TGB Hornet 50 Service Manual
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TGB Hornet 50 Service Manual

TGB Hornet 50 Service Manual

Tgb hornet atv service manual
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1. REGULAR INSPECTION -----------------------------------------
1-1 Delivery Introduction ---------------------------------------------------2
1-2 Inspection Before Running -------------------------------------------4
1-3 Regular Inspection ------------------------------------------------------5
1-4 General Inspection ------------------------------------------------------6
2. MAINTENANCE INFORMATION------------------- ------------
2-1 Specification Sheet -----------------------------------------------------7
2-2 Maintenance Data ---------------------------- ---------------------------8
2-3 Special Tools --------------------------------------------------------------9
2-4 List of Grease & Oil Adopted ----------------------------------------12
2-5 Circuit Drawings ---------------------------------------------------------13
2-6 Tighting Torque of Screws---------------------------------------------14
2-7 Simplified Troubleshooting -------------------------------------------16
2-8 Troubleshooting ----------------------------------------------------------17
3. DESCRIPTION OF COMPONENTS AND ASSEMBLY ---
3-1 Cover and Seat -----------------------------------------------------------26
3-2 Engine ----------------------------------------------------------------------27
3-3 Transmission Mechanism --------------------------------------------30
3-4 Electric System -----------------------------------------------------------35
3-5 Body --------------------------------------------------------------------------37
4. DISASSEMBLY REPAIRMENT
4-1 Notice for Disassembly Repairment ------------------------------40
4-2 Removal and lnstallation of Engine -------------------------------41
4-3 Disassembly and Assembly of Engine ---------------------------43
4-4 Removal and Assembly of Carburetor ---------------------------73
4-5 Removal and Inspection and Assembly of Electric Parts --75
CONTENT
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Summary of Contents for TGB Hornet 50

  • Page 1 CONTENT 1. REGULAR INSPECTION ----------------------------------------- 1-1 Delivery Introduction ---------------------------------------------------2 1-2 Inspection Before Running -------------------------------------------4 1-3 Regular Inspection ------------------------------------------------------5 1-4 General Inspection ------------------------------------------------------6 2. MAINTENANCE INFORMATION------------------- ------------ 2-1 Specification Sheet -----------------------------------------------------7 2-2 Maintenance Data ---------------------------- ---------------------------8 2-3 Special Tools --------------------------------------------------------------9 2-4 List of Grease & Oil Adopted ----------------------------------------12 2-5 Circuit Drawings ---------------------------------------------------------13 2-6 Tighting Torque of Screws---------------------------------------------14 2-7 Simplified Troubleshooting -------------------------------------------16...
  • Page 2 CHAPTER I ¡ G REGULAR INSPECTION 1-1 Delivery Introduction To inform customers of correct methods to use: To practically and correctly ride ATV according to the Instruction of Manual and Maintenance Handbook. Customers should also try in person according to this manual. 1.
  • Page 3 B. TGB Gear Oil GA50400004 ( OR SAE 85W-90 ) will be adopted as gear oil to be changed on a periodical basis. Gear oil and engine oil are different in their nature.
  • Page 4 1-2 Inspection Before Running Items to be Inspected Before Running by Customers: ITEM CONTENT GUIDELINE Is the oil volume 1.Check Oil Warning Lamp to see if 1. Starter proper? the oil volume is proper? Is the fuel volume 1.Check fuel volume to see if it is 2 .Fuel sufficient? enough to the destination.
  • Page 5 1-3 Regular Inspection The chart below lists the recommended intervals for all the returned periodic service work necessarily to keep the motorcycle operating at peak performance and utmost efficiency. Mileages are expressed in terms of months. These intervals judged by recorded run-hours or month whichever comes first. 1000 6000 12000...
  • Page 6 Be aware of smoke and fire while performing maintenance. New Packing, Gasket, O Ring, locking pin should be used while assembling. Only designated TGB oils should be used on spare parts. Clean the vehicle before maintenance to avoid dirt or mud on disconnected parts.
  • Page 7 2-1 Specification Sheet ITEM NO. Hornet 50 Hornet 90 Exhaust Volume 49.3c.c 82.4c.c Stroke Overall Length mm 1420 1490 Overall Width mm Overall Height mm 112kg 120kg Weight (Empty) Maximum Load 95kg 95kg Front ¡ G 16 x 8 – 7 Front ¡...
  • Page 8 0.9L 0.9L Residual Capacity when Light on 0.23L 0.23L Oil Used TGB Super Engine Oil (JASO FC ) TGB Super Engine Oil (JASO FC ) Oil Capacity of Gear Box 90c.c 90c.c Ignition 15 ¢ X ¡ Ó 3 ¢ X BTDC /4000rpm 15 ¢...
  • Page 9 2-3 Special Tools...
  • Page 10 2-3 Special Tools...
  • Page 11 2-3 Special Tools...
  • Page 12 Supper Grease No.3 No.0 Apply in Axle Shaft, Apply in Oil Seal. inside of Oil Seal. GA50400001 GA50400004 1104 Sealing Three- TGB Gear Oil 85w/90 Bond Apply on Right Transmission Gear Oil Hand Crank Surface. for Scooters. GA55100002 GA50400002 Three-Bond 1322...
  • Page 13 2-5 Circuit Drawing...
  • Page 14 2-6 Tighting Torque of Screws Screw Torque of Body Torque ¡ ] kg-cm ¡ ^ Item Locking Location Thread Rear Fork Nut 600-800 Crank Case Bracket Nut 550-600 Rear Swing Assy. Nut Rear Swing Assy. Bolt Fixed Nut for Rim 500~550 Self-lock Nut for Rim 400~450...
  • Page 15 2-6 Tighting Torque of Screws Screw Torque of Engine Torque ¡ ] kg.cm ¡ ^ Locking Location Thread Spark Plug 250-300 Flywheel Magneto 350-450 Nut of Kick Starter, RH 400-600 Bolt of Kick Starter 80-120 Nut of Driven Pulley Assy. 400-600 Nut of Clutch Housing 400-600...
  • Page 16 2.7 Simplified Troubleshooting Complaint Possible Reason Remedy No action for I. Fuse breaks. Replace starter motor 2. No power in battery. Charging 3. Defective action of brake switch. Replace 4 Short circuit of starter relay. Replace No sparking or I . Defective spark plug. Replace poor sparking 2.
  • Page 19 Check item ¡ G ¡ ³ No fuel ¡ ³ Dirty fuel filter ¡ ³ Obstructed ventilation tubing of th efuel tank ¡ ³ Poor carburector buoyant needle valve ¡ ³ Carburetor buoyant with impurities ¡ ³ Poor carburetor buoyant ¡...
  • Page 20 2-8-2 Troubleshooting for poor skip of spark plugs...
  • Page 21 2-8-3 Troubleshooting for no-skip of spark plugs Analysis of potential causes No skip of spark plugs Loose spark plug cap Check for proper loading of the spark plug cap Poor spark plug Loose C.D. adapter Poor C.D.I. Poor PICK UP Fair Poor Poor distributor high-...
  • Page 22 2-8-4 Troubleshooting for slow run (troubled engine) Analysis of potential causes Poor slow run Dirty spark plugs Check for contamination in spark plugs and excessive gap Incorrect spark plug gaps Incorrect ignition Fair Poor timing Obstructed air Cleaning and Alarming abnormality of ignition timing adjustment filter grill Poor carburetor...
  • Page 23 2-8-5 Poor acceleration and horse power...
  • Page 24 Fair Poor Check for Cleaning or normal fluid level in the buoyant Fair Poor (low Check the Check of needle Check for leaka ge in Fair Poor cylinder washer; check cylinder, piston, piston ring Check fuel pi pe Adjustment for wear. Correct, and carburetor adjustment or for obstruction...
  • Page 25 CHAPTER 3. DESCRIPTION OF COMPONENTS AND ASSEMBLY 3-1 COVER AND SEAT 3-1-1 Cover 3-1-2 Seat 3-2 ENGINE 3-2-1 Combustion & Air In-Take & Exhaust System 3-2-2 Carburetor 3-2-3 Lubrication & Cooling System 3-3 TRANSMISSION MECHANISM 3-3-1 Power Transmission 3-3-2 Continuous Variable Transmission 3-3-3 Reducing Gear 3-3-4 Kick Starter 3-4 ELECTRIC SYSTEM...
  • Page 26 3-1 COVER AND SEAT 3-1-1 COVER A. The cover of the ATV can be cleaned with vacuum cleaner. It can also be washed and put back after dried. ¡ ] please do not wash with volatile fluid, such as gasoline ¡ ^ If thecovers were damaged, please replace the new covers.
  • Page 27 3-2 ENGINE 3-2-1 Combustion & Air Inlet-Outlet System I . Combustion System A. Cylinder Head: made of aluminum alloy. the combustion chamber. B. Spark Plug: NGK BPR7HS ¡ ] for 50C.C. ¡ ^ ,BPR7HS-10 ¡ ] for 90C.C. ¡ ^ . C.
  • Page 28 3-2-2 Carburetor I. idle Jet : When ATV idling, gasoline will pass through idle jet and mix with air and go into the crank case. When the throttle handle opens, the piston valve and needle jet are elevated to let gasoline pass through the main jet and mix with air and go into the crank case 2 .
  • Page 29 3-2-3 Lubrication & Cooling System ¡ G A. Lubrication of engine The Pump Gear is driven by the Screw Crank Shaft to rotate the Plunger valve of oil-Pump and send the lubricating oil into the Crank to completely mix with the carburetted air and then go into the Combustion Chamber.
  • Page 30 3-3 TRANSMISSION MECHANISM 3-3-1 Path of Power Transmission: The torque of Crank-Shaft from Drive Face to Belt ¡ ÷ Driven Face ¡ ÷ Clutch Shoe ¡ ÷ Clutch Housing ¡ ÷ Drive Shaft, through Idle Gear in Mission Chamber ¡ ÷ Turning Speed reduced by Final-Gear and Power transmitted to Rear-Axle Shaft to move Rear Wheel.
  • Page 31 3-3-2 Continuous Variable Transmission I . V-Belt : Made of rubber fiber, resistant to heat, pressure and abrasion. The inner side of the Belt is toothed. 2 . Drive Pulley : A. Due to the increasing revolution speed of Engine, the Roller in the Movable Drive Face is expanded by the centrifugal force to...
  • Page 32 3-3-2 Continuous Variable Transmission 4. Running Curve: A. During general speeding, continuous variable transmission is achieved smoothly along with its speed. B. During quick speeding, because the torque cam begins to act,the quick transformation can be achieved in high speed. C.
  • Page 33 3-3-3 Reducing Gear The power received by the Drive Shaft will be transmitted by the speed reduction of two sets of Gear to Rear Axle Shaft. 3-3-4 Starting Mechanism: The starting mechanism includes I. Electric Self-Starter : A. Starting Motor of BENDIX type.With Safety Starting Mechanism. B.
  • Page 34 3-3-4 Starting Mechanism: 2 . Kick starter : A. To start ATV by kicking, and the Brake-Lever has to be under brake condition. B. When the Kick-Starter Lever is kicked, the umbrella type gear of Starter Shaft will drive the right hand kick starter to revolve the crank shaft to start the engine. C.
  • Page 35 3-4 ELECTRIC SYSTEM 3-4-1 Ignition & Charging Device 1. Ignition Device: CDI Unit of two ignitions per revolution is adopted. 15 ¢ X ¡ Ó 3 ¢ X /4,000rpm The ignition Lead is 2. Charging Device: Power is given by flywheel magneto. The voltage is controlled by voltage regulator.
  • Page 36 3-4-1 IGNITION CHARGING DEVICE FOR THE IGNITION B. Battery : The Battery is the type of Water-Adding Free. 1. Battery Caution: 1. The electrolyte contains sulphuric acid is poisonous. avoid to contact with eye, skin and clothes. Immediately wash with abundant water and call a doctor at once in case of contact with the eyes or skin.
  • Page 37 3-5 BODY 3-5-1 Frame & Fuel and Oil System I . Frame : A. steel pipe and steel sheet are adopted to compose reinforced frame. 2 . Fuel Tank Fuel Tank is made of plastic with the capacity of 5.6L. The fuel tank is able to disassemble only after the removal of the steering shaft assy.
  • Page 38 3-5-2 Front & Rear Suspension System 1. Front-Suspension A. The Type OF Front Suspension is A-Arm control linkageType. B. The function of Front Suspension is to connect the frame and front wheel. C. Each Front Fork includs an absorber with compression spring and hydraulic buffer on right hand and left hand side each.
  • Page 39 CHAPTER 4 . DISASSEMBLY REPAIRMENT 4-1 NOTICE FOR DISASSEMBLY REPAIRMENT 4-2 REMOVAL AND INSTALLATION OF ENGINE 4-2-1 Removal of Engine 4-2-2 Installation of Engine 4-3 DISASSEMBLY AND ASSEMBLY OF ENGINE 4-3-1 Disassembly of Engine 4-3-2 Inspection of Engine Parts 4-3-3 Assembly of Engine 4-4 REMOVAL AND ASSEMBLY OF CARBURETOR 4-4-1 Removal of Carburetor 4-4-2 Inspection of Carburetor...
  • Page 40 4-1 NOTICE FOR DISASSEMBLY lNSPECTION 1. In order to avoid mixing and loss of disassembled parts before reassembling, the disassembled parts have to be arranged according to their function during the process. 2. The damage to Cover and Frame should be avoided while disassembling and assembling. 3.
  • Page 41 4-2-1 Removal of Engine A. Remove Ignition Coil Lead(I) Flywheel Magneto Lead(2) Engine Earth Ground Lead(3) Auto-Choke cable (4) . B. Remove the Throttle Cable on Carburetor Piston(5). C. Remove Oil Hose(6). D. Remove Negative Pressure Hose (7) and Remove Fuel Hose(8). E.
  • Page 42 4-2-2 Installation of Engine A. Lift the body and point the bottom end hole of crank case bracket to the two front holes of engine crank case. Install Engine Mounting Shaft and lock. B. Install Ignition Coil , Flywheel Magneto , Engine, Earth , and Auto-Choke Cable . C.
  • Page 43 4-3-1 Disassembly Sequence of Engine I . Remove the Muffler. 2. Remove the Kick Starter. Remove the Clutch. Remove the Spring of Kick Starter Rod. Remove the Kick Starter Shaft Comp. 3. Remove the Spring Seat. Remove the Washer. Remove the Left Hand Starter. ¡...
  • Page 44 4-3-1 Disassembly Sequence of Engine Remove the Ignition Coil. Remove the Spark Plug. Remove the Cylinder Cover. Remove the Cylinder Head. Remove the Cylinder. 10. Remove the Snap Ring of Piston Pin. Remove the Piston Pin. Remove the Piston. Remove the Piston Ring. Remove the Needle Bearing.
  • Page 45 4-3-1 Dis-assembly of Engine: ( Muffler, Kick Starter Lever Assy , Drive Pulley Assy .) 1. Removal of Muffler A. Hold the brake cable and lift the body until the rear carry bar touch the ground. B. Remove two bolts connected with the engine. C.
  • Page 46 4-3-l Disassembly of Engine: (Removal of Driven Pulley Assy) 4. Removal of Driven Pulley Assy: A. Remove Nut of Clutch Housing with pneumatic wrench or stop tool as shown. special Tool: GA5000051F04. B. Remove the Clutch Housing. C. Remove the Driven Pulley Assy.
  • Page 47 4-3-1 Disassembly of Engine: (Removal of Flywheel Magneto and Starter Motor) 5. Removal of Flywheel Magneto: A. Remove the Screw of Air Filter and remove the air filter. B. Remove the Screw of Fan-Cowling and remove Fan-Cowling. C. Remove the Screw of Cooling Fan and remove the Cooling-Fan and Fan Case. D.Tools should be adopted to prevent the rotation of Flywheel Magneto.
  • Page 48 4-3-1 Disassembly of Engine: (Removal of In-Take Pipe, Oil-Pump and Cylinder) 7. Removal of In-take Pipe: A. Remove the Fixed Plate of Fender (1). B. Remove the In-take Pipe (2). C. Remove the Reed Valve (3). 8 . Removal of Oil-Pump: A.
  • Page 49 4-3-1 Disassembly of Engine: ( Removal of Reducing Gear) 11. Removal of Reducing Gear: A. Drain the oil in the reducing gear box. ¡ · The Drain Screw of Engine has two designs, in the clutch cover or under the crank case. B.
  • Page 50 4-3-1 Disassembly of Engine: (Removal of Crank Case) 12. Removal of Crank Case : A. Release Fixing Screw(1) by diagonal step. B. Use a special tool to lock Crank Case (2) and Crank Shaft (3) to remove RH Crank Case. Special Tool: GA5000051F05 C.
  • Page 51 4-3-1 Disassembly of Engine: ¡ ] Removal of Crank Case ¡ ^ F. Pull the Oil Seal (1) of LH crank Shaft with a screw driver and remove the oil seal by tapping. G. Remove the bearing (2) of LH crank shaft by tighting the nut of the special tool.
  • Page 52 4-3-2 Inspection of Engine Components I. Measurement of Compression Pressure of Engine : A. start the engine to warm running up with a full- charged battery. B. Remove the spark plug and install the pressure gauge. C. Fully open the throttle lever and start the starter motor.
  • Page 53 B. Remove the bolt and drain bolt of outlet to drain the gear oil. C. Relock the outlet screw. Screw Torque: 40 ~ 70kg.cm D. Refill 90cc of TGB gear oil from the oil inlet. E. Tighten the oil inlet bolt. Screw Torque: 90 ~150kg . cm...
  • Page 54 4-3-2 Inspection of Engine Components 5. Inspection of Cylinder: A. Check if any damage appears on the bore. B. Check if any damage or crack appear on surface. C. Excessive carbon deposit in the air outlet has to be cleaned. D.
  • Page 55 C. Check for any damage and foreign material in the air cleaner. Clean the inside of the air cleaner. D. Clean the Filter with cleaning oil or diesel fuel. E. Dry the Filter and soak in 10g of TGB Supper Oil No. GA50400002.
  • Page 56 4-3-3 Assembly Sequence of Engine I. Assemble the Bearing of LH Crankcase. Assemble the Oil Seal of LH Crankcase. Assemble the Bush. Assemble the Bearing of RH Crankcase. Assemble the Oil Seal of RH Crankcase. Assemble the Crank Shaft. Assemble the RH Crankcase. 2.
  • Page 57 4-3-3 Assembly Sequence of Engine 8. Assemble the Pinion Gear Assy. Assemble the Starting Gear. Assemble the Cap Set of Starter Idler Gear. Assemble the Starting Motor. 9. Assemble the Coil Assy. Assemble the Flywheel Magneto. ¡ · Tighten the Nut of Flywheel Magneto. 10.
  • Page 58 4-3-3 Assembly of Engine: 1.Assembly of Crank Case A. Assemble the front Bush (1) of crank case with a vice. ¡ · The knurled side of Bush should face inwards when installing the buffer into the LH and RH crank cases. ¡...
  • Page 59 4-3-3 Assembly of Engine: E. Apply a thin layer of grease GA50400005 onto the lip of oil seal of the left hand crank case and install the oil seal with special tool. Special Tool: GA5000051F32 Slanting of oil seal and damage to the lip shall not be allowed.
  • Page 60 The drain hole for engine is located on the gear box cover or outside the crank case, for we have two designs. N. Fill 90cc of TGB gear oil (GA50400004) Q. Tighten the refilling bolt(12). Screw Torque : 90 kg ¡...
  • Page 61 4-3-3 Assembly of Engine 3. Assembly of Piston A. Apply TGB oil (GA50400002) on the needle roller bearing ¡ @ at the small end of con-rod. B. Install the piston ring (3) on the piston (2). (FOR 50C.C.) a. The 2nd ring (6) is engraved 2R mark which should face upwards while installing.
  • Page 62 ¡ · The cir-clip has to be actually installed to its position, or it will cause cylinder jam during operation. C.Apply more than 3cc of TGB oil (GA50400002)evenly on the inside of the cylinder and the outside of the piston.
  • Page 63 4-3-3 Assembly of Engine: 5. Assembly of Oil-Pump: A. Apply a layer of grease (GA50400005) on the sliding part and gear tooth of oil-pump driven gear (1) and then insert into the crank case. B. Install the oil-pump (2). 6. Assembly of Reed Valve: A.
  • Page 64 4-3-3 Assembly of Engine: D. Install the starter gear(I) into the left hand crank shaft(2). E. Install the starter motor and tight the bolt with cable clamp.
  • Page 65 4-3-3 Assembly of Engine: 8. Assembly of Flywheel Magneto A. Screw the coil. B. Let the coil lead go through the opening of Crank Case. C. Clean the taper of crank shaft and install the key . Tap lightly to its position. D.
  • Page 66 4-3-3 Assembly of Engine: 9. Assembly of Cooling Fan: A. Install fan case(1) . ¡ · The lead has to go through the groove of right hand crank case and damage should be avoided. B. Install cooling fan(2). C. Install fan cowling(3) . ¡...
  • Page 67 4-3-3 Assembly of Engine : 10. Assembly of Movable Driven Pulley Assy : A. Install the ball bearing(I) into the fixed driven face comp(2). ¡ · The outer diameter of bearing press fitted with the hole of face comp. Pay attention to press to the outer ring by special tool.
  • Page 68 4-3-3 Assembly of Engine: (Assembly of Movable Driven Pulley Assy) M. Move the movable driven face (1) of movable driven pulley assy towards the clutch (2) by hand. Install V-belt and then install to the drive shaft. ¡ · Wipe cleanly the grease on belt surface and the pulley surface. N.
  • Page 69 4-3-3 Assembly of Engine: 11. Assembly of Drive Pulley Assy A. Apply about 3 ~ 4g of grease (GA50400008) to the roller groove of drive pulley and then install the roller assy into the groove. B. Inlay the guide block (1) into the movable drive plate(2) and then install the movable drive plate(2) into...
  • Page 70 4-3-3 Assembly of Engine: (Assembly of Movable Driven Pulley Assy) F. Clean the grease on the surface of drive pulley and then install into the left hand crank shaft. ¡ · Press the movable drive plate with fingers all the time while installing, or the roller will stand up.
  • Page 71 4.3.3 Assembly of Engine: 12. Assembly Kick starter Lever Assy. A. Apply a layer of grease(GA50400005) inside the bush(1) and then press into the clutch cover. B. Apply a thin layer of grease(GA50400005) to the kick starter shaft(2) and then install the spring (3).
  • Page 72 4.3.3 Assembly of Engine: 13. Assembly of Muffler A. Install the muffler ,Put on the bolt and nut first. B. Screw the bracket bolt of Exhaust pipe. screw Torque: 80~120 kg.cm C. Tighten the bolt with the bracket of frame screw Torque: 300~400 kg .
  • Page 73 4-4 REMOVAL AND ASSEMBLY OF CARBURETOR : Removal of Carburetor : I. Removal of Carburetor : A. Remove the right hand side cover. B. Remove the air cleaner. C. Remove the fuel-hose (I). D. Remove the negative pressure hose (2). E.
  • Page 74 4-4 REMOVAL AND ASSEMBLY OF CARBURETOR: Inspection and Assembly of Carburetor 2. Inspection of Carburetor: A. Inspect and clean the jets and airway of the carburetor. Cleaning by compressed air. B. Check if the float operates normally to its position. C.
  • Page 75 4-5 INSPECTION OF ELECTRIC ITEMS ¡ · Notice for Inspection and Arrangement of Electric Components: A. Use pocket tester for inspection and testing of electric parts. B. The battery for Testing should be of full charging. C. The setting of the position of Tester Range has to be performed accurately. D.
  • Page 76 4-5-1 Removal and Inspection of Ignition and Charging System C. Inspection of Rectifier a. Testing Range - X 1 K £ [ b. Terminals shall not connect with the rectifier surface. c. Check the electric resistance value between each wire. Electric Resistance of Rectifier White/Red Yellow/White...
  • Page 77 4-5-1 Removal and Inspection of Ignition and Charging System E. Inspection of the Spark Plug a. Remove the spark plug cap. b. Remove the spark plug. c. Check for any dirt and damage of electrode with eyes. d. Clean with special tool or wire brush if it is dirty. e.
  • Page 78 4-5-2 Removal and Inspection of Starter Mechanism A. Circuit of Starter Mechanism: a. Circuit Description: Ignition Switch ON ¡ ÷ Brake Switch ON ¡ ÷ Starter Relay ¡ ÷ Starter Switch ON ¡ ÷ Starter Motor started. B. Inspection of Starter Relay: a.
  • Page 79 4-5-3 Removal and Inspection of Fuel tank A. Inspection of Fuel tank ¡ G Take off the cover and Check whether the tank is in leankage or not? If it does, change the fuel tank. B. Removal the fuel tank: dis-assemble the front steering system, then it can take out the fuel tank.
  • Page 80 4-6 REMOVAL AND INSPECTION AND ASSEMBLY OF BODY PARTS 4-6-1Removal and Inspection and assembly of Steering Shaft Assy. 4-6-1.1 Removal of Steering shaft Assy. A. Lift the Front Wheel B. Remove the upper and lower brake cable and throttle cable in the right handle bar. C.
  • Page 81 4-6-1 Removal and Inspection and assembly of steering shaft assy. 4-6-1.2 Inspection of Steering shaft Assy.: A. Check for any unusual wear of the sliding spacer. B. Check for any damage in the welding part. C. Check for any unusual wear of tube. D.
  • Page 82 4-6-2 REMOVAL AND INSPECTION AND ASSEMBLY OF REAR AXLE 4-6-2.1 Removal of Rear Axle A. Lift the Rear Wheel B. Remove the rear brake cable in the left handle bar. C. Remove the left handle bar. D. Remove the chain from the engine case. ¡ ] 1 ¡ ^ E.
  • Page 83 4-6-2 Removal and Inspection and Assembly of Rear Axle 4-6-2.2 Inspection of Rear Axle: A. Check for any unusual wear of the sliding spacer. B. Check for any damage in the welding part. C. Check for any unusual wear of tube. D.
  • Page 84 4-6-3 REMOVAL AND INSPECTION AND ASSEMBLY OF BRAKE WHEEL 4-6-3.1 Removal of Front and Rear Wheel A. Remove the Pin. B. Release the Fixed Nut and Self-lock Nut. C. Remove the Wheel. D. Remove the Front Brake drum. E. Remove the Rear Brake disc. 4-6-3-2 Inspection of Brake Parts:(FOR Front and Rear Brake) A.
  • Page 85 4-6-3 Removal and Inspection and Assembly of Brake and wheel 4-6-3.3 Assembly of Brake and wheel A. Assemble the Brake drum and disc. B. Assemble the wheel. C. Assemble the Slf-lock nut. Nut torque: 400~450kg.cm D. Assemble the Fixed nut. Nut torque: 500~550kg.cm E.
  • Page 86 UNPACK & ASSEMBLE ATV Remark¡ G ATV was fixed and packaged by a iron box due to shipment. After unpacking the box, it can be found that several parts were dis-assembled, including with wheel, battery, handle bar and caliper. Please follow the steps to assemble ATV. Step 1¡...

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