Crossfire HS800ATV-2 Maintenance Handbook

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Brief introduction to maintenance handbook of HS800ATV-2

The handbook is edited by Technical Center of Chongqing Huansong Industries

(Group) Co., Ltd., and is supplied to dealers and technicians as document of technique.

Mainly, the handbook gives methods to check, maintain and repair four wheel

all-terrain vehicles （ATV）, and supplies some relevant technique and performance data.

Some techniques and method inside may be used to check, maintain and repair other

models of ATV, although it is mainly for HS800ATV-2.

Please read the handbook through and fully understand it; otherwise, any improper

repairing and amounting would bring you problems, and accident may occur in your use.

Proper use and maintenance can guarantee ATV being driven safely, reduce its

malfunction, and help the vehicle remain its best performance.

The standards, performances and specifications mentioned in interpretation are

based on the sample in design, and they are subject to changes according to the

product's improvement without prior notice.

First version , November 15, 2012

Published by Chongqing Huansong Industries (Group) Co., Ltd.

Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.

No publishing and reprinting without permission.

FOREWORD

Table of Contents

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Summary of Contents for Crossfire HS800ATV-2

Page 1 （ATV）, and supplies some relevant technique and performance data. Some techniques and method inside may be used to check, maintain and repair other models of ATV, although it is mainly for HS800ATV-2. Please read the handbook through and fully understand it; otherwise, any improper repairing and amounting would bring you problems, and accident may occur in your use.
Page 2: Table Of Contents
CONTENT CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION……………………………………………………………………1 WATNINGS CAUTIONS AND NOTES……………………………………………………1 DESCRIPTION……………………………………………………………………………………2 IDENTIFICATION CODE……………………………………………………………………… 3 Frame No. ………………………………………………………………………………… 3 Engine No. ………………………………………………………………………………… 3 SAFETY ………………………………………………………………………………………… 4 Handing gasoline safely…………………………………………………………………… 4 Cleaning parts……………………………………………………………………………… 5 Warning labels……………………………………………………………………………… 5 SERIAL NUMBERS…………………………………………………………………………… 6 FASTENERS…………………………………………………………………………………… 6 Torque specifications ………………………………………………………………………...
Page 3 Wrenches ………………………………………………………………………………… 11 Adjustable wrenches …………………………………………………………………… 12 Socket wrenches, ratchets and handles ……………………………………………… 12 Impact drivers …………………………………………………………………………… 13 Allen wrenches…………………………………………………………………………… 13 Torque wrenches………………………………………………………………………… 14 Torque adapters ………………………………………………………………………… 14 Pliers……………………………………………………………………………………… 15 Snap ring pliers…………………………………………………………………………… 16 Hammers ………………………………………………………………………………… 16 Ignition grounding tool…………………………………………………………………… 16 PRECISION MEASURING TOOLS …………………………………………………………...
Page 4 Removal…………………………………………………………………………………… 27 Installation…………………………………………………………………………………28 Interference fit ……………………………………………………………………………29 Seal replacement…………………………………………………………………………30 STORAGE………………………………………………………………………………………31 Storage area selection……………………………………………………………………31 Preparing the motorcycle for storage ……………………………………………………31 Returning the UTV to service……………………………………………………31 TROVBLESHOOTING………………………………………………………………………32 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS…………………………33 STARTING THE ENGINE …………………………………………………………………33 Engine is cold ……………………………………………………………………………33 Engine is warm……………………………………………………………………………33 Starting the engine after a fall or after the engine stalls………………………………34 Flooded engine……………………………………………………………………………34 Engine cold with air temperature ………………………………………………………34...
Page 5 FUEL SYSTEM……………………………………………………………………………… 42 Rich mixture……………………………………………………………………………… 42 Lean mixture……………………………………………………………………………… 43 ENGINE………………………………………………………………………………………… 43 Engine smoke……………………………………………………………………………… 43 Black smoke ……………………………………………………………………………… 43 Blue smoke………………………………………………………………………………… 43 White smoke or steam…………………………………………………………………… 43 Low engine compression ………………………………………………………………… 44 High engine compression ……………………………………………………………… 44 Engine overheating (cooling system) ………………………………………………… 44 Engine overheating (engine)……………………………………………………………...
Page 6 TEST PROCEDURES………………………………………………………………………… 54 Voltage test……………………………………………………………………………… 54 Voltage drop test………………………………………………………………………… 54 Peak voltage test………………………………………………………………………… 55 Continuity test……………………………………………………………………………… 55 Testing for a short with a self-powered test light or ohmmeter……………………… 55 Testing for a short with a test light or voltmeter………………………………………… 56 BRAKE SYSTEM………………………………………………………………………………...
Page 7 HYDROGRAPHIC CHART…………………………………………………………………… 82 LUBRICATION OIL WAY…………………………………………………………………… 83 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE ATV MAINTENANCE SCHEDULE……………………………………………………………… 84 ENGINE Adjusting the valve clearance…………………………………………………………… 86 Checking the spark plug ………………………………………………………………… 89 Checking the ignition timing……………………………………………………………… 90 Measuring the compression pressure………………………………………………… 91 Checking the engine oil level ……………………………………………………………...
Page 8 Checking the steering system………………………………………………………… 112 Adjusting the toe-in ……………………………………………………………………… 114 Adjusting the rear shock absorbers…………………………………………………… 115 Checking the tires ……………………………………………………………………… 116 Checking the wheels…………………………………………………………………… 118 Checking and lubricating the cables ………………………………………………… 118 ELECTRICAL Checking and charging the battery…………………………………………………… 119 Checking the fuses ……………………………………………………………………… 125 Adjusting the headlight beam …………………………………………………………...
Page 9 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 184 STEERING OPERATION SYSTEM……………………………………………………… 187 The structure of steering………………………………………………………………… 187 The steering handle and cable………………………………………………………… 190 The handle switch and lever…………………………………………………………… 191 BRAKE SYSTEM…………………………………………………………………………… 200 Preparation for checking before the maintenance of the brake system …………… 200 Brake system………………………………………………………………………………...
Page 10 SEAT ………………………………………………………………………………………… 269 FUEL TANK………………………………………………………………………………… 272 Fuel tank cover parts …………………………………………………………………… 247 Fuel tank parts…………………………………………………………………………… 252 CHAPTER 6 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 277 ELECTRICAL………………………………………………………………………………… 278 ELECTRICALCOMPONENTS……………………………………………………………… 278 IGNITION SYSTEM………………………………………………………………………… 283 Circuit diagram………………………………………………………………………… 283 ELECTRIC STARTING SYSTEM ……………………………………………………… 287 Circuit diagram…………………………………………………………………………...
Page 11 EMS (Engine Management System) …………………………………………………… 319 Typical Components Of EMS…………………………………………………………… 319 Layout of EMS Components…………………………………………………………… 320 COMPONENTS OF EMS…………………………………………………………………… 321 Electronic Control Unit…………………………………………………………………… 321 Multec 3.5 Injectors……………………………………………………………………… 322 Throttle Body Assembly(with stepper motor) ………………………………………… 326 Engine Coolant Temperature Sensor………………………………………………… 327 Intake Air Pressure and Temperature Sensor…………………………………………...
Page 12 Malfunction ……………………………………………………………………………… 344 UNSTABLE HANDLING…………………………………………………………………… 344 Unstable handling ……………………………………………………………………… 344 LIGHTING SYSTEM………………………………………………………………………… 345 Head light is out of work………………………………………………………………… 345 Bulb burnt out…………………………………………………………………………… 345 CHAPTER 9 HS800ATV-2 WIRING DIAGRAM HS800ATV-2 WIRING DIAGRAM………………………………………………………… 346 HS800ATV-2 WIRING EFI DIAGRAM…………………………………………………… 347 - 11 -...
Page 13: General Information
GENERAL INFORMATION GENERAL INFORMATION The text provides complete information on maintenance，tune-up repair and overhaul，Hundreds of photographs and illustrations created during the complete disassembly of four wheel all-terrain vehicles (ATV) guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the ATV for the first time.
Page 14: Description
GENERAL INFORMATION DESCRIPTION 1. Headlights 13. Front carrier 2. Radiator part 14. Front sundry box 3. Shock absorber comp 15. Ignition switch 4. Meter 16. Auxiliary dc plug 5. Left handle bar 17. Steering bar part 6. Air filter 18. Gearshift bracket 7.
Page 15: Identification Code
GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved on the right of the rear frame Engine No. Engine NO. Is carved on the right side of the engine, Figure. - 3 -...
Page 16: Safety
GENERAL INFORMATION SAFETY Professional mechanics can work for years and never sustain a serous injury or mishap. Follow these guidelines and practice common sense to safely service the utility terrain venires. Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide.
Page 17: Cleaning Parts
GENERAL INFORMATION always present in the fuel tank, fuel line and carburetor. To avoid a disastrous accident when working around the fuel system, carefully observe the following precautions: Never use gasoline to clean parts. Refer to Cleaning Parts in this section. When working of the fuel system, work outside or in a well-ventilated area.
Page 18: Serial Numbers
GENERAL INFORMATION SERIAL NUMBERS Serial and identification numbers are stamped on various locations on the frame, engine and carburetor body. Record these numbers in the Quick Reference Data section in the front of the manual. Have these numbers available when ordering parts. FASTENERS Proper fastener selection and installation is important to ensure the motorcycle operates as designed and can be serviced efficiently.
Page 19: Cotter Pins
GENERAL INFORMATION As with fasteners. When replacing washers make sure the replacement washers are of the same design and quality Cotter Pins A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In certain applications, such as the rear axle on an ATV or motorcycle, the fastener must be secured in this way.
Page 20: Shop Supplies
GENERAL INFORMATION Compress or expand snap rings only enough to install them. If overly expanded. Lose their retaining ability After installing a snap ring. Make sure it seats completely Wear eye protection when removing and installing snap rings SHOP SIPPLIES Lubricants and Fluids Periodic lubrication help ensure a long service life for any type of equipment.
Page 21: Greases
GENERAL INFORMATION Greases Grease is lubricating oil with thickening agents added to it. The National Lubricating Grease Institute (NLGI) grades grease. Grades range from No.000 to No.6, with No.6 being the thickest. Typical multipurpose grease is NLGI No.2. For specific applications, manufacturers may recommend water-resistant type grease or one with an additive such as molybdenum disulfide (MoS2).
Page 22: Gasket Sealant
GENERAL INFORMATION cleaning. For safety, use only nonflammable or high flash point solvents. Gasket Sealant Sealant is used in combination with a gasket or seal. In other applications, such as between crankcase halves, only a sealant is used. Follow the manufacturer’s recommendation when using a sealant.
Page 23: Screwdrivers
GENERAL INFORMATION specialized equipment or expertise may make it impractical for the home mechanic to attempt the procedure. When necessary, such operations are recommended to have a dealership or specialist perform the task. It may be less expensive to have a professional perform these jobs, especially when considering the cost of equipment.
Page 24: Adjustable Wrenches
GENERAL INFORMATION distance of the fastener head. The box-end wrench is an excellent tool because it grips the fastener on all sides. This reduces the chance of the tool slipping. The box-end wrench is designed with either a 6 or 12-point opening. For stubborn or damaged fasteners, the 6-point provides superior holding because it contacts the fastener across a wider area at all six edges.
Page 25: Impact Drivers
GENERAL INFORMATION hand-driven attachments WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury. Always wear eye protection when using impact or air tools Various handles are available for sockets. Use the speed handle for fast operation. Flexible ratchet heads in varying length allow the socket to be turned with varying force and at odd angles.
Page 26: Torque Wrenches
GENERAL INFORMATION Torque Wrenches Use a torque wrench with a socket, torque adapter or similar extension to tighten a fastener to a measured torque. Torque wrenches come in several drive sizes (1/4, 3/8, 1/2 and 3/4) and have various methods of reading the torque value. The drive size indicates the size of the square drive that accepts the socket, adapter or extension.
Page 27: Pliers
GENERAL INFORMATION TW = TA×L TW is the torque setting or dial reading on the wrench. TA is the torque specification and the actual amount of torque that is applied to the fastener. A is the amount that the adapter increases (or in some cases reduces) the effective lever length as measured along the centerline of the torque wrench.
Page 28: Snap Ring Pliers
GENERAL INFORMATION needle nose pliers to hold or bend small objects. Locking pliers (Figure 16), sometimes called Vise- Grips, are used to hold objects very tightly. They have many uses ranging from holding two parts together, to gripping the end of a broken stud. Use caution when using locking pliers, as the sharp jaws will damage the objects they hold.
Page 29: Precision Measuring Tools
GENERAL INFORMATION PRECISION MEASURING TOOLS The ability to accurately measure components is essential to perform many of the procedures described in this manual. Equipment is manufactured to close tolerances, and obtaining consistently accurate measurements is essential to determine which components require replacement or further service.
Page 30: Micrometers
GENERAL INFORMATION the measurement. The digital caliper uses a liquid-crystal display (LCD) to show the measurement. Properly maintain the measuring surfaces of the caliper. There must not be any dirt or burrs between the tool and the object being measured. Never force the caliper to close around an object. Close the caliper around the highest point so it can be removed with a slight drag.
Page 31: Adjustment
GENERAL INFORMATION (3-4 in.). Micrometers that cover a wider range of measurements are available. These use a large frame with interchangeable anvils of various lengths. This type of micrometer offers a cost savings, but its overall size may make it less convenient. When reading a micrometer, numbers are taken from different scales and added together.
Page 32: Metric Micrometer
GENERAL INFORMATION Metric micrometer The standard metric micrometer (Figure 24) is accurate to one one-hundredth of a millimeter (0.01 mm). The sleeve line is graduated in millimeter and half millimeter increments. The marks on the upper half of the sleeve line equal 1.00 mm. Each fifth mark above the sleeve line is identified with a number.
Page 33: Telescoping And Small Bore Gauges
GENERAL INFORMATION These numbers indicate 0.100, 0.200, 0.300, and so The tapered end of the thimble has 25 lines marked around it. Each mark equals 0.001 in. One complete turn of the thimble will align its zero mark with the first mark on the sleeve or 0.025 in. To read a standard inch micrometer, perform the following steps and refer to Figure 27.
Page 34: Dial Indicator
GENERAL INFORMATION tightening can damage the bore surface and damage the tool. Remove the gauge and measure the outside dimension (Figure 30). Small bore gauges are typically used to measure valve guides. Dial Indicator: A dial indicator (Figure 31) is a gauge with a dial face and needle used to measure variations in dimensions and movements.
Page 35: Electrical System Fundamentals
GENERAL INFORMATION Some manufacturer’s specifications for electrical components are based on results using a specific test meter. Results may vary if using a meter not recommended manufacturer. Such requirements are noted when applicable. Ohmmeter (analog) calibration Each time an analog ohmmeter is used or if the scale is changed, the ohmmeter must be calibrated.
Page 36: Amperage
GENERAL INFORMATION cause the coil to malfunction, even though it tests acceptable during a resistance test. Resistance generally. Increases with temperature. Perform all testing with the component or circuit at room temperature. Resistance tests performed at high temperatures may indicate high resistance readings and cause unnecessary replacement of a component.
Page 37: Removing Broken Fasteners
GENERAL INFORMATION 13. Repairs are much faster and easier if the ATV is clean before starting work. Degrease the motorcycle with a commercial degreaser; follow the directions on the container for the best results. Clean all parts with cleaning solvent when removing them. CAUTION Do not direct high-pressure water at steering bearings,...
Page 38: Repairing Damaged Threads
GENERAL INFORMATION out, try gripping it with locking pliers. If the projecting portion is too small, file it to fit a wrench of cut a slot in it to fit a screwdriver (Figure 35) If the head breaks off flush, use a screw extractor.
Page 39: Removing Hoses
GENERAL INFORMATION stud or thread two nuts onto the stud. Apply thread locking compound to the threads of the stud. Install the stud and tighten with the stud removal tool or the top nut. Install the stud to the height noted in Step 1 or its torque specification. Remove the stud removal tool or the two nuts.
Page 40: Installation
GENERAL INFORMATION between the hammer and shaft (Figure 41) and make sure to support both bearing races with wooden blocks as shown. 3. The ideal method of bearing removal is with a hydraulic press. Note the following when using a press: Always support the inner and outer bearing races with a suitable size wooden or...
Page 41: Interference Fit
GENERAL INFORMATION same time, a tight fit is required for both outer and inner bearing races. In this situation, install a spacer underneath the driver tool so that pressure is applied evenly across both races. See Figure 46. If the outer race is not supported as shown, the balls will push against the outer bearing race and damage it Interference fit 1.
Page 42: Seal Replacement
GENERAL INFORMATION CAUTION Do not heat the housing with a propane or acetylene torch. Never bring a flame into contact with the bearing or housing. The direct heat will destroy the case hardening of the bearing and will likely warp the housing.
Page 43: Storage
GENERAL INFORMATION STORAGE Several months of non-use can cause a general deterioration of the motorcycle, ATV This is especially true in areas of extreme temperature variations. This deterioration can be minimized with careful preparation for storage. A properly stored motorcycle is much easier to return to service. Storage Area Selection When selecting a storage area, consider the following: 1.
Page 44: Trovbleshooting
GENERAL INFORMATION the following: 1. Remove the covers from the intake and exhaust openings. 2. Service the air filter as described in Chapter Three. 3. Inspect the cooling system. Check the drain plug and hose connections for leaks. 4. Refill the fuel tank. Turn the fuel shutoff valve on and check for fuel leaks. 5.
Page 45: Engine Principles And Operating Requirements
GENERAL INFORMATION ENGINE PRINCIPLES AND OPERATING REQUIREMENTS An engine needs three basics to run properly: Correct air/fuel mixture Engine Compression runs A spark at the right time If one basic requirement is missing the engine will not run. STARTING THE ENGINE When experiencing engine-starting troubles, it is easy to work out of sequence and forget basic starting procedures.
Page 46: Starting The Engine After A Fall Or After The Engine Stalls
GENERAL INFORMATION Starting the engine after a fall or after the engine stalls 1. Shift the transmission into neutral. 2. Release the hot start lever as the engine starts. 3. If the engine fails to start, refer to Flooded Engine in this section. Flooded engine If the engine fails to start after several attempts, it is probably flooded.
Page 47: Engine Is Hot
GENERAL INFORMATION 2. Turn the fuel valve on 3. If the temperature is below 32°F (0℃), open the throttle two or three times to allow the accelerator pump to feed additional fuel to the engine. 4. Pull the choke knob all the way out to richen the air/fuel mixture. NOTE Do not open the throttle when starting the engine in Step 4.
Page 48: Engine Will Not Start
GENERAL INFORMATION too much fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident when the engine is flooded. Troubleshoot a flooded engine as follows: 1. Look for gasoline overflowing from the carburetor or overflow hose. If gasoline is evident, the engine is flooded and/or the float in the carburetor bowl is stuck.
Page 49: Spark Test
GENERAL INFORMATION NOTE Engine misfire can also be caused by water that enters through connectors. Check the connectors for loose wire ends. On waterproof connectors, check for damage where the wires enter the connector. 6. Perform the Spark Test in this section. If there is a strong spark, perform Step 7. If there is no spark or if the spark is very weak, refer to Ignition System Testing in Chapter Ten.
Page 50: Starter Does Not Turn Over Or Turns Over Slowly
GENERAL INFORMATION 4. Shift the transmission into neutral. WARNING Do not hold the spark tester, spark plug or connector or a serious electrical shock may result. 5. Turn the engine over using the starter and push the starter button. A fat blue spark must be evident between the spark tester or spark plug terminals.
Page 51: Engine Backfires, Cuts Out Or Misfires During Acceleration
GENERAL INFORMATION 8. Contaminated or stale fuel. 9. Clogged air filter. 10. Intake pipe air leak. 11. Plugged exhaust system. Check the silencer or muffler, especially if the utility terrain vehicle was just returned from storage. 12. Faulty ignition system component. Engine Backfires, Cuts Out or Misfires During Acceleration A backfire occurs when fuel is burned or ignited in the exhaust system.
Page 52: Poor Fuel Mileage
GENERAL INFORMATION Poor Fuel Mileage 1. Clogged fuel system. 2. Dirty or clogged air filter. 3. Incorrect ignition timing. Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4.
Page 53: Poor Idle Or Low Speed Performance
GENERAL INFORMATION NOTE A clogged exhaust system will prevent some of the burned exhaust gasses from exiting the exhaust port at the end of the exhaust stroke. This condition effects the incoming air/fuel mixture on the intake stroke and reduces engine power 4.
Page 54: Poor High Speed Performance
GENERAL INFORMATION Poor High Speed Performance Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. Perform the Peak Voltage Check the fuel system as described in this chapter Check the valve clearance as described. Note the following: a.
Page 55: Lean Mixture
GENERAL INFORMATION Choke valve stuck open Float level too high Contaminated float valve seat Worn or damaged float valve and seat Leaking or damaged float Clogged carburetor jets Incorrect carburetor jetting Lean Mixture The following conditions can cause a lean air/fuel mixture: 1.
Page 56: Low Engine Compression
GENERAL INFORMATION oil in the crankcase, sludge is produced. Sludge can eventually cause engine damage as it circulates through the lubrication system and blocks off oil passages. Large amounts of steam can also be caused by a cracked cylinder head or cylinder block surface that allows coolant to leak into the combustion chamber.
Page 57: Engine Overheating (Engine)
GENERAL INFORMATION Engine Overheating (Engine) 1. Improper spark plug heat range. 2. Low oil level. 3. Oil not circulating properly. 4. Valves leaking. 5. Heavy carbon deposits in the combustion chamber. 6. Dragging brake(s). 7. Slipping clutch. Preignition Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber. Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all cause preignition.
Page 58: Englne Lubrication
GENERAL INFORMATION spark plug heat range or carbon buildup in the combustion chamber. 2. Slapping or rattling noises at low speed or during acceleration—May be caused by excessive piston-to-cylinder wall clearance (piston slap). NOTE Piston slap is easier to detect when the engine is cold and before the piston has expanded.
Page 59: High Oil Pressure
GENERAL INFORMATION 4. Clogged oil filter. 5. Internal oil leakage. 6. Oil relief valve stuck open. 7. Incorrect type of engine oil. High Oil Pressure 1. Oil relief valve stuck closed. 2. Clogged oil filter. 3. Clogged oil gallery or metering orifices. No Oil Pressure 1.
Page 60 GENERAL INFORMATION percent of leakage. A cylinder leak down tester and an air compressor are needed to perform this test. When performing a leak down test, the engine is first set at TDC on its compression stroke so that all the valves are closed. When the combustion chamber is pressurized, very little air should escape. However, the difficulty in performing a leak down test on a single cylinder engine(especially on the engines described in this manual with low static engine compression) is in preventing the piston from moving as the combustion chamber starts to pressurize.
Page 61 GENERAL INFORMATION WARNING Do not attempt to lock the engine by trying to use a tool to hold the Allen bolt on the end of the crankshaft. Once the combustion chamber becomes pressurized, any crankshaft movement can throw the tool away from the engine under considerable force, attempting to hole the tool can cause serious injury.
Page 62: Electrical Testing
GENERAL INFORMATION bore. 11. If the cylinder leak down is 10 percent or higher, further service is required. 12. Disconnect the test equipment and install all the parts previously removed. ELECTRICAL TESTING This section describes basic electrical testing and test equipment use. Preliminary Checks and Precautions Refer to the color wiring diagrams at the end of the manual for component and connector identification;...
Page 63: Electrical Component Replacement
GENERAL INFORMATION b. Lightly pull or wiggle the connectors while repeating the test. Do the same when checking the wiring harness and individual components. especially where the wires enter a housing or connector c. A change in meter readings indicates a poor connection. Fine and repair the problem or replace the part.
Page 64: Test Equipment
GENERAL INFORMATION include: the testing meter’s internal circuitry, ambient temperature and conditions under which the machine has been operated. All instructions and specifications have been for accuracy: however. Successful test results depend to a great degree upon individual accuracy. Test Equipment A test light can be constructed from a 12-volt light bulb with a pair of test leads carefully soldered to the bulb.
Page 65: Jumper Wire
GENERAL INFORMATION component to be tested. If an analog meter id used, is must be calibrated by touching the teat leads together and turning the set-adjust knob until the meter needle reads zero. When the leads are uncrossed, the needle reads zero. When the leads are uncrossed, the needle should move to the other end of the scale indicating infinite resistance.
Page 66: Test Procedures
GENERAL INFORMATION TEST PROCEDURES Voltage test Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing. If the test lead only touches the wire insulation.
Page 67: Peak Voltage Test
GENERAL INFORMATION b. A voltage drop of 1 or more volts indicates that a circuit has excessive resistance. c. For example, consider a starting problem where the battery is fully charged but the starter motor turns over slowly. Voltage drop would be the difference in the voltage at the batter (source) and the voltage at the starter (destination) as the engine is being started (current is flowing through the batter cables).
Page 68: Testing For A Short With A Test Light Or Voltmeter
GENERAL INFORMATION along the harness. 6. If the test light blinks or the needle on the ohmmeter moves, there is a short-to-ground at that point in the harness. Testing for a short with a test light or voltmeter 1. Remove the blown fuse. 2.
Page 69: Brake Drag
GENERAL INFORMATION WARNING As the brake pads wear, the brake fluid level in the master cylinder reservoir drops. Whenever adding brake fluid to the reservoir, visually check the brake pads for wear. If it does not appear that there is an increase in pad wear, check the brake hoses, lines and banjo bolts for leaks.
Page 70: Hard Brake Lever Or Pedal Operation
GENERAL INFORMATION Hard Brake Lever or Pedal Operation When applying the brakes and there is sufficient brake performance but the operation of brake lever feels excessively hard, check for the following possible causes: 1. Clogged brake hydraulic system. 2. Sticking caliper piston. 3.
Page 71: Leaking Master Cylinder
GENERAL INFORMATION Leaking Master Cylinder 1. Damaged piston secondary seal. 2. Damaged piston snap ring/ snap ring groove. 3. Worn or damaged master cylinder bore. 4. Loose banjo bolt washers. 5. Damaged banjo bolt washers. 6. Damaged banjo bolt threads in master cylinder body. 7.
Page 72: Specifications
SPECIFICATIONS SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY...
Page 73: Geberar Specifications
SPECIFICATIONS GEBERAR SPECIFICATIONS Item Standard Dimensions : Overall length 2,510mm (98.8in) Overall width 1,220mm（48.0 in） Overall height 1,390mm（54.7in） Seat height 900mm（35.4in） Wheelbase 1,490mm（58.7in） Minimum ground clearance 310 mm（12.2 in） 2,480mm（97 in）） Minimum turning radius Basic weight : With oil and full fuel tank 420kg (926 lb) Engine : Engine type...
Page 74 SPECIFICATIONS Item Standard Ignition system Type/quantity MT05 / 1 Spark plug DCPR7E / 1 (NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Clutch type Wet ,centrifugal automatic Transmission Primary reduction system V-belt Secondary reduction system Shaft drive Transmission type V-belt automatic Operation Left hand operation Single speed automatic...
Page 75 SPECIFICATIONS Item Standard Electrical Ignition system E.C.U Generator system A.C. magneto Battery type U1-21 Battery capacity 12 V, 21Ah Headlight type Bulb wattage×quantity 12V 55W / 55W × 2 Headlight Front Position Lamp 12V 10W×2 Front direction indicator 12V 10W×2 Rear direction indicator Rear position lamp 12V 10W×1...
Page 76: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder Bore size 91.000 ~ 91.035mm ---- Measuring point (3.583~ 3.584 in) 50 mm (1.97 in) Camshaft Drive method ---- Cam dimensions 25.95~26.05mm Intake (1.2165~1.0256） “A”...
Page 77 SPECIFICATIONS Item Standard Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.011~ 12.018 mm (0.4729 ~ 0.4731 in) Shaft outside diameter 11.982~ 11.989 mm ---- (0.4717 ~ 0.4720 in) Arm-to-shaft clearance 0.022 ~ 0.036 mm ----...
Page 78 SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.040 ~ 0.067 mm 0.08 mm (0.0016 ~ 0.0026in) (0.0031 in) 0.040 ~ 0.067 mm 0.10 mm (0.0016 ~ 0.0026 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
Page 79 SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 90.940 ~ 90.955mm ---- (3.5803 ~ 3.5809 in) ---- Measuring point “H” 4.0 mm (0.15 in) ---- Piston off-set 0.5mm(0.0394 in)
Page 80 SPECIFICATIONS Item Standard Limit Oil ring ---- 4.0×3.40mm Dimensions (B×T) (0.1575× 0 .1339in) ---- 0.20 ~ 0.70 mm End gap (installed) (0.0079 ~ 0.0276 in) ---- 0.06 ~ 0.15 mm Side clearance (0.0024 ~ 0.0059 in) Crankshaft 90.523~ 90.577mm ---- Crank width “A”...
Page 81 SPECIFICATIONS Item Standard Limit Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Engine oil ---- Oil pump Oil filter type Chartaceous ---- Oil pump type Trochoid Tip clearance 0.15 mm ---- (0.0059 in) ---- Side clearance 0.03 ~ 0.10 mm ---- (0.0012 ~ 0.0039 in)
Page 82: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 147 mm (4.25 in) ---- Spring free length 541 mm (21.29 in) ---- Spring fitting length 394 mm (15.51in) ---- Rear suspension Shock absorber travel 174 mm (4.02 in) ----...
Page 83 SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.6 mm (0.22 in) ---- Pad thickness outer 5.6 mm (0.22 in) ---- Master cylinder inside diameter 17.4mm (0.69in) ----...
Page 84: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (BTDC) 15°±1°before TDC ---- Advancer type ECU Digital type ---- C.D.I. 459 ~ 561 Ωat 20 °C (68 °F)/ Pickup coil resistance/color ---- White/Red – White/Green ---- 0.063 ~ 0.077 Ωat 20 °C (68 °F)/ Rotor rotation direction sensing coil...
Page 85 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor ---- Output 0.8 kW ---- 0.025 ~ 0.035 Ωat 20 °C (68 °F) Armature coil resistance ---- Brush overall length 12.5 mm (0.49 in) 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N ----...
Page 86: Tightening Torques
SPECIFICATIONS TIGHTENING TORQUES Engine tightening torques Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt — Spark plug Cylinder head (exhaust pipe) Stud bolt Bolt Cylinder head cover Tappet cover (exhaust) —...
Page 87 SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Bolt Bolt Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
Page 88 SPECIFICATIONS Tightening torque Thread Remarks Part to be tightened Part name Q’ty ft · lb m.kg size Left-hand Shift rod locknut (select lever unit) — threads Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) —...
Page 89: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm...
Page 90 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half 26.0 Stake shaft Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt...
Page 91: General Tightening Torque Specifications
SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 92: Lubrication Pionts And Lubricant Types
SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES Engine Lubrication points Lubricant Oil seal lips Apply lithium-soap-based grease Bearings Apply engine oil O-rings Apply lithium-soap-based grease Piston, piston ring Apply engine oil Piston pin Apply engine oil Buffer boss and balancer drive gear Apply engine oil Crankshaft seal and spacer Apply engine oil...
Page 93: Chassis
SPECIFICATIONS CHASSIS Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing Front &...
Page 94: Hydrographic Chart
SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure - 82-...
Page 95: Lubrication Oil Way
SPECIFICATIONS LUBRICATION OIL WAY LUBRICATION OIL WAY ：Pressure ：splashing oil - 83-...
Page 96: Maintence And Adjustment Of The Atv
MAINTENANCE AND ADJUSTMENT OF THE ATV MAINTENCE AND ADJUSTMENT OF THE ATV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL Whichever...
Page 97 MAINTENANCE AND ADJUSTMENT OF THE ATV · Check condition. · ○ ○ ○ ○ ○ Spark plug Adjust gap and clean. · Rep; ace if necessary. · ○ ○ ○ ○ Throttle body * Replace if necessary. · Check operation. ○...
Page 98: Engine
MAINTENANCE AND ADJUSTMENT OF THE ATV ENGINE Adjusting the valve clearance NOTE: · The valve clearance must be adjusted when the engine is cool to the touch. · Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke.
Page 99 MAINTENANCE AND ADJUSTMENT OF THE ATV 3. Check: ·valve clearance ·Beyond the standard Adjust. Valve clearance (cold) Intake 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) Exhaust 0.12 ~ 0.16 mm (0.0047 ~ 0.0063 in) 4. calibration adjusting tools ○ Spin the crank, when the rotoflex’s scale shows 1, it is cylinder 1’s timing;...
Page 100 MAINTENANCE AND ADJUSTMENT OF THE ATV 5. Adjust the valve clearance of cylinder 1, and cylinder 2 the same way valve clearance ① Lock nut ② （ Valve thickness gauge Regulation） ③ Regulator ④ Adjust tools · Loosen the locknut ①...
Page 101: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE ATV CHECKING THE SPARK PLUG 1. lift up cargo box and dismount the seat 2. Remove: pull out the spark plug cap ① 3. Check: ·spark plug type Incorrect Replace. Standard spark plug DCPR7E / NGK 4.
Page 102: Checking The Ignition Timing
MAINTENANCE AND ADJUSTMENT OF THE ATV CHECKING THE IGNITION TIMING NOTE: Before checking the ignition timing, adjust the engine’s racing speed and throttle cable. 1. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the cargo bed up. 3.
Page 103: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE ATV · timing light 9. Lower the cargo bed. 10. Install: ·console ·passenger seat ·driver seat Refer to “SEATS” in chapter 5. MEASURING COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1.
Page 104: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE ATV Compression pressure(with oil introduced into cylinder) Reading Diagnosis Higher than Worn damaged without oil pistons Same Defective ring(s), without oil valves, cylinder head gasket or piston is possible. Compression pressure (at sea level) Standard: 1,324Kpa (13.24 kg/cm2, 188.31Psi) Minimum: 1,150Kpa (11.5 kg/cm2, 163.57Psi)
Page 105: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE ATV ·engine oil level Oil level should be between the maximum ②and minimum ③marks. Oil level low Add oil to the proper level. NOTE: Do not screw the dipstick ① in when checking the oil level. Recommended oil Follow the left chart.
Page 106 MAINTENANCE AND ADJUSTMENT OF THE ATV Place the vehicle on a level surface. 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the engine. 3. Remove: ·driver seat ·passenger seat ·console 4.
Page 107 MAINTENANCE AND ADJUSTMENT OF THE ATV 6. Install： ·engine oil drain bolt ② ·Final gear oil drain bolt ③ 7. conditions · Change for new oil filter before impouring oil to crankcase, and make sure it is in good working condition before assembling. ·...
Page 108: Chassis
MAINTENANCE AND ADJUSTMENT OF THE ATV CHASSIS CLEANING THE AIR FILTER NOTE: There is a check hose ③at the bottom of the air filter case. If dust and/or water collect in this hose, clean the air filter element and air filter case.
Page 109: Checking The Coolant Level
MAINTENANCE AND ADJUSTMENT OF THE ATV WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. squeeze the excess solvent out of the element and let it dry.
Page 110: Changing The Coolant
MAINTENANCE AND ADJUSTMENT OF THE ATV ·coolant level The coolant level should be between the minimum level mark ③ and maximum level mark ②.Below the minimum level mark Add the recommended coolant to the proper level. CHANGING THE COOLANT 1. Remove: Front faceplate ·coolant reservoir cap ①...
Page 111 MAINTENANCE AND ADJUSTMENT OF THE ATV 5. Remove: ·radiator cap ① WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
Page 112 MAINTENANCE AND ADJUSTMENT OF THE ATV 12. Remove: ·air bleed bolt ① 13. Fill cooling (with specified amount recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 : 1 (antifreeze : water) Quantity total amount 1.8 L Coolant reservoir capacity...
Page 113: Checking The Coolant Temperature Warning Light
MAINTENANCE AND ADJUSTMENT OF THE ATV NOTE: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.
Page 114: Checking The V-Belt
MAINTENANCE AND ADJUSTMENT OF THE ATV Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning light does not come on. come on. Turn the main switch to “START” with the transmission in neutral position.
Page 115: Cleaning The Spark Arrester
MAINTENANCE AND ADJUSTMENT OF THE ATV V-belt width: 31.2 mm <Limit:> 26 mm ·Replace V-belt: Install the bolts ① into the secondary fixed sheave hold. NOTE: ① will Tightening bolts push secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.
Page 116: Adjusting The Brake Pedal
MAINTENANCE AND ADJUSTMENT OF THE ATV WARNING: · Select a well-ventilated area free of combustible materials. · Always let the exhaust system cool before performing this operation. · Do not start the engine when removing the tailpipe from the muffler. 3.
Page 117: Checking The Brake Fluid Level
MAINTENANCE AND ADJUSTMENT OF THE ATV b. Turn brake rod ② in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. c. Tighten the locknut to specification. Locknut 17 Nm (1.7 m ·...
Page 118: Checking The Front Brake Pads
MAINTENANCE AND ADJUSTMENT OF THE ATV master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in a vapor lock. 4. Close the hood. CHECKING THE FRONT BRAKE PADS 1. Remove: ·front wheels 2.
Page 119: Checking The Brake Hoses And Brake Pipes
MAINTENANCE AND ADJUSTMENT OF THE ATV CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: ·front cover 2. Lift the hood up. 3. Check: ·front brake hoses ① ·front brake hoses ② Cracks/wear/damage Replace. Fluid leakage Replace all damaged parts. Refer to “FRONT AND REAR BRAKES”...
Page 120 MAINTENANCE AND ADJUSTMENT OF THE ATV has been reached, then release the pedal. i. Repeat steps (e) to (h) until all the air bubbles have disappeared from the fluid. j. Tighten the bleed screw. Front brake caliper bleed screw 6 Nm (0.6 m · kg, 4.3 ft · lb) Rear brake caliper bleed screw 5 Nm (0.5 m ·...
Page 121: Adjusting The Select Lever Shift Rod
MAINTENANCE AND ADJUSTMENT OF THE ATV ADJUSTING THE SELECT LEVER SHIFT ROD ① select lever shift rod L：low H：high N：neutral R：reverse WARNING Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. 1.
Page 122: Changing The Final Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE ATV Recommended oil SAE 90 API GL-5 gear oil WARNING Take care not allow foreign material to enter the final gear case. 3. Install: ·oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHANGING THE FINAL GEAR OIL 1.
Page 123: Changing The Differential Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE ATV WARNING Take care not allow foreign material to enter the differential gear case. 4. Install: ·oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHANGING THE DIFFERENTIAL GEAR OIL 1. Place the vehicle on a level surface. 2.
Page 124: Checking The Constant Velocity Joint Dust Boots
MAINTENANCE AND ADJUSTMENT OF THE ATV WARNING Take care not to allow foreign material to enter the differential gear case. 7. Install: • oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1.
Page 125 MAINTENANCE AND ADJUSTMENT OF THE ATV Check: ● tie-rod ends Ball pin unit of steering tension rod. Rotate the steering bar leftward and / or rightward, Then orate from left to right lightly . If the ball pin unit of steering tension rod have any vertical clearance , replace it .
Page 126: Adjusting The Toe-In
MAINTENANCE AND ADJUSTMENT OF THE ATV ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification Adjust. Toe-in 0 ~ 10 mm (0.00 ~ 0.39 in) (with tires touching the ground) NOTE: Before measuring the toe-in, make sure that the tire pressure is correct.
Page 127: Adjusting The Rear Shock Absorbers
MAINTENANCE AND ADJUSTMENT OF THE ATV a. Mark both tie-rods ends. This reference point will be needed during adjustment. ① b. Loosen the locknut (tie-rod end) on each tie-rod. c. The same number of turns should be given to ② both the right and left tie-rods until the specified toe-in is obtained.
Page 128: Checking The Tires
MAINTENANCE AND ADJUSTMENT OF THE ATV CHECKING THE TIRES WARNING • TIRE CHARACTERISTICS Tire characteristics influence the handling of vehicle’s. If other tire combinations are used, they can adversely affect your vehicle’s handling characteristics and are therefore not recommended. Size Type Front 25 ×...
Page 129 MAINTENANCE AND ADJUSTMENT OF THE ATV 1. Measure: • Tire pressure (cold tire pressure) out of specification Adjust. NOTE: ① • The tire pressure gauge is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings.
Page 130: Checking The Wheels
MAINTENANCE AND ADJUSTMENT OF THE ATV CHECKING THE WHEELS 1. Check: ① • Wheels Damage/bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel.
Page 131: Electrical
MAINTENANCE AND ADJUSTMENT OF THE ATV ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries;...
Page 132 MAINTENANCE AND ADJUSTMENT OF THE ATV The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably; • Therefore, take special care when charging the battery. NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of...
Page 133 MAINTENANCE AND ADJUSTMENT OF THE ATV NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the open-circuit voltage equals or exceeds 12.8 b.
Page 134 MAINTENANCE AND ADJUSTMENT OF THE ATV battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it.
Page 135 MAINTENANCE AND ADJUSTMENT OF THE ATV Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 20 ~ 25 V Monitor the amperage for 3 ~ 5 Adjust the voltage to obtain the...
Page 136 MAINTENANCE AND ADJUSTMENT OF THE ATV Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging.
Page 137: Checking The Fuses
MAINTENANCE AND ADJUSTMENT OF THE ATV NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ②, and then the negative battery lead ①. •...
Page 138 MAINTENANCE AND ADJUSTMENT OF THE ATV c. Turn on switches to verify operation of the related electrical devices. d. If the fuse immediately blows again, check the electrical circuit. Current Description Quantity rating Dash board 、 ECU 15 A switch battery fuse Headlight fuse 15 A Auxiliary DC jack...
Page 139: Adjusting The Headlight Beam
MAINTENANCE AND ADJUSTMENT OF THE ATV ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) ① • turn the adjuster in or out Turning in Headlight beam raised. Turning out Headlight beam lowered. CHANGING THE HEADLIGHT BULB Remove: • Lift the hood up. •...
Page 140: Changing The Tail/Brake Light Bulb
MAINTENANCE AND ADJUSTMENT OF THE ATV NOTE: Avoid touching the glass part of the bulb. Keep free from oil; otherwise, transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
Page 141 MAINTENANCE AND ADJUSTMENT OF THE ATV NOTE: Avoid touching the glass part of the bulb. Keep free from oil; otherwise, transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on the bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
Page 142: Engine
ENGINE ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air.
Page 143: Engine Removal
ENGINE ENGINE REMOVAL Part Name Remarks Removing throttle and intake Remove the parts in the order listed. manifold. Dampers Dampers joint (intake manifold) Intake manifold Bushing Φ8.5×Φ11.2×34 Intake manifold washer Pressure sensor Pressure plate TMAP Fuel Injector Fuel Injector seat Drain blind nut Drain plug -131-...
Page 144 ENGINE Part Name Remarks Removing throttle and intake Remove the parts in the order listed. manifold. High-pressure efi molding tubing Oil pipe clip Φ14.8 Trifurcate tube High-pressure efi tubingΦ8×Φ14×43 For installation, reverse the removal procedure. -132-...
Page 145 ENGINE 1、CHECK • Throttle sheet free movement If throttle valve cannot go back, change for a new throttle. 2、NOTE • Removing the drain blind nut and drain plug NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. 3、INSTALL •...
Page 146: Cylinder Head And Cylinder Head Cover
ENGINE CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head and Remove the parts in the order listed. cylinder head Thermostat cover Cylinder water outlet connector Washer O-ring Cylinder head cover Cylinder cover pad Spark plug Temperature sensor Cylinder head Timing chain tensioner cap bolt...
Page 147 ENGINE Part Name Remarks Dowel pin Timing chain guide (exhaust side) For installation, reverse the removal procedure. -135-...
Page 148 ENGINE 1、CHECK 1). Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2). Checking the cylinder head cover • cylinder head cover Cracks/damage Replace the cylinder head cover and cylinder head as a set. 3).
Page 149 ENGINE 5). Checking the cylinder head (1). Eliminate: • carbon deposits (from combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats (2). Check: • cylinder head Scratches/damage Replace the cylinder head cover and cylinder head as a set.
Page 150 ENGINE WARNING Always use a new gasket. NOTE: The “UP” mark on the timing chain tensioner should face up. Timing chain tensioner bolt (10 Nm) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and tighten the cap bolt to the specified torque. Timing chain tensioner cap bolt (7 Nm) -138-...
Page 151: Rocker Arms And Camshaft
ENGINE ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Rocker arm shaft Wave washer Rocker arm (exhaust) Rocker arm (intake) Valve adjuster Locknut Camshaft sprocket Camshaft station plate Camshaft Cylinder head...
Page 152 ENGINE 1、CHECK 1). Checking the rocker arms • rocker arm lobes • valve adjusters Blue discoloration/pitting/scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. b.
Page 153 ENGINE 2). Checking the camshaft • cam lobes Pitting/scratches/blue discoloration Replace • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3).
Page 154: Valves And Valve Springs
ENGINE VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the removal procedure.
Page 155 ENGINE 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
Page 156 ENGINE • valve stem runout Out of specification Replace. Runout limit 0.01 mm NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
Page 157 ENGINE NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Install the new valve guide using a valve guide remover ① and valve guide installer ②. b.
Page 158 ENGINE NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. d. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
Page 159: Cylinder And Piston
ENGINE CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Dowel pin Cylinder head gasket Cylinder Cylinder gasket Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal procedure.
Page 160 ENGINE 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) NOTE: Check whether the piston and the piston groove is cracked and abraded.
Page 161 ENGINE • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves rings before measuring...
Page 162 ENGINE 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
Page 163: Engine Cooling Fan And A.c. Magneto
ENGINE ENGINE LEFT CRANKCASE COVER AND A.C. MAGNETO Part Name Remarks Removing the engine left crankcase Remove the parts in the order listed. cover and A.C. magneto Engine oil Water pump assembly Left crankcase cover Inspection port cover /O-ring Crankcase location sensor/ O-ring Plug oil level gauge/O-ring A.C.
Page 164 ENGINE Part Name Remarks Starter idle gear Starter idle gear shaft For installation, reverse the removal procedure. -152-...
Page 165 ENGINE 1、CHECK 1). Checking the A.C. magneto • stator coil • pickup coil Damage Replace. 2). Checking the starter clutch • starter clutch ① Cracks/damage Replace. • starter clutch bolts ② Loose Replace with new ones, and clinch the end of the bolts. NOTE: •...
Page 166 ENGINE 2、INSTALL • woodruff key • dowel pins • A.C. magneto rotor NOTE: • Before installing the rotor, clean the outside of the crankshaft and the inside of the rotor. • After installing the rotor, check that the rotor rotates smoothly. If not, reinstall the key and rotor.
Page 167: Starter Motor And Oil Filter
ENGINE STARTER MOTOR AND OIL FILTER Part Name Remarks Removing the starter motor and oil Remove the parts in the order listed. filter A.C. magneto rotor Starter idle gear Starter idle gear shaft Relief valve spring/steel ball Chain plate Timing chain guide(first cylinder) Timing chain Pump Oil filter cover...
Page 168 ENGINE Part Name Remarks Starter motor Oil pressure sensor Dual bolts Dual bolts Positioning sell The lock not For installation, reverse the removal procedure. -156-...
Page 169 ENGINE 1、CHECK 1) Checking the starter idle gear • starter idle gear Cracks/wear/damage Replace 2) Checking the timing chain and guides • timing chain Cracks/stiff Replace the timing chain and camshaft sprocket as a set. • timing chain guides Wear/damage Replace.
Page 170 ENGINE 2、INSTALL • starter motor • oil filter cartridge • Starter idle gear shaft • Starter idle gear NOTE: Apply the molybdenum disulfide grease to the thread of axle and nut. -158-...
Page 171: Primary And Secondary Sheaves
ENGINE PRIMARY AND SECONDARY SHEAVES Part Name Remarks Removing the primary and secondary Remove the parts in the order listed. sheaves Engine assembly Drive belt cover Rubber gasket V-belt Secondary fixed sheave Secondary sliding sheave Compression spring Guide Base, Driven Gear Driving Flyweight Primary fixed sheave Compression spring/Spring seat...
Page 172 ENGINE Part Name Remarks Spacer Fixing Base, One-Way Bearing Guide pin/spring Primary sliding sheave Drive belt case For assembly, reverse the disassembly procedure. -160-...
Page 173 ENGINE 1、Check 1). Checking the primary sheave • primary pulley slider • primary sliding sheave splines Wear/cracks/damage Replace. • spacer • primary pulley cam Cracks/damage Replace. • primary sliding sheave • primary fixed sheave Cracks/damage Replace. 2、Measure • secondary sheave spring free length (a) Out of specification Replace the secondary sheave spring.
Page 174 ENGINE 2). Assembling the secondary sheave (1)Apply: • assembly lube (to the secondary sliding sheave ① inner surface and oil seals)。 • assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ②) 3). Installing the primary and secondary sheaves (1) Install: •...
Page 175: Crankcase Cover And Oil Pump
ENGINE CRANKCASE COVER AND OIL PUMP Part Name Remarks Removing the Crankcase cover and oil Remove the parts in the order listed. pump Crankcase separation Crankshaft cover Gasket Dowel pin Crankcase Exhaust pipe Crankcase block Oil seal Oil pump gasket Oil pump Outer rotor Innter rotor...
Page 176 ENGINE Part Name Remarks Shaft/pin Oil pump housing Oil pump gear Water pump Ⅱ gear/circlip Shaft/pin Water pump Ⅰ gear/washer Oil pump middle gear Shaft Bearing Fuel and air separator assy V-ring Shaft Valve piece plate -164-...
Page 177 ENGINE Part Name Remarks Valve piece Chain plate Timing chain guide(secondly cylinder) Timing chain Right crankcase For assembly, reverse the disassembly procedure. -165-...
Page 178 ENGINE 1、CHECK 1). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts. 2) Checking the timing chain and guides • timing chain Cracks/stiff Replace the timing chain and camshaft sprocket as a set.
Page 179: Crankcase And Middle Driven Shaft
ENGINE CRANKCASE AND MIDDLE DRIVEN SHAFT Part Name Remarks Remove the crankcase and middle Remove the parts in the order listed. drive shaft Crankcase separation Right crankcase Crankcase gasket Dowel pin Crankshaft Shaft Connection rod cover/Rod Bushing Universal joint Oil seal Bearing retainer Bearing seat dowel pin -167-...
Page 180 ENGINE Part Name Remarks Bearing Middle driven shaft Bearing O-ring/bearing Left crankcase For installation, reverse the removal procedure. -168-...
Page 181 ENGINE 1、CHECK 1). Checking the middle drive • O-ring Damage Replace. • bearings Clean and lubricate, then rotate the inner race with a finger. Pitting/damage Replace. • universal joint movement Roughness Replace universal joint. 2). Checking the crankcase (1) Thoroughly wash the case halves in a mild solvent.
Page 182 ENGINE CAUTION: The buffer boss and woodruff key should be replaced when removed from the crankshaft. 2). Assembling the crankcase (1) Apply: • sealant (Quick Gasket) (to the mating surfaces of both case halves) (2) Install: • dowel pins (3) Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer CAUTION: Before installing and torque the crankcase...
Page 183 ENGINE 2). Installing the middle driven shaft • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. CAUTION: Check each bearing. The needles can easily fall out of their races.
Page 184 ENGINE CAUTION: Before installing and torque the crankcase holding bolts, be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions. 4)Tighten: • crankcase bolts (follow the proper tightening sequence) Right crankcase NOTE: •...
Page 185: Output Shaft
ENGINE OUTPUT SHAFT Part Name Remarks Remove the output shaft Remove the parts in the order listed. Middle drive gear Left gearcase cover Drive shaft coupling Drive shaft spring/bearing Output shaft Y-1 Washer/collar Washer/o-ring Drum-shaped gear/washer Fuel seal Collar/o-ring Rear drive bearing seat -173-...
Page 186 ENGINE Part Name Remarks Dowel pin Gearcase For installation, reverse the removal procedure. -174-...
Page 187 ENGINE 1、CHECK 1). Checking the output shaft Y-1 • Drive shaft coupling • Output shaft Y-1 Pitting/galling/wear Replace. • O-ring Damage Replace. • bearings Pitting/damage Replace. 2、MEASURE • Output shaft Y-1 swing a. Temporary install the gearcase . b. Wrap a rag ① around a screwdriver ②, and then insert it into the installation hole ③...
Page 188 ENGINE • shims ① • universal joint yoke • washer • nut ① NOTE: Use the universal joint holder ② to hold the yoke. • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c.
Page 189: Gearcase
ENGINE GEARCASE Shift lever and oil pump Part Name Remarks Removing the shift lever and gearcase Remove the parts in the order listed. Gearcase separation Shift lever cover/gasket Shift lever 2 assembly Shift lever 1 Oil pump/o-ring Outer rotor Inner rotor Oil pump shaft/pin Connecting pipe1/2 Gearcase exhaust nozzle...
Page 190 ENGINE Part Name Remarks Oil filler cap/o-ring Gearcase gasket/dowel pin Shift drum stopper/spring/steel ball Reverse switch/washer Gearshift indicator/o-ring Spring seat/circlip Guide bar Shift fork 1/long spring Shift fork 2/short spring Right gearcase cover Right gearcase cover seat bracket For assembly, reverse the disassembly procedure.
Page 191: Gearcase Transmission
ENGINE Gearcase transmission Part Name Remarks Removing the gearcase transmission Remove the parts in the order listed. Gearcase separation Oil seal/ Bushing Main shaft transmission assembly L gear driving gear/ bearing H gear driving gear/needle bearing Main shaft/dowel pin Main shaft Bearing press plate/ Bearing Countershaft transmission assembly Needle bearing Ⅰ...
Page 192 ENGINE Part Name Remarks BearingⅠ L gear driven gear H gear driven gear Needle bearing R gear driven gear Bearing Ⅱ R shaft transmission assembly Reverse shaft R gear idle gear/ R gear idle gear shaft For assembly, reverse the disassembly procedure.
Page 193 ENGINE 1、CHECK 1). Checking the shift forks • shift fork follower ① • shift fork pawl ② Scoring/bends/wear/damage Replace. • guide bar Roll the guide bar on a flat surface. Bends Replace. ： WARNING Do not attempt to straighten a bent guide bar. •...
Page 194 ENGINE • bearings Clean and lubricate, then rotate the inner race with a finger. Roughness Replace 4). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts.
Page 195 ENGINE 3、INSTALL 1). Assembling the shift fork • guide bar ① • shift fork 2 ② • long spring ③ • shift fork 1 ④ • short spring ⑤ 2). Installing the shift levers • shift lever 2 assembly ① (14Nm) •...
Page 196: Malfunction Inspection
CHASSIS MALFUNCTION INSPECTION Appearance malfunction inspection Phenomenon Measure 1. Replace new plastic cover. 2. Check whether installation supporter deformed, repairing Plastic cover damaged or re-painting is needed before replacing new plastic cover. 3. Re-paste decals and re-rivet warning labels. 1. Replace new bumper. 2.
Page 197 CHASSIS 4. Check whether front wheel and front wheel axle nut loosen or damaged. Off tracking by braking at 5. Check whether front wheel hub inner spline and front high-speed wheel axle outer spline worn or loosen. 6. Check whether rubber cushion connected to front suspension rocker and frame damaged.
Page 198 CHASSIS Phenomenon Measure 1. Check whether spline of front and rear axle intermediate propeller shaft damaged. 2. Check whether front and rear axles splines damaged. 3. Check whether gears of front gearbox and differential Front and rear axles arise over worn. abnormal sound during drive 4.
Page 199: Steering Operation System
CHASSIS CHASSIS STEERING OPERATION SYSTEM THE STRUCTURE OF STEERING Part Name Remarks Removing the structure of steering Column, steering saaembly Handle pipe upper bracket Handle pipe lower bracket Hexagon flange bolt M8×55 Plane bearing, steering Oil seal Bushing Φ9×Φ13.5×43.5 Stopper Hexagon bolt M8×60 -187-...
Page 200 CHASSIS Part Name Remarks Bearing pressing plate Hexagon flange bolt M8×16 Hexagon flang locked nut M8 Axle sleeve ,steering stem Hexagon flange bolt M8×35 Power-assisted steering Hexagon flange bolt M8×30 Turning arm,Steering stem Flat gasket Φ16×Φ30×3 Circlip for shaft-20 Hexagon nut M16×1.5 Cotter pin 2.5×40 Rod, tie -188-...
Page 201 CHASSIS Part Name Remarks Hexagon adjusting nut(L) Ball head pin combination Hexagon adjusting nut(R) Straight rod gimbal Spring washer -10 Nut M10×1.25 Pin ,cotter 2×32 -189-...
Page 202: The Steering Handle And Cable
CHASSIS THE STEERING HANDLE AND CABLE Part Name Remarks Removing steering handle and cable Handle bar Handle grip Greaser assy Cable, accelerator Two/Four drives shifting switch Greaser assy -190-...
Page 203: The Handle Switch And Lever
CHASSIS THE HANDLE SWITCH AND LEVER Part Name Remarks Removing handle switch and lever Left handle switch assy Left handle switch Lock block, left handle switch Left handle grip Bolt M6 Nut M6 Hex flang bolt M6×16 Nylon self-locked bolt M5 Drive switch Adjusting bolt,left handle bar cable Adjusting bolt,left handle bar cable...
Page 204 CHASSIS Part Name Remarks Left switch comp. Right rear mirror assy Left rear mirror assy Hoist controller Hoist switch mounting bracket 1 Hoist switch mounting bracket 2 Hoist switch mounting bracket 3 Hoist switch mounting bracket 4 Inner hex screw M5×16 Rear mirror mounting bracket Hexagon flange bolt M6×25 -192-...
Page 205 CHASSIS THE STEERING OPERATION SYSTEM DIASSEMBLING THE PARTS OF STEERING BAR 1. Remove: • Speedometer cover.① a. Takes down the speedometer cover. ① 2. Remove: • all connecting wires • cable, wind-proofed door • cable, accelerograph • cable, front brake •...
Page 206 CHASSIS 2. Remove: • pin,cotter ① • nut ② CAUTION: When removing the rod tie end and pin cotter form the column steering assemly and front seat assembly of front brake with common bearing tension tool and other pay attention to not damage the relvent parts.
Page 207 CHASSIS CHECKING STEERING OPERATION SYSTEM 1. Check: • handle bar Bent/damaged Replace The handle bar to rotate whether nimble, do not have stagnation Adjust 2. Check: • column, steering assembly Bent/damaged Replace WARNING: In order to avoid decreasing the performance of column steering assembly, if it is bent do not straighten it forcefully.
Page 208 CHASSIS 5. Crorrecting: • Straight rod gimbal ① • turning ② • rocky ledge ③ Wear/damaged Replace Free play Replace the straight rod gimbal. Turns roughly Replace the straight rod gimbal. 6. Adjustment: • Shift straight rod assembly Adjustment steps of shift straight rod assembly length.
Page 209 CHASSIS 2. Install: • oil seal ① • Bushing ② • plane bearing, steering ③ 3. Install: When installing the plane bearing steering ① and ② ③. column steering assembly take them as a unit WARNING: In order to ensure the correct circuit of brake cable and wire, never damage and wind the cables and wires.
Page 210 CHASSIS 6. Mounting: • pin,cotter ① CAUTION: Don’t loosen the nut after the torque is fixed. If the nut recess is not correspondance with pin cotter, cotter hole on the double-screw bolt, tighten the nut to align them. WARNING: Always use new pin cotter. 7.
Page 211 CHASSIS INSTALLING THE STEERING HANDLE 1. Install: • lower holding seat ① • handle bar ② • upper holding seat ③ WARNING: When tightening the bolt of holding seat, make ⓑ ensure the even of clearance 2. Install: • throttle grip unit CAUTION: The projection of throttle grip must correspond to the sunken part on the right lever seat when...
Page 212: Brake System
CHASSIS BRAKE SYSTEM PREPARATION FOR CHECKING BEFORE THE MAINTENANCE OF THE BRAKE SYSTEM. Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained. This vehicle uses the single return route hydraulic pressure disc brake system. Please follow the tips of inspection as below.
Page 213: Brake System
CHASSIS BRAKE SYSTEM DISK BRAKE COMPONENTS Part Name Remarks Removing brake components Disc brake parts Front brake cylinders Front brake handle Front left disc brake pads Outer brake pad assy Inner brake pad assy Front right brake caliper -201-...
Page 214 CHASSIS Part Name Remarks Oil cup Oil cover Auxiliary bumper assy Rear triplet joint Rear left brake caliper Rear right brake caliper Hexagon flange bolt M6×25 Hexagon flange bolt M6×16 -202-...
Page 215: Front Brake Pads
CHASSIS FRONT BRAKE PADS Part Name Remarks Removing front brake pads Brake disc F Hexagon step bolt M8×15-Φ15×5 Front left brake caliper Front right brake caliper brake pad Hexagon flange bolt M8×16 brake pad Spring washer -8 -203-...
Page 216: Front Brake Caliper
CHASSIS FRONT BRAKE CALIPER Part Name Remarks Removing front brake caliper Brake pad holding bolt Brake pad Pad spring Brake caliper piston Dust seal Caliper piston seal Bleed screw -204-...
Page 217 CHASSIS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
Page 218 CHASSIS REPLACING THE FRONT BRAKE PADS NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1.Check: • brake pad ① Damage/wear Replace 2.Measure: • brake pad thickness ⓐ Out of specification Replace the brake pads as a set.
Page 219 CHASSIS 4. Check: • brake fluid level • minimum level mark ① 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 of fluid as was recommended by the manufacturer to ensure the fluid level is higher than the minimum mark.
Page 220 CHASSIS DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons • dust seals ① • caliper piston seals ② a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING: •...
Page 221 CHASSIS ASSEMBLING THE FRONT BRAKE CALIPERS WARNING: • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Must use DOT4 Brake Fluid • Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled. 1.
Page 222 CHASSIS NOTE: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING: Proper brake hose routing is essential to insure safe vehicle operation. 2. Fill: • brake reservoir Must use DOT4 Brake Fluid NOTE: Brake fluid may damage painted surfaces...
Page 223: Rear Brake Caliper (Option 1)
CHASSIS REAR BRAKE CALIPER (OPTION 1) Part Name Remarks Removing rear brake caliper Brake disc Hexagon step bolt M8×15-Φ15×5 Hexagon flange bolt M10×22 Rear right brake caliper Brake pad assy-outer Brake disc L Brake pad assy- inner -211-...
Page 224: Rear Brake Caliper (Option 2)
CHASSIS REAR BRAKE CALIPER (OPTION 2) Part Name Remarks Removing rear brake caliper Spring Brake caliper mounting bolt Brake pad (piston side) Brake pad Insulator/pad shim Pad spring Brake caliper bracket Parking brake arm nut Parking brake arm Set bolt Parking brake arm shaft Parking brake case bolt Parking brake case...
Page 225 CHASSIS Part Name Remarks Gasket Brake caliper piston Dust seal Caliper piston seal Bleed screw -213-...
Page 226 CHASSIS CHECKING THE REAR BRAKE DISC 1. Check: • brake disc ① Replace. Galling/damage 2. Measure: • brake disc deflection Out of specification Replace. Brake disc maximum deflection 0.10 mm (0.004 in) • brake disc thickness ⓐ Out of specification Replace.
Page 227 CHASSIS REPLACING THE REAR BRAKE PADS 1. Check: • brake pad ① • brake pad plate ② Damage/wear Replace 2. Measure: • brake pad thickness ⓐ Out of specification Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 3.
Page 228 CHASSIS 5. Check: • brake pedal operation • Distance between brake pedal and footrest ⓐ The top of the brake pedal should be positioned 86 mm (3.3 in) above the top of the footrest. If not, ask a dealer to adjust it. Soft or spongy feeling Bleed the brake system.
Page 229 CHASSIS ASSEMBLING THE REAR BRAKE CALIPER WARNING: • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Must use DOT4 Brake Fluid • Replace the caliper piston seal and dust seal whenever a brake caliper is disassembled. 1.
Page 230 CHASSIS INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper assembly • brake caliper mounting bolts 40Nm (4.0m · kg,29 ft · lb) • brake hose ① • copper washers • union bolt ② 48Nm (4.8m · kg,35 ft · lb) NOTE: Tighten the union bolt while holding the brake hose as shown.
Page 231 CHASSIS CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder Wear/scratches Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air. ...
Page 232 CHASSIS INSTALLING THE BRAKE MASTER CYLINDER 1. Install: • brake master cylinder 16Nm (1.6 m · kg,11 ft · lb) 2. Install: • brake pipe 19Nm (1.9 m · kg,13 ft · lb) • washer plate • brake hose • union bolt 27Nm (2.7 m ·...
Page 233: Footrest Assembly
CHASSIS FOOTREST ASSEMBLY Part Name Remarks Removing the footrest Right footrest comp. Left footrest comp. Footrest metal-tooth Hexagon bolt M6×16 Fuel tank twin adhensive sleeve Nut clip M6×2 Inner hexagon flange screw M6×12 Front frame body right protective plate Front frame body left protective plate Nut clip -221-...
Page 234: Wheel And Tyre Parts
CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Part Name Remarks Removing the front wheel Front wheel hub Front tyre Valve cock Tapered nut M10 Wheel decoration cover Ⅳ WARNING: Hexagon nut M22×1.25 Securely support the vehicle so There is no danger of it falling over. Mounting seat for front hub Cotter pin 3.2×50 -222-...
Page 235: Rear Wheels
CHASSIS REAR WHEELS Part Name Remarks Rear wheel hub Rear tyre Valve cock Tapered nut M10 Cover for wheel Ⅰ WARNING: Slotted nuts M22×1.5 Securely support the vehicle so There is no danger of it falling over. Mounting seat for rear hub Cotter pin Φ3.2×50 -223-...
Page 236: Front And Rear Wheel Rim (Different Model)
CHASSIS FRONT AND REAR WHEEL RIM (different model) Part Name Remarks Front rim Rear rim Front rim Rear rim Front rim Rear rim Wheel decoration cover Ⅰ Front rim Rear rim Wheel decoration cover Ⅱ -224-...
Page 237 CHASSIS Part Name Remarks Wheel decoration cover Ⅲ Clamping spring, decoration cover Front rim Rear rim Front rim Rear rim Wheel decoration cover -225-...
Page 238 CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the ① wheel or check the wheel bearing play 3. Check: • wheel balance Out of balance           Adjust.
Page 239 CHASSIS INSTALLING THE WHEEL HUB 1. Install: • axle nut 260 Nm (26.0 m · kg, 190 ft · lb) INSTALLING THE WHEEL TYRE 1. Install: • wheel NOTE: The arrow mark ① on the tyre must point in the direction of rotation □ of the wheel.
Page 240 CHASSIS SPECIFICATION OF WHEEL AND TYRE Wheel hub Tyre Tyre Pressure （Kpa /PSI） Dimension Dimension 25×8-12 70/10 Front 12×6.AT Wheel 26×9-12 45/6.5 25×10-12 70/10 Rear 12×8.AT Wheel 26×10-12 45/6.5 • Since wheels and tyres are crucial to the vehicle operation, inspection for tyre pressure and profile depth is necessary.
Page 241: Transmission System
CHASSIS TRANSMISSION SYSTEM Axle, front wheel Part Name Remarks Removing the axle, front wheel Circlip Double off-set joint assembly Circlip Ball bearing Circlip Anchor ear A for rubber dust-proof Rubber dust-proof C-1605 , front axle Anchor ear B for rubber dust-proof Rubber dust-proof C-1610, front axle Joint shaft C.V.
Page 242: Front Bridge
CHASSIS Front Bridge Part Name Remarks Removing the front bridge Front differential assy Differential case Ⅱ Differential caseⅠ Driven gear Front bridge driving gear mounting bracket Hexagon flange locked nut M14×1.25 O-type ring Φ14×Φ7 Oil seal,front bridge input shaft Oil seal,front bridge output shaft Washer, differential Inner hexagon screw M8×25 -230-...
Page 243 CHASSIS Part Name Remarks Driving gear Inner hexagon screw M8×25 Inner hexagon screw M8×10 Oil drain bolt M10×16 O-ring Φ66.2×2 Column pin Φ5×80 Divide device assembly Divide device connection Rack Power transfer O-seal ring Φ2×Φ81 Front tank cover O-ring Φ2.4×Φ140 Bearing 6007R -231-...
Page 244 CHASSIS Part Name Remarks Bearing 6912 Bearing 16007 Bearing HK152112 Hexagon flange bolt M14×1.5×10 Copper washer Φ14×2 Hexagon flange locked nut M10×1.25 Needle sleeve Shaft fork Ⅳ Front dustproof rubber cover Hexagon flange bolt M14×1.5×15 Washer Φ10 Gas capsule -232-...
Page 245 CHASSIS Part Name Remarks Pipe clip Φ8 Front bridge transmission shaft Front bridge transmission shaft spring Hexagon flange bolt M10×1.25×25 Washer Φ10 Hexagon flange bolt M10×1.25×110 Rear dustproof rubber cover Connection forkⅡ Front transmission shaft comp. -233-...
Page 246 CHASSIS Front Bridge DISASSEMBLING THE UNIVERSAL JOINT Remove: • universal joint ① a. Remove the circlips b. Place the universal joint in a press. ② c. With a suitable diameter pipe - eath the ③ ④ yoke , press the bearing into the pipe as shown.
Page 247 CHASSIS Front Bridge CHECKING THE JOINTS 1.Check: • Rubber dust-proof Cracks/damage Replace 2.Check: • double off-set joint spline • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set joint Pitting/wear/damage Replace.
Page 248 CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
Page 249: Axle, Rear Wheel
CHASSIS Axle, rear wheel Part Name Remarks axle, rear wheel Removing the Spring ring Double off-set joint assembly Circlip Ball bearing Circlip Anchor ear A for rubber dust-proof Rubber dust-proof C-1520, front axle Anchor ear B for rubber dust-proof Double off-set joint assembly Rubber dust-proof C-1520 , front axle Joint shaft C.V.
Page 250: Rear Bridge
CHASSIS Rear Bridge Part Name Remarks Removing the rear bridge Speed reducer component，rear bridge Rear differential case Ⅰ Bolling bearing HK223013 Bolling bearing HK556720 Driven gear Bearing 6305 Mounting bracket, rear disk brake plate Oil seal Φ61×Φ35×9, input shaft Bolling bearing 55BM6720 O-ring gasket Φ3.1×Φ63.8 Flat washer Φ12×Φ30×4 -238-...
Page 251 CHASSIS Part Name Remarks Hexagon flange locked nut M12×1.25 Mounting bracket, rear brake caliper Rear adjustment gasket Ⅰ Rear adjustment gasket Ⅱ Speed sensor comp. O-ring Φ19.4×Φ2.3 Inner hexagon screw M8×35 Flat washer Φ8.5 Hexagon flange bolt M8×25 Flat washer Φ8.5 oil pipe joint Rear differential case Ⅰ...
Page 252 CHASSIS Part Name Remarks Flat washer Φ8.5 Hexagon flange nut M8 Hexagon flange bolt M8×12 Flat Washer Φ8.5 Oil seal Φ65×Φ90×9, output shaft Bearing 16017 O-ring Φ3.1×Φ150 Rear adjustment gasket Ⅲ Hexagon flange bolt M10×1.25×25 Hexagon flange bolt M14×1.5×15 Copper washer Φ14×2 Needle sleeve -240-...
Page 253 CHASSIS Part Name Remarks Circlip Rear bridge transmission shaft Circlip d=24 Circlip Clip Φ11 Front dustproof cover, rear bridge 1 Front dustproof cover, rear bridge 2 Gas capsule Driving gear Connection forkⅡ Circlip d=24 Rear transmission shaft springΦ30.5×Φ3×30 Criss-cross shaft -241-...
Page 254 CHASSIS Rear Bridge The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.) NOTE: Apply lithium-soap-based grease to the bearing assembly and o-ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing.
Page 255: Reverse Mechanism Parts
CHASSIS REVERSE MECHANISM PARTS Part Name Remarks Removing the shift shaft Gear shift knob Gear shift mechanism body Gear shift blockII Gear shift blockⅠ Gear shift mechanism block Torsional springⅣ Locating pin Shifting poleⅠ Shifting poleII Circlip Hexagon flange bolt M8×16 -243-...
Page 256 CHASSIS Part Name Remarks Flat washer Φ8.5×Φ22×1.2 Hexagon flange bolt M6×16 Flat washer Φ6.4×Φ18×1.6 Hexagon flange locked nut M8 -244-...
Page 257 CHASSIS Reverse mechanism parts ADJUSTING REVERSE MECHANISM PARTS ① Neutral ② High ③ Low ④ Reverse ⑤ Shifting pole assy ⑥ Connecting rod, gear shift mechanism assy NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged.
Page 258 CHASSIS Reverse mechanism parts CHECKING AND SERVICE OF REVERSE MECHANISM 1. Check the mobility of gear shift handle. If it is not working properly, remove the gear shift Mechanism to check if the fork , ball and spring is stuck., in which case replace the defective component and try again.
Page 259: Suspension
CHASSIS SUSPENSION Front Suespension and arm Part Name Remarks Removing the front suspension and arm Right front lower swing arm Left front lower swing arm Left front shock absorber Right front shock absorber Right front lower swing arm comp. Hexagon nut M10×1.25×65 Dust cover B Middle rubber tube, swing arm Hexagon flange locked nut M10×1.25...
Page 260 CHASSIS Part Name Remarks Left front lower swing arm comp. Front left knuckle assy Front right knuckle assy Front upper joint A Front upper joint pressing plate Cross sunk screw M6×12 Hexagon flange bolt M10×1.25×70 Hexagon nut M12×1.25 Cotter pin 2×32 Front left lower rocker shield Front right lower rocker shield Hexagon flange bolt M6×16...
Page 261 CHASSIS Front Suspension and arm DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. ·If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
Page 262 CHASSIS Front Suspension and arm · Check whether these components are greased with butter then tighten 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, and make these tension rods bisection on feet.
Page 263 CHASSIS Front Suspension and arm I NSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front lower swing arm ⑥ • front shock absorber ② • front joint shaft ④ a. Install the front lower swing arm ⑥. NOTE: •...
Page 264: Rear Suspension
CHASSIS Rear Suspension Part Name Remarks Removing the rear suspension Right rear swing arm Dust cover,rear swing arm I Rear swing arm bush Spring circlip-B Rear swing arm bearing Round nut Spring circlip-45 Rear anti-roll bar rocker Rear swing arm dust cover II Flat washer Φ20×Φ45×3 -252-...
Page 265 CHASSIS Part Name Remarks Hexagon flang locked nut M18×1.5 Left rear swing arm Rear anti-roll bar connecting rod Rear right swing arm protective plate Rear left swing arm protective plate Cross recessed plate head screw M6×16 Rear shock absorber Hexagon flange bolt M10×1.25×60 Hexagon flange locked nut M10×1.25 Hexagon flange bolt M10×1.25×55 -253-...
Page 266 CHASSIS CHECKING SERVICE REAR SUSPENSION 1. It is similar to the front suspension ,check if here exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2. Inspect the rocker bushing and the middle rubber separate is integrant.( According to the front suspension) 3.
Page 267 CHASSIS Rear Suspension and arm CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue Replace the shock absorber assembly.
Page 268 CHASSIS INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1. Install: • rear swing arm • rear shock absorber a. Install the rear swing arm ② and rear shock absorber ④. NOTE: • Lubricate the bolts ① with lithium-soap-based grease. •...
Page 269: Rear Arm Shaft
CHASSIS COOLING SYSTEM RADIATOR Part Name Remarks Removing the radiator Cooling water tank assy Water tank cover Rubber cushion,water tank Screw hoop Φ20×32 Water pipe A Three-way tube Thermostat Water pipe C Water pipe D Water temperature sensor Hexagon flange bolt M6×25 -257-...
Page 270 CHASSIS Part Name Remarks Hexagon flang locked nut Auxiliary water tank assembly Auxiliary water tank cover Hexagon flange bolt M6×16 Clip Φ9 Carburetor rubber tubing ⅥΦ5×Φ9×300 One-way valve negative pressure pipeΦ5×Φ9×360 Screw hoop Φ12×20 Pressure-proof rubber pipeline（Φ18×Φ10×930） Pressure-proof rubber pipeline（Φ18×Φ10×380） Pressure-proof rubber pipeline（Φ18×Φ10×330）...
Page 271 CHASSIS Part Name Remarks Metal pipeline II Metal pipelineIII Pressure-proof rubber pipeline（Φ18×Φ10×280） Pressure-proof rubber pipeline（Φ18×Φ10×250） Pressure-proof rubber pipeline（Φ18×Φ10×250） Pipeline H-shaped rubber ring, Metal pipe fixed clamp Hexagon flange bolt M6×16 Pattern M fixed clamp Water pipe K -259-...
Page 272 CHASSIS RADIATOR CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • all rubber hose Cracks/damage Replace.
Page 273 CHASSIS INSTALLING THE RADIATOR 1. Fill: • cooling system Start engine when pour full the refrigerating fluid, loose the exhaust nut on the pipe, the water level will get lower at this time, Supply the refrigerating fluid until the water level stop to change, then screw the exhaust nut, cover the water tank lid.
Page 274: Water Pump
CHASSIS WATER PUMP Part Name Remarks Removing the water pump Alarm switch, water temperature Water temperature sensor Water outlet connector, cylinder Temperature saver cover Bolt M6×12 Bolt M6×50 Water pipe clip Water pipe C Washer Φ6×Φ12×1.5 Bolt M6×25 Thermostat cover Washer Φ20.5×Φ30×1 Gasket -262-...
Page 275 CHASSIS Part Name Remarks Water pipe clip Water pipe D Screw hoop Φ20×32 Three-way tube Water pipe fixing clip Bolt M6×10 -263-...
Page 276 CHASSIS Part Name Remarks Removing the water pump Water pump assy Secondary gear, water pump Transmission shaft, water pump Column pin Φ4×21 Circlip Φ10 Bearing Oil seal Φ15×Φ10×5 Gasket, water pump cover O-ring Φ34×2.5 water pump housing Gasket, water pump cover Water pump seal -264-...
Page 277 CHASSIS Part Name Remarks Impeller water pump housing cover Clamp Balance pipe -265-...
Page 278 CHASSIS DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder ① • rubber damper ② NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal ① • Water pump housing② NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 279 CHASSIS CHECKING THE WATER PUMP 1. Check: • water pump housing cover ① • water pump housing ② • impeller ③ • rubber damper ④ • rubber damper holder ⑤ • o-ring ⑥ Cracks/damage/wear Replace. NOTE: Apply lithium-soap-based grease to the o-ring.
Page 280 CHASSIS ASSEMBLING THE WATER PUMP 1. Install: • oil seal ① (into the water pump housing ②) NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket ③ that matches its outside diameter.
Page 281: Seat
CHASSIS SEAT Part Name Remarks Removing the seat Front seat cushion comp. Rear seat cushion comp. Rubber pad Circlip -6 Front seat cushion latch hook Front seat cushion torsional spring Hexagon bolt M6×125 Rear backrestI Backrest inner bearing plate Rear backrest II -269-...
Page 282 CHASSIS Part Name Remarks Backrest bearing plate Backrest mounting plateⅠ Rear seat cushion drawstring Backrest mounting plateII Backrest supporting assy (R) Backrest supporting assy (L) Rear seat cushion latch hook Rear seat cushion torsional spring Hexagon bolt M6×50 Hexagon flange bolt M8×20 Hexagon flange locked nut M8×1.25 -270-...
Page 283 CHASSIS DISASSEMBLING THE SEAT Remove: • seat ① • seat lock lever ② To remove the seat, pull the seat lock lever upward and pull up the seat at the rear. Install: • Seat holder ① • Projection ② To install the seat, insert the projections on the front of the seat into the seat holders and push down on the seat at the rear.
Page 284: Fuel Tank
CHASSIS FUEL TANK FUEL TANK COVER PARTS Part Name Remarks Removing the fuel tank cover parts Meter mounting plate Air filter cover Hexagon flange bolt M6×16 H-type rubber ringⅠ Rigth gear shift cover plate Left gear shift cover plate Inner hexagon half-round screw M6×12 Nut clip M6×2 Meter mounting plate -272-...
Page 285 CHASSIS Part Name Remarks Left side cover, frame body Seat cushion protective plate, chassis Sheathing paper Ⅸ -273-...
Page 286 CHASSIS FUEL TANK PARTS Part Name Remarks Removing the fuel tank parts Fuel tank Fuel tank cover Fuel tank cap Lid for fuel pump Seal gasket for fuel pump Fuel pump assy Fuel pipe Ⅳ Φ8×Φ14-250 High pressure fuel filter Fuel pipe ⅤΦ8×Φ14×130 -274-...
Page 287 CHASSIS Part Name Remarks Clip Three-way petrol pipe Fuel pipe ⅤΦ8×Φ14×170 Oil-in plug Oil-out plug Rubber pipe Ⅵ Φ7×Φ11-300 Exhausted pipe cover Ⅲ Sheathing paper Ⅸ Hexagon flange bolt M6×16 Hexagon flange locked bolt M6 Hexagon flange bolt M8×25 Bush Φ12×Φ8.5×9 Hexagon flange locked bolt M8 -275-...
Page 288 CHASSIS • Fuel tank cap Remove the fuel tank cap by turning it counterclockwise. -276-...
Page 289: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Phenomenon Measure 1、 Check whether switches normal. 2、 Check whether cables damaged. Abnormal lights 3、 Check whether lights damaged. 1、 Check whether four wheel drive switch normal. Fail to shift into 2、 Check whether power divider damaged. four-wheel-drive or lock differential.
Page 290: Electrical
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1. Speed sensor 2. Thermo switch 2 3. Radiator fan 4. Stator assembly 5. Thermo switch 1 6. Gear position switch 7. Reverse switch - 278 -...
Page 291 ELECTRICAL COMPONENTS 1. relay assembly 2. Light switch 3. Indicator light assembly 1 4. Indicator light assembly 2 5. On-Command four-wheel drive switch and differential gear lock switch 6. Main switch 7.Rectifier/regulator - 279 -...
Page 292 ELECTRICAL COMPONENTS CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: • Set the pocket tester to “0” before starting the test. •...
Page 293 ELECTRICAL COMPONENTS Checking the switch continuity Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. 1. Four-wheel drive switch 2. Main switch 3.On-Command four-wheel drive switch and differential gear lock switch 4.
Page 294 ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
Page 295: Ignition System
ELECTRICAL COMPONENTS IGNITION SYSTEM CIRCUIT DIAGRAM - 283 -...
Page 296 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 7. Main switch 2. Battery 8. Pickup coil resistance 3. Spark plug 9. Rotor rotation direction detection coil 4. Ignition spark gap resistance 5.
Page 297 ELECTRICAL COMPONENTS 4. Ignition spark gap INCORRECT • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker ① as shown. Repair or replace the spark plug. ② Spark plug cap •...
Page 298 ELECTRICAL COMPONENTS . resistance Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead Orange lead terminal Tester (–) lead Spark plug lead •...
Page 299: Electric Starting System
ELECTRICAL COMPONENTS ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM - 287 -...
Page 300 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, ignition, signaling system) 6. Gear position switch 2. Battery 7. Brake light switch 3. Starter motor 8. Diode 1 4. Starter relay 9. Wiring connection (the entire starting system) 5.
Page 301 ELECTRICAL COMPONENTS DOSE NOT TURN Repair or replace the starter motor. TURNS 4. Starter relay • Remove the starter relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals. Battery (+) terminal Yellow/Blue terminal ①...
Page 302 ELECTRICAL COMPONENTS Tester (+) lead Yellow/Blue terminal ① Tester(–)lead Blue/White1 terminal ② Continuity Tester(+) lead Yellow/Blue terminal ① Tester (–) lead Yellow1 terminal ③ NOTE: Tester (+)lead When you switch the tester’s positive and Blue/White1 terminal ② negative probes, the readings in the left chart Tester (–) lead will be reversed.
Page 303: Starter Motor
ELECTRICAL COMPONENTS STARTER MOTOR Part Name Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Disassembling the starter motor Remove the parts in the order listed. ①...
Page 304 ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter Out of specification Replace the starter motor. 3. Measure: • mica undercut ○ Out of specification Scrape the mica using a hacksaw blade.
Page 305 ELECTRICAL COMPONENTS ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 ① NOTE: Align the projection ○ on the brush seat 1 with the slot ○ on the yoke. 2. Install: • yoke • brackets NOTE: Align the match marks ○ on the yoke with the match marks ○...
Page 306: Charging System
ELECTRICAL COMPONENTS CHARGING SYSTEM CIRCUIT DIAGRAM - 294 -...
Page 307 ELECTRICAL COMPONENTS TROUBLESHOOTING Procedure IF THE BATTERY IS NOT CHARGED: Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage NOTE: Remove some parts before maintenance 1. Cushion Repair with following special toolings 1.
Page 308 ELECTRICAL COMPONENTS 4. Charging coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. White terminal ① Tester (+) lead White terminal ② Tester (–) lead White terminal ①...
Page 309: Lighting System
ELECTRICAL COMPONENTS LIGHTING SYSTEM CIRCUIT DIAGRAM - 297 -...
Page 310 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check 1. Fuses (main, lighting system) 4. Light switch 2. Battery 5. Wiring connections(the entire lighting system) 3. Main switch NOTE: • Remove following part(s) before troubleshooting: 1.
Page 311 ELECTRICAL COMPONENTS CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 312 ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2) . Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light couplers.
Page 313: Signaling System
ELECTRICAL COMPONENTS SIGNALING SYSTEM CIRCUIT DIAGRAM - 301 -...
Page 314 ELECTRICAL COMPONENTS TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure Check: 1. Fuses (main, signaling system) 3. Main switch 2. Battery 4. Wiring connections (the entire signal system) NOTE: • Remove the following part(s) before troubleshooting: 1.
Page 315 ELECTRICAL COMPONENTS CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Bake light switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 316 ELECTRICAL COMPONENTS 2. If the neutral lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Gear position switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 317 ELECTRICAL COMPONENTS 3. If the parking brake indicator light fails to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Parking brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 318 ELECTRICAL COMPONENTS 4. If the reverse indicator light fails to come on: (1). If the “green-white” outgoing line of the engine’s reverse gear falls off: NO CONTINUITY Check if the “green-white” outgoing line of the engine’s reverse gear falls off. Replace the outgoing line.
Page 319 ELECTRICAL COMPONENTS 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F): (1).
Page 320 ELECTRICAL COMPONENTS (3). Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Brown terminal ① Tester (+) lead White/Blue terminal ② Tester (–) lead • Turn the main switch to “ON”. OUT OF SPECIFICATION •...
Page 321 ELECTRICAL COMPONENTS 6. If the differential gear lock indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Differential gear lock indicator light relay •...
Page 322 ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Brown terminal ① Tester (+) lead White / Black terminal ② Tester (–) lead OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 323 ELECTRICAL COMPONENTS 7. If the four-wheel drive indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). four-wheel drive indicator light relay •...
Page 324 ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Brown terminal ① Tester (+) lead Black /Red terminal ② Tester (–) lead OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 325: Cooling System
ELECTRICAL COMPONENTS COOLING SYSTEM CIRCUIT DIAGRAM - 313 -...
Page 326 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1. Fuse (main) 5. Thermo switch 3 2. Battery 6. Wiring connection(the entire cooling system) 3. Main switch 4. Radiator fan motor NOTE: • Remove the following part(s) before troubleshooting.
Page 327 ELECTRICAL COMPONENTS 4.Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Blue terminal ① Battery (+) lead Black terminal ② Battery (–) lead DOES NOT TURN • Check the operation of the radiator fan motor.
Page 328 ELECTRICAL COMPONENTS 5.Thermo switch 3 • Remove the thermo switch 3 from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 3 ①. • Immerse the thermo switch 3 in coolant ②. • Check the thermo switch 3 for continuity. While heating the coolant use a thermometer ③...
Page 329: 2Wd/4Wd Selecting System
ELECTRICAL COMPONENTS 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM - 317 -...
Page 330 ELECTRICAL COMPONENTS TROUBLESHOOTING 1. Check if the 2/4WD switch is working. a. Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable. b.
Page 331: Engine Management System
ENGINE MANAGEMENT SYSTEM INTRODUCTION EMS (Engine Management System) EMS is a self contained set of components including a custom built computer and sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature and providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.
Page 332: Layout Of Ems Components
ENGINE MANAGEMENT SYSTEM Layout of EMS Components Legend: Dotted line indicates inputs Solid line indicates outputs -320-...
Page 333: Components Of Ems
ENGINE MANAGEMENT SYSTEM COMPONENTS OF EMS Electronic Control Unit 1．Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.
Page 334: Multec 3.5 Injectors
ENGINE MANAGEMENT SYSTEM software/calibration reflashing procedure. In the event of ECU hardware failure or malfunction (during warranty period only) the ECU should be sent back to the vehicle manufacturer giving complete details of the ECU Part No, Serial number, Vehicle Model & Make, manufacturing Date, Total kms run on the vehicle, Location of use, Vehicle No, Date of return.
Page 335 ENGINE MANAGEMENT SYSTEM DO NOT: Use the injector as a handle. Do not use the injector to lift assemblies DO NOT: Rack, stage, or handle parts in a Damage will occur. manner that allows contact between parts. DO NOT: Remove packing in a way that Damage could occur due ton contact allows contact between parts.
Page 336 ENGINE MANAGEMENT SYSTEM • Avoid applying lubricant over the director plate holes – this may restrict injector flow. Do not dip the injector tip in lubricant. • Multec 3.5 injectors come from the factory with the seal rings attached. The re-use of seal rings is not preferred when replacing an injector.
Page 337 ENGINE MANAGEMENT SYSTEM • Remove the fuel line connection from the injector • Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces. • Remove the injector from the manifold • Apply a light coating of a lubricant to both the upper and lower injector seal ring of the replacement injector.
Page 338: Throttle Body Assembly(With Stepper Motor)
ENGINE MANAGEMENT SYSTEM Throttle Body Assembly(with stepper motor) 1．Description and Working Principle The Throttle Body Assembly is an interactive system comprised of the following subsystems: the main casting body, bearing system, shaft and valve system, return spring system, cable interface system, throttle position sensing system, and the bypass air control system. The subsystems interact and support each other to provide all the functional requirements, which are mentioned below - •...
Page 339: Engine Coolant Temperature Sensor
ENGINE MANAGEMENT SYSTEM DO NOT: Release the throttle cam abruptly from any position without throttle linkage Damage could occur. attached. DO NOT: Let the by pass holes be blocked by dirt or This could effect idle stability foreign particles. DO NOT: Rake, stage, or handle parts in a manner Damage will occur.
Page 340: Intake Air Pressure And Temperature Sensor
ENGINE MANAGEMENT SYSTEM 2．Installation Requirements • Dynamic Torque Requirement: The sensor shall be hand into the application and then driven by a driver with a maximum no load speed of 400 rpm or installed to the desired torque by a hand torque wrench (5/8”...
Page 341: Ignition Coil
ENGINE MANAGEMENT SYSTEM Ignition Coil 1．Description and Working Principle This coil provides energy to the spark plug in the combustion chamber. The coil itself doesn’t have a driver. The high voltage tower of the coil is connected to the spark plug using a high voltage cable assembly.
Page 342 ENGINE MANAGEMENT SYSTEM DO NOT: Pierce or probe the secondary This creates an electrical path to outside the leads. system permitting improper system operation, misfire, or even possible personal injury if arcing occurs. DO NOT: Operate without the spark plug If a technician or mechanic comes in contact attached.
Page 343 ENGINE MANAGEMENT SYSTEM DO: Operate with gasoline based internal Other fuels or combustion designs may require combustion engines. additional design considerations. DO: The power feed line should be fused. This could protect the system in the event of an electrical short DO: The module heat sink and back plate must The high level of voltage and current which the not be used as a connection point when jump...
Page 344 ENGINE MANAGEMENT SYSTEM DO: For removing spark plugs follow the following To remove spark plugs from Aluminum heads, steps: allow the engine to cool. The heat of the engine, 1- Grasp the spark plug boot and gently in combination with a spark plug that is still hot, 2- rotate 90°;...
Page 345: Fuel Pump Module
ENGINE MANAGEMENT SYSTEM DO: When replacing spark plugs with new ones, -Higher heat range plug(hotter plug) could lead always use equivalent plugs with same heat to pre-ignition & possible piston damage range, thread, size, etc…. -Lower heat range (colder plug) could lead to cold fouling &...
Page 346 ENGINE MANAGEMENT SYSTEM • Disconnect negative cable at battery. • DO NOT smoke, and place ‘No SMOKING” sign near work area • Make sure to have fire extinguisher handy. Step Action Switch on Ignition key. Fuel Pump primes for 3 seconds when the ignition If fuel pump running If fuel pump running key is ON.
Page 347 ENGINE MANAGEMENT SYSTEM • After servicing make sure to fill at least 3 liters gasoline before pump is primed (ignition key should be turned on only after ensuring there is minimum 3 liters of fuel in the fuel tank) Fuel Module Diagnosis: 3．Fuel Module Removal: •...
Page 348 ENGINE MANAGEMENT SYSTEM Mounting Bolts – Star Tightening Pattern 5. Pressure Regulator Assembly Replacement: • Remove the regulator retainer from module. • Apply gradual pull force on retainer to avoid any personal injury due to spring action of retainer. • Take out the pressure regulator assembly from module.
Page 349 ENGINE MANAGEMENT SYSTEM • Fill about 3 ~ 5 liters of fuel in tank. • Turn Ignition key to ON position for 3 seconds (to operate fuel pump) and then turn to OFF position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines. •...
Page 350 ENGINE MANAGEMENT SYSTEM DO: Use designated hose clamps. To ensure no leakages/ seepages thru hose joint. DO: Clamp fuel module harness to vehicle Clamp provides mechanical support for chassis wiring harness in vibrations. DO: Use only standard gasoline for operating Fuel Module is intended to run in standard vehicle/ module.
Page 351: Ems Fault Diagnosis
ENGINE MANAGEMENT SYSTEM EMS FAULT DIAGNOSIS EME Fault Diagnosis When fault comes up, the odometer's clock will turn into a number， which is a fault code, find out the cause with this numbe;press clock button,then it will turn back to clock mode, and five second later,the fault code will show again.
Page 352 ENGINE MANAGEMENT SYSTEM 0562 System Voltage Low KsDGDM_SysVoltLow System Voltage 0563 System Voltage High KsDGDM_SysVoltHigh 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer 1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow Oxygen Sensor 2 0138 O2S 2 Circuit High Voltage...
Page 353: Troubleshooting
TROUBLESHOOTING NOTE: The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to relevent contents for the inspection, adjustment and replacement of part. STARTING FAILURE/HARD STARTING FUEL SYSTEM 1、No oil 2、Fuel filter is clogged Fuel tank 3、Fuel filter net is clogged 4、Breather tube is clogged...
Page 354: Compression System
TROUBLESHOOTING COMPRESSION SYSTEM 1、Loose spark plug 2、Loose cylinder head or cylinder 3、Broken cylinder head gasket Cylinder and cylinder head 4、Broken cylinder gasket 5、Worn, damaged or seized cylinder 1、Improperly installed piston ring 2、Worn, fatigued or broken piston ring Piston and piston rings 3、Seized piston ring 4、Seized or damaged piston 1、Improperly sealed valve...
Page 355: Faulty Gear Shifting
TROUBLESHOOTING FAULTY GEAR SHIFTING SHIFT LEVER DOES NOT MOVE 1、Groove jammed with impurities 2、Seized shift fork Shift drum, shift forks 3、Bent shift fork guide bar Broken shift guide 4、 1、Seized transmission gear Transmission 2、Incorrectly assembled transmission Shift guide Shift guide JUMPS OUT OF GEAR Shift forks Worn shift fork...
Page 356: Faulty Brake
TROUBLESHOOTING FAULTY BRAKE POOR BRAKING EFFECT 1、Worn brake pads 2、Worn disc 3、Air in brake fluid 4、Leaking brake fluid Disc brake 5、Faulty master cylinder kit cup 6、Faulty caliper kit sea 7、Loose union bolt 8、Broken brake hose and pipe 9、Oily or greasy disc/brake pads 10、Improper brake fluid level SHOCK ABSORBER MALFUNCTION MALFUNCTION...
Page 357: Lighting System
TROUBLESHOOTING LIGHTING SYSTEM HEAD LIGHT IS OUT OF WORK 1、Improper bulb 2、Too many electric access ories 3、Hard charging( broken stator coil and/or faulty rectifier/regulator) Head light is out of work 4、Incorrect connection 5、Improperly grounded 6、Bulb life expired BULB BURNT OUT 1、Improper bulb 2、Faulty battery 3、Faulty rectifier/regulator...

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