Eton ATV8F Service Manual
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Eton ATV8F Service Manual

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VECTOR 300
Service Manual
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Summary of Contents for Eton ATV8F

  • Page 1 VECTOR 300 Service Manual...

  • Page 2: Table Of Contents

    Contents 1. INFORMATION 1-1 Safety 1-2 Notes 1-3 Engine Specifications 1-4 Serial Number 1-5 Torque Values 1-6 Special Tools 2. MAINTENANCE 2-1 Maintenance Data 2-2 Maintenance Schedule 2-3 Fuel Tube 2-4 Throttle Operation 2-5 Throttle Cable Adjustment 2-6 Air Cleaner 2-7 Spark Plug 2-8 Idle Speed 2-9 Drive Chain...
  • Page 3 6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram 6-2 Precautions In Operation 6-3 Troubleshooting 6-4 Cylinder Head Removal 6-5 Cylinder Head Inspection 6-6 Valve Stem Replacement 6-7 Valve Seat Inspection And Service 6-8 Cylinder Head Reassembly 6-9 Cylinder Head Installation 6-10 Valve Clearance Adjustment 7.
  • Page 4 11. CRANKCASE / CRANK 11-1 Mechanism Diagram 11-2 General Information 11-3 Trouble Diagnosis 11-4 Disassembly Of Crankcase 11-5 Crankshaft Inspection 11-6 Assembly Of Crankcase 12. COOLING SYSTEM 12-1 Mechanism Diagram 12-2 General Information 12-3 Trouble Diagnosis 12-4 Trouble Diagnosis For Cooling System 12-5 System Test 12-6 Radiator 12-7 Water Pump...
  • Page 5 17. ELECTRICAL SYSTEM 17-1 Troubleshooting 17-2 Ignition Coil 17-3 Ignition Timing 17-4 Battery Information 17-5 Electric Starter 17-6 Light Bulbs Replacement 17-7 Instrument Pane 17-8 Wiring Diagram 18.TROUBLESHOOTING 18-1 Engine Can Not Work 18-2 Poor Performance At Low And Idle Speeds 18-3 Poor Performance At High Speed 18-4 Loss Power 18-5 Poor Handling...

  • Page 6: Information

    1. INFORMATION Safety Serial Number Notes Torque Values Engine Specifications Special Tools 1-1 Safety GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. ● CARBON MONOXIDE Never run the engine in a closed area.

  • Page 7: Engine Specifications

    1-3 Engine Specifications 4 Stroke，Single Cylinder, Water cooled Type Displacement 287.2c.c. Bore and Stroke 75 mm x 65 mm Compression 10.0:1 Maximum Hp 20ps / 6500 Maximum Torque (Nm/rpm) 24.6 Nm / 5000 Carburetor Ignition DC-CDI Starting Electric Lubrication Auto oil injection Transmission Automatic (C.V.T.

  • Page 8: Serial Number

    1-4 Serial Number The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number...

  • Page 9: Torque Values

    1-5 Torque Values STANDARD ● 5 mm bolt and nut 5 N.m (3.5 lbf.ft) ● 6 mm bolt and nut 10 N.m (7.2 lbf.ft) ● 8 mm bolt and nut 22 N.m (16 lbf.ft) ●10 mm bolt and nut 35 N.m (25 lbf.ft) ●12 mm bolt and nut 55 N.m (40 lbf.ft) ENGINE...

  • Page 10: Special Tools

    1-6 Special Tools For Frame 1. Adjustable Hook Spencer (E1105-LRA0-FT1) Purpose: Adjusting of suspension 2. Ball Joint Puller(E0205-LRA0-FT1) Purpose: Taking out the ball joint from front knuckle as repairing.
  • Page 11 For Engine 1. TACKING ACG FLY WHEEL TOOL (C1110-RB1-FT1) 2. COUNTER SHIFT IMPLEMENT (I1003-RB1-FT1) 3. ADJUST TAPPET IMPLEMENT (A4721-HMA-FT1) 4. SLEEVE OF FABRICATING TRANSMISSION SHAFT & OIL SEAL (I1202-RB1-FT1)
  • Page 12 5. SLEEVE OF FABRICATING L CRANK & OIL SEAL (I1201-HMA-FT1) 6. TAKING 6205 BRG. TOOL (I6150-6205-FT1) 7. 6205 BRG. KNOCK TOOL (I6150-6205-FT2) 8. L CRANK CASE COVER 6006 BRG. FABRICATING TOOL (I6150-6006-FT1)
  • Page 13 9. FABRICATING R CRANK CASE COVER 6201 BRG. TOOL (I6140-6201-FT1) 10. TAKING BRG. RB1 TOOL (I6150-RB1-FT1) 11. PNEUMATIC TAKING BRG. 6205 TOOL (I6150-6205-FT3) 12. TAKING TAPPET PIN TOOL (A4451-HMA-FT1)
  • Page 14 13. A S S E MBLING D R I V E S H A FT TOOL (B3411-RB1-FT1) 14. TAKING TRAN S M I S S I ON S H A FT BRG. 6305 TOOL (I6100-6305-FT1) 15. KNOCKING BRG.(6901) WATER PUMP IMPLEMENT (I1001-KJ9-FT1)
  • Page 15 16. KNOCKING WATER PUMP OIL SEAL IMPLEMENT (INSIDE) (I1205-KF0-FT1 ) 17. KNOCKING WATER PUMP OIL SEAL(IRON) IMPLEMENT (A9217-H9A-FT1) 18. TAKING & LOCKING SPECIAL NUT 36MM SLEEVE (I0202-HMA-FT1) 19. TAKING & FABRICATING IN. VALVE TOOL (A4711-HMA-FT1)
  • Page 16 20. TAKING BRG. 62040 LARGE-SIZE TOOL (I6100-6204-FT3 ) 21. ALL-PURPOSE FIXER (B2101-HMA-FT1) 22. KNOCKING BRG.(6204) IMPLEMENT (I6100-6204-FT2)

  • Page 17: 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 Shaft Holder Bushing 2-6 Air Cleaner 2-13 Toe-In 2-7 Spark Plug 2-1 Maintenance Data SPECIFICATION...

  • Page 18: Maintenance Schedule

    2-2 Maintenance Schedule The internal maintenance in the following table is based on average riding, normal conditions. Riding in unusually dusty areas, require more frequent servicing. 300KM Every Every Every Every Notes 1 Month 3 Months 6 Months 1 Year 2 Years Fuel Lines Throttle Operation...

  • Page 19: Throttle Operation

    2-4 Throttle Operation Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever.

  • Page 20: Idle Speed

    Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.8mm With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading.

  • Page 21: Brake System

    2-10 Brake System Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the brake lever free play at the end of the brake lever trip. Front Brake lever free play is 15-25 mm. Brake lever Adjustable nut Parking Brake...
  • Page 22 NOTE: The second method to adjust brake level is under the driver seat and rear brake component. In order to avoid a pre-load occurred between brake disk and lining. After all adjusting of brake system are completed, please check the small clearance between brake disk and lining.

  • Page 23: Wheels And Tires

    2-11 Wheels And Tires Inspect the tire surfaces for cuts, nails or other sharp objects. Check the each tire surface at cold tire condition. *The standard of tire pressure is 12(0.8) psi ( kgf/cm2) 2-12 Steering Shaft Holder Bushing Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage.
  • Page 24 If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m Lock Nuts...

  • Page 25: Engine Remove And Installation

    3. ENGINE REMOVE AND INSTALLATION 3-1 General Information 3-3 Engine Installation 3-2 Engine Removal 3.1 General Information ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3-2 Engine Removal Before removing engine, you need to remove all of components such as seat, front and back fender, fuel tube, exhaust pipe, carburetor cable and drive chain…etc.

  • Page 26: Engine Installation

    3-3 Engine Installation The Engine installation is essentially in the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly.

  • Page 27: Lubrication System

    4. LUBRICATION SYSTEM 4-1 Mechanism Diagram 4-5 Engine Oil Strainer Clean 4-2 Precautions In Operation 4-6 Oil Pump 4-3 Troubleshooting 4-7 Gear Oil 4-4 Engine Oil 4-1 Mechanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Oil Route Spray Lubrication...
  • Page 28 4-2 Precautions In Operation General Information: This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 1400 c.c. Change: 1200c.c. Oil viscosity SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: 750c.c.
  • Page 29 4-4 Engine Oil Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 30 4-6 Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) 。 Clip Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.
  • Page 31 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and outer rotors. Limit: 0.20 mm Check clearance between rotor side face and pump body Limit: 0.12 mm Oil Pump Re-assembly Pins Install inner and outer rotors into the pump body.
  • Page 32 Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value：0.8~1.2kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Clip Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft.
  • Page 33 4-7 Gear Oil Gear Oil Change Gear oil join bolt Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.0~1.5kgf-m Make sure that the drain bolt washer can be re-used. Add oil to specified quantity from the join hole.

  • Page 34: Fuel System

    5. FUEL SYSTEM 5-1 Mechanism Diagram 5-6 Throttle Valve 5-2 Precautions in Operation 5-7 Float Chamber 5-3 Trouble Diagnosis 5-8 Adjustment Of Idle Speed 5-4 Carburetor Remove / Install 5-9 Fuel Tank 5-5 Air Cut-Off Valve 5-10 Air Cleaner 5-1 Mechanism Diagram Fuel tank cap Fuel unit Fuel tank...
  • Page 35 5-2 Precautions In Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline.
  • Page 36 5-3 Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of Fuel level too low in float chamber ignition system ) Clogged fuel tank cap vent...
  • Page 37 5-4 Carburetor Remove / Install Removal Drain out fuel in the float chamber. Drain bolt 1 screw Loosen the choke cable fixed iron sheet screw from plate. Remove the choke cable. Choke cable Disconnect the fuel hose. Vacuum pipe Fuel pipe Release the clamp strip of air cleaner.
  • Page 38 5-5 Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. O-ring Spring Inspection Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly.
  • Page 39 5-6 Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Disconnect the throttle cable from the throttle valve and remove the valve spring. Throttle valve Remove the fuel needle clamp and fuel needle. Assembly Place the fuel needle onto the throttle valve and clip it with needle clamp.
  • Page 40 5-7 Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the fuel level plate, float pin, float and float 3 Screws valve. Float Float valve Inspection Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat Fuel level plate face for wear, dirt.
  • Page 41 Remove main jet, needle jet holder, needle jet, slow Needle jet holder Main jet jet and air adjustment screw. Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all Needle jet Slow jet the way down and note the number of turns.
  • Page 42 5-8 Adjustment Of Idle Speed Ignition cable Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Park the ATV warm up engine.
  • Page 43 5-9 Fuel Tank 4 bolts Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Caution Coupler ․Do not bend the float arm of fuel unit...
  • Page 44 5-10 Air Cleaner Clamp Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts). Installation Install the tank in the reverse order of removal.

  • Page 45: Cylinder Head/Valve

    6. CYLINDER HEAD/VALVE 6-6 Valve Stem Replacement 6-1 Mechanism Diagram 6-7 Valve Seat Inspection And Service 6-2 Precautions In Operation 6-8 Cylinder Head Reassembly 6-3 Troubleshooting 6-9 Cylinder Head Installation 6-4 Cylinder Head Removal 6-10 Valve Clearance Adjustment 6-5 Cylinder Head Inspection 6-1 Mechanism Diagram 1.0~1.4kgf-m 1.0~1.4kgf-m...
  • Page 46 6-2 Precautions In Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. Specification of CYLINDER HEAD Item Standard Limit...
  • Page 47 6-3 Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage Valve carbon deposit.
  • Page 48 6-4 Cylinder Head Removal 2 nuts Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove the thermostat. Thermostat bolts Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.
  • Page 49 Remove left crankcase cover, and turn the Timing mark Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the 2 bolts sprocket by prying chain out.
  • Page 50 Remove the 2 cylinder head mounting bolts from 4 Nuts cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. 2 bolts Gasket Remove cylinder head gasket and 2 dowel pins. Remove chain guide.
  • Page 51 Remove valve stem seals. Valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. 6-5 Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
  • Page 52 Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.10 Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm. Service Limit: Replace when it is less than 11.91 Calculate the clearance between the rocker arm shaft and the rocker arm.
  • Page 53 Valve guide 5.0 mm valve guide reamer Caution Before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer Measure and record each valve guide inner diameters. Service limit: 5.03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
  • Page 54 6-6 Valve Stem Replacement Heat up cylinder head to 100~150 ℃ with heated Valve guide driver plate or toaster. 5.0mm Caution Do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. Wear on a pair of glove to protect your hands when operating.
  • Page 55 6-7 Valve Seat Inspection And Service Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 56 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width Use 45° cutter to grind the valve seat to specified width. 60° Caution Make sure that all roughness and uneven faces 1.0mm had been ground.
  • Page 57 After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. 6-8 Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide.
  • Page 58 6-9 Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of cylinder and cylinder head.
  • Page 59 Install cam chain on to sprocket and align the Timing mark timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. 2 bolts Caution Make sure timing marks are matched. 3 bolts Install cylinder head side cover (3 bolts).
  • Page 60 Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder 4 bolts Spark plug Install and tighten spark plug Torque value: 1.0~2.0kgf-m Caution This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.
  • Page 61 6-10 Valve Clearance Adjustment Loosen Air Injection system (AI) pipe upper side bolt Caution Checks and adjustment must be performed when Timing mark the engine temperature is below 35℃. Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. Remove cylinder head side cover.

  • Page 62: Cylinder/Piston

    Contents 7. CYLINDER/PISTON 7-1 Mechanism Diagram 7-5 Piston Ring Installation 7-2 Precautions In Operation 7-6 Piston Installation 7-3 Trouble Diagnosis 7-7 Cylinder Installation 7-4 Cylinder And Piston Removal 7-1 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m...
  • Page 63 To this chapter contents 7-2 Precautions In Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. UA25A Specification Unit：mm Item Standard Limit 74.995~75.015 75.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring 0.015~0.050...
  • Page 64 7-4 Cylinder And Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
  • Page 65 Check cylinder if warp. Service limit: 0.05 mm Measure clearance between piston rings and grooves. Service Limit: Top ring: 0.09 mm ring: 0.09 mm Remove piston rings Check if the piston rings are damaged or its grooves are worn. Caution Pay attention to remove piston rings because they are fragile.
  • Page 66 Measure the outer diameter of piston pin. Service Limit: 16.96 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.064 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.
  • Page 67 To this chapter contents 7-5 Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
  • Page 68 To this chapter contents Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution Soap the residues into solvent so that the residues can be removed more easily. 7-6 Piston Installation IN mark Install piston and piston pin, and place the IN...
  • Page 69 Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。...

  • Page 70: V-Belt Driving System

    8. V-BELT DRIVING SYSTEM 8-1 Mechanism Diagram 8-5 Drive Belt 8-2 Maintenance Description 8-6 Drive Face 8-3 Trouble Diagnosis 8-7 Clutch Outer/Driven Pulley 8-4 Left Crankcase Cover 8-1 Mechanism Diagram 8.5~10.5kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m...
  • Page 71 8-2 Maintenance Description Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Drive belt and drive pulley must be free of grease. Specification Item Standard value Limit Driving belt width 24.000 mm 22.500 mm OD of movable drive face boss 29.946~29.980 mm...
  • Page 72 Clamp strips 8-4 Left Crankcase Cover Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (10 bolts) Remove 2 dowel pin and gasket. 10 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
  • Page 73 2 bolts Left crankcase cover inspection Remove 2 bolts to remove left crankcase cover bearing setting plate. 9 bolts Check bearing on left crankcase cover. Rotate bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly.
  • Page 74 Disassembly Remove 5 screws from l cover plate and remove l cover plate. 5 screws Remove 1 bolt from ratchet cover 1 bolt Remove 2 starter ratchets and 2 ratchet springs...
  • Page 75 Remove starter drive pulley and volute spring Caution If remove the volute spring from the l crank cover then its has to be replaced. Loosen the starter rope from the starter grip. Installation Install in reverse order of removal procedures Caution First before installing the drive pulley must establish 2 1/2 of the pressures transferred to...
  • Page 76 8-5 Drive Belt Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool： Tool number : SYM-2210100 Tool name: universal holder Bearing stay collar Universal holder Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
  • Page 77 Installation Caution Pull out driven face to avoid it closing. Driven face Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.
  • Page 78 8-6 Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face Movable drive face boss from crankshaft. Crankshaft Drive face boss Remove ramp plate.
  • Page 79 Inspection Weight roller The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary.
  • Page 80 With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Movable drive face Drive face boss Install movable drive face comp.
  • Page 81 8-7 Clutch Outer/Driven Pulley Clutch nut wrench Disassembly Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service...
  • Page 82 Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 3.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 97.4 mm Free length Driven pulley Check following items:...
  • Page 83 To this chapter contents Clutch weight Replacement Spring Driving plate Remove snap ring and washer, and then remove clutch weight and spring from driving plate. Caution Some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity.
  • Page 84 Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Remove inner bearing. Outer bearing Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 85 Installation of Clutch OUTER/Driven Pulley Oil seal Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Specified grease O-ring Install the movable driven face onto driven face. Movable driven face Guide pin Install the guide pin and guide pin roller.

  • Page 86: Final Driving Mechanism

    9. FINAL DRIVING MECHANISM 9-1 Mechanism Diagram - Transmission 9-5 Inspection Of Mission Mechanism Cover 9-6 Bearing Replacement 9-2 Precautions In operation 9-7 Re-assembly Of Final Driving 9-3 Trouble Diagnosis Mechanism 9-4 Disassembly Of Transmission 9-1 Mechanism Diagram - Transmission Cover...

  • Page 87: Precautions In Operation

    9-2 Precautions In operation Specification Application oil: scooter gear oil Recommended oil: KING MATE serial gear oils Oil quantity: 750c.c. (650c.c. when replacing) Torque value Gear box cover 2.6~3.0kgf-m Gear oil drain bolt 0.8~1.2kgf-m Gear oil fill bolt 3.5~4.5kgf-m Tools Special tools Bearing driver (6204): SYM-9110400...

  • Page 88: Disassembly Of Transmission

    9-4 Disassembly Of Transmission Remove gear change lever (1 bolt). 1 bolt Speedometer cable Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove 3 bolts speedometer gear box.
  • Page 89 Remove gear box cover bolts (9 bolts) and then remove the cover. 9 bolts Remove shift drum catch ball, spring and bolt. Shift drum fixed catch bolt Shift drum Remove shift spindle, shift fork shaft, shift fork and shift drum. Shift spindle Shift fork shaft and fork Reverse shaft...
  • Page 90 Remove drive shaft bearing setting plate (1 bolt). Bearing setting plate Remove the drive shaft. Special tool: Shaft protector Remove gasket and dowel pin. Caution If non- essential do not remove the drive shaft from the case upper side. If remove the drive shaft from the gear box, then its bearing and oil seal has to be replaced.

  • Page 91: Inspection Of Mission Mechanism

    9-5 Inspection Of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Check if the counter shaft is wear or damage.
  • Page 92 Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Drive shaft bearing Gear box Check bearings on gear box and gear box cover. Reverse shaft Rotate each bearing’s inner ring with fingers. bearing Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is...

  • Page 93: Bearing Replacement

    9-6 Bearing Replacement Caution Inner bearing puller Never install used bearings. Once bearing removed, it has to be replaced with new one. Crankcase side Remove drive shaft bearing setting plate, and then remove drive shaft bearing from left crankcase using following tools. Remove reverse shaft bearing and counter shaft Bearing driver bearing from left crankcase using following tools.
  • Page 94 Install drive shaft. Special tool: Drive shaft and Clutch nut wrench Drive shaft puller seal install bush Drive shaft and oil seal install bush Clutch nut wrench Drive shaft puller Apply with grease onto new drive shaft oil seal lip, Drive shaft and and then install the oil seal.
  • Page 95 Special tool: Inner bearing puller Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearing and bearing driver into gear Universal bearing puller box cover outer side. Install the universal bearing puller and bearing driver.

  • Page 96: Re-Assembly Of Final Driving Mechanism

    9-7 Re-assembly Of Final Driving Mechanism Apply with grease onto the oil seal lip of final Oil seal driving shaft. Reverse shaft Drive shaft Install counter shaft, reverse shaft and final shaft onto gear box. Final shaft Counter shaft Shift drum Install shift drum, shift fork and fork shaft onto gear box.
  • Page 97 Align the position mark on the shift spindle Position mark sprocket with that of shift drum, and then install shift spindle. Dowel pins Install dowel pins and new gasket. 9 bolts Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4kgf-m Install the shift spindle bracket, drive chain protector, speedometer gear box and gear change lever.

  • Page 98: Alternator/Starting Clutch

    10. ALTERNATOR/STARTING CLUTCH 10-1 Mechanism Diagram 10-6 Flywheel Removal 10-2 Precautions In Operation 10-7 Starting Clutch 10-3 Right Crankcase Cover Removal 10-8 Flywheel Installation 10-4 A.C.G. Set Removal 10-9 A.C.G. Set Installation 10-5 Right Cover Bearing 10-10 Right Crankcase Cover Installation 10-1 Mechanism Diagram 0.8~1.2kgf-m 1.0~1.4kgf-m...
  • Page 99 10-2 Precautions In Operation General information Refer to chapter 17: The troubleshooting and inspection of alternator Refer to chapter 17: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear 25.026~25.045 25.100 OD of starting clutch gear...
  • Page 100 10-3 Right Crankcase Cover Removal Remove left footrest. 11 bolts Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket.
  • Page 101 Check the oil seal for wear or damage. Replace it if necessary. Oil seal Install a new one bearing (6201LU) by bearing driver. Special tool: Bearing driver Bearing driver 10-6 Flywheel Removal Reduction gear Flywheel nut Remove right crankcase cover. Remove left crankcase cover.
  • Page 102 Remove starter reduction gear and shaft. Pull out flywheel with A.C.G. flywheel puller. flywheel puller Special tool: A.C.G. Flywheel puller Remove flywheel and starting driven gear. 10-7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear.
  • Page 103 Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely, but not C.W direction. (View as shown in this figure.) One way clutch removal Starting driven gear Remove starting driven gear.
  • Page 104 One way clutch Installation Install the components in the reverse procedures 3 socket bolts of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Starting driven gear Install starting driven gear. 10-8 Flywheel Installation Groove Align the key on crankshaft with the flywheel groove, and then install the flywheel.
  • Page 105 Install reduction gear shaft and reduction gear. Reduction gear Wire 2 bolts 10-9 A.C.G. Set Installation Install the A.C.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase.
  • Page 106 Install right crankcase cover (11 screws). Install the dowel pin, new gasket and water pump 11 bolts cover onto crankcase cover. Water pump cover bolts Connect water hoses to the right crankcase cover and water pump cover.
  • Page 107 11. CRANKCASE / CRANK 11-1 Mechanism Diagram 11-4 Disassembly Of Crankcase 11-2 General Information 11-5 Crankshaft Inspection 11-3 Trouble Diagnosis 11-6 Assembly Of Crankcase 11-1 Mechanism Diagram 1.0~1.4kgf-m 0.8~1.2kgf-m 0.8~1.2kgf-m Eng. Oil drain bolt 3.5~4.5kgf-m...

  • Page 108: General Information

    11-2 General Information Operational precautions This Section concerns disassembly of the crankcase for repair purpose. Remove following components before disassembling crankcase. －Engine remove Section 5 －Cylinder head Section 6 －Cylinder and piston Section 7 －Drive face and driven pulley Section 8 －AC generator/Start one way clutch Section 10 In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing...

  • Page 109: Disassembly Of Crankcase

    11-4 Disassembly Of Crankcase Tensioner Remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Cam chain setting plate Loosen 2 bolts on the right crankcase. 2 bolts 11 bolts Loosen 11 bolts on the left crankcase. Place right crankcase downward and left crankcase Tap the left crankcase with a plastic hammer to remove it.
  • Page 110 Remove balance shaft from right crankcase. Balance shaft Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping.

  • Page 111: Crankshaft Inspection

    11-5 Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions.

  • Page 112: Assembly Of Crankcase

    Check bearings on right and left crankcase. Balance shaft bearings Rotate each bearings inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 113 Install 2 dowel pins and new gasket. Dowel pins Install the left crankcase onto the right crankcase. 11 bolts Tighten 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m 2 bolts...
  • Page 114 Clean the crankshaft. Apply a layer of grease on the lip of oil seal, Puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. Oil seal By oil seal driver (27×42×7), oil seal will knock into driver located.

  • Page 115: Cooling System

    12. COOLING SYSTEM 12-1 Mechanism Diagram 12-5 System Test 12-2 General Information 12-6 Radiator 12-3 Trouble Diagnosis 12-7 Water Pump 12-4 Trouble Diagnosis For Cooling System 12-8 Thermostat 12-1 Mechanism Diagram Radiator filler cap Reserve tank By-pass pipe To cylinder head Coolant outlet pipe Radiator Cooling fan...
  • Page 116 12-2 General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. Refill the radiator with distilled water or specified additives.
  • Page 117 12-4 Trouble Diagnosis For Cooling System The temperature indicated is too high A. Stop and waiting for the A1.Refill the radiator with engine is completely coolant then check for any Water leaking problem cooled down, open cap to leakage? check the capacity of coolant in radiator.
  • Page 118 Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch and inspect cooling fan was to confirm voltage be Replace thermal switch operating after the changed (12→0V)? temperature gauge over 3 checks? E-2. Connect cooling fan F. Confirm the cooling fan was terminals with battery Replace cooling fan convulsion?
  • Page 119 12-5 System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low. The specified pressure shall be maintained at least for 6 seconds in the test Relief pressure for the filler cap: 0.9-0.15 kgf/cm...
  • Page 120 Check reserve tank Remove the front center cover, and then remove reserve tank filler cap. Check the liquid level in the front fender right side. Add coolant to proper level if too low. Reinstall the reserve tank filler cap. Upper Caution The reserve tank liquid level coca too is not high, Lower...
  • Page 121 Loosen the radiator 4 bolts. Coolant inlet pipe Remove coolant upper side pipes. 4 bolts Coolant outlet pipe Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. Thermo switch coupler Disassembly Loosen the 3 bolts from the fan duct, and then remove the Cooling fan...
  • Page 122 12-7 Water Pump Check water pump seal / cooling system divulges inspection Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
  • Page 123 Check any wear and damage of the mechanical seal and Mechanical seal inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Replacement of Mechanical Seal Water pump bearing driver Remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase.
  • Page 124 Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Water pump bearing Install a new outside bearing to the right crankcase cover. driver (6901) Special tools: Water pump bearing driver (6901) Caution Do not reuse old bearing.
  • Page 125 Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal. Water pump rotor Install the rotor onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m Caution The rotor is left thread. Install the dowel pin and right cover gasket. The rotation water pump rotor, causes the water pump drive shaft scoop channel, aligns the oil pump drive shaft flange, install the right crank case.
  • Page 126 12-8 Thermostat Temperature sensor By-pass pipe Please refer to chapter 17 for inspection of temperature sensor. Removal Drain out the coolant. Remove the thermostat set. (2 bolts) 2 Bolts Inspection Visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation.

  • Page 127: Steering And Suspension

    13. STEERING AND SUSPENSION 13-1 Parts Drawing 13-4 Throttle Housing 13-2 Troubleshooting 13-5 Steering System 13-3 Handlebar 13-1 Parts Drawing Steering Handle bar...

  • Page 128: Troubleshooting

    13-2 Troubleshooting ★ Faulty tire HARD STEERING ★ Steering shaft holder too tight ★ Insufficient tire pressure ★ Faulty steering shaft bushing ★ Damaged steering shaft bushing ★ Faulty tire FRONT WHEEL WOBBLING ★ Worn front brake drum bearing ★ Bent rim ★...
  • Page 129 Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Bolts Screws Remove the handle cover and instrument panel by four screws at right and left side as shown in picture. Screws Remove the bolts attaching the handlebar upper holder. Remove the handlebar.
  • Page 130 INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch marks match with the top end of the handlebar of lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts.

  • Page 131: Throttle Housing

    13-4 Throttle Housing DISASSEMBLY Loosen the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. NOTE: Assembly is in the reverse order of disassembly. Screws 13-5 Steering System When the steering shaft needs to be repaired, you need to remove three kinds of components: the tie-rods, front wheels...
  • Page 132 Step 1 Tie-rod Inspection Inspecting the tie-rod for damage or bending. Inspecting the ball joint rubbers for damage, wearing or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. Steering Shaft Removal Remove the handle bar cover and handle bar. (See Chapter 13-3) Remove the front fender.
  • Page 133 Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50 N.m (37 lbf.ft)

  • Page 134: Front Wheel And Brake System

    14. FRONT WHEEL AND BRAKE SYSTEM 14-1 Parts Drawing 14-4 Hydraulic Brake 14-2 Troubleshooting 14-5 Suspension Adjustment 14-3 Front Wheels 14-1 Parts Drawing FRONT WHEEL FRONT BEAKE...

  • Page 135: Troubleshooting

    14-2 Troubleshooting ★ Faulty tire HARD STEERING ★ Insufficient tire pressure ★ Faulty tire FRONT WHEEL WOBBLING ★ Worn front brake drum bearing ★ Bent rim ★ Axle nut not tightened properly ★ Incorrect brake adjustment BRAKE DRAG ★ Sticking brake cable ★...

  • Page 136: Hydraulic Brake

    14-4 Hydraulic Brake This type of brakes are applying in front of two wheels of REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures.
  • Page 137 Wheel hub Before loosening castle nut, you have to remove cotter pin Castle nut Then using the power tools to take the screw out from brake stopping plate. You can take the brake disc off. When change brake shoe wear, you must push the master piston to rearward.
  • Page 138 ADD BRAKE OIL The brake oil tank is under the driver seat at right hand side. Please check the brake oil level position at outside of tank. To open the cap of brake oil tank, please turn “CCW” direction. Brake oil tank...

  • Page 139: Suspension Adjustment

    14-5 Suspension Adjustment Suspension system in this type of AVT can be adjustable its hardness and softness (fig 1). 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner, E1105-LRA0-FT1 ) to adjust the suspension.

  • Page 140: Rear Wheel And Brake System

    15. REAR WHEEL AND BRAKE SYSTEM 15-1 Parts Drawing 15-3 Remove Rear Wheel And Rear Brake 15-2 Troubleshooting 15-4 Swingarm & Rear Axle Holder 15-5 Suspension Adjustment 15-1 Parts Drawing REAR WHEEL REAR Wheel Axel...
  • Page 141 REAR BRAKE...

  • Page 142: Troubleshooting

    15-2 Troubleshooting ★ Brake shoes are worn Bad Brake Performance ★ Bad brake adjustment ★ Brake linings are oily, greasy or dirty ★ Brake drums are worn ★ Brake arm setting is improperly engage ★ Axle is not tightened well Vibration or Wobble ★...
  • Page 143 Loosen two bolts to take out rear brake disk as shown in picture. Bolts Loosen bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE To replace the brake shoe, please loosen this bolt as shown in picture.
  • Page 144 Eventually, you can take all brake shoe out the hub. There are two kind of brake linings as shown in picture TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open the cover Loosen the bolt and drain the used oil out. Tighten the bolt after the used oil being drained out completely Bolt...

  • Page 145: Swingarm & Rear Axle Holder

    15-4 Swingarm & Rear Axle Holder This section is to introduce how to repair the swing-arm, The following pictures are going to teach you how to Install the swing-arm. 1. Put the swingarm at proper position as shown in picture. Two hanger bolts will be used to hold the swing-arm at right and left side.
  • Page 146 3. Screw another hanger bolt on the left side as shown in picture. But do not tighten it. Let the cross-section of bolt and cross-section of hole in the same plane nearly. Hanger bolt 4. Tighten the nut NOTE: If you make a wrong assembly procedure, it will cause: 1.

  • Page 147: Suspension Adjustment

    15-5 Suspension Adjustment Suspension system in this type of AVT can be adjustable its hardness and softness (fig 1). 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner) to adjust the suspension.

  • Page 148: Fenders And Exhaust Pipe

    16. FENDERS AND EXHAUST PIPE 16-1 Fenders Drawing 16-3 Front Fender Removal 16-2 Rear Fenders Removal 16-4 Exhaust Pipe Removal 16-1 Fenders Drawing EXHAUST PIPE (For all serials)

  • Page 149: Rear Fenders Removal

    16-2 Rear Fenders Removal There are two seat release bars located at the right and left hand side of the seat. Please remove the seat first. Release Bars Procedures of remove the rear fender: Remove the rear rack. 1. Open the seat. 2.
  • Page 150 There are two screws on the top of seat compartment. Bolts Please remove them. Next, there are two screws on side of the tail. Screw Bolts Finally, you must remove the bolts on the footrest.

  • Page 151: Front Fender Removal

    16-3 Front Fender Removal To remove the front fender, there are sever trips to indicate users how to remove it. 1. First picture shows there are two screw, loosen it. Screws Remove the mounting bolts from the front fender. Bolts Please remove the two screws on the top of the headlight.

  • Page 152: Exhaust Pipe Removal

    Screws 16-4 Exhaust Pipe Removal You must wait at least 15 minutes after stopping the engine. You need to remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Loosen the two exhaust pipe bolts that fixed on the engine. Warning：DO NOT service the exhaust pipe while they are hot.
  • Page 153 Bolt EXHAUST PIPE INSTALLATION Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30 N.m (22 lbf.ft) CATUATION: After installing, make sure that there are no exhaust leaks.

  • Page 154: Electrical System

    17. ELECTRICAL SYSTEM 17-1 Troubleshooting 17-5 Electric Starter 17-2 Ignition Coil 17-6 Light Bulbs Replacement 17-3 Ignition Timing 17-7 Instrument Pane 17-4 Battery Information 17-8 Wiring Diagram 17-1 Troubleshooting ★ IMPROPER IGNITION TIMING ENGINE STARTS BUT STOPS ★ FAULTY SPARK PLUG ★...

  • Page 155: Ignition Coil

    17-2 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℃) 17-3 Ignition Timing The ignition advance is 15°±...

  • Page 156: Electric Starter

    CHARGING Firstly, connect the charged positive cable to the battery positive terminal. Secondly, connect the charged negative cable to the battery negative terminal. Using 0.9A-charging current about 11 hours. (Normal charging) Or using 4A-charging current about 3 hour. (Quick charging) Keep flames and sparks away from a battery being charged.
  • Page 157 After loosen these three screws, users can find a connector. Please disjoin the connector in order to replace an electrical bulb conveniently and safely. The steps show on pictures. Installation is in the reverse order of disassembly. Screws TAILLIGHT The taillight combines a position and a rear brake light. Normally, when users switch the key to “ON”...
  • Page 158 Please rotate the electrical bulb, and then it could be removed. Screws Rear Direction lights remove The same disassembling procedure like front direction light. Please use the pliers to remove the seat. Then the bubble could be see and replaced. Rear Brake Lights...

  • Page 159: Instrument Pane

    17-7 Instrument Pane The instrument panel includes fuel gauge, speed meter, water Temperature gauge, right and left turn signal, trip do-meter, and indicator camp. A LCD is used on ATV8E’s instrument panel to display all driving information for users. Therefore, this is an all-in-one instrument panel.
  • Page 160 Cable...

  • Page 161: Wiring Diagram

    17-8 Wiring Diagram...

  • Page 162: Troubleshooting

    18.TROUBLESHOOTING 18-1 Engine Can Not Work 18.4 Loss Power 18.2 Poor Performance At Low And Idle Speeds 18.5 Poor Handling 18.3 Poor Performance At High Speed 18-1 Engine Can Not Work Possibility N.G. CHECK FUEL FLOW TO CARBURETOR ★ No fuel In fuel tank ★...

  • Page 163: Poor Performance At Low And Idle Speeds

    18.2 Poor Performance At Low And Idle Speeds Possibility 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 Loose carburetor O.K.

  • Page 164: Loss Power

    18-4 Loss Power Possibility 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 CHECK TIRE PRESSURE ★...

  • Page 165: Poor Handling

    18-5 Poor Handling Possibility STEERING IS HEAVY ★ Damaged steering bearing ★ Damaged steering shaft bushing ONE WHEEL IS WOBBLING ★ Bent rim ★ Improperly installed wheel hub ★ Excessive wheel bearing play ★ Bent swingarm ★ Bent frame ★ Swing arm pivot bushing excessively ★...

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Vector 300Vsl-300st

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