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Linhai HY200X 2022 Service Manual
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Linhai HY200X 2022 Service Manual

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2022 ATV
SERVICE MANUAL
HY200X
Z210 ATV
General Information
※
Maintenance
※
Engine
※
Chassis
※
Brakes
※
Electrical
※
22.0

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Summary of Contents for Linhai HY200X 2022

  • Page 1 2022 ATV SERVICE MANUAL 22.0 HY200X Z210 ATV General Information ※ Maintenance ※ Engine ※ Chassis ※ Brakes ※ Electrical ※...
  • Page 2 ATV SERVICE MANUAL22.0 LH200ATV-E 维修手册英文 版本 22.0...
  • Page 3 Foreword This manual is designed primarily for use by the ATV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
  • Page 4 CONTENTS ……………………………………………..…General Information CHAPTER1 ………………………………………….……...………Maintenance CHAPTER2 CHAPTER3…………………………………..…………..……..…….….Engine CHAPTER4………………………..…………..…………..……..….…Chassis CHAPTER5…………………………………………………………..……Brakes CHAPTER6………………………………………………….….…..…Electrical...
  • Page 5 WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 6 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 CHAPTER 1 GENERAL INFORMATION WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
  • Page 7 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
  • Page 8 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 Replace distorted circlips. When installing a circlip ①, make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives. See sectional view. ④ Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector.
  • Page 9 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
  • Page 10 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 1.2 V.I.N AND ENGINE SERIAL NUMBER CE/T3b PAGE. 1- 5 CHAPTER 1 GENERAL INFORMATION...
  • Page 11 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 1.3 VEHICLE DIMENSIONS PAGE. 1- 6 CHAPTER 1 GENERAL INFORMATION...
  • Page 12 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 PAGE. 1- 7 CHAPTER 1 GENERAL INFORMATION...
  • Page 13 CHAPTER 1 GENERALINFORMATION Z210 ATV SERVICE MANUAL 22.0 NOTES PAGE. 1- 8 CHAPTER 1 GENERAL INFORMATION...
  • Page 14 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 CHAPTER 2 MAINTENANCE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. 2.1 PERIODIC MAI NTENANCE 2.2 FUEL SYSTEM 2.3 TOE ALIGNME NT...
  • Page 15 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
  • Page 16 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 Brake pad wear Weekly Engine Cylinder Head and 3 months Cylinder Base Fasteners (re-torque required at first service only) ▲ General Lubrication 3 months all fittings, pivots, cables, etc. Engine Oil-Level Daily Engine Oil Change 30 hrs 3 months Break-in Service at 1 month.
  • Page 17 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 Brake fluid 200 hrs 24 months Change every two years Toe adjustment Periodic inspection, adjust when parts are Required replaced Headlight Aim Adjust if necessary Required ▲ Ball joint (knuckle assembly) 10 hrs monthly I, (for damage, wear, and play) R.
  • Page 18 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 LUBRICATION RECOMMENDATIONS NOTE: More often under severe use, such as wet or dusty conditions. Grease: Light weight lithium-soap grease. Grease M：Molybdenum disulfide (MoS ) grease (water resistant). When suspension action becomes stiff or after washing. Hours are based on 10 mph(16Km/h) average.
  • Page 19 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 FUEL LINES Check fuel lines signs wear, deterioration, damage or leakage. Replace if necessary. Be sure fuel lines are routed properly and fixed solidly. CAUTION: Make sure lines are not kinked or pinched. Replace all fuel lines every two years.
  • Page 20 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.3 TOE ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered NOTE: String should just touch side surface of rear tire on each side of the ATV. Measure from string to rim at front and rear of rim.
  • Page 21 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.4 BRAKING SYSTEM INSPECTION DISC BRACK The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.
  • Page 22 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.5 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen ents. Adjust sion spring preload requirem sary. neces FRONT SUSPENSION Compress and release front suspension. Damping should be smooth throughout the range of travel.
  • Page 23 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.6 WHEELS Inspect all wheels for runout of damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL, HUB TORQUE TABLE Specification Youth/Mini ATV Front Wheel Nuts 45-50N.m 33-37 Ft.Lbs Rear Wheel Nuts...
  • Page 24 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.7 TIRE PRESSURE TIRE INSPECTION Tire Pressure Inspection CAUTION : Front Rear ⚫ Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. ⚫Improper tire inflation may affect ATV maneuverability.
  • Page 25 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 2.8 FRAME , NUTS, BOLTS, FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. Torque （Ft-Lb）...
  • Page 26 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 13...
  • Page 27 CHAPTER 2 MAINTENANCE Z210ATV SERVICE MANUA 22.0 CHAPTER 2 MAINTENANCE PAGE. 2- 14...
  • Page 28 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 CHAPTER 3 ENGINE 3.1 MAINTENANCE SPECIFICATIONS 3.1.1 SPECIFICATIONS 3.1.2 TIGHTENING TORQUES 3.2 PARTS INSPECTION AND SERVICE 3.2.1 ENGINE OIL LEVEL INSPECTION 3.2.2 ENGINE OIL CHANGE 3.2.3 ENGINE MOUNT INSPECTION 3.2.4 SPARK PLUG INSPECTION 3.2.5 VALVE CLEARANCE ADJUSTMENT 3.2.6 COMPRESSION PRESSURE 3.2.7 SPARK ARRESTOR SERVICE...
  • Page 29 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.5.2 CAMSHAFT INSPECTION 3.5.3 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 3.5.4 CAMSHAFT AND ROCKER ARM INSTALLATION 3.6 VALVES AND VALVE SPRINGS 3.6.1 VALVES AND VALVE SPRINGS REMOVAL 3.6.2 VALVE AND VALVE SPRINGS INSPECTION 3.6.3 VALVE SEATS INSPECTION 3.6.4 VALVES AND VALVE SPRINGS INSTALLATION 3.7 CYLINDER AND PISTON...
  • Page 30 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.9 A.C. MAGNETO AND STARTER CLUTCH 3.9.1 A.C. MAGNETO REMOVAL 3.9.2 CRANKCASE COVER REMOVAL 3.9.3 STARTER DRIVE ONE-WAY CLUTCH REMOVAL AND INSPECTION 3.9.4 STARTER DRIVE ONE-WAY CLUTCH INSTALLATION 3.9.5 CRANKCASE COVER INSTALLATION 3.9.6 A.C.
  • Page 31 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.15.1 AIR BOX REMOVAL 3.15.2 AIR BOX INSTALLATION 3.16 FUEL INJECTION SYSTEM 3.16.1 ECU 3.16.1.1 Description & Working Principle 3.16.1.2 Appearance 3.16.1.3 Handling –Don’ts & Do’s 3.16.1.4 Installation requirements 3.16.1.5 Power Requirements 3.16.1.6 Operating Temperature 3.16.1.7 Maintenance service and Repair 3.16.2 INJECTOR...
  • Page 32 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.7.3 Service Procedure 3.16.7.4 Fuel Pump Removal 3.16.7.5 Fuel Pump Installation 3.16.7.6 Fuel Pressure Relief Procedure 3.16.7.7 Fuel Leakage Check Procedure: 3.16.8 MOTOR SCANNER (For Motion SE08) 3.16.8.1 Precautions 3.16.8.2 Preparations Connection 3.16.8.3 Functions 3.16.8.4 SE08 ECU Malf Code CHAPTER 3 ENGINE...
  • Page 33 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.1 MAINTENANCE SPECIFICATIONS 3.1.1 SPECIFICATIONS Item Standard Limit ….. Cylinder head Surface warpage limit 0.05mm Surface warpage limit (mating with ….. 0.05mm cylinder head) Cylinder Bore size 62.515-62.520 mm 62.56mm ….. Out of round limit 0.05mm Cam dimensions Intake "A"...
  • Page 34 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Item Standard Limit 4.970-4.980mm 4.9mm Stem outside diameter 4.955-4.970mm 4.9mm 5.000-5.012mm 5.03mm Guide inside diameter 5.000-5.012mm 5.03mm Valve, Valve seat, 0.02-0.032mm 0.08mm Stem-to-guide clearance Valve guide 0.03-0.057mm 0.10mm ….. Stem runout limit 0.10mm 0.6-0.8mm 1.5mm...
  • Page 35 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Item Standard Limit Clutch shoe thickness 3.5mm 2.0mm Clutch hosing inside diameter 113.5-113.8mm 113.8mm Automatic centrifugal Clutch shoe spring free length 156mm 39mm clutch Weight outside diameter 20mm 19mm … Clutch- in revolution 2600-2800r/min V-belt Width...
  • Page 36 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.1.2 TIGHTENING TORQUES Tightening Part Thread Q’ty Part to be tightened Remarks Torque name size m.kg Cylinder head cover Bolt Cylinder head & cylinder Bolt Cylinder head & cylinder Spark plug Camshaft platen Bolt Timing sprocket Bolt...
  • Page 37 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Tightening Part Thread Q’ty Part to be tightened Remarks Torque name size m.kg Temperature sensor Oxygen sensor Spark arrestor fasteners Bolt Exhaust pipe Exhaust mounting fastener Bolt Locating Bolt Bolt CHAPTER 3 ENGINE PAGE.
  • Page 38 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.2 PARTS INSPECTION AND SERVICE 3.2.1 ENGINE OIL LEVEL INSPECTION 1. Position vehicle on a level surface and apply the parking brake. 2. Start the engine and allow the engine to run for 30 seconds to properly circulate the oil.
  • Page 39 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 7. When finished, reinstall the dipstick. 8. Start the engine and allow the engine to run for 30 seconds to properly circulate the oil. 9. Turn off the engine. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.
  • Page 40 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 8.Inspect the sealing washer on the drain plug. Replace the washer if it is damaged. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.
  • Page 41 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 CAUTION: Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinder. 2. Check: ⚫Spark plug type Incorrect →...
  • Page 42 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 (T.D.C.) on the compression. 1. Remove: ⚫ Valve cover 2. Remove: ⚫Spark plug 3. Remove: ⚫Cooling fan cover 4. Verify cam lobes are pointed down. 5.Measure: ⚫Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve 0.04-0.06mm Exhaust valve 0.05-0.07mm...
  • Page 43 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Out of specification → Adjust. Refer to “3.2.5VALVE CLEARANCE ADJUSTMENT” section. 2.Start the engine and let it warm up for several minutes. 3.Turn off the engine. 4. Remove: ⚫Spark plug NOTE : Before removing the spark plug, use com pressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder.
  • Page 44 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 WARNING : Before cranking the engine, ground all spark plug leads to prevent sparking. 8. Install: ⚫Spark plug TORQUE Spark plug: 12N.m 3.2.7 SPARK ARRESTOR SERVICE WARNING : ⚫Do not clean spark arrestor immediately after the engine has been run, as the exhaust system becomes very hot.
  • Page 45 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 10N.m 3.2.8 TRANSMISSION OIL LEVEL CHECK NOTE : To check and ensure proper transmission lubricant level, the transmission needs to be drained and filled to the proper specification. The fill plug ○, is located on the side of the transmission gearcase.
  • Page 46 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 properly. 3.3 ENGINE REMOVAL AND INSTALLATION 3.3.1 ENGINE REMOVAL 1.Remove side panels and pedals. 2.Remove axle. 3.Remove air box and muffler from the engine. ○ 4.Remove the fuel supply line 5.Disconnect the following electrical components: ○...
  • Page 47 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ○ ⚫Engine Ground ○ ⚫ Oxygen Sensor ○ 8.Remove starter cable ,13. ○ 9.Remove the Shifting rocker arm ,14 from the transmission. ○ ○ 10.Remove engine mounting bolt ○ ,17. CHAPTER 3 ENGINE PAGE.
  • Page 48 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 11.Remove small sprocket and protective cover. 12.Remove engine out vehicle. 3.3.2 ENGINE INSTALLATION 1.Install the engine into the frame. ○ ○ 2.Install the engine mounting bolt ○ Torque to specification TORQUE Engine Mounting Bolt: 50N.m CHAPTER 3 ENGINE PAGE.
  • Page 49 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ○ 3.Install the Shifting rocker arm ,4 to the transmission. TORQUE Shifting rocker arm Bolt: 10N.m ○ 4.Install starter cable TORQUE Starter cable nut: 10N.m 5. Connect the following electrical components: ○ ⚫...
  • Page 50 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ○ ⚫ Oxygen Sensor 6.Install accelerator cable into the carburetor, ○ adjust accelerator cable and tighten nut ,12. 7. Connect the following electrical components: ○ ⚫ Sensor (throttle body) ○ ⚫ Stepper motor (throttle body) ○...
  • Page 51 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.4 CYLINDER HEAD Q’ty Order Job/Parts to remove Remarks Exhaust pipe Disconnect. Engine oil Disconnect. Spark plug Cylinder head breather hose Cooling fan cover Intake pipe Dowel pin Shroud comp b Shroud comp a Timing chain tensioner cap bolt Timing chain tensioner...
  • Page 52 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.4.1 CYLINDER HEAD COVER REMOVAL 1. Loosen: ⚫ Bolts ① 2. Remove: ⚫ Cylinder head cover ② 3.4.2 CYLINDER HEAD REMOVAL 1. Loosen: ⚫Nuts ① 2. Remove: ⚫Throttle body adapter ② 3. Remove: ⚫Engine temperature sensor ③...
  • Page 53 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 6. Loosen: ⚫ Bolts ① 7. Remove: ⚫Timing chain tensioner assembly ⚫Timing chain tensioner gasket NOTE: The plunger is under spring tension. Maintain inward pressure on the tensioner body while removing. 8.Inspect: ⚫Tensioner and plunger ②...
  • Page 54 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.4.3 CYLINDER HEAD INSPECTION 1. Eliminate: ⚫Carbon deposits (from combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: ⚫Spark plug threads ⚫Valve seats 2.
  • Page 55 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 2. Tighten: ⚫Nuts (cylinder head) TORQUE Cylinder head Nuts: 25N.m ⚫Bolts (cylinder) TORQUE Cylinder Bolts: 10N.m 3. Install: ⚫Cam sprocket ⚫Timing chain Installing steps : ⚫Turn the cooling fan clockwise until the TDC mark ○, matches the stationary pointer ○, ⚫Align the "T"...
  • Page 56 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 4. Tighten: ⚫Bolts (cam sprocket) TORQUE Cam sprocket Bolts: 15N.m 5. Install: ⚫Timing chain tensioner Installing steps: ⚫Using a small flat blade screwdriver, turn the tensioner clockwise to retract the plunger ② all the way into the tensioner body.
  • Page 57 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.5 CAMSHAFT AND ROCKER ARMS Q’ty Order Job/Parts to remove Remarks Refer to “CYLINDER HEAD” Cylinder head Camshaft bearing pressure platen Intake rocker shaft Exhaust rocker shaft Rocker arm assembly Pressure reducing valve stop plate Camshaft Locknut...
  • Page 58 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 1.Loosen: ⚫ Bolt ① 2. Remove: ⚫ Camshaft bearing platen ② ⚫Rocker arm shaft (intake) ⚫Rocker arm shaft (exhaust) 3. Remove: ⚫Rocker arm (intake) ⚫Rocker arm (exhaust) ⚫Camshaft 3.5.2 CAMSHAFT INSPECTION 1. Inspect: ⚫Camshaft lobes Pitting/Scratches/Blue discoloration →Replace.
  • Page 59 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.5.3 ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect: ⚫Camshaft lobe contact surface  Excessive wear → Replace. ⚫Adjuster surface  discoloration → Wear/Pitting/Scratches/Blue Replace. 2. Inspect: ⚫Rocker arm shaft hole. Excessive wear →...
  • Page 60 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.5.4 CAMSHAFT ROCKER INSTALLATION 1. Lubricate: ⚫Cam shaft Camshaft: Molybdenum disulfide oil Camshaft bearing: Engine oil 2. Install: ⚫Cam shaft 3. Apply: ⚫Molybdenum disulfide oil onto the rocker arm and rocker arm shaft. Molybdenum disulfide oil 4.
  • Page 61 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.6 VALVES AND VALVE SPRINGS Q’ty Order Job/Parts to remove Remarks Refer to “CYLINDER HEAD” Cylinder head Refer to “CAMSHAFT AND Camshaft ROCKER ARMS” Valve cotter Valve spring retainer Valve spring Valve stem seal Exhaust valve Intake valve CHAPTER 3 ENGINE...
  • Page 62 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.6.1 VALVES VALVE SPRINGS REMOVAL NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Inspect: ⚫ Valve sealing Leakage at the valve seat →...
  • Page 63 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Valve stem diameter: Intake: 4.970-4.980mm <Limit: 4.90mm> Exhaust: 4.955-4.970mm <Limit: 4.90mm> 2. Measure: ⚫Valve guide inside diameter Out of specification → Replace. Valve guide inside diameter: Intake: 5.000-5.012mm <Limit: 5.03mm> Exhaust: 5.000-5.012mm <Limit: 5.03mm>...
  • Page 64 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 5. Inspect: ⚫Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 6. Measure: ⚫Free length (valve spring) Out of specification → Replace. Valve spring free length: Intake: 37 mm...
  • Page 65 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Valve seat width: Intake: 0.6-0.8mm <Limit:1.5mm> Exhaust: 0.6-0.8mm <Limit:1.5mm> Measurement step: ⚫Apply Mechanic’s blueing dye (Dykem)  to the valve face. ⚫Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern.
  • Page 66 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ⚫Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Make sure to clean off all compound from the valve face and valve seat after every lapping operation.
  • Page 67 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 NOTE: ⚫Make sure each valve is installed in its original place. ⚫Install the valve springs with the larger pitch “a” facing up. 4. Install: ⚫Valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor “1”...
  • Page 68 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.7 CYLINDER AND PISTON Q’ty Order Job/Parts to remove Remarks Refer to “CYLINDER HEAD” Cylinder head Timing chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Top ring 2nd ring Oil ring...
  • Page 69 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.7.1 PISTON AND PISTON RINGS REMOVAL 1. Remove: ⚫Piston pin circlip  ⚫Piston pin  ⚫Piston  NOTE: Before removing the piston pin circlip, cover the crankcase opening with a clean tow el or rag to prevent the circlip from falling into the crankcase cavity.
  • Page 70 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Cylinder bore: 62.515-62.520 < Limit:62.600mm> < Difference limit between A,B and C :0.03mm > 3. Measure: ⚫Warpage Out of specification → Replace. Cylinder warpage limit: 0.05mm 3.7.3 PISTON AND PISTON PIN INSPECTION 1.
  • Page 71 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 4. Measure: ⚫Piston pin outside diameter Out of specification → Replace. Piston pin bore diameter: 14.994-15.000mm <Limit:14.960mm> 5. Inspect: ⚫Piston pin Blue discoloration/groove → Clean or replace. 3.7.4 PISTON RINGS INSPECTION 1. Measure: ⚫Side clearance ○, Out of specification →...
  • Page 72 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Piston ring end gap: Top ring: 0.10-0.25mm <Limit:0.45mm> 2nd ring: 0.20-0.40mm <Limit:0.60mm> Oil ring: 0.20-0.70mm 3.7.5 PISTON RINGS, PISTON AND CYLINDER INSTALLATION 1. Install: ⚫Lower oil ring rail “1” ⚫Oil ring expander “2” ⚫Upper oil ring rail “3”...
  • Page 73 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 NOTE: Offset the piston ring end gaps as shown. ○, Top ring end ○, Oil ring end (lower) ○, Oil ring end (upper) ○, 2nd ring end 5. Lubricate: ⚫Piston outer surface ⚫Piston ring ⚫Cylinder inner surface (with the recommended lubricant)
  • Page 74 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.8 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE COVER (LEFT) Q’ty Order Job/Parts to remove Remarks Crankcase cover (left) Crankcase cover (left) gasket Dowel pin Hose clamp A Joint A Hose clamp B Joint B Left Little Guy Left Little Guygasket...
  • Page 75 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 PRIMARY SHEAVE Q’ty Order Job/Parts to remove Remarks Nut/Plain washer Primary fixed sheave O-ring Nut/Plain washer Clutch housing Clutch assembly V-belt Primary sliding sheave Collar Weight Slider Starting driven gasket CHAPTER 3 ENGINE PAGE.
  • Page 76 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 SECONDARY SHEAVE Q’ty Order Job/Parts to remove Remarks Clutch carrier Clutch shoe spring Spring seat A Compression spring Spring seat B Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave CHAPTER 3 ENGINE PAGE.
  • Page 77 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.8.1 PRIMARY SHEAVE REMOVAL 1. Loosen: ⚫Nut (primary sheave) 2. Remove: ⚫Plate washer  ⚫Primary fixed sheave 3.8.2 SECONDARY SHEAVE AND V-BELT REMOVAL 1. Remove: ⚫Seal  2. Loosen: ⚫Nut  3. Remove: Washer ...
  • Page 78 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.8.4 CLUTCH INSPECTION 1.Measure: ⚫Clutch shoe thickness Scratches → Glaze using coarse sandpaper. Wear /Damage → Replace. Clutch shoe thickness: 3.5mm <Limit:2.0mm> NOTE: ⚫After using the sandpaper, clean off the polished particles. ⚫Inspect the other clutch shoes.
  • Page 79 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.8.7 SECOMDARY SHEAVE INSPECTION 1. Inspect: ⚫Secondary fixed sheave smooth operation ⚫Secondary sliding sheave smooth operation 2. Inspect: ⚫Torque cam groove  Wear /Damage → Replace. 3. Inspect: ⚫Guide pin  Wear /Damage → Replace. 3.8.8 PRIMARY SHEAVE ASSEMEBLY 1.
  • Page 80 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.8.9 SECOMDARY SHEAVE INSTALLATION 1. Apply: ⚫Lightweight lithium-soap base grease (to the secondary sliding sheave  inner surface, grease nipple groove, and oil seals) ⚫ Lightweight lithium-soap base grease (to the bearings, oil seals and inner surface of the secondary fixed sheave ...
  • Page 81 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 With assembly compressed and threads exposed, have assistant thread a new nut onto shaft. 7. Install: ⚫ V-belt  ⚫ Clutch assembly  NOTE: Install the V-bet with clutch assembly to the primary sheave side.
  • Page 82 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.9 A.C. MAGNETO AND STARTER CLUTCH A.C. MAGNETO Q’ty Order Job/Parts to remove Remarks Refer to “CYLINDER HEAD” Cooling fan cover Couplers (A.C. magneto lead) Disconnect the couplers. Cooling fan Magneto flywheel Clamper (A.C.
  • Page 83 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 STARTER CLUTCH AND STARTER MOTOR Q’ty Order Job/Parts to remove Remarks Engine oil Disconnect. Crankcase cover (right) Crankcase cover (right) gasket Dowel pin Shaft (idle gear) Idler gear Nut/Plain washer Starter one way clutch assembly Starter motor O-ring CHAPTER 3 ENGINE...
  • Page 84 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.9.1 A.C. MAGNETO REMOVAL CAUTION: Avoid damage to the flywheel or crankshaft end. Do not strike components or special tools with hammers or heavy objects. 1. Loosen: ⚫Bolts  2. Remove: ⚫Cooling fan  3.
  • Page 85 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.9.2 CRANKCASE COVER REMOVAL 1. Loosen: ⚫Bolts  2. Remove: ⚫Crankcase cover  NOTE: Pay attention to location and length of each fastener for assembly purposes. 3.9.3 STARTER DRIVE ONE-WAY CLUTCH REMOVAL AND INSPECTION 1.
  • Page 86 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.9.4 STARTER DRIVE ONE-WAY CLUTCH INSTALLATION 1. Install: ⚫Starter wheel gear  ⚫ Washer  2.Tighten: ⚫ Slotted nut ③ TORQUE Slotted nut: 95N.m NOTE: ⚫ Install the slotted nut ③ using the Slotted Nut Socket .
  • Page 87 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ⚫Bolts (stator coil) ④ TORQUE Bolts(stator coil): 10N.m 3. Install:  ⚫ Cord clamp 4.Tighten: ⚫Bolts (cord clamp) ⑥ TORQUE Bolts(cord clamp): 10N.m NOTE: ⚫ Route the wires appropriately to avoid contact with any moving parts.
  • Page 88 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.10 OIL PUMP Q’ty Order Job/Parts to remove Remarks Refer to “A.C. MAGNETO AND A.C. magneto STARTER CLUTCH” Cover Nut/Plain washer Overrunning Clutch Chain Oil pump driven sprocket Oil pump CHAPTER 3 ENGINE PAGE.
  • Page 89 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.10.1 OIL PUMP REMOVAL AND INSPECTION 1. Loosen: ⚫ Bolts  ⚫ Nut ② 2. Remove: ⚫ Oil pump cover  3. Loosen: ⚫ Nut  4. Remove: ⚫ Oil pump drive sprocket ② ⚫...
  • Page 90 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Tip clearance “a” : 0.15-0.20 mm <Limit: 0.23mm> Side clearance “b” : 0.15-0.22 mm <Limit:0.26mm> Housing and rotor clearance “c” : 0.05-0.12 mm <Limit: 0.14mm> 3.10.2 OIL PUMP INSTALLATION 1. Install: ⚫ Oil pump  NOTE: Install a new pump with the oil galley "a"...
  • Page 91 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 5. Install: ⚫ Oil pump cover  ⚫ Washer ② 6. Tighten: ⚫Bolts  TORQUE Oil pump cover bolts: 10N.m ⚫ Nut ④ TORQUE Oil pump drive sprocket nut: 65N.m CHAPTER 3 ENGINE PAGE.
  • Page 92 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.11 CRANKCASE AND CRANKSHAFT Q’ty Order Job/Parts to remove Remarks Engine removal Refer to "ENGINE REMOVAL". Cylinder head Refer to "CYLINDER HEAD" Refer "CYLINDER Cylinder, and piston PISTION" Refer to "V-BELT, CLUTCH V-belt, clutch, secondary/ primary AND SECONDARY/ PRIMARY sheave...
  • Page 93 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Q’ty Order Job/Parts to remove Remarks Bolt Pressure Plate Timing chain guide (intake) Bolt Crankcase (right) Crankcase (right) gasket Dowel pin Flat key Flat key Crankshaft assembly Crankcase (left) Timing chain CHAPTER 3 ENGINE PAGE.
  • Page 94 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.11.1 CRANKSHAFT&BALANCER REMOVAL 1. Remove: ⚫NUT ③ ⚫Balancer drive gear② ⚫Balancer shaft ① 2.Loosen: ⚫ Bolts ④ 3. Remove: ⚫ Crankcase RH ⚫ Crankshaft assembly ⚫ Balancer ⚫ Timing chain ① NOTE: ⚫Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket.
  • Page 95 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 2. Measure: ⚫Big end side clearance Out of specification → Replace big end bearing, crank pin and/or connecting rod. Big end side clearance: 0.10-0.35mm 3. Measure: ⚫Crank width Out of specification → Replace crankshaft. Crank width: 45.05-45.15mm 4.
  • Page 96 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 4. Tighten: ⚫Bolts (Crankcase RH) TORQUE Crankcase RH Bolts: 10N.m 5. Install: ⚫Balancer drive gear ⚫nut ⚫Balancer shaft NOTE: Align the punch mark “a” on the balancer drive gear with the punch mark “b” on the balancer driven gear.
  • Page 97 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.12 TRANSMISSION Q’ty Order Job/Parts to remove Remarks Refer "ENGINE Engine removal REMOVAL". Transmission cover Transmission cover gasket Dowel pin Shift indicator cable Shift indicator contact Oil seal Oil seal Circlip Washer Output shaft assembly Bolt Washer...
  • Page 98 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Q’ty Order Job/Parts to remove Remarks Shift fork shaft Shift fork Gearshift drum Gearshift shaft assembly Washer Reverse gear shaft assembly Drive shaft Circlip Oil seal CHAPTER 3 ENGINE PAGE. 3- 71...
  • Page 99 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 GEARSHIFT SHAFT ASSEMBLY Q’ty Order Job/Parts to remove Remarks Transmission removal Main shaft Washer Gear Bearing Splined washer Circlip Sliding dog gear Washer Gear Washer Shaft collar Circlip CHAPTER 3 ENGINE PAGE. 3- 72...
  • Page 100 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.12.1 TRANSMISSION DISASSEMBLY AND INSPECTION 1. Remove: ⚫ Drain plug ① ⚫ Washer 2. Drain ⚫ Transmission oil 3. Loosen: ⚫ Bolt ① 4. Remove: ⚫ Shift indicator cable ② ⚫ Shift indicator contact ③ 5.
  • Page 101 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 8. Remove: ⚫ Shift lever shaft ① ⚫ Shift drum ② ⚫ Shift fork guide bar ③ ⚫ Shift fork ④ 9. Inspect: ⚫ Shift fork cam follower “1” ⚫ Shift fork pawl “2” Bends/damage/scoring/wear →...
  • Page 102 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 13. Remove: ⚫ Gearshift shaft assembly ① ⚫ Washer ⚫ Reverse gear shaft ② 14. Loosen: ⚫ Bolt ① 15. Remove: ⚫ Drive shaft ② 16. Remove: ⚫ Circlip ① ⚫ Output shaft ② 17.
  • Page 103 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 18. Inspect: ⚫ Bearings Wear/ Crack /Damage → Replace. NOTE: All bearings should rotate freely without binding. Bearing inner race should have no detectable radial (up and down) movement of inner race. 3.12.2 TRANSMISSION INSTALLATION 1.
  • Page 104 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 6. Install: ⚫ Ball ① ⚫ Spring ② ⚫ Washer ③ ⚫ Detent bolt ④ TORQUE Detent bolt: 19N.m 7. Install: ⚫ Dowel pins ⚫ Gasket (transmission cover) ⚫ Transmission cover assembly ① 8.
  • Page 105 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.13 OIL COOLER 3.13.1 OIL COOLER REMOVAL 1.Position vehicle on a level surface and apply the parking brake. 2.Place a drain pan beneath the oil line connections. 3.Remove the banjo bolt ① and two crush washers securing the oil supply or return hose to the oil cooler.
  • Page 106 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.Install two new crush washers and banjo bolt to secure the oil supply or return hose to the oil cooler. Torque banjo bolt to specification. TORQUE Oil Hose Banjo Bolt: 39N.m 4.Install two new crush washers and banjo bolt to secure the oil supply or return hose to the engine.
  • Page 107 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.14 EXHAUST 3.14.1 EXHAUST REMOVAL 1.Remove the bolt ①. 2.Remove the nuts ② retaining the exhaust to the engine. 3.14.2 EXHAUST INSTALLATION 1.Install nuts ① retaining the exhaust to the engine. Torque to specification. TORQUE Exhaust Nuts: 13N.m...
  • Page 108 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.15 AIR BOX / INTAKE SYSTEM CAUTION: Make sure the air box cover is properly seated upon installation or severe engine damage could occur. 3.15.1 AIR BOX REMOVAL 1.Remove the side plate ①. 2.Loosen the gear clamp ②.
  • Page 109 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 2.Install the plate ② and the fasteners ③ ④ that secure the air box to the engine. Torque fasteners to specification. TORQUE Air Box Fasteners: 15N.m 3.Install the side plate ⑤. CHAPTER 3 ENGINE PAGE.
  • Page 110 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16 FUEL INJECTION SYSTEM 3.16.1 ECU 3.16.1.1 Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. also provides 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 111 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.1.4 Installation requirements The ECU shall be mounted using M6 machined screws with a torque of 8 Nm ±10%. The mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and warping the PCB.
  • Page 112 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.2.2 Temperature Requirements : Typical injector temperature environments are defined below. The injector will not experience any loss of the ability to comply with the flow tolerance requirements after exposure to the following temperature environments.
  • Page 113 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ●The injectors come from the factory with the seal rings attached. The re-use of seal rings is not preferred when replacing an injector. If an injector is to be re-used, and no new seal rings are available, take care to inspect each seal ring for signs of damage.
  • Page 114 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ● Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine. ● Disconnect the electrical connector from the injector wiring harness. ● Relieve fuel pressure. ●...
  • Page 115 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.3 THROTTLE BODY ASSEMBLY 3.16.3.1 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...
  • Page 116 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 back in place. ● Reinstall any necessary part which have not been reinstalled. 3.16.4 ENGINE TEMPERATURE SENSOR 3.16.4.1 Description and Working Principle This sensor is used in air cooled engines. It provides a resistance that varies as a function of temperature within prescribed tolerance limits.
  • Page 117 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.5.3 Fuel Quality Requirements Pb≤0.005g/L P≤0.0002g/L S≤0.04% (weight proportion)x MMT≤0.0085g/L Si≤4ppm 3.16.6 IGNITION COIL 3.16.6.1 Description and Working Principle This coil provides energy to the spark plug in the combustion chamber. The coil itself doesn’t have a driver.
  • Page 118 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ACTION REASON These leads are not designed to support the weight of the ignition system. It can create a DO NOT: Support the ignition system by the wiring poor electrical connection become harness or plug wire.
  • Page 119 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ACTION REASON Liquid intrusion into the terminal connection area might occur causing an electrical DO: Insure the appropriate seals are included in the intermittent or short condition. In the event of connector system. severe terminal corrosion, an open condition might occur.
  • Page 120 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ACTION REASON DO: For removing spark plugs follow the following steps: To remove spark plugs from Aluminum heads, allow the engine to cool. The heat of the 1- Grasp the spark plug boot and gently rotate 90°; and engine, in combination with a spark plug that then pull the spark plug boot and cable away from the is still hot, may cause the spark plug threads...
  • Page 121 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ACTION REASON If the thread is damage, it prevents a good heat transform from the shell to the cylinder head. DO: For installing spark plugs follow the following steps: Do not use any type of anti-seize compound 1- Make sure the cylinder head threads and spark plug on spark plug threads.
  • Page 122 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 contact vehicle manufacture to check whether the fuel pump module itself can survive or not. ● Make sure there is at least 3 liters of gasoline in the fuel tank before priming for first time (don’t run the pump dry).
  • Page 123 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Fuel Module Diagnosis: Step Action Switch on Ignition key. Fuel Pump primes for 3 seconds when the ignition fuel pump running fuel pump running noise can be heard, go to noise cannot be heard, key is ON.
  • Page 124 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ● Take out Fuel Pump assembly from fuel tank with care. 3.16.7.5 Fuel Pump Installation ● Replace the Fuel Pump gasket in Fuel Pump assembly with a new one. Old / Used gaskets can cause leakages.
  • Page 125 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 ● 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 126 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Seconds later, the unit will display: 3.16.8.3 Functions Motion Motor-Scanner can be used to diagnose Motion Engine Management System with functions: Read DTC, Clear DTC, Data Stream, Status Stream, and Record Data. Operations When the unit is powered up, the screen will display the interface as right.
  • Page 127 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Select ‘SE08 K’ and press key, it will display information about function list, as shown right Available functions are as follows: ● Read DTC ● Clear DTC ● Data Stream ● Record Data Press key to select function you needed, as shown right...
  • Page 128 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 2. Clear DTC Select ‘Read DTC ’, and press , it will display function list as right. key to select ‘Clear DTC ’ , the screen Press will display "SUCCESS", as shown right. This means the fault code has been removed successfully.
  • Page 129 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 4. Data Record Select ‘Read Date ’, and press , it will display function list as right. to select ‘Record Data ’ , it will display Press as right. (The recorded data can be used to analyze engine conditions) CHAPTER 3 ENGINE PAGE.
  • Page 130 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 3.16.8.4 SE08 ECU Malf Code Malf code Description 0107 MAP Sensor Circuit Low Voltage or Open 0108 MAP Sensor Circuit High Voltage 0112 IAT Circuit Low Voltage 0113 IAT Circuit High Voltage or Open 0117 Coolant/Oil Temperature Sensor Circuit Low Voltage 0118...
  • Page 131 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 Malf code Description 014C Cylinder 1 Sensor Reaction Time From Thick to Thin Slow 0601 ECM Read-Only Memory Check Error 0262 Cylinder 1 Fuel Injector Short to High Voltage 0261 Cylinder 1 Fuel Injector Short to Low Voltage/Open 3106 Steady State Intake Pressure Low 0105...
  • Page 132 CHAPTER 3 ENGINE Z210 ATV SERVICE MANUAL 22.0 NOTES CHAPTER 3 ENGINE PAGE. 3- 105...
  • Page 133 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 CHAPTER 4 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. 4.1 FRONT WHEE L / HUB / BRAKE 4.2 A-RM REPLACEMENT 4.3 FINAL DRIVE...
  • Page 134 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 4.1 FRONT WHEEL/ HUB WHEEL SUB-ASSY VALVE，RIM TIRE FRONT HUB FOR WHEEL ASSY HUB ASSY SHRT BOLT BEARING 6202RZ BEARING 6204RZ WASHER 14 10 NUT M14 11 COTTER PIN 4X28 12 NUT M10，WHEEL 13 CAP，WHEEL SUB-ASSY 14 FRONT BRAKE DISC 15 BOLT M6X16 BRAKE CALIPER，LEFT，...
  • Page 135 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 HUB BEARING REPLACEMENT 1. Remove the bearing 6202RZ. 2. Remove the brake disc. 3. Remove the bearing 6204RZ. 1. Apply grease to the bearings. 2. Drive the bearing 6204RZ in first, seal side facing out, 3.
  • Page 136 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 3. Remove BOLTS (9) and removal FRONT SHOCK ABSORBER. 4. Remove bolts (1/15) and removal A-ARM. INSPECTION Clean and Inspect whether the BUSHING（2）, SEAL-BALL HEAD,DUST,SPINDLE（10） and BUSHING,LONG（17） is damaged. Replace if necessary. INSTALLATION NOTE: Always use new A-ARM PIVOT SHAFT SEALED RING for re-installation.
  • Page 137 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 DRIVE CHAIN Chain Removal 1. Place the vehicle on level ground with engine off, 2. Rotate rear wheel to place master link in accessible position between two sprockets. 3. Remove the rear wheels as described above. 4.
  • Page 138 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 CAUTION: The master link should be installed with the open end of the retaining clip (1) facing away from direction of chain rotation (4). 7. Turn the chain adjuster to obtain 1/4’’ (6mm) to 3/8’’ (10mm) chain flex. To tighten the chain, turn the chain adjuster clockwise.
  • Page 139 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 REAR AXLE HOUSING-AXLE BEARING DRIVEN SPROCKET PLATE-RETAINER，BEARING CHAIN BEARING 6206-2RS BOLT M8X28 BRACKET，HOUSING-AXLE BEARING，L NUT M8 BRACKET，HOUSING-AXLE BEARING，R REAR BRAKE DISC BOLT M8X30 SCREW M8X25 BRAKE CALIPER，REAR BOLT M12X1.25X30 BOLT M12X1.25X34 SPRING WASHER 8 NUT M12X1.25 BOLT，PARKING CALIPER WASHER...
  • Page 140 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 4.4 SWING ARM SHOCK ABSORBER REAR BOLT M10X1.25X42 NUT M10X1.25 SWINGARM ASSY SHAKER CUSHION SLEEVE SWING ARM PIVOT BUSHING SWING ARM PIVOT NUT M14X1.5 MOUNTING BRACKET， CHASSIS GUARD PLATE 10 BOLT M6X16 11 BOLT M6X12 12 CRADLE PLATE Removal 1.
  • Page 141 CHAPTER 4 CHASSIS Z210ATV SERVICE MANUAL22.0 NOTES CHAPTER 4 CHASSIS PAGE. 4-...
  • Page 142 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 CHAPTER 5 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. NOTE Also See Chapter 2 for Maintenance Information.
  • Page 143 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 5.1 SPECIFICATIONS Brake Caliper Item Standard Service Limit Brake Pad Friction hydraulic 0.157"/ 4mm 0.08"/ 2mm material Thickness Brake Disc Thickness 0.137"/3.5m m 0.125"/3.2mm Brake Disc Thickness Variance 0.002 "/ 0.051m m Between Measurements Brake Disc Runout 0.005 "/ 0.12 7m m 5.2 TORQUE...
  • Page 144 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 1. Choose an area large enough to safely accelerate the ATV to 24km/h (15 mph ) and to brake to a stop. 2. Using Fgear, accelerate to 50 km/h (30 mph); then compress brake handle to decelerate to 0-8km/h (5 mph).
  • Page 145 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 to the fitting and place the other end in a clean container. Be sure the hose fits tightly on the fitting. NOTE: Fluid may be forced from supply port when brake lever is pumped. Place diaphragm in reservoir to prevent spills.
  • Page 146 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 5.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION CAUTION: The master cylinder is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
  • Page 147 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 Brake Line Banjo Bolt Torque 15 ft. lbs. (21 Nm ) 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure, Check all connections for leaks and repair if necessary. 5.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set.
  • Page 148 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease. Front Caliper Mounting Bolts Torque 18 ft. lbs. (25 Nm ) 3.
  • Page 149 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 4. Install new disc on hub. 5. and tighten to specified. CAUTION: Always use new brake disc mounting bolts. Front Brake Disc Mounting Bolt Torque : 18 ft. lbs. (25 Nm ) 5.9 REAR CALIPER REMOVAL/ INSPECTION / INSTALLATION CAUTION: The caliper is a non-serviceable Component;...
  • Page 150 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 5.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL and INSPECTION 1. Lift caliper off of disc. NOTE. When removing caliper, be careful not to damage brake hose .
  • Page 151 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 5.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
  • Page 152 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 REMOVAL / REPLACEMENT 5.12 REAR BRAKE DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1"...
  • Page 153 CHAPTER 5 BRAKES Z210ATV SERVICE MANUAL 22.0 NOTES CHAPTER 5 BRAKES PAGE. 5- 12...
  • Page 154 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 CHAPTER 6 ELECTRICAL 6.1 PARTS INSPECTION AND SERVICE 6.2 BATTERY 6.3 IGNITION SYSTEM 6.4 CHARGING SYSTEM 6.5 ELECTRICS STARTING SYSTEM 6.6 LIGHTING SYSTEM 6.7 GEAR SHIFT SENSOR TEST 6.8 SPEEDOMETER SYSTEM 6.9 MAIN SWITCH AND HANDLE SWITCH 6.10FUEL GAUGE/ FUEL LEVEL SENSOR 6.11 WIRING DIAGRAM CHAPTER 6 ELECTRICAL PAGE.6-...
  • Page 155 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 6.1 PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT FOR Halogen lens lamp 1. Pull the cable plug off the conducting strip in the socket, remove the clip ① before dismounting the bulb ④. 2.
  • Page 156 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 HEADLIGHT ADJUSTMENT(For Halogen Lens Low Beam Headlamp ) To lower headlight brightness cut-off line, turn adjusting bolt backward. And to raise brightness cut-off line, turn the bolt forward. HEADLIGHT ADJUSTMENT(For LED Headlamp) To lower headlight brightness cut-off line, turn adjusting bolt backward.
  • Page 157 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 6.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 158 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 Load Test CAUTION: Remove spark plug high tension leads and connect securely to engine ground before proceeding. NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly.
  • Page 159 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 6.3 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark ⚫ Spark plug gap incorrect ⚫ Fouled spark plug ⚫ Faulty spark plug cap or poor connection to high tension lead ⚫...
  • Page 160 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 ⚫ Check the spark plug type. Repair or replace the spark plug ⚫ Check the spark plug gap Spark plug gap: 0.6 ～ 0.8mm 4.lgnition spark gap ⚫ Disconnect the spark plug cap from the spark plug ⚫Connect the ignition tester 1 as shown.
  • Page 161 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 Spark plug cap resistance: Replace the spark plug cap 5.0±1 KΩ(23±5℃) Tester (+) lead Spark plug lead ① CORRECT Tester (— ) lead 6. Ignition coil resistance Spark plug lead ② Disconnect the ignition coil connector from the wire harness.
  • Page 162 CHAPTER 6 ELECTRICAL Z210 ATV SERVICE MANUAL 22.0 ⚫ Check the pickup coil has the specified resistance. Replace the pickup coil. Primary coil resistance: 130±10Ω (20℃) MEETS SPECIFICATION NO CONTINUITY 8.Main switch CHECK SWITCHES Replace the main switch CONTINIUTY 9.Wiring connection ⚫Check the connection of the POOR CONNECTIONS entire ignition system...
  • Page 163 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6.4 CHARGING SYSTEM DIAGRAM REFER TO "6.11 WIRING DIAGRAM" REFER TO CIRCUIT DIAGRAM CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs. Connect an ammeter in series with the negative battery cable.
  • Page 164 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 start the engine and accelerate to about 5,000rpm ⚫check the terminal voltage Measured voltage-terminal Voltage: 0.2-2.5V up NOTE: Use a fully changed MEETS SPECITICATION battery. The charging circuit is not faulty MEETS SPECIFICATION Replace the battery 3.
  • Page 165 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6.5 ELECTRICS STARTING SYSTEM DIAGRAM REFER TO "6.11 WIRING DIAGRAM" TROUBLESHOOTING 1. Turn the main switch to “ ”position. 2. Shift into neutral, apply the handbrake lever and press the engine start button. 3.
  • Page 166 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 WARNING A wire used as a jumper lead must have the equivalent capacity as that of the battery lead or more, otherwise it may burn. This check likely produce sparks, so be sure that no flammable gas or fluid is in the vicinity 4.
  • Page 167 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6. Left/Right handbrake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 7. Starter switch NO CONTINUITY CHECKING SWITCHES Replace the handlebar switch 8. Wiring connection Check the connections of the entire POOR CONNECTION starting system.
  • Page 168 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 LIGHTING SYSTEM DIAGRAM REFER TO "6.11 WIRING DIAGRAM" TROUBLESHOOTING Procedure Check: 1. Fuse 4. Lights switch 2. Battery 5. Dimmer switch 3. Main switch 6. Wiring connection (entire lighting system) 1.Fuse CHECK FUSE NO CONTINUITY Replace the fuse 2.
  • Page 169 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 POOR CONNECTIONS 6. Wiring connection Check the connections of the entire lighting system correct 1. Check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1.
  • Page 170 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 2.The taillight fails to come on The taillight or turn signal light is LED. 1. Connector Check Connector. If the connector is loose or dropped Replace the connector or Plug in tightly 2. Voltage Connect the pocket tester (DC20V) to the taillight couplers.
  • Page 171 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6.7 GEAR SHIFT SENSOR TEST DIAGRAM REFER TO "6.11 WIRING DIAGRAM" Sensor table CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 18...
  • Page 172 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the rear cradle Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor. Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
  • Page 173 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 LCD Meter 1. Turn Left Indicator 10. Turn Right Indicator 2. MIL Indicator 11. High Beam Indicator 3. Fuel Volume Alarm Indicator 12. Neutral Indicator 4. Parking Brake Indicator 13. Brake Failure Alarm Indicator(Option) 5.
  • Page 174 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 Telephone Indicator You need to turn on your mobile Bluetooth ,search for and connect the Bluetooth "BX-XXXXXX" (XXXXXX is a number or parent code). When the mobile phone is successfully connected to the Bluetooth, if there is a call coming in or answering the phone, the Telephone Indicator is always display.
  • Page 175 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 MAIN SWITCH AND HANDLE SWITCH Main switch Left handle switch CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 22...
  • Page 176 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6.10 FUEL GAUGE/ FUEL LEVEL SENSOR Remove fuel tank cap and the cover, and then remove fuel pump attached to fuel tank Hold fu in an upright position after el pump removing it. It is normal if indicator shows “E”, otherwise, circuitry connection, fuel sensor or instrument should be inspected Turn fuel sensor upside down.
  • Page 177 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 6.11 WIRING DIAGRAM CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 24...
  • Page 178 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 25...
  • Page 179 CHAPTER 6 ELECTRICAL Z210ATV SERVICE MANUAL 22.0 CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 26...

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Z210 2022