85
4-6-5. Camshaft removal
01. remove the camshaft set plate (1) Fig. 4-86
02. remove the spring (1), camshaft (2), washer, and cam (Fig. 4-86A, 4-86B)
03. inspect the camshaft o-ring for wear or damage
04. measure the cam lobe height (a) Fig. 4-87 x service limit: less than 32.628mm -- replace
04. measure the camshaft hole I.D. (a) Fig. 4-88
* service limit: more than l2.0-l2.02mm -- replace
05. measure the camshaft O.D. Fig. 4-89
* service limit: less than 11.97-11.98mm -- replace
06. remove the push rod holder bolt (1) Fig. 4-90
07. remove the push rod holder (2). Fig. 4-90A
08. check the bearing road for proper operation Fig. 4-90B
09. check the bearing push rod and o-ring for any damage Fig. 4-90B
4-6-6. Camshaft installation Fig. 4-91, 4-86
- The installation should follow the reverse order of removal.
01. install the bearing push rod by pressing it in squarely and tighten the bolt. Don’t forget to install the 2
washers.
02. install the cam (1) by aligning the punch mark (2) on the cam with the punch mark on the timing gear (3).
03. install the washer, camshaft, spring, and camshaft set plate and tighten the bolt.
* torque: 0.8 - 1.2 kg-m
4-6-7. Starter gear installation
- The installation should follow the reverse order of removal.
01. install the generator flywheel by aligning the groove in the flywheel with the key on the crankshaft. Do
not damage the starter clutch roller during installation.
02. hold the flywheel and tighten the flywheel lock bolt.
* torque: 4.0 - 5.2 kg-m
4-6-8. L crankcase cover installation
The installation should follow the reverse order of removal.
01. install the L crankcase cover and tighten the 8 bolts
* Torque: 0.8 - 1.2 kg-m
02. install reduction gear, shaft, and washers. Then, install reduction gear shaft by aligning shaft pin with
seat groove.
03. apply engine oil on reduction gear cover o-ring.
04. install the reduction gear cover and tighten the 3 bolts
* torque: 0.8 - 1.2 kg-m
4-6-9. Scarier motor installation
- The installation should follow the reverse order of removal.
01. apply engine oil to the starter motor and o-ring
02. install the starter motor
03. tighten the 2 mounting bolts.
* torque: 0.8 - 1.2 kg-m
Summary of Contents for ATV DXR 200
Page 1: ...ATV DXR 200 WORKSHOP MANUAL ...
Page 3: ......
Page 8: ...7 ...
Page 9: ...8 ...
Page 11: ...10 ...
Page 18: ...17 ...
Page 19: ...18 ...
Page 23: ...22 ...
Page 28: ...27 ...
Page 31: ...30 ...
Page 35: ...34 ...
Page 37: ...36 ...
Page 39: ...38 ...
Page 41: ...40 ...
Page 45: ...44 ...
Page 47: ...46 ...
Page 49: ...48 ...
Page 56: ...55 ...
Page 61: ...60 ...
Page 63: ...62 ...
Page 65: ...64 ...
Page 69: ...68 ...
Page 71: ...70 ...
Page 73: ...72 ...
Page 77: ...76 ...
Page 79: ...78 ...
Page 81: ...80 ...
Page 85: ...84 ...
Page 87: ...86 ...
Page 91: ...90 ...
Page 93: ...92 ...
Page 97: ...96 ...
Page 99: ...98 ...
Page 101: ...100 ...
Page 103: ...102 ...
Page 107: ...106 ...
Page 109: ...108 ...
Page 111: ...110 ...
Page 115: ...114 ...
Page 117: ...116 ...
Page 123: ...122 ...
Page 127: ...126 ...
Page 129: ...128 ...
Page 133: ...132 ...
Page 135: ...134 ...
Page 139: ...138 ...
Page 141: ...140 ...
Page 143: ...142 ...
Page 145: ...144 ...
Page 147: ...146 ...
Page 151: ...150 ...
Page 153: ...152 ...
Page 154: ...153 6 2 IGNITION SYSTEM BRIEFING 01 AC generator 03 Ignition coil 02 C D I 04 plug cap ...
Page 159: ...158 ...
Page 165: ...164 ...
Page 166: ...165 6 4 STARTING SYSTEM BRIEFING 01 starter motor 03 start button 02 starter relay ...
Page 169: ...168 ...
Page 171: ...170 ...
Page 175: ...174 ...
Page 177: ...176 ...
Page 194: ...create by w w w ciandisseny com ...