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JI-EE ATV BXL 100 Service Manual

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Summary of Contents for JI-EE ATV BXL 100

  • Page 2: Table Of Contents

    CONTENTS 1. INFORMATION…………………………………………………...2 2. MAINTENANCE………………………………………………….6 3. ENGINE REMOVAL AND INSTALLATION………………….12 4. ENGINE FUEL SYSTEM………………………………………14 5. ENGINE LUBRICATION AND COOLING SYSTEM………..18 6. ENGINE COMBUSTION SYSTEM…………………………...21 7. TRANSMISSION SYSTEM……………………………………25 8. FRONT WHEEL AND STEERING SYSTEM………………..29 9. REAR WHEEL SYSTEM………………………………………42 10. FENDERS AND EXHAUST PIPE…………………………...45 11.

  • Page 3: Information

    1. INFORMATION 1.1 SAFETY 1.4 SPECIFICATION 1.2 NOTES 1.5 TORQUE VALUES 1.3 SERIAL NUMBER 1.1 SAFETY Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
  • Page 4 1.3 SERIAL NUMBER The frame serial number is stamped on the right side of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Engine serial number...
  • Page 5 1.4 SPECIFICATION ENGINE Type Forced Air-Cooling 2-Stroke Displacement 49.3cc/95.6cc Bore and Stroke 40.0*39.2mm/52.0*45.0mm Compression 6.8:1/7.8:1 Maximum Torque N-m@6500rpm/8.0N-m@4500rpm Carburetor Mikuni VM16 Ignition Capacitor Discharge Ignition Starting Electric/Kick Starter Lubrication Oil Pump Separate Supply Oil Capacity 1. 0 liter Transmission Automatic (C.V.T V-belt) CHASSIS Overall Length 1600mm(62.9inch)
  • Page 6 1.5 TORQUE VALUES ENGINE Item N•m Lbf-ft Cylinder head nut 28-30 20.7-22.1 park plug 12-19 8.9-14.0 Cylinder head bolt 20-30 14.8-22.1 Alternator bolt 8-12 5.9- 8.9 FRAME Item N•m Lbf-ft Handlebar upper holder bolt 24-30 17.7-22.1 Steering shaft nut 50-60 36.9-44.3 Steering shaft bushing holder nut 24-30...

  • Page 7: Maintenance

    2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES 2.5 THROTTLE CABLE ADJUSTMENT 2.12 STEERING SYSTEM 2.6 AIR CLEANER 2.13 TOE-IN 2.7 SPARK PLUG 2.14 GEAR OIL MAINTENANCE DATA SPECIFICATION...
  • Page 8 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace any parts if necessary. 2.4 THROTTLE OPERATION Inspect throttle lever for smooth full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if occur any damage.
  • Page 9 2.7 SPARK PLUG This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Inspect the spark plug electrodes for wear. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
  • Page 10 When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged.
  • Page 11 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead.
  • Page 12 2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. OIL DRAIN Unscrew this release bolt and can let the dirty oil flow out. BOLT The re-add oil hole is on the engine case beside gearbox. FILL OIL...

  • Page 13: Engine Removal And Installation

    3. ENGINE REMOVALS AND INSTALLATION 3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 SERVICE INFORMATION Engine shall be removed in the conditions of necessary repairment or adjustment in the transmission and combustion system only. 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 10) Remove the spark plug cap from the spark plug.
  • Page 14 Remove the three engine hanger nuts and bolts. Two hanger nuts are outside and one is inside. Remove the engine from the left side of frame. ENGINE HANGER NUTS 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm Route the wires and cable in reverse order properly.

  • Page 15: Engine Fuel System

    4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.3 CARBURETOR 4.2 FUEL TANK 4.4 ASSEMBLY 4.1 TROUBLESHOOTING ★ N NGINE CAN NOT START O FUEL IN TANK ★ N O FUEL TO CARBURETOR ★ T OO MUCH FUEL INTO CYLINDER ★ N O SPARK AT PLUG ★...
  • Page 16 4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. Unscrew the fuel tank fixed bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. 4.3 CARBURETOR REMOVAL Remove the air cleaner.
  • Page 17 Unscrew the float chamber screws and remove the float chamber. Disassembly the float arm pin, float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassembly the idle jet, main jet, idle speed adjust screw and idle mixtures adjust screw.
  • Page 18 4.4 ASSEMBLY Clean all parts in solvent and blow it dry with clean compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assemble the throttle cable, spring and the throttle valve.

  • Page 19: Engine Lubrication And Cooling System

    5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.4 COOLING SYSTEM 5.2 CAUTION 5.5 TROUBLESHOOTING 5.3 OIL PUMP 5.1 ENGINE LUBRICATION SYSTEM The engine crankshaft drives the pump gears of oil pump. Pump gears rotate the plunger shaft in oil pump.
  • Page 20 5.5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE ★ THE OIL LEVEL IN OIL TANK IS TOO LOW. ★ OIL TUBES WERE NOT FIXED WELL. ★ OIL HAS LEAKAGED FROM TUBE ENDS. ★ OIL TUBES WERE BROKEN. ★ OIL TUBES WERE CLOGGED. ★...

  • Page 21: Engine Combustion System

    6. ENGINE COMBUSTION SYSTEM 6.1 TROUBLESHOOTING 6.3 CYLINDER AND PISTON INSPECTION 6.2 CYLINDER AND PISTON REMOVAL 6.4 INSTALLATION 6.1 TROUBLESHOOTING LOW COMPRESSION ★ CYLINDER HEAD HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD ★ CYLINDER OR PISTON RINGS WORN OUT HIGH COMPRESSION ★...
  • Page 22 6.2 CYLINDER AND PISTON REMOVAL Remove the seat and rear fender. Remove the exhaust pipe. Remove the spark plug cap. Disconnect the wire. Drag out the engine. Disassembly the air cleaner and carburetor. Remove the intake pipe mounting bolts. Remove the cylinder bolt nuts. Remove the cylinder head.
  • Page 23 Check the cylinder head mating surface for warp with a straight edge and feeler gauge. Service limit: 0.10 mm Insert each piston ring into the cylinder, and measure the end gap. Service limit: 0.5 mm Measure the clearance between ring and groove. Service limit: 0.09 mm Measure the piston outer diameter at 10 mm high from the skirt’s bottom.
  • Page 24 Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter service limit: 9.96 mm (for 50cc engine) 11.6 mm (for 100cc engine) Pin bore service limit: 10.04 mm (for 50cc engine) 12.04 mm (for 100cc engine) Measure the connecting rod small end inner diameter with an inside micrometer.
  • Page 25 Apply some oil to inside of the connecting rod small end. Install the piston, piston pin and clip. Install the piston with the arrow mark facing the exhaust pipe. Do not align the piston pin clip end gap with the piston cutout. Install a new cylinder gasket.

  • Page 26: Transmission System

    7. TRANSMISSION SYSTEM 7.1 TROUBLESHOOTING 7.5 CONTINUOUS VARIABLE TRANSMISSION 7.2 THE PARTS DRAWING OF TRANSMISSION 7.6 GEAR BOX SYSTEM 7.3 PATH OF POWER TRANSMISSION 7.7 ELECTRIC SELF-STARTER MECHANISM 7.4 AUTOMATIC CONTINUOUS VARIABLE 7.8 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM TRANSMISSION 7.1 TROUBLESHOOTING SCOOTER CAN NOT MOVE AFTER ENGINE START ★...
  • Page 27 7.3 PATH OF POWER TRANSMISSION The torque of crank-shaft drive the front pulley The torque (drive) pulley turn the belt The belt drive the rear (driven) pulley The force through the clutch shoe, clutch housing and drive shaft The drive shaft turn the idle gear in gearbox Turning speed reduced by final-gear and transmitted to rear-axle shaft to move rear wheel 7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal...
  • Page 28 Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. There is a Torque Cam on the Movable Drive Face. Torque Cam is loaded from outside.
  • Page 29 7.7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can act only when the left hand brake is applied. 7.8 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM Remove the engine clutch cover, by unscrew the fixed bolts. Check the belt for wear.

  • Page 30: Front Wheel And Steering System

    8. FRONT WHEEL AND STEERING SYSTEM 8.1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING 8.5 FRONT BRAKES SYSTEM 8.2 TROUBLESHOOTING 8.6 SPEEDOMETER 8.3 HANDLEBAR 8.7 STEERING SYSTEM 8.4 FRONT WHEEL 8.1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM FRONT WHEEL FRONT BRAKE STEERING SYSTEM...
  • Page 31 8.2 TROUBLESHOOTING HARD STEERING ★ FAULTY TIRE ★ STEERING SHAFT HOLDER TOO TIGHT ★ INSUFFICIENT TIRE PRESSURE ★ FAULTY STEERING SHAFT BEARINGS ★ DAMAGED STEERING SHAFT BEARING FRONT WHEEL WOBBLING ★ FAULTY TIRE ★ WORN FRONT BRAKE DRUM BEARING ★ BENT RIM ★...
  • Page 32 PS: ADJUST THE SUSPENSION Both the suspension is soft or too hard. One must adjust the suspension to an appropriate elasticity position. See the top right of the picture for adjustment tool. 8.3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. Remove front brake cable.
  • Page 33 When take the three up toward screws, it can remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark with the tops of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward.
  • Page 34 8.4 FRONT WHEELS REMOVAL Raise the front wheels off the ground by placing a block under the frame. Remove the front wheel nuts, washer and wheels. INSTALLATION Install and tighten the four-wheel castle nuts Torque: 40-60 N.m Remember put a cotter pin in the castle nut. 8.5 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel.
  • Page 35 Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings. BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm. Remove the brake panel from the knuckle.
  • Page 36 Install the brake arm on the cam by aligning the punch mark and the groove on the cam. Tighten the brake arm bolt and nut. Torque: 4-7 N.m Install the brake panel on the knuckle. Connect the brake cable to the brake arm. Install the brake arm cover.
  • Page 37 Last, tune the nuts of handle bar on both sides. The steps just like above. FRONT BRAKE ADJUSTMENT HANDLEBAR RIGHTSIDE BRAKE ALLOT ASSEMBLY RIGHT FRONT LEFT FRONT BRAKE BRAKE PEDAL BRAKE Any parts of brake system were replaced, or poor brake force. The adjustment should be done. The brake adjustment steps are below;...
  • Page 38 8.6 SPEEDOMETER TROUBLESHOOTING INSTRUMENT PANEL LIGHT OFF ★ BATTERY LOW/DISCHARGE ★ METER MAIN WIRE NOT CONNECTED PANEL LCD NOT DISPLAY ★ BATTERY LOW/DISCHARGE ★ ADJUST SETTINGS METER MODLE ★ BROKEN METER CABLE BROKEN METER SENSOR ★ BROKEN DRUM MAGNET ★ REMOVAL First disassemble the screws on top of the panel.
  • Page 39 The speedometer sensor is located on the back of wheel hub. Use hexagon wrench to disassemble the nut. LEFT FRONT BRAKES INSPECTION Remove the left front wheel. Remove the brake drum. Make sure the magnet steady in the drum. Install front brake drum...
  • Page 40 Install the end of meter sensor on front brake panel. Be careful, when assemble the speedometer sensor and magnetic block, there are a distance about 1mm. Please use thickness gauge to make it be in place. Tie the wires of speedometer with front brake cable. 8.7 STEERING SYSTEM REMOVAL OF KINGPIN AND TIE-ROD Remove the front wheels and brakes drum.
  • Page 41 TIE-ROD INSPECTION Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. KINGPIN INSPECTION Inspect the kingpin for damage or cracks. STEERING SHAFT REMOVAL Remove the speedometer and handle bar cover.
  • Page 42 STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks. Measure the steering shaft outer diameter in the location of the bushing. Minimum limit: Ø22.0 mm STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with finger. The bearing is on the front part of frame. The bearing should turn smoothly and quietly.

  • Page 43: Rear Wheel System

    9. REAR WHEEL SYSTEM 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 9.3 DRIVE MECHANISM 9.2 TROUBLESHOOTING 9.4 INSTALLATION 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM...
  • Page 44 9.2 TROUBLESHOOTING BAD BRAKE PERFORMANCE ★ BRAKE SHOES ARE WORN ★ BAD BRAKE ADJUSTMENT ★ BRAKE LININGS ARE OILY, GREASY OR DIRTY ★ BRAKE DISC IS WORN ★ BRAKE ARM SETTING IS IMPROPERLY ENGAGE ★ AXLE IS NOT TIGHTENED WELL VIBRATION OR WOBBLE ★...
  • Page 45 Let the rear axle lie in V-blocks and check the run out. The run out limit is 0.5 mm Check the turning of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. 9.4 INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket.

  • Page 46: Fenders And Exhaust Pipe

    10. FENDERS AND EXHAUST PIPE 10.1 FENDERS DRAWING 10.4 EXHAUST PIPE DRAWING 10.2 REAR FENDERS REMOVE 10.5 EXHAUST PIPE REMOVE 10.3 FRONT FENDER REMOVE 10.6 EXHAUST PIPE INSTALLATION 10.1 FENDERS DRAWING 10.2 REAR FENDERS REMOVE First, pull the “Seat Fixer Assembly” to take off the seat.
  • Page 47 INSIDE Last, unscrew the bolts of the footrest on both sides. Then it can take apart the front and rear fender away. 10.3 FRONT FENDER REMOVE Remove the rear fender and seat. (See 10-1 paragraph) Pull the front fender upward. Remove the handle bar assembly and handle bar cover.
  • Page 48 10.4 EXHAUST PIPE DRAWING 10.5 EXHAUST PIPE REMOVE Do not service the exhaust pipe while they are hot. You must wait at least 15 minutes after turn off the engine. You need remove the seat, rear fender and footrest plate, before you take off the exhaust pipe.

  • Page 49: Hydraulic Disc System

    11. HYDRAULIC DISC BRAKE SYSTEM 11.1 TROUBLESHOOTING 11.4 REPLACE THE BRAKE HYDRAULIC OIL 11.2 REPLACE BRAKE DISC 11.5 REAR BRAKE ADJUSTMENT 11.3 REPLACE THE BRAKE SHOE 11.1 TROUBLESHOOTING ★ Improper brake adjustment POOR BRAKE PERFORMANCE ★ Worn brake shoes ★ Brake linings oily, greasy or dirty ★...
  • Page 50 Unscrew the rear wheel axle nut and then remove the mounting seat of the disc. Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm. 11.3 REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown and remove caliper.
  • Page 51 Press the plate to the end Remove the brake shoe as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm. Press the piston to the end prior to installation of brake shoe PISTON...
  • Page 52 11.4 REPLACE THE BRAKE HYDRAULIC OIL Unscrew the bolts and open the cover. Unscrew the bolt and drain out the used oil drain. Fasten the bolt after the used oil being drained out completely. Add the brake oil (Dot 3 or Dot 4) Keep oil level at least half of the cup to avoid air get into brake system, such like caliper and tube.
  • Page 53 Fill the brake oil to the level shown on the cup when no air comes out. Assemble the cover 11.5 REAR BRAKE ADJUSTMENT HANDLEBAR LEFTSIDE BRAKE OIL RESERVOIR MASTER CYLINDER WHEEL CYLINDER PEDAL BRAKE REAR BRAKE SYSTEM When repairs some parts about rear brake system, it must be tuned in handlebar, master cylinder adjustment nut and rear brake.

  • Page 54: Electrical System

    12. ELECTRICAL SYSTEM 12.1 TROUBLESHOOTING 12.5 BATTERY CAUTION 12.2 IGNITION COIL 12.6 BATTERY INSPECTION 12.3 IGNITION TIMING 12.7 WIRING DIAGRAMS 12.4 ALTERNATOR EXCITER COIL 12.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS ★ IMPROPER IGNITION TIMING ★ FAULTY SPARK PLUG NO SPARK AT PLUG ★...
  • Page 55 12.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3Ω(20℃) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7.4 – 12 kΩ(20℃) 12.3 IGNITION TIMING The ignition advance is 17°±...
  • Page 56 12.5 BATTERY CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 57 12.7 WIRING DIAGRAMS...

  • Page 58: Trouble Shooting

    13.TROUBLESHOOTING 13.1 ENGINE DOES NOT START 13.4 LOSS POWER 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 13.5 POOR HANDLING 13.3 POOR PERFORMANCE AT HIGH SPEED 13.1 ENGINE DOES NOT START POSSSIBLE REASON N.G. CHECK FUEL FLOW TO CARBURETOR ★ No fuel In fuel tank ★...
  • Page 59 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE REASON N.G. CHECK IGNITION TIMING ★ Faulty CDI unit or pulse generator O.K. CHECK carburetor N.G. ★ Improperly adjusted air screw AIR SCREW ADJUSTMENT CHECK FOR LEAKING ★ Deteriorated insulator o-ring INTAKE PIPE ★...
  • Page 60 13.4 LOSS POWER POSSIBLE REASON RAISE WHEELS OFF GROUND DOES NOT SPIN FREELY ★ Brake dragging AND SPIN BY HAND ★ Drive chain too tight SPIN FREELY ★ Damaged wheel bearing ★ Wheel bearing needs lubrication PESSURE LOW CHECK TIRE CHECK TIRE PRESSURE ★...
  • Page 61 13.5 POOR HANDLING POSSIBLE REASON ★ Damaged steering bearing STEERING IS HEAVY ★ Damaged steering shaft bushing ONE WHEEL IS WOBBLING ★ Bent rim ★ Improperly installed wheel hub ★ Excessive wheel bearing play ★ Bent swingarm ★ Bent frame ★...

This manual is also suitable for:

Atv bxl 50Atv bxl 90Bxl 50Bxl 90Bxl 100

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