DAELIM ET300 - SERVICE Service Manual Download Page 48 | Manualshive

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6-4 Cylinder Head Removal

Remove engine. (Refer to chapter 5)
Remove the inlet pipe (2 nuts).

Remove 1 bolt of thermostat and then remove the
thermostat.
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).

Remove Air Injection system (AI) pipe mounting
bolts.
Remove spark plug.

Remove the side cover mounting blots of cylinder
head, and then take out the side cover.

2 nuts

Tensioner bolts

Thermostat bolts

3 bolts

4 bolts

Spark plug

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Summary of Contents for ET300 - SERVICE

Page 1: ...1 ET 300 Service Manual ...

Page 2: ...ires 2 12 Steering Shaft Holder Bushing 2 13 Toe In 3 ENGINE REMOVE AND INSTALLATION 3 1 General Information 3 2 Engine Removal 3 3 Engine Installation 4 LUBRICATION SYSTEM 4 1 Mechanism Diagram 4 2 Precautions In Operation 4 3 Troubleshooting 4 4 Engine Oil 4 5 Engine Oil Strainer Clean 4 6 Oil Pump 4 7 Gear Oil 5 FUELSYSTEM 5 1 Mechanism Diagram 5 2 Precautions In Operation 5 3 Trouble Diagnosis...

Page 3: ...G SYSTEM 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 9 FINALDRIVING MECHANISM 9 1 Mechanism Diagram Transmission Cover 9 2 Precautions In Operation 9 3 Trouble Diagnosis 9 4 Disassembly Of Transmission 9 5 Inspection Of Mission Mechanism 9 6 Bearing Replacement 9 7 Re assembly Of Final...

Page 4: ...mostat 13 STEERING AND SUSPENSION 13 1 Parts Drawing 13 2 Troubleshooting 13 3 Handlebar 13 4 Throttle Housing 13 5 Steering System 14 FRONT WHEEL AND BRAKE SYSTEM 14 1 Parts Drawing 14 2 Troubleshooting 14 3 Front Wheels 14 4 Hydraulic Brake 14 5 Suspension Adjustment 15 REAR WHEEL AND BRAKE SYSTEM 15 1 Parts Drawing 15 2 Troubleshooting 15 3 Remove Rear Wheel And Rear Brake 15 4 Swingarm Rear Ax...

Page 5: ...ng 17 4 Battery Information 17 5 Electric Starter 17 6 Light Bulbs Replacement 17 7 Instrument Pane 18 TROUBLESHOOTING 18 1 Engine Can Not Work 18 2 Poor Performance At Low And Idle Speeds 18 3 Poor Performance At High Speed 18 4 Loss Power 18 5 Poor Handling 17 8 Wiring Diagram ...

Page 6: ...ter and call a doctor if electrolyte gets in your eyes HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts USED ENGINE GEAR OIL Used engine oil and gear oil may cause skin disease if repeatedly contact with the skin for long periods Keep out of reach of children 1 2 Notes All information illustratio...

Page 7: ...on Transmission Automatic C V T V belt Reverse CHASSIS Overall Length 1830mm Overall Width 1040mm Overall Height 1150mm Wheel base 1190mm Ground Clearance 150mm Dry Weight 225Kg Fuel Tank Capacity 12L SUSPENSION Front Double A Arm Adjustable Rear Swing Arm Adjustable Shock BRAKES Front Front Hydraulic Disc 2 Rear Rear Hydraulic Disc 1 TIRES Front 21x7 10 Rear 22x10 10 PRESSURE psi kgf cm2 Front 12...

Page 8: ...8 1 4 Serial Number The frame serial number is stamped on the front of the frame The engine serial number is stamped on the left side of the crankcase Frame serial number ...

Page 9: ...in nut 40 N m 29 lbf ft Handlebar lower holder nut 40 N m 29 5 lbf ft Front wheel bolt 24 N m 17 7 lbf ft Front axle castle nut 40 60 N m 30 45 lbf ft Front brake arm nut 4 N m 3 0 lbf ft Rear brake arm nut 7 N m 5 2 lbf ft Rear axle castle nut 40 60 N m 30 45 lbf ft Rear wheel bolt 24 N m 17 7 lbf ft Exhaust muffler mounting bolt 30 N m 22 1 lbf ft Engine hanger bolt 30 N m 22 lbf ft Rear axle ho...

Page 10: ...0 1 6 Special Tools For Frame 1 Adjustable Hook Spencer E1105 LRA0 FT1 Purpose Adjusting of suspension 2 Ball Joint Puller E0205 LRA0 FT1 Purpose Taking out the ball joint from front knuckle as repairing ...

Page 11: ...11 For Engine 1 TACKING ACG FLY WHEEL TOOL C1110 RB1 FT1 2 COUNTER SHIFT IMPLEMENT I1003 RB1 FT1 3 ADJUST TAPPET IMPLEMENT A4721 HMA FT1 4 SLEEVE OF FABRICATING TRANSMISSION SHAFT OIL SEAL I1202 RB1 FT1 ...

Page 12: ...12 5 SLEEVE OF FABRICATING L CRANK OIL SEAL I1201 HMA FT1 6 TAKING 6205 BRG TOOL I6150 6205 FT1 7 6205 BRG KNOCK TOOL I6150 6205 FT2 8 L CRANK CASE COVER 6006 BRG FABRICATING TOOL I6150 6006 FT1 ...

Page 13: ...13 9 FABRICATING R CRANK CASE COVER 6201 BRG TOOL I6140 6201 FT1 10 TAKING BRG RB1 TOOL I6150 RB1 FT1 11 PNEUMATIC TAKING BRG 6205 TOOL I6150 6205 FT3 12 TAKING TAPPET PIN TOOL A4451 HMA FT1 ...

Page 14: ...13 ASSEMBLING DRIVE SHAFT TOOL B3411 RB1 FT1 14 TAKING TRANSMISSION SHAFT BRG 6305 TOOL I6100 6305 FT1 15 KNOCKING BRG 6901 WATER PUMP IMPLEMENT I1001 KJ9 FT1 14 ...

Page 15: ...WATER PUMP OIL SEAL IMPLEMENT INSIDE I1205 KF0 FT1 17 KNOCKING WATER PUMP OIL SEAL IRON IMPLEMENT A9217 H9A FT1 18 TAKING LOCKING SPECIAL NUT 36MM SLEEVE I0202 HMA FT1 19 TAKING FABRICATING IN VALVE TOOL A4711 HMA FT1 ...

Page 16: ...16 20 TAKING BRG 62040 LARGE SIZE TOOL I6100 6204 FT3 21 ALL PURPOSE FIXER B2101 HMA FT1 22 KNOCKING BRG 6204 IMPLEMENT I6100 6204 FT2 ...

Page 17: ... Bushing 2 6 Air Cleaner 2 13 Toe In 2 7 Spark Plug 2 1 Maintenance Data SPECIFICATION SPARK PLUG SPARK PLUG GAP 0 8 mm RECOMMENDED SPARK PLUGS NGK CR8E THROTTLE LEVER FREE PLAY 5 10 mm IDLE SPEED 1700 100 rpm BRAKE LEVER FREE PLAY 15 25 mm DRIVE CHAIN SLACK 10 25 mm TOE IN 5 10 mm TORQUE VALUES SPARK PLUG 12 19 N m TIE ROD LOCK NUT 35 43 N m ENGINE OIL 1 4 Liter 1 2Liter for change GEAR LUBRICATI...

Page 18: ...nth Brake Shoes I Brake System I I Brake Fluid I R Nuts Bolts Fasteners I WHEEL TIRES I I Wheels I I Steering System I I Suspension System I I C V T Drive belt I R Transmission Oil R Replace for every 3 000km or 6 Months Engine Oil R Replace for every 3 000km or 6 Months Battery I I C I C Oil Filter Screen C C Valve Clearance I I Coolant I I R Cooling Fan I I Carburetor Idle Speed I I Choke I Note...

Page 19: ...e play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttle lever 2 6 Air Cleaner Please remove the four hooks and then disassemble two screws inside the air cleaner case Pull out the air filter element from the air cleaner case Washing the element in non flammable solvent squeeze out the solvent thoroughly Let it dry Soak the filter element i...

Page 20: ...ise will get lower speed IDLE SPEED 1700 100 rpm 2 9 Drive Chain Stopping the ATV and shift the transmission into neutral N Measure the drive chain slack midway between the sprockets Chain slack 15 25mm 5 8 1 inch Adjust the chain slack Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack Tighten the axle holder bolts Torque 90N m 65 lbf ft When the drive chain beco...

Page 21: ...the parking brake which has been decreased its brake ability you might screw the adjustable nut to modify the clearance of brake shoe to the correct position Also another method of adjustment of parking brake please refer to next page Inspect the rear brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the rear brake lever free play at the end of the lev...

Page 22: ... the small clearance between brake disk and lining Loosen the adjustable nut near the rear brake caliper Screw the adjustable bolt by hand with C W turn to the end then back to a quarter turn Tighten the nut to complete the parking brake adjustment Also as you fount out the brake ability which is a bit insufficient you can screw the adjustable nut of parking Brake Adjustable nut Rear Brake Front B...

Page 23: ...hange a new one Grease the steering shaft bushing and install the parts in the reverse order of removal Torque steering shaft holder bolt 33 N m 24 lbf ft 2 13 Toe In Keep the vehicle on level ground and the front wheels facing straight ahead Mark the centers of the tires to indicate the axle center height Measure the distance between the marks Carefully to move the vehicle back let the wheels tur...

Page 24: ...24 If the toe in is out of standard adjust it by changing the length of the tie rods equally by turning the tie rod while holding the ball joint Tighten the lock nuts Torque 35 43 N m Lock Nuts ...

Page 25: ...as seat front and back fender fuel tube exhaust pipe carburetor cable and drive chain etc You can then see three hanger bolts which have screwed on engine Loosen these three hanger bolts You have succeeded to remove this engine There are some pictures to describe main step of removing engine Disconnect the wire connectors There are three connectors for carburetor auto choke starter motor and gener...

Page 26: ...26 3 3 Engine Installation The Engine installation is essentially in the reverse order of removal The torque of engine hanger bolt is 30 N m Route the wires and cable in reverse order properly ...

Page 27: ...Troubleshooting 4 4 Engine Oil 4 5 Engine Oil Strainer Clean 4 6 Oil Pump 4 7 Gear Oil 4 1 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication Oil Route Con Rod Oil Route Oil Pump Rotate Direction Oil Strainer ...

Page 28: ...nce 0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 5 3 0kgf m Engine oil drain bolt 1 9 2 5kgf m Gear oil drain bolt 1 0 1 5kgf m Gear oil join bolt 1 0 1 5kgf m Oil pump connection bolt 0 8 1 2kgf m 4 3 Troubleshooting Low engine oil level y Oil leaking y Valve guide or seat...

Page 29: ...After drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m 4 5 Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O ring can be re used Install oil strainer and spring Install oil strainer cap Torque value 1 5 3 0kgf m Add oil to crankcase oil viscosity SAE 10W 30 Recommended using King serial oil Engine oil...

Page 30: ...ip and take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover Remove oil pump shaft roller and shaft 2 screws Clip 1 screw Roller ...

Page 31: ...r and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the oil pump shaft and roller Install the oil pump cover and fixing pins properly Pins ...

Page 32: ...and then tighten screws Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install starting gear and generator Refer to chapter 10 1 screw Roller 2 screws Clip ...

Page 33: ...e drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Start engine and run engine for 2 3 minutes Turn off engine and make sure that oil level is in correct level Make sure that no oil leaking Gear oil join bolt Gear oil drain bolt ...

Page 34: ...rouble Diagnosis 5 4 Carburetor Remove Install 5 5 Air Cut Off Valve 5 6 Throttle Valve 5 7 Float Chamber 5 8 Adjustment Of Idle Speed 5 9 Fuel Tank 5 10 Air Cleaner 5 1 Mechanism Diagram Carburetor Fuel unit Inlet pipe Auto fuel cock Fuel tank cap Fuel strainer Fuel tank ...

Page 35: ...y When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly y There is a drain screw in the float chamber for draining residual gasoline y Do not disassemble air cut valve arbitrarily Tool Special service tools Vacuum air pressure pump Fuel level gauge Specification of CARBURETOR ITEM UA25A Carburetor diameter Ø22mm I D number PTG 050 Fuel level 14 8...

Page 36: ...lfunction of carburetor y Dirty fuel Intermittently misfire as acceleration y Malfunction of ignition system Late ignition timing y Malfunction of ignition system y Malfunction of carburetor Power insufficiency and fuel consuming y Fuel system clogged y Malfunction of ignition system Mixture too lean y Clogged fuel injector y Vacuum piston stick and closed y Malfunction of float valve y Fuel level...

Page 37: ...ve the choke cable Disconnect the fuel hose Release the clamp strip of air cleaner Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the carburetor Installation Install in reverse order of removal procedures Drain bolt 1 screw Choke cable Fuel pipe Vacuum pipe Clamp 2 nuts ...

Page 38: ...ve Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assembly Install in reverse order of removal procedures 2 screws O ring Spring Air cut off valve Cover ...

Page 39: ...ottle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body Tighten the carburetor upper part Adjust the free play of throttle valve c...

Page 40: ...lve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt Caution In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one 3 Screws Fuel level plate Float valve Pin Float valve Float Pin ...

Page 41: ...d air adjustment screw Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking fuel level Caution y Check again to ensure float valve float for proper installation y To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 14 8m...

Page 42: ...m Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle valve stopper screw and let engine runs in 1600 100 rpm 3 Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe Adjust the air adjustment screw so that emission value in idle speed is within st...

Page 43: ... unit installation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fuel tank Remove the side covers and lower side covers Remove the front fender Covers remove please refer chapter 13 Disconnect fuel unit coupler Remove fuel unit 4 bolts Remove the fuel tube Remove the...

Page 44: ...Remove the air cleaner cover 4 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleaning engine oil and then squeeze it out Install ...

Page 45: ...nder Head Inspection 6 6 Valve Stem Replacement 6 7 Valve Seat Inspection And Service 6 8 Cylinder Head Reassembly 6 9 Cylinder Head Installation 6 10 Valve Clearance Adjustment 6 1 Mechanism Diagram 0 7 1 1kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 2kgf m 3 6 4 0kgf m 2 4 3 0kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 4kgf m 1 0 1 2kgf m ...

Page 46: ...012 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Intake 38 700 35 200 Free length of valve spring Exhaust 40 400 36 900 Valve seat width 3 400 4 000 Intake 0 10 0 02mm Valve Valve clearance Exhaust 0 15 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cover bolt 1 0 1 4kgf m Exhaust pipe stud bolt 2 4 3 0kgf m Cylinder head bolt...

Page 47: ...er valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure y Too much carbon deposit on combustion chamber or piston head Noise y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Chain wear out or loos...

Page 48: ...t Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove spark plug Remove the side cover mounting blots of cylinder head and then take out the side cover 2 nuts Tensioner bolts Thermostat bolts 3 bolts 4 bolts Spark plug ...

Page 49: ...d then remove the sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller Remove cam shafts Special Service Tool Rocker arm and cam shaft puller 2 bolts Timing mark Cam shaft setting plate Cam shafts Rocker arm shaft and cam Rocker arm shafts Rocker arm shaft and cam shaft puller ...

Page 50: ...and cylinder head y Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution y In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve cotter in which can be removed Special Service Tool Valve cotter remove assembly to...

Page 51: ...Head Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 5 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 34 45mm EX Replacement when less than 34 30mm Inspect the camshaft bearing for looseness or wear out If any damage replace whole set of camshaft and bearing Va...

Page 52: ...mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valve springs Service limit Inner spring 35 00 mm Outer spring 39 00 mm Valve stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure recor...

Page 53: ...ce between the valve stem and valve guide Service Limit IN 0 08 mm EX 0 10 mm Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace va...

Page 54: ...y When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 0 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer Caution y Using cutting oil when correcting valve guide wit...

Page 55: ...ve seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the contact condition of valve seat Valve seat grinding The worn valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat chamfer cutter Use 45 valve seat chamf...

Page 56: ...ve seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too low grind the valve seat with 60 cutter The...

Page 57: ...remove assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve cotter remove assembly tool Tap the valve stems gently with a plastic hammer to make sure valve retainer and ...

Page 58: ...and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head mounting bolts of cylinder head right side Torque value Nut 3 6 4 0kgf m Bolt 1 0 1 4kgf m Install camshaft into cylinder head and install rocker arm rocker arm shaft Install rocker arm pin mounting ...

Page 59: ...procket mounting bolts Caution Make sure timing marks are matched Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and spring Install tensioner and install spring and adjustment bolt Install cylinder cover 4 bolts 2 bolts Timing mark 3 bolts Thermostat bolts Tensioner adjustment bolt 4 bolts ...

Page 60: ... 0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation engine noise and leaking so that motorcycle s performance be effected 4 bolts Spark plug Install the engine onto frame refer chapter 5 ...

Page 61: ...at piston is placed at TDC position in compression stroke Caution Do not turn the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check adjust valve clearance with feeler gauge Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Loosen fixing nut and turn the adjustment nut for adjustment Caution Re check the valve clearance after tightened the ...

Page 62: ...inder head cover and AI pipe Caution y If lubricant does not flow to cylinder head engine components will be worn out seriously Thus it must be confirmed y When checking lubricant flowing condition run the engine in idle speed Do not accelerate engine speed ...

Page 63: ...ts 0 8 1 2kgf m 1 0 1 4kgf m 7 CYLINDER PISTON 7 1 Mechanism Diagram 7 2 Precautions In Operation 7 3 Trouble Diagnosis 7 4 Cylinder And Piston Removal 7 5 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation ...

Page 64: ...00 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 17 016 17 034 17 064 7 3 Trouble Diagnosis Low or Unstable Compression Pressure y Cylinder or piston ring worn out Knock or Noise y Cylinder or piston ring worn out y Carbon deposits on cylinder head top side...

Page 65: ...e cylinder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be removed more easily Inspection Check if the inner diameter of cylinder is wear out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y values respective in the cylinde...

Page 66: ...ston rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal level in cylinder push the rings with piston Service Limit Top ring 0 50 mm 2nd ring 0 65 mm ...

Page 67: ...eter of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 75 380 mm Compare measured value with service limit to calculate the clearance between piston and cylinder ...

Page 68: ...ce the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston rings can be rotated freely after installed Top ring 2 nd ring Oil ring Top groove 2 nd groove Oil groove To this chapter contents ...

Page 69: ...tallation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution y Do not let the opening of piston pin clip align with the piston cutout y Place a piece of cloth between piston and crankcase in order to prevent snap ring from falling into crankcase as operation 7 7 Cylinder Installation Install dowel pins and new gask...

Page 70: ...taken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install coolant hose onto cylinder Install cylinder head refer to Chapter 6 Coolant hose ...

Page 71: ...EM 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 8 1 Mechanism Diagram 5 0 6 0kgf m 5 0 6 0kgf m 8 5 10 5kgf m ...

Page 72: ... 40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive plate nut 5 0 6 0kgf m Special Service Tools Clutch spring compressor SYM 2301000 Inner bearing puller SYM 6204002 Clutch nut wrench 39 x 41 mm SYM 9020200 Universal holder SYM 2210100 Bearing driver S...

Page 73: ... bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Dowel pins Clamp strips 10 bolts Left cover plate Ratchet cover Dowel pins L bearing setting plate Left cover plate gasket L crank case cover Starter drive pulley Volute spring Starter grip Starter drive pulley L crank case cover gasket ...

Page 74: ...n smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Remove the bearing 6006 with inner bearing puller Tools number SYM 6204025 Tools name INNER BEARING PULLER Bearing 6006 install with special tool Tools number SYM 1134600 HMA RB1 6006 Tools name L CRANK CASE COVER BEARING INSTALL TOOL 2...

Page 75: ...Disassembly Remove 5 screws from l cover plate and remove l cover plate Remove 1 bolt from ratchet cover Remove 2 starter ratchets and 2 ratchet springs 5 screws 1 bolt ...

Page 76: ...ring from the l crank cover then its has to be replaced Loosen the starter rope from the starter grip Installation Install in reverse order of removal procedures Caution First before installing the drive pulley must establish 2 1 2 of the pressures transferred to pressure springs ...

Page 77: ... belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Service Limit 22 5 mm Replace the belt if exceeds the service limit C...

Page 78: ...ve shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value Torque value 8 5 10 5kgf m Driven f...

Page 79: ...hen remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft Drive face boss Movable drive face Ramp plate Movable drive face Weight roller Universal holder ...

Page 80: ... outer diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Service limit 30 060 mm Reassembly installation Install weight rollers Caution The weight roller two end surfaces are not certainly same In order to lengthen the roller life and prevented exceptionall...

Page 81: ...pulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution Make sure that two sides of pulley surfaces have to be free of grease Clean it with cleaning solvent Hold drives face with universal holder Tighten nut to specified torque Torque value 8 5 10 5kgf m Install left crankcase cover Drive face boss Crank shaft Drive ...

Page 82: ...vice tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable driven face and then remove O ring oil seal seat from movable driven face Inspection Clutch outer Measure the inner diameter of clutch outer Replace the clutch outer if exceed service limit Service l...

Page 83: ... the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is damage Replace it if necessary Check if needle bearing is damage or too big clearance Replace it if necessary Rotate the inside of inner bearing with fingers to check if the bearing rotat...

Page 84: ...if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block should not be greased If so replace it Caution Grease or lubricant will damage the clutch weight and affect the block s connection capacity Install the spring into groove with pliers Shock absorption rubber Clut...

Page 85: ...e of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution y Its sealing end should be forwarded to outside as bearing installation y Install needle bearing with hydraulic presser Install ball bearing by means of hydraulic presser Install snap ring into the groove of drive face Align oil se...

Page 86: ...d clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specified torque with clutch nut wrench Remove the clutch spring compressor Torque value 5 0 6 0kgf m Install clutch outer driven pulley and drive belt onto drive shaft Collar O ring Guide pin Gu...

Page 87: ...m Transmission Cover 9 2 Precautions In operation 9 3 Trouble Diagnosis 9 4 Disassembly Of Transmission 9 5 Inspection Of Mission Mechanism 9 6 Bearing Replacement 9 7 Re assembly Of Final Driving Mechanism 9 1 Mechanism Diagram Transmission Cover ...

Page 88: ...er 6204 SYM 9110400 Bearing driver 6205LLU SYM 9100400 HMA Bearing driver 6305 SYM 9100400 RB1 Needle bearing driver HK2016 SYM 9100300 RB1 Drive shaft and oil seal driver SYM 9120200 HMA Drive shaft puller SYM 2341100 Inner bearing puller SYM 6204002 9 3 Trouble Diagnosis Engine can be started but motorcycle can not be moved y Damaged drive gear y Burnt out drive gear y Damaged gear shift system ...

Page 89: ...on The socket bolt is provided with left turn thread Remove 2 bolts and then remove the drive sprocket fixing plate drive chain and drive sprocket Remove gear fill bolt Place an oil pan under the ATV and remove gear oil drain bolt After drained make sure washer can be re used Install oil drain bolt Torque value Gear oil fill bolt 3 5 4 5kgf m Gear oil drain bolt 0 8 1 2kgf m 1 bolt Fill bolt Drain...

Page 90: ... catch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft 9 bolts Shift drum fixed catch bolt Shift drum Shift spindle Shift fork shaft and fork Reverse shaft Counter shaft Final shaft Drive shaft ...

Page 91: ...Special tool Shaft protector Remove gasket and dowel pin Caution y If non essential do not remove the drive shaft from the case upper side y If remove the drive shaft from the gear box then its bearing and oil seal has to be replaced Bearing setting plate Bearing Oil seal ...

Page 92: ...ction Of Mission Mechanism Check if the shift spindle is wear or damage Check if the shift drum is wear or damage Check if the shift fork and shaft is wear or damage Check if the counter shaft is wear or damage ...

Page 93: ...bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Caution y If remove the drive shaft from the crankcase upper side then its bearing has to be replaced Final shaft bearing Gear box cover Counter shaft bearing Reverse shaft bearing Drive shaft bearing Gear box Rev...

Page 94: ...eal Special tool Inner bearing puller Install new final shaft counter shaft and reverse shaft bearings into left crankcase Special tool Bearing driver 6204 Needle bearing driver HK2016 Install new drive shaft bearings and baring driver into left crankcase Install the universal bearing puller and bearing driver Turn the universal bearing puller to install drive shaft bearing Special tool Bearing dr...

Page 95: ...stall bush Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the cover inner side Special tool Inner bearing puller Remove cir clip of final shat out side bearing Drive shaft puller Drive shaft and seal install bush Clutch nut wrench Drive shaft and seal install bu...

Page 96: ...tall drive shaft bearing Special tool Bearing driver 6205 Universal bearing puller Install new oil seal and bearing driver into gear box cover inner side Install the universal bearing puller and bearing driver Turn the universal bearing puller to install drive shaft oil seal Special tool Bearing driver 6205 Universal bearing puller Inner bearing puller Bearing driver Universal bearing puller Beari...

Page 97: ...nter shaft reverse shaft and final shaft onto gear box Install shift drum shift fork and fork shaft onto gear box Install shift drum fixed catch ball spring and bolt onto gear box Oil seal Reverse shaft Counter shaft Final shaft Drive shaft Shift drum Shift spindle Shift fork shaft and fork Shift drum fixed catch bolt ...

Page 98: ...all shift spindle Install dowel pins and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Install the shift spindle bracket drive chain protector speedometer gear box and gear change lever Add gear oil Gear oil quantity 750c c Dowel pins 9 bolts Position mark ...

Page 99: ... 10 3 Right Crankcase Cover Removal 10 4 A C G Set Removal 10 5 Right Cover Bearing 10 6 Flywheel Removal 10 7 Starting Clutch 10 8 Flywheel Installation 10 9 A C G Set Installation 10 10 Right Crankcase Cover Installation 10 1 Mechanism Diagram 5 0 6 0kgf m 1 0 1 4kgf m 0 8 1 2kgf m ...

Page 100: ...s of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 5 0 6 0kgf m Starting clutch hexagon bolt 1 0 1 4kgf m with adhesive 8 mm bolts 0 8 1 2kgf m 12 mm bolts 1 0 1 4kgf m Tools Special tools A C G flywheel puller SYM 3110A00 Universal holder SYM 2210100 ...

Page 101: ...val Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set 10 5 Right Cover Bearing Inspection Rotate the bearing with finger to check if the bearing rotation is in smooth and silent Check if the bearing outer parts are closed and fixed Replace it if necessary Remove the cir clip and then remove bearing Special ...

Page 102: ... 6201LU by bearing driver Special tool Bearing driver 10 6 Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with universal holder Remove flywheel nut Special tool Universal Holder Oil seal Bearing driver Flywheel nut Reduction gear ...

Page 103: ...ng driven gear 10 7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch driven gear Service Limit ID 25 1 mm OD 42 10 mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage flywheel puller ID OD ...

Page 104: ...ear The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting driven gear Remove 3 socket bolts and then remove one way clutch Starting driven gear 3 socket bolts One way clutch Starting driven gear ...

Page 105: ...bolt Torque value 1 0 1 4kgf m Install starting driven gear 10 8 Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque value 5 0 6 0kgf m Special tool Universal Holder 3 socket bolts Starting driven gear Groove ...

Page 106: ... wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator 10 10 Right Crankcase Cover Installation Install dowel pin and new gasket Remove water pump cover Install right crankcase cover onto the crankcase Note Align the water pump shaft indent with the oil pump shaft Reduction gear 2 bolts 3 screws Wire Dowel pin ...

Page 107: ... right crankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover 11 bolts Water pump cover bolts ...

Page 108: ... Diagram 11 2 General Information 11 3 Trouble Diagnosis 11 4 Disassembly Of Crankcase 11 5 Crankshaft Inspection 11 6 Assembly Of Crankcase 11 1 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1 2kgf m 1 0 1 4kgf m 0 8 1 2kgf m ...

Page 109: ...hain of engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Specification Unit mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Vertical clearance of the big end of the connecting rod 0 0 008 0 050 Crankshaft Run out 0 030 0 100 Torque value Bolts for crankcase 0 8 1 2kgf m Engine oil drain bolt 3 5 4 5kgf m Cylinder stud bolt 1...

Page 110: ...move the tensioner Loosen 2 bolts on the right crankcase Loosen 11 bolts on the left crankcase Place right crankcase downward and left crankcase up Tap the left crankcase with a plastic hammer to remove it Caution Care should be taken not to damage the contact surfaces Cam chain setting plate Tensioner 2 bolts 11 bolts ...

Page 111: ...m right crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue for easy scrapping Drive out left crankcase oil seal Balance shaft ...

Page 112: ...he crankshaft Service limit 0 10 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If any roughness noise and loose linkage are detected replace the bearing with new one Caution The bearing shall be replaced in pair Special tool outer bearing puller Check balance shaft bearing 90 mm Cra...

Page 113: ...n is uneven noising or loose bearing mounted then replace it Special tool Inner bearing puller Bearing driver 11 6 Assembly Of Crankcase Install wave washer into right crank bearing seat Install crank shaft on the right crankcase Align the position mark on the balance shaft drive gear with that of balance shaft driven gear and then install balance shaft onto right crankcase Balance shaft bearings ...

Page 114: ...nd new gasket Install the left crankcase onto the right crankcase Tighten 11 bolts on the left crankcase Torque value 0 8 1 2kgf m Tighten 2 bolts on the right crankcase Torque value 0 8 1 2kgf m Dowel pins 11 bolts 2 bolts ...

Page 115: ...nkcase with care not to damage the lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Oil seal driver 27 42 7 Install the tensioner and tighten the pivot bolt Torque value 0 8 1 2kgf m Install the cam chain Install the cam chain setting plate Oil seal driver Cam chain setting plate Tensioner ...

Page 116: ...12 4 Trouble Diagnosis For Cooling System 12 5 System Test 12 6 Radiator 12 7 Water Pump 12 8 Thermostat 12 1 Mechanism Diagram Radiator filler cap Radiator Reserve tank Thermo switch fan Coolant inlet pipe Coolant outlet pipe By pass pipe Water pump Thermostat Cooling fan To cylinder head ...

Page 117: ... 850c c 420c c Thermostat Begins to activate at 82 95 Stroke 0 05 3mm Thermos switch fan Begins to activate at 98 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump rotor 1 0 1 4kgf m Tools Requirement Special tools Water pump bearing driver 6901 SYM 9100100 Water pump oil seal driver Inner SYM 9120500 H9A Water pump mechanical seal driver SYM 1721700 H9A Inner bearin...

Page 118: ...o unit Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coolant have circulated C 1 Eng stop and remove water pump cover start the motor to inspect pump its rotation Water pump repair N N A1 Refill the radiator with coolant then check for any leakage Water lea...

Page 119: ... until the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then check again Y Replace thermostat N E Keep eng 3000 4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks Replace thermal switch N E 1 Measure thermal switch to confirm...

Page 120: ...letely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilling system with coolant and bleeding the air bubbles y Run the engine and remove by pass pipe y Check by pass hole whether has the air bubble to emit y If emits without the air ...

Page 121: ...evating in the cooling system the refrigerant backflow floods 12 6 Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt use low pressure water jet to clean it Care shall be taken when straightening the sink fan Removal Place a water pan under the wa...

Page 122: ...or shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please refer to chapter 17 for the inspection of the thermo switch Caution Liquid packing must be applied to the thermo switch before installing to avoid damaging the radiator Installation Install the removed parts in the reverse or...

Page 123: ...irms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain bolt to drain out the coolant Remove the water hose Loosen 4 bolts and remove the pump cover Loosen 9 bolts and remove the right cover Take off the gasket and dowel pins Turn pump rotor clockwise and remov...

Page 124: ... seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of the right crankcase before installing the new mechanical seal Install the mechanical seal onto the right crankcase Special tools Water pump mechanical seal driver Mechanical seal Water pump bearing dr...

Page 125: ... Special tools Water pump bearing driver 6901 Caution Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right crankcase cover Install the cir clip to hold the inner bearing Water pump oil seal driver inner Water pump bearing driver 6901 Inner bearing Water pump shaft ...

Page 126: ...hten Torque Value 1 0 1 4kgf m Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil pump drive shaft flange install the right crank case 9 bolts Install the dowel pin and new gasket Install the water pump cover with 4 bolts Water pump rotor ...

Page 127: ...the thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not corresponding to the temperature change then it must be replaced Technical Data Valve begins to open 82 95 Valve stroke 0 05 3mm Installation Install the thermostat Install the thermostat cover 2 bolts ...

Page 128: ...13 STEERING AND SUSPENSION 13 1 Parts Drawing 13 2 Troubleshooting 13 3 Handlebar 13 4 Throttle Housing 13 5 Steering System 13 1 Parts Drawing Steering Handle bar ...

Page 129: ... Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment Loose front suspension fasteners Binding suspension link Faulty front swing arm bushings Improperly installed front swing arms Bent front shock absorber swing rod Weak front shock absorber springs Worn or damage front swing arm bushings 13 3 Handlebar REMOVAL Remove t...

Page 130: ...dle bar Remove rear brake lever bracket assembly Remove the handle cover and instrument panel by four screws at right and left side as shown in picture Remove the bolts attaching the handlebar upper holder Remove the handlebar Bolts Screws Screws ...

Page 131: ...with the L or R marks facing forward Tighten the forward bolts first and then tighten the rear bolts Install the handlebar upper holder s cover Install the switch housing aligning the small dot of the handlebar Tighten the upper screw firstly after that tighten the lower one Install the rear brake lever bracket aligning the small dot of the handlebar Tighten the screw securely dot ...

Page 132: ...from the throttle arm and remove from the throttle housing NOTE Assembly is in the reverse order of disassembly 13 5 Steering System When the steering shaft needs to be repaired you need to remove three kinds of components the tie rods front wheels and hub assy Following the steps to check these components if broken please change the new one Screws ...

Page 133: ...aft holder bolt and remove steering shaft holder Take off the cotter pin below steering shaft Loosen the steering shaft fixed out below shaft Pull steering shaft carefully Step 2 Steering Shaft Holder Inspection Remove the steering shaft Remove the bushing from the shaft Inspect the bushing for damage or wear replace if necessary Measure the bushing inner diameter Maximum limit Ø39 5 mm Step 3 Ste...

Page 134: ...Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 N m 37 lbf ft ...

Page 135: ...14 FRONT WHEEL AND BRAKE SYSTEM 14 1 Parts Drawing 14 2 Troubleshooting 14 3 Front Wheels 14 4 Hydraulic Brake 14 5 Suspension Adjustment 14 1 Parts Drawing FRONT WHEEL FRONT BEAKE ...

Page 136: ...correctly Unequal tire pressure Incorrect wheel alignment Brake shoes worn Worn brake drum Brake linings oily greasy or dirty Improper brake adjustment 14 3 Front Wheels REMOVAL The disassemble of front wheel system in this serials are the same Raise the front wheels off the ground by placing a jack or other support under the frame Remove the front wheel nuts washer and wheels INSTALLATION Install...

Page 137: ...asher and wheels Please follow the next three steps of right pictures Loosen fours nuts as shown in picutre Then take the wheel out you can find two bolts fixed at front hydraulic disk component Loosen these two bolts and you can take out disk component After disassembling the wheel please inspect the disk plate If the disk plate needs to be changed you have to loosen castle nut to take wheel hub ...

Page 138: ...g the power tools to take the screw out from brake stopping plate You can take the brake disc off When change brake shoe wear you must push the master piston to rearward After removal the front brake assembly you must fabricate in reverse sequence Castle nut Wheel hub ...

Page 139: ...RAKE OIL The brake oil tank is under the driver seat at right hand side Please check the brake oil level position at outside of tank To open the cap of brake oil tank please turn CCW direction Brake oil tank ...

Page 140: ...l ATV body up by using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner E1105 LRA0 FT1 to adjust the suspension How to use the Adjustable Hook Spanner When you use the adjustable hook spanner please depress the slider fig 2 3 to a proper position Fig 1 Fig 2 Depress Fig 3 Depress ...

Page 141: ...AR WHEEL AND BRAKE SYSTEM 15 1 Parts Drawing 15 2 Troubleshooting 15 3 Remove Rear Wheel And Rear Brake 15 4 Swingarm Rear Axle Holder 15 5 Suspension Adjustment 15 1 Parts Drawing REAR WHEEL REAR Wheel Axel ...

Page 142: ...REAR BRAKE ...

Page 143: ...earings are worn Faulty tires Rear axle bearing holder is faulty Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bushings Soft Suspension Weak shock absorber damper Weak shock absorber spring 15 3 Remove Rear Wheel And Rear Brake To replace brake disk The produce of removing the rear left tire is same as removing ...

Page 144: ...move the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE To replace the brake shoe please loosen this bolt as shown in picture Please push the plate back to take a shoe out as shown in picture Bolts Bolt Plate Piston ...

Page 145: ... oil being drained out completely Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup in order to avoid air in the brake system Loosen the bolt to vent the air from brake system Tighten the bolt if there isn t any air in the brake system Tighten torque 40 70kgf cm Pull left brake lever slightly in order to extract air from brake system Fill the brake oil in the level shown on ...

Page 146: ...llowing pictures are going to teach you how to Install the swing arm 1 Put the swingarm at proper position as shown in picture Two hanger bolts will be used to hold the swing arm at right and left side 2 Tighten a hanger bolt on the right side as shown in picture Hanger bolt Swingarm Hanger bolt ...

Page 147: ...t tighten it Let the cross section of bolt and cross section of hole in the same plane 4 Tighten the nut NOTE If you make a wrong assembly procedure it will cause 1 A damage of bearings 2 The main frame will be extended at the area of assembly swim arm Unalignment Hanger bolt ...

Page 148: ... using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner to adjust the suspension How to use the Adjustable Hook Spanner When you use the adjustable hook spanner please depress the slider fig 2 3 to a proper position You can then adjust your ATV s suspension fig 4 Fig 2 Press it Fig 1 Fig 4 Fig 3 ...

Page 149: ...16 FENDERS AND EXHAUST PIPE 16 1 Fenders Drawing 16 3 Front Fender Removal 16 2 Rear Fenders Removal 16 4 Exhaust Pipe Removal 16 1 Fenders Drawing EXHAUST PIPE For all serials ...

Page 150: ...emove the rear fender Remove the rear rack 1 Open the seat 2 Loosen four bolts which connect the front fender and rear fender 3 Loosen three bolts which connect the rear tender and frame these two bolts just below the seat Loosen the three screws which connect with footrest plate Pull the rear fender backward So the rear fender can be removed Release Bar ...

Page 151: ...Pull the seat handle up first There are two screws on the top of seat compartment Please remove them Finally you must remove the bolts on the footrest Bolts ...

Page 152: ... 1 First picture shows there are two screw loosen it Remove the mounting bolts from the front fender Please remove the two screws on the top of the headlight Then you can see there is a screw on the tip of the vehicle Please remove it There is a screw near the suspension as shown in picture Bolt Screws Screws ...

Page 153: ...aust pipe bolts that fixed on the engine Warning DO NOT service the exhaust pipe while they are hot Remove the exhaust pipe bolts mounting on the frame below the seat Remove the exhaust pipe carefully EXHAUST PIPE INSTALLATION Installation is the reverse order of removal Torque Exhaust muffler bolts 30 N m 22 lbf ft CATUATION After installing make sure that there are no exhaust leaks Nuts Bolts Bo...

Page 154: ... Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit CHARGING SYSTEM FAILURE LOOSE BROKEN OR SHORTED WIRE FAULTY ALTERNATOR ...

Page 155: ...ry in an open area The battery contains sulfuric acid Electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous If swallowed drink large quantities of water or milk and call a physician BATTERY VOLTAGE INSPECTION Battery is under the seat Measure the battery voltage by using a multifunction electric meter VOLTAGE Fully charged ...

Page 156: ...ition but engine can not be start Please go back to service TROUBLESHOOTING Starter Motor Turns Slowly Weak battery Poorly connected starter motor cable Failed starter motor Poorly connected battery ground cable Starter Motor Cannot Work Engine stop switch at off position Gearshift bar is not at neutral position Check for a blown fuse near battery Make sure that the battery is fully charged and in...

Page 157: ...rical bulb Turn around the cap you could see the connector Turn the seat to replace the electrical bulb TAILLIGHT The taillight combines a position and a rear brake light Normally when users switch the key to ON position the front rear position lights are always keep the light slightly Until a brake handlebar is depressed the rear position light become more light Screws Direction light Front posit...

Page 158: ... fix this cap loosen them can open the cap Please rotate the electrical bulb and then it could be removed Rear Direction lights remove The same disassembling procedure like front direction light Please use the pliers to remove the seat Then the bubble could be see and replaced Screws Rear Brake Lights ...

Page 159: ...r users Therefore this is an all in one instrument panel Instrument Panel REMOVAL There is a cable and connector on the back of the instrument panel After removing instrument panel users can find out an electrical connector which is connected with a driving sensor at the back of the instrument panel The sensor is installed at the brake disk and a cable is tightened on the left side of knuckle comp...

Page 160: ......

Page 161: ...17 8 Wiring Diagram ...

Page 162: ...ition coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire disconnected Improperly adjusted air screw Improperly ignition timing Fuel air mixture ratio is too lean Carburetor flooded Improperly adjusted air screw Fuel air mixture ratio too rich Auto choke stuc...

Page 163: ...lternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch 18 3 Poor Performance At High Speed N G CHECK IGNITION TIMING O K CHECK FUEL TUBE AT FUEL FLOW RESTRICTED CARBURETOR FUEL FLOWS FREELY REMOVE CARBURETOR CLOGGED CHECK FOR CLOGGED JETS NOT CLOGGED CHECK AIR CLEANER DIRTY FILTER ELEMENT Possibility ...

Page 164: ...rings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn piston and cylinder Fuel air mixture ratio is lean Wrong type of fuel Ignition timing too advanced Excessive carbon deposited in Combustion chamber CHECK TIRE PRESSURE ACCELERATE LIGHTY CHECK IGNITION TI...

Page 165: ...properly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Improper wheel alignment Bent frame STEERING IS HEAVY ONE WHEEL IS WOBBLING VEHICLE PULLS TO ONE SIDE ...

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