Page 1 ORKSHOP MANUAL ATV DXR 200...
Page 2 For Area Importer and Territorial Distributor: * All rights reserved. No part of this manual may be reproduced or unauthorized use in any form or by any means, without prior permission of the Maker, NACIONAL MOTORS. S.A.U. http: www.derbi.com NACIONAL MOTOR, S.A.U.
Page 4: Part 3. Periodic Maintenance And Adjustment
PART 1. GENERAL INFORMATION l-0l. Service Precautions Pág. 9 1-02.Briefing Service Information Pág. 11 1-03.Cleaning Pág. 12 1-04.Storage Pág. 13 PART 2. SPECIFICATION 2-01.General Specification Pàg. 14 2-02.Location & Cable Routing Pág. 16 2-03.Torque Value Pág. 19 2-04.Special Tools -- OPTION (reference) Pág.
Page 5 3-21.Rear shock absorber adjustment -- option Pág. 39 3-22.Tire inspection Pág. 41 3-23.Tire wear limit Pág. 42 3-24.Wheel removal and installation Pág. 43 3-25.Replacing the headlight Pág. 43 3-26.Replacing the rear-light Pàg. 43 3-27.Battery charging system Pág. 43 3-28.Battery removal Pág.
Page 6 PART 6. ELECTRIC DETAILS 6-01.Service Precautions(Electric Devices) Pág. 149 6-02.Ignition System Pág. 153 6-03.Charging System Pág. 159 6-04.Starting System Pág. 165 6-05.Lights/Instruments/Switches Pág. 171 PART 7. TROUBLE-SHOOTING 7-01.Engine does not start or hard to start Pàg. 179 7-02.Poor performance (especially at low and idle speed) Pág.
Page 7 1-1 I MPORTANT SAFETY MESSAGE BE SURE TO INFORM THE END-USER FOLLOWS; 1 . TO READ THE OWNER MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THE ATV. . MAKE SURE THE END-USER UNDERSTAND ALL INSTRUCTIONS. 2. PAY ATTENTION TO THE WARNING AND CAUTION. LABELS ON THE ATV. 3.
Page 10: Part 1. General Information
PART 1. GENERAL INFORMATION PART 1. GENERAL INFORMATION 1-1. S ERVICE RECAUTIONS 01. Be sure to use the new gaskets, o-rings, ring clamps, cotter pins... during the re-assembly or any service. (Fig. 1-01). 02. When tightening bolts, screws, or nuts, should start with large diameter boles to smaller ones. Be tighten to the specified torque diagonally.
Page 12 1-2. B RIEFING ERVICE NFORMATION WARNING TO AVOID THE ENGINE RUNNING DURING REPAIR OR SERVICE, THE EXHAUST SMOKE CONTAINS POISO- NOUS CARBON MONOXIDE GAS WHICH MAY CAUSE SERIOUS INJURY OR DEATH. SOLUTION 1. Never run the engine in a close area. 2.
Page 13 1-3. C LEANING Clean ATV regularly to protect the surface finishes and check for the damage, wear, and oil or brake fluid leakage will enhance ATV overall appearance and general performance. 01. Block off the end of the exhaust pipe to preven 1 water entry. Next. make sure the spark plug and fuel caps are fastened.
Page 14 1-4. S TORAGE Before long term storage (says 60 days or more), be sure to check the ATV for needed repairs and have it corrected. 01. Change engine oil and oil filter. 02. Drain the fuel from tank and carburettor. 03.
Page 15: Part 2. Specification
PART 2. SPECIFICATION PART 2. SPECIFICATION 2-1. G ENERAL PECIFICATION Dimension L/W/H: 1.610 / 1.35 / 1.010 mm or 634/40. 7/39. 7in Seat height 770 mm or 30.3in Wheel base 1.080 mm or 42.5in Min. ground clearance 120 mm Min. turning radius 3.000 mm Weight (125/50) 152 Kg.
Page 16 Clutch type Wet, multi-blade Operation Left hand operation Fuel type Unleaded gasoline Fuel tank capacity 8,0 L (1,76 lmp gal; 2,12 US gal) Reserve fuel 2,0 L (0,44 lmp gal; 0,53 US gal) Chassis type Steel tube frame Caster angle 9.0 degree Trail 40mm (1.57 in)
Page 17 2-2. L & C OCATION ABLE OUTING Clutch cable Parking brake cable Front brake cable Throttle switch lead Throttle cable Handlebar switch Voltage regulator lead Main switch Wire harness Ground lead Front brake cable Clutch cable Main switch lead Wire holder Clamp Carburettor overflow hose Flywheel magneto lead...
Page 20: Torque Value
2-3. T ORQUE ALUE 2-3-1. Standard Torque Value TYPE TYPE TORQUE (KG.-M) TORQUE (KG.-M) 05mm bolt, nut 0,45 - 0,60 05mm screw 0,45 - 0,60 06mm bolt, nut 0,80 - 1,20 06-nim nut, SH bolt 1,00 - 1,40 08mm bolt, nut 1,80 - 2,00 06mm flange bolt.
Page 21 2-3-3. Chassis Parts Torque Value ITEMS (S) Q’TY THREAD DIA. TORQUE Steering column holder and frame 08 * 1,25 mm 2,3 Kg.-m Steering column and handlebar 10 * 1,25 mm 3,0 Kg.-m F. shock absorber (upper & lower) 10 * 1,25 mm 4,5 Kg.-m Front arm (upper-frame) 10 * 1,25 mm...
Page 22 2-04. S -- O PECIAL OOLS PTION REFERENCE (02) cylinder valve adjuster (01) ignition timing light (04) rpm tester (03) pocket tester (06) dial gauge (1/l00mm) (05) micrometer (25-50mm) (08) micrometer (0-25-mm) (07) magnetic stand (10) V-block (09) cylinder bore gauge (12) snap ring pliers (11)
Page 24: Part 3 . Periodic Maintenance
PART 3 . PERIODIC MAINTENANCE PART 3 . PERIODIC MAINTENANCE 3-01. P ERIODIC INSPECTION ADJUSTMENT AND LUBRICATION WILL KEEP ATV in the safest and best operation condition. Be sure to use only genuine maker parts for replacement. WARNING 1 SERVICING AN ENGINE WHILE IT IS RUNNING. AWARENESS 1 Hot surface or moving parts can harm people, Electrical components can be damaged.
Page 25 3-03. P ERIODIC AINTENANCE Be sure to perform periodic inspections and maintenances as the manual suggestion. 1). “*” should be settled by local dealer or service station 2). “I” should, be inspect and clean, adjust, replaced or lubricate when it is necessary. 3).
Page 26 & ABLE OF PERIODICAL CHECK SERVICE 1000 2000 - (every 1000 km) ITEM´S - (every 100 hrs) 01. Engine oil 02. engine oil filter 03. Engine idle speed 04. Value clearance 05. Spark plug 06. Air cleaner 07. Air cleaner tube 08.
Page 27 3-04. E . 3-02, 3-03, 3-04 PIGONE OIL STROKE ENGINE OIL ONLY Maker recommends engine oil viscosity: SAE 10W-40, a qualified synthetic oil is strongly recommended. Other viscosities shown in (Fig. 3-05) may be used when the average temperature in your area is within the indicated range.
Page 29: Spark Plug Inspection
3-05. S . 3-07, 3-08) PARK PLUG INSPECTION Standard spark plug: NGK DR-8EA o D-8EA 0.1. Remove the spark plug (1) (Fig. 3-07). 02. Check the spark plug for wear, fouling deposits and cracks. 03. Remove the fouling deposits with a wire brush. 04 .
Page 30 3-06. A . 3-09, 3 10, 3 11, 3 1.2) IR CLEANER CLEANING NOTE THERE IS A HOLE AT THE BOTTOM OF THE AIR CLEANER CASE. ANY DUST OR WATER COLLECTS IN THIS HOLE, BE SURE TO EMPTY THE HOLE AND CLEAN THE AIR FILTER ELEMENT; AND AIR CLEANER CASE. 01.
Page 32 3-07. I . 3-13) DLE SPEED ADJUSTMENT 01. Warm up the engine. 02. Turn pilot air screw clockwise until it is lightly seated. 03. Loosen pilot air screw by turning it counterclockwise 1-1/2. 04. Stop the engine and check the inductive tachometer. 05.
Page 33 <continue the 3-11-1. Check the brake fluid level> CAUTION 1. NEVER ALLOW FOREIGN MATERIALS(DIRT, WATER, ...) ENTER THE BRAKE FLUID RESERVOIR. 2. BRAKE FLUID CAN DAMAGE ANY PAINTING AND PLASTIC. WARNING BRAKE FLUID CONTACTING THE SKIN AND EYES. AWARENESS May cause irritation. SOLUTION Avoid contacting brake fluid with the skin or eyes.
Page 34 3-12. F RONT BRAKE LEVER FREE PLAY ADJUSTMENT The front brake lever free play should be adjusted to 3-5 mm (0.12-0.20 in) at the brake lever pivot. If the free play is incorrect, adjust as follows: (Fig. 3-19, 3-20, 3-21) 01.
Page 36 3-14. C . 3-22, 3-24) LUTCH ADJUSTMENT AND LUBRICATION 3-14-1. The clutch cable free play should be 5-8 mm (0.20 - 0.31in); (a) . If the free play is incorrect, adjust as follows. 01. Loosen the lockout. 02. Turn the adjuster clockwise or counter-clockwise until proper free play is attained. * clockwise = free play is increased * counter-clockwise...
Page 38 3-16. C . 3-28) ABLE INSPECTION AND LUBRICATION WARNING POTENTIAL HAZARD: DAMAGED CONTROL CABLES. AWARENESS Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. SOLUTION Inspect cables frequently.
Page 40: Front Shock Absorber Adjustment
3-19. T . 3-32, 3-32/ 3-33/ 3-34/ 3-35) DJUSTMENT 01. place the ATV on a level place 02. check the Toe-in, if out of specification, be adjusted. NOTE 1. MARK BOTH FRONT TIRE TREAD CENTRES. 2. RAISE THE FRONT END OF THE ATV 3.
Page 42 3-22. T , 3-39. 3-40) NSPECTION 3-22-1. Tire Deals Be sure to keep the tire pressure. Operating this ATV with improper tires, or with improper or uneven tire pressure. CAUTION USE OF IMPROPER TIRES ON THIS ATV OR OPERATION OF THIS ATV WITH IMPROPER OR UNEVEN TIRE PRESSURE MAY CAUSE LOSS OF CONTROL AND INCREASE RISK OF ACCIDENT.
Page 43: Tire Wear Limit
03. Be sure no more than follows pressures when seating tire Beads. Front: 250 kPa (2,5 kgf/cm2, 36 psi) Rear: 250 kPa (2,5 kgf/cm2, 36 psi) 3-22-2. The low-pressure tire gauge (Fig. 3-35) Keep the low-pressure tire gauge with the ATV for ready use all the time. Take out dirt or dust in the gauge. Always make two measurements of tire pressure and take the 2nd.
Page 44 3-24. W . 3-42, 3 -42) HEEL REMOVAL AND RE INSTALLATION 3-24-1. Removal 01. Elevate the wheel by placing a suitable stand under frame. 02. Remove the nuts from the wheel. 03. Remove the wheel assembly. 3-24-2. Installation When installing the wheels, reverse the removal procedure. Tighten. the wheel nuts to the specified torque. Wheel nut torque: Front: 45 Nm (4,5 Kg.-m, 32 ft*lb);...
Page 46 3-28. B . 3-49) ATTERY EMOVAL When recharging or store, remove battery from ATV. The procedure; 01. be sure the ignition (main) switch is “OFF” 02. take out the seat 03. disconnect the negative (-) terminal lead from battery 04. disconnect the positive (+) terminal lead from battery 05.
Page 48 3 31. E . 3-55, 3.56, 3-57, 3-58, 3-59. 3-60) NGINE DJUSTMENT 3-31-1. Valve clearance 01- remove the cylinder head cover Fig. 3-55 02. rotate the generator flywheel on camshaft on the top dead centre (TDC) and align the “T” mark. Fig. 3-56, 3-57 03.
Page 50: Part 4. Engine Details
PART 4. ENGINE DETAILS PART 4. ENGINE DETAILS 4-01. F YSTEM AND ARBURETION NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING <Q-A> 01. Throttle disassembly 02 . Carburettor removal 03. Float/float inspection 04. Jets/air screw/throttle screw removal 05. Fuel outlet ball removal and inspection 06.
Page 51 4-05. C YLINDER ISTON NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING <Q-A> 1. Cylinder removal 2. Cam follower removal 3. Piston removal and inspection 4. Cylinder head inspection 5. Piston installation 6. Cylinder installation 4-06. S / L C TARTER ENERATOR RANKCASE TART LUTCH...
Page 52 4-1.F YSTEM AND ARBURETION RIEFING (01) Dutch (02) Cleaner cover (03) Seal of air cleaner cover (04) Plate of element sec. (05) Element of air cleaner (06) Side cover (07) Fuel tank (08) Fuel hose (09) Carburettor (10) Joint of air-cleaner...
Page 53 4-1. F YSTEM AND ARBURETION NOTE SERVICE INFORMATION Carburettor Float level: 125 cc on 12,5 mm; 150 cc on 13 mm Main jet: 125 cc on # 90; 150 cc on # 102 Slew jet: 125 cc on # 35; 150 cc on # 40 Idle speed: 125 cc on # 1400 +/- 100 rpm 150 cc on # 1500 +/- 50 rpm...
Page 54 <Q-A> Engine Cranks but do not start? - no fuel in the tank - no fuel in the carburettor - cylinder flooded with fuel - no spark at plug - clogged air cleaner - intake air leak - improper throttle operation <Q-A>...
Page 55 4-1-1. Throttle disassembly (Fig. 4-01, 4-02, 4-03, 4-04) 01. remove the carburettor cap (1) Fig. 4-01 02. pull out the throttle valve (Option) disconnect the accelerating pump cable 03. disconnect the choke knob cable 04. disconnect the throttle cable and remove the spring Fig. 4-03 05.
Page 57 4-1-7. Choke(refer to Fig. 4-10, 4-11) For different requirements, the choke position may locate on left handle-bard;, below the start button. Fig. 4-11. Starting a cold engine requires a richer air-fuel mixture (2) on direction (3) to open the choke and (4) to close the choke.
Page 58 4-2. L UBRICATION YSTEM RIEFING (01). oil filter rotor (02). oil pump (03). primary gear (1ST) CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL (A QUALIFIED SYNTHETIC 4-STROKE OIL IS STRONGLY RECOMMENDED), CLEANING ENGINE OIL FILTER, .. AFTER 1ST 20HRS (OR 100KM) OPERATION.
Page 59: Troubleshooting
4-2. L UBRICATION YSTEM NOTE SERVICE INFORMATION ITEMS STANDARD (RAM.) SERVICE LIMIT (MM.) <0IL PUMP> 01. Inner rotor - outer / rotor clearance 0,20 mm 02. Outer rotor - pump body / clearance 0,20 mm 03. Rotor end - pump body / clearance 0,015 - 0,1 mm 0,15 mm CAUTION...
Page 60 4-2-1. Engine oil (4-stroke engine oil only) -- refer to part 3-04 4-2-2- Oil Pump/Oil Filter Rotor Removal: (Fig. 4-13) (option) remove the kick lever --- if this engine has kick 01. disconnect the clutch cable. 02. remove the right crankcase cover bolts and crankcase cover. 03.
Page 62: Engine Removal
4-3. E NGINE EMOVAL NSTALLATION ERVICE NFORMATION CAUTION 1. WHEN REMOVING ENGINE, A FIRM ENGINE STAND IS REQUIRED TO SUPPORT THE ENGINE. BE SURE DO NOT USE HAMMER OR SCREW DRIVER TO STRIKE OR PRY THE ENGINE. DO NOT DAMAGE THE CRANKCASE MATTING SURFACES AND CLEAN OFF ALL GASKET MATERIAL FROM THE MATING SURFACES.
Page 64 continue 4-3-1. Engine removal 06. remove the starter motor wire (1) Fig. 4-33 07. remove the drive gear and chain Fig. 4-34, 4-35 08 remove the gear shift lever bolt and gear shift lever Fig. 4-36, 4-37 09. remove the bolts Fig. 4-38, 4-39 10.
Page 66 4-4. C YLINDER ALVE RIEFING (01). cylinder head (02). gasket, head cover (03). spark plug (04). rocker arm holder (05). guild push rod (06). nut, tapping adjuster (07). screw tapping adjusting (08). cotter (09). retainer valve spring (10). spring, valve inner (11).
Page 67 4-4. C YLINDER ALVE NOTE SERVICE INFORMATION ITEM SERVICE LIMIT (MM) STANDARD (MM) 01. Valve clearance (cold engine) 0,05 - 0,1 0,05 - 0,1 02. Cylinder compression 10 - 14 Kg./cm2 8 Kg./cm2 or less 03. Cylinder head war page 0,05 or less 0,1 or more 04.
Page 68 NOTE PROBLEMS SHOOTING: <Q-A> Poor performance at idle speed - compression too low? - incorrect valve clearance too small - burned or bend valve - incorrect valve timing - broken valve spring - valve seas not airtight - leaking cylinder head gasket - warped or cracked cylinder head - poorly installed spark plug <Q-A>...
Page 70 4-4-4. Cylinder head disassembly and check (Fig. 4-44, 4-45) 01 remove the valve spring cotters by spring compressors 02. remove the retainers, springs, springs seats, washers, and valve stem seals. 03. remove carbon deposits from the combustion chamber (1) and Nexhaust ports Fig. 4-45 04.
Page 72 4-4-5. Cylinder head assembly and installation - The installation should follow the reverse order of removal. 01. lubricate each valve stem with engine oil. 02. insert the valves into the valve guides. 03. apply oil on valve stem seals and install them into guides 04.
Page 74 4-5. C YLINDER ISTON RIEFING (01). gasket cylinder head (02). cylinder (03). gasket cylinder (04). washer wave 12.3*21*0.2 (05). follower cam (06). shaft caw follower (07). piston ring (08). circlip (09). piston pin (10). piston...
Page 75 4-5. C YLINDER ISTON NOTE SERVICE INFORMATION CYLINDER ITEM STANDARD (MM) 125/150 SERVICE LIMIT (MM)125/150 01. Cylinder bore 56,5 - 56,6 / 62 - 62,1 56,6 / 62,1 or more 02. Cylinder war page 03. Cylindricity 0,01 or less 0,05 or more 04.
Page 76 NOTE PROBLEMS SHOOTING <Q-A> Compression too low? - worn, stuck, or broken piston rings - worn or damaged cylinder or piston <Q-A> Compression too high? - excessive carbon build-up in combustion chamber or on piston head <Q-A> White smoke from exhaust muffler? - worn or damaged cylinder or piston - worn or damage piston ring <Q-A>...
Page 78 4-5-4. Cylinder inspection 01. inspect the cylinder bore for any wear. scratches, or damage. 02. measure the cylinder bore at 3 levels (top. middle, bottom) in X and Y directions, 90 degree to the piston pin. Fig. 4-64 * service limit: 62.1mm 03.
Page 80 4-5-5. Piston installation Fig. 4-72 - The installation should follow the reverse order of removal. 01. install 3rd. ring rail onto the piston 02. install oil-ring, side rail, and 2nd. ring onto the piston 03. install top ring onto the piston 04.
Page 82 4-6. S /L. C TARTER OTOR ENERATOR RANKCASE OVER TARTER LUTCH AMSHAFT RIEFING (02). stertor (01). starting motor (04). camper, wire harness (03). L crankcase (06). shaft reduction gear (05). bearing needle (08). cover reduction gear (07). gear reduction (10). o-ring (09).
Page 83 4-6. S /L. C TARTER OTOR ENERATOR RANKCASE OVER TARTER LUTCH AMSHAFT NOTE SERVICE INFORMATION ITEMS STANDARD (MM) 125/150 SERVICE LIMIT (MM)125/150 9,932 or less 01. Reduction pinion: 9,972 - 9,987 shaft O.D. 02. Reduction pinion: 10,096 or more 10,031 - 10.056 shaft hole I.D.
Page 84 4-6-1. Starter motor removal 01. remove the 2 starter motor mounting bolts (1) and the motor Fig. 4-”4 02. inspect the start motor o-ring on any damage. 03. inspect the start motor pinion on any damage. 04. remove the 3 bolts (1) Fig. 4-75 05, remove the reduction gear cover (2) Fig.
Page 86 4-6-5. Camshaft removal 01. remove the camshaft set plate (1) Fig. 4-86 02. remove the spring (1), camshaft (2), washer, and cam (Fig. 4-86A, 4-86B) 03. inspect the camshaft o-ring for wear or damage 04. measure the cam lobe height (a) Fig. 4-87 x service limit: less than 32.628mm -- replace 04.
Page 88 4-7.C LUTCH HIFT ECHANISM RIEFING (01). outer clutch (02). washer spline (03). plate clutch pressure (04). disc, clutch friction (05). plate clutch (06). center clutch (07). circlip (08). spring clutch (09). plate clutch lifter (10). bearing (11). pin, clutch lifter guide (12).
Page 89: Shift Mechanism
4-7. C LUTCH HIFT ECHANISM NOTE SERVICE INFORMATION STANDARD (MM) SERVICE LIMIT (MM) ITEM 01. Clutch spring free: / length 34,2 or less 35,5 2,6 or less 02. Reduction friction: 2,9 - 3,0 disk thickness 03. Clutch place: / bending 0,2 or more 0 - 0,1 111 - 111,5...
Page 90 4-7-1. R. crankcase cover removal 01. drain the engine oil out 02. (option) remove the kick lever 03. disconnect the clutch cable Fig. 4-92 04. remove the R crankcase cover bolts (1) Fig. 4-92 05. remove the R crankcase cover 06.
Page 92 4-7-4. Gear shift mechanism removal 01. remove the gear shift pedal (1) Fig. 4-103 02. remove the gear shift spindle (2) and washer (3) Fig. 4-103 03. remove the stopper (1) and spring (2) Fig. 4-104 04, remove the gear shift cam bolt (3.) Fig. 4-204 05.
Page 94 4-8.C RANKCASE RANKSHAFT RANSMISSION YSTEM TARTER PINDLE (C-l). holder clutch wire (02). R crankcase (03). counter shaft (04). bearing (05). main shaft (06). gear shift fork (07). fork R gear shaft (08). fork center gear shaft (09). fork L gear shaft (10).
Page 95: Crankcase /Crankshaft
4-8. C RANKCASE RANKSHAFT RANSMISSION YSTEM TARTER PINDLE NOTE SERVICE INFORMATION < TRANSMISSION FORK> STANDARD (MM) SERVICE LIMIT (MM) ITEMS 01. Claw thickness 4,93 - 5,0 4,43 or less 02. Fork I.D. 12 - 12,018 12,058 or more 03. Fork shaft O.D. 11,97 - 11,984 11,936 or less <TRANSMISSION DRUM>...
Page 96 NOTE PROBLEMS SHOOTING <Q-A> Excessive engine noise? - worn main shaft journal bearing, or worn crankshaft pin bearing - worn transmission system bearing <Q-A> Transmission gear tripping? - worn gear teeth, or bent transmission fork - damaged gear shift cam stopper <Q-A>...
Page 98 4-8-3. Transmission gears/crankshaft removal 01. remove the transmission main-shaft and counter-shaft from L crankcase, when removing gears must remove as a set base Fig. 4-119 02. remove crankshaft and disassemble main shaft & counter-shaft 4-8-4. Gear/shaft collar inspection 01. check each gear and teeth for any wear and damage -- replace 02.
Page 100 4-8-5. <OPTION> Starter spindle removal and inspection • this section is only for engine with kick (OPTION) 01. disassemble the starter spindle 02. check starter ratchet and pinion for any wear or damage 03. check starter spindle return spring any deformation/damage 04.
Page 102 4-8.7. Crankshaft inspection Fig. 4 128, 4-129, 4 130, 4-131 01. measure the connecting rod big end side clearance * service limit.: more than 0.80mm - replace 02. measure the connecting rod big end radial clearance at points at right angles to the shaft. * service limit: more than 0.05mm -- replace 03 .
Page 104: Part 5. Chassis Details
PART 5. CHASSIS DETAILS PART 5. CHASSIS DETAILS 5-01. F RONT HEEL RONT RAKE 1. Removal 2. Inspection 3. Wheel bearing and oil seal replacement 4. Brake shoe and brake plate inspection 5. F wheel installation 5-02. R HEEL 1. Rear wheel removal 2.
Page 105 5-1. F HEEL AND RONT RAKE RIEFING (02). plate brake shoe (01). lever camshaft (04). brake shoe set (03). camshaft (05). o-ring (06). spacer, bearing (07). tire (08). wheel (10). collar (09). (12). indicator plate (11). washer (13). oil seal...
Page 106: Front Brake
5 -1. F RONT HEEL AND RONT RAKE 5-1-1. Removal 01- place the ATV on a level place 02. out parking braked (1) and place a stand under frame Fig. 5-01 03. remove the front wheel nuts (1) Fig. 5-02 04.
Page 108 <continue 5-1-2, Inspection> 04. inspect the brake drum(inner face) to wipe off oil from brake drum with rag sacked in lacquer thinner or solvent. Fig. 5-11 05. inspect the brake drum(inner face); (a) to polish brake drum lightly on the scratches place Fig. 5-12 06.
Page 110 5-1-5. Front wheel installation - Reverse the “5-1-1” procedure and follows the lubricate as 01. lubricate brake cam (1), brake shoe pivot pin (2) oil seal (3) - Fig. 5-17. * use: lightweight lithium-soap base grease 02. lubricate oil seal lips and bearing * use: lightweight lithium-soap base grease (lightly) 03.
Page 112 5-2.R HEEL AND RIEFING (02). spacer (01). axle (04). collar sprocket axle (03). (05). sprocket driven 40T (06). chain (07). nut hexagon (08). washer lock (10). tire (09). collar wheel (11). wheel...
Page 113 5-2. R HEEL AND 5-2-1. Rear wheel removal 01. place the ATV on a level place 02. put the parking brake on (1) Fig. 5-23 03. loosen rear wheel nut (1) Fig. 5-24 04. elevate the rear wheel by placing a stand under frame Fig. 5-24 05.
Page 114 <continue 5-2-1. Rear wheel removal> 11. remove under guard (1) Fig. 5-28 12. loosen rear axle hub upper nut (2) Fig. 5-28 13. loosen rear axle hub lower nut (3) Fig. 5-28 14. loosen chain tensioner adjuster (4) Fig-. 5-28 15.
Page 116 5-2-2. Inspection 01. inspect wheel -- refer to part 3-22 02. measure wheel runout -- refer to pare 3-23 03. check wheel hub (1) for any crack or damage -- replace Fig. 5-36 04. check wheel hub Splines (2) for any wear or damage -- replace Fig. 5-36 05.
Page 118 5-2-4. Installation - Reverse the “5-1-1” procedure and follows the lubricate as; 01. lubricate oil seal lips 02. lubricate bearing * use: lightweight lithium-soap base grease (lightly) 03. lubricate splines * use: lightweight lithium-soap base grease 04. install rear axles hub. On this step, the rear axles should not be tighten completely. The firm tightening is done after the chain slack adjustment.
Page 119 < continue 5-2-4. Installation> - Reverse the “5-1-1” procedure and follows the lubricate as; 18. tighten rear axle inner nut (1) * torque: 1st. tighten 5.0 kg-m; final tighten 24 kg-m tighten rear axle outer nut (2) * torque: 19 kg-m NOTE REAR AXLES NUT TIGHTEN STEPS -- RARER 5-2-5 19.
Page 120 5-3. R RAKE RIEFING (02). brake hose (01). master cylinder (04). caliper (03). brake pad caliper (05). bracket caliper (06). bracket disc (07). disc (08). brake fluid reservoir (09). hose...
Page 121: Rear Disc Brake
5-3. R RAKE 5-3-1. Brake fluid change - refilling 01. remove the brake fluid tank cap (1), be sure to put a towel to prevent the brake fluid dropping Fig. 5-45 02. connect with a transparent hose on caliper bleed valve and loosen the lock nut (1) to draw the existing brake fluid out.
Page 122 5-3.2. Brake shoe (lining) , disc, master cylinder inspection 01. remove the brake shoe (lining) from caliper Fig. 5 49 02. inspect the brake shoe (lining) for any wear or damage -- replace. Fig. 5-50 03. be sure to replace the whole set of brake shoe (lining) (1) Fig. 5-51 04.
Page 124 5-4.S TEELING YSTEM RIEFING (02). holder handle upper (01). blot flange (04). steering (03). plug taper (05). holder handle lower (06). washer (07). joint universal (08). collar (10). washer lock (09). bracket (11). tie rod...
Page 125 5-4. S TEELING YSTEM 5-4-1. Removal 01. remove handlebar cover Fig. 5-55 02. disconnect fuel breather hose 03. remove the L and R lever holder Fig. 5-56, 5-57 04. remove the front cover (1) Fig. 5-58 05. disconnect main switch (1), neutral (2), front lamp leads (3)
Page 126 <continue 5-4-1. Removal> 06. remove the stay (1) Fig. 5-61 07. remove the handlebar holders (2) Fig. 5-61 08. remove the handler (3) Fig. 5-61 09. remove cotter pins (1), nuts (2) and tie rods (3) Fig. 5-62 10. remove cotter pins (1) nut (steering column) (2) , and washer (3) Fig. 5-63 11.
Page 128 5-4-2. Inspection 01. handlebar for any cracks/bends/damage -- replace Fig. 5-67 02. steering column for any bends/damage -- replace Fig. 5-68 WARNING DO NOT ATTEMPT TO STRAIGHTEN A BENT SHAFT, WHICH MAY DANGEROUSLY WEAKEN THE SHAFT. 03. inspect bearing (1) and oil seals (2) for any wear/damage -- replace Fig. 5-69 04.
Page 130 5-4-3. Installation - reverse the “5-4-1” procedure and follows the points as; 01. lubricate steering column bushings 02. lubricate steering column bearings and lip oil seals * use: lightweight lithium-soap base grease. 03. install lower bearing (1) Fig. 5-75 04. install oil seals (2), collars (3), upper bearing (4). Be sure co do not damage the oil seals during installation.
Page 131: Front - Shock
5-5. F RONT HOCK BSORBER AND RONT RIEFING (02). cover thrust (01) . shaft pivot (04). collar (03). bush solid (05). upper arm (06). nipple grease (07). collar lower (08). lower arm (09). shock absorber...
Page 132: Front Shock Absorber And Front Arms
5 - 5. F RONT HOCK BSORBER AND RONT 5-5-1. Removal 01. remove the f. wheel, hub, and brake shoe plate -- part 5-1 02. remove the front bumper Fig. 5-77 03. remove the shock absorber Fig. 5-78 04. remove the cotter pin (1), nut (2), tie-rod (3) (from knuckle arm) Fig. 5-9 05.
Page 134 5-5-2. Inspection shock absorber 01. check shock absorber rod for any bend/damage -- replace Fig. 5-85 02. check shock absorber any oil leaks -- replace 03. check shock absorber spring fatigue -- replace 5-5-3. Inspection steering knuckled (1) and joint rod (2) Fig. 5-86, 5-87 for any cracks/pitting/ damage -- replace 5-5-4.
Page 136 5-5-5. Installation - reverse the “5-5-1” procedure and follows points as; Fig. 5-93 01. lubricate bushing (1), inner collar (2), thrust cover (3) * use: lightweight lithium soap base grease 02. tighten upper front arm nut (4) 03. tighten lower front arm nut (5) 04.
Page 137: Rear Shock Absorber And Swing - Arm
5-6. HOCK BSORBER AND WING RIEFING (02). Cover thrust (01). Shaft pivot (04). Oil seal (03). Washers (06). Bearing needle roller (05). Bush (08). Spacer (07). O-ring (10). Rear arm (09). Seal guard (12). Support chain (11). Under guard (14). Bolt (13).
Page 138 5 .6. R HOCK BSORBER AND WING WARNING NORMALLY, THE REAR SHOCK ABSORBER JUST REPLACE A NEW ONE WHENEVER ANY WEAR/DAMAGE SHOWING UP. IT IS RARELY REQUIRE DISASSEMBLY THE REAR SHOCK ABSORBER. THE SHOCK ABSORBER CONTAINS HIGHLY COMPRESSED NITROGEN GAS, THE MAKER WILL TAKE NO ANY RESPONSIBLE FOR PROPERTY DAMAGE OF PERSONAL INJURY THAT MAY RESULT FROM IMPROPER HANDLING.
Page 140 5.6.2 . Inspection and remove the swing arm 01. check the swing arm free play under (1) Fig. 5-103 1) check the tightening torque of the pivot shaft (swing arm securing nut * torque: 8.5 kg-m 2) check the swing arm side play “A” by moving it from side to side. Any noticeable, check the inner collar, bearing bushing, and thrust cover, or adjust the shim.
Page 142 5-6-4. installation - reverse the “5-6-1” procedure and follows points as; Fig. 5-110 01. lubricate bearings (1), bushing (2) on inner surface, o-ring (3), pivot shaft outer surface (4), dust cover lips(5). Fig. 5-110 * use: lightweight lithium soap base grease 02.
Page 144 5 - 7. D RIVE HAIN AND PROCKET 5-7-1. Removal 01. remove the change pedal 02. remove the L crankcase cover (1) Fig. 5-113 03. remove the drive sprocket holder (2) Fig. 5-114 04. loosen L rear wheel nuts (1) Fig 5-115 05- elevate the rear wheels by placing suitable stand under frame 06.
Page 146 5-7-2. Inspection 01. measure the 10-link length -- out of specification for replacement Fig. 5-120 * 10-Link length limit: 150-1mm (5.91 in) 02. by using finger to check the chain tense, the 10-link is a distance between (1) and (11). Every time to check 2 or 3 “10-link”...
Page 148 PART 6. ELECTRIC DETAILS PART 6. ELECTRIC DETAILS 6-01. S ERVICE RECAUTIONS LECTRIC EVICE 6-02. I GNITION YSTEM NOTE: SERVICE INFORMATION NOTE: TROUBLE SHOOTING <Q-A> 1. Ignition Coil 2. CD I unit removal 3. GDI Inspection 4. Test with a CDI tester. 5.
Page 149 ENERAL LECTRIC YSTEM RIEFING (02). wire harness (01). neutral light (04). battery (YUASA YTX7A-BS) (03). fuse (15A 250V) (05). earth cable (06). ignition coil (07). plug cap (08). rectifier & regulator (10). C.D.I. (09). main switch (11). starter relay...
Page 150 6-1. S ERVICE RECAUTIONS LECTRIC EVICES 01. After operation, the terminal caps must be installed securely (Fig. 6-01). 02. When disconnecting the connector, the lock on the connector shall be released first (Fig. 6-02) 03. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire (Fig. 6-03). 04.
Page 152 11. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts (Fig. 6-11). 12. When fixing the wire harnesses, do not make it contact with the parts which generate high heat (Fig. 6-12).
Page 154 6-2. I GNITION YSTEM RIEFING (02). C.D.I. (01). AC generator (04). plug cap (03). Ignition coil...
Page 155 6-2. I GNITION YSTEM NOTE SERVICE INFORMATION STANDARD ITEM Spark plug Standard type DR-8EA NGK Hot type DR-7EA NGK Cold type DR-9EA NGK Spark plug gap 0,6 - 0,7 mm Ignition timing “F” mark: Max. aligning angle: 15 +/-2 or 1.400 rpm 33 +/-2 a 3.900 rpm Ignition coil Primary coil...
Page 156 CAUTION 1. THE IGNITION SYSTEM HAS AN ELECTRICAL AUTO ALIGNED IN THE CDI UNIT. SO THE IGNITION TIMING IS NOT ADJUSTABLE. 2. DO NOT DROP OR IMPACT THE CDI UNIT WITH STRONG FORCE TO AVOID DAMAGE. BE CAREFUL WHEN REMOVING IT. 3.
Page 157 6-2-1. Ignition Coil 01. continuity test (Fig. 6-21) 1) . remove the front cover under the fuel tank. 2). disconnect the ignition coil (1) wire coupler and measure resistance between ignition coil primary wire terminals. * Resistance: 0.2-0.3 OHM 02. remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil terminal (Fig.
Page 158 6.2-2. CDI unit removal (F¡g. 6-24) 01. remove the front lamp cover. 02. disconnect the CDI unit (1) coupler and remove the CDI unit. NOTE C.D.I. CONDENSER DISCHARGE IGNITION 6-2-3. CDI Inspection (Fig. 6-25, 6-26) 01. measure the resistance between the CDI unit terminals. 02.
Page 160 6-3. C HARGING YSTEM RIEFING (02). rectifier & regulator (01). AC generator (03). battery (YUASA YTX7A-BS)
Page 161 6-3. C HARGING YSTEM NOTE SERVICE INFORMATION Battery capacity 12V7AH (MF) Electrolyte specific gravity 1.320 20 C Charging current 3,0A max. A.C Generator - Charging RPM 2.100 rpm (min.) - Capacity 2A min. / 3000 rpm Regulator/Rectifier No contact point Charging coil resistance 0,2 - 0,3 OHM CAUTION...
Page 162 NOTE TROUBLESHOOTING <Q-A) No power? - Dead battery - Fuse burned out - Disconnected battery cable - Faulty ignition switch <Q-A> Low battery? - Weak battery - Loose battery connect ion(terminal) - Charging system failure - Faulty regulator/rectifier <Q-A> Intermittent power? - Loose battery cable connection - Loose charging system connection - Loose lighting system connection...
Page 163 6-3-1. Battery Removal (Fig. 6-29) 01. remove the seat. 02. disconnect the negative cable first, then the positive cable. 03. remove the battery (1). CAUTION WHEN DISCONNECTING THE POSITIVE CABLE, THE TOOL SHOULD NOT TOUCH THE FRAME; OTHERWISE IT WILL CAUSE FLAMES TO IGNITE GASOLINE AND DAMAGE THE BATTERY. 6-3-2.
Page 164 6-3-5. Performance Test -- when the battery is fully charged. 01. start and warm up the engine for 10 minutes. 02. connect battery positive cable to the ammeter positive probe. 03. connect the voltmeter across the battery terminals to test the charging voltage. Headlight Switch Position Charging rpm 3000 rpm...
Page 166 6-4. S TARTING YSTEM RIEFING (02). starter relay (01). starter motor (03). start button...
Page 167: Service Information
6-4. S TARRING YSTEM NOTE SERVICE INFORMATION Item Standard (mm) Service Limit (mm) Starter motor brush length 8,5 mm CAUTION 1. THE REMOVAL OF STARTER MOTOR CAN BE ACCOMPLISHED WITH THE ENGINE INSTALLED. 2. WHEN CONNECTING THE STARTING SYSTEM WIRES, CONNECT THEM SECURELY TO AVOID HARD STARTING DUE TO POOR CONNECTION.
Page 168 6-4-1. Starter motor removal(Fig. 6-34, 6-35) 01. remove the starter motor wire lock. nut (1) Fig. 6-34 02. remove the two starter motor mounting bolts (1) and the motor. Fig. 6- 35 CAUTION BEFORE SERVICING THE STARTER MOTOR, TURN OFF THE IGNITION SWITCH AND DISCONNECT THE BATTERY GROUND.
Page 170 <continue de 6-4-5 Assembly> 05. apply a thin coat of grease to the front cover oil seal and bearing. 06. install the special washer and the front cover to the motor body and do not damage the oil seal. 07. after the front and rear covers are installed, the punch marks must aligns each other. 08.
Page 172 6-5. L IGHTS NSTRUMENTS WITCHES RIEFING (02). main switch 01). head light (04). taillight 03). neutral light (06). Hi/Lo beam switch 05). engine stop switch...
Page 173 6 - 5. L IGHTS NSTRUMENTS WITCHES NOTE SERVICE INFORMATION Headlight 12V 18W/18W Stoplight/Taillight 12V 21W Neutral beam indicator 12V 3,4W Fuse General Instructions: l. All plastic plugs have locking tabs that must be released before disconnecting. 2. All plastic plugs have locking tabs that must be released before disconnecting. 3.
Page 174 6-5-1. Light/switch/wire ... inspection 01. removal the front cover (Fig. 6-43) 02. check front lamp wire (Fig. 6-44) 03. check the front lamp bulb (1) (Fig. 6-45) 04. check the neutral position lights (1) (Fig. 6-46) 05. check the neutral lights-AC generator wire (Fig. 6-47) 06.
Page 176 6-5-2. Main switch inspection 01. the main switch (1) (Fig. 6-51) 02. check the ON (Fig. 6-52) 03. check the NO 2 (Fig. 6-53) NOTE 1. ON 1: ENGINE CAN BE STARTED AT THIS POSITION. 2. ON 2: ENGINE CAN BE STARTED AT THIS POSITION AND THE HEADLIGHT AND TAILLIGHT COME ON AT THE SAME TIME.
Page 178: Electrical System
ELECTRICAL SYSTEM RAM 125/150 BLACK FRONT LIGHT BLUE 2- NEUTRAL LIGHT GREEN 3- MAIN SWITCH YELLOW 4- LEFT HANDLE SWITCH 5- IGN. COIL WHITE 6- SPARK PLUG PINK STARTER RELAY BROWN 8- FUSH BLUE/WHITE 9- RECT./REGU. G/W GREEN/WHITE 10- BATTERY BLACK/RED 11- STARTER YELLOW/RED...
Page 179 PART 7. PROBLEMS SHOOTING PART 7. PROBLEMS SHOOTING NOTE THE FOLLOWING PROBLEMS SHOOTING DOES NOT COVER ALL THE POSSIBLE CAUSES OF TROUBLE. IT SHOULD BE HELPFUL, THE GUIDE TO PROBLEMS SHOOTING ON THIS SECTION AND THE OTHERS ON EACH PARTS. REFER TO THE RELATIVE PROCEDURE IN THIS MANUAL FOR INSPECTION, ADJUSTMENT, AND REPLACEMENT OF PARTS SUCH AS PART $ ELECTRIC, PART 5 CHASSIS, OR PART 4 ENGINE DETAIL ON CASES OF <Q-A>...
Page 180 7-1. E NGINE DOES NOT START OR HARD TO START 7-1-1. Check if fuel reaches carburettor by loosening drain screw A. Fuel does not reach carburettor 1). No fuel in tank 2). Clogged fuel line between fuel tank and carburettor 3).
Page 181: Poor Performance
7-1-4. Start engine again A. Engine fires but does not start 1). Faulty choke control system 2). Leaking intake manifold 3). Incorrect ignition timing or incorrectly adjusted air screw B. Engine does not fire --- refer to 7-2-5. 7-1-5. Remove the spark plug and test it again A.
Page 182 7-2-4. Remove the spark plug and install it into spark plug cap to test spark by connecting it to the engine ground A-. Weak or intermittent spark 1). Faulty or fouled spark plug 2). Faulty CDI unit 3)- Faulty A.C. generator 4).
Page 183 7-3-3. Check valve clearance A. Incorrect 1). Incorrectly adjusted valve clearance 2). Excessively worn valve seat (Protruded valve stem) 3. Correct --- refer to 7-3-4. 7-3-4. Test cylinder compression A. Too low 1). Faulty valve seat 2). Worn cylinder and piston 3).
Page 184 7-3-8. Check cylinder head for oil lubrication A. Abnormal 1). Clogged oil cooler 2). Clogged oil line 3). Faulty oil pump B. Normal --- refer to 7-3-9. 7-3-9. Check for engine overheating A. Overheating 1). Worn cylinder and piston 2). Mixture too lean 3).
Page 185 7-4. P ERFORMANCE AT HIGH SPEED 7-4-1. Check ignition timing A. Incorrect 1). Faulty CDI unit 2). Faulty pulse coil B. Correct --- refer to 7-4-2. 7-4-2. Check valve clearance adjustment A. Incorrect 1). Incorrect adjustment or worn valve seat B.
Page 186 7-5. P HARGING BATTERY OVER DISCHARGE OR OVERCHARGE 7-5-1. Start the engine and measure the limit voltage between the battery terminals A. Battery voltage is normal 1). Dead battery 2). Faulty battery B. Battery voltage does not increase --- refer to 7-5-2. 7-5-2.
Page 187 7-6. S PARK LUG HAS NO FUNCTION 7-6-1. Replace with a new spark plug and test again A. Good spark 1). Faulty spark plug B. Weak or no spark --- refer to 7-6-2. 7-6-2. Check spark plug cap and ignition coil wire for looseness A.
Page 188: Shock Absorber Malfunction
7-7. F. R. B RAKE ERFORMANCE OORLY 7-7-1. F. Drum brake poor Check: 1). brake shoe wear out, or 2). worn or rusty brake drum, or 3). improperly adjusted brake free play. or 4). improper brake cam lever position, or 5).
Page 189 7-9. I NSTABLE ANDLING 7-9-1. check handlebar for any improperly installed or bent 7-9-2. check steering for any; 1). incorrect toe-in 2). bent Steering shaft 3). improperly installed steering shaft 4). damaged bearing or bearing race 5). deformed steering knuckles 7-9-3.
Page 190 PART 8. APPENDIX PART 8. APPENDIX 8-1. N OTES OF ELIVERY NSPECTION The dealer or service station will assemble and inspect the ATV according to the following pre-delivery checklist before delivering no the customer. CONTENTS ITEMS Appearance * check the overall out-looking and correct any surface damage or missing parts Battery * fill with electrolyte...
Page 191 Standard Motor Corp. - Sports Quads 125/150/170/250cc SK - 125/150/170/250cc (double light) STGs - l25/l50/l70/250cc (double light + separate front fender) BL - 125/150/170/250cc (single light) STGb - l25/150/l70/250cc (single light + separate front fender)
Page 192 8-2. UPDATE - 170 & BLAST INFORMATION MODEL > for page 2-1. General Specification Weight(125/150/170): 152 Kg. / 154 Kg. / 155 Kg. Engine 4 Stroke Air-Cooled Cylinder Single - Forward Inclined Bore * Stroke 125 cc: 56,5 x 49,5 mm; 150 cc: 62 x 49,5 mm 170 cc: 65,0 mm x 49,5 mm Displacement 124,5 cm3;...
Page 193 By: Sales and Service Department of NACIONAL MOTORS, S.A.U. For Territorial Distributor: - All rights reserved. Ho part of this manual may be reproduced or unauthorized use in any form or by any means, without prior permission of the Maker http://www.derbi.com.

Derbi ATV DXR 200 Workshop Manual

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