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Eton VECTOR ST 250 Service Manual

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1.Information................................................................2
2.Maintenance...............................................................6
3.Engine Removal & Installation.....................................14
4. Lubrication System...................................................16
5. Fuel System.............................................................23
6. Cylinder HEAD & Cylinder Valve.................................34
7. Cylinder & Piston......................................................50
8. V-Belt driving system................................................58
9. Transmission............................................................72
10. ACG & Start one way clutch......................................84
11. Crankcase & Crank..................................................93
12. Cooling System.....................................................101
13.Steering & Suspension..............................................113
14. Front Wheel & Brake System..................................121
15. Rear Wheel & Brake System...................................127
16. Fenders & Exhaust Pipe.........................................136
17. Electrical System..................................................142
18. Trouble Shooting..................................................151
CONTENTS
ENGINE
CHASSIS
1

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Summary of Contents for Eton VECTOR ST 250

  • Page 1 CONTENTS GENERAL INFORMATION 1.Information…………………………………………………….…2 2.Maintenance………………………………………………….…..6 3.Engine Removal & Installation…………………………..…..14 ENGINE 4. Lubrication System……………………………………………16 5. Fuel System…………………………………………………….23 6. Cylinder HEAD & Cylinder Valve……………………….…..34 7. Cylinder & Piston…………………….………………………..50 8. V-Belt driving system…………………………………………58 9. Transmission…………………………………………………...72 10. ACG & Start one way clutch………………………………..84 11. Crankcase & Crank…………………………………………..93 12.

  • Page 2: Information

    1. INFORMATION SAFTY SERIAL NUMBER NOTES TORQUE VALUE SPECIFICATION 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. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
  • Page 3 Compression 10.6:1 Maximum Hp 19ps / 5600 Maximum Torque (Nm/rpm) 22.3 Nm / 5500 Carburetor Ignition DC-CDI Starting Electric Lubrication Auto oil injection Transmission Automatic (C.V.T. V-belt + Reverse) CHASSIS Overall Length 1815mm Overall Width 1062mm Overall Height 1130mm Wheel base 1193mm Ground Clearance 150mm...
  • Page 4 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. Side Frame serial number Engine serial number Frame serial number...
  • Page 5 1.5 TORQUE VALUES STANDARD ¡ ´ 5 mm bolt and nut 5 N.m (3.5 lbf.ft) 10 N.m (7.2 lbf.ft) ¡ ´ 6 mm bolt and nut ¡ ´ 8 mm bolt and nut 22 N.m (16 lbf.ft) 35 N.m (25 lbf.ft) ¡...

  • Page 6: Maintenance

    2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBLE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES 2.5 THROTTLE CABLE AJUSTMENT 2.12 STEERING SYSTEM 2.6 AIR CLEANER 2.13 TOE-IN 2.7 SPARK PLUG 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG...
  • Page 7 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 1000KM 3000KM 6000 KM 12000KM 1 Month 3 Months 6 Months 1 Year 2 Years Fuel Lines...
  • Page 8 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 9 2.7 SPARK PLUG This spark plug is located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the condition of spark plug electrodes 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. Please use special chain oil to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for any possible wearing or damaging. Replace the chain, if it is worn excessively or damaged.
  • Page 11 Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 15-25 mm. Adjustment Brake level NOTE: The second method to adjust brake level is under the driver seat and rear brake component.
  • Page 12 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. 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 13 Carefully to move the vehicle back, let the wheels turn 180 degree, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod...
  • Page 14 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 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 15 Hanger bolt 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 16: 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 17: Troubleshooting

    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 18: Engine Oil Change

    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 19 4-6 Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) ¡ C 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 20 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 Pins Oil Pump Re-assembly Install inner and outer rotors into the pump body.
  • Page 21 Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value¡ G 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 22 4-7 Gear Oil Gear oil join bolt Gear Oil Change 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.

  • Page 23: 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 24 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 25 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 ignition Fuel level too low in float chamber system ) Clogged fuel tank cap vent...
  • Page 26 5-4 Carburetor Remove / Install Removal Drain out fuel in the float chamber. Drain bolt Loosen the choke cable fixed iron sheet screw 1 screw from plate. Remove the choke cable. Choke cable Vacuum pipe Fuel pipe Disconnect the fuel hose. Release the clamp strip of air cleaner.
  • Page 27 5-5 Air Cut-Off Valve 2 screws Disassembly Remove 2 screws. Remove air cut-off valve cover, spring and valve. O-ring Spring Air cut-off valve Cover 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 28 5-6 Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Throttle valve Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Spring Assembly Place the fuel needle onto the throttle valve and Needle clamp...
  • Page 29 5-7 Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. 3 Screws Float Remove the fuel level plate, float pin, float and Float valve float valve. Fuel level plate Inspection Check float valve and valve seat for damage, blocking.
  • Page 30 Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns. Does not turn adjust screw forcefully to avoid damaging valve seat face.
  • Page 31 5-8 Adjustment of Idle Speed Parking brake Caution Air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. The parking brake must be used to stop the ATV to perform the adjustments.
  • Page 32 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 £...
  • Page 33 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 34 6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram 6-6 Valve Stem Replacement 6-2 Precautions in Operation 6-7 Valve Seat Inspection and Service 6-3 Troubleshooting 6-8 Cylinder Head Reassembly 6-4 Cylinder Head Removal 6-9 Cylinder Head Installation 6-5 Cylinder Head Inspection 6-10 Valve Clearance Adjustment 6-1 Mechanism Diagram 1.0~1.4kgf-m 1.0~1.4kgf-m...
  • Page 35 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 36 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 37 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 bolts thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner.
  • Page 38 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 sprocket by prying chain out. 2 bolts Cam shaft setting plate Remove cam shaft setting plate (1 bolt).
  • Page 39 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 40 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 41 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 mm. 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 mm.
  • Page 42 Valve guide Caution 5.0 mm valve guide reamer 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 43 6-6 Valve Stem Replacement Heat up cylinder head to 100~150 ¢ J with heated Valve guide driver 5.0mm plate or toaster. 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 44 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 45 Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm Caution Make sure that all roughness and uneven faces had been ground.
  • Page 46 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 Valve spring retainer Lubricate valve stem with engine oil, and then Valve stem seal insert the valve into valve guide.
  • Page 47 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 48 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. Caution 2 bolts Make sure timing marks are matched. Install cylinder head side cover (3 bolts).
  • Page 49 Install Air Injection system (AI) pipe. (4 bolts) 4 bolts Spark plug Install inlet pipe onto cylinder 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...
  • Page 50 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 51 7-2 Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification of CYLINDER Item Standard Limit 70.995~71.015 71.100 Cylinder Bend 0.050 Top ring 0.015~0.050 0.090 Clearance between piston rings ring 0.015~0.050 0.090 Top ring...
  • Page 52 7-4 Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Coolant hose 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 53 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 54 Measure the outer diameter of piston pin. Service Limit: 17.00 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.02 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.
  • Page 55 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. Make sure that all piston rings can be rotated freely after installed.
  • Page 56 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 57 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 58: 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 5.0~6.0kgf-m 8.5~10.5kgf-m 5.0~6.0kgf-m...
  • Page 59 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 of V-BELT SYSTEM Item Standard value (mm) Limit (mm) Driving belt width 24.000 22.500...
  • Page 60 8-4 Left Crankcase Cover Clamp strips Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket. 9 bolts Left crankcase cover install Install left crankcase cover in the reverse procedures of removal.
  • Page 61 Left crankcase cover inspection Clamp strips Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket. 9 bolts...
  • Page 62 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¡ G universal holder Hold clutch outer with universal holder, and Bearing stay collar Universal holder remove nut, bearing stay collar and clutch outer. Caution Using special service tools for tightening or loosening the nut.
  • Page 63 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 64 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. Drive face boss Crankshaft Remove ramp plate.
  • Page 65 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 66 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 67 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 68 Clutch lining Clutch lining Measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm Clutch weight Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 83.2 mm Free length Driven pulley Check following items:...
  • Page 69 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. Snap ring Clutch weight Check if shock absorption rubber is damage or...
  • Page 70 Install snap ring and mounting plate onto setting pin. Snap ring Replacement of Driven Pulley Bearing Outer bearing Remove inner bearing. Clipper Caution If the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly.
  • Page 71 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 Oil seal...

  • Page 72: Transmission

    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 Reverse shaft Gear oil fill bolt 3.5~4.5kgf-m...
  • Page 73 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 74 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 speedometer gear box.
  • Page 75 Remove gear box cover bolts (9 bolts) and then 9 bolts remove the cover. 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 76 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 77 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 78 Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. Drive shaft bearing Gear box Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and Reverse shaft silent, and also check if bearing outer ring is...
  • Page 79 9-6 Bearing Replacement Inner bearing puller Caution 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 from left crankcase using following tools.
  • Page 80 Install drive shaft. Drive shaft and Clutch nut wrench Special tool: seal install bush Drive shaft puller 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 seal install bush and then install the oil seal.
  • Page 81 Remove final shat out side bearing. Inner bearing puller Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal Install new bearing and bearing driver into gear Universal box cover outer side. bearing puller Install the universal bearing puller and bearing driver.
  • Page 82 9-7 Re-assembly of Final Driving Oil seal Mechanism Apply with grease onto the oil seal lip of final 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 83 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 84: Table Of Contents

    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 85 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 86: A.c.g. Set Removal

    10-3 Right Crankcase Cover 11 bolts Removal Remove left footrest. 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 87: Flywheel Removal

    Check the oil seal for wear or damage. Replace Oil seal it if necessary. 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 88: Starting Clutch

    Remove starter reduction gear and shaft. flywheel puller Pull out flywheel with A.C.G. 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 89 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 90: Flywheel Installation

    One way clutch Installation 3 socket bolts Install the components in the reverse procedures 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. Groove 10-8 Flywheel Installation Align the key on crankshaft with the flywheel groove, and then install the flywheel.

  • Page 91: Right Crankcase Cover Installation

    Install reduction gear shaft and reduction gear. Reduction gear 10-9 A.C.G. Set Installation Wire 2 bolts 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 92 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 93 11. CRANKCASE / CRANK 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 94: General Information

    11-2 General information Operational precautions This Section concerns disassembly of the crankcase for repair purpose. Remove following components before disassembling crankcase. ¡ Ð Engine remove Section 5 ¡ Ð Cylinder head Section 6 ¡ Ð Cylinder and piston Section 7 ¡...
  • Page 95 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 up.
  • Page 96 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 97 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 98 Check bearings on right and left crankcase. Rotate each bearings inner ring with fingers. Balance shaft bearings 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 99 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 100 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. By oil seal driver (27×42×7), oil seal will knock into Oil seal located.

  • Page 101: 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 102 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 103 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 104 Preceding page E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to and inspect cooling fan was 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 105 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.
  • Page 106 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 107 Loosen the radiator 4 bolts. Coolant inlet pipe Remove coolant upper side pipes. 4 bolts Remove coolant outlet pipe. 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 Cooling fan...
  • Page 108 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 109 Check any wear and damage of the mechanical Mechanical seal seal and inside seal. Caution The mechanical seal and inside seal must be replaced as a unit. Replacement of Mechanical Seal Water pump bearing Remove the inside bearing by inner bearing puller. driver Drive the mechanical seal and inner seal out of the right crankcase.
  • Page 110 Install the new inner seal onto the right crankcase. Water pump oil seal Special tools: driver (inner) Water pump oil seal driver (inner) Install a new outside bearing to the right Water pump bearing crankcase cover. driver (6901) Special tools: Water pump bearing driver (6901) Caution Do not reuse old bearing.
  • Page 111 Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and Water pump rotor 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 112 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 113 13. STEERING AND SUSPENSION 13.1 PARTS DRAWING 13.4 THROTTLE HOUSING 13.2 TROUBLESHOOTING 13.5 STEERING SYSTEM 13.3 HANDLENAR 13.1 PARTS DRAWING STEERING...
  • Page 114 Handle bar...
  • Page 115 13.2 TROUBLESHOOTING HARD STEERING ¡ ¹ Faulty tire ¡ ¹ Steering shaft holder too tight ¡ ¹ Insufficient tire pressure ¡ ¹ Faulty steering shaft bushing ¡ ¹ Damaged steering shaft bushing FRONT WHEEL WOBBLING ¡ ¹ Faulty tire ¡ ¹ Worn front brake drum bearing ¡...
  • Page 116 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 117 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 118 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 Removal of Kingpin and Tie-rod...
  • Page 119 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. Steering Shaft Removal Remove the handle bar cover and handle bar. (See section 8-3) Remove the front fender.
  • Page 120 Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50 N.m (37 lbf.ft)
  • Page 121 14. FRONT WHEEL AND BRAKE SYSTEM 14.1 PARTS DRAWING 14.4 HYDRAULIC BRAKE 14.2 TROUBLESHOOTING 14.5 SUSPENSION SYSTEM 14.3 FRONT WHEEL .1 PARTS DRAWING FRONT WHEEL FRONT BEAKE...
  • Page 122 14.2 TROUBLESHOOTING Faulty tire ¡ ¹ ¡ ¹ Insufficient tire pressure HARD STEERING ¡ ¹ Faulty tire ¡ ¹ Worn front brake drum bearing FRONT WHEEL WOBBLING ¡ ¹ Bent rim ¡ ¹ Axle nut not tightened properly ¡ ¹ Incorrect brake adjustment ¡...
  • Page 123 .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 124 After disassembling the wheel, please inspect the disk plate. Wheel hub If the disk plate needs to be changed, you have to loosen castle nut to take wheel hub apart. 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.
  • Page 125 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 126 .5 SUSPENSION SYSTEM Suspension system in this type of AVT can be adjustable. There are two ways to adjust suspension: 1. You can raise the all ATV body up by using a repair platform. The four wheel are in the free position, you can easy to adjust the suspension.
  • Page 127 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 15.1 PARTS DRAWING REAR WHEEL REAR Wheel Axel...
  • Page 128 REAR BRAKE...
  • Page 129 15.2 TROUBLESHOOTING ¡ ¹ Brake shoes are worn Bad Brake Performance ¡ ¹ Bad brake adjustment ¡ ¹ Brake linings are oily, greasy or dirty ¡ ¹ Brake drums are worn ¡ ¹ Brake arm setting is improperly engage ¡ ¹ Axle is not tightened well Vibration or Wobble ¡...
  • Page 130 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 131 Please push the plate back to take a shoe out as shown in picture Plate Eventually, you can take all brake shoe out the hub. Piston 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.
  • Page 132 (Dot 3 or Dot 4) Add the brake oil Keep oil level at least half of the cup in order to avoid air in the brake system. Loosen the bolt to vent the air from brake system. Tighten the bolt if there isn’t any air in the brake system Tighten torque 40~70kgf-cm Pull left brake lever slightly in order to extract air from brake system...
  • Page 133 15.4 SWINGARM & REAR AXLE HOLDER This section is to introduce how to repair the swingarm, The following pictures are going to teach you how to Install the swingarm. 1. Put the swingarm at proper position as shown in picture. Two hanger bolts will be used to hold the swingarm at right and left side.
  • Page 134 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. Hanger bolt 4. Tighten a nut...
  • Page 135 Suspension adjustment Suspension system in this type of AVT can be adjustable its height. There are two ways to adjust suspension: 1. You can raise the all ATV body up by using a repair platform. The four wheel are in the free position, you can easy to adjust the suspension.

  • Page 136: Table Of Contents

    16. FENDERS AND EXHAUST PIPE 16.1 FENDRES 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 137: 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 138 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 139: 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 140: Exhaust Pipe Removal

    Screws 16.4EXHAUST 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¡...
  • Page 141 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 142: Troubleshooting

    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 PANEL 17.4 BATTERY INFORMATION 17.8 WIRING DIAGRAM 17.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS ¡ ¹ IMPROPER IGNITION TIMING ¡ ¹ FAULTY SPARK PLUG NO SPARK AT PLUG ¡...
  • Page 143 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 - 0.3£ [ (20¢ J ) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7.4 –...
  • Page 144 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 145 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 Front Direction lights remove To replace the direction lights must loosen the screws as shown in picture.
  • Page 146 Front position light removes There are two screws inside the cap. Please disassemble first then push the cap upward. You could replace the electrical bulb. Front position light Turn around the cap, you could see the connector. Turn the seat to replace the electrical bulb TAILLIGHT The taillight combines a position and a rear brake light.
  • Page 147 Rear Brake lights remove On the back of the brake light, you could see the cap. There are two screws to fix this cap, loosen them can open the cap. Please rotate the electrical bulb, and then it could be removed. Screws Rear Direction lights remove The same disassembling procedure like front direction light.
  • Page 148 17.7 Instrument Panel 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 150 12.8 WIRING DIAGRAM...

  • Page 151: Trouble Shooting

    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 ¡ ¹ No fuel In fuel tank ¡...
  • Page 152 18.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS Possibility N.G. CHECK IGNITION TIMING ¡ ¹ Faulty CDI unit or pulse generator O.K. CHECK carburetor N.G. ¡ ¹ Improperly adjusted air screw AIR SCREW ADJUSTMENT CHECK FOR LEAKING ¡ ¹ Deteriorated insulator o-ring INTAKE PIPE ¡...
  • Page 153 18.4 LOSS POWER Possibility RAISE WHEELS OFF GROUND DOES NOT SPIN FREELY ¡ ¹ Brake dragging AND SPIN BY HAND ¡ ¹ Drive chain too tight SPIN FREELY ¡ ¹ Damaged wheel bearing ¡ ¹ Wheel bearing needs lubrication PESSURE LOW CHECK TIRE CHECK TIRE PRESSURE ¡...
  • Page 154 18.5 POOR HANDLING Possibility STEERING IS HEAVY ¡ ¹ Damaged steering bearing ¡ ¹ Damaged steering shaft bushing ONE WHEEL IS WOBBLING ¡ ¹ Bent rim ¡ ¹ Improperly installed wheel hub ¡ ¹ Excessive wheel bearing play ¡ ¹ Bent swingarm ¡...

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