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Parklands 700ATV Maintenance Manual

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700ATV Maintenance Manual
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  • Page 1 700ATV 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 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 6: 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. Figure 1-1 1.1.2.Engine No. The engine No. is engraved in the right side of the engine. See...

  • Page 7: Special Tools, Instruments And Meters

    figure 1-2 Figure 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 Outside micrometer To accurately measure external diameter of a column...
  • Page 8 1.2.5 Inside micrometer To accurately measure internal diameter of a hole 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...

  • Page 9: Periodic Maintenance Chart

    To measure pressure of the tyre 1.2.11 Magneto drawing device To detach the magneto 1.2.12 Snap ring clampTo 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)

  • Page 10: Engine

    ●Replace.(Wamenginebefore draining.) ○ ○ ○ ○ Engine oil Engine oil filter ○ ○ ○ ○ ●Replace. cartridge ○ ○ ○ ○ ●Clean. Engine oil strainer* Final gear oil ● Check for oil leakage. ○ ○ ● Replace eveny 12 months. Differential gear oil ●...
  • Page 11 valve Preheat the engine ,then misfire and unplug the spark plug.Fix pressure gauge into the hole, open the choke and throttle handle,and start for 4-6 times. Note: Giving leakage check pressure gauge.Rotate the engine until the pressure gauge stop rising.The maximum reading would be greater than 0.7-0.9Mpa after starting for 4-6 times.

  • Page 12: And Exhaust Valve

    Note: The piston must be fixed to the dead enter. (Figure 2-2) Figure 2-2 Remove cylinder valve cover,check the lash 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...

  • Page 13: Inspection Of Spark Plug

    check the valve lash .Afterword install the cylinder valve cover , vision hole cover,the fuel tank and cushion. See figure 2-4. Figure 2-4 2. 2. 2. 2.2 2 2 2 Inspection of spark Plug 1. Unplug the Spark-Plug cap:remove the spark plug by box key,look over whether the spark-plug insulator and electrode is damaged or sooting.

  • Page 14: Inspection Of Cylinder, Piston And Piston Ring

    standard value:mm limit value:mm item φ102～φ102.03 φ102.1 cylinder bore diameter of cylinder taper 0.0040 0.005 out of roundness 0.0035 0.005 degree of toruosity 0.04 0.06 φ101.95～φ101.97 φ101.92 Piston,piston external diameter of piston ring and bore diameter of piston pin φ22.002～φ22.010 φ22.010 piston pin hole...
  • Page 15 diagnosing and eliminating of malfunction: Emission of black smoke for abrasion of cylinder ● ● ● ● or piston, 1. Cylinder , piston of piston ring is worn out. 2.The piston ring is not properly assembled. 3. The piston or cylinder wall is scraped. overheated overheated overheated...
  • Page 16 Note:It is forbidden to damaging the piston ring when assembling.Check whether the piston and the piston groove is cracked and abraded.See figure 2-7 Figure 2-7 2.Insert piston ring into cylinder,and measure the end gap.repairing limit value:the first ring/the second ring: 0.5mm See figure 2-8.

  • Page 17: Inspection Of Crankshaft

    3.Measure the external diameter 10mm above the bottom of the piston skirt. Extreme position :the gap between cylinder and pistonrepairing limit value: 0.1mm See figure 2-10 Figure 2-10 Measure the external diameter of piston pin: the gap between piston and piston pin: repairing limit value: 0.02mm .See figure 2-11 Figure 2-11 2.4 Inspection of crankshaft...

  • Page 18: Inspection Of Clutch

    Figure 2-12-1 Figure 2-12-2 Inspection of clutch 2. 2. 2. 2.5 5 5 5 The wear condition of shoe block and friction plate:See figure 2-13 Figure 2-13 2.6 Inspection of carburetor 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.If not so, rotate the carburetor idle adjusting screw clockwise to rise the idle ,anti- clockwise to lower.When...

  • Page 19: Inspection Of Air Filter

    adjusting is unavailable,check that if there is a jam in carburetor idle nozzle or a air-leakage of intake pipe. See figure 2-14 Figure 2-14 2. 2. 2. 2.7 7 7 7 Inspection of air filter 1、Disassemble the air cleaner,remove cartridge,clean the cartridge with non-flammable cleaning solvent,and then make it dry.

  • Page 20: Inspection Of Oil Filter

    2 2 2 2 ． ． ． ． 8 8 8 8 Inspection of oil filter Cleaning of lubricator oil strainer:remove clarifier (Figure 2-17),clean it to ensure a well work- condition.Then fix it up. Note:Clean the clarifier before injecting oil into crankcase.

  • Page 21: Lubrication Of Engine

    measure clearance of the top of internal external rotor Limit value: 0.20mm 2. 2. 2. 2.10 10 10 10 Lubrication of engine Check the oil level,start the engine and let it running for a fow 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 22 Figure 2-19 2 Remove and examine the width of valve . Repairing limit value: 2.0mm. See figure 2-20-1 ,2-20-2, 2-20-3. If the mating surfaces is coarse,corrode or cannot contact with valve seat normally.repalce it. Figure 2-20-1 Figure 2-20-2 Figure 2-20-3 Measure the width of mating surfaces of valve...
  • Page 23 repairing limit value: 1.5mm If the valve seat is to wide or narrow or cracked,grind it to ensure impermeability. 4、 Measure bore diameter of valve guide with internal micrometer and special gauge.At last calculate clearance between valve stem and valve guide. Repairing limit value: intake : 0.12mm exhaust: 0.14mm Note :Eliminate...
  • Page 24 Figure 2-21 Inspection of valve spring Measure the free height and squareness Repairing limit value:(intake and exhaust) See figure 2-22-1, 2-22－2 free height inlet valve spring: 32.5mm, squareness:0.10mm free height exhaust valve spring: 36.2mm squareness:0.10mm Figure 2-22-1 Figure 2-22-2 6、Examining lifting distance of breaker cam. Measure the length of fillet with micrometer and check If it is worn out.
  • Page 25 Figure 2-23 7、Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal. Repairing limit value: φ22.939mm 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 breaker cam measure the bore diameter of rocker arm...

  • Page 26: Disassembly Of Engine

    The repairing limit value of clearance between rocker arm shaft and hole : 0.05mm ,See figure 2-25 Figure 2-25 3. 3. 3. 3. disassembly of engine 3. 3. 3. 3.1 1 1 1 cylinder head and block ① Unplug the intake pipe and spark plug.( Figure 2-26-1, 2-26-2) Figure 2-26-1 Figure 2-26-2...
  • Page 27 ③remove valve chain wheel Figure 2-27-2 Figure 2-27-1 Figure 2-27-2 ④remove lower rocker arm shaft.See figure 2-28 Figure 2-28 ⑤Remove vision hole cover of left front cover .See figure 2-29 Figure 2-29...
  • Page 28 Alignment: asjust these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover. alignmentment of top dead center: Rorate the crankshaft with “T” sleeve anti-clockwise until these two ＂●＂symbols of the cam chain wheel to be at the same level with cylinder cover .That is to say the piston of cylinder is at the top dead center.
  • Page 29 rocker arms of cylinder head. See figure 2-31 Figure 2-31 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 30: Piston And Connecting Rod

    Figure 2-33 remove adjuster cotter sealed ring of cylinder headtensioner adjuster guide board See figure 2-34. Figure 2-34 remove cylinder block0-seal adjuster cotter sealed ring of cylinder head See figure 2-35. Figure 2-35 3. 2 piston and connecting rod...
  • Page 31 ① ① ① ① remove the piston snap ring remove the piston snap ring remove the piston snap ring remove the piston snap ring Note:block the crankcase breather with a piece of cleaning .See f .See figure igure .See f .See f igure igure...

  • Page 32: Sensor

    3. 3. 3. 3.3 3 3 3 Manual starting mechanism Manual starting mechanism Manual starting mechanism Manual starting mechanism See figure 2-38. Figure 2-38 3.4 sensor Figure 2-39 3. 5 left crankcase cover See figure 2-40. Figure 2-40...

  • Page 33: Magneto

    3. 6 magneto remove the stator coil remove the pluse coil Remove the stator with rotor stripper.See figure 2-41. Figure 2-41 Remove the whitney key. See figure 2-42. Figure 2-42 3.7 oil pump remove the bolt of oil pump cover .See figure 2-43. Figure 2-43...
  • Page 34 remove right cover .See figure 2-44. Figure 2-44 Remove the right support frame,clutch pulley disc .See figure 2-45-1, figure 2-45-2, figure 2-45-3. Figure 2-45-1 Figure 2-45-2...

  • Page 35: Clutch

    Figure 2-45-3 3. 3. 3. 3.8 8 8 8 clutch clutch clutch clutch ①remove the clutch Remove bolts. See figure 2-46. 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.

  • Page 36: Carburetor

    3.9 carburetor 3.9.1 structure of carburetor 1．carburetor assembly 2.oil needle component 3.Plunger spring 4. Big diaphragm 5.Plunger 6.Diaphragm circlip7.Screw on upper cover 8.Mixture ratio adjusting screw component。9 .idle metering jet 10.High speed jet 11.Liner 12.Foam pipe 13.0-ring of foam pipe 14.Float 15。Screw M4×816。Float pin 17.Big screw 18.Float seal ring 19.Fuel inlet valve component 20.High speed jet 21.Drain screw 22.idle metering...
  • Page 37 48.Non-return valve 49.Flood pipe 3.9.2 2 2 2 Inspection and adjusting he carburetor decomposition 1.Remove the evacuated chamber cover 2.spring 3.piston valve remove permanent seat spring spring block oil needle remove pilot screw spring washer Note:the pilot screw is set at maximum performance.Before removing pilot screwd,note the revolutions of screw in order to fix it back.
  • Page 38 triangular needle remove the cover 0-rings spring starting plunger pilot jet check the carburetor body float bowl oil passage gas-fouling block→cleaning chap/damage→replace the carburetor assembly cleaning steps: check the float damaged→replace check the float triangular needle triangular needle seat 0-rings filter gauze Damaged/worn out/block→replace check the piston valve...

  • Page 39: Chassis

    diaphragm rupture→replace piston valve oil stick bent/worn out→replace Note:If the piston valve is damaged,inject the petrol into valve.Replace it when there is oil leakage. check the main jet main jet pilot jet pilot screw 0-scrapers pilot jet bent/worn out/damaged→replace gas-fouling block→blow with compressed air 4.Chassis 4.1 Steering operation system Structure of Steering Vertical Column...
  • Page 40 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、 Hexagon open-groove nut M14 13 cotter pin 3.2×32 14、tension rod assembly...
  • Page 41 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 4.1.1Disassembly, inspection and assembly of Steering 4.1.1 Disassembly, inspection and assembly of Steering 4.1.1 4.1.1 Disassembly, inspection and assembly of Steering Disassembly, inspection and assembly of Steering Vertical Column 4.1.1.1Disassembly of Steering Vertical Column...
  • Page 42 1.Remove all of the Plastic cover and Plastic oranments on Steering Bar (Figure 4-1-1 1）. Front Mud Shield 2）.Plastic Ornament 3）.Rear Mud Shield 2.Remove Steering Bar Holder (Figure 4-1-2) Figure 4-1-1 1）. Hexagon Flange Bolt M8×30 2）.Steering Bar Holder 3）.Steering Bar Clip 3.Unplug all cables and connecting wires and remove the Steering Bar (Figure 4-1-3)
  • Page 43 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 3)safety cushion Figure 4-1-5 6.Remove outer ball pin components on tension rod form turning joint (Figure 4-1-6)
  • Page 44 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 45 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 46 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. Rotating Torque of the steering vertical column: 3-5N.m 4.1.1.3 Assembly of steering vertical column...
  • Page 47 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 48 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 φ12 (2pcs), M10 hexagon open-groove nuts (2pcs) and cotter pins 3.2×32 (2pcs).
  • Page 49 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） 3.Unplug all cables and wires and remove the steering bar (Figure 4-1-3) 4.1.2.2 Inspection of steering bar 1.Check any existing or potential crack on the steering...

  • Page 50: Brake System

    3.Check if there exists any slip thread, crack or other defects on the fastening bolts, in which case the bolts must be replaced. 4.Check whether steering clip damaged(Figure 4-1-12).(Radial runout and wear condition of the inner surface must be less than 0.8mm) Otherwise, replace the steering bar clip.

  • Page 51: Brake System

    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 9、hexagonal locknut M8 10、disk brake switch 11、disk brake handle bolt 12、disk brake oil pipe branch seat hex bolt...
  • Page 52 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 of fluid as was recommended by the manufactureFigure 4-2-1 (Figure 4-2-1 to ensure the fluid level 1)、Brake fluid box is higher than the minimum mark.
  • Page 53 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 54 f)Disk brake plate uses hydraulic pressure of the brake fluid. Therefore, fuel pipe must be periodically inspected and replaced. Inspection Method: Fuel pipe must be replace when worn out, cracked or distorted. 4.2.1.1 Disassembly, inspection, maintenance and assembly of Front Disk Brake System. 4.2.1.2 Disassembly of front disk brake plate 1、Removing the wheel component see Figure 4-2-4 1)front wheel hub...
  • Page 55 2)Rront brake plate clip 4.2.1.3 Disassembly of the Front Disk Brake system: 1.Remove the bottom seat 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...
  • Page 56 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.
  • Page 57 1.5mm 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 58 4-2-15) 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 --14 Caution: Do not operate the vehicle immediately after assembling the brake system.
  • Page 59 Brake system is crucial to the life safety of the 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 60 e)Inspect the elasticity 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.
  • Page 61 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 62 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 63 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 64 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 65 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 66: Wheels And Tires

    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 67 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 68 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 69: Transmission System

    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 70 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 71 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 72 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 . 5..Disassemble the front tank and check whether the gears Is engaged properly.
  • Page 73 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 74 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. Torque of the bolt: 23N.m 3、Fix the fore bridge differential onto the frame with hexagon flange bolt M10×110 (2pcs), M10 nuts (2pcs), cushion 10 (2pcs) ( Figure 4-2-21).
  • Page 75 2、 fore bridge case 4.4.2 Rear Bridge 4.4.2.1transmissioncase of rear bridge 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...
  • Page 76 oil seal 9、clamp sheath 0-ring of rear drive gear rear drive gea 10、 11、 cushionφ12 12、 nutM12X1.25 13、 seat 14、rear adjuster cushionⅠ 15、rear adjuster cushionⅡ 16、oiling plug 17、0-rings of grease hex bolt hex bolt hole 18、 M8X35 19、 cushionφ8 20、 M8X25 21、...
  • Page 77 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 10、waste oil pipe of gear shift mechanism 11、waste oil pipe thimble of gear shift mechanism...

  • Page 78: Suspension

    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; ② whether gearshift greased reliable(whether the oil pipe of gear shift mechanism is blocked) ③...
  • Page 79 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 3、hexagon flange bolt M10×65 4、dust-proof cover of rear rocker arm...

  • Page 80: 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 9、stopper elastic ring for shaft 10、middle spacer sleeve of fore L/R rocker...
  • Page 81 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 20、fore L/R damper 21、 M10×50 22、hex locknut M10×1.25 hexagon flange bolt 23、cover of fore bottom-left 24、cover of fore bottom-right rocker arm rocker arm...
  • Page 82 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 pcs),and make these tension rods bisection on feet.

  • Page 83: 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 84 3.Yellow┄┄Ｙ 20.Red Black┄┄R/B 4.Green┄┄G 21.Red White┄┄R/W 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...
  • Page 86 phenomena cause measure remark ignition system 1.switch lock １,no spark ※carve out a way or ★repair short circuit,connection ★repair badness ※ line bonding badness ★replace 2.CDI set ※ After electrify no noise from the CDI ★repalce 3.high voltage ※ high voltage lead ★repalce...

  • Page 87: 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 88: Magneto And Charging 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 into rectifier ,through rectifier into direct current pressure and...
  • Page 89 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 90: Lighting System

    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. Eyes, wash cleaning water at least 15 minutes and hospitalize as soon as possible.
  • Page 91 ：Operation and working way： １、 Headlight Headlight Switch yellow green function yellow / red ２、 Emergency light switch ３、Turing light switch green green nigger function gray dark function /red /black brown green When using this function, left and right turning lights will shine at the same time.

  • Page 92: Electrical Starting System

    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 93: Appendix

    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. 2.
  • Page 94 (Normal condition) disk/front and rear linkage, Right foot/left hand operation Braking pattern Front dual disk, Rear single Primary Brake（1） ： disk/front and rear linkage, right (E-mark) foot/right hand operation Front dual disk, Rear single Primary Brake（2） ： disk/front and rear linkage, right foot/right hand operation Emergency brake：...
  • Page 95 exhaust, four stroke Bore×Stroke 102mm×84mm Compression Ratio 9.2:1 Volume 686ml Max. power 25kW (5000r/min- 5500r/min) Max. power（E-mark） 13kW （5500r/min） Rated power 24kW (6000r/min-6500r/min) Max. Torque 49N·m （5000r/min） Max. Torque （E-mark） 27.5N·m （4500r/min） Mini. Idle speed 1400±100r/min Fuel type Unlead #90 Lubrication Pressure Splash Starting system...
  • Page 96 choose either SAE 5W-40 or SAE 10W-30 （Cold region）SAE.20W-40（Warm region） Oil capacity 1.9L Engine dry weight 71kg c） Components Specification Carburetor PD42J Pattern Parallel Vacuum Spark plug DR8EA Speed meter Electronic Battery 12V 21Ah Headlight 12V 35W/35W White light Front Indicator 12V 3W White light Rear Indicator...
  • Page 97 Rocker arms Front and Rear dual rocker arms Parking brake Mechanical Frame Steel pipe Magneto Rotate DC output Spark plug gap 0.6-0.7 mm Safety fuse 6.1.2 Performance Requirement a) Starting Performance Starting time must be less than 15s b) Accelerating Performance Starting acceleration performance must be less than 14s/200m,,and overtaking acceleration performance must be less than 13s/200m.
  • Page 98 a） idle emissions CO≤3.8 %，HC≤800 ppm b） mode emissions CO ≤ 7.0 g/km，HC≤1.5g /km，NOx≤0.4 g/km i) deceleration and stopping performance a） braking distance : ≤27m(starting velocity is 60km/h ) b）braking deceleration must be greater than 5.88m/s j) noise The aon running noise must be less than 79dB (A). Static noise is 94dB (A),and the eagine speed is 2750mim k) radio-frequency interference The allowable radiation , the loss of suppress of ignition...

  • Page 99: Requirements For Torque Of Fastener

    of 8000cd. 6.2 Requirements for torque of fastener fastening parts （N.m）torque pillar 35～45 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...

  • Page 100: Electrical Circuits

    Nut on rear wheel 45～50 6.3 Electrical circuits the characteristic of the electrical circuits, 1.Actualize the electrial starting when it is at N,parking and brake. 2.When it is in the H gear,the H gear switch of the engine is on the ground,the H gear is lighting by the CDI inner transistor to control the dash light earth connection.
  • Page 101 OVERRIDE m m i n 1000 FUEL...

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