ATV ATV110-M Service Manual
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ATV ATV110-M Service Manual

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  • Page 2 BRIEF INTRODUCTION TO FOUR-WHEELED CROSS-COUNTRY VEHICLE MODEL ATV110-M Four-wheeled cross -country vehicle, model ATV110-M is a full road condition vehicle which can be driven on every kinds of road conditions such as sand beach, grassland, forest, village,construction site country road , This maintenance manual of four-wheeled vehicle model ATV110-M (Hereafter called cross -country vehicle for short) compiled by Chongqing Indus- tries Co., Ltd is specially provided for saler and technical staff of our Group.

  • Page 3: Table Of Contents

    Section 8 Lubrication .......................... 16 Section 9 Lubrication point and type of lubricants ................17 (1) Lubrication point and type of lubricants(ATV body) ............17 (2) Lubrication point and type of lubricants(Engine) ............... 18 Chapter II Maintenance and adjustment of vehicle ................19 Section 1 Periodic maintenance/ lubrication ..................
  • Page 4 Section 3 Maintenance and adjustment of vehicle body ..............26 (I) Wear inspection of front and rear brake ................26 (II) Adjustment of front brake ....................26 (III)Adjustment of free clearance of left lever and rear brake pedal ......... 27 (IV) Inspection of steering system ..................
  • Page 5 Section 8 Inspection of lighting system ..................... 85 Chapter V Engine ..........................86 Section 1 Disassembly of engine ....................... 86 (I) Remove the engine from finished ATV ................86 (II) Disassembly of engine ...................... 88 section 2 Inspection and maintenance of engine ................96 Chapter VI Vecicle ordinary trouble and its judgement ..............
  • Page 6 (III) Poor middle and high speed performance ................ 117 (IV) Shifting troubler ....................... 117 (V) Clutch slips ........................118 (VI) Clutch is locked ....................... 118 (VII) Engine is overheat ......................118 (VIII) Brake trouble ......................... 118 (IX) Shock absorber failure/improper operation ..............118 (X) Lighting system ........................

  • Page 7: Chapter I General Description

    11. Left lever of rear brake 12. Left switch unit 13. Fuel tank cover 14. Throttle grip 15. Right lever of front brake Caution: The ATV you purchased maybe slightly differ from the pictures in the manual due to im- provement or other changement.

  • Page 8: Section 2 Special Tools, Instruments & Meters

    Section 2 Special tools, instruments and meters (I) Special tools Special tools is the necessary tools used for accurately adjustment and assembly, it is helpful to prevent the maintenance defects and components damage caused by using improper tools. 1.Wrench for valve adjustment mainly used for adjusting valve clearance. Specification: 3mm 90890-01311 2.Puller for piston pin, mainly used of removing pistion pin.

  • Page 9: (Ii) Instruments & Tools

    (II) Instruments and meters The following instruments and meters can be selected with reference to the same type of vehicle. speedometer of engine multimeter (90890-03113) Ignition timing meter spark tester of spark plug (90890-03141) barometer ignition checker measuring tool of gasoling dial indicator (90890-01312)

  • Page 10: Section 3 Identification Code, Label Of Model And Engine No

    3.1 When disassembling to maintain the of each other when operation with other people. engine, in order to ensure that the reassembled 1.4 When disassembling the ATV, put the engine have good sealing and connecting part is mated components, such as gear pairs, cylinder, fixed and reliable, all the oil seal, shim, o-ring, piston and other “mated”...
  • Page 11 4. Clip 4.1Before assembling, be sure to check all the clips carefully.Use a new one after remov- ing the clip of piston pin. When mounting clip ring ¢Ùmake the sharp face ¢Úon the opposite position of impacted face ¢Ûof clip.(see left fig) 5.Locking washer /shim and location pin 5.1When reassembling after disassembling.
  • Page 12 7.Check of electirc parts 7.1 Check the rust, dirt and moisture etc. of connector, if there is moisture, please blow it dry and clear the rust and dirt. 7.2 The eclectolyte inside the battery is a kind of corrosive, when operation exercise shall be taken not to let the electrolyte splash on the body.
  • Page 13 b. If joint is slack, bend the plug pin upward, then connect with connector plug(see fig7.5) 7.6 Before mounting new fuse, check if the load of fuse of components is right, especially for the portion being burned broken regularly, Plug pin then mount the fuse having proper current value.

  • Page 14: Section 5 Specification

    Section 5 Specification (I) How to use conversion table of unit (1)How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the follow- ing conversion table, metric unit could be conversed into imperial unit. METRIC MULTIPLY IMPERIAL...

  • Page 15: Ii.basic Specification

    II.Basic specification...

  • Page 16: Iii.atv Body

    III.ATV body Item Standard Limit Spock rim, tubeless tire Type Steel plate Material of rim Front AT 19 ¡Á7-8 Size of tire wheel 2.0mm Radial runout of rim 2.0mm Lateral swing of rim Drum type Type Front brake Spoke rim, tubeless tire...

  • Page 17: Maintenance Specification Of Engine

    IV.Maintenance specificationof engine -11-...
  • Page 18 -12-...
  • Page 19 -13-...

  • Page 20: Section 6 Wiring Diagram Of Atv

    Section 6 Wiring diagram of ATV 1. Front brake cable 2. Throttle cable 3. Rear brake cable 4. Wire of handle bar switch 5. Hight voltage coils and wire 6. Wire of starting motor 7. Wire of gear indicator 8. Rectifier 9.

  • Page 21: Section 7 Requirements For Torque Of Fastener

    Section 7 Requirements for torque of fastener (I) General torque specification General torque specification (standard screw) This table is screw locking specification drawn up by International Standard Association. In order to avoid the twist or unbalancing phe- nomenon when locking screw. please cross lock or londuit as per appointed orders.

  • Page 22: Section 8 Lubrication

    Section 8 Lubrication Standard Item (I) Lubrication oil way :Pressure :Splashing oil Piston/cylinder Piston pin Valve Connecting rod Camshaft Automatic centrifugal clutch Crank Rocker Bearing Spindle Fine filter Branch valve Sprocket chamber Driving shaft Oil pump Middle gearbox Rough filter -16-...

  • Page 23: Section 9 Lubrication Point And Type Of Lubricants

    Section 9 Lubrication point and type of lubricants (I)Lubrication point and type of lubricants(ATV body) Lubrication point Type of lubricants Lip of oil seal (full) Light lithium-base grease O-ring (full) Light lithium-base grease Steering shaft(upper end,lower end) Light lithium-base grease...

  • Page 24: Lubrication Point And Type Of Lubricants(Engine)

    (II)Lubrication point and type of lubricants(Engine) Lubrication point(name of component) Type of lubricant Lip of oil seal (Crank,shift gear shaft,spindle,shift gear operation shaft) Light lithium-base grease All bearing (Crank spindle, driving shaft, shift gear camshaft, Lubricating-oil pneumatic canshaft) O-ring (Contact position of o-ring) Light lithium-base grease Stem end of intake and exhaust valve (Intake and exhaust valve, vale adjsuting screw )

  • Page 25: Chapter Ii Maintenance And Adjustment Of Vehicle

    Chapter II MAINTENANCE AND ADJUSTMENT OF VEHICLE Note: The correct maintenance and adjustment are necessary to ensure vehicles, normal driving.The repair personnel should be familiar with the contents of this article. Section 1 Periodic Maintenance/Lubrication Every time Every Item Requirement month month month...

  • Page 26: Section 2 Disassembly And Assembly Of Cushion, Fender And Fuel Tank

    Section 2 Diassembly and assembly of Cushion, Fender and Fuel fank (1) Cushion 1.Disassembly (1) Place the vehicle on the horizontal ground. (2) Disassemble the cushion; Pull the cushion lock lever upward, then raise the tail part of cushion. By that, you can disas- semble the cushion.
  • Page 27 Caution Should disconnect the negative wire fistly. (4)Take out the battery. (5)Disassemble the rear fender. 2.Installation Operate according to reverse procedure of “Disassembly”.Pay attention to following points: (1)Install: Rear fender (2)Install: Battery -21-...

  • Page 28: (Iii)Front Fender

    (3)Install the cushion Caution Insert the support lug ¢Ú of cushion into the plug seat ¢Ûon the frame, then press down the cushion. (III)Front fender 1. Disassembly: (1) Place the vehicle on the horizontal ground. (2) Take off bolt (3) Dismantle the connecting pipe. (4)Disassemble the front fender.

  • Page 29: (Iv)Fuel Tank

    (1)Install: Front fender (2)Install: Assembly of the connecting pipe. (3)Install: Bolt (IV)Fuel tank 1.Disassembly (1)Place the vehicle on the horizontal ground. (2)Disassemble the cushion -23-...
  • Page 30 (3) Demove the front fender. (4) Demove the fuel tank bolt. (5)Pull the fuel cock lever to “OFF”position. (6)Remove the fuel inlet pipe Caution Place a cloth on the engine to absorb the splashed gasoline. Warning The gasoline is inflammable. Avoid to splash it on the hot engine.
  • Page 31 (3)Install the bolt, bushing of rubber hood and washer. (4) Install: front fender (5) Install: Cushion (6) To turn the fuel cock lever to “on” position. -25-...

  • Page 32: Section 3 Maintenance And Adjustment Of Vehicle Body

    Section 3 Maintenance and Adjustment of Vechicle Body (I) Wear inspection of front&rear brake 1. Check the front brake (1) Brake the vehicle with front brake (2) Check: .Wear indication .If the wear indication reach the wear limit mark ,replace the brake shoe assy. Refer to section“Front wheel and front brake”...

  • Page 33: (Iii)Adjustment Of Free Clearance Of Left Lever And Rear Brake Pedal

    2.Adjustment Adjusting procedure of free clearance of right lever: .Loosen the locking nut¢Ù,and rotate the cable adjsuting screw ¢Úclockwise to reduce the tension of front brake cable. .Pick up the front wheel form ground, and ro- tate the two front wheels, and ensure the two front brake light brake force.
  • Page 34 2.Adjust .Free clearance of left lever .Free clearance of rear brake pedal Adjusting procedure: Caution Before adjusting, tread the rear brake pedal 2-3times. .Loosen the locking nut completely, and screw in the cable adjusting screw completely. .Loosen the adjusting nut of rear brake cable and adjusting nut of rear brake pedal.

  • Page 35: (Iv)Inspection Of Steering System

    (IV)Inspection of steering system 1.Place the vehicle on the flat ground 2.Check: .Clamp seat of steering vertical column and sliding bearing on the lower end of steering vertical column, upper &lower and front &rear moving steering bar If the clearance is too large, replace the sliding bearing 3.Check: .Ball pin unit of steering tension rod.

  • Page 36: (V)Adjustment Of Toe-In Of Front Wheel

    (V)Adjustment of toe-in of front wheel, 1.Rest the motorcycle on the flat ground 2.Measurement: .Toe-in .Adjust if out of specification .Adjustment steps of toe-in. .Mark the centers of tire thread of two front wheel. .Lift the front end of motorcycle to keep the front wheel from force.

  • Page 37: (Vi)Adjustment Of Rear Shock Absorber

    Inspecion of front/rear shock absorber 1. Rest the motorcycle on the flat ground 2. Inspection (1) Front/rear shock absorber If scraped/damaged replace the front/rear shock absorbe (2) Oil leakage If the heary oil leakage of front/rear shock absorbers is found, replace it. 3.Inspection .Operation: .Shock the fornt /rear shock absorbers up and...

  • Page 38: (Vii)Inspection Of Tire

    .Tire characterics 1)Quality characterics of tire will affect the driving reliability of ATV. The following types of tires reliability by our company be used safely by this motorcycle. If adpot other tires it will cause the disadvantageous effect.So they are out of recommendation.

  • Page 39: (Viii) Inspection Of Rim

    1.Measurement .Tire pressure(nomal atmospheric temperature): If out of specification, adjust. Caution .The manometer of tire belongs to spare parts of the motorcycle(Never use the high pressure). .If the foreign matters such as dust, etc are absorbed in the tire pressure manoeter, the readig of the meter will be not correct, at the moment, the second measurement should be conducted and the second measurment reading should be...

  • Page 40: Section 4 Maintenance And Adjustment Of Electrical Appliance

    Section 4 Maintenance and Adjustment of Electrical Appliance (I)Inspection of battery Warning: The electrolyte is dangerous article, whitch in- cludes sulphuric acid, so it is poisonous and corrosive. .Please operate by the following steps: a.Avoid the body touching the electrolyte so as to protect the eye from burn or damage.

  • Page 41: (Ii)Inspection Of Fuse

    4.Inspection of battery If damaged, replace it 5.Installment of battery ¢Û 6.Connect .Battery electrode(positiove electrode ¢Ù negative electrode ¢Ú) First connect the positive electrode ¢Ù 7.Installment: a.Battery clamp plate ¢Ü b.Cushion (II)Inspection of fuse Caution Closet the main switch when checking or re- placing the fuse, otherwise, it will cause the short circuit.

  • Page 42: Section 5 Maintenance And Adjustment Of Engine

    Section 5 Maintainace and Adjustment of Engine (I)Adjustment of clutch Adjustment steps: a.Loosen the locking nut ¢Ù b.Turn the adjusting screw rod ¢Úcounter- clockwise slowly up to be unable to turn,then turn1/8 clockwise, and fasten the adjusting screw rod¢Úto this position and tighten up the locking nut ¢Ùwith the torque of N.m.

  • Page 43: (Iii)Inspection Of Spark Plug

    6.Installment: a.Install the foam filter core to the foam sup- porting cylinder to combine a air filter assy. b. Install the air filter assy. c.Install the air filter cover. Caution Make sure that the close fit surface of air fiter is engaged with the close fit surface of air fil- ter box, and the air leakage is not allowed.

  • Page 44: (Iv)Adjustment Of Idle Speed

    (IV)Adjustment of idle speed 1.Rest the vehicle on the flat ground 2.Start the engine and prewarm it at the speed of 1000-2000r/min, after several minutes, in- crease the engine speed to 4000-5000r/min. 3.Set the specified idle speed through adjust- ing the throttle adjusting screw ¢Ù , Screw in to incresase the engine speed and screw out to decrease the speed.

  • Page 45: (Vi)Adjustment Of Speed Limitator

    (VI)Adjustment of speed limitator: The speed limitator can limit the throttle in full opening condition when the throttle grip is pulled to the Max position, screwing the ad- juster inward can stop increasig the speed. 1.Adjust speed limiting length@ Adjustment steps: a.Loosen the locking nut ¢Ù...
  • Page 46 b.Make the mark“T”on the rotor is align with the mark on the crankcase. When it is done that is the pistion ties in top dead center(TDC) c.Inspection of top dead center in pressure stoke: (i)When the mark on the rotor is align with the mark on the crankcase,the two arms must have clearance.

  • Page 47: (Vii) Inspection Of Ignition Timing

    3.Installation: Carry out it according to opposite steps of “Removal”. (1)Mount: a.Valve cap ¢Ù (Side of outlet door) b.Valve cap ¢Ú(Side of inlet door) Caution (i)Project of valve cap ¢Ù ¢Úsould be up ¢Û when mounting. (ii)Check if O-ring ¢Üis damaged. if any, re- place it immediately.

  • Page 48: (Ix)Measuring Of Compressive Force

    Warning When the engine is running, the machine, oil maybe splash out, so be careful to start the engine. c.Check if the mark on the crankcase is in the range of ignition under the magneto rotor indication.If it is out of range, check if the ro- tor and pulse coil is loosen or damaged.

  • Page 49: (X) Inspection Oil Quantity Of Engine

    d.If the pressure is lower than the min,value: (i)Drop some oil to action cylinder. (ii)Measure the pressure again Compression force(The machine oil has been filled in the cylinder) Compressure read Reason Read is highter than one Piston or piston ring is before filling worn or damaged Piston ring, throttle...

  • Page 50: (Xi)Replacement Of Engine Oil And Inspection Of Oil Flow

    b.Turn out the dipstick ¢Ùentirely, and clean it, then insert it¢Ùback into oil hole. c.Take out the dipstick ¢Ùto check if the oil level is between the Max. value and the Min. value ¢Û . d.If the oil quantity is too small, fill some en- gine oil to make the oil quantity get to proper quantity.
  • Page 51 6.Inspection One of parts of O-ring¢Ù , compressure spring ,rough filter ¢Û ,fine filter ¢Üis damaged, repalce it. 7.Cleaning Clean the compressure spring¢Ú , filter¢Û ,filter ¢Ü , filter plug of crankcase¢Ýand filter net cap with cleaner. 8.Coat the engine oil on the O-ring slightly. 9.Install the fire filter¢Ù...

  • Page 52: Chapter Iii Repair And Maintenance Of Vehicle Body

    Chapter III Repair and Maintenance of Vehicle body Section 1 Front wheel and Front Brake Technical Parameter Ser No. Item Parameter Tire specification AT22¡Á7-10 Rim dimension 5.5¡Á10 Standard value 20KPa(Standard value) Tire air pressure(normal Min value 17KPa(Min vlaue) temperature) 23KPa(Max value) Max value Radia run-out Run-out...
  • Page 53 3)Disassmeble split pin¢Ù, slotted nut¢Ú ,plain washer ¢Û,front brake ¢Ü and gasket ¢Ý . 4)Disassmeble adjusting nut¢Ù, pin¢Ú, spring ¢Û, circlip ¢Ü spring ¢Ýand circlip ¢Þ. 5)Remove the front brake cable and front brake air pipe. ¢Ú 6)Disassemble brake shoe assy ¢Ùand front cover assy ¢Ú...

  • Page 54: Ii.inspecting Procedures

    II.Inspecting procedures 1.Check Front wheel:refer to “Tire inspection”and “Hub inspection”of chapter2. 2.Measure Radial run-out of front wheel:If exceeding the specified limit, replace the front wheel or check the bearing clearance(¢Ùin figure) Attached:Rim run-out limit: Radial run-out 2.0mm(¢Úin figure) End face run-out 2.0mm(¢Ûin figure) 3.Check: Tire surface:If worn or damaged, replace it.
  • Page 55 4.Check Friction wafer:polish the surface needing polishment with rough sand paper. 5.Measure Thickness of friction wafer of brake: if it does not conform to specified thickness, replace it . Attached: Thicknes of friction wafer of brake:4.0mm Wear limit :2.0mm Caution If the worn thickness of any part of friction ¢Ù...
  • Page 56 9.Check ¢ÙIf the bearing ¢Ùof front brake hub runs out in brake hub or front wheel runs out when rotating, replace the bearing. ¢ÚIf the oil seal ¢Úis worn or damaged, re- place it. ¢Ù Replacing procedures of front wheel bearig and oil seal Wash the outer side of brake hub ¢ÚRemove the oil seal ¢Ùwith plain screw...

  • Page 57: (Iii)Installation Procedure

    (III)Installation procedure: The installation procedure is the riversal of “Disassembly ”.But pay attention to following points: 1.Lubrication:as shown in figure: ¢ÙDust-proof seal ¢ÚBearing ¢ÛCam shaft ¢ÜRotating pin seat ¢Ý“O”sealing ring Attached:use lithum base grease Warning When installing the cam shaft and rotating pin seat, should apply a little grease firstly.
  • Page 58 4.Install Brake shoe assy Do not apply lubricating grease on brake fric- tion wafer. 5.Connect a.front brake air pipe. b. connect the front brake cable with brake cover. 6.Install (as shown in figure) ¢ÙCirclip ¢ÚSpring ¢ÛCirclip ¢ÜSpring ¢ÝPin ¢ÞAdjusting nut 7.Install(as shown in figure) ¢ÙFront brake hub ¢ÚGakset, O-ring 17 ¡Á1.8G...
  • Page 59 9.Installment: When installing the front wheel¢Ù , the fasten- ing torque of connecting nut¢Ú of front and rear wheels is 55N.m. The rotation direction of front wheel (A) is the arrow direction marked on the tire. 10.Adjustment Free clearance of front brake cable R e f e r t o t h e “...

  • Page 60: Section 2 Rear Wheel/Rear Brake/Rear Wheel Axle

    Section 2 Rear wheel/rear brake/rear wheel axle (I) Removal steps 1. Rest the motorcycle on a flat ground 2. Stop up the front wheel with wood, then put a proper supporting article under the frame so as to lift the rear wheel and make the rear wheel leave the earth.

  • Page 61: (Ii) Inspection Steps

    6. Dismantle the rear disk Brake plate. 7. Disambly of rear Disk brake bracket (1) Connecting 8. Caution Take out the rear wheel axle from the end of rear wheel axle bushing and gear box with soft hammer Warning During taking out the rear wheel axle, in or- der to protect the thread and gear groure from damage, do nut beat the rear wheel axle di- rectly with hammer...
  • Page 62 5.Inspection of rear wheel axle ¢Ù a:If the rear wheel axle is heavily scraped or broken, replace it. b.If the thread or gear groove on the rear wheel axle is worn or damaged, replace it. 6.Measurement The radial runout of the pisition @on the rear wheel axle, if out of specification, repalce it.

  • Page 63: Section 3 Steering Operation System

    Section 3 Steering Operation System (I)Removal steps of steering bar 1.Removal Handlebar decration cover 2.Removal Front brake cable Remvoal Throttle grip assy 3.Removal After stopping the vehicle, remove the rear brake cable ¢Ù ¢Ù 4.Removal ¢Ù Steering bar pipe ¢Ú Lower holder of steering bar -57-...

  • Page 64: (Ii)Removal Steps Of Steering Vertical Column Welding

    (II)Removal steps of steering vertical column welding 1.Plain move ¢ÙThe locking part of locking pad as shown 2.Removal ¢ÚBolt ¢ÛLocking washer ¢ÜClip assy 3.Remocal Install the steering vertical column with split Washer 4.Removal Split pin Tension rod ¢Ù Caution When removing the tension rod end and steer- ing ball pin from the steering vertical column welding assy and front seat assy of front brake with common bearing tension tool and other...

  • Page 65: (Iii)Inspection Content

    (III)Inspection content 1.Check if the steering bar is cracks bent, is bent or damaged. If it is, replace it. 2.Inspect if the steering vertical column weld- ing assy is bent or damaged. if it is, replace it Warning In order to avoid decreasing the performance of steering vertical column, if it is bent do not straighten it frocefully.

  • Page 66: (Iv)Installment Steps

    6.Adjustment Assembly length of tension rod Adjustment steps of tension rod assembly length Loosen the connecting nut (A).(B) Adjusting the assembly length of tension rod by rotating the tension rod. Attached:Tension rod assembly length @: 297mm (A)Right-hand thread (B)Left-hand thread Connect (C)position to the steering vertical col- umn welding assy.
  • Page 67 2.Lubricate the steering vertical column holder ¢Ùand seal ring ¢Úduring installing the steer- ing vertical column welding. 3.Installment Install the seal ring ¢Ùto the steering vertical column welding, then install bushing¢Ú , finally install the steering vertical column holder¢Û. Caution: Never damage the seal ring when installing.
  • Page 68 7.Mounting split pin¢Ù Caution Don’t loosen the nut after the torque is fixed. If the nut recess is not correspondance with split pin hole on the double -screw bolt, tighten the nut to align them. Warning Always use new split pin 8.Tighting After mounting the washer,nut, split pin under the steering vertical column.

  • Page 69: (V)Installation Steps Of Steering Bar

    (V)Installation steps of steering bar 1.Install the lower holding seat¢Ù , steering tube ¢Ú and upper holding seat ¢Û. Warning When tightening the bolt of holding seat, make ensure the even of clearance Attached:bolt torque:20Nm 2.Install the throttle grip unit Caution The projection ¢Ùof throttle grip must corre- spond to the sunken part ¢Úon the right lever...

  • Page 70: Section 4 Front Shock Absorber And Front Wheel Fork

    Section 4 Front shock absorber and Front wheel fork (I)Disassembly: 1.Take off front feder front wheel. 2.Take off split pin, nut and steering rod ball pin assembly. 3.Dismantle the bolt of the front shock- absorber. 4.Take off the bolt under the front shock ab- sorber nut of front shock absrober and front shock absrober.

  • Page 71: (Ii) Inspection Steps

    d:Move the left/right front wheel fork up and down to check its vertical clearance. If the vertical moving is tight, limited or uneven, re- place the bushing sub-assembly or whole front wheel fork. 8.Take off nut ¢Ù , bolt ¢Ú , left/right front wheel fork ¢Û...

  • Page 72: (Iii)Installment Steps

    Warning If the left/right front wheel fork welding is bent, don’t strighten it seriously in order to avoid re- ducing its performance. 4.Check the bushing sub-assembly ¢Ù, if it is worn or damaged, replace it. (III)Installment steps The opposit steps of “Disassembly”is the mounting steps.
  • Page 73 3.Mount left/right front seat assy ¢Ù 4.Fix the nut ¢Úof left/right front seat assy. Attached: Nut torque :25Nm 5.Mount the split pin ¢Û Caution Don’t loosen the nut after marking the stan- dard torque.If the recess on the nut is not cor- respondence with split pin hole on the bolt, correct it by tightening the nut.
  • Page 74 Caution Don’t loosen the nut after markingthe stan- dard torque.If the recess on the nut is not cor- respondence with the split pin on the bolt, cor- rect it by fixing the nut. Warning Must use new split pin ¢Û 9.

  • Page 75: Section 5 Rear Shock Absorber And Rear Wheel Fork

    Section 5 Rear shock absorber and Rear wheel fork 1. Take of cushion/rear fender/drive sprocket 2. Take off rear shock absorber check: a. If rear shock absorker is leakage, if any, replace it b. If rear shock absorber is bent or damaged, if any, replace it.

  • Page 76: Chapter Iv Electric Appliance

    Chapter IV Electric Appliance Section 1 Inspect switch (I)Inspect switch Inspect if the circuit between wire end is on with pocket multimeter. If there is any failure ,replace the switch. Pocket multimter Remark .Adjust the multimeter to “O”before inspect- .Adjust the multimeter to “ ¦ ¸ ¡ Á 1”when in- specting the circuit.

  • Page 77: Section 2 Check Lamp(Headlight)

    Section 2 Troubleshooting the ignition system failure If the ignition system does not work(no spark or spark stops) Step Check 1.Spark plug 6.Main switch 2.Ignition park clearance 7.Resistance value of triggering coil 3.Resistance value of spark plug cap 8.Resistance value of charge coil 4.Resistance value of ignition coil 9.Circuit connection (whole ignition system) 5.Engine stop switch...
  • Page 78 2.Ignition spark clearance .Remove the spark plug cap from spark plug .Connect as shown in figure ¢ÙSpark testing instrument ¢ÚSpark plug cap ¢ÛSpark plug .Rotate the main switch to “ON” .Check the ignition spark clearance. .Press down the starting switch to start the engine. And increase the spark clearance until the engine can not be started.
  • Page 79 .Inspect if the resistance of primary coil con- forms to specification Primary coil resistance 20¡æ(68¡ã F)0.43~0.5 ¦¸ .Connect the multitester£¨¦¸¡Á1K£©to ignition coil .Inspect if the secondary coil resitance conforms to specification Not conforming to specification Secondary coil resistance 20¡æ(68¡ãF)4.6-7.6K ¦¸ Replace ignition coil All conform to specification Abnormal...
  • Page 80 8.Resistance value of charge coil .Remove the corresponding connector of charge coil from cable. .Connect the mulitester( ¡Á100 ) to wire end ¦¸ of charge coil Multitester pen (+) ¡ú yellow/green wire end ¢Ù Multitester pen (-) ¡ú yellow/green wire end ¢Ú Inspect if the resistance value conform to speci- Not conforming to specification fication...

  • Page 81: Section 3 Troubleshooting The Ignition System Failure

    Section 3 Running of starting circuit The starting circuit of this vehicle include start- ing motor, cut-off relay, rear brake switch and neutral switch. If the main switch is in position, the startig motor could be operated only at the following conditions: .Driving device is at neutral position(neutral switch is closed)

  • Page 82: Section 4 Troublshooting Electric Starting System

    Section 4 Troubleshooting electric starting system If starting motor doesn’t work Pocket-multimeter Remark .Remove the following parts before troubleshooting 1)Cushion 2)Fuel tank 3)Front fender .Use the following special tool to troubleshoot No electrification 1.Safety Pass Incorrect 2.Battery .Check the battery condition Voltage of open circuit .Clean the battey terminal At 20¡æ(68¡ãF)12.8V or much more...
  • Page 83 No rotation Repair or replace starting motor 4.Power off relay .Remove the relay from cable .Connect portable multitester (¦¸¡Á1)and battery (12V) to wire end of power off relay Battery end(+)¡úred/white wire end ¢Ù Battery end(-)¡úgreen/yellow wire end¢Ú Multitester pen(+)¡úred/white wire end ¢Ù Multitester pen(-)¡úblue/white wire end ¢Û...
  • Page 84 Incorrect 6.Main switch Replace main switch Correct Incorrect 7.Neutral switch Replace neutral switch Correct Incorrect 8.Rear brake switch Replace rear brake switch Correct Incorrect 9.Starting switch Replace handlebar switch (left) Correct Incorrect 10.Circuit connection .Check the circuit connection of whole starting Connect the whole starting system correctly system -78-...

  • Page 85: Section 5 Check Starting Motor

    Section 5 Check starting Motor 1.Check .Reverser Not clean ¡úClean with #600 sand paper 2.Ensure .Reverser diameter @ Not conforming to specification ¡ú change the startig motor 3.Measure .Mica cut sheet Not conform to specification ¡úScrape the mica with square scraper Mica cut sheet:0.7mm(0.028 in) Remark Scrap the mica with square scraper to get...
  • Page 86 5.Measure .Length @of brush (every one) Out of specification ¡úreplace it Length of brush:10mm(0.39 inches) Range of wear:<6mm(0.14 inches)> 6.Measure .Brushing spring force Fatigue/out of specification ¡ú replace whole device Brushing spring force:326~970g(3.2~3. 7.Check .Oil sealing .Bushing .O-ring Wear/damage ¡úrepalce it Installation of starting motor: 1.Mount .Magnetic steel...

  • Page 87: Section 6 No Charging In The Battery

    Section 6 No charging in the Battery Steps Check: 4.Startor coil 1.Safety 5.Coupling of circuit 2.Battery (Whole charging system) 3.Charging voltage Coil techometer Engine techometer Pocket multimeter .Repair with following special toolings NO.electrification 1.Safety Refer to “Inspection of switch” Pass Replace the safety 2.Battery .Check battery condition...
  • Page 88 .Start the engine and accelerate to 2000r/m or so. Meet specification Charging voltage:14-15V at 2000r/m Remark: Use battery with full capacity No failure on charging circuit Oil of specification 4.Resistance value for startor coil .Take out the lighting coil of AC magneto from in- serter .Connect pocket multiconeter to stator coil(¦...

  • Page 89: Section 7 Troubleshooting

    Section 7 Troubleshooting If the or taillight is not work Steps Check: 1.Safety 4.Lamp switch 2.Battery 5.Coupling of wires(for entire lighting system) 3.Main switch Pocket multimeter:P/N YU-03112 90890-03112 No electrification 1.Safety Refer to “Inspection of switch” Replace fuse Pass 2.Battery .Check the battery condition Incorrect Voltage of open circuit...
  • Page 90 Incorrect 4.Switch for lamps Refer to “Inspection of switch” Correct If the lamp switch is failure replace the switch of handle(left) 5.Coupling of wires .Check the wire compling or whole lighting sys- Poor coupling Correct Connect whole lighting system correctly. Check the returning condition of each lighting system.

  • Page 91: Section 8 Inspection Of Lighting System

    Section 8 Inspection of Lighting system (II)If the taillight is out of work No electricfication 1.Bulb and bulb socket .Check if the bulb and bulb socket is correct Meet specification Replace bulb and bulb socket 2.Voltage .Connect the pocket tester (DC 20V)to the terminal of taillamp.

  • Page 92: Chapter V Engine

    Chapter V Engine Section 1 Disassembly of engine (I)Remove the engine from finished ATV 1.Remvoe .Cushion .Front fender .Rear fender 2.Oil draining Screw out oil draining screw plug. Drain off the lubricating oil of the engine from the oil drain- ing hole.
  • Page 93 2)Remove .Connecting plate of sharting motor¢Ú .Starting motor ¢Û 6. Remove .Left footrest .Right footrest 7. Take off drive sprocket 8. Disassembly of engine 2)Remove the engine unit from right side -87-...

  • Page 94: (Ii) Disassembly Of Engine

    (II) Disassembly of engine ¢Ù 1.Remove .Sproket cabinet cover 2. Remove ¢Ú .Spark plug ¢Ù ¢Û .Upper valve cap(intake)¢Ú .Lower valve cap(exhaust)¢Û ¢Ù ¢Ù 3.Remove ¢Ú .Bolt ¢Û Timing sproket ¢Ü -88-...
  • Page 95 4.Remove ¢Ú ¢Û .All the bolts and nut on the cylinder cover. Caution: Loosen every bolt and nut by1/4 circle, then disassembly ¢Ü .Loosen them, from big one to small one ac- ¢Ù cording to the numbers marked on the cylin- der cover.
  • Page 96 Caution ¢Ú .Before disassembling the piston pin circlip, cover the crankcase with a clean cloth to avoid the circlip to drop into case suddenly. .Before disassembling the piston pin, remove the burr of circlip groove and pistion pin. If it is still difficult to remove the piston pin, remvoe it with ¢Ù...
  • Page 97 12.Remove .Driving sprocket 13. Remove ¢Ü .Fine filter cover of engine oil¢Ù ¢Þ .Fine filter of engine oil¢Ú ¢Û .O-ring ¢Û ¢Ù ¢Ú .Right crankcase cover ¢Ü .Location pin ¢Ý ¢Ý .Gasket of right crankcase cover ¢Þ 14.Remove .Main clutchnut ¢Ú Caution Loosen the locking pad¢Ùbefore removing the nut, and fix the main clutch shoe¢Ûwith spe-...
  • Page 98 16.Remove .Locking washer ¢Ù .Clutch hub assy ¢Ú ¢Ù .Friction wafer ¢Û ¢Ú ¢Ü ¢Û .Clutch piece ¢Ü ¢Þ ¢Ý .Compressing plate ¢Ý ¢ß .Spline washer ¢Þ .Clutch gear assy ¢ß 17.Remove .Right connecting case ¢Ù ¢Ù .Location pin ¢Ú ¢Ú...
  • Page 99 20.Remove ¢Ù .Star-shaped gear ¢Ù (on shift cam) .The location pin is easy to drop down. pay attention not to lose it. 21.Remove .All the closing case screw. Caution Loosen every screw1/4 circle with cross-slot screwdriver, then remove all of them 22.Remove .Left crankcase .Location pin...
  • Page 100 24.Remove ¢Ù .Main shaft assy and driving shaft unit¢Ù 25.Remove .Distribution cam shaft ¢Ù Caution .Screw in the bolt¢Ú 10mm to cam shaft screw hole to draw out the distribution cam shaft. 26. Remove .Rocker shaft ¢Ù .Air intake and exhaust rocker ¢Ú Caution .Screw the slip hammer assy into rocker shaft, then pull out the rocker.
  • Page 101 Caution .Pay attention to position of each component for installation to original position. -95-...

  • Page 102: Section 2 Inspection And Maintenance Of Engine

    Section 2 Inspection and Maintenance of Engine 1.Cylinder cover 1)Clean .Carbon eposit Use circular scraper ¢Ù Caution Please do not use sharp tool to avoid scraping .Nut of spark plug .Valve seat ring .Bottom face of cylinder 2)Measure .Flatness of cylinder cover bottom face Recorrect the bottom face or replace if unquali- fied Flatness of cylinder bottom face is less than 0.
  • Page 103 3)Measure .Rod part run-out of valve rod Replace it if unqualified The rod part run-out of valve rod is less than (0.03mm0.0012in) 4)Measure .Clearance between valve rod and valve guide pipe Clearance=A-B Inner diameter of valve guide pipe A Valve rod diameter B Repalce the valve or valve guide pipe if unqualified.
  • Page 104 3)Install .Circlip ¢Ù (new) .Valve guide pipe ¢Ú(new) Use the installing and disassembling device of valve guide pipe 4)Ream the inner diameter of valve guide pipe to get proper valve rod clearance. Caution Regrind the valve race after installing valve guide pipe 4.Valve race 1).Clean...
  • Page 105 .Press the valve on through valve guide pipe to leave clear trace on the valves. .Remove the valve from cylinder cover .When the valve contancts with valve race, the redle is marked on the valve form vavle race, Then can measure the contacting width of valve and valve race.
  • Page 106 The contacting part B is the middle of valve face. But the width is too narrow Reamer assy of valve rale Result Get unified contacting width Reamer 45¡ã 1.0mm(0.04 in) The contacting part C is too narrow, and on the upper edge of valve face Reamer assy of valve rale Result Make the contacting part in...
  • Page 107 .Pain molybdenum disulfide oil on the valve rod part. Apply molybdemum .Place the valve into the cylinder cover disulfide oil .Rotate the valve to grind in with seat fully on the valve face, then clean the dirty .repeat procedure until the contacting width of valve face and valve seat In order to get the best grinding quality, you may slap the valve lightly when rotating the...
  • Page 108 2)Measure Installation .Installing pressure of valve spring length If unqualified, replace the inner and outer spring totally. Installing pressure of valve spring When it is 30.5mm(1.2 in),the Inner spring(intake/ p r e s s u r e 8 . 4 ~ 1 0 . 2 k g ( 1 8 . 5 ~ 2 2 . exhaust) 5pods) When it is 32.0mm(1.26 in),the...
  • Page 109 Caution Must install the long pitch end of all valve spring upward. 2)Check the valve seal If there is leakage on the valve face, repair again and regrind or replace the valve and regrind. Inspecting procedure of valve seal .Inject the clean solvent ¢Ù into intake way and exhaust way respectively.
  • Page 110 Limit value “B” of Limit value “A” of distribution cam distribution cam 36.437mm 30.031mm Intake cam (1.435 in) (1.182 in) 36.482mm 30.152mm (1.436in) Exhaust cam (1.187 in) 8.Valve rocker and rocker shaft 1)Check .Rocker hole .Contacting surface with distribution cam If over worn, replace it 2)Check .Rocker shaft surface...
  • Page 111 .Substract the outer diameter of rocker shaft from inner diameter of valve rocker hole to calculate the clearance. Clearance between rocker hole and shaft=@- Inner diameter of valve rocker hole@ Outer diameter of rocker shaft Replace a set if unqualified Clearance between rocker shaft and hole: 0.009-0.037mm(0.0004-0.0031 in) Limit:...
  • Page 112 12.Valve cover and sproket cabinet cover 1)Check .Valve cover (upper valve cover and lower valve cover) .spocket cabinet cover .O-ring Replace it if there is crack and damaged 13.Cylinder and piston 1)Check .Carbon deposit (from piston top to ring slot) 2)Check .Surface of cylinder and piston Rebore cylinder or replace cylinder and piston...
  • Page 113 If out of specification, rebore or replace the cylinder and piston (Replace in a set) .Measure the diameter “P”of piston lower part with micrometer, is the measuring position If out of specification. replace the piston and piston ring as a set at the same time. .Calculate the mating cylinder clearance with the following formula Mating cylinder clearance= “C”- “P”...
  • Page 114 Clearance between piston ring and ring groove Limit Standard 0.03-0.07mm 0.12mm First ring (0.001-0.003 in) (0.005 in) 0.02-0.06mm 0.12mm Second ring (0.008-0.024 in) (0.005 in) ring 2)Measurement .Closed clearance of piston ring ¡ý .Install the piston ring to the cylinder,pull for- 20mm(0.8 in) ward about 20mm(0.8 in),then pull the piston ¡ü...
  • Page 115 Piston pin 1)Inspection .If the color is changed, or indent is found,re- place piston pin, then inspect the Lubrication system. 2)Measurement: .Outer diameter @ (Piston pin) Out of specification,replace it 3)Measurement: .Inner diameter of piston pin Out of specification,replace it 4)Measurement .Clearance between piston pin and piston pin hloe...
  • Page 116 15.Crankshaft 1)Measurement .Dimension A of crankshaft assy If out of specification replace it or repair it .Runout C If out of specification replace it or repair it Runout Limit C1:0.03mm(0.0012 in) C2:0.06mm(0.0024 in) .Side clearance D of big head of connecting If out of specification, replace it or repair it Max side clearance 0.35mm-0.65mm(0.014-0.026 in)
  • Page 117 Main points of reassembly of crankshaft: The oil traces on crankshaft ¢Ùand crank pin ¢Ú should be connected correctly, the malpo- sition of two oil traces should be with in 1mm (0.04 in) 16. Clutch Clutch case Inspection .Split groove of clutch case If there is pressing mark,worn or damaged on the groove face,remove the burr,or replace it.
  • Page 118 Wear Limit: 2.8mm(0.110 in) Clutch plate Measurement: .Planeness of clutch plate Use flat plate and feeler gauge ¢Ù If out of specification,replace it. Planeness Limit: 0.2mm(0.008 in) Clutch post rod and earing Inspection: .Bearing ¢Ù(Post rod) If rough in surface or jammed in rotation,re- place it .Clutch post rod ¢Ú...
  • Page 119 2)Measurement .Side clearance between outer rotor¢Ù and in- ner rotor ¢Ú If out of specification,replace oil pump Side clearance limit 0.2mm(0.008 in) 18.Shift fork and fork shaft 1)Inspection .Fork Connection surface to gear and shift cam If worn,scraped,bent or damaged,replace it. 2)Inspection .Fork shaft (Roll the fork shaft on a plane)
  • Page 120 20.Main/vice shaft and gtar 1)Measurement .Runout of shaft ¢Ù (Main/vice shaft) Measure with bracket and runout meter If out of specification,replace it. Runout Limit 0.08mm(0.0031 in) 2)Inspection .Gear (refer to shift mechanism and output gear ¢Ú ) .Engaging jaw position If cracks ,damage,wear,replace it.
  • Page 121 21.Shift shaft 1)Inspection .Shift shaft ¢Ù .Hook plate ¢Ú If bent,worn,damaged,replace it. 2)Inspection .Shift torsion spring¢Ü(on the shift shaft) .Tension spring¢Ý(Hook plate) 22.Bearing and oil seal 1)Inspection .Bearing If jammed in operation or there are pits and dammagd,replace it. 2)Inspection .Oil seal If damaged or worn replace it.

  • Page 122: Chapter Vi Vecicle Ordinary Trouble And Its Judgement

    ChapterVI Vehicle Ordinary Trouble and Judgment .Spark plug is polluted Trouble Caution: .wrong spark plug heat value The following trouble, not including all .Inefficient spark plug cap possible troubles, is a help for trouble guide .Please refer to relevent contents for the ( 2 )Ignition coil inspection, adjustment and replacement of...

  • Page 123: (Ii)Poor Idle Speed Performance

    ( 2 )Piston and piston ring .Wrong needle valve position .Improper piston ring installation .Main jet is clogged or loosened .Piston ring is worn and out of elastic- .Fuel is deteriorated or polluted .Wrong float chamber oil level .Piston is damaged or crack (2)Air filter ( 3 )Valve, camshaft and crank shaft .Core of air filter is clogged...

  • Page 124: (V) Clutch Slips

    (2) Fuel system (4) Driving system ¡¤ Main jet of carburetor is wrong ¡¤ Claw of gear end is worn ¡¤ Improper oil level ¡¤ Core of air filter is clogged (V) Clutch slips (3) Cylinder system (1) Clutch ¡¤ Serious carbon deposition ¡¤...

  • Page 125: (X) Lighting System

    ¡¤ Improper installation of steering pillar bear- ¡¤ Battery fails ings ¡¤ Rectifier fails ¡¤ Holding seat of steering pillar or sealing ring ¡¤ Wrong connection of ground is damaged ¡¤ Main switch or lighting switch fail ¡¤ Rod is bent ¡¤...
  • Page 126 Our group reserve the right to change structure, dimension and parameter of the vehicle’s parts without additional notice.

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