Hisun HS500ATV-2 Maintenance Manual
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Hisun HS500ATV-2 Maintenance Manual

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500ATV-2 Maintenance Manual
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Summary of Contents for Hisun HS500ATV-2

  • Page 1 500ATV-2 Maintenance Manual...

  • Page 2: Table Of Contents

    Catalogue General Information ……………………………...5 1 Description …………………………………………………..5 1.1 Identification code………..……………………………..6 1.1.1. Frame No. …………………………………………………6 1.1.2. Engine No.…………………………………………………7 1.2 Special tools, instruments and meters…………………7 1.3 Periodic maintenance chart……………………………….9 Engine ………………………………………………………….11 2. Inspection and adjustment of engine …………….11 2.1 Inspection of cylinder head, intake and exhaust valve………………………………………….11 2.2 Inspection of spark Plug………………………………….12 2.3 Inspection of cylinder, piston and piston ring…….14...

  • Page 3: Table Of Contents

    3.Disassembly of engine ……………………………………27 3.1 Cylinder head and block………………………………….27 3.2 Piston and connecting rod……………………………….31 3.3 Manual starting mechanism……………………………….32 3.4 Sensor………………………………………………….…….32 3.5 Left crankcase cover……………………………….…….33 3.6 Magneto…………………………………………………..….33 3.7 Oil pump………………………………………….……..….34 3.8 Clutch…………………………………………………...….35 3.9 Carburetor……………………………………………...….36 3.9.1 Structure of carburetor………………………...…..36 3.9.2 Inspection and adjustment of carburetor…..….37 4.Chassis 4.1 Steering operation system………………………...…..39 4.2 Brake system…………………………………………...….51...
  • Page 4 5.1 Ignition system…………………………..……..….87 5.2 Magneto and charging system…………..……..….88 5.3 Battery……………………………………..……..….88 5.4 Lighting system…………………………..……..….90 5.5 Meterand signal system…………………………..……91 5.6 Electrical starting system…………….……..…….92 6.Appendix ………………..…………………..……..…93 6.1 Specification………..…………………..……..….93 6.2 Requirements for torque of fastener……………….99 6.3 Electrical circuits……………………………..….100...

  • Page 5: General Information

    General Information 1 Description...

  • Page 7: Identification Code

    1.1 Identification code 1.1.1. Frame No. The frame No. is engraved in the right bottom of the supporting frame. See Figure 1-1 图 1-1 1.1.2. Engine NO. The engine No. is engraved in the right side of the engine. See figure 1-2...

  • Page 8: Special Tools, Instruments And Meters

    图 1-2 1.2 Special tools, instruments and meters 1.2.1 Oil filter detacher To fasten and detach the oil filter 1.2.2 Height gauge To gauge the height of various components 1.2.3 Vernier To measure the length of various components 1.2.4 尺 Outside micrometer To accurately measure external diameter of a column 1.2.5 Inside micrometer...
  • Page 9 1.2.6 Dial indicator To accurately measure a small distance 1.2.7 Torque Spanner To measure torque force 1.2.8 Feeler gauge To measure gap-width 1.2.9 Multimeter To check electrical circuits and parts 1.2.10 Barometer To measure pressure of the tyre 1.2.11 Magneto drawing device...

  • Page 10: Engine

    To detach the magneto 1.2.12 Snap ring clamp To install and detach snap rings 1.3 Pe riodic maintenance chart EVERY INITAL month Whicheve ITEM 1,200 2,400 2,400 4,800 ROUTINE comes first (mi) (200) (750) (1,500) (1,500) (3,000) hours ● Check valve clearance. ○...

  • Page 11: Inspection And Adjustment Of Engine

    ● Check operation/fuid leakage.(See NOTE ○ ○ ○ ○ ○ Front brake* page 8). ● Correct if necessary. ● Check operation. ○ ○ ○ ○ ○ Rear brake* ● Adjust if necessary. ● Check operation. Select lever safety ○ ○ ○...
  • Page 12 The maximum reading would be greater than0.7- 0.9Mpa after starting for 4-6 times. See figure 2-1. Figure 2-1 Check the valve clearance Note: when adjust valve clearance, the engine must be cooled.(The tempreture should be less than 35℃ ) Remove the seat cushion and fuel tank, unplug the vision hole cover ,round the flywheel of magneto anti-clockwise to aim “T”...

  • Page 13: And Exhaust Valve

    Remove cylinder valve cover, check the clearance between the valve stem by feeler gauge . Valve clearance: inlet and exhaust valve: 0.05～0.08mm. See figure 2-3. Figure 2-3 Loose the lock nut, rotate the adjusting screw until it appears that the feeler gauge be pulled .Then fasten the adjusting screw by valve adjuster, tighten the lock nut and check the valve clearance .After installing the cylinder...
  • Page 14 2.1.2 2.1.2 2.1.2 2.1.2 Spark Plug checking 1.Unplug the Spark-Plug cap:remove the spark plug by spanner,look over whether the spark-plug insulator and electrode is damaged or sooting. If so ,see figure 2-5. Figure 2-5 Check the spark clearance by feeler gauge whether it is 1 ．...
  • Page 15 3.Swirl the spark plug and tighten to 18 ～ 20N.m by spanner ,then fix the spark plug cap when assembling. cylinder, piston, piston ring 2.1.3 Specification...
  • Page 16 项 目 item 标准值 mm 维修极限值 mm limit value:mm standard value: mm 气缸内径 Inner diameter of φ84.503～φ84.527 φ84.6 cylinder cylinder taper 0.0040 0.005 out of roundness 0.0035 0.005 degree of warp 0.04 0.10 φ84.47～φ84.45 φ84.35～φ84.25 Outside diameter of piston φ20.002～φ20.01 φ20.05～φ20.1 Inner diameter of piston pin hole...
  • Page 17 1. Check whether the cylinder is damaged. 2. Measure the bore diameter of cylinder at three spots. 3. At the top, the middle and the bottom of the piston stroke .And measure the bore diameter at directions of right-angle intersection repairing limit value: 0.05 mm ，...
  • Page 18 Figure 2-9 ：0.5mm。 Insert piston ring into cylinder,and measure the end gap. repairing limit value:the first ring/the second ring: 0.5mm See figure 2-10 . Figure 2-10 Measure the bore diameter of piston pin hole. repairing limit value: see figure 2-11.
  • Page 19 Figure 2-11 Measure the external diameter 10mm above the bottom of the piston skirt. Extreme position :the gap between cylinder and piston repairing limit value: 0.1mm See figure 2-12. 1、 Figure 2-12 7． Measure the external diameter of piston pin: the gap between piston and piston pin: 0.02mm repairing limit value: 0.02mm .See figure 2-13.
  • Page 20 Figure 2-13 2.1.4 Inspection of crank and connecting rod Check that whether crank and connecting rod can rotate without stuck and whether the clearance between crank and connecting rod is 0.5～0.6mm.The hop of crank shaft should be 0.05mm.If not so,replace it. See figure 2-14-1, figure 2-14-2. Figure 2-14-1 Figure 2-14-2...

  • Page 21: Inspection Of Clutch

    Inspection of clutch 2. 2. 2. 2..1.5 The wear condition of shoe block and friction plate: See figure 2-15 Figure 2-15 Inspection of Carburetor 2.1. 1、Inspect the idle of carburetor The engine speed should be 1500±150r/min 10 minutes after starting at normal idle and will not misfire when briskly accelerate.
  • Page 22 Figure 2-16 Inspection of air cleaner 2.1.7 1、Disassemble the air cleaner, remove filter element, clean the filter element with non-flammable cleaning solvent, and then make it dry. Note: Petrol is forbidden. 2.Dip the air filter element into 20# oil, then take it out and squeeze the excessive oil, assemble it orderly.

  • Page 23: Inspection Of Lubrication System

    Figure 2-18-1 2.1.9 Inspection of lubrication system 1．Lubricant of engine: the vehicle is oiled with lubricant of APISGSAE10W/40. APISGSAE10W/40. Others are forbidden. APISGSAE10W/40. APISGSAE10W/40. The capacity is 1.9L after disassembly and assembly. 2、 The capacity is 1.8L when fueling up after drain. Inspection of oil pump: 三...

  • Page 24: Lubrication Of Engine

    2.1.10 2.1.10 2.1.10 2.1.10 lubrication lubrication of engine Check the oil level, start the engine and let it running for a few minutes to make it heated and lubricated completely ,then misfire. Unplug the dip stick to do cleaning and dip it into the oil case again. Then unplug the dip stick and look whether oil level is lower than the indicator.
  • Page 25 whether the cylinder head is out of shape. Examine the flatness of cylinder head by flat or knife edge gauge and clearance gauge . Repairing limit value: 0.05mm.See figure 2-21 Figure 2-21 2．Remove and examine the width of valve . Repairing limit value: 2.0mm.See figure 2-21-1 ,2-21-2, 2-21-3.
  • Page 26 Figure 2-21-3 Measure the width of mating surfaces of valve 1.5mm repairing limit value: 1.5mm If the valve seat is to wide or narrow or cracked, grind it to ensure impermeability. Measure bore diameter of valve guide with internal micrometer and special gauge. At last calculate clearance between valve stem and valve guide.
  • Page 27 Fix valve into guide,and look over the motion. Inspection of valve spring Measure the free height and squareness Repairing limit value:(intake and exhaust) See figure 2-23-1, 2-23－2 free height of external spring: 43mm squareness: 0.8mm free height of inner pring: 39.5mm squareness0.8mm Figure 2-23-1，...
  • Page 28 Figure 2-2 Inspection of rocker arm Check whether the rocker arm is worn out,or damaged and whether the oil hole is blocked. Note:If there is a rocker arm to be replaced,examine the peak of cam measure the bore diameter of rocker arm φ12 +0.038mm +0.020mm Repairing limit value: φ12 +0.038mm +0.020mm .See figure 2-25 Figure 2-25...

  • Page 29: Disassembly Of Engine

    Examine if the rocker arm if worn out or cracked. Measure the external diameter of rocker arm shaft with micrometer. − Repairing limit value: φ12 − The repairing limit value of clearance between rocker arm shaft and hole : 0.09mm ,See figure 2-26 Figure 2-26 3.1 disassembly of engine 3.1.1...
  • Page 30 Remove cylinder valve cover,cam sprocket cover and ④remove timing sprocket Figure 2-28-1 Figure 2-28-2 ⑤remove lower rocker arm shaft.See figure 2-29-1. Figure 2-29-1 ⑥ Remove vision hole cover of left front cover .See figure...
  • Page 31 2-30. Figure 2-30 Alignment: align the ＂1＂indicator of the cam chain wheel and the “ ” symbol of cylinder. alignmentment of top dead center: 。 Rorate the crankshaft with “T” sleeve anti-clockwise until the indicator of the cam chain wheel to be at the same level with the“...
  • Page 32 there defects,rotate crankshaft anti-clockwise,and repeat the above-mentioned steps. See figure 2-31-1 ，Figure 2-31-1 ⑦ Remove chain tensioner adjuster.See figure 2-32. Figure 2-32 remove the cylinder head Loosen the bolt by intersection manner before remove the bolt.see figure 2-33.
  • Page 33 Figure 2-33 remove 。dowel pin cushion(cylinder head) chain guide board .See figure 2-34. Figure 2-34...

  • Page 34: Piston And Connecting Rod

    Remove cylinder Oil seal Dowel pin 。Shim(cylinder) See figure 2-35. Figure 2 Figure 2- - - - 3 3 3 3 5 5 5 5 Figure 2 Figure 2 3.1.2 3.1.2 3.1.2 3.1.2 piston and connecting rod ①remove the piston circlip Note:block the crankcase breather with a piece of cleaning cloth to avoid the circlip falling into the case.
  • Page 35 Figure 2-36 ②remove piston pin and piston Clean the buckle of piston and piston pin hole to facilitate the removing of piston pin. Note:it is forbidden to knock the piston pin with a hammer .See figure 2-37. Figure 2-37 3.1.3 3.1.3 remove pull-out hand start assy 3.1.3 3.1.3...
  • Page 36 3.1.5 3.1.5 3.1.5 3.1.5 left crankshaft case cover See figure 2-40. Figure 2-40 3.1.6 3.1.6 magneto 3.1.6 3.1.6 remove the stator coil remove the pluse coil Remove the stator with rotor stripper. See figure 2-41. Figure 2-41 Remove the woodruff key. See figure 2-42.
  • Page 37 Figure 2-42 3.1.7 3.1.7 3.1.7 3.1.7 oil pump remove the bolt of oil pump cover .See figure 2-43. Figure 2-43 remove right cover .See figure 2-44.
  • Page 38 Figure 2-44 Remove the right bracket, clutch pulley disc .See figure 2-45-1, figure 2-45-2, figure 2-45-3. Figure 2-45-1 Figure 2-45-2 F F F F igure 2 igure 2 igure 2 igure 2- - - - 45 45 45 45- - - - 3 3 3 3 3 3 3 3 .1.8 .1.8 .1.8...
  • Page 39 Figure 2-46 Remove the clutch shoe block and clutch cover. See figure 2-47. Figure 2-47 Check the wear condition of the clutch shoe block and clutch cover. See figure 2-48. Figure 2-48...
  • Page 40 3.9 carburetor 3.9.1 structure of carburetor...
  • Page 41 carburetor serial part name and standard code quantity number 16100-F12-0000 carburetor assy 16101-F12-0000 fuel needle part 16102-F12-0000 column-filled spring 16103-F12-0000 big diaphragm 16104-F12-0000 column filler 16105-F12-0000 diaphragm circlip 16106-F12-0000 adjusting screw comp,mixing rate 16107-F12-0000 adjusting screw washer,mixing rate 16108-F12-0000 adjusting screw o-ring,mixing rate 16109-F12-0000 main measure hole 16110-F12-0000...
  • Page 42 Inspection and adjusting carburetor 3.2 .2 decomposition Remove the evacuated chamber cover 1． spring 2． piston valve remove permanent seat spring spring seat oil needle...
  • Page 43 remove pilot screw spring washer 0-rings Note: The pilot screw is set at maximum performance. Before removing pilot screwed, note the revolutions of screw in order to fix it back. remove pontoon chamber cover...
  • Page 44 shim remove pontoon pin pontoon triangular needle remove the cover 0-rings spring starting plunger pilot jet...
  • Page 45 check the carburetor body pontoon chamber oil passage gas-fouling block→cleaning chap/damage→replace the carburetor assy cleaning steps: check the pontoon damaged→replace...
  • Page 46 check the pontoon triangular needle triangular needle seat 0-rings filter net Damaged/worn out/block→replace check the piston valve crack→replace diaphragm rupture→replace piston valve oil needle bent/worn out→replace Note:If the piston valve is damaged,inject the petrol into...
  • Page 47 valve. Replace it when there is oil leakage. check the main jet main jet pilot jet pilot screw 0-ring pilot jet bent/worn out/damaged→replace gas-fouling block→blow with compressed air...
  • Page 48 4.Chassis 4.1 Steering operation system Structure of Steering Vertical Column 1、steering vertical column components 2、turning rocker arm components 3、 Steering Bar Clip 4、hexagon flange bolt M8×35 5、inner and external bearing of steering vertical column 6. supporting seal ring of steering vertical column 7、Supporting stent 8、hex bolt M8×60 9、stop reverse piece 10、Supporting Collar Sheath 11、cushionф14×ф32×4 12、...
  • Page 49 Components of Steering Bar 1、Steering Bar 2、steering Rubber Sheath 3、air duct door pull cable 4、oiler components 5、acceelerator pull cable components 6、left switch components...
  • Page 50 4.1.1Disassembly, inspection and assembly of 4.1.1Disassembly, inspection and assembly of Steering Steering 4.1.1Disassembly, inspection and assembly of 4.1.1Disassembly, inspection and assembly of Steering Steering Vertical Column 4.1.1.1Disassembly of Steering Vertical Column 1.Remove all of the Plastic cover and Plastic oranments on Steering Bar (Figure 4-1-1 1）.
  • Page 51 4.Remove the cotter pin, Figure 4-1-3) open-groove nut and cushion at the bottom of the Steering Vertical Column. (Figure 4-1-4) 1）.cotter pin 3.2×32 2）.cushionф14×ф32×4 3）.Hexagon open-groove nut M14 5、Remove the supporting brackets of the steering vertical column Figure 4-1-4 (Figure 4-1-5) 1)Supporting stent 2)Inner and outer supporting Bracket...
  • Page 52 Figure 4-1-6 1)Tension rod 2)front right Yanggakdo 3)cotter pin 3.2*32 4)Hexagon open-groove nut M10 7.Pull out the components of the steering vertical column from the bottom seat. ( Figure 4-1-7) Figure 4-1-7 1、 Steering Vertical Column 2、 Bottom Seat 4.1.1.2 Inspection of steering vertical column components: 1.Check whether the nut between the inner ball pin of tension rod and the Turning rocker arm...
  • Page 53 Torque: 32-36N.m 1)Steering drop arm assembly 2)Hexagon open-groove nutM10 3)cotter pin 3.2*32 4)Tension rod 2.Check whether the inner and outter ball pin of the tension rod is loosen or got stuck. (Figure 4-1-8) In occasion of above defects, further inspection of the exact causation must be carried out and replace with new ball pin components.
  • Page 54 the steering vertical column. Figure 4-1-5 Inspection method: Assemble the steering vertical column to the main frame with supporting bracket and M8 bolts etc. and rotate the steering bar to ensure the column is not stuck or swinging. In occasion of above problems, the supporting bracket must be replaced.
  • Page 55 seals must greased with lithium lubrication. Figure 4-1-9 1)、Steering bottom seat 2)、Cushion 3)、Hexagon open-groove nut M14 4)、Cotter pin 3.2×32 2.Fix the steering vertical column onto the frame with hexagon flange bolt M8*60 (2pcs), supporting stent (1pcs), inner and outer supporting bracket (2pcs), stop reverse piece (1pcs) and collar pipes (2pcs).
  • Page 56 Figure 4-1-10 1)、 hexagon flange bolt M8*6 2)、Inner and outer supporting bracket 3)、stop reverse piece 4)、Supporting stent 5)、Supporting Collar Sheath 6)、Supporting ferrel 4.Fix the tension rod into the conical bore of the steering vertical column with tension rod components (2sets), cushion ф12 (2pcs), M10 hexagon open-groove nuts (2pcs) and cotter pins 3.2×32 (2pcs).
  • Page 57 Figure 4-1-11 1)Turning rocker arms comp 2)Cushion ф10 3)Hexagon open-groove nut M12 4)Cotter pin 3.2×32 4.1.2 Disassembly, inspeciton and assembly of steering bar 4.1.2.1 Disassembly of steering bar 1.Remove all of the Plastic cover and Plastic oranments on Steering Bar (Figure 4-1-1) 2.Remove steering bar clip（附图4-1-2）...
  • Page 58 Figure 4-1-12 2.Altitude balance on each end of the steering bar must be less than 3mm, otherwise replace the steering bar. Figure 4-1-12 3.Check if there exists any slip thread, crack or other defects on the fastening bolts, in which case the bolts must be replaced.

  • Page 59: Brake System

    Fastening Torque of the M8*30 Bolt is: 26-30N.m Brake System 4.2.1Front Disk Brake components 1、 disk brake pump assembly 2、 disk brake compressed bearing 3、 disk brake oil bowl sealing washer 4、disk brake oil bowl cover 5、cross recess half-countersunk head screw M5×12 6、disk brake pump seat 7、cross recess pan head screw M5×60 8、disk brake handle...
  • Page 60 disk brake system. Brake system is crucial to the life safety of the operator therefore must periodically inspected maintained. The vehicle uses brake plate. Please follow the tips of inspection as below: a)Inspect the brake fluid box level on the right handlebar. Should the fluid level falls under the minimum mark, please refill the box with the same type...
  • Page 61 Figure 4-2-2 c) Inspect the elasticity of the brake handlebar. d))Brake fluid will be automatically injected into the brake fuel pipe in the process of abrading brake pad reducing the fluid level in the box. Therefore, periodical inspection of the fluid level is necessary. Caution: must use DOT4 Brake Fluid e) Periodical inspection of the wear condition of front disk brake plate is also necessary.
  • Page 62 is less than 1.5mm, it must be replace. 2. In occasion of crack or distortion, the disk brake plate must be replaced. Figure 4-2-3 1)Brake plate clip 2)Hexagon self-lock nut M8 f)Disk brake plate uses hydraulic pressure of the brake fluid.
  • Page 63 1、Removing the wheel component see Figure 4-2-4 Figure 4-2-4 1)front wheel hub 2)Hexagon open-groove nut M30 3) cotter pin 3.2*32 4)cushion 5)taper nut M10 2.Sequently remove the cotter pins, open-groove nuts, cushion and front wheel hub from the front wheel shaft. (Figure 4-2-4) 3.Remove the disk brake plate from the front wheel...
  • Page 64 of Disk Brake Pump and then remove the whole unity. Figure 4-2-6 Figure 4-2-6 1)bottom seat of Disk Brake Pump 2)Disk Brake Pump unity 2、Remove the Front Fuel Pipe Brackets(Figure4-2-7) Figure4-2-7 1).branch seat of Disk Brak Fuel Pipe 2).Hexagon Flange Bolts M8 3.Detach the Plate Clip nut and remove the Plate Clip(Figure4-2-3).
  • Page 65 1.Check the Brake Fluid Box for crack, leakage and other potential defects. 2.Check Fastening Bolts of all Fuel Pipes for possible looseness or damage. 3.Check all Fuel Pipes for deterioration, distortion, crack, wear and other hidden defects. 4.Check the Brake Plate Clip for distortion, crack, rust and stuck. 5.Inspect the Brake Shoe for wear condition.
  • Page 66 4.2.1.5 Assembly of Front Brake System 1.Use Fuel Pipe Brackets (2pcs) and Hexagon Flange Bolts M8*16 (2pcs) to connect the Fuel Pipe Clip with both left and right Lower Front L/R rocker armss. Caution: Fuel Pipe must avoid physical contact with other components in movement.
  • Page 67 stening Torque of Conical Nut: 55 N.m-40N.m 6、Fix Front Disk Brake Pump onto the Right Handlebar with M5*60 hexagon bolts (2pcs) (Figure 4-2-16) astening Torque of the bolt is: 10 Caution: Do not operate the vehicle immediately after assembling the brake system. Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating before riding the vehicle...
  • Page 68 operator and therefore must be periodically inspected and maintained. b)Rear wheels of the vehicle use brake plates mechanized by a rear brake pedal. Please follow the tips of inspection as below. c)Inspect the brake fluid box level on the right handlebar.
  • Page 69 of the brake handlebar. f)Brake fluid will be automatically injected into the fuel pipe in Figure 4-2-10 1、Rear Brake Pedal the process of abrading brake pad reducing the fluid level in the box. Therefore, periodical inspection fluid level necessary. Caution: must use DOT4 Brake Fluid 。...
  • Page 70 Figure 4-2-11 1、Disk Brake Plate Caution: 1. If the thickness of the disk brake plate is less than 2.5mm, it must be replace. occasion crack distortion, the disk brake plate must be replaced. h)Disk brake plate uses hydraulic pressure of the brake fluid.
  • Page 71 1.detach Rear Disk Brake Pump from the Frame (Figure 4-2-6) 2.Remove Rear Disk Brake oil bowl from the Frame (Figure 4-2-9) 3.Release assembling Bolt（M8*14） and detach the Rear Disk Brake Clip. (Figure 4-2-12) Figure 4-2-12 1)Rear Disk Brake Clip 2)hexagon flange bolt M18×14 4、Remove Rear Disk Brake System 4.2.2.4.
  • Page 72 of Rear Disk Brake Plate from the Rear Bridge. (Figure 4-2-14) Figure 4-2-14 1)hexagon flange bolt M10×115 2)rear transmission case 3)rear central transmission shaftv 3.Remove the Rear Disk Brake Plate from Bottom Seat see Figure 4-2-15 Figure 4-2-15 1).Bottom Seat of Rear Disk Brake Plate 2)Rear Disk Brake Plate 4.2.2.5Inspection of Rear Brake System: 1、Check the Brake Fluid Box for crack, leakage and other...
  • Page 73 3、Check all Fuel Pipes for deterioration, distortion, crack, wear and other hidden defects. 4、 Check the Brake Plate Clip for distortion, crack, rust and stuck. 5、Inspect the Disk Brake Shoe for wear condition. Brake shoe must be replaced when worn out. 1、Brake Shoe 6、Inspect the Brake Shoe for maximum wear, distortion and crack, in which case it must be replaced.
  • Page 74 when fastening Fastening Torque of bolt: 22 N.m -28N.m 2、Mount the Bottom Seat of Rear Disk Brake Plate onto rear transmission case .Then configure the rear central transmission shaft, rear transmission case in turn. See Figure 4-2-15 3、 Mount the Disk Brake Clip onto rear transmission case with M10×30 Bolts (2pcs) Fastening Torque: 18 N.m --22 N.m 4、...
  • Page 75 Caution: Do NOT operate the vehicle immediately after assembling the brake system. Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating before riding the vehicle. 4.3 Wheel and Tyre 4.3.1：Preparation for maintenance of wheel: 1.Inspect wear condition of the tyre.
  • Page 76 4.3.2.1 Disassembly of wheel components: Remove M10 Conical Nuts (4pcs) and detach the tyre. (Figure 4-2-13) 4.3.2.2 Inspection of wheel components: 1.Check if the wheel hub has any distortion, rust, crack or other potential defects. If so, please replace the wheel hub. 2、Check if the tyre has reached its maximum wear condition in which case it should be replaced.
  • Page 77 Attach wheel hub onto the wheel with M10 Conical ball Nuts (4pcs)and dust-proof cover.(1pcs). Fastening Torque: 45～55N.m Caution: assemble the wheel in correct direction (shown as the arrow). Front and Rear Wheels are not interchangeable. (Figure 4-2-17). 4.3.2 Speicification and operation guide of Wheel Hub and Tyre.
  • Page 78 profile depth. Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle (such as hard turning). Excessive tyre pressure can also reduce the friction force between the tyre and ground, causing spinning or lose of control.
  • Page 79 Figure 4-2-19 1 、 front wheel hub 2 、 L/R transmissionshaft 3 、 fore bridge differential components 4、middle transmissionshaft components of fore bridge 5、L/R turning joint front tank components 4、 cushion φ 1、 gear-box assembly of front bridge 2、 the right cover 3、...
  • Page 80 10.5 5、drive gear of front bridge 6、front driving axis pin sleeve 7、M10X1.25 flange locknut 8、0-ring of front bridge drive gear f9、φ65Xφ48oil seal 10、oil seal of rear constant velocity joint assenbly 11、differential –adjusted washer 12、 M8X20 engine gearbox bolt 13、 differential assembly 14、 inner M8X25 hex bolt M8X10 16、...

  • Page 81: Sensor

    Yanggakdo. 3.Check if the constant velocity joint is matched up well. If not so or there is gear-cracked and abnormal noise,remove the constant velocity joint and align it . 4.Check if there exists any slip thread or flaw on the open-groove nut .
  • Page 82 3.disassemble the fore bridge differential( Figure 4-2-20) 4、Take out the fore bridge from the frame 5、Release engine oil in the differential 6 、 Unplug transmissionshaft from differential( Figure 4-2-19) 4.4.1.3 Inspection and Maintenance of fore bridge: 1.If dust-proof Rubber Sheath transmissionshaft is worn out or cracked, plesae have it replaced immediately.
  • Page 83 4 、 Open the differential, and inspect wear condition of gear,shaft and cushion,then replace the defective component. 4.4.1.4 assembly of fore bridge component 1、Fix transmissionshaft onto fore bridge differential. ( Figure 4-2-19) 2、Inject 0.32L of GearLubricant of SAE 80 API GL-4 into fore bridge differential.Then tighten the bolt.
  • Page 84 1、 hexagon flange bolt M10×110 2、 fore bridge case 4.4.2 Rear Bridge 4.4.2.1transmissioncase of rear bridge...
  • Page 85 needle bearing 1、 rear bridge transmission case assembly 2、 the left case 3、 22BM3010 4、 needle bearing 55BM6720A needle bearing 5、cluster gear of rear bridge 6、 7、rear disk brake seat 8、φXφ oil seal 9、clamp sheath 0-ring of rear drive gear rear drive gea 10、...
  • Page 86 1、gear shift mechanism assembly 2、gear shift mechanism handle 3、换档机构 plastic screw of gear shift mechanism 4、dust-proof cover of gear shift mechanism 5、dust-proof cover thimble of gear shift mechanism 6、elocity joint robber sheath of gear shift mechanism 7、velocity joint of gear shift mechanism 8、hex nut(anti)M8 9、waste oil pipe thimble of gear shift mechanism...
  • Page 87 there are tripstop or lack. If these situation exists, call for the maintanance staff to test and repair it. 6.If the gear can not be engaged, we can test it from the following aspects: ① whether the clutch can completely declutch;...
  • Page 88 1、rear damper components 2、hexagon flange bolt M10×50 3、locknutM10×1.25 4、horizontal rear-fin components 5、 the right horizontal rear-fin velocity joint 6、the left horizontal rear-fin velocity joint 7、locknutM12×1.25 8. horizontal rear-fin robber sheath 9. horizontal rear-fin press plate 10. hexagon flange bolt M8×14 4.6.2rear rocker arm 1、rear left-upper rocker arm assembly 2、middle spacer sleeve of fore L/R rocker...

  • Page 89: Front Suspension

    4.6.3.front Suspension 1、fore upper-left rocker arm 2、middle spacer sleeve of fore L/R rocker arm 3、fore upper-right rocker arm assembly 4、middle spacer sleeve of rocker arm 5、open-groove nut M10 6、cotter pin 3.2×32 7、fore bottom-left rocker arm assembly 8、fore bottom velocity joint assembly...
  • Page 90 9、stopper elastic ring for shaft 10、middle spacer sleeve of fore L/R rocker 11、fore bottom-right rocker arm 12、fore bottom velocity joint assembly 13、stopper elastic ring for shaft 14、middle spacer sleeve for security 15、 M10×40 16、hex locknut hexagon flange bolt 17、elastic cushion 18、 M10×65 19、hex locknut M10×1.25 hexagon flange bolt...
  • Page 91 M10locknuts(4pcs)to ensure a torque of 40～45Nm. Caution:A:These components should be greased with butter before assembly. B:The surface of components can not be cracked. Check whether these components are greased with butter and then tighten the up-and-down rocker arm assembly and L/R fore dampers and ther components.Fix the L/R tension rods into hole by way of the trough of open-groove nut with cotter pin(4...

  • Page 92: Electrical System

    4.6.5.Inspection and Maintenance of rear Suspension 1.Inspection and Maintenance are similar to the fore Suspension 2.Check whether the assemble shaft of the rear damper deformed in which case it must bu changed. 3.Check the Collar Sheath and Rubber Sheath 4.Check if the cotter pin on the assembly shaft of the rear damper is reliable.
  • Page 93 5.Orange┄┄O 22.Green White┄┄G/W 6.White┄┄Ｗ 23.Brown White┄┄Br/W 7.Gray┄┄Gr 24.Brown Blue┄┄ Br/L 8.Blue┄┄L 25.Red Brown┄┄R/Br 9.Brown┄┄Br 26.Yellow Red┄┄Y/R 10.Dark Green┄┄Dg 27.Green Red┄┄G/R 11.Dark Red┄┄Dr 28.Green Black┄┄G/B 12.White Green┄┄W/G 29.Black White┄┄B/W 13.White Red┄┄W/R 30.White Blue┄┄W/L 14.White Black┄┄W/B 31.Yellow White┄┄Y/W 15.Light Blue┄┄Lb 32.Green Blue┄┄G/L 16.Light Green┄┄Lg 33.Purple┄┄V 17.Black Yellow┄┄B/Y...

  • Page 94: Magneto

    phenomena cause measure remark ignition system 1.switch lock １,no spark ※ ★repair carve out a way or short circuit,connection badness ※ line bonding ★repair badness 2.CDI set ※ ★replace After electrify no noise from the CDI 3.high voltage ※ high ★repalce voltage lead...

  • Page 95: Ignition System

    5.1 ignition system The key diagram of ignition elements ignition elements: Ignition pressure provided by magneto ignition coil through diode commutated,by R(red line)input CDI(capacitance discharge ignition),charge to capacitance C.at the same time ,spring coil produce spring signal ,provided to SCR as the turnon spring signal ,when reaching the ignition timing,SCR turnon capacitance began to discharge at the elementary coil L1 caused instant lower pressure ,while at the secondary coil...
  • Page 96 charge system The key diagram of charge elements 5.2 magneto and charge system the elements of charge: When engine running,driven magnet rotor circumgyrate,so on the stator coil produce alternating current then induce electromotive force come into to being the pressure.Through lines Y(yelloe output...
  • Page 97 electrode have become white or the case with a sulfate function 3. Electrode former scratched or scratched by press or insulation without work. Pay attention when using 1. Long time out of using but without charge is not correct. 2. Too much charge (so long time charge is not correct, generally if battery empty, the normal charge time hours) 3.
  • Page 98 If under such accidents, please deal with it as follows or ask for help from the doctors. 1. Exterior, wash lots of cleaning water 2. Interior, drink milk or water and then milk of magnesia or egg or rap oil and hospitalize as soon as possible. 3.
  • Page 99 the key diagram of illumination system 5.5 Meterand signal system ：Operation and working way： １、 Headlight Headlight Switch yellow function green yellow / red ２、 Emergency light switch ３、Turing light switch nigger gray dark green green function function brown green /red /black When using this function, left and right turning lights will...
  • Page 100 When press the button, the horn will move. But if without sound or with unclear sound or with little sound please check the problem according to the guide 5.6：Electrical starting system Starting Circuit Starting system working process Turn on the start switch on the left handlebar, the battery can supply power for the CDI.
  • Page 101 Note: 1. When electrical starting, please keep the battery with enough power and the time of pressing button will be within 55 seconds. If longer time more than 5 seconds, it may cause the damange of startor relay and the startor relay motor and may also cause the damage of the battery that it can not be charged or not charge enough.
  • Page 102 Mini. Clearance to 260mm the ground Seat height 900mm(B model) turning radius 2000mm Front：Hydraulic spring swing arm Suspension Rear：Hydraulic spring swing arm Braking pattern Front dual disk, Rear single (Normal condition) disk/front and rear linkage, Right foot/left hand operation （1） ：(E-mark) Front dual disk,...
  • Page 103 Total weight(including 509kg hitch)： weight of the drawbar 100kg hook Total weight of the drawbar hook 609kg b） Specification and modle of engine Engine Model/Brand HS185MR/ HSUN Pattern Single cylinder, water cool, exhaust, four stroke Bore×Stroke 84.5mm×84mm 压 缩 比 Compression 9.4:1 Ratio Volume...

  • Page 104: Clutch

    Transmission 无级变速 Belt drive 5.0695～0.7679 ratio L Drive 5.3595（35/17×41/21× ratio 24/18） H Drive 3.2230（26/21×41/21× ratio： 24/18） R Drive 3.8282（25/17×41/21× ratio 24/18） Engine Drive 16.339～2.475 ratio Clutch Wet automatic centrifugation Lubrication Comply with GB11121-1995 standard. (Crankcase) Depending regional weather condition, choose either SAE 5W-40 or SAE 10W-30（Cold region）SAE.20W-40 （Warm region）...
  • Page 105 12V 21W 12V 21W Brake light 12V 21W 12V 21W Red light Rear license 12V 5W White light plate light Turning light 12V 10W Amber light Rear reflector Red light d）ecification and modle of other parts and structure Disk brake hydraulic DOT4 Turning operation...
  • Page 106 The Max. Speed is 82km/h(e-mark is 80km/h) d) Climbing power the climbing angle must more than 22° e) Lowest fuel oil consumption rate Lowest fuel oil consumption rate is ≤340g/Kw·h f) Reliability The reliable actual service life is 6000KM. The testing method carries on according to GB/T5374-1995.
  • Page 107 The multipurpose vehicle produces the radiated interference permissible value and the ignition system noise remover insertion loss loss value, the radio harassment characteristic should conform to GB14023-2006 l) Parking performance Multipurpose vehicle when neutral position use parking brake, of in thevehicle arresting gear should guarantee the vehicles in the slope are 18%, coefficient of adhesion between the tire and the road surface isnot smaller than on 0.7 slopeway, the counter- two directions...

  • Page 108: Suspension

    nut on chain stay 45～50 Upper nut on fore damper 35～45 bottom nut on fore damper 35～45 Upper nut on rear damper 45～55 bottom nut on rear damper 45～55 Nut on upper rocker arm of the 40～50 left Nut on bottom rocker arm of the 40～50 left Nut on upper rocker arm of the...
  • Page 109 OVERRIDE m mi n 1 0 0 0 FUEL...

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