Page 1 2009 ATV SERVICE MANUAL EUROPE 09.0 PN. F010102A01 ATV 260/300 ● Model ： 2004 2005 Special Edition - Anniversary Mini 50/80/100/150 ● B-Type 150/200, 2x4 ● 260/300, 2x4/ 4x4 ATV520 ● ATV400-2 ● ATV400-2B ● Attachment Delphi Small Engine Management System Service ●...
Page 2 Foreword This manual is designed primarily for use by the ATV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
Page 3 CONTENTS ↖ CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3A…………………………………….……….260 300 400 Engine ↖ CHAPTER3B…………………………………….……….…….…50 80 Engine ↖ CHAPTER3C……………………………………. …. 100 125 150 200Engine ↖ CHAPTER4A…………………………………………..…………………Chassis ↖ CHAPTER4B………………………..……………Chassis (Youth/ mini ATV) ↖ CHAPTER5………………………………………………….………Final Drive ↖ CHAPTER6……………………………………………….………Transmission ↖ CHAPTER7………………………………………………………………Brakes ↖ CHAPTER8………………………………………………….….………Electrical ↖...
Page 4 WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
Page 5: Chapter 1 General Page
CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 CHAPTER 1 GENERAL INFORMATION WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 6 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
Page 7 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip①, make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives. See sectional view. ④Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc.
Page 8 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
Page 9: V.i.n And Engine Serial Number
CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 V.I.N AND ENGINE SERIAL NUMBER ATV 260 / 300 / 400-2 /400-2B Mini / Youth CHAPTER 1 GENERAL PAGE. 1- 5...
Page 10 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 VEHICLE DIMENSIONS 2004 2005 Special Edition - Anniversary DEMON Mini / Youth B-Type ATV400-2 ATV400-2B 520ATV 520ATV-B Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. CHAPTER 1 GENERAL PAGE.
Page 11 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 ATV 260 / 300 ’05 Model ATV 260 / 300 CHAPTER 1 GENERAL PAGE. 1- 7...
Page 12 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 Demon ATV 260 / 300 Europe Mini / Youth CHAPTER 1 GENERAL PAGE. 1- 8...
Page 13 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 Special Edition - Anniversary B-Type 260/ 300 CHAPTER 1 GENERAL PAGE. 1- 9...
Page 14 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 B-Type 150/ 200 ATV 400-2 CHAPTER 1 GENERAL PAGE. 1- 10...
Page 15 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 ATV 400-2B ATV 520 CHAPTER 1 GENERAL PAGE. 1- 11...
Page 16 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 ATV 520-B CHAPTER 1 GENERAL PAGE. 1- 12...
Page 17 CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09.0 NOTES CHAPTER 1 GENERAL PAGE. 1- 13...
Page 36 CHAPTER 2 MAINTENANCE ATV SERVICE MANUA 09.0 CAUTION: Tire Pressure Inspection If wheels are improperly installed it could affect Vehicle handling and tire wear. Front Rear 2.7 TIRE PRESSURE 260/300 4PSI 4PSI TIRE INSPECTION (27±0.5KPa) (27 ±0.5KPa) CAUTION : B-Type Maintain proper tire pressure.
Page 38 CHAPTER 2 MAINTENANCE ATV SERVICE MANUA 09.0 LT* Only ATV 260 early EARLY DESIGN Bolt M10 Attaching A-Arm and model Frame MANTENANCE-FREE PIVOT DESIGN Bolt M12 37-44 50-60 Attaching A-Arm and Frame Nut M10X1.25 Attaching A-Arm to Ball Joint Stud 22-25 30-35 Screw M6 Attaching Ball Joint Mounting Bracket to...
Page 40: Chapter 3 Engine Page. 3A
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 CHAPTER 3 A ENGINE 260cc / 300 cc /400 cc 3.1 MAINTENANCE SPECIFICATIONS 3.1.1 SPECIFICATIONS 3.1.2 TIGHTENING TORQUES 3.2 PARTS INSPECTION AND SERVICE 3.2.1 VALVE CLEARANCE ADJUSTMENT 3.2.2 IDLING SPEED ADJUSTMENT 3.2.3 SPARK PLUG INSPECTION 3.2.4 COMPRESSION PRESSURE 3.2.5 ENGINE OIL LEVEL INSPECTION...
Page 41: Maintenance Specifications
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.1 MAINTENANCE SPECIFICATIONS 3.1.1SPECIFICATIONS Item Standard Limit Cylinder head : 0.03 mm Warp limit Cylinder: 260:70.000- 70.014 mm 260:70.025 mm Bore size 300:72.500- 72.514 mm 300;72.525 mm 400: 80.000- 80.014 mm 80.025mm 400: Out of round limit...
Page 42 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 "A" head diameter 33.9-34.1mm … 28.4-28.6mm … "B" face width 3.394-3 .960mm … 3.394-3.960 mm … "C " seat width 0.9-1.1mm … 0.9-1.1 mm … "D" margin thickness 0.8-1.2 mm …...
Page 43 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Piston rings : 260 /300: Top ring : Type Barrel … End gap (installed) 0.15- 0 .30 mm 0 .45 mm Side clearance (installed ) 0.04- 0.08 mm 0 .12 mm 2nd ring : Type Taper...
Page 44 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Standard Limit I t e m Automatic centrifugal clutch: 3.0 mm 2.0 mm Clutch shoe thickness 135 mm 135 .5 mm Clutch hosing inside diameter 2 8.1 mm … Clutch shoe spring free length 20 mm 19 .5 mm...
Page 45 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Standard Limit I t e m Radiator: Type Cooling fin with electric fan … Width/height/thickness 260 /300: 288/238/42 mm … 400: 360/246/68 m … Radiator cap opening pressure 110-140kPa (1.1-1.4kg/cm 1.1-1.4bar) …...
Page 46 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.1.2TIGHTENING TORQUES Tightening Part name Thread Part to be tightened Q’ty Remarks Torque size m.kg Oil check bolt Exhaust pipe stud bolt Spark plug Cam sprocket cover Bolt Cylinder head and cylinder 2 .2 Cylinder head and cylinder Bolt...
Page 47 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Tightening Part to be tightened Part name Thread Q’ty Remarks torque size m.kg Cover (oil pump) Bolt P lug M 16 0 .8 Timing check plug One way clutch Bolt M 14 Clutch housing...
Page 48: Chapter 3 Engine Page
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.2 PARTS INSPECTION AND SERVICE 3.2.1VALVE CLEARANCE ADJUSTMENT NOTE: Valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression.
Page 49 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Adjustment steps: Loosen the locknut Turn the adjuster ③ in or out with the valve adjusting tool until specified clearance is obtained . Turning in → Valve clearance is decreased Turning out →...
Page 50 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 4. Adjust: Engine idle speed Adjustment steps: Turn the pilot screw until it is lightly seated. Turn the pilot screw out by the specified number of turns. Pilot screw: turn out Turn the throttle stop screw in or out until...
Page 51 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Spark plug gap : 0.6-0.7 mm 6. Install: Spark plug NOTE: Before installing a spark plug, clean the Gasket surface and plug surface. 3.2.4COMPRESSION PRESSURE MEASUREMENT NOTE : Insufficient compression pressure will result in performance loss.
Page 52 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 If it is below the minimum pressure → Squirt a few drops of oil into the affected cylinder and measure again. Follow the table below. Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher than...
Page 53 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atmospheric temperature. API STANDARD: API SE or higher grade CAUTION: Do not put in any chemical additives or use oils with a grade of CD or higher.
Page 54 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 5. Fill: Crankcase Oil quantity: 1.4L 6. Check: Engine oil level Refer to "ENGINE OIL LEVEL INSPECTION" section ENGINE OIL PRESSURE INSPECTION Inspection steps: Slightly loosen the oil check bolt Start the engine and keep it idling until the oil begins to seep from the oil check bolt.
Page 55 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and inspect the coolant level again. NOTE: Wait a few minutes until the coolant settles before inspecting the coolant level.
Page 56 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 4. Clean: Radiator Fill soft water into the filer neck support (reservoir tank). 5. Install: Gasket Drain bolt 6. Loosen: Hose 7. Connect: Hose (reservoir tank) 8. Fill: Radiator ( to specified level Fill the coolant slowly, until the coolant comes out from the head hose.
Page 57 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Handling notes for coolant: Coolant is potentially harmful and should be handled with special care. WARNING: splashes in your eyes: Thoroughly wash your eyes with water and consult a doctor. If coolant splashes on your clothes: Quickly wash it away with water and then with soap and water.
Page 58: Cylinder Head
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.3CYLINDER HEAD CHAPTER 3 ENGINE PAGE. 3A- 19...
Page 59 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Order Job name / Part name Q ’ty Remarks Cylinder head removal Remove the parts in order. Drain the coolant. Side panel Footrest board Carburetor Thermo unit lead Refer to "CARBURETOR" Plug cap section .
Page 60 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 CYLINDER HEAD REMOVAL 1. Align: "I" mark ○ on the rotor (with stationary pointer ○ on the crankcase cover ) NOTE: If any special mark found, contact the ATV manufacture via the agent for the parts and special instruction.
Page 61 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 CYLINDER HEAD INSPECTION: 1. Eliminate: Carbon deposits (from combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seats 2.
Page 62 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 2. Tighten: Nuts (cylinder head) Bolts (cylinder) 3. Install: Cam sprocket Timing chain Installing steps : Turn the primary sheave counterclockwise until the TDC mark ○ matches the stationary pointer ○...
Page 63 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Installing steps: Remove the tensioner cap bolt and springs Release the timing chain tensioner one-w ay and push the tensioner rod all the way Install the tensioner with a new gasket onto the cylinder.
Page 64: Camshaft And Rocker Arms
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.4CAMSHAFT AND ROCKER ARMS Order Job name / Part name Q ’ty Remarks Remove the parts in order. Cam shaft and rocker arms Refer to "CYLINDER HEAD" section. removal Cylinder head Lock washer Plate...
Page 65 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 ROCKER ROCKER SHAFTRE MOVAL 1. Remove: Rocker arm shaft (intake) Rocker arm shaft (exhaust) NOTE: Attach a rocker arm shaft puller bolt weight to the rocker arm shaft and slide out the shaft.
Page 66 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Inspection steps: Inspect the two contact areas on the rocker arms for signs of unusual wear. Rocker arm shaft hole. Cam-lobe contact surface. Excessive wear → Replace. Inspect the surface condition of the rocker arm shafts.
Page 67 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 4. Install: Rocker arm Rocker arm shaft (exhaust) NOTE: Exhaust: Install the rocker arm shaft (exhaust) completely pushed in. 5. Install: Rocker arm Rocker arm shaft (intake) NOTE: Intake: Insert the guide shaft (8 mm) into the stud bolt hole in the cylinder head to the rocker arm shaft...
Page 68: Valves And Valve Springs
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.5VALVES AND VALVE SPRINGS Order Job name / Part name Q ’ty Remarks Valves and valve springs removal Remove the parts in order. Cylinder head Refer to "CYLINDER HEAD " section . Rocker arm , rocker arm shaft Refer to "ROCKER ARM SHAFT AND ROCKER ARMS"...
Page 69 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 VALVES AND VALVE SPRINGS REMOVAL 1. Remove: Valve cotters NOTE: Attach a valve spring compressor and attachment between the valve spring retainer and cylinder head to remove the valve cotters. CAUTION: Do not compress so much as to avoid damage to the valve spring.
Page 70 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 4. Measure: Spring tilt Out of specification → Replace. Spring tilt limit: 1.7mm (2.5º) 5. Inspect: Spring contact face Wear/Pitting/Scratches → Replace. 6. Measure: Valve guide inside diameter Out of specification → Replace. Valve guide inside diameter: Intake: 6.000-6.012 mm...
Page 71 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3. Measure: Valve seat width ○ Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9-1.1mm <Limit:1.6mm> Exhaust: 0.9-1.1mm <Limit:1.6mm> Measurement step: Apply Mechanic’s blueing dye (Dykem) the valve face.
Page 72 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Make sure to clean off all compound from the valve face and valve seat after every lapping...
Page 73 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 4. Instal: Valve cotters NOTE: Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment 5. Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood.
Page 74: Cylinder And Piston
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.6CYLINDER AND PISTON Order Job name / Part name Q ’ty Remarks Cylinder and piston removal Remove the parts in order. Cylinder head Refer to " CYLINDER HEAD " Joint section .
Page 75 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 PISTON AND PISTON RINGS REMOVAL 1. Remove: Piston pin circlip Piston pin Piston NOTE: Before removing the piston pin circlip, cover the crankcase opening with a clean tow el or rag to prevent the circlip from falling into the crankcase cavity.
Page 76 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 PISTON AND PISTON PIN INSPECTION 1. Measure: Piston skirt diameter Out of specification → Replace . 5.0mm from the piston bottom edge. ○ Valve skirt diameter: 260; 69.965-69.980 mm 300;...
Page 77 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 PISTON RINGS INSPECTION 1. Measure: Side clearance ○ Out of specification → Replace the piston and the piston rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance.
Page 78 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Side rails (oil ring) Expander spacer (oil ring) NOTE: Make sure to install the piston rings so that the manufacturer’s m arks or numbers are located on the upper side of the rings. Lubricate the pistons and piston rings liberally with engine oil.
Page 79 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 5. Lubricate: Piston outer surface Piston ring Cylinder inner surface Engine oil 6. Install: Cylinder NOTE: Install the cylinder with one hand while com pressing the piston rings with the other hand. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
Page 80 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.7V-BELT,CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE COVER (LEFT) Order Job name / Part name Q ’ty Remarks Crankcase cover (left) Remove the parts in order. removal Crankcase cover (left) Hose clamp B Joint B Air strainer B Hose clamp A...
Page 81 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 PRIMARY SHEAVE *Apply molybdenum disulfide grease Order Job name / Part name Q ’ty Remarks V-belt, clutch and secondary/ Remove the parts in order primary sheave removal Nut/Plain washer Refer to "PRIMARY SHEA VE Primary fixed sheave REMOVAL"...
Page 82 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 SECONDARY SHEAVE **Apply lightweight lithium-soap base grease Order Job name / Part name Q ’ty Remarks Secondary sheave disassembly Disassemble the parts in order. Clutch carrier Refer to "SECONDARY SHEAVE Clutch shoe spring DISASSEMBLY"...
Page 83 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 PRIMARY SHEAVE REMOVAL 1. Remove: (primary sheave) Plate washer Primary fixed sheave NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder . SECONDARY SHEAVE V-BELT...
Page 84 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 SECONDARY SHEAVE DISASSEMBLY 1. Remove: (secondary sheave) NOTE: Loosen the nut while attaching the clutch spring compressor and clutch spring holder and release the compressed spring after removing the nut. CAUTION: Use the spacer (diameter:￠30mm...
Page 85: Primary Sheave Assemebly
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 WEIGHT INSPECTION 1. Inspect: Weight minimum outside diameter Cracks/Wear /Scaling /Chipping → Replace. Out of specification → Replace Weight out side diameter: 20.0 mm <Limit: 19.5mm> SECOMDARY SHEAVE INSPECTION 1.
Page 86 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3. Install: Spacer Slider Primary sliding sheave cap. SECOMDARY SHEAVE INSTALLATION 1. Apply: Lightweight lithium-soap base grease (to the secondary sliding sheave inner surface, grease nipple groove, and oil seals) Lightweight lithium-soap base grease (to the bearings, oil seals and inner surface of the secondary fixed sheave...
Page 87 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 5. Install: Secondary sheave complete Compression spring Clutch carrier NOTE: Temporarily tighten the nut while attaching the clutch spring holder and clutch spring holder and compress the spring. CAUTION: Use the spacer (30mm, thickness: 2-3mm).
Page 88 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 8. Install: Clutch housing Nut (clutch housing) NOTE: Tighten the nut (clutch housing),using the sheave holder 9. Set: V- belt NOTE: Move the V-belt to minimum diameter of the primary sheave , maximum diameter of the secondary sheave...
Page 89: A.c. Magneto And Starter Clutch
CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.8A.C. MAGNETO AND STARTER CLUTCH MAGNETO COVER AND STATOR COIL Order Job name/ Part name Q'ty Remarks Remove the parts in order. Magneto cover and stator coil Refer to "ENGINE OIL REPLACEMENT" removal Drain the engine oil.
Page 90 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 A. C. MAGNETO AND STARTER CLUTCH CHAPTER 3 ENGINE PAGE. 3A- 51...
Page 91 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Order Job name/ Part name Q'ty Remarks Remove the parts in order. A.C. magneto and starter clutch removal Rotor Refer to "A.C. MAGNETO ROTOR REMOVAL /INSTALLATION" section. Shaft (idle gear) Idler gear Starter one way clutch assembly Woodruff key...
Page 92 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 1. Inspect: Starter idle gear teeth Starter drive gear teeth Starter wheel gear teeth Burrs /chips /roughness /wear → Replace. 2. Check: Starter clutch operation Push the dowel pins to the arrow direction. Unsmooth operation →...
Page 93 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.Tighten: Nut(rotor) NOTE: Tighten the nut (rotor) while holding the magneto rotor with a sheave holder . CHAPTER 3 ENGINE PAGE. 3A- 54...
Page 94 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.9OIL PUMP Order Job name/ Part name Q'ty Remarks Remove the parts in order. Oil pump removal Refer to "A.C. MAGNETO AND STARTER A.C. magneto Cover CLUTCH" section. Pump driven gear Dowel pin Oil pump assembly Gasket...
Page 95 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 OIL PUMP INSPECTION 1. Inspect: Drive gear (oil pump) Pump housing Pump housing cover Wear /cracks/ damage → Replace. 2. Measure: Tip clearance (between the inner rotor and the outer rotor ) Side clearance (between the outer rotor and the pump...
Page 96 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.10CRANKCASE AND CRANKSHAFT CHAPTER 3 ENGINE PAGE. 3A- 57...
Page 97 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Order Job name/ Part name Q'ty Remarks Remove the parts in the order. Crankcase and crankshaft removal Refer to "ENGINE REMOVAL" section. Engine removal Refer to "CYLINDER HEAD" section. Cylinder head Refer to "CYLINDER AND PISTION"...
Page 98 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Order Job name/ Part name Q'ty Remarks Timing chain guide (intake) Crankcase (right) Refer to "CRANKSHAFT INSTALLATION" section. Dowel pin Crankshaft assembly Refer to "CRANKSHAFT REMOVAL/ Timing chain INSTALLATION" section. Crankcase (left) Oil seal Oil seal...
Page 99 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 2. Measure: Big end side clearance Out of specification → Replace bearing, crank pin and/or connecting rod. Big end side clearance: 0.35-0.85 mm 3. Measure: Crank width Out of specification → Replace crankshaft. Crank width: 59.95-60.00 mm 4.
Page 100 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3. Install: Dowel pins Timing chain NOTE: Install the timing chain not to be seen through the crankshaft hole○ on the crankcase (left) . 3.11COOLING SYSTEM 3.11.1RADIATOR CHAPTER 3 ENGINE PAGE.
Page 101 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Remarks Order Job name/ Part name Q'ty Remove the parts in order. Radiator removal Drain the coolant. Refer "COOLANT REPLACEMENT" section. Fan motor leads Thermo switch leads hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator...
Page 102 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Radiator cap opening pressure: 110-140kPa (1.1-1.4kg/cm , 1.1-1.4 bar) Measurement steps: Attach the radiator cap tester and adapter to the radiator cap Apply the specified pressure for 10 seconds, and make sure there is no pressure drop.
Page 103 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3.11.2WATER PUMP Remarks Order Job name/ Part name Q'ty Water pump removal Remove the parts in order. Drain the coolant. Refer to "COOLANT REPLACEMENT" section. A.C. magneto Refer to "A.C. MAGNETO AND STARTER CLUTCH"...
Page 104 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Order Job name/Part name Q’ty Remarks Impeller shaft Refer to “WATER PUMPINSTALLATION” O-ring section. O-ring Reverse the removal procedure for installation. NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant temperature and/ or level, discoloration of coolant, or milky...
Page 105 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 1. Install: Mechanical seal Installation steps: Apply the bond to the outside of the mechanical seal. Install the mechanical seal by using the mechanical seal installer and middle shaft bearing driver 2.
Page 106 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Housing cover 7. Install: Shaft Align the slot on the impeller shaft with the projection on the shaft when installing. 3.11.3THERMOSTAT CHAPTER 3 ENGINE PAGE. 3A- 67...
Page 107 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 Remarks Order Job name/ Part name Q'ty Remove the parts in order. Thermostat removal Refer "COOLANT REPLACEMENT" Drain the coolant section. Clip Hose Hose clamp Inlet hose (radiator) Thermostatic cover Refer to "THERMOSTAT INSTALLATION"...
Page 108 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 INSTALLATION 1. Install: Thermostatic valve Thermostatic cover 3.12CARBURETOR （ATV260/300） WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 109 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 3. Remove: Nut① Throttle cable 4.Lossen: Bolt② Bolt③ 5. Remove: Carburetor assy CARBURETOR DISASSEMBLY/ INSPECTION 6.Auto choke inspection (Ambient temperature lower than 45℃) Connect auto choke unit leads to the 12V battery for 5 minutes.
Page 110 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 VACUUM CHAMBER 10.Remove: Cover① 11.Remove: Diaphragm spring① Piston valve② 12.Inspection: Jet needle Wear→Replace. Piston valve Wear→Replace. Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for holes, deterioration or damage.
Page 111 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 14.Inspection: Needle valve Wear→Replace. Check the float valve and valve seat for scoring scratches, clogging or damage. check the tip of the float valve, where it contacts valve seat, for stepped wear or contamination. check the operation of the float valve.
Page 112 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 17.Remove: Main nozzle Check the main nozzle for wear or damage. Clean the main nozzle with cleaning solvent and blow this open with compressed air. 18.Remove: Pilot screw set Turn the pilot screw in and carefully count the number of turn until it seats lightly.
Page 113 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 23.Inspection: Compressing spring① Distortion→Replace. Diaphragm② Wear→Replace. Reverse removal procedure installation. 3.12CARBURETOR(ATV400-2/ATV400-2B) 1. Remove: Fuel hose 2. Remove: Manual enriching starter rope① 3. Remove: Nut② Throttle cable 4.Lossen: Bolt③ Bolt④ CHAPTER 3 ENGINE PAGE.
Page 114 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 5. Remove: Carburetor assy 6.Remove: Cover① 7.Remove: Diaphragm spring① Piston valve② 8.Inspect: Jet needle Wear→Replace. Piston valve Wear→Replace. 9.Remove: Float chamber① Float② Needle valve③ CHAPTER 3 ENGINE PAGE. 3A- 75...
Page 115 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 10.Inspect: Needle valve Wear→Replace. 11.Remove: Idling jet 12.Remove: Pilot jet 13.Remove: Main jet CHAPTER 3 ENGINE PAGE. 3A- 76...
Page 116 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 14.Remove: Main nozzle 15.Remove Mixture adjusting screw 16. Remove Nut① Throttle valve mounting arm② Torsion-bar spring③ Gasket④ CHAPTER 3 ENGINE PAGE. 3A- 77...
Page 117 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 17.Remove： Screws①&② Throttle valve mounting bracket③ Reverse removal procedure installation. CHAPTER 3 ENGINE PAGE. 3A- 78...
Page 118 CHAPTER 3A ENGINE 260/ 300 / 400 cc ATV SERVICE MANUAL09.0 NOTES CHAPTER 3 ENGINE PAGE. 3A- 79...
Page 119: Table Of Contents
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 CHAPTER 3B ENGINE 50cc/80cc 3.6 The crankcase ＆the crankshaft 3.1 Scheduled Maintenance 3.1.1 General information 3.6.1 Important points 3.1.2 Air Filter 3.6.2 Dismantling the crankcase 3.1.3 Spark plug 3.6.3 The crankshaft 3.1.4 Valve Adjustment 3.6.4 Assembling the crankcase 3.7 Lubricating system 3.1.5 Carburetor idle speed...
Page 120: Scheduled Maintenance
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.1 Scheduled Maintenance 3.1.1General information Warning ● Always make sure it is well-ventilated around before the engine starts. Never start the engine in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death.
Page 121 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Specified spark plug: NGK:C7HSA LD: A7TC Check spark plug gap: 0.6-0.7mm Check plug for dirt, carbon build-up, cracking of insulator. 3.1.4 Valve Adjustment Always check and adjustment with engine temperature lower than 35℃(95℉) Remove cylinder head cover.
Page 122 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.1.5 Carburetor idle speed ● Idle adjustment should be made with the engine warmed up. Remove cover After the engine warms up, connect it to an engine revolution counter. Adjust idle screw until specified revolution is obtained.
Page 123 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Piston or cylinder worn Check combustion chamber and piston top for excessive carbon deposit if compression pressure is too high. 3.1.8 Final reduction gear oil checking Checking oil volume, build up main foot rest so that build up body becomes vertical on plain ground.
Page 124: Important Information
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.2 Cylinder head、Valve 3.2.1 Important information ●When working on the cylinder head and valve train, always use engine oil to lubricate sliding parts when assembling. Never assembly dry parts into the valve train. ●The camshaft is lubricated by engine oil supplied via an oil passage in the cylinder head.
Page 125: Abnormal Noise
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 4.975-4.990 Valve bar outer diameter 4.955-4.970 Valve guide pipe inner 5.0-5.012 diameter 5.0-5.012 Gap between valve bar and 0.010-0.037 0.08 guide pipe 0.030-0.057 0.10 Inner spring 30.5 26.1 Valve spring Outer spring 33.5 30.5 Torque Value Camshaft bolt...
Page 126: Disassembling Of Camshaft
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.2.2 Disassembling of camshaft Remove four bolts and two nuts and take off cylinder head cover. Disassemble tension seal bolt and spring. Use the kick start lever to turn engine slowly until “T” mark on flywheel lines up with indicator on crankcase and check position of camshaft to find if both valves are closed.
Page 127 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove camshaft gear from camshaft chain. Remove camshaft. Check camshaft Check cam lift. Use limit :IN: 25.681mm below change EX:25.524mm below change Check surface of cam lobes for weary surface break down, scuffing or cracking. Check camshaft and bearing for loose fit or damage.
Page 128 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Checking camshaft bearing rocker arm. Check if camshaft fixed seat and camshaft rocker arm and camshaft rocker arm bearing is worn or broken. Measure outer diameter of camshaft rocker arm bearing and inner diameter of camshaft rocker arm.
Page 129 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Disassembly cylinder head Take off location pin and cylinder head gasket. Take off camshaft chain guide bar. Breaking down cylinder head Use valve spring compressor to take off lock clip 、supporter、valve spring and valve. ·...
Page 130 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Measure length of inner and outer springs Used limit: Inner spring below 26.1mm change Outer spring below 30.5mm change Valve and valve guide Check if valve is curved, burnt or broken. Check if valve and valve guide is blocked. Measure every valve stem outer diameter.
Page 131 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 pry out valve guide pipe Be careful to not damage cylinder head Surface. Press in the new valve guide pipe. Spread engine oil on new O-ring and build up new valve guide pipe. Make sure cylinder head is still warm when pressing in new guides.
Page 132 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Valve seat cutting Do not polish or cut excessively. Cut primary surface with 45°cutting head. Chamfer inner edge with 32°cutting head. Chamfer outer edge with 60°cutting head. Correct inner surface by 60°chamfered tool. Trim valve seat to assigned width with 45°chamfered cutting tool.
Page 133 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Check contact place of valve seat. Polish by 30°chamfered cutting tool if the contact place is too low. Trim to assigned width by 45°chamfered cutting tool. Polish valve contact surface with emery and polishing bar after correcting bar.
Page 134 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Installing Cylinder Head Install locating pin and gasket. Install cam chain adjuster plate. Slide cylinder head over studs and into place 3.2.4 Camshaft assembly Install camshaft fixed seat. Assemble rocker arm and rocker shaft. Make alignment between shaft end and hole of camshaft seat when valve rocker shaft is assemblied.
Page 135 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assemble locating pin. Assemble camshaft seat and nut into cylinder head. Lock cylinder head nuts securely. Torque value: Camshaft fixed nut: 20N.m 15 ft lbs Camshaft chain regulator assembling Firstly build up camshaft chain regulator and spacer.
Page 136: The Cylinder And The Piston
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.3 The cylinder and the piston 3.3.1 Important points ·The work on the cylinder and piston can be done on the engine without complete disassemble. · After taking them apart, clean and dry the cylinder and piston with the compressed air before measuring and testing.
Page 137: Removing The Cylinder
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 ID of piston pin hole 13.002-13.008 13.04 OD of the piston pin 13.992-13.000 12.96 Clearance between the piston pin and the hole 0.002-0.014 0.02 ID of the small end of the connecting rod 13.016-13.027 13.06 Trouble shooting...
Page 138 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Install the ring and measure the clearance of the ring groove. Max. service allowance: The top ring: Replace when is goes beyond 0.09mm. The 2nd ring: Replace when it goes beyond 0.09mm Remove the piston rings. Install the piston into the bottom of the cylinder, Attention: Use the piston head to press the rings in place in...
Page 139 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Checking the cylinder Check whether it’s scratched, worn or damaged in it’s inner surface. Measure its ID in three positions(upper, middle and lower) which is 90°(x-y direction) from the piston pin hole. Replace if it goes beyond 39.1mm (50cc) Replace if it goes beyond 47.1mm (80cc) Between the piston and the cylinder.
Page 140: Assembling The Piston
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Attention: · Don’t scratch the piston and break the piston ring. ·When replacing the ring, keep the surface with a mark facing upwards. · After assembling make sure that the ring can be turned freely in the ring groove.
Page 141: Assembling The Cylinder
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.3.5 Assembling the cylinder Install the locating pin and the gasket to the crankcase. Lubricate the inner surface of the cylinder, the piston and the piston ring with engine oil. When assembling the piston rings, they must be compressed into the cylinder.
Page 142 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.4 Driving belt device ＆ the starting lever 3.4.1 Important points ·This chapter is about the driving unit, the clutch / driven unit and the starting lever. The assembly and disassembly of the driving unit can be done without dismounting the engine. ·...
Page 143: The Left Crankcase Cover Detaching
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Torque The nut of the driving plate 45N.m 33ft lbs The nut of the clutch housing 40N.m 30ft lbs The locknut clutch assembly 55N.m 40ft lbs Tool(Common) (special) Universal stand compressing device for clutch spring Driver rod A Socket (39mm) for the fix nut Driver(for housing)32X35mm...
Page 144 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Turn the starting pivot gently, and remove the driving gear and the friction spring together. Remove the starting pivot and the return spring. Detach the starting pivot sleeve. Checking the starting pivot Check if the pivot and the gear are worn. Check if there is any softness of the starting return spring.
Page 145: Installing The Starting Assembly
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Check if there is any excessive wear on the bearing part of the starting pivot and of the shaft of the driven gear. Replace any parts showing excessive or unusual wear. 3.4.3 Installing the starting assembly Install the starting pivot sleeve and the return spring to the crankcase cover.
Page 146: The Driving Belt
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assembling the left crankcase cover First, install the locating pin. Then, the gasket. Assemble the left crankcase cover, then tighten the eight fix bolts diagonally. Install the air tube to the left crankcase, then install the clip.
Page 147: The Driving Pulley Dismounting
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assembling the driving belt Turn the driving pulley clockwise to keep the notches of the belt in expanded condition, then install the new driving belt. Install the driving belt on the driving pulley. Install the driving pulley, the starting ratchet and 12mm washer.
Page 148: Assembling The Driving Pulley
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove the retainer Remove the rollers Checking the driving pulley. Measure the ID of the driving pulley Max service allowance: Replace, when it is beyond 20.062mm. Check the wear of the rollers. Measure the OD of the roller. Max service allowance: Replace, when it is below 15.4mm.
Page 149: The Clutch/Transmission Pulley
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Checking Check if the bearing part of the overrunning clutch shaft is worn. Check if the clutch runs smoothly. Check the wear of the gear and the bearing part of the shaft. Assembling Lubricate the bearing part of the clutch shaft with a bit of grease.
Page 150 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove the sealing cover of the shaft collar. Remove the guide rolling pin from the transmission pulley assembly, then take out the o-ring and the oil seal. Checking the clutch transmission pulley Check the wear of the clutch housing. Measure the ID of the clutch housing.
Page 151 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Measure the free length of the transmission pulley spring. Max service allowance: Replace, when it is below 87.2mm. Check the wear of the transmission pulley Measure the OD of the pulley Max service allowance Replace, when it is below 33.93mm Check the wear of the transmission pulley.
Page 152 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Attention: Grease new bearings When installing Grease able to resist > 230 . ℃ Drive in the new needle bearing, keeping the “mark” side up. The clutch / transmission Pulley assembly Assemble the transmission pulley guide pin and oil seal.
Page 153 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assembling the clutch/transmission pulley Put the driving belt onto the clutch/transmission pulley, then onto the driving shaft. Assembly the clutch housing Use a spanner wrench to hold the housing, then install the 10mm nut and tighten it Torque:40N·m 30ft lbs Assemble the left crankcase cover CHAPTER 3B ENGINE...
Page 154 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.5 The final transmission assembly 3.5.1 Instructions CHAPTER 3B ENGINE PAGE 3B - 36 -...
Page 155: Dismantling The Final Transmission
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Designated oil: SEA 15W/40SE Filling 0.12L Changing 0.1L Tool Special tool Bearing pulling set 12mm Bearing pulling set 15mm Sleeve shaft for assembling the crankshaft Sleeve lever for assembling the crankshaft Common tool Bearing outer race driver 3740mm Bearing outer race drive 3235mm Guide lever for the bearing driver 17mm...
Page 156 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.5.3 Detach final transmission gearbox cover Checking the final transmission assembly. Check if countershaft gear is worn or damaged. Check if the final transmission gear is burn or damaged. Check if the bearing in the left crankcase and the oil seal are worn / damaged.
Page 157: Assembling The Final Gear Set
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove the oil seal on the final transmission shaft. Heat the final transmission gearbox to 120℃ to remove the bearing. Drive in the new bearing to the final transmission cover. Oil leakage ·Too much oil ·The oil seal broken Replacing the bearing (on the side of the crankcase)
Page 158: The Crankcase ＆The Crankshaft
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Tighten the bolts of the final gearbox cover. Assemble the clutch/driving pulley disk. After assembling, fill it with the gear oil. Designated gear oil: SEA 15W/40SE Volume of the gearbox: Filling: 0.12L Changing:0.10L Screw up the oil screw and tighten it Torque: 17-23N·m 12.5-17ft lbs Start the engine to check if there is oil leakage.
Page 159: Important Points
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.6.1 Important points ·The chapter gives instructions related to the crankshaft and dismantling the crankcase Before striking, it’s necessary to take the engine apart. ·Complete the following work before taking the crankcase apart. Remove the following. —The cylinder head —The cylinder &...
Page 160: Dismantling The Crankcase
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Crankcase bolt 9 N.m 6.6ft.lbs Bolt for the chain adjusting guide lever the cam 10N.m 7.4ft.lbs Trouble Shooting Abnormal noise from the engine ·The crankshaft bearing getting slack ·The crankshaft pin bearing getting loose 3.6.2 Dismantling the crankcase Detach the bolt of the chain adjusting guide lever of the cam and remove the lever.
Page 161: The Crankshaft
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Scrape the gasket away from the joint surfaces. Attention: Be sure not to scratch the joint surfaces. Remove the oil seal from the left crankcase. Remove the oil seal from the right crankcase. 3.6.3 The crankshaft Measure the left and right clearance between both sides of the big end of the connecting rod.
Page 162: Assembling The Crankcase
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Check the clearance of the journal of the big end of the connecting rod in X—Y directions Max. service allowance: Replace, when it goes beyond 0.05mm Measure the run out of the crankshaft Max service allowance: Replace, when it goes beyond 0.10mm Check if there is any abnormal noise and...
Page 163 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Install the cam chain into the left crankcase. Assemble the crankshaft into the left crankcase. Attention: Be sure not to let the chain damaged the oil seal. Put the new locating pin and gasket onto the left crankcase.
Page 164: Lubricating System
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Attention: Be sure to put the O-ring into the groove. 3.7 Lubricating system CHAPTER 3B ENGINE PAGE 3B - 46 -...
Page 165 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.7.1 Over all engine requirements Special attention ● Use proper Motor oil SAE 15W/40SE ● Use only clean fresh oil. ● Do not rebuild oil pump. Replace with a new pump when needed. ●...
Page 166: Engine Oil / Filter Screen
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 item Standard value Replace at gap between inner rotator and external 0.12mm 0.005in rotor Engine oil pump gap between external rotor and pump body 0.12mm 0.005in gap between and surface of rotor and 0.05-0.10mm 0.2mm 0.008in 0.001-0.004in...
Page 167 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove engine right outer cover fan magnetor. Remove alternator rotor. Remove stator pulse coil. Remove 8 bolts of right crankshaft case cover and take off crankshaft case cover. Remove washer and fixed pin. Remove the fixed nut of gear in oil pump.
Page 168 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove three fixed screws in oil pump body. Disassembly oil pump. Checking Check the gap between oil pump body and external rotator. Used limited: 0.12mm(0.005inch) Check the gap between inner rotator and external rotator.
Page 169 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assemble pump cover and tighten screws. Installation First put two O-rings at oil pump seat. Put oil pump in crankshaft case. First add oil to pump and then assembly. Tighten three fixed screws. Install gear of oil pump and then fixed nut.
Page 170 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Assemble right crankshaft case cover, tighten 8 screws . Assemble pulse coil and stator and rotor. Install fan and cover. CHAPTER 3B ENGINE PAGE 3B - 52 -...
Page 171 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.8 Carburetor CHAPTER 3B ENGINE PAGE 3B - 53 -...
Page 172: General Information
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.8.1General Information: WARNING! Work on the fuel system in a well-ventilated area free form sparks or open flames. Do not breath the vapors from the gasoline. Wear protective gloves to prevent skin irritation. ·Open the bowl drain and allow all gasoline in the carburetor to drain into an appropriate container prior to removing or servicing it.
Page 173: Disassembly Of Carburetor
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 ·Blocked air passage in carburetor ·Dirty air filter ·Air leak at carburetor or manifold Backfire from exhaust at idle ·Air mixture screw set too lean ·Bad auto choke operation Misfire under acceleration ·Poor spark ·Air mixture screw too lean ·Bad accelerator pump 3.8.2 Disassembly of carburetor...
Page 174 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Checking auto choke Check resistance value. Standard value below 5Ω when cold. Connect auto choke to 12V battery. Plunger should extend 3/8 inch in 5 minutes. Disassembling Disassemble fixed plate screw and take off fixed plate.
Page 175 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 ·Be sure that furrow of vacuum plate is aligned with carburetor furrow. ·Make sure that cover tightens into place. Vacuum Chamber break-down Remove two screws and take off cover. Remove spring, diaphragm piston. Remove needle and slide.
Page 176 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Float Bowl Disassembling Disassembling three screws and take off float bowl. Remove float pin spring. Remove high speed jet, low speed jet and fuel volume control screw. · Be careful not to break fuel jets and control screw. ·Count the turns when removing the fuel volume control screw.
Page 177 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Any leakage of the valve or a build up of dirt will affect the fuel level in the float bowl and cause drivability problems. Assemble the low speed jet, fuel pin spray nozzle, fuel pin spray seat and main jet into the bottom of the carburetor housing.
Page 178: Assembly Of Carburetor
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Accelerator pump disassembling Remove two screws on pump and take off cover. Take off spring and acceleration pump plate. Checking Check acceleration pump plate for cracks or hardening of the rubber. Replace if necessary. Check for blocked fuel passages.
Page 179 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Securely tighten the clamp screw to fix the carburetor in place. Do not over tighten the screws as this can cause damage to the manifold. Attach the inlet pipe to the rear of the carburetor and tighten the clamp screw.
Page 180: Starter System
CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Check for engine return to idle speed after running at part throttle. Make sure that the throttle cable allows the throttle control plate return to the stop screw. If needed, readjust the mixture screw to help stabilize idle performance.
Page 181 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Troubleshooting Starter motor does not turn Starter motor turns over slowly ● Fuse broken ● Battery discharged ● Battery discharged ● Poor or faulty cable connections ● Faulty main switch ● Starter motor gear seized by a foreign object ●...
Page 182 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Measure the resistance between each contact surface of the components. Make sure there is no conduction current between each commutator segment and the armature shaft. Check starter motor housing conductivity. Be sure there is no conduction current between the cable terminal and starter motor housing.
Page 183 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 and for looseness when installed. Replace it if necessary. Inspect dust cover for wear or damage. Apply grease to the dust cover. Install spring brush in its holder. Apply a light film of grease to both ends sliding surfaces of armature shaft.
Page 184 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Clean assembly with solvent and lube with dry graphite or light grease. Do not use heavy grease. This will limit the fast movement of the starter pinion. INSTALLATION Apply a light film of grease to the gears and install the starter pinion by reversing the removal procedure.
Page 185 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Remove the four bolts and remove the cooling fan. Use a universal solid wrench to secure the flywheel. Detach the fix nuts of the flywheel. Use a spanner wrench hold fly wheel while removing the retaining nut.
Page 186 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Attach the triggering coil to the right crankcase. Lock the fix bolts of the triggering coil. Torque: The triggering coil:5N.m 44in.lbs the staror:9N.m 6.6ft.lbs Set up the rubber sleeve of the magneto wire. Clean the cone part of the crankshaft and of the flywheel.
Page 187 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Universal solid wrench Set up the cooling fan Torque:9N.m Install the fan cover and securely tighten fastness. CHAPTER 3B ENGINE PAGE 3B - 69 -...
Page 188 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 3.11 IGNITION SYSTEM 3.11.1 INSTALLATION INFORMATION OPERATING POINTS ● Check ignition system in accordance with the troubleshooting procedure in section 3.11.2 ● As the ignition system has an electric automatic spark control in CDI unit, there is no need for spark advance angle adjustment.
Page 189 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 ● Faulty main switch ● Faulty Ignition coil ● Faulty CDI unit No or Intermittent High Tension Voltage ● Faulty Ignition coil 3.11.3 CDI INSPECTION Remove the three screws from the battery case cover. Disconnect the CDI module from the wire harness Test resistance of the terminals with an multi-meter.
Page 190 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 Test the secondary coil resistance from spark plug cap negative terminals, the standard value of which should be 7-9kΩ(with cap) and 3-4kΩ(without cap). Coil test using after market spark tester. Perform the following inspection in accordance with the operating instructions in the Manual.
Page 191 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 align within ±2°with the engine revolving at a speed of 1500rpm. The spark advance angle should be 13 ° ± 1 ° (1500r/min) CHAPTER 3B ENGINE PAGE 3B - 73 -...
Page 192 CHAPTER 3B ENGINE 50cc/80cc ATV SERVICE MANUAL09.0 NOTES CHAPTER 3B ENGINE PAGE 3B - 74 -...
Page 193: B-Type
CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 CHAPTER 3C ENGINE 100cc/125cc Chain Drive 150cc /200cc Shaft Drive WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 194: Replacement Parts
CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.1 PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dust and dirt before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. During machine disassembly, clean all parts and place them in the order of disassembly, which will speed up assembly and allow for the correct installation of all parts.
Page 195: Periodic Inspection And
CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.3 PERIODIC INSPECTION AND ADJUSTMENT 3.3.1 Air filter (for MINI ATV100/150) 1. Remove air filter case cover and fixing screws. 2. Remove filter element and wash in soapy water and dry it. 3. Install the air filter in the reverse order of removal.
Page 196 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 NOTE: Since crankshaft equipped with decompression, cannot rotated counterclockwise, or it is impossible to adjust the valve. 3. Measure the valve clearance by using a feeler gauge. Valve clearance specification: Intake valve 0.04—0.06mm; Exhaust valve 0.04—0.06mm 4.
Page 197 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.3.6 Transmission oil inspection (for B-type 150/200) 1. Remove the oil level plug. 2. Wipe the oil on the plug and insert it into the filler hole without screwing. The oil level should reach the fourth mark.
Page 198 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.4 ENGINE REMOVAL AND INSTALLATION 3.4.1 Cylinder head A. Camshaft removal 1. Remove cylinder head cover 2. Remove camshaft chain pensioner screw and then O-ring. 3. Lock camshaft chain pensioner by turning it clockwise. 4.
Page 199 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 6. Remove camshaft holder and pins 7. Remove camshaft. 8. Check for intake and exhaust cam damage. Replace when intake valve ： below 25.75mm exhaust valve ： below 25.41mm. 9. Check camshaft bearing for looseness and wear and tear and sprocket for abnormal wear.
Page 200 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 2. Check camshaft holder, rocker arms and rocker arm shafts for abnormal wear and tear. 3. Measure the inside diameter of rocker arm shaft hole in camshaft holder. Limit: 10.10mm. 4. Measure the inside diameter of rocker arm hole.
Page 201 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 5. Remove dowel pin, cylinder head gasket and take out chain guide. 6. Remove the gasket on cylinder surface. NOTE: Make sure the contact cylinder surfaces are not scratched. Make no other objects fall into the crankcase. NOTE: The cylinder head gasket must not be reused.
Page 202 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 15. Eliminate carbon deposits from valve seat. NOTE: Be sure not to scratch the valve seat contact face. 16. Measure valve guide inside diameter. Limit: Intake： 5.08mm exhaust ：5.10mm Install cylinder head in the reverse order of removal.
Page 203 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 Remove piston ring. Eliminate the carbon deposits from the piston ring grooves and rings. NOTE: Be sure to keep the piston ring undamaged. Position piston ring. Measure the gap between piston ring and ring groove. Limit: first ring：...
Page 204 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 8. Measure piston outside diameter from an angle of 90º to piston pin bore, in a position some 9mm from piston bottom. piston diameter limit ：46.9 mm (100cc) 52.3 mm (125cc) 56.9mm (150cc) 62.4mm (200cc) 9.
Page 205 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 Take out V-belt. Check belt for cracks, wear, scaling or chipping. Measure V-belt width. limit ：19.0mm, Remove sliding sheave. Remove movable cams. Remove clutch weights. CHAPTER 3C ENGINE PAGE.3C - 13 -...
Page 206 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 Check weights wear. 10. Measure weight outside diameter. Limit ： 17.44mm 11. Measure sliding sheave inside diameter Limit ：24.06mm. 12. Check collar wear. Measure collar outside diameter. Limit ：23.94mm, replace. 13. Remove clutch. 14. Check clutch disk wear. Limit ：125.5mm CHAPTER 3C ENGINE PAGE.3C - 14 -...
Page 207 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 15. Check spacer wear. Measure its thickness. Limit ：1.5mm 16. Remove clutch assembly. 17. Remove clutch locknut. 18. Take out secondary fixed sheave and sliding sheave. 19. Measure compression spring free length. Limit: 163mm CHAPTER 3C ENGINE PAGE.3C - 15 -...
Page 208 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 20. Check secondary sliding sheave wear. Measure its shaft inside diameter. Limit ：34.06mm 21. Check secondary fixed sheave wear. Measure its shaft diameter. Limit ： 33.94mm Install them in the reverse order of removal. NOTE: Never smear grease to the V-belt, secondary sheave and clutch.
Page 209 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 7. Check oil seals and axles wear. 8. Take out primary gear axle and check its wear. Install it in the reverse order of removal. And add sufficient oil. 3.4.5 Transmission (for B-type 150/200) 3.4.5.1 Transmission Disassembly 1.
Page 210 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 4. Remove input shaft, forward/reverse shaft, middle shaft and shift fork as an assembly. 5. Remove bearing and helical gear. 6. Remove pinion shaft retainer plate and pinion shaft. 7. Remove front cover bolts from transmission case.
Page 211 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 8. Remove output shaft. 9. Clean all components and inspect for wear. 10. Inspect engagement dogs of gears and replace if edges are rounded. 11. Inspect gear teeth for wear, cracks, chips or broken teeth. 12.
Page 212 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 10. Prior to reinstalling the transmission make sure the mating surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon glue to mating surfaces. 11. Reinstall left crankcase and torque bolts in a cross pattern in 3 step to 14.5 ft.lbs.
Page 213 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.4.6 Crankcase and crankshaft 13. Remove chain guide fixing bolt to take out chain. 14. Remove driven gear from crankshaft and inspect gear for wear. 15. Remove crankcase fixing bolts separate the left crankcase from the right one.
Page 214 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 17. Take out crankshaft and timing chain. 18. Clean gasket on crankcase contact face . NOTE: Make sure the contact faces are not scratched to avoid oil leakage. 19. Remove oil seal from crankcase. Inspect oil seal for wear.
Page 215 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 23. Inspect crankshaft bearings for abnormal noise and looseness. If so, replace. Install them in the reverse order of removal. NOTE: Be sure to drain crankcase oil before crankcase removal. 3.4.7 Magneto 1. Remove magneto cover fixing bolts and screws to dismount magneto cover.
Page 216: Electric Starter
CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 Remove stator fixing screw to take out stator. Install it in the reverse order of removal. NOTE: As there is magnetism inside the magneto rotor, make sure no metal object is taken in and the inside of the rotor is cleaned out before installation.
Page 217: Oil Pump
CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 8. Measure clutch disk hub outside diameter. Limit ：27.94mm 9. Inspect idler gear and idle gear shaft for abnormal wear. If so, replace. 10. Measure idle gear shaft orifice inside diameter. Limit ：10.05mm 11. Measure idle gear shaft outside diameter. Limit ：9.94mm Install them in the reverse order of removal.
Page 218 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 5. Measure tip clearance between rotors and pump housing. Limit ：0.2mm Inspect oil pump inner and outer rotors for abnormal wear. If so, replace the oil pump assembly. 7. Fasten pump with screws after assembling.
Page 219 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 2. Remove fuel hose and air pressure tube. 3. Remove throttle cable locknut to take out throttle cable. Loosen inlet-valve seat screw and air filter fixing screw to remove carburetor. NOTE: Make sure the fuel in the fuel bowl is drained before the carburetor removal lest the cylinder head be sprinkled with the fuel, which is likely to bring about a fire.
Page 220 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 8. Remove screw to take out air pressure diaphragm cover, spring and diaphragm. Inspect spring for distortion and diaphragm for damage. If that is the case, replace as a set. Install in the reverse order of removal. NOTE: Make sure the slot on the air pressure diaphragm is in alignment with the corresponding setting slot...
Page 221 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 11. Remove fixing device on top of needle by depressing the device and turning it left. Remove spring and needle. 12. Inspect needle for wear, air pressure piston for damage and diaphragm for cracks and aging. Replace as a set if necessary.
Page 222 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 16. Wash jet and nozzle in clean gasoline and clear them of filth with compressed air. Blow each fuel passage of carburetor clean with compressed air. And install them in their original positions. 17. Measure fuel level by holding the gauge vertically to the float chamber and in alignment with the main jet.
Page 223 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.6 TIGHTENING TORQUES OF ENGINE MAIN FASTENERS Description Thread size Tightening torque (Nm) Cylinder head bolt Oil filter screen cover bolt Exhaust pipe nut Camshaft seat nut Valve adjuster locknut Cam chain tensioner bolt Transmission case drain bolt Clutch drive plate nut Clutch driven disk nut...
Page 224 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.7 IGNITION SYSTEM 3.7.1 INSTALLATION INFORMATION OPERATING POINTS ● Check ignition system in accordance with the troubleshooting procedure in section 3.11.2 ● As the ignition system has an electric automatic spark control in CDI unit, there is no need for spark advance angle adjustment.
Page 225 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 High Tension Voltage Intermittent ● Faulty main switch ● Poor CDI terminal connection ● Poor CDI ground ● Faulty pickup coil ● Poor high tension lead terminal connection ● Faulty CDI unit High Tension Voltage Normal but No Spark ●...
Page 226 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.7.4 IGNITION COIL Removal Steps Remove the middle box. Remove the spark plug cap. Disconnect the wires, remove ignition coil Jam nuts and remove the ignition coil. Inspection Check the ignition coil circuit. The spark advance angle does not need to be adjusted.
Page 227 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 3.7.5 MAGNETO Pickup Coil Inspection This test is to be conducted with the stator mounted in the engine. Remove the cover. Disconnect the magneto. Test the pickup coil resistance between the blue/yellow and the green lead terminals, whose standard value is 80-160Ω.
Page 228 CHAPTER 3C ENGINE 100/125/150/200 SERVICE MANUAL09.0 NOTES CHAPTER 3C ENGINE PAGE.3C - 36 -...
Page 229: Atv Service Manual
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 CHAPTER 4A CHASSIS ATV 260 / 300 / 400 and B-Type ATV400-2 / ATV400-2B WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance.
Page 230 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 4.1 A-RM REPLACEMENT (MacPherson) EARLY DESIGN ( Only ATV 260 EARLY MODEL) 1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup.
Page 231 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 MANTENANCE-FREE PIVOT DESIGN 1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup.
Page 232 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 4.2 SWING ARM（EXCEPT ATV400-2，ATV400-2B） Swing Arm Assembly Installation 1, Screw swing arm pivots into frame on each side (about 3 turns). 2, Install swing arm assembly in frame with lubricated bearing taper roll, and install seal in each side of swing arm asm .
Page 233 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 4.3 FRONT STRUT REPLACEMENT ATV260/ 300 /400 /400-2 /400-2B 1. Hold strut rod with wrench and remove top 2. Compress spring. 3. Remove upper strut pivot assembly.
Page 234 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV260/300/400/400-2B 1. Loosen front wheel nuts. 2. Elevate and safely support ATV under footrest/frame area. . CAUTION: Serious injury may result if ATV tips or falls.
Page 235: Steering Post Assembly
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 4.5 STEERING POST ASSEMBLY Note: 1, Hand tighten the crown nut of the steering post. 2, Align cotter pin hole. 3, Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. 4, Check steering, must move freely and easily from full left to full right without binding.
Page 236 CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B ATV SERVICE MANUAL 09.0 NOTES CHAPTER 4 A CHASSIS PAGE. 4A-...
Page 237 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 CHAPTER 4 B CHASSIS Youth ATV for USA: 50 / 80 Mini ATV for Europe: 50 / 100 /125 / 150 WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance.
Page 238 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 4.1 FRONT WHEEL/ HUB TIRE FRONT COTTER PIN BOLT M10X1.25X20 CASTLE NUT M12X1.25 WASHER VALVE WHEEL FRONT OIL SEAL SPACER 1 BEARING 6002Z SPACER 2 HUB ASSY BEARING 6003Z SPRING. LEFT/ RIGHT BRAKE CAM RUBBER CAP RETURN SPRING BRAKE SHOE SET...
Page 239 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 NOTE: Replace the brake shoes as a set either is worn to the limit. HUB BEARING REPLACEMENT 1. Remove the oil seals. 2. Remove the SPACER 1. 3. Remove the bearings. 1. Apply grease to the bearings. 2.
Page 240 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 NOTE: If reinstalling old brake shoes, install them into their correct locations on the brake panel. Refer to the “R U”, “L U”, “L U”, “L L” *marks made in the Note of Disassembly. *R-right, L-left, U-upper, L-lower NOTE: If new linings are bring installed, file off the leading edge of each shoe a little so that the brake...
Page 241 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 INSTALLATION NOTE: Always use new A-ARM PIVOT SHAFT SEALED RING for re-installation. Apply grease on A-ARM PIVOT SHAFT Reverse the hub removal procedure for installation. 4.3 FINAL DRIVE REAR WHEEL Removal 1. Place the vehicle on level ground with engine off and fuel off, set the front parking brake, 2.
Page 242 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 Chain Inspection, Installation and Adjustment 1. Clean and Inspect chain and chain sprocket for wear. NOTE: To clean the chain, remove the chain from the ATV, dip it in solvent, and clean out as much dirt as possible.
Page 243 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 8. Securely tighten the mounting bolts. Torque Specifications: 41-44Ft.Lbs (55-60N.m) 9. Recheck the chain tension: At the center point between the two sprockets, push and pull the chain and note total flex. If flex is more than 1/2’’ (12mm), readjust chain. 10.
Page 244 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 REAR AXLE COTTER PIN 50/ 80 M16X1.5 CASTLE NUT 100/125/150 M20X2 WASHER 1 REAR HUB SPROCKET HUB. SPROCKET BOLT M10X1.25X28 SPACER RIGHT BOLT M10X1.25X20 BRAKE DISC FLANGE NUT M10X1.25 SPECER LEFT AXLE TUBE SPACER BEARING OIL SEAL, REAR AXLE TIRE REAR AT19X7-8...
Page 245: Swing Arm
CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 Final Drive Assembly 1. Drive in bearings to the AXLE TUBE. NOTE: Drive the bearing which near the brake disc first by press the bearing outer race, then put in the SPACER (15) and drive in another bearing by press the bearing both inner and outer race till it touch the SPACER (15).
Page 246 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 Removal 1. Removal rear shock absorber. 2. Removal NUT (6), washer, and SWING ARM PIVOT (5). Inspection Inspect the SWING ARM PIVOT BUSHINGs and the SWING ARM PIVOT shaft for nicks, scratches, or damage. Replace if necessary. Installation Reverse the removal procedure for installation.
Page 247 CHAPTER 4B CHASSIS ATV SERVICE MANUAL09.0 NOTES CHAPTER 4 CHASSIS PAGE. 4B- 11...
Page 248: Table Of Contents
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 CHAPTER 5 FINAL DRIVE ATV 260/300/400-2 and B-Type/400-2B WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 249: Front Hub Disassembly/Inspection
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts ATV26./300/B Type：20 Ft.Lbs 27 N.m Front W ATV400：48 Ft.Lbs 66 N.m heel Nuts ATV26./300/B Type：50 Ft.Lbs 69 N.m Rear W ATV400：48 Ft.Lbs...
Page 250 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 roughness is evident. 7. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. Do not damage the surface of the seal. Clean the hub. 8. Drive bearing out through opposite side of hub and discard.
Page 251 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 bearing for moisture, dirt, or corrosion, or roughness is evident. 5.3 a. FRONT HUB ASSEMBLY (ATV150/200/260/300) 1. Drive or press one new bearing in to hub using a bearing driver (2WD). 2. Drive or press the other bearing into hub until seated against the hub shoulder (2WD).
Page 252 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.3 b. FRONT HUB INSTALLATION 4X4 (ATV400-2 / ATV400-2B) 1. Inspect the hub strut bearing surface for wear or damage. 2. Apply grease to drive axle spindle. 3. Install spindle through the backside of the hub strut.
Page 253: Chapter 5 Final Drive
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.4 .a .FRONT HUB INSTALLATION (ATV150/200/260/300) 1. Inspect spindle seal on strut and bearing surface for wear or damage. 2. Apple grease to spindle and bearing. 3. Install spindle into strut. 4. Install bearing to spindle. 5.
Page 254 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 8. Install hub. 9. Install bearing 30205 on spindle. 10. Install washer and spindle nut. Torque spindle nut to 160-170 inch lbs (18-19N.m), while rotating hub continuously, back off nut 1/2 turn, and rotate the hub several turns. Re-torque spindle nut to 110-140 inch lbs CHAPTER 5 FINAL DRIVE.
Page 255 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 (12-16N.m). 11. Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 12. Rotate hub and check for smooth operation. Bend both ends of cotter pin around end 13.
Page 256: Front Drive Axle (Inner And Outer Cv Joint) Remaval
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. inspect for rough spots, discoloration, The bearings should turn smoothly and quietly, no detectable up and down movement and minimal movement sideways between inner and outer race.
Page 257 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 REMOVAL 1. Place the vehicle on level ground and set the parking brake, Block the rear wheels so the vehicle will not roll in either direction. 2. Remove the front wheels, steering tie rods, disconnect the A arm on the ball joint end as described in this Chapter and Chapter CAUTION...
Page 258: Front Drive Axle Installation (4X)
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.6 FRONT DRIVE AXLE INSTALLATION (4X4) CAUTION To avoid damage to the front differential oil seal and the strut oil seal, hold the front drive shaft horizontal and straight into the strut during installation. 1.
Page 259 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5. Remove the inner CV joint. 6. Remove the circlip and slide off the bearing assembly. Be careful not to drop Inspect groove any of the steel balls from the bearing cage. 7.
Page 260: Front Drive Axle Assembly (4X)
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 for wear or damage. Check the movement of the joint 10. Check the stopper ring in the end of the inboard joint. Make sure it seats in the groove correctly, if damage the ring must be replaced.
Page 261 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 a. Position the bearing race and install the race into the bearing case. Align the steel ball receptacles in both parts. b. Install the steel balls into their receptacles in the bearing case. c.
Page 262: Rear Axle
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 vehicle . 15. Move the small boot band onto the boot. Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer. Make sure they are locked in place.
Page 263: Rear Axle Installation
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 2. Remove cotter pin. 3. Loosen- but do not remove- the hub retaining nut. 4. Loosen- but do not remove- the wheel nuts. 5. Safely support the rear of the ATV. CAUTION 7.
Page 264: Rear Axle Bearing Installation
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 until it engages the swing arm asm . 5. Insta l new axle tube bolts loosely. 6. Insta l left s ing arm asm bolts and torque to 59-67 ft. lbs ( 80-90Nm). 7.
Page 265: Rear Gearcase Disassembly
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 install new bearing (s), retaining ring and seals reversing steps of rear axle bearing removal.. 2. Torque brake caliper, rear hub nut, and rear wheel nuts to specifications. 5.14 REAR GEARCASE DISASSEMBLY 1.
Page 266 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side . Clean pinion shaft and snap ring and apply Loctite™...
Page 267 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.16 FRONT GEARCASE SLIP LIMIT TORQUE TEST CAUTION: Slip limit torque relate to the preload on the differential (see 5.20 FRONT DIFFRENTIAL ASSEMBLY), and affect the Steering Effort (heavy steering). Always field test the ATV carefully and thoroughly after front gearcase and differential service for vehicle maneuvers and operation.
Page 268 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.17 FRONT GEARCASE DISASSEMBLY/ INSPECTION 1. Drain and properly dispose of used oil. 2. Remove bolts and selector cover.. 3. Remove screws and selector switch from the selector cover. 4. Remove bolt, washer, spring and detent ball from the selector cover.
Page 269 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 8. Remove selector fork, splined dog and input shaft. 9. Remove bearing and seal. Remove gear, screws, pinion shaft retainer plate and pinion shaft. Remove seal from the case. CHAPTER 5 FINAL DRIVE. 5- 22...
Page 270 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 Remove bolts, left cover and differential. → Differential 13. Remove seal from left cover. 14. Clean all components and inspect for wear. Inspect gears for wear, cracks, chips or broken teeth. Inspect engagement dogs and detent ball housing, replace if edges are rounded. Inspect casting for crack.
Page 271 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5.18 FRONT GEARCASE ASSEMBLY 1. Install pinion shaft with bearing. 2. Install retainer plate with flat side toward bearing and torque screws. Apply Loctite 243(Blue) screw threads and torque screws to 8ft.lbs. (12Nm) 3.
Page 272 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 8ft.lbs. (12Nm) Install differential into case., Apply LocTite 518 to mating surfaces, reinstall left cover torque bolts. 14ft.lbs. (20Nm) Install new seals. 5.19 FRONT DIFFRENTIAL DISASSEMBLY/ INSPECTION 1. Remove bolts and bevel crownwheel. Remove bolts and differential cap A.
Page 273 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 4. Remove bolts and differential cap B. Remove spring seat, springs, outer single clutch plate, differential plat, outer double clutch plate, bevel gear and gear axle washer. CHAPTER 5 FINAL DRIVE. 5- 26...
Page 274 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 6. Remove roll pin from center pin. 7. Remove center pin, bevel pinion washers, bevel pinions and center spacer from differential housing. 8 Clean all components and inspect for wear. Inspect gears for wear, cracks, chips or broken teeth.
Page 275 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 Install bevel gear, gear axle washer, outer double clutch plate ,differential plate, outer single clutch plate, springs, spring seat. 3. Install differential cap A. 4. Check the preload clearance. Clearance: 1.2—1.5mm Out of specification→ change spring seat, spring, .replace clutch plate as necessary, CHAPTER 5 FINAL DRIVE.
Page 276 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 5. Install bevel crownwheel, Apply Loctite 271 （red） to screw threads and torque bolts to 24ft.lbs. (32Nm) 6. Install bevel gear, gear axle washer, outer double clutch plate, differential plate, outer single clutch plate, springs, spring seat. .
Page 277 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 FRONT GEARCASE EXPLODED VIEW TROUBLE SHOOTING Symptom: Gears won’t stay in position when shift 2WD/ 4WD. Solution: Increase the preload to indent ball by turning the grub screw or change a new spring. Note: Make sure not to over press the spring by shifting 2WD/ 4WD.
Page 278: Rear, Front Prop Shaft Removal
CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 DIFFERENTIAL CENTRE EXPLODED VIEW 5.21 REAR, FRONT PROP SHAFT REMOVAL Using roll pin remover, remove the roll pin from prop shaft Slide the prop shaft back and away from the gear case. (The swing arm must be disassembly from the frame before the rear prop shaft removal).
Page 279 CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09.0 NOTES CHAPTER 5 FINAL DRIVE. 5- 32...
Page 280 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 CHAPTER 6 TRANSMISSION ATV 260/300/400-2 and B-Type 260/300/400-2B WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
Page 281 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 6.1 SHIFTER REMOVAL 1. Remove parts that interfere with access to shift selector (seat, right side panel etc.). 2. Disconnect the two linkage rods from gear shift selector slides. 3. Remove five bolts attaching gear shift selector to the mounting bracket.
Page 282 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 detent bullets and the dowel pin out of the shifter housing . 7. Remove the two slides, one at a time. NOTE : The LH (low ) slide has two short notches and the R H (high/rev) slide has one short and one long notch.
Page 283 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 6.4 SHIFTER INSTALL ATION Place shift rod back into the mounting bracket and replace five bolts. Reconnect linkage rods to shift rod slides. Adjust as required. See linkage adjustment procedures. Replace remaining parts. 6.5 SHIFT LINKAGE ADJUSTMENT Linkage rod adjustment is necessary when symptoms include:...
Page 284 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 attached to the gear selector slides. Adjust the low range (inside) rod so the rod end is centered on the transmission bell crank. Mark for counter Install the lock nut to the rod end and torque to 35 in.lbs ( 4 Nm).
Page 285 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 connect the engine/ transmission between brackets between engine the frame, except the 2 brackets between transmission the engine and transmission and left them on the transmission. See picture. 10. Remove right and left side engine mount bolts, and remove engine from engine stay.
Page 286 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 different order. Transmission Mounting Bolts Torque: 25 ft. lbs. (35 Nm ). 4. Drive in a new roll pin. Engine 5. Position Engine in frame, Install all brackets, loosely install new fasteners, but not tighten fasteners.
Page 287: Transmission Disassembly
CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 6.8 TRANSMISSION DISASSEMBLY 1. Place gears in neutral. 2. Remove gear position indicator switches. IMPORTANT: The gear position indicator switches must be removed prior to disassembly. 3. Remove the transmission cover bolts. 4. Carefully remove the cover with a soft face hammer tap on the cover bosses.
Page 288 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 8. Remove front drive output housing cover screws. Carefully remove the cover with a soft face hammer tap on the cover bosses. 9. Note position of shim washers and thrust button. 10. Remove shafts as an assembly. 11.
Page 289: Transmission Assembly
CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 6.9 TRANSMISSION ASSEMBLY 1. Install sprocket on front output shaft with sprocket step side inward as shown (only for 4X4). 2. Assemble front ( only for 4X4).and rear output shafts 3. a. (4X4) Install front and rear output shafts with chain as an assembly.
Page 290 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 6. Install new front ( only for 4X4) and rear output shaft seals. 7. Install pinion shaft with bearing . 8. Install retainer plate with flat side toward bearing. 9. Apply Loctite 242(Blue) to screw threads and torque screws to 8 ft-lb.
Page 291 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 along with sprocket and chain. 13.Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon to mating surfaces. 14.
Page 292 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 2X4 TRANSMISSION EXPLODED VIEW CHAPTER 6 TRANSMISSION PAGE. 6- 13...
Page 293 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 4X4 TRANSMISSION EXPLODED VIEW CHAPTER 6 TRANSMISSION PAGE. 6- 14...
Page 294 CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09.0 NOTES CHAPTER 6 TRANSMISSION PAGE. 6- 15...
Page 295 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 CHAPTER 7 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. NOTE Also See Chapter 2 for Maintenance Information.
Page 296 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 7.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness 0.150- 0.164"/3.810- 4.166m B rake Disc Thickness 0.140"/3 .556m m Brake Disc Thickness Variance 0.002 "/ .051m m Between Measurements Brake Disc Runout 0.005 "/ .12 7m m...
Page 297 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 Check and adjust master cylinder reservoir fluid level after pad service. Make sure atmospheric vent on reservoir is unobstructed. Adjust foot brake after pad service. Test for brake drag after any brake system service and investigate cause if brake drag is evident.
Page 298 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 1. Clean reservoir cover thoroughly. 2. Remove screws, cover and diaphragm from reservoir. 3. Inspect vent slots in cover and remove any debris or blockage. 4. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool.
Page 299 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 Maintain at least 1/2 " (13mm of brake fluid in the reservoir to prevent air from entering the master cylinder. 10. Tighten bleeder screw securely and remove bleeder hose. 11. Repeat procedure steps 5- 9 for the remaining caliper (s).
Page 300 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction. REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components.
Page 301 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 7.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support front of ATV safely. CAUT ION: Use care w hen supporting vehicle so that it does not tip or fall.
Page 302 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 has been built up. Maintain at least 1/2 ". (13 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counter clockwise).
Page 303 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 7.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
Page 304 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 7.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL and INSPECTION 1. Remove caliper mounting bolts and lift caliper off of disc. NOTE. When removing caliper, be careful not to damage brake hose .
Page 305 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation. 7.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction.
Page 306 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 REMOVAL / REPLACEMENT 7.12 REAR BRAKE DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1"...
Page 307 CHAPTER 7 BRAKES ATV SERVICE MANUAL 09.0 NOTES CHAPTER 7 BRAKES PAGE. 7- 13...
Page 308 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM COOLING SYSTEM LIGHTING SYSTEM REVERSE LIMIT SYSTEM GEAR POSITION INDICATOR SWITCH TEST 8.10 SPEEDOMETER SYSTEM 8.11 MAIN SWITCH AND HANDLE SWITCH 8.12 FUEL GAUGE/ FUEL LEVEL SENSOR 8.13...
Page 309 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.1 PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT A. ‘O5 model 1. Remove the cover 1 from the ATV. 2. Remove the bulb socket with the wire harness from the backside of the lens unit by turn the socket CCW.
Page 310 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 D. Special Edition – Anniversary and B-Type /400ATV-2 1. Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip① before dismounting the bulb. 3. Fit a new bulb into the socket, sitting properly in the three slots, install the clip as shown in the fig.
Page 311 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Special Edition – Anniversary and B-Type and 400ATV-2 To turn the two adjusting screws ③ clockwise is to lower the beam. To turn the two adjusting screws ③ counterclockwise is to heighten the beam. TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT 1.
Page 312 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 INDICATOR LAMP REPLACEMENT 1. Disconnect light from harness, depress locking tabs and remove from pod. 2. Install new light and reassemble pod 8.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water.
Page 313 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 BATTERY INSPECTION / REMOVAL The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line.
Page 314 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Load test CAUTION: Remove spark plug high tension leads and connect securely to engine ground before proceeding. NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly.
Page 315 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CIRCUIT DIAGRAM CHAPTER 8 ELECTRICAL PAGE.8-...
Page 316 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 IF THE IGNITION SYSTEM FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 7.Pickup coil resistance 2. Battery 8.Main switch 3. Spark plug 9.Engine stop switch 4. lgnition spark gap 10.Wiring connection 5. Spark plug cap resistance (entire ignition system) 6.
Page 317 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 4.lgnition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition tester 1 as shown. 2 Spark plug Turn the main switch to "ON". Check the ignition spark gap . Check the spark by pushing the MEETS SPECIFICATION starter switch, and increase the spark...
Page 318 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Tester (+) lead Pink Terminal Tester ( ) lead B/Y 6. Ignition coil resistance Terminal Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (1) to the ignition coil. Check if the primary coil has the specified resistance.
Page 319 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 7. Pickup coil resistance Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead → BI/Y Terminal Tester (- ) lead→ B/R Terminal OUT OF SPECIFICATION Check the pickup coil has the...
Page 320: Charging System
CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable.
Page 321 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHARGING SYSTEM Procedure Check: 1. Fuse (Main) 4.Stator coil resistance 2. Battery 5.Wiring system (entire charging system) 3.Charging voltage 1. fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION"...
Page 322 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) the stator coil Tester (+) lead –yellow terminal Tester (-) lead –yellow terminal OUT OF SPECITICATION Measure the stator coil resistance Stator coil resistance 0.5-0.8Ω（20℃）...
Page 323 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.5 ELECTRICS STARTING SYSTEM D I A G R A M CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 16...
Page 324 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check: 7. Engine stop switch 1. Fuse (Main) 8. front/rear brake switch 2. Battery 9. starter switch 3. starter motor 10. wiring connection (entire starting system) 4.
Page 325 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 WARNING 4.Starter relay A wire used as a jumper lead Disconnect the relay unit coupler from must have the equivalent the wire harness. capacity as that of the battery Connect the pocket tester (Ωx1) and lead or more, otherwise it battery (12V) to the relay unit coupler may burn.
Page 326 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 6. Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 7. Engine stop switch NO CONTINUITY Replace the handlebar switch 8 Front /rear brake switch NO CONTINUITY CHECKING SWITCHES Replace the brake switch 9.
Page 327: Cooling System
CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check: 1. Fuse (Main, Fan) 2. Battery 4. Fan motor (inspection) 3. Main switch 5. Thermo switch 6. Wiring connection (entire cooling system) CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 20...
Page 328 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 1. fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION" section Clean battery terminals Recharge or replace the battery 3 Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 4.
Page 329 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 6. Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (ΩX1) to the thermo switch . Immerse the thermo switch in the water Check the thermo switch for continuity. NOTE: Measure temperatures while heating the coolant with the temperature gauge...
Page 330 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 IF THE HEAT ALARM UNIT WORKING When the main switch is turned on, the temperature of the engine begins to go up. As it comes to 88±3 the thermostat is connected and the fan starts to work, cooling the coolant, if ℃...
Page 331 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Handle the thermo unit with 4.Thermo unit special care. Drain the coolant and remove the Never subject it to strong thermo unit from the cylinder head. shocks or allow it to be Immerse the thermo unit in the dropped.
Page 332: Lighting System
CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 LIGHTING SYSTEM FOR USA MODEL CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 25...
Page 333 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 FOR EUROPE MODEL CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 26...
Page 334 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch 2. Battery 5.Dimmer switch 3. Main switch 6. Wiring connection (entire lighting system) 1.fuse refer “CHECKING SWITCHES” NO CONTINUITY section Replace the fuse 2. Battery Check the battery condition.
Page 335 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 POOR CONNECTIONS 6. Wiring connection Check the connection of the entire lighting system correct 7. check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1.
Page 336 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 2. the taillight fails to come on 1. Bulb and bulb socket NO CONTINUITY CHECK SWITCHES Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the bulb socket connector.
Page 337 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.8 REVERSE LIMIT SYSTEM The limit set for the speed limiter by the manufacturer is 13~15 km/h, which can be reset in accordance with the user’s practice. Turning the adjusting bolt clockwise increase speed, while counterclockwise decrease it.
Page 338 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.9 GEAR POSITION INDICATOR SWITCH TEST Switch table CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 31...
Page 339 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Switch schematic CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 32...
Page 340 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.10 SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the rear axle Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
Page 341 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Speed Sensor on the Transmission Out Put Shaft. Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter： Item Code Vol value Unit Operating voltage 5-20 Operating current ≤15 Operating distance 1mm≤D≤8mm The following is the graphic illustration for sensor installation。...
Page 342 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 LCD Meter 1. Neutral indicator light 7. Engine rpm meter 2. High beam indicator light 8、9. The odometer 3. Turn indicator light 10.Engine working hour counter 4. Reverse indicator light 11. 2WD/4WD indicator* 5.
Page 343 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 HANDLE SWITCH SCHEMATIC FOR USA MODEL 2004 model 2005 model HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 36...
Page 344 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 400ATV-2 / 400ATV-2B HANDLE SWITCH SCHEMATIC FOR USA MODEL 400ATV-2 / 400ATV-2B HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 37...
Page 345 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.12 FUEL GAUGE/ FUEL LEVEL SENSOR Removal Turn the ignition switch to“OFF”. Remove the fuel tank cover. Remove the three bolts, retaining plate and fuel level sensor from the fuel tank. Installation Install a new seal rubber onto the fuel level sensor.
Page 346 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 Segment“RES”should blink. With the fuel level sensor float at the top (FULL) position, turn the ignition switch to “ON” and check the fuel gauge. All segments up to segment “F”should come on. If the fuel gauge does not function properly, check the fuel level sensor If the fuel level sensor is OK, replace the LCD Meter.
Page 347 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.13 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT (Fig 1) 1, The rider shifts 2WD to 4WD by the Switch on handlebar. 2. The Switch gives signal to Controller. 3, The controller gives power to the Shift Motor. 4, If the Splined Dog (Fig 2) is in right position, 4WD will engage immediately.
Page 348 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 (Fig 2) （Fig 3）Page from owner’s manual CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 41...
Page 349 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 （Fig 4） CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 42...
Page 350 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 8.14 WIRING DIAGR CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 43...
Page 351 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 44...
Page 352 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 45...
Page 353 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 46...
Page 354 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 47...
Page 355 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 48...
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Page 361 CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09.0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8- 54...
Page 362 ATV SERVICE MANUAL EUROPE 09.0 PN. F010102A01 ATV 第一综合维修手册欧标英文版本 09.0 零件代号 F010102A01...

Linhai 2004 ATV 260 Service Manual

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