ATV 200 Off Road Vehicle Manuals

Manuals and User Guides for ATV 200 Off Road Vehicle. We have 1 ATV 200 Off Road Vehicle manual available for free PDF download: Service Manual

ATV 200 Service Manual (223 pages)

Four-Wheeled Cross-Country Vehicle

Brand: ATV | Category: Offroad Vehicle | Size: 6.19 MB

Table of Contents
3
Chapter I General Description
7
Section 1Description
7
Section 2 Special Tools, Instruments & Meters
8
(I) Special Tools
8
(II) Instruments & Meters
9
Section 3 Identification Code, and Engine no
10
Section 4 Points for Attention in Maintenance
10
Section 5 Specification
14
How to Use Conversion Table of Unit
14
How to Use Conversion Table
14
Definition of Unit
14
II.basic Specification
15
III.ATV Body
16
IV.electric System
17
Maintenance Specification of Engine
19
Section 6 Wiring Diagram of ATV
22
(I)Technical Explanation and Requirement, Details of Relative Component
22
(II) Wiring Diagram(1)
24
(III) Wiring Diagram(2)
25
(IV) Wiring Diagram(3)
26
Section 7 Requirements for Torque of Fastener
27
ATV Body
27
Engine
29
General Torque Specification
31
Section 8 Lubrication
32
Lubrication Oil Way
32
Lubrication Diagram
33
Section 9 Lubrication Point and Type of Lubricants
35
Lubrication Point and Type of Lubricants(ATV Body)
35
Lubrication Point and Type of Lubricants(Engine)
36
Chapter II Maintenance and Adjustment of Vehicle
37
Section 1 Periodic Maintenance/Lubrication
37
Section 2 Disassembly and Assembly of Cushion, Fender and Fuel Tank
38
(I) Cushion
38
(II) Rear Fender
39
(III)Fuel Tank
41
(IV)Front Fender
43
Section 3 Maintenance and Adjustment of Vehicle Body
45
(I) Wear Inspection of Front and Rear Brake
45
(II)Adjustment of Front Brake
45
(III)Adjustment of Free Clearance of Left Lever and Rear Brake Pedal
46
(IV)Position Adjustment of Steering Lever
48
(V) Lubricating Oil Level Inspection of Rear Driving Gearcase
48
(VI)Replacement of Engine Oil of Rear Driving Gear Case
49
(VII) Rubber Sleeve Inspection of Rear Wheel Fork
50
(VIII)Inspection of Steering System
50
(IX)Adjustment of Toe-In of Front Wheel
51
(X) Inspection of Front/Rear Shock Absorber
52
(XI)Adjustment of Rear Shock Absorber
52
(XII) Inspection of Tire
53
(XIII)Inspection of Rim
54
Section 4 Maintenance and Adjustment of Electrical Appliance
55
(I)Inspection of Battery
55
(II)Inspection of Fuse
56
(III)Replacement of Headlight Lamp
57
Section 5 Maintenance and Adjustment of Engine
59
(I)Adjustment of Clutch
59
(II)Clean of Air Filter
59
(III)Inspection of Spark Plug
61
(IV)Adjustment of Idle Speed
62
(V)Adjustment of Free Clearance of Throttle Grip
62
(VI)Adjustment of Speed Limitator
63
(VII)Adjustment of Valve Clearance
64
(VIII)Adjustment of Timing Chain Tension
66
(IX)Inspection of Ignition Timing
67
(X)Measuring of Compressive Force
68
(XI) Inspection Oil Quantity of Engine
69
(XII)Replacement of Engine Oil and Inspection of Oil Flow
70
Chapter III Repair and Maintenance of Vehicle Body
73
Section 1 Rear Driving Gearcase and Driving Shaft
73
(I)Trouble
73
(II)Inspection
73
(III)Trouble-Shooting Table
74
(IV)Disassembly
75
(V)Inspection
78
(VI)Pad Choice of Main Driving Gear and Shift Gear
79
(VII)Installation
81
Section 2 Front Wheel and Front Brake
82
(I)Disassembly
82
II.inspecting Procedures
84
(III)Installation Procedures
87
Section 3 Rear Wheel/Rear Brake/Rear Wheel Axle
90
(I)Removal Steps
91
(II)Inspection Steps
93
(III)Installment Steps
96
Section 4 Steering Operation System
100
(I)Removal Steps of Steering Bar
100
(II)Removal Steps of Steering Vertical Column Welding
101
(III)Inspection Content
102
(IV)Installment Steps
103
(V)Installation Steps of Steering Bar
106
Section 5 Front Shock Absorber and Front Wheel Fork
107
(I)Disassembly
107
(II)Inspection Steps
109
(III)Installment Steps
110
Section 6 Rear Shock Absorber and Rear Wheel Fork
113
(I)Disassembling Steps
113
(II)Checking Steps
115
(III)Mounting Steps
117
Chapter IV Electrical Appliance
120
Section 1 Inspect Switch
120
(I)Inspect Switch
120
Section 2 Check Lamp(Headlight)
121
Section 3 Troubleshooting the Ignition System Failure
123
Section 4 Running of Starting Circuit
128
Section 5 Troublshooting Electric Starting System
129
Section 6 Check Starting Motor
132
Section 7 no Charging in the Battery
135
Section 8 Troubleshooting
138
Section 9 Inspection of Lighting System
140
(I)If the Headlight Is out of Work
140
(II)If the Taillight Is out of Work
141
Section 10 Troubleshooting
143
(I)If Indicated Lamp Is out of Work
143
Section 11 Inspection of Signal System
145
(I)If the Neutral Indicated Lamp Is out of Work
145
(II)If the Reverse Indicated Lamp Is out of Work
146
(III)If the HB Indicated Lamp Is out of Work
147
Chapter V Engine
148
Section 1 Disassembly of Engine
148
(I)Remove the Engine from Finished ATV
148
(II) Disassembly of Engine
151
Section 2 Inspection and Maintenance of Engine
161
Section 3 Assembly and Adjustment of Engine
185
(I) Closing Assembly of Left & Right Crankcase
185
(II) Assembly of Right Crankcase
186
(III) Assembly of Left Crankcase
186
(IV) Assembly of Cylinder Head
205
(V) Manual Starting Mechanism and Others
212
(VI) Mount the Engine on the Finished Vehicle
214
Chapter VI Vecicle Ordinary Trouble and Its Judgement
219
( I )Starting Trouble/Difficulty
219
(II)Poor Idle Speed Performance
220
(III) Poor Middle and High Speed Performance
220
(IV)Shifting Trouble
220
(V) Clutch Slips
221
(VI) Clutch Is Locked
221
(VII) Engine Is Overheat
221
(VIII) Brake Trouble
221
(IX) Shock Absorber Failure/Improper Operation
221
(X) Lighting System
222

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ATV 200 Off Road Vehicle Manuals

ATV 200 Service Manual (223 pages)

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