KAYO MOTOR A180 Service Manual
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KAYO MOTOR A180 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
A180
SERVICE MANUAL
ManualSERVICE
MANUALSERVICE MANUAL
www.kayomoto.com
www.kayomoto.com

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Summary of Contents for KAYO MOTOR A180

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. KAYO MOTO A180 SERVICE MANUAL ManualSERVICE MANUALSERVICE MANUAL www.kayomoto.com www.kayomoto.com...
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. Preparation Instructions Catalogue This SERVICE MANUAL introduces detailed information for A180 four- wheeled vehicle (ATV),including the maintenance and adjustment procedures, disassembly and assembly instructions, inspection and maintenance points, troubleshooting methods and maintenance technical data and detailed graphical data to guide the operation .
  • Page 4 The contents in this manual are subject to change due to vehicle improvements and other reasons without further notice.The actual state of the vehicle shall prevail during maintenance. ZHEJIANG KAYO MOTOR CO., LTD. R & D department August, 2021...
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. Unit conversion table in this book Item Unit conversion 1kgf/cm =98.0665kPa；1kPa=1000Pa Pressure 1psi=6.8948kPa Torque 1kgf·m=9.80665N·m 1mL=1cm =1cc Volume 1L=1000cm Moment of force 1kgf=9.80665N Length 1in=25.4mm Danger/Warning/Caution Please read the following explanation carefully,which emphasize the special meanings of the words "danger", "warning"...
  • Page 6 Danger: Be alert to high danger Warning: Be alert for moderate danger Caution: Pay attention to minor hazards However, please note that the “ danger ” and “ warning ” contained in this SERVICE MANUAL cannot cover all potential risks during the use and maintenance of the engine. Therefore, in addition to the “danger”...
  • Page 7 1 Maintenance information Maintenance information 1.1 Operation note….……………....……………………………………………….……1-1 1.2 Vehicle identification number…………….……………..………………………….……1-3 …….……………………………………………..…..……………1-4 1.3 Main parameter list ………… ………………..……………………….……..…1-6 1.4 Maintenance parameter list 1.5 Tightening torque……..……………………………………………………………...……1-8 1.6 Lubricants and sealants……………………………………………………………………1-10 1.7 Cable, hose and cable wiring diagram………..………..………………………………1-11 1.1 Operation note Safety Precautions 1、Work clothes (coveralls), hats and safety boots suitable for the operation must be worn, and if necessary, safety protection such as dust-proof glasses, dust masks and gloves should be worn to...
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. safety. Precautions for disassembly and assembly 1、Parts, Parts, lubricants and greases must use KAYO designated recommended products. 2、The parts of each system should be sorted and kept separately to ensure that the parts can be installed back to their original positions.
  • Page 9 1 Maintenance information 7、surface before assembling. 8、When disassembling, check the necessary places and measure relevant data so that it can be restored to the state before disassembly. 9、 Fasteners such as bolts, nuts and screws should be pre-tightened first and then tightened on the diagonal with the specified tightening torque according to the principle of from large to small and from inside to outside.
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD.  Apply grease to the oil seal lip before assembling. 19、When installing hose parts, insert the hose into the root of the joint. If there is a pipe clamp, install the pipe clamp in the dent of the pipe. Replace the hoses that are not tight during installation.
  • Page 11  After the running-in is over, the whole machine can be maintained before entering the normal driving stage. 1.2 Vehicle identification number ①VIN number ②Vehicle nameplate ③Engine number Model A180 VIN number Engine number...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. -4 4...
  • Page 13 1 Maintenance information 1.3 Main parameter list Item Parameter Model A180 Length（mm） 1560 Width（mm） 1020 Height（mm 1000 Wheelbase（mm） 1085 Engine mode 1P63QML Displacement（ml） Fuel type No. 92 gasoline and above Dry Weight(kg) Number of passengers 1 person（only rider） 1 person ＋ 80kg = 140kg Max.
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. Item Parameter Air filter type Sponge filter element filtering type Throttle body Fuel capacity 5.6L Clutch type Automatic clutch Variable speed method CVT Shift gear F-N-R Shift mode/sequence Manual/F-N-R Output type Rear axle output Transmission...
  • Page 15 1 Maintenance information 1.4 Maintenance parameter list Lubricating device Item Standard Limitation － Change oil 800ml(No oil filter replaced） Change oil 850ml（Replace the oil filter） Engine oil － Full capacity 900ml capacity Only use SF MA 15W-40 or equivalent engine oil, do not substitute or mix Recommended engine oil different brands of engine oil, which will cause engine damage and cause...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. Battery / charging device / trigger coil Item Standard Type Permanent magnet alternator Output Three-phase full wave Magneto trigger coil resistance Magneto no-load voltage (engine in cold state) Maximum output power of magneto 180w Regulated voltage 14.5 ±...
  • Page 17 1 Maintenance information Lighting / Meter / Switch Item Standard Fuse Headlamp 12V—35W Light, bulb Tail light/brake light 12V—2.8W Valve train + cylinder head (see 05- Engine section for details) Cylinder + Piston + Piston Ring + Crank Connecting Rod (see 05-Engine section for details) Clutch + transmission mechanism (see 05-engine section for details)
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. 1.5 Tightening torque Note: Before installing the thread, apply anti-rust grease on the threaded part and the joint surface. Tightening torque of the designated part-Whole vehicle Item Fastener code Quantity Tightening torque （N·m） 1 Suspension lower rocker bolt GB5789 M10×1.25×70...
  • Page 19 1 Maintenance information Tightening torque of the specified part - engine part (see 05-engine part for details) Tightening torque of fasteners at unspecified positions Type Torque（ N·m） Type Torque（ N·m） 5mm bolt and nut 5mm screw 4.5~6 3.5~5 6mm bolt and nut 6mm screw 8~12 7~11...
  • Page 20 ZHEJIANG KAYO MOTOR CO., LTD. GB/T5671 Parking cable connection Lubricate Engine operating materials and installation accessories (see 05-Engine section for details) Engine operating materials include lubricating oil (oil), grease (butter) and coolant, etc. Installation accessories include plane sealant, thread locking glue, etc.
  • Page 21 1 Maintenance information 1.7 Cable, hose and cable wiring diagram 1. Gear display connector 2. Gear indication connector 3. Headlamp connector 4. Spare neutral display connector 5. Electric door lock switch connector 6. Left handle multi-function switch connector 7. Igniter connector...
  • Page 22 ZHEJIANG KAYO MOTOR CO., LTD. Note: The front panel must be removed before inspecting and repairing the above components. For detailed disassembly, please refer to Chapter 2 Body Covering Parts...
  • Page 23 1 Maintenance information 8. Brake sensor (one for left and right) 9. Throttle cable 10. Brake oil pipe...
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. 1. Carburetor negative pressure pipe 2. Carburetor 3. Carburetor drain pipe 4. Starter motor line 5. Engine exhaust pipe 6. gear display connector 7. Magneto trigger connector 8.Stabilized rectifier connector Note: The front and rear jerseys must be removed before checking and repairing the above...
  • Page 25 1 Maintenance information 8. Relay 9. Battery negative wire 10. Starting motor wire 11. Battery positive wire 12. Voltage stabilizer rectifier...
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. 1. Taillight connection cord 2. Taillight...

  • Page 27: Table Of Contents

    2 Vehicle cover 2 Vehicle cover 2.1 Maintenance information………………………..………………..………2-2 2.2 Installation torque……………………………..……………………..……2-2 2.3 Disassembly and assembly of the seat cushion 2.3.1 Seat cushion………………………………………………....………..2-3 2.4 Assembly and disassembly of front cover of the hood, front gear display lampshade,gear display meter,and shift lever assembly 2.4.1 Front cover of the hood…………………..………………………..…2-3 2.4.2 Front gear display lampshade………………………..………...

  • Page 28: Installation Torque

    2.1 Overhaul information Operation notes When replacing the covering parts affixed and riveted with the warning signs of laws and regulations on vehicles, the corresponding signs shall be filled correctly and completely as they are. This chapter describes the disassembly and assembly sequence of the body cover. When the relevant covers need to be disassembled for the maintenance of the internal parts of the finished vehicle, refer to this chapter.This chapter describes the disassembly and assembly operations of shelves, seat cushions, and exterior parts.

  • Page 29: Disassembly And Assembly Of The Seat Cushion

    2 Vehicle cover 2.3 Disassembly and assembly of the seat cushion Disassembly Pull up the seat cushion hook 2 Lift the back of the seat cushion and pull the seat cushion backward 1 Remove the seat cushion Assembly Follow the reverse order and direction of disassembly After installation, check whether the seat cushion is in place and firm, etc.
  • Page 30 Disassembly Remove the front panel fixing bolt 1, and remove the head cover in the direction of the arrow (Note: the buckle on the head cover is easy to break, and proceed with caution) Assembly Follow the reverse order and direction of disassembly...

  • Page 31: Front Gear Display Lampshade

    2 Vehicle cover 2.4.2 Front gear display lampshade Disassembly 1. Remove the fixing bolt 1 of the front lampshade Remove the instrument front cover 2 (Note: before removing the front lampshade, remove the head cover and pull out the main lock insert) Assembly Follow the reverse order and direction of disassembly.

  • Page 32: Shift Lever Assembly

    Follow the reverse order and direction of disassembly 2.4.4 Shift lever assembly Disassembly Remove the foot stop lever mounting bolt 6 Remove the foot stop lever Assembly Follow the reverse order and direction of disassembly.

  • Page 33: Left And Right Pedal Tubes

    ZHEJIANG KAYO MOTOR CO., LTD 2.5.1 Left and right pedal tubes Remove the left foot pedal tube Remove fastening screws 1/2, 3, 4/5 (Note: 2 and 4 are on the corresponding right side) Remove the left foot pedal tube Remove the left foot tube...

  • Page 34: Left And Right Iron Pedals

    2.5.2 Left and right iron pedals Remove the left iron pedal Remove the pedal fixing bolt 1 and the iron pedal 2 Disassembly method of right iron pedal and left iron pedal...

  • Page 35: Middle Guard Plate

    ZHEJIANG KAYO MOTOR CO., LTD 2.6 Middle guard plate, front vehicle cover and rear vehicle cover 2.6.1 Middle guard plate Disassembly Remove the fixing bolt 1 of the middle guard plate, and remove the middle guard plate in the direction of the arrow...

  • Page 36: Rear Vehicle Cover

    Assembly Follow the reverse order and direction of disassembly Note Before disassembly, remove the cables on the front assembly board, and check the cables and connectors after installation to prevent wrong connection 2.6.3 Rear vehicle cover Disassembly Remove the fixing bolts 1, 2, 3, and take off the rear vehicle cover Assembly Follow the reverse order and direction of...
  • Page 37 ZHEJIANG KAYO MOTOR CO., LTD disassembly Note Before disassembling, disconnect the cables of the tail lamp and rear turn signal lamp, and when disassembling the battery, turn off the ignition switch, disassemble the positive pole of the battery first, and install the negative pole of the battery.
  • Page 38 ZHEJIANG KAYO MOTOR CO., LTD. 3 Regular inspection and adjustment Maintenance Information……………………………………………………………3-1 3.1 Determination of maintenance cycle……………...……………………….……3-2 3.2 Inspection and maintenance method……………………...………………….…3-3 3.3 Steering column, brake system……………………………..…………………3-5 3.4 Wheel………………………………………………………………..……...…3-9 3.5 Suspension system…………………………………..…………………...……3-12 3.6 Gear shifting mechanism and fuel device……………………………..…….…3-13 3.7 Throttle check……………………………………………...……………...……3-14 3.8 Gear display meter…………………………..……………………..…...……3-15...
  • Page 39 Note Don't let the rotating parts such as the drive system catch your hands and clothes Note The vehicle must be placed on a flat and stable ground...

  • Page 40: Determination Of Maintenance Cycle

    ZHEJIANG KAYO MOTOR CO., LTD. Determination of maintenance cycle Engine maintenance is a regular periodic work. It is very important to maintain the engine at a certain time interval. Standardized maintenance can ensure excellent engine performance, reliable operation, economy and durability. The following is the maintenance cycle schedule of LT180 engine：...
  • Page 41 I: Inspect Note ① : When driving in a dusty place, it should be cleaned frequently...

  • Page 42: Inspection And Maintenance Method

    ZHEJIANG KAYO MOTOR CO., LTD. 3.2 Inspection and maintenance method Inspection and maintenance items Maintenance period Dail Half year Judgment criteria Inspect parts Inspection item year ○ Steering wheel Flexibility of operation ○ Damage Steering ○ Installation status of the steering...
  • Page 43 Gearbox Oil spill and oil volume Loosen the oil filler bolt, and the oil ○ ○ quantity should reach the orifice.
  • Page 44 ZHEJIANG KAYO MOTOR CO., LTD. Inspection and maintenance items Maintenance period Daily Half year Judgment criteria Check parts Inspection item year ○ ○ Transmissio Looseness of connecting part Output shaft ○ Shake of the spline (transmission ○ The state of the spark plug Spark plug clearance：0.6~0.7mm...

  • Page 45: Steering Column, Brake System

    3.3 Steering column, brake system Place the ATV on a level place, hold the direction handle firmly in the direction shown in the figure, and check if there is any shaking. If shaking is felt, it should be confirmed whether the steering column is shaking or other shaking, and corresponding maintenance should be carried out.
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. to the inability to control the direction of the handle Clearance of the front brake handle: Operate the front brake handle to check the braking effect and the movement of the handle. Check the play at the front brake lever...
  • Page 47 Front brake pump combination <Fluid volume> Check the brake fluid volume Check the brake fluid quantity through the observation hole 3. When the brake fluid quantity decreases to near the lower limit of hole 3, the vehicle will not be used continuously at this time, so it is necessary to check the leakage of the brake pump, brake pipe and various connections.
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. and right, and then remove the oil cup cover after the brake pump assembly is in a horizontal state. 1. Exhaust screw 2. Lower limit line 3. Oil cup cover 4. Observation hole...
  • Page 49 Front brake disc, brake pad <brake pad wear> Check the wear of the brake pads, if the wear has reached the wear limit, replace the brake pads. Note: Brake pads need to be replaced as a whole Inspection and replacement of brake discs Check whether the sliding surface of brake disc 1is worn or damaged.
  • Page 50 ZHEJIANG KAYO MOTOR CO., LTD. Please check the position of the brake Note: fluid level frequently to keep the fluid level at a safe position; check the oil circuit and connection points for damage, if any, please replace it in time; check the main pump/caliper for damage, if any, please replace it in time .
  • Page 51 Rear brake pump combination < liquid quantity > Check the brake fluid quantity Check the brake fluid quantity through the observation hole 3. When the brake fluid quantity is reduced to the vicinity of the lower limit of the hole 3, the vehicle can no longer be used.
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. safe position; check whether the oil circuit and connection points are damaged, and if there is any damage, please replace it in time; check whether the main pump/caliper is damaged, and if there is any damage, please replace it in time .
  • Page 53 Rear brake disc, brake pad <brake pad wear> Check the wear of the brake pads If the wear has reached the wear limit, replace the brake pads. Note: The brake pads should be replaced as a complete set Inspection and replacement of brake discs Check whether the sliding surface of brake disc 1 is worn or damaged.
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. Oil change <brake fluid replacement> Brake fluid is replaced once a year...

  • Page 55: Wheel

    3.4 Wheel Lift the front wheel with tools in a horizontal position, make sure that the body has no acting force on the wheels, shake the front wheel left and right, check whether the connection of the front wheel is firm, check whether there is shaking, and check and tighten the rocker arm, axle, rim bolts and nuts.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. the steering rod 1 Note: After adjusting the toe size, drive the vehicle slowly and make sure that the handlebars can correctly restrict the direction of the vehicle body...
  • Page 57 Tire pressure Check the tire air pressure with tyre gauge Note: Check the tire pressure when the Tire pressure tire is cold. If the tire is used under an improper tire pressure, it will worsen the gauge operation and riding comfort, and cause adverse effects such as tire eccentric wear.
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. Tire pattern Check the tire pattern, once the pattern height is less than 3mm, replace with a new tire. More than 3cmm Note When the tire pattern is less than 3mm, it must be replaced immediately.

  • Page 59: Suspension System

    Wheel nut and wheel axle Remove the front and rear hub caps 1. Check the front axle, rear axle nuts and bolts for looseness. If there is looseness, tighten it to the specified torque. Torque: Front axle nut: 126N·mm～218N·mm (12.6kgf·mm ～ 22kgf·mm) Rear axle nut: 199N·mm～311N·mm （20kgf·mm ～...
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. Place the car body in a horizontal position and compress the car body up and down several times according to the position shown in the figure. If there is shaking or abnormal noise, check the shock absorber for oil leakage, and whether the fastening parts are damaged or loose, etc.

  • Page 61: Gear Shifting Mechanism And Fuel Device

    Use the special tool to adjust the adjusting cam 1 of the shock absorber according to the load. Clockwise rotation is from high to low, and counterclockwise rotation is from low to high.Two-way adjustable 3.6 Gear shifting mechanism and fuel device Shift mechanism Change gears, check whether gear shifting mechanism 2 is flexible and whether the...

  • Page 62: Throttle Check

    ZHEJIANG KAYO MOTOR CO., LTD. Status of fuel system Remove the seat cushion (→ 2.3.1) and check whether the fuel pipe is aged or damaged. Replace the fuel pipe with a new one when it is aged or damaged. Check whether the vent pipe...
  • Page 63 When the clearance is not within the specified range, adjust the clearance. Remove the sheath 3, loosen the throttle cable lock nut 2, and turn the regulator to adjust the free stroke of the throttle button; After adjustment, tighten the lock nut 2 and install the throttle cable sheath 3;...

  • Page 64: Gear Display Meter

    ZHEJIANG KAYO MOTOR CO., LTD. Pinch the brake lever with your hand and observe the tail light. If the tail light does not light up, please check whether the line connector is loose or fall off. If the wiring is normal, replace the tail light in time.
  • Page 65 Turn the headlight switch 1 forward to the first gear, and observe whether the front fog lamp is on. If it does not, please check whether the line connector is loose or falling off. If the wiring is normal, replace the anti- fog lamp in time;...
  • Page 66 Engine surroundings Maintenance Information…………..……………………………………………4-1 4.1 Fuel System…………………………………………………………………4-2 4.2 Intake system……………………..…………………………………………4-2 4.3 Exhaust system…………………………………...…………………………4-3 4.4 Disassembly and installation of engine…………………………..…………4-5 Maintenance Information Operation notes Note:  During operation and maintenance, please ensure that the vehicle is turned off and stand still for no less than 1 hour. Confirm that the heating components are cooled before performing maintenance to avoid injury to maintenance personnel.
  • Page 67 ZHEJIANG KAYO MOTOR CO., LTD Tightening torque Engine bracket mounting bolt GB5787 M10×1.25×160 45~59N·m...
  • Page 68 Fuel System Disassemble 4.1 Fuel System Remove the foot gear, remove the seat cushion, the front cover of the gear indicator, and the front Disassemble assembly board (→Chapter 2 Body Cover) Remove the foot gear, remove the seat Remove the mounting bolt 1 cushion, the front cover of the gear indicator, Remove screw 3 and the front assembly board (→Chapter 2...
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD Remove the seat cushion and rear assembly board (→Chapter 2 Body Cover) Remove the mounting bolts 5 (1 each on the left and right) Remove the carburetor 6...
  • Page 70 Remove the fuel tank (→4.1 Removal and installation of the fuel tank) Loosen the clamp 1 Remove the air filter 2 Assembly Installation shall be carried out in the reverse order of disassembly...
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD 4.3 Exhaust system Disassemble Remove the seat cushion, front cover of gear indicator, front assembly plate and rear assembly plate (→ Chapter 2 Body Covers) Remove two screws 3 Remove muffler fixing bolt 3 Assembly...
  • Page 72 Disassemble Remove the muffler mounting screw 1 Remove the muffler mounting screw 2 Remove the silencer 3 4.4 Disassembly and installation of engine Disassemble Remove the seat cushion, the front cover of the gear display meter, the left foot pedal, the right foot pedal, and the rear body assembly (→Chapter 2 Body Covers) Remove the fuel tank (→...
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD Remove bolt 4 Remove bolt 5 Remove the chain 6 Assembly Installation shall be carried out in reverse order of disassembly...
  • Page 74 5. Engine information Catalogue Page Content Index Preparation of information, fault diagnosis 1-1～1-8 Maintenance information 2-1～2-10 Lubrication system 3-1～3-6 Cylinder head/valve 4-1～4-14 Cylinder, piston 5-1～5-8 V-belt drive system 6-1～6-14 Final mover 7-1～7-6...
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. Generator/starting clutch 8-1～8-9 Crankshaft, axle box 9-1～9-5...
  • Page 76 1.Preparation of information, fault diagnosis -------------------- ----------------- ----------- ---------------- ----------------- Symbol sign These symbols are used in this manual to indicate special maintenance procedures. If supplementary information about these symbols is needed, special annotations will be made in this article instead of using symbols.

  • Page 77: Preparation Of Information, Fault Diagnosis

    1. Preparation of information, fault diagnosis...
  • Page 78 1.Preparation of information, fault diagnosis Wrong assembly Wrong Instructions for machine parts Instruction Indicates the direction of action position and the direction of action. Direction Position and orientation of the matching parts folded with each other. Bolt, assembly direction position--means wear General safety matters carbon monoxide Battery...
  • Page 79 1. Preparation of information, fault diagnosis NOTE NOTE Inhalation of asbestos fibers can cause respiratory Using engine oil or transmission oil, although it is not diseases and cancer. confirmed that skin contact for a long time may cause Brake fluid skin cancer, it is recommended to wash hands with soapy water immediately after contact with engine oil, NOTE...
  • Page 80 1.Preparation of information, fault diagnosis...
  • Page 81 1. Preparation of information, fault diagnosis Operation rules Please use the factory parts and recommended oil, The wire head must not be bent or twisted, otherwise the use of nondesign specification parts will it will cause rigid operation and premature damage. Rubber parts will deteriorate due to aging and are easily damaged by solvents and oils.
  • Page 82 1.Preparation of information, fault diagnosis Torque value(Engine part） Thread size Torque value 备注 Item Quantity （ kgf-m ） (mm ） Cylinder head cover bolt 1.0-1.4 Cylinder head nut 1.8-2.2 Threaded part coated with engine oil Cylinder/cylinder head stud 0.7-1.0 Torque on the side of the crankcase Left side bolt of cylinder head 1.0-1.4 Valve adjusting fixing nut...
  • Page 83 1. Preparation of information, fault diagnosis The torque value of the above-mentioned important locking parts. Please refer to the standard reference value for the parts not listed. Torque standard reference value Type Tightening torque Type Tightening torque 5mm bolt and nut 0.45-0.60 kgf-m 3mm screw 0.05-0.08 kgf-m 6mm bolt and nut...
  • Page 84 1.Preparation of information, fault diagnosis Fault diagnosis The engine cannot be started or is difficult to start Possible causes of failure Inspection/Adjustment Failure situation Loosen the drain screw to 1. Whether there is gasoline in the gasoline tank check if there is gasoline inside the carburetor 2.
  • Page 85 1.Preparation of information, fault diagnosis Unable to speed up, weak Inspection/Adjustment Possible causes of failure Failure situation Slowly rotate the throttle and observe the engine rotation 1. The air filter is blocked Engine speed can be Engine speed cannot increased be increased 2.
  • Page 86 1.Preparation of information, fault diagnosis C. Engine running poorly (especially at low speed and idling speed) Possible causes of failure Inspection/Adjustment Failure situation Check ignition time (using ignition timing lamp) correct Incorrect 1.Bad ignition time (C.D.I. group or generator bad) Adjust carburetor air screw Poor adjustment Well adjusted...
  • Page 87 1.Preparation of information, fault diagnosis Clutch, driving/driven pulley Possible causes of failure Fault condition 1. The drive belt is worn and broken 2. The swash plate of the sliding drive plate is damaged The engine can be started, but 3. The drive disc spring is damaged the vehicle cannot be driven 4.
  • Page 88 2. Maintenance information 1.Preparation of information, fault diagnosis Operation precautions Ignition system / spark plug Check the dispaly regularly Cylinder compression pressure Lubrication system Drive System Crankcase blow-by system Catalog of Specialized Tools Check and adjust the valve clearance Operation precautions specification Engine oil Capacity...

  • Page 89: Maintenance Information

    2.Maintenance information Check the dispaly regularly Item first a month three three a year time months months every every 300KM 6000KM every every 12000KM 6000KM ☆ Air filter 3000KM ☆ Secondary air filter ☆ Gasoline filter ☆ Oil filter Change every 1000 kilometers Engine oil change Bolt locking inspection of each part Check the gearbox for oil leakage...
  • Page 90 Environmental Protection Agency, normal maintenance must be carried out in accordance with the provisions of the instruction manual. 2.When driving on gravel roads or under severe environmental pollution, you should increase the frequency of cleaning the air filter to extend the service life of the engine. 3.Frequent high-speed driving and more mileage, the maintenance frequency must be increased.
  • Page 91 2.Maintenance information Lubrication system Engine oil quantity NOTE Oil dipstick Change the engine oil Turn off the engine and remove the oil dipstick. Remove the oil leakage bolt at the bottom left side of the crankcase to drain the oil. After the oil leaks completely, the bolts and washers can be cleaned to install the bolts.
  • Page 92 2.Maintenance information equivalent quality. Engine oil volume: Decomposition: 900 c.c. Replacement: 850 c.c. Start the engine at idle for a few minutes, and check for oil leaks. Then remove the oil dipstick to check the oil level. Oil filter cover Clean the oil filter To leak the oil from the engine, remove the oil filter cover, spring and filter from the lower right side of...
  • Page 93 2.Maintenance information Transmission gear oil Check Check the gearbox for oil leakage. Erect the locomotive with the main parking frame on the flat ground. Turn off the engine and remove the gear oil filler bolt. Place a measuring cup under the drain hole. Remove the bolt of oil leakage hole and drain the gear oil into the measuring cup.
  • Page 94 2.Maintenance information Gear oil viscosity 85W/90 GL-5 Drain bolt Gearbox oil quantity: When decomposed: 400 c.c. When replacing: 350 c.c. Please make the main adjustment from the lower Adjusting nut end of the wire. Loosen the fixing nut and turn the adjusting nut to adjust.
  • Page 95 2.Maintenance information Fixed nut Crankcase blow-by system Pull out the plug from the lower end of the drain pipe to drain the internal deposits. NOTE Riding in rainy conditions or at full throttle, the maintenance schedule needs to be shortened, and any deposits can be seen on the transparent section of the drain pipe.
  • Page 96 2.Maintenance information NOTE The machine with the starting embryo reducing val ve mechanism should not move in the reverse direc tion of the time slot to prevent the pressure reducin Timing g valve from operating and the valve clearance can mark not be measured.
  • Page 97 2.Maintenance information Valve clearance inspection and adjustment Check and adjust the valve clearance with a thickness gauge. Valve clearance (inlet /exhaust): 0.03~0.05mm. When adjusting, the fixed nut is sent, and the adjusting bolt is rotated to adjust. NOTE When adjusting the valve rocker arm gap, it is necessary to confirm whether all adjustments are made to the reference value, and after the fixed nut is tightened, the valve gap should be...
  • Page 98 2.Maintenance information Set up the main stand of the locomotive and start the engine warming. Connect the tachometer (tachometer wire clamp, clamped on the high-voltage coil wire). Lift the carburetor cover from the luggage compartment. Turn the throttle and throttle positioning bolt to adjust the specified idle speed.
  • Page 99 2.Maintenance information Ignition system Ignition timing NOTE The C.D.I. ignition system is set at the factory, so it cannot be adjusted. Timing light Ignition timing inspection program: to confirm whether the C.D.I. function is normal. Remove the right side cover of the body. Remove the timing inspection hole cover on the cooling fan cover, or remove the cooling fan cover.
  • Page 100 3.Lubrication system Spark plug Specified spark plug (A7TC, A7RTC) Remove the spark plug cover. Clean the dirt around the spark plug hole. Remove the spark plug. Measure the electrode gap of the spark plug. Spark plug electrode gap: 0.6~0.7 mm Adjust the side electrode carefully to change the gap.
  • Page 101 2.Maintenance information Cylinder compression pressure Turn off the engine after warming up the engine. Remove the spark plug. Put the cylinder pressure gauge into the spark plug hole. Spark plug The electric starter motor will be turned on to turn the engine.
  • Page 102 3.Lubrication system and the cover. Check the belt for cracks, eccentric wear or excessive wear. If necessary or according to the regular checklist maintenance and replacement period, replace with new products. Clutch plate Width limit: 20.8mm or more Clutch plate clutch Start the vehicle and gradually increase the throttle opening to check the movement of the clutch.
  • Page 103 2.Maintenance information Catalog of Specialized Tools Crankcase bushing Crankcase bushing Valve spring name name name drawing press-in device drawing press-in device remover/installer Valve spring Valve clearance Valve lash adjuster name name name removal/installation adjustment wrench compressor Oil seal knock-in fixture Oil seal knock-in fixture name Oil seal knock-in fixture name...
  • Page 104 3.Lubrication system Internally drawn bearing Out-drawing bearing Clutch spring compressor name name name extractor extractor...
  • Page 105 2.Maintenance information Catalog of Specialized Tools name Clutch fixed nut wrench name Universal fixator name Alternator flywheel remover ‐...
  • Page 106 3.Lubrication system...

  • Page 107: Lubrication System

    3.Lubrication system Rocker arm Forced lubrication Camshaft Splash lubrication Inner oil passage connecting rod Forced lubrication Crankshaft Oil filter screen Oil pump...
  • Page 108 3.Lubrication system...
  • Page 109 Operational notes: 3.Lubrication system General matters This section covers the maintenance work of the oil pump, engine oil and gear oil. Oil viscosity Specification Engine oil capacity: Decompose 900c.c. Replace 850c.c. Use oil viscosity SF MA 15W-40 or equivalent Unit:mm Item Standard value Available limit...
  • Page 110 3.Lubrication system Engine oil Turn off the engine, erect the locomotive vertically on a flat ground, and check the oil level with a dipstick after 3-5 minutes. Do not screw in the dipstick when checking. If the oil level is close to the lower limit, replenish it to the upper limit with recommended engine oil.
  • Page 111 3.Lubrication system Check the O-ring of the oil filter cover and the condition of the filter. If it is damaged, replace it. Reinstall the oil filter and spring. Lock back the filter cover. Torque value: 1.3-1.7 kgf-m Pour engine oil (oil viscosity SF MA 15W-40) into the engine oil hole.
  • Page 112 3.Lubrication system Oil pump disassembly Remove the generator (refer to Chapter 8) Remove the one-way clutch and start gear (fixed nut X1). Confirm that the pump shaft can rotate freely. Remove the oil pump cover (bolt x2), and then remove the oil pump drive gear fixing clip and gear.
  • Page 113 3.Lubrication system Engine right side cover Start gear Start clutch group Oil pump outer cover Oil pump drive gear Oil pump Oil pump shaft Outer rotor Inner rotor Oil pump cover Right crankcase cover...
  • Page 114 3.Lubrication system Install the drive gear and fixing clip. Note Check whether the oil pump can rotate smoothly. Oil pump installation bolt X2 Install the oil pump (bolt X2) Oil pump chain Install the oil pump chain and lock the oil pump cover (bolt X2)
  • Page 115 三、 Lubrication system bolt X2 Install the starting gear and alternator set. (See Chapter 8)

  • Page 116: Cylinder Head/Valve

    4.Cylinder head/valve Gear oil inspection Turn off the engine and remove the oil filler bolt and drain bolt Grease bolt Remove the gear oil injection port bolt, place a measuring cup under the drain bolt, remove the gear oil drain bolt, introduce the gear oil into the measuring cup, and check whether the gear box oil meets the standard value.
  • Page 117 4.Cylinder head/valve Pour new gear oil (350cc.) from the gear oil injection hole, replenish it, install the gear oil injection hole bolts and tighten. Torque value: 1.0-1.4 kgf-m ※After changing the gear oil Start the engine for a test ride for 2 to 3 minutes.
  • Page 118 4.Cylinder head/valve Mechanism diagram Valve guide rod replacement Precautions Inspection and correction of valve seat Fault diagnosis Cylinder head assembly Camshaft disassembly Cylinder head installation Camshaft installation ‐...
  • Page 119 4.Cylinder head/valve Precautions for operation General matters ● This section covers the maintenance of cylinder heads, valve valves, camshafts and rocker arms. ● The maintenance of the cylinder head cannot be done while the engine is still installed on the frame. Specification unit：mm Item...
  • Page 120 4.Cylinder head/valve Valve adjusting fixing nut 0.7-1.1 kgf-m (Threaded part and seat surface coated with engine oil) Spark plug 1.0-1.4 kgf-m Tool Special tools Valve wire reamer 5.0mm Valve guide driver 5.0mm Valve spring compressor ‐...
  • Page 121 4.Cylinder head/valve Fault diagnosis The problems at the upper end of the engine usually affect the engine performance. These problems can be judged by measuring the compression pressure or tracking the source of abnormal sound. Idle speed is not smooth The compression pressure is too low.
  • Page 122 4.Cylinder head/valve  Burned valve or damaged valve spring  Camshaft wear or damage  The cam chain is worn or loose  The cam chain tensioner is worn or damaged  Camshaft chain gear wear  Wear of rocker arm or rocker shaft The exhaust pipe emits white smoke ...
  • Page 123 4.Cylinder head/valve Camshaft disassembly Remove the engine body fan cover, cover A component, and cover B component, and remove the crankcase blow-by air duct from the cylinder Blow-by gas conduit head. Remove the cylinder head cover bolts and remove the cylinder head cover (bolt X4) bolt X4 Remove the screw cover of the cam bar adjuster and remove the O-ring.
  • Page 124 4.Cylinder head/valve Remove the camshaft fixing seat and rocker arm group. Remove the cam chain from the cam gear. Remove camshaft Check camshaft Check whether the cam height is damaged. Available limit: IN: Exchange under 29.440 mm EX: Replace under 29.160 mm. Check whether the camshaft bearings are loose or worn.
  • Page 125 4.Cylinder head/valve Measure the inner diameter of the valve rocker shaft hole of the camshaft fixing seat. Available limit: 10.1mm above exchange. Determination of the inner diameter of the valve rocker arm. Available limit: 10.1mm above exchange. Measurement of the inner diameter of the valve rocker arm.
  • Page 126 4.Cylinder head/valve Cylinder head removal Remove the fan cover. Remove the engine cooling cover (bolt x4) Remove the camshaft Blow-by gas conduit Bolt X 4 Remove the 2 bolts on the left side of the cylinder head. Remove the cylinder head gasket and 2 positioning pins. Positioning pin Remove the chain guide.
  • Page 127 4.Cylinder head/valve Note Do not damage the cylinder and the cylinder joint surface. When scraping out the debris, avoid debris or Chain guide foreign matter from entering the crankcase. Gasket Cylinder head decomposition Use a valve spring compressor to press down the valve spring.
  • Page 128 4.Cylinder head/valve Do not damage the joint surface of the cylinder head.
  • Page 129 Inspection 4.Cylinder head/valve Cylinder head Check the spark plug hole and valve hole for cracks. Measure the flatness of the cylinder head with a straight Free length of valve spring Measure the free length of the inlet and exhaust valve springs. Available limit: Large spring 33.5mm Small spring 31.5mm Valve lever...
  • Page 130 Note 4.Cylinder head/valve Before measuring the catheter, remove the carbon deposits with a reamer. Special tool: valve guide reamer 5.0mm Measure and record the inner diameter of each catheter with a plug gauge. Available limit: 5.03mm Valve guide reamer 5.0mm Subtract the outer diameter of the matched valve stem from the inner diameter of each catheter to obtain the clearance value between the valve stem...
  • Page 131 4.Cylinder head/valve Valve guide replacement Valve guide knocker 5mm Heat the cylinder head to 100-150°C with heating plate or oven. NOTE Do not use flames to directly heat the cylinder head during heating, otherwise the cylinder head may be deformed. Wear insulated gloves to avoid burns during operation.
  • Page 132 4.Cylinder head/valve Trim the valve seat and clean the cylinder head to remove any metal debris. Special tool: valve guide reamer 5mm Valve seat inspection and repair Remove all carbon deposits on the intake and exhaust valve parts. Apply a thin layer of emery to the contact surface of the valve valve and the valve seat, and use a special grinding tool to drive the valve valve to grind each other.
  • Page 133 4.Cylinder head/valve Roughness Check the valve seat If the valve seat is too wide, too narrow or has dents, the valve seat must be ground and trimmed. Valve seat width Available limit: 1.6mm Check the contact surface of the valve seat. Grinding valve seat The worn seat surface must be trimmed with a special valve seat surface dresser.
  • Page 134 Width of old valve seat 4.Cylinder head/valve Use a 45° cutter to grind the seat surface to the specified width. NOTE Confirm that all rough potholes and irregular surfaces have been completely removed. Trim again if necessary. Apply a thin layer of Prussian blue or red lead on the valve seat surface.
  • Page 135 Grind the seat surface with a 45° cutter to the 4.Cylinder head/valve specified width. The contact surface is too low Width of old valve seat If the contact surface on the valve valve is too low, grind the inner valve seat with a 60° cutter. Grind the seat surface with a 45°...
  • Page 136 4.Cylinder head/valve After the valve seat is trimmed, apply a thin layer of emery on the contact surface between the valve and the valve seat, and the valve is driven by a special grinding tool to grind each other. After grinding, clean all the emery coated on the cylinder head and cylinder valve.
  • Page 137 4.Cylinder head/valve In order to prevent the spring from losing its elasticity, do not over-compress the spring, and use the most suitable length to install the safety valve. Special tool: valve spring compressor Tap the valve stem with a rubber hammer to make the valve plug and the valve stem fit well.

  • Page 138: Cylinder/Piston

    Cylinder head installation 5.Cylinder/piston Install the positioning pin and the new cylinder Positioning pin head gasket on the cylinder. Install the cam chain guide. Install the cylinder head Chain guide Gasket Camshaft installation Combined camshaft fixing seat. Assemble the exhaust valve rocker arm on the side marked "EX"...
  • Page 139 First align the 4.Cylinder head/valve mark "T" on Turn the the magneto side with flywheel with the "EX" the mark mark of the convex line on cam holder the right cover assembly of the toward the crankcase, and exhaust then install the port.
  • Page 140 5.Cylinder/piston Valve clearance adjustment Loosen the gap adjustment nuts and bolts on the valve rocker arm.Measure with thickness gauge and adjust the gap of each valve.After adjusting to the standard value, fix the adjusting bolt and tighten the adjusting nut. Standard value: 0.03-0.05 mm Turn the cam chain tensioner counterclockwise with a thin flat-blade screwdriver to make it pop out and...
  • Page 141 Mechanism diagram Piston removal/inspection Precautions Piston ring installation Fault diagnosis Piston installation ‐...
  • Page 142 5.Cylinder/piston Precautions in operation General matters ● Cylinders and pistons cannot be repaired while the engine is installed on the vehicle. Specification unit：mm Item Standard value Available limit Inner diameter 62.450~62.550 62.650 － Top surface parallelism 0.050 cylinder － Cylindricity 0.050 －...
  • Page 143 5.Cylinder/piston Knocking or abnormal sound Cylinder and piston wear. Too much carbon deposits on the piston head. Piston tip hole and piston tip wear. Cylinder disassembly Remove the cylinder head (refer to Chapter 6). Remove 2 bolts and take out the cam chain automatic adjuster.
  • Page 144 5.Cylinder/piston Remove the cylinder gasket and fixed pin. The residue of the gasket attached to the joint surface of the cylinder head and the crankcase is scraped out clean.
  • Page 145 5.Cylinder/piston Plug the crankcase hole and cam chain hole with a cleaning cloth. Remove all gasket debris and foreign matter on the joint surface of the cylinder and the crankcase. NOTE The gasket debris can be soaked with the solution, which is easier to remove. Inspection Check whether the inner diameter of the cylinder is worn or damaged.
  • Page 146 Usable limit: 5.Cylinder/piston Roundness: correction or replacement above 0.05 mm Cylindricity: correction or replacement above 0.05 mm Check the flatness of the cylinder. Usable limit: correction or replacement above 0.05mm Piston disassembly Use a clean cloth to plug the crankcase opening and cam chain hole to prevent the piston pin buckle and other parts from falling into the crankcase during disassembly.
  • Page 147 5.Cylinder/piston Push out the piston tip from the end of the buckle. Remove the piston ring. The piston ring is easy to break, please be careful when removing it. NOTE The piston ring is easy to break, please be careful when removing it.
  • Page 148 5.Cylinder/piston Measure the outer diameter of the piston tip. Usable limit: 14.96 mm Measure the inner diameter of the small end of the connecting rod. Usable limit: 15.06 mm Measure the inner diameter of the piston pin hole. Usable limit: 15.04 mm Calculate the clearance between the piston tip and the piston tip hole.
  • Page 149 5.Cylinder/piston Measure the outer diameter of the piston. NOTE The measurement position is 9mm from the bottom of the piston and 90° from the tip hole of the piston. Usable limit: 62.410mm Compare this measurement with the usable limit, and calculate the piston and cylinder clearance.
  • Page 150 5.Cylinder/piston Piston ring installation Clean the piston head, ring groove and piston skirt. Carefully spread the piston ring into the piston. NOTE Do not damage the piston and piston ring during installation. All the marks on the piston ring must be upward when installed. After the installation is complete, it must be confirmed that all piston rings can rotate freely, and there ‐...
  • Page 151 Top ring Second ring Side rail Oil wiper Spacer Side rail 20mm or more Top groove Second groove Scraping oil groove...
  • Page 152 5.Cylinder/piston Piston installation Install the piston and piston tip, and place the mark IN on the top surface of the piston on the side of the intake valve. Install the new piston pin buckle. NOTE Do not make the buckle ring gap on the piston tip, and align the gap for assembling the buckle ring on the piston.
  • Page 153 When inserting, insert one ring at a time in accordance with the piston ring. NOTE Do not use force to sleeve the cylinder into the piston, as it is easy to damage the piston and piston ring. Install the cam chain guide, cylinder head gasket and positioning pin.
  • Page 154 6.V-belt drive system Mechanism diagram Drive belt Maintenance instruction Sliding drive plate Fault diagnosis Clutch/drive pulley Left crankcase cover ‐...
  • Page 155 6.V-belt drive system Maintenance instruction Matters needing attention in operation General matters ● The driving disc, clutch and transmission disc can be repaired on the vehicle. ● There shall be no grease on the surface of drive belt and drive plate. Specification unit:mm Item...
  • Page 156 6.V-belt drive system Left crankcase cover Disassembly of box cover Remove the left engine cover (bolt x9) Inspection The inside of the left side cover is dirty and blown out with an air gun. Whether the left side cover and bearing hole are worn or damaged, replace them with new ones if they are defective.
  • Page 157 6.V-belt drive system...
  • Page 158 6.V-belt drive system Drive belt Disassemble Remove the left crankcase cover. Use the universal fixing clip to fix the drive plate, and remove the nut and drive plate. Use the universal fixing clip to fix the clutch cover, Universal fixing clip and remove the nut and clutch cover.
  • Page 159 6.V-belt drive system the drive belt from the groove of the clutch drive pulley. Inspection Check the drive belt for cracks and wear, and replace it if necessary. Measure the width of the drive belt as shown in the figure. Tooth layer If it exceeds the maintenance limit, replace the width...
  • Page 160 6.V-belt drive system Installation First pull the drive pulley disk apart, and then insert the drive belt into the drive pulley disk. Sliding NOTE drive pulley After the drive belt pulley is pulled apart and positioned, the drive belt is then inserted into the drive pulley plate, so that the belt can be easily assembled on the sliding belt pulley.

  • Page 161: V-Belt Drive System

    6.V-belt drive system Sliding drive plate Disassemble Remove the left crankcase cover. Fix the drive plate with a universal clamp, and remove the fixing nut of the drive plate. Remove the drive disk. Universal fixing clip Remove the drive belt from the belt pulley. Remove the sliding drive plate assembly and Sliding drive plate drive plate hub from the crankshaft.
  • Page 162 Remove the hammer roller from the sliding Sliding drive plate drive plate. Hammer roller...
  • Page 163 6.V-belt drive system Inspection Hammer roller Hammer roller The function of the sliding drive disc is to use the centrifugal force of the heavy hammer roller to roll according to the angle of the swash plate and push the sliding drive disc to achieve the function of speed change;...
  • Page 164 The two end faces of the heavy hammer roller are different. In order to prolong the life of the Closed end face roller and prevent abnormal wear, please assemble the closed end face on the sliding drive plate in a counterclockwise direction. Guide rubber sleeve...
  • Page 165 6.V-belt drive system Use 4-5 kg of butter to coat the inside of the drive shaft hole. Install the drive shaft hub. NOTE There should be no grease on the belt surface, remove unnecessary grease with oil removing agent. Belt pulley surface Install the sliding drive plate assembly on the Sliding drive plate crankshaft.
  • Page 166 Drive belt Install the drive plate, washer and nut. NOTE Make sure that there is no grease on both sides of the belt pulley, and remove unnecessary grease with oil removing agent. Fix the drive disk with a universal clamp. Tighten the nut to the specified torque.
  • Page 167 6.V-belt drive system Use 4-5 kg of butter to coat the inside of the drive shaft hole. Install the drive shaft hub. NOTE There should be no grease on the belt surface, and remove unnecessary grease with oil removing agent. Belt pulley surface Sliding drive plate Install the sliding drive plate assembly on the...
  • Page 168 that the belt is separated from the drive plate shaft hub. NOTE Pressing down the upper and lower ends of the drive belt can prevent the belt from being damaged and ensure that the drive plate can be locked. Drive belt Install the drive plate, washer and nut.
  • Page 169 6.V-belt drive system Clutch/drive belt pulley Special nut wrench Decomposition Remove the drive plate and clutch/drive belt pulley. Compress the clutch spring and install it on the clutch assembly, and tighten the spring compressor to make the nut easy to fit. NOTE Do not over-tighten the spring compressor.
  • Page 170 Inspection Clutch cover Guide pin roller O-ring Guide pin Measure the inner diameter of the friction surface of the clutch jacket. If the maintenance limit is exceeded, replace the clutch jacket. Available limit: 135.40 mm. Clutch cover ‐...
  • Page 171 6.V-belt drive system Clutch plate Measure the thickness of each piece and replace it Clutch plate if it exceeds the maintenance limit. Usable limit: 1.5mm Clutch Drive pulley spring Measure the length of the drive belt pulley spring and replace it if it exceeds the maintenance limit. Usable limit: 125 mm.
  • Page 172 Inspection of the transmission belt pulley bearing Sliding plate Guide sulcus Check whether the inner bearing oil seal is damaged.Replace if necessary. Check the needle bearing for damage or excessive clearance, and replace it if necessary. Rotate the inner side of the outer bearing with your fingers to check whether the bearing can rotate smoothly and silently, whether the outer side of the Ball bearing...
  • Page 173 6.V-belt drive system Replacement of clutch block spring Remove the retaining ring and washer, and then Driver board remove the clutch block and spring from the drive plate. Check the spring for damage or insufficient tension. Clutch block Buckle Check whether the shockproof rubber is damaged or deformed.
  • Page 174 Clutch block Use pliers to snap the spring into the groove. spring...
  • Page 175 6.V-belt drive system Install the buckle and the bearing plate on the fixed pin. Buckle Oil seal Outer bearing Replacement of drive belt pulley bearing Remove the inner bearing. NOTE Inner needle Ring clip bearing The drive pulley is equipped with an oil seal on one side of the internal bearing.
  • Page 176 Specified grease Outer bearing Sealed end Sealed end Install the new inner bearing. NOTE When installing the bearing, pay attention that the sealed end should face outward. Use the hydraulic press to install needle bearings, and use the hydraulic press or drive Inter bearing Align the oil seal lip with the bearing and install a new oil seal (if necessary).
  • Page 177 6.V-belt drive system Installation of clutch/drive pulley assembly Install a new oil seal and O-ring on the sliding Oil seal drive wheel. Use the specified grease to lubricate the inside of the sliding plate. Specified grease O-ring Sliding drive belt pulley Guide pin Install the sliding drive plate on the drive belt plate.
  • Page 178 Install the drive belt disc, spring and clutch into the clutch spring compressor, and turn the compressor handle to press down the assembly until the fixed nut can be installed. Clamp the clutch spring compressor on the vice, and screw the nut to the specified torque with a special Fixed nut wrench nut wrench.
  • Page 179 7.Final reduction mechanism/reverse gear mechanism 7.Final reduction mechanism/reverse gear mechanism Mechanism diagram Bearing replacement Fault diagnosis Final reduction mechanism/reverse gear Final deceleration mechanism/reverse gear mechanism decomposition combination Output shaft Wire Intermediate Gearshift lever clip shaft group Drive shaft Lower end bushing Variable speed Gear box cover gear set...
  • Page 180 七、Final reduction mechanism/reverse gear mechanism Precautions in operation Specification Torque value Use gear oil: four-stroke lubricating oil. Gear box cover 2.0-2.4 kgf-m Gear oil volume: 400 c.c. (350 c.c. when Gearbox drain bolt 1.0-1.4 kgf-m replacing). Tool Special tools Internally drawn bearing extractor Out-drawing bearing extractor ‐...
  • Page 181 Fault diagnosis 7.Final reduction mechanism/reverse gear mechanism ATV can't move after the engine starts Damaged transmission gear set Transmission gear set burned out Gear oil leaking Broken drive belt Oil level is too high Worn or damaged oil seal...
  • Page 182 7.Final reduction mechanism/reverse gear mechanism Final deceleration mechanism/reverse gear mechanism decomposition Drain the gear oil and remove the clutch Remove the gear box cover bolts (M6X35) X10, and remove the gear box cover and final drive shaft. Bolt X 10 Remove the gasket and positioning pin.
  • Page 183 7.Final reduction mechanism/reverse gear mechanism Reverse gear inspection Whether it is worn or damaged. Check the bearings on the gearbox and the cover. Turn the inner ring of each bearing with your fingers. The bearing needs to rotate smoothly and quietly, and check whether the outer ring of the bearing is tightly combined with the gear box and the cover.
  • Page 184 7.Final reduction mechanism/reverse gear mechanism Check whether the drive shaft and gears are worn or damaged. Bearing replacement NOTE Never assemble used bearings. Once the bearings are removed, they must be replaced. When pulling out the gearbox bearings or the bearings on the cover, the following special tools are required: Internally drawn bearing extractor Install the new bearing into the gearbox or cover.
  • Page 185 7.Final reduction mechanism/reverse gear mechanism Press the drive shaft out of the gear box. Remove the oil seal from the gear box. Use the inner pull-out bearing extractor to remove the drive shaft bearing from the cover. NOTE Press the drive shaft out of the gear box, and use a shaft guard during operation.
  • Page 186 7.Final reduction mechanism/reverse gear mechanism Install the new final shaft bearing on the gear box cover. Special tools: Press into the bearing with a C-shaped press or bearing knock-in jig. Grease the lips of the new final shaft oil seal and install it.
  • Page 187 7.Final reduction mechanism/reverse gear mechanism gear box cover and bolts (10 pieces) and Final reduction mechanism/reverse gear lock them. combination Output shaft Intermediate shaft Torque value：2.0~2.4 kgf‐m Install the drive shaft, intermediate shaft, output Drive shaft shaft, shift gear set, shift shaft, shift drum and Install the clutch/sliding drive belt pulley.
  • Page 188 8.Alternator/Starting clutch Mechanism diagram Starting clutch inspection Precautions Starting clutch installation Flywheel disassembly Right crankcase cover installation Disassembly of generator coil set Generator coil set installation ‐...
  • Page 189 Alternator/Starting clutch Operation precautions General matters  Refer to Chapter 1 Engine Fault Diagnosis and Inspection. Specification unit:mm Item Available limit Inner diameter of starting driven gear 22.1 Torque value 5.0-6.0 kgf-m Flywheel nut 1.5-2.0 kgf-m Bolt 8mm 1.3-1.7 kgf-m Oil filter cover 9.0-10.0 kgf-m Add oil to the thread Starting clutch fixing bolt...
  • Page 190 8.Alternator/Starting clutch Flywheel puller Universal fixator ‐...
  • Page 191 8.Alternator/Starting clutch Alternator disassembly flywheel pulser fan cover wire fixing plate coil Flywheel removal Drain the engine oil and remove the cooling fan cover (bolt X4) Remove the cooling fan (bolt X4)
  • Page 192 8.Alternator/Starting clutch cooling fan Universal fixing clip Use the universal fixing clip to fix the flywheel. Remove the 10 mm nut on the flywheel. Special tools:Universal fixator ‐...
  • Page 193 8.Alternator/Starting clutch Use the flywheel extractor to remove the flywheel. Special tools: Flywheel extractor Shaft guard NOTE Before installing the flywheel extractor, insert the shaft protector on the end of the right crankshaft to avoid damage to the crankshaft. Flywheel extractor Pulser line connector Disassembly of generator coil set Remove the alternator wire connector and pulse...
  • Page 194 Right crankcase cover removal Remove the right crankcase cover (bolt X9) Remove the positioning pin and gasket. Clean the gasket debris and foreign matter on the joint surface of the cover and the crankcase. NOTE The joint surface must not be damaged. Bolt X 9 ‐...
  • Page 195 8.Alternator/Starting clutch Starting clutch Start clutch removal Fix the starting driven gear with a universal fixer. Remove the 22mm anti-falling fixing bolts and gaskets. Fixed nut Special tools: Anti-dropping fixed nut sleeve Universal fixator NOTE Fixed nut sleeve The fixed nut is a left-handed thread. Remove the starting driven gear.
  • Page 196 Fix the starting clutch and rotate the starting driven gear. Lifting driven gear must be rotatable clockwise, but not counterclockwise. ‐...
  • Page 197 8.Alternator/Starting clutch Check whether the starting driven gear is worn or damaged. Measure the inner diameter of the starting driven gear. Usable limit: Inner diameter: below 22.1 mm Check whether the starting idler gear and shaft are worn or damaged. Measure the inner diameter of starting idler gear.
  • Page 198 clutch. Separate the clutch and clutch cover. Roller Remove the clutch roller, plunger and spring from the one-way clutch. Check each roller and plunger for wear and damage. Clutch body Install the roller, plunger and spring. Clutch cover...
  • Page 199 8.Alternator/Starting clutch Alternator/Starting clutch Installation Assemble in the reverse order of disassembly. NOTE Apply adhesive to the threads of the hexagon socket bolts. Torque value: 1.0-1.4 kgf-m Starting clutch installation Install the idler shaft and idler. Install the starting clutch. Install the starting driven gear on the starting clutch.
  • Page 200 Apply engine oil to the threads of the fixed nut. Special tools: Anti-dropping fixed nut sleeve Universal fixator Torque value: 9.0-10.0 kgf-m...
  • Page 201 8.Alternator/Starting clutch Right crankcase cover installation bolt x9 Install positioning pins and new gaskets on the crankcase. Replace the oil seal on the right side of the crankshaft on the crankcase cover and apply oil to the oil seal lip. Install the right crankcase cover on the right crankcase (bolt x9) Wire fixing plate...
  • Page 202 Install the cooling fan 8.Alternator/Starting clutch (boltX4) cooling fan Remove the cooling fan cover (bolt X4) Replenish engine oil according to the specified quantity.
  • Page 203 Generator/starting clutch 9.Crankcase/Crankshaft/Balance Shaft Mechanism diagram‐‐‐‐‐‐‐‐‐‐‐‐‐-----------‐‐‐ 9‐1 Crankshaft inspection‐‐‐‐‐‐‐‐‐‐‐---------------‐‐ 9‐3 Precautions in operation ‐‐‐‐‐‐‐----------‐‐ 9‐2 Balance shaft inspection‐‐‐‐‐‐‐-------------‐‐‐‐ 9‐4 Fault diagnosis‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐----------‐--‐‐‐‐‐‐ 9‐2 Crankshaft, balance shaft installation‐--- 9‐5 Crankcase separation ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐-‐-‐ 9‐3 ‐...
  • Page 204 9.Crankcase/Crankshaft/Balance Shaft Precautions in operation General matters ● In this section, the crankcase is separated to maintain the crankshaft and balance shaft set. ● Before separating the crankcase, remove the following parts: Cylinder Head Chapter 4 Cylinder/Piston Chapter 5 V-belt drive mechanism Chapter 6 Generator/starting clutch chapter 8 ●...
  • Page 205 9.Crankcase/Crankshaft/Balance Shaft Special tools Internally drawn bearing extractor Out-drawing bearing extractor Bearing press-in fixture Oil seal press-in fixture Fault diagnosis Engine noise is too loud ● The bearing clearance is too large ● Excessive clearance of crankshaft tip bearing ● Piston tip or piston tip hole wear ●...
  • Page 206 9. Crankcase/Crankshaft/Balance Shaft Crankcase separation Screw X 2 Remove the 2 connecting bolts of the right crankcase from the right side of the crankcase Cam chain Remove 5 balance shaft cover bolts from the left crankcase, and remove and pull Force rod fixing bolts 3 Turn the left crankcase down and disassemble the right crankcase.
  • Page 207 9.Crankcase/Crankshaft/Balance Shaft NOTE Never pry the joint surface of the crankcase to separate it, otherwise it will damage the joint surface and cause oil leakage. Before pressing the left/right crankcase, the cam chain must be separated from the drive...
  • Page 208 9. Crankcase/Crankshaft/Balance Shaft Remove the crankshaft and balance shaft from the left crankcase. NOTE The left/right side bearing of the crankshaft is press-fitted on the crankshaft. Remove the chain tension rod and lock the fixing bolt X3 Remove the gasket and fixed pin (2). Remove the shim debris on the crankcase joint surface with the shim scraper.
  • Page 209 9.Crankcase/Crankshaft/Balance Shaft Balance Shaft Scrape surface debris The upper surface of the oil seal is required to be level with the surface of the balance shaft cover, and not excessive pressure Oil seal Tension rod fixing bolt X3...
  • Page 210 9.Crankcase/Crankshaft/Balance Shaft Crankshaft inspection Measure the axial clearance of the big end of the connecting rod with a thickness gauge. Usable limit: replace new products above 0.55 mm Measure the radial clearance of the big end of the connecting rod in the vertical direction of the crankshaft.
  • Page 211 9.Crankcase/Crankshaft/Balance Shaft Bearing inspection Use your fingers to rotate the bearing. The bearing Clearanc needs to rotate freely, smoothly and quietly. Clearanc And check whether the inner ring is firmly connected to the crankshaft. If there is irregularity, abnormal sound or weak combination, replace the whole set of crankshafts.
  • Page 212 9.Crankcase/Crankshaft/Balance Shaft Install 2 locating pins and new right crankcase gasket. Right crankcase gasket Install the right crankcase and tighten the Positioning crankcase bolts (2 bolts). Torque value: 1.5-2.0 kgf-m.

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