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Ace Sports Maxxam 150 2R, Service Manual, Page: 29 / 79

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Ace Sports Maxxam 150 2R Service Manual Download Page 29

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Summary of Contents for Maxxam 150 2R

Page 1: ...150 2R ACE Maxxam 002 02 2007 239 County Road 4435 Brundidge AL 36081 www acesportsonline com P 1 888 562 9ACE F 1 888 562 8ACE Buggy Service Manual...

Page 2: ......

Page 3: ...speci cations contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this man...

Page 4: ...ION CONPONENTS ELECTRICAL STARTING SYSTEM REDUCTION MECHANISM CONTROLLING MECHANISM BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING CLUTCH DRIVEN BELT PULLEY REAR TRANSMISSION MECHANISM INSPECTION...

Page 5: ...lower front left side of the engine case FUEL AND OIL RECOMMENDATIONS H VXUH WR XVH WKH VSHFL HG IXHO DQG RLO FUEL Gasoline should be 85 to 95 octane or higher Unleaded gasoline is recommended ENGINE...

Page 6: ...5J Output Power 9HP 7500 rpm Maximum Torque N m r min 1 8 0 4000 4500 Starting Electric Ignition CDI Lubrication Force Splash Transmission Automatic CVT CAPACITIES Load 1 rider or 90kg 198Ibs Fuel tan...

Page 7: ...7 U HLJKW NJ OEV 7 5 35 6685 URQW 103VL 68 95N3D FP 70NJI FP 5HDU 103VL 68 95N3D FP 70NJI FP 55 17 7KH VSHFL FDWLRQV DUH VXEMHFW WR FKDQJH ZLWKRXW QRWLFH...

Page 8: ...4 LOCATION OF PARTS DRIVE CHAIN DRIVE CHAIN...

Page 9: ...f necessary L Lubricate R Replace MAINTENANCE AND TUNE UP PROCEDURES Descriptions of the servicing procedures for each item in the Periodic Maintenance table SPARK PLUG Clean up the carbon around the...

Page 10: ...an in the following appropriate manner Paper Filter Maintenance Remove the air cleaner from its housing T Replace the element if it is wrinkled or torn Foam Filter Maintenance Wash in non ammable clea...

Page 11: ...19 0 94 137 5 200 280 20 28 0 144 5 202 5 FUEL SWITCH PETCOCK Periodically clean the petcock externally with grease remover and water Check for any leaks or seeping fuel Replace the petcock if there...

Page 12: ...ZLWK HQJLQH RLO DQG UXQ IRU PLQXWHV KHFN RLO OHYHO RQ WKH OOHU FDS VWLFN WR DVVXUH SURSHU OHYHO 7KH FDS QHHGV WR EH VFUHZHG LQ IRU D SURSHU UHDGLQJ 66 6 UHDVH FKDVVLV EXVKLQJV DQG EHDULQJV ZLWK JUHDVH...

Page 13: ...s mutually perpendicular which is the circularity of the cylinder In the situation without a dial gauge a feeler gauge can be used to make relativity measurement Put a new piston into the cylinder and...

Page 14: ...VKRXOG EH UHSODFHG IWHU UHSODFHPHQW FKHFN WKH FOHDUDQFH EHWZHHQ WKH KROHV RI WKH SLVWRQ SLQ DQG PDNH VXUH LW FRP SOLHV ZLWK WKH UHTXLUHG PHDVXUHPHQW 3 6721 5 1 6 163 7 21 1 6 59 1 QVSHFW WKH SLVWRQ UL...

Page 15: ...UHODWLRQV RI WKH FUDQN FRQQHFWLQJ URG FRPSRQHQW 5 1 6 1 5 1 6 7 5 029 HIRUH UHPRYLQJ WKH FUDQNFDVH DQG FUDQNVKDIW IROORZ WKHVH SURFHGXUHV 5HPRYH WKH HQJLQH 5HPRYH WKH F OLQGHU FRYHU 5HPRYH WKH F OLQG...

Page 16: ...JDVNHW DQG WKH GRZHO SLQV 5HPRYH WKH FUDQNVKDIW IURP WKH FUDQNFDVH 7DNH RXW WKH FDP FKDLQ 5HPRYH WKH JDVNHW RQ WKH FUDQNFDVH MRLQW IDFH EH FDUHIXO WR QRW GDPDJH WKH MRLQW IDFH 5HPRYH WKH RLO VHDO IURP...

Page 17: ...nspecting Service Limit 0 10mm A 90 0 10mm B 105 Examine if there is any loose or unusual sound when the crank journal bearing turns If there is the whole set should be changed After cleaning the cran...

Page 18: ...H RLO RQ WKH 2 ULQJ 7LJKWHQ WKH FDP FKDLQ WHQVLRQHU EROW 9 9 0 1 60 163 7 21 1 6 59 1 7KH SLFWXUH VKRZV WKH FRPPRQ YDOYH WUDLQ RI D IRXU VWURNH HQJLQH 7KLV LV D NLQG RI RYHUKHDG YDOYH WUDLQ LWV LQWDNH...

Page 19: ...RWKHU PDUN RI WKH PDJQHWR ZKHHO DOLJQV WR WKH FUDQN FDVH PDUN KHQ DGMXVWLQJ ORRVHQ WKH ORFN QXWV DGMXVW WKH EROWV ZLWK D YDOYH DGMXVWLQJ ZUHQFK WKHQ WXUQHG FORFNZLVH WKH YDOYH FOHDUDQFH GHFUHDVHV WKH...

Page 20: ...LQ WHQVLRQHU E DGMXVWLQJ EROW FORFNZLVH 7XUQ WKH ZKHHO FRXQWHUFORFNZLVH WR PDNH WKH 7 PDUN RQ WKH ZKHHO DOLJQ ZLWK WKH PDUN RQ WKH FUDQNFDVH KHQ WKH KROH RQ WKH FDP FKDLQ WLPLQJ GULYH FKDLQ ZKHHO LV X...

Page 21: ...FKDLQ WHQVLRQHU FRYHU EROW 5HSODFH WKH YDOYH FRYHU JDVNHW DQG PRXQW WKH FRYHU 7LJKWHQ WKH YDOYH FRYHU SRVLWLRQLQJ EROW ROCKER ARM AND ROCKSHAFT ROCKER ARM AND ROCKSHAFT REMOVAL 5HPRYH WKH FDPVKDIW KR...

Page 22: ...rocker arm to the rockshaft Apply some oil to the rockshaft before mounting CAM CHAIN TENSIONER The chain tensioner must be in good working condition for proper chain tension 1 Cam chain 2 Cam chain t...

Page 23: ...nner spring 31 2mm 31 2mm Outer spring 34 1mm 34 1mm VALVE AND VALVE SPRING INSTALLATION Mount the spring retainer valve guide oil seal After applying oil on the valve stem mount it into the valve gui...

Page 24: ...ter diameter of the valve stem Valve Inlet valve Exhaust valve Service Limit 0 08mm 0 10mm VALVE GUIDE REPLACEMENT Heat the cylinder head to 212 302 F 100 150 C Tap the valve guide out with a valve gu...

Page 25: ...r too narrow it will result in poor contact between the valve and the valve seat and not seal tight At this time it must be reamed with a custom ized valve seat milling cutter The valve seat milling c...

Page 26: ...KH YDOYH DQG REVHUYH WKH FRQWDFW VXUIDFH RQ WKH YDOYH IDFH I WKH FRQWDFW SRVLWLRQ LV WRR KLJK FXW RXW VRPH RI WKH XSSHU SDUW RI WKH YDOYH VHDW ZLWK D PLOOLQJ FXWWHU WR UHGXFH WKH ZRUNLQJ IDFH RI WKH Y...

Page 27: ...rea EHWZHHQ WKH YDOYH OHYHU DQG WKH YDOYH JXLGH 9 9 1 9 9 6 7 5 03 50 7 163 7 21 IWHU ODSSLQJ WKH YDOYH DQG YDOYH VHDW WKH DLU LPSHUPHDELOLW RI WKH MRLQW VXUIDFH VKRXOG EH LQ VSHFWHG 0HWKRG 2QH Follow...

Page 28: ...is pumped by the rotator oil pump Some of the oil goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod the rest goes through some oil p...

Page 29: ...ODFLQJ O O 6WDUW WKH HQJLQH DQG UXQ IRU VHYHUDO PLQXWHV LQ WKH LGOH SRVLWLRQ WR PDNH VXUH WKHUH LV QR RLO OHDkage Stop the engine and inspect for proper oil level 527 5 2 3803 7KH RLO SXPS LV WKH FULW...

Page 30: ...RLO SXPS SRVLWLRQLQJ EROWV UHPRYH WKH RLO SXPS DVVHPEO 5HPRYH WKH VFUHZV DQG GLVDVVHPEOH WKH RLO SXPS 2 3803 163 7 21 QVSHFW WKH FOHDUDQFH EHWZHHQ WKH RLO SXPS ERG DQG WKH RXWHU URWDWRU 6HUYLFH LPLW...

Page 31: ...H RLO SXPS VKDIW DQG PDNH VXUH WKH RLO SXPS FDQ WXUQ VPRRWKO 2 3803 167 7 21 QVWDOO WKH RLO SXPS RQ WKH FUDQNFDVH HIRUH LQVWDOOLQJ OO WKH RLO SXPS ZLWK RLO KHQ LQVWDOOLQJ WKH DUURZ RI WKH RLO SXPS ERG...

Page 32: ...Float Set 4 Float Chamber Set 5 Screw Set A 6 Screw Set B 7 Valve Plate Set 8 Auto Bystarter Assy 17 Binder 18 Bystarter Cap 19 Rubber Tube 20 Pan Screw M04X8 21 Pan Screw M4X14 22 Screw Washer M04X8...

Page 33: ...he CV carburetor VACUUM CHAMBER REMOVAL Remove the body cover Remove the automatic choke lead wire Loosen the fuel drain bolt and drain the fuel in the oat chamber Remove the fuel line and the vacuum...

Page 34: ...ODPS DQG UHPRYH WKH FDUEXUHWRU KHFN WKH FRQGLWLRQ RI WKH FRQQHFWLRQ EHWZHHQ WKH WZR OHDG ZLUHV 7KH FKRNH YDOXH VKRXOG EH EHORZ 9 I LW H FHHGV WKH VSHFL F YDOuH LW VKRXOG EH UHSODFHG KHQ WKH HQJLQH LV...

Page 35: ...Install the air adjusting screw and choke adjusting screw and turn them to the proper position ac cording to the noted number of turns while removing 0RXQW WKH RDW YDOYH WKH RDW DQG WKH RDW SLQ TLJKWH...

Page 36: ...the vacuum membrane on the carburetor Mount the spring the vacuum membrane cover and the lock bolt The bottom side of the vacuum membrane should be aligned with the carburetor The top side should be...

Page 37: ...a v o M 4 5 Weight roller set 6 Ramp plate 7 Slide piece 8 Starting driver pulley 9 Starter gear friction spring 10 Starter idle gear comp 11 Starter idle shaft 13 Face drive collar 1 Clip SPIRAL SPL...

Page 38: ...bon Brush Negative Electrode 12 O ring 13 Screw STARTER MOTOR REMOVAL HIRUH UHPRYDO UVW VKXW Rff the main switch and disconnect the battery connecting wire Then press the starting button at this time...

Page 39: ...XUH DFFRUGLQJ WR WKH far ULJKW SLFWXUH W VKRXOG EH QRQ FRQ GXFWLYH I LW V QRW LW VKRXOG EH UHSODFHG 5 21 586 163 7 21 QVSHFW WKH LQVXODWLQJ FRQGLWLRQ EHWZHHQ WKH FRQQHFWLQJ ZLUH WHUPLQDO DQG WKH VWDUW...

Page 40: ...e When installing do not damage the lip of the dust seal Mount the new O ring on the carbon brush base Install armature into starter motor case making sure not to damage the carbon brushes Tighten mot...

Page 41: ...more than 10 05mm Measure the outer diameter of the reduction gear shaft It should be replaced when the diameter is less than 9 94mm 1 Starter reduction gear 2 Starter reduction gear shaft 3 Starting...

Page 42: ...QWDFW VXUIDFH EHWZHHQ WKH GULYLQJ JHDU DQG WKH QHHGOH EHDULQJ for abrasion or other damage W VKRXOG EH replaced if the surface is damaged Measure the inner diameter of the driving gear W VKRXOG EH UH...

Page 43: ...WKH PDLQ VZLWFK WR WKH 21 SRVLWLRQ PUHVV GRZQ WKH VWDUWLQJ PRWRU EXWWRQ DQG OLVWHQ IRU D FOLFN VRXQG If clicking sound is not heard IROORZ WKH EHORZ SURFHGXUHV WR LQVSHFW QVSHFW WR VHH LI WKH EUDNH VZ...

Page 44: ...eed decreases when the diameter of the driving belt pulley changes from big to small and the diameter of the driven belt pulley changes proportionally from small to big BELT DRIVEN CVT MECHANISM INSPE...

Page 45: ...HOW SXOOH LV VKRZQ LQ WKH SLFWXUH 7KH SLFWXUH VKRZV WKH ZRUNLQJ WKHRU RI WKH GULYLQJ EHOW SXOOH 7KH SLFWXUH VKRZV WKH VWUXFWXUH RI WKH GULYHQ EHOW SXOOH 7KH FOXWFK VKRZHG LQ WKLV SLFWXUH LV WKH DXWRPD...

Page 46: ...holding WKH GULYH SODWH ZLWK D XQLYHUVDO ZUHQFK remove the QXWV DQG JDVNHW RQ WKH GULYH SODWH VKDIW 5HPRYH WKH GULYH SODWH 5HPRYH WKH GULYHQ EHOW IURP WKH GULYH SODWH 5HPRYH WKH PRYDEOH GULYH SODWH W...

Page 47: ...WH KXE 0HDVXUH WKH RXWHU GLDPHWHU RI WKH GULYH SODWH KXE V PRYDEOH surIDFH 6HUYLFH LPLW PP 5 9 7 38 167 7 21 SSO VRPH JUHDVH HYHQO LQ WKH PRYDEOH GULYH SODWH 3XW WKH FHQWULIXJDO UROOHUV LQWR WKH PRYDE...

Page 48: ...YHU 5HPRYH WKH GULYH SODWH DQG WKH GULYHQ EHOW ROG WKH FOXWFK IULFWLRQ SODWH ZLWK D PXOWLXVH KROGHU DQG UHPRYH WKH QXW 5HPRYH WKH FOXWFK IULFWLRQ SODWH 87 163 7 21 QVSHFW for DQ DEUDVLRQ RU GDPDJH RQ...

Page 49: ...g piece Remove the clutch centrifugal weight set and the spring CLUTCH INSTALLATION Mount the clutch damper rubber onto the drive plate pin Mount the new clutch weight set and spring on the drive plat...

Page 50: ...PRYDEOH GULYHQ SODWH 5 9 1 7 38 163 7 21 0HDVXUH WKH IUHH OHQJWK RI WKH GULYHQ EHOW SXOOH VSULQJ 6HUYLFH LPLW PP QVSHFW for DQ DEUDVLRQ RU GDPDJH RQ WKH GULYHQ SODWH 0HDVXUH WKH RXWHU GLDPHWHU RI WKH...

Page 51: ...XVHG 5HPRYH WKH FLUFOLS IURP WKH GULYHQ SODWH ULYH WKH EDOO EHDULQJ RXW 7KH UHPRYHG EHDULQJ FDQQRW EH UHXVHG SSO VRPH JUHDVH RQ WKH QHZ EDOO EHDULQJ ULYH WKH EDOO EHDULQJ LQWR WKH GULYHQ SODWH ZLWK LW...

Page 52: ...YH WKH H FHVVLYH JUHDVH R QRW JHW JUHDVH RQ WKH PRYDEOH IDFHV RI WKH GULYHQ SODWH VVHPEOH ZLWK WKH FOXWFK DQG LQVWDOO RQ WKH OHIW FUDQNFDVH 75 160 66 21 7 75 160 66 21 7 163 7 21 5HPRYH WKH OHIW FUDQN...

Page 53: ...IWHU WKH HQJLQH VWRSV UHPRYH WKH WUDQVPLVVLRQ FDVH RLO OHYHO EROW 2EVHUYH WKH RLO OHYHO TKH RLO OHYHO VKRXOG EH SDUDOOHO ZLWK WKH REVHUYLQJ KROH KHQ WKH RLO OHYHO LV WRR ORZ DGG XQWLO WKH RLO RZV IUR...

Page 54: ...ey Drain out the oil in the transmission case Remove the drive sprocket Remove the bolt and remove the transmission case cover Remove the gasket and the dowel pin 5HPRYH WKH QDO JHDr WKH QDO JHDU VKDI...

Page 55: ...WUDQVPLVVLRQ FRYHU 5HPRYH WKH RLO VHDO DQG GULYH RXW WKH EHDULQJ 5HPRYH WKH QDO JHDU VKDIW EHDULQJ 5HPRYH WKH VXE VKDIW EHDULQJ ULYH LQ WKH QHZ QDO JHDU VKDIW DQG EHDULQJ KHQ GULYLQJ LQ WKH QDO JHDU V...

Page 56: ...DQG RLO VHDO RQ WKH OHIW FUDQNFDVH IRU ZHDU RU GDPDJH I LW LV GDPDJHG LW PXVW WKHQ EH UHSODFHG 5HPRYH WKH RLO VHDO ULYH RXW WKH QDO JHDU VKDIW EHDULQJ 5HPRYH WKH VXE VKDIW EHDULQJ 5HPRYH WKH GULYHQ EH...

Page 57: ...VXE VKDIW JHDU DQG WKH QDO JHDU VKDIW LQWR WKH OHIW FUDQNFDVH 0RXQW WKH QDO JHDU RQ WKH QDO JHDU VKDIW QVWDOO WKH QHZ GRZHO SLQ DQG JDVNHW QVWDOO WKH WUDQVPLVVLRQ FDVH FRYHU DQG EROW 0RXQW WKH GULYHQ...

Page 58: ...ck for is a short circuit of the main switch and the main wiring CHARGING STATUS INSPECTION Install the fully charged battery Connect the voltmeter between the binding posts of the battery Remove the...

Page 59: ...oes through the vehicle Disconnect the negative battery lead wire rst Disconnect the positive battery The disconnecting order cannot be reversed When disconnecting the positive cable do not touch the...

Page 60: ...n re near the battery when charging At the beginning or the end of charging turn off the FKDUJHU UVW LQ RUGHU WR DYRLG WKH FRQQHFWLQJ SDUW DUFLQJ Measure the voltage 30 minutes after charging is nishe...

Page 61: ...WLQJ ZLUH RI WKH YHKLFOH ERG 6WDQGDUG YDOXH a KHQ WKH DFWXDO YDOXH LV PRUH WKDQ WKH VWDQGDUG YDOXH WKH FRLO VKRXOG EH UHSODFHG 1 5 725 5 029 1 163 7 21 1 5 725 5 029 5HPRYH WKH FRROLQJ IDQ FRYHU EROW...

Page 62: ...DV EROWV RU QXWV DWWDFKed WR WKH LQQHU ZDOO RI WKH ZKHHO IWHU WKH LQVWDOODWLRQ LV QLVKHG VWDUW WKH HQJLQH WR LQVSHFW DQG DGMXVW WKH LJQLWLRQ WLPLQJ 5 8 7 5 7 5 0 1 5 1 68 75 5 8 7 21 7 21 163 7 21 Per...

Page 63: ...HHQ a 5 8 7 5 7 5 163 7 21 KHQ WKH PDLQ ZLULQJ VXE HOHFWULF FLUFXLW FRQGLWLRQ LV QRUPDO LQVSHFW WKH UHJXODWH UHFWL HU KHFN WKDW WKH UHJXODWH UHFWL HU SOXJ FRQWDFWV ZHOO 0HDVXUH WKH UHVLVWDQFH YDOXH EH...

Page 64: ...ed Slowly increase the engine rpm when the 150 model increases to 5000 r min at this time if the mark on the crankcase aligns with the rotor ignition advance angle mark the advance angle device is goo...

Page 65: ...XUWKHU PHDVXUHPHQWV I LW LV PHDVXUHG WKDW WKH FRPSRQHQW HQG LV DEQRUPDO and KRZHYHU WKH WHUPLQDO YROWDJH RI WKH JHQHUDWRU LV QRUPDO WKHQ WKHUH LV D EDG ZLUH RU EDG FRQQHFWLRQ KHQ ERWK DUH QRW QRUPDO W...

Page 66: ...Q FKDUJLQJ FRLO the trigger winding and the ignition coil When the main switch is in OFF position it should be conducted The resistance value of every coil should be the standard value QVSHFW WKH UHVL...

Page 67: ...the resistance value is in the standard range it is good however LQGLFDWHV WKH FRLO LV EDG Remove the spark plug cap and measure the resistance value of the secondary ignition coil Standard Value a I...

Page 68: ...64 CHASSIS b...

Page 69: ...front The a the 65 The r...

Page 70: ...bearings are dirty or muddy it goes seat Fills teering gear R is...

Page 71: ...grease of ball joint Clean it if it is dirty and lled with grease Replace the steering knuckle support if the ball joint is loose or steering TIE ROD Tie rods should be checked for ease of movement i...

Page 72: ...er Element 2 3 TO SERVICE PRE CLEANER Clean foam lter with non ammable cleaner If lter is made of paper lter e lter SPARK PLUG a i clean and free of carbon b h c FRONT WHEEL ALIGNMENT 1 T A dimension...

Page 73: ...ion check the chain adjustment and readjust if is has more than Loosen Nut 1 Adjust Nut 2 Turn nut clockwise in 1 2 turn increments then turn nut 1 clockwise until nut is REVERSE GEAR CHECK replace th...

Page 74: ...eadlight L G Y R G HL Low SW L B B B G Y Brake SW G W Y R G G GW R R G R Y Y Regulator Rectifier LW GW BY GW G W L W GY L G WIRING DIAGRAM w LG R Low green Red GR Colour Sign table White Gray BR O P S...

Page 75: ...BODY REPLACEMENT BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING BRAKE PERFORMANCE BREAK IN PROCEDURE CAM CHAIN TENSIONER CAMSHAFT CAMSHAFT INSPECTION CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CAPACIT...

Page 76: ...PULLEY INSTALLATION DRIVE BELT PULLEY REMOVAL DRIVEN BELT PULLEY DRIVEN BELT PULLEY INSTALLATION DRIVEN PLATE BEARING REPLACEMENT ELECTRIC LEAKAGE TESTING ELECTRICAL STARTING SYSTEM ELECTRICAL SYSTEM...

Page 77: ...ER MOTOR INSTALLATION STARTER MOTOR REMOVAL STARTER RELAY INSPECTION STARTING CLUTCH INSPECTION STARTING CLUTCH INSTALLATION STARTING CLUTCH REMOVAL STARTING MECHANISM INSPECTION AND SERVICING STEERIN...

Page 78: ...NG MAIN WIRING SUB ELECTRIC CIRCUIT CONDITION INSPECTION MAINTENANCE AND TUNE UP PROCEDURES MODEL IDENTIFICATION OIL PUMP ASSEMBLING OIL PUMP INSPECTION OIL PUMP INSTALLATION OIL PUMP REMOVAL OIL REPL...

Page 79: ...E AND VALVE SPRING VALVE AND VALVE SPRING INSPECTION VALVE AND VALVE SPRING INSTALLATION VALVE AND VALVE SPRING REMOVAL VALVE CLEARANCE VALVE CLEARANCE ADJUSTMENT VALVE GUIDE VALVE GUIDE INNER DIAMETE...

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