Sched dule ve your AT TV checked d, adjusted d, and reco orded main ntenance d ata period ically by yo our SMC horized De ealer to ma aintain the ATV at the e optimum...
  • Page 21 Chapter 2 Maintenan nce Informa ation ectrical Syst Dashboard/s speedometer Lights /elect rical equipm Front and re ear brake swi I ~ In nspection, , cleaning , and adju ustment R ~ Repla acement C ~ c cleaning ( (replaced if necessa ary) L ~ Lubric...
  • Page 22 Chapter 2 Maintenan nce Informa ation 03 Fuel/ /Oil Hose  Check fue el tank, fue el cock, an d fuel hose e if any deter rioration, d amage, be end or fuel leaking. R Replace it w with new o one if necessar ...
  • Page 23 Chapter 2 Maintenan nce Informa ation aution ever use ga asoline or acid organ nized solve clean the e element. oap the ele ement into cleaning e ngine oil a en squeeze e it out. Ins stall the ele ement onto e element s seat and th hen install...
  • Page 24 Chapter 2 Maintenan nce Informa ation 08. Drivi ing Chai Inspect th he chain sl ack. The sta andard is 1 10-25mm. Adjust the e chain sla ack. Loose the e lock bolts s (4 pcs) o n the connectio on between n rear swin ng arm and...
  • Page 25 Chapter 2 Maintenan nce Informa ation 09 Brake e System m (drum b brake) Inspect th he front bra ake lever a and cable f excessive e free play or other d amage. Replace o or repair if necessary easure the free play o of the brak ke lever at...
  • Page 26 Chapter 2 Maintenan nce Informa ation 10. Brak ke System m (Disk B Brake) he Disk bra ake version n, apply by foot peda l, to tive the thr ree caliper (front 2 an nd rear 1) a as a mbine bra king system m.
  • Page 27 Chapter 2 Maintenan nce Informa ation aution ever mix or r use dirty brake fluid d to preven om damagi ng brake s system or r reducing ake perform mance. Parking b brake  Apply th e right han nd brake le ever and ho old, then pus...
  • Page 28 Chapter 2 Maintenan nce Informa ation 11. Brak ke Light S Switch/S tarting Inhibito or Switc he brake lig ght switch i is to light u up brake lig brake ped dal applied ake sure th hat electric cal starter c can be erated onl y under br...
  • Page 29 Chapter 2 Maintenan nce Informa ation 14. Stee ring Han ndle aution heck all wir res and ca bles if they y are erfered wit th the rotat tion of stee ering hand ft the front wheel out of ground. urn handle from right to left alte...
  • Page 30 Chapter 2 Maintenan nce Informa ation 17 Toe-i Let the v vehicle on level grou nd and the front wh eels facing g straight a ahead. Mark the e centers o of the tires to indicate the axle center hei ight.
  • Page 31 Chapter 2 Maintenan nce Informa ation Not t e: SMC C ATV 50 0 /100 S S ervice M Manual...
  • Page 32 Chapte er 3 Engin e Removal 01. Preca autions in n Operat tion 02. Remo oval of En ngine 03. Engin ne Install lation 01. Preca autions in n Operat tion neral Inf formation  The engin ne has to be e supported with specia al service to...
  • Page 33 Chapte er 3 Engin e Removal 02. Engin ne Remov gine shall b be remove d in the co onditions of cessary rep pair or adju ustment in tran nsmission a and combu ustion syst tem only. a. R Remove th he seat, re ear carrier ...
  • Page 34 Chapte er 3 Engin e Removal e. R Remove R & L footre est stay a nd mudgu uard  Screw ou ut 3 bolts o n each R a and L footr rest mudguard d cover, an nd then rem move out t footrest m mudguard c...
  • Page 35 Chapte er 3 Engin e Removal i. re emove the e exhaust pipe prote ector. PLATE WASH PLATE WASH  Screw ou ut 2 fixing s screw  Remove the exhaus st protecto SWITCH AS S'Y, REAR STOP j. re emove the e stop swit tch &...
  • Page 36 Chapte er 3 Engin e Removal SPROCKET DRI m. d disconnec ct the spa rk plug ca ap (ignitio coil  Remove out the ign nition coil (s spark plug cap) from m cylinder h head n. R Remove ca ables and fuel/oil ho ose from...
  • Page 37 Chapte er 3 Engin e Removal q. R Remove th he gear sh hifting leve er from gine case.  Remove cotter pin f from the sh hifting leve er on the engin ne case.  Disconne ect the rem move the ge ear shifting cable from...
  • Page 38 Chapte er 3 Engin e Removal t. R Remove th e carbure  Remove the clamp in connect ting betwe intake an d carburet  Remove the carbur retor. u. R Remove th he intake p pipe and r reed valve ...
  • Page 39 Chapte er 3 Engin e Removal 03. Engin ne Install lation eck the bus sh of engin ne hanger parts for a mage. Inst tall the eng gine in the reverse pr rocedures moval. ution  Be carefu ul when rem moving an d installing g the...
  • Page 40 Chapte e r 3 Engin e Removal NO OTE: 36 - SMC C ATV 50 0 /100 S S ervice M M anual...
  • Page 41 Chapte er 4 Fuel S System 01. Mecha anism D iagram 02. Preca autions in n Operat tion 03. Troub ble Shoo ting 04. FUEL TANK 05. Carbu uretor 06. Intake e, Reed V Valve 07. Air Cl leaner 01. Mech hanism D Diagram 37 -...
  • Page 42 Chapte er 4 Fuel S System 02. Preca autions in n Operat tion General Informat tion arning soline is a low ignitio n point and d explosive e materials s, so alway ys work in a a well-ven tilated plac d strictly pro ohibit flam e when wo...
  • Page 43 Chapte e r 4 Fuel S System 03. Troub ble Shoo ting or engin ne start  No fuel in n fuel tank  Clogged f fuel tube  Too much h fuel in cy ylinder  No spark from spar rk plug(mal lfunction of f ignition s...
  • Page 44 Chapte e r 4 Fuel S System 4 FUEL TA REMOVAL  Remove the seat an nd rear fen nder.  Remove the side co overs  Turn the fuel cock s switch to O OFF positio  Disconne fuel line from carbureto...
  • Page 45 Chapte e r 4 Fuel S System mbly of Car rburetor c componen or cap/ thr rottle valve e/jet need dle. the throttle e cable from m the throt ttle ile depress sing the thr rottle valve the needle e clip retain ner (or spri e jet needle e and need...
  • Page 46 Chapte er 4 Fuel S System parts in so olvent and blow it dry n compres ssed air. As ssembly is ly the reve erse order o mbly. er cover b bolt torque 2 Nm cable free play adjus stment (2 ent of Idle Speed ometer whe...
  • Page 47 Chapte e r 4 Fuel S System stopper he eight shoul ld be 6.0 ~ ~ 6.4 of specific cation, adju ust the stop pper the valve ance of ree ed valve s should be l less mm. if out of specific cation, repl lace...
  • Page 48 Chapte e r 4 Fuel S System No otes: 44 - SM M C ATV 5 5 /100 Se e rvice M M anual...
  • Page 49 Chapter r 5 Oil lubr ricant Syste 01. Mecha anism D iagram 02. Preca autions in n Operat tion 03. Troub ble Shoo ting 04. Oil Ta 05. Oil ga auge 06. Oil pu 07. Air co ooling Sy ystem 01.
  • Page 50 Chapter r 5 Oil lubr ricant Syste 02. Preca autions in n Operat tion ving enoug gh oil supp ly to engin e is very im mportant. I If the oil qu uantity is no ot enough , this engin will be serious s scratched...
  • Page 51 Chapter r 5 Oil lubr ricant Syste 04 Oil Tan Removal  Remove the front to op cover, f front fende er fuel tank, righ ht side of fl oor panel, engine co ooling shroud. ( Refer to ch hapter 3 & ...
  • Page 52 Chapter r 5 Oil lubr ricant Syste  Check k if the oil b being pum p out. If no ot oil comes s out, plea ase check t the oil flow system m if air bub bble or clog gged inside Repla ace with ne...
  • Page 53 Chapter r 5 Oil lubr ricant Syste No otes: 49 - SMC C ATV 50 0 /100 S S ervice M M anual...
  • Page 54 Chapte er 6 Cylind der Head/V Valves 01. Mecha anism D iagram 02. Preca autions in n Operat tion 03. Troub bleshoot 04. Cylind der / Pist ton/ Ring gs Remo oval 05. Parts inspecti 06. Cylind der/Pisto on/Ring i installati 01.
  • Page 55 Chapte er 6 Cylind der Head/V Valves 02. Preca autions i n Opera tion eneral In nformatio ● This chapt ter is conta ained main tenance an nd service for cylinde r head, Cy ylinder, and d reed valve piston/pis ton ring/pis ston pin an nd clip.
  • Page 56 Chapte er 6 Cylind der Head/V Valves 6-04. Cyli inder / P Piston/ Ri ings Removal a. Refer to o the chapt ter 3 for en ngine remo oval process s to remove e the engin ne from fra b. Use spa ark plug wr rench to re move the...
  • Page 57 Chapte e r 6 Cylind der Head/V Valves Caution Wet the res sidues by s solvent so t that the esidues ca an be remo oved more easily. h. Spread each pisto on ring lubr ricant and remove it by lifting g up at a po oint just opposite...
  • Page 58 Chapte er 6 Cylind der Head/V Valves 6-05. Part ts inspec ction a. Cylinder r Head Ins spection   Check the cylinde er head if a any damag distort. Replace w with new if f necessary   Clean t the carbon n residues on the...
  • Page 59 Chapte er 6 Cylind der Head/V Valves   Measu re the clea arance betw ween ring and gro oove. Service limi it: 0.06 mm   Measu re the pisto on outer d iameter at 10 mm m high from m the skirt’s s bottom.
  • Page 60 Chapte er 6 Cylind der Head/V Valves 6-06 Cylin nder/Pis ton/Ring nstallatio   Install t the stud bo olt onto cra ankcase if remove The torque is 10-14N   Install t the piston rings with the marks facing up.
  • Page 61 Chapte e r 6 Cylind der Head/V Valves Not t e: 57 - SMC C ATV 50 0 /100 S S ervice M M anual...
  • Page 62 Chapte er 7 CVT d riving Syst 01. Mecha anism 02. Maint tenance D Descript tion 03. Troub ble Diagn nosis 04. Left C Crankcas se Cover 05. Drive Belt 06. Move able Driv ving Fac e(MDF) Assy 07. Rear D Driven P Pulley As 08.
  • Page 63 Chapte er 7 CVT d riving Syst 02. Maint tenance Descript tion ecaution s in Ope eration neral Inf formation  Drive face e, clutch o uter, and d driven pulle ey can be serviced o n the vehic cle. ...
  • Page 64 Chapte er 7 CVT d riving Syst 04. Left C Crankcas e Cover ft crankc case cov ver remov move left c crankcase cover bolts s (9 bolts). move 2 dow wel pin d gasket. ft crankc case cov ver instal lation Inst tall left cran...
  • Page 65 Chapte er 7 CVT d riving Syst of grease. V-BELT  Clean up a all grease o or dirt before e installatio 16~14.5 mm 06. Mov eable Dr riving Fa ce Assy (MDF Assy) e to the inc creasing en ngine spee ed, the rolle sh the mov...
  • Page 66 Chapte er 7 CVT d riving Syst 07. Drive n Pulley (second dary Shea ave) Assy Disassem mbly Remove th he fixing nu ut on the c clutch weig and remov ve the clutc ch weight a assy, comp press spring, slid ding sheav ve and fix s...
  • Page 67 Chapte er 7 CVT d riving Syst Driven sh eave bear ring Inspe ection  Check k if the inne er bearing oil seal is dama ge. Replac ce it if nece essary.  Check k if needle bearing is damage o or too big cle...
  • Page 68 Chapte e r 7 CVT d riving Syst NO OTE: 64 - SMC C ATV 50 0 /100 S S ervice M M anual...
  • Page 69 Chapter 8 E Engine Sta arting Syste 01. Mecha anism 02. Maint tenance D Descript tion 03. One W Way Clut tch (Start t clutch) 04. Electr rical Star rting Mot 05. Kick s starter 01. Mech anism D iagram This s ATV 50 e equipped w...
  • Page 70 Chapter 8 E Engine Sta arting Syste Way Clut ch(Start Clutch) wing mentio oned servic ce, please er 7, for fro ont pulley / /MDF assy out 2 pan h ead screw w, and remo e gear plat he plate wa asher on th he idle gea he idle gea...
  • Page 71 Chapter 8 E Engine Sta arting Syste Re-install ation  Add grea ase to the s start clutch needle bearing.  Install the e start clutc ch in rever rse way of disassem mbly.  Grease th he needle bearing ins side the id gear and then insta...
  • Page 72 Chapter 8 E Engine Sta arting Syste starter (O Optional) er is fixed at the left c crankcase composed d by kick st arter, spind spring, bus sh and pick k pinion e starter, fi rst slightly push to m make is engage d, and the...
  • Page 73 Chapter 8 E Engine Sta arting Syste NO OTE: 69 - SMC C JMAX 70 700 ATV S S ervice Manual...
  • Page 74 Chapt ter 9 A.C. G Generator/ /Oil Pump/C Crankshaft 01. Mecha anism D iagram 02. Maint tenance N Notice 03. A.C. G Generato or Assy 04. Oil pu ump and oil pum mp drive g gear 05. Crank kshaft 01. Mech anism D Diagram 70 -...
  • Page 75 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft 02. Maint tenance Notice rque value shroud fixi ng bolt: 0.7kgf-m/ /7Nm oling fan fix xing bolt: 0.7kgf-m/ /7Nm Flyw wheel nut 3.8 kgf-m m/38Nm Stat tor fixing b bolt: 0.8kgf-m/ /8Nm Pump Bolt...
  • Page 76 Chapt ter 9 A.C. G Generator/ /Oil Pump/C Crankshaft 03. A.C. G Generato or Assy. Remova  Remove the air coo oling shrou d. (refer to chapter 3 3, engine re emoval)  Remove the 4 screw ws on the air cooling g fan, and remo...
  • Page 77 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft ation. e gasket ease with li ithium soa p base on wheel cab ble through h the crank kcase ator assem mbly r assembl ly): 0.8 kg f-m/8Nm y  oodruff key ...
  • Page 78 Chapt ter 9 A.C. G Generator/ /Oil Pump/C Crankshaft the pin and d cir-clip o n the CIRCL e oil pump d driven gear teeth if W Wear/ Replace the e oil pump a assy if e oil pump d drive e drive gear teeth of the...
  • Page 79 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft kcase/cra ankshaft ssing crank kshaft rem oval, pleas ous chapte rs for engi ne remova and A.C. G Generator, oil pump/o ear remova he air-intak ke/reed val lve/gasket e screw an nd remove the oil sea he 6 pan h...
  • Page 80 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft tching the crankshaf ft and to ea n procedur re, lubricat e the oil se se and eac ch bearing with engin ne oil. kcase side ankshaft. e Cranksh aft Installin ng tool to t aft through the L cran...
  • Page 81 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft nkcase owel pins a and engine mount spa acer alant (pack king paste) ) to the ma ating of both ca se helves. e Cranksh aft Installin ng tool to t aft through the R cran nkcase hole...
  • Page 82 Chapt ter 9 A.C. G Generator/ / Oil Pump/C Crankshaft NO OTE: 78 - SMC C ATV 50 0 /100 S Service M Manual...
  • Page 83 Chapter 10 0 Transmis ssion Gears -01. Mech hanism -02. Main ntenance e Notice -03. Trou uble Diag gnosis -04. Tran nsmissio n Disass sembly -05. Tran nsmissio n Inspec ction -06. Bear ring Rep lacemen -07. Tran nsmissio n Reass embly -01.
  • Page 84 Chapter 10 0 Transmis ssion Gears -02. Main ntenance e Notice This s Section c concerns d disassembl ly-assemb ly of the tra ansmission n gears for r repair pu rpose. move follow wing comp ponents be fore disass sembling c crankcase.
  • Page 85 Chapter 10 0 Transmis ssion Gears -04.Tran smission n Disasse embly Transmiss sion cove er removal Remove th he drain bo olt on the b bottom of th transmissi on cover a and then dr rain out the gear oil. Af fter drain o out the oil, tighten the...
  • Page 86 Chapter 10 0 Transmis ssion Gears sion gears s removal e chain sp rocket driv ve axle ( fin he dowel p pin from ge ear shift ca shift fork to oward the t top of e primary d drive gear he main ax xle assemb bly and shif...
  • Page 87 Chapter 10 0 Transmis ssion Gears -06. L. Cr rankcase e / Trans smission se cover Inspection Screw out the 3 flang ge bolt on the drive a axle cover and remove dr rive axle co over and gasket, ch eck the oil l seal, if oil leaking or...
  • Page 88 Chapter 10 0 Transmis ssion Gears 4. A Align the g gear shift c cam with ge ear shift fo ork, and then in nstall the d dowel pin o onto gear s shift cam axle. Install the (final) driv e shaft wit h sprocket Install the...
  • Page 89 Chapter 10 0 Transmis ssion Gears NO OTE: 85 - SMC C ATV 50 0 /100 S S ervice M M anual...

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