Derbi ATV DXR 200 Workshop Manual Download

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4-7.C

LUTCH

EAR

HIFT

ECHANISM

RIEFING

(01). outer

clutch

(03). plate

clutch

pressure

(05). plate

clutch

(07). circlip
(09). plate

clutch

lifter

(11).

pin, clutch lifter guide

(13). spindle

gear

shift

(15).

spring shaft drum stop

(02).

washer spline

(04).

disc, clutch friction

(06). center

clutch

(08).

spring clutch

(10).

bearing

(12).

rod clutch lifter

(14).

cam gear shift

(16).

stopper gear shift

Summary of Contents for ATV DXR 200

Page 1: ...ATV DXR 200 WORKSHOP MANUAL ...

Page 2: ...es the right to make changes at any time without notice and without incurring any obligation 3 This manual has been specially prepared to provide the necessary information for the Area importer dealers and their qualified mechanics of proper maintenance and repair details 4 This manual covers all series of products RAM 125 150 that user has to find out what details belong to By Sales and Service D...

Page 3: ......

Page 4: ... Idle speed adjustment 3 08 Throttle lever adjustment 3 09 Speed limited adjustment 3 10 Front drum brake inspection 3 11 Rear disc brake fluid inspection 3 12 Front brake lever free play adjustment 3 13 Parking brake adjustment 3 14 Clutch adjustment 3 15 Drive chain slack check and adjustment 3 16 Cable inspection and lubrication 3 17 Upper and lower arm pivot lubrication 3 18 Steering shaft ins...

Page 5: ...Cylinder Head Valve 4 05 Cylinder Piston 4 06 Starter Generator L Crankcase Start Clutch Camshaft 4 07 Clutch Gear Shift Mechanism 4 08 Crankcase Crankshaft Transmission Starter Spindle PART 5 CHASSIS DETAILS 5 01 Front Wheel Front Brake 5 02 Rear Wheel Rear Axle 5 03 Rear Brake 5 04 Steeling System 5 05 Front Shock Absorber and Front Arm 5 06 Rear Shock Absorber and Swing Arm 5 07 Drive Chain and...

Page 6: ...gine lacks power 7 04 Poor performance at high speed 7 05 Poor charging battery over discharge or overcharge 7 06 Spark plug has no function 7 07 F or R Brake Performance Poorly 7 08 Shock Absorber Malfunction 7 09 Instable Handling PART 8 APPENDIX 8 01 Notes of Pre Delivery Inspection 8 02 UPDATE information 170cc BLAST model 8 03 UPDATE information EEC 92 61 On Road Model Pág 149 Pág 153 Pág 159...

Page 7: ... or symbols is described as follows Failure to follow 1 WARNING instructions could result in severe injury or death to the ATV rider an on looker or a worker inspecting or repairing the ATV CAUTION marks special precautions that must be taken to avoid damage 10 the ATV NOTE provides principal information OPTION or APPENDIX provides others specification of product 1 3 IMPORTANT NOTICE The ATV is de...

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Page 10: ... parts before reassembly Fig 1 05 06 Apply designated greases and lubricants to the specified lubrication points Fig 1 06 07 After reassembly check all parts for proper tightening and operation Fig 1 07 08 Disconnect battery negative terminal before operation Fig 1 08 09 When connecting the battery the positive terminal should be connected first After connection apply grease to battery terminals T...

Page 11: ...10 ...

Page 12: ...cation number VIM marks on the frame 02 Engine number is marked on the engine 1 2 2 Engine details refer to Pare 4 01 Cylinder compression 13 Kg cm2 02 Idle speed 1 500 100 rpm 03 Valve clearance IN 0 05 mm EX 0 05 mm 04 Ignition timing 15 degree I 500 rpm 05 Engine oil 4 stroke disassembly 1 1L change l 0 L 1 2 3 Chassis Frame details refer to Part 5 01 Front brake lever free play 10 20mm 02 Rear...

Page 13: ...irt Once the majority of the dirt has been taken off wash all surfaces with warm water and mild detergent type soap 05 Rinse the ATV off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth 06 Dry the chain and lubricate it to prevent rust 07 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 08 Automotive wax can be ...

Page 14: ... rusty rust inhibiting oil into the inside of fuel tank 05 Clean the drive chain thoroughly and lubricate it 06 Lubricate all control cables 07 Remove the battery Be sure to re charge battery before storage Do not put the battery on hot or cold place 08 Check the tire pressure and block up the frame to raise all wheels off the ground 09 Wash and dry the ATV and wax all painting surfaces 10 Cover a...

Page 15: ...24 5 cm3 149 5 cm3 Carburettor DTG 017 o PD 19D KEIHIN Spark DR 8EA NGK Starting Electric Ignition C D I Generator ACG Fly Wheel Magneto Battery YUASA YTX 7A BS Engine Oil 4 Stroke qualified synthetic oil Engine Oil capacity 1 10 l Air Filter Wet type element Transmission National 5 speeds Primary reduction Helical gear Primary red Ratio 4 055 73 18T Secondary reduction drive chain Secondary red R...

Page 16: ...m single disc Front drum brake Right hand operation Rear disc brake Right foot operation Rim steel Front 10 x 5 5 AT Rear 8 x 8 0 AT Wheel travel F R 180mm 7 09in 180mm 7 09in Headlight type bulb type Front 12V 18W 18W x 2 Rear 12V 21W x 1 Indicator neutral 12V 3 4W x 1 Fuse 15A 250V NOTE THE ATV Z S DESIGNED FOR OFF ROAD USE MAINLY TO MATCH DIFFERENT AREA REGULATION ATV MAY CHANGE OR INSTALL EXTR...

Page 17: ...ltage regulator lead 08 Main switch 09 Wire harness 10 Ground lead 11 Front brake cable 12 Clutch cable 13 Main switch lead 14 Wire holder 15 Clamp 16 Carburettor overflow hose 19 Flywheel magneto lead 18 Cable guide 19 Rear brake cable 20 Crankcase ventilation hose 21 Spark plug lead 22 Tail brake light lead 23 Rear brake fluid reservoir 24 Master cylinder ...

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Page 19: ...18 ...

Page 20: ... m Crankcase assembly bolt 10 06 1 0 mm 0 8 1 5 Kg m L crankcase cover bolt 14 06 1 0 mm 0 8 1 2 Kg m R crankcase cover bolt 11 06 1 0 mm 0 8 1 2 Kg m ACG bolt 03 05 0 8 mm 0 4 0 7 Kg m ACG coil lock bolt 02 05 0 8 mm 0 4 0 7 Kg m Perno del generador A C 01 10 1 25 mm 4 0 5 0 Kg m 0 45 0 60 0 80 1 20 1 80 2 00 3 00 4 00 5 00 6 00 05mm screw 06 nim nut SH bolt 06mm flange bolt nut 08mm flange bolt ...

Page 21: ...0 Kg m Rear wheel 08 10 1 25 mm 4 5 Kg m Front shield bolt 03 08 1 25 mm 2 6 Kg m Rear shield bolt 03 08 1 25 mm 2 6 Kg m Engine Mounting F engine and frame 01 12 1 25 mm 4 5 Kg m Swing Arm 01 08 1 50 mm 8 5 Kg m Under guard 04 08 1 25 mm 2 3 Kg m Chain supporter 02 08 1 25 mm 1 5 Kg m Tensioner 02 08 1 25 mm 0 9 Kg m Footrest L R 04 08 1 25 mm 5 5 Kg m Rear shock absorber upper bolt 01 08 1 25 mm...

Page 22: ...ck gasket NOTE 1 THE REPLACEMENT OWNER S MANUAL AND TOOL KIT ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 2 THE PARTS LISTS ARE AVAILABLE FROM EACH AREA IMPORTER OR TERRITORIAL DISTRIBUTOR 3 BE SURE TO USE ONLY GENUINE MAKER PARTS FOR REPLACEMENT 02 cylinder valve adjuster 04 rpm tester 06 dial gauge 1 l00mm 08 micrometer 0 25 mm 10 V block 12 snap ring pliers 14 thickness gaug...

Page 23: ...22 ...

Page 24: ...is poisonous and may cause loss of consciousness and death within a short time SOLUTIONS 2 Only run ATV in an area with ample atmosphere 3 02 OWNER S MANUAL AND TOOL KIT FIG 3 02 Be sure to keep the owner s manual and tool kit which include low pressure tire gauge all the time with ATV The owner s manual and tool kit are part of the ATV and please keep it with the ATV for ready use even when the A...

Page 25: ...r requires more frequently cleaning or replacement after riding on 1 dusty rain days 2 sand area 3 snow days PS3 Air cleaner tube requires more frequently checking on 1 very wet 2 muddy conditions PS4 Brake fluid replaces every 2 years period PS5 Check battery before riding ATV Re charge battery or replace a new battery if it necessary CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGIN...

Page 26: ... to instructions 01 Engine oil 02 engine oil filter 03 Engine idle speed 04 Value clearance 05 Spark plug 06 Air cleaner 07 Air cleaner tube 08 Carburettor choke 09 Throttle lever 10 Speed limiter 11 Fuel line 12 Upper A arm 13 Lower A arm 14 Rear brake fluid 15 Steering 16 Brake function 17 Brake shoe 18 Clutch system 19 Suspension 20 Wheel tire 21 Nuts bolts fasteners 22 Drive chain 23 Battery 2...

Page 27: ...the oil level 05 The oil level should be between the maximum and minimum marks If the level is low add oil to the proper level 05 Re start the engine and warm up a few minutes While warming up if oil leakage stop engine immediately and check 07 Check the oil level CAUTION BE SURE NO EXOTIC MATERIAL ENTERS THE CRANKCASE 3 04 2 Engine oil replacement 01 Place the ATV on a level place 02 Warm up the ...

Page 28: ...27 ...

Page 29: ... Fig 3 08 Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specification When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten to the specified torque Spark plug gap 0 6 0 7 mm 0 024 0 0 3 in Tightening Torque Spark plug 25 Nm 2 5 m kg 18ft 1b NOTE A PLUG WITH VERY WHITE CENTRE...

Page 30: ...element 05 Squeeze the excess solvent out of the filter and let it dry Do not twist the filter element when squeezing it 06 Inspect the element If damaged replace it 07 Apply some motor oil to the element which element should be wet but not dripping 08 Reinstall the element to the element guide 09 Reinstall the element assembly and parts removed for access NOTE 1 CLEAN THE AIR FILTER ELEMENT EVERY...

Page 31: ...30 ...

Page 32: ...rettor throttle from becoming full open even when the throttle lever is turned to a maximum Screwing in the adjuster stops the engine speed from increasing 01 Loosen the lockout 02 Turn the adjuster clockwise or counter clockwise until proper length is attained Finally Tighten the locknut speed limited length 12mm 0 47 in a 3 10 FRONT DRUM BRAKE INSPECTION FIG 3 16 A wear indicator is provided on ...

Page 33: ...NEVER ALLOW FOREIGN MATERIALS DIRT WATER ENTER THE BRAKE FLUID RESERVOIR 2 BRAKE FLUID CAN DAMAGE ANY PAINTING AND PLASTIC WARNING BRAKE FLUID CONTACTING THE SKIN AND EYES AWARENESS May cause irritation SOLUTION Avoid contacting brake fluid with the skin or eyes ...

Page 34: ...e brakes operate smoothly and the free play is correct after serviced Be sure brakes do not restraint 3 13 PARKING BRAKE ADJUSTMENT FIG 3 22 3 13 1 Parking brake adjustment may be required if the parking brake does not function properly 01 Loosen the lockout of the parking brake cable adjuster 02 Turn the adjuster until there is little or no free play 03 Tighten the lockout 3 13 2 Brake lever peda...

Page 35: ...34 ...

Page 36: ...m 1 2 1 6in If the deflection exceeds 40 mm l 6 in a adjust the chain slack 3 15 2 Drive chain slack adjustment 01 Loosen the rear wheel hub bolts 1 2 Fig 3 26 02 Loosen the adjuster lockouts on each side To lighter the chain turn the chain adjuster clockwise To loosen chain turn adjuster counterclockwise and push the wheel forward 03 Turn each adjuster exactly the same amount to maintain correct ...

Page 37: ...36 ...

Page 38: ... pivot and the lower arm pivot Recommended lubricant Lithium soap base grease 3 18 STEERING SHAFT INSPECTION LUBRICATION FIG 3 30 01 place the vehicle on a level place 02 check the steering column bushings and bearings 03 move the handlebar up and down and or back and forth 04 if excessive play replace the steering column bushings and or bearing 05 check the tie rod ends 06 turn the handlebar to t...

Page 39: ...38 ...

Page 40: ...D END LOCKOUTS 2 OF BOTH TIRE RODS TORQUE LOCKNUT 3 0 KG M 3 20 FRONT SHOCK ABSORBER ADJUSTMENT FIG 3 35 01 adjust the spring prelate by turning adjuster increase or decrease 02 the police softer 2 position A standard position B stiffer 3 position C D E WARNING ALWAYS ADJUST BOTH FRONT SHOCK ABSORBER SPRING PROLATE TO THE SAME SETTING UNEVEN ADJUSTMENT CAN CAUSE POOR HANDLING AND LOSS OF STABILITY...

Page 41: ...40 ...

Page 42: ...d pressure NOTE CHECK AND ADJUST TIRE PRESSURES WHEN THE TIRES ARE COLD TIRE PRESSURES NUTS BE EQUAL ON BOTH SIDES TIRE PRESSURE ABOVE THE MINIMUM SPECIFIED COULD CAUSE THE TIRE TO DISLODGE FROM ME RIM UNDER SEVERE RIDING CONDITIONS HIGHER PRESSURES MAY CAUSE THE TIRE CO BURSE INFLATE THE TIRES SLOWLY AND CAREFULLY FAST INFLATION COULD CAUSE BURST FRONT REAR MANUAFACTURE DURO CHENG SHIN DURO CHENG...

Page 43: ... the low pressure tire gauge with the ATV for ready use all the time Take out dirt or dust in the gauge Always make two measurements of tire pressure and take the 2nd reading 01 Set pressure with tires cold 02 Set tire pressures to match the suggested tire pressure 3 23 TIRE WEAR LIMIT FIG 3 40 When the tire groove decreases to 3 mm 0 l2 in a due to wear be sure to replace the tire ...

Page 44: ...EADLIGHT BULB IS HOT WHEN IT IS ON AND IMEDIATELY AFTER IT IS TURNED OFF AWARENESS People can be burned or a fire could stare if the bulb touches something flammable SOLUTION Wait for the bulb to cool before couching or removing it 3 26 REPLACING THE REAR LIGHT FIG 3 47 3 48 If the rear light bulb burns out be sure co replace the new bulb 01 Remove the rear light cover 1 Fig 3 47 02 Take out bulb ...

Page 45: ...44 ...

Page 46: ... SHORT CIRCUITING ON ELECTRICAL SYSTEM IT A FUSE TAILS FREQUENTLY WHICH MEANS A SHORT CIRCUIT OR AN OVERLOAD IN THE ELECTRICAL SYSTEM BE SURE TO CHECK IT ON ONLY USE THE FUSE SPECIFIED AS 15A 3 30 FUEL TANK FIG 3 50 3 51 3 52 3 53 3 54 3 54A 3 30 1 Fuel tank arid fuel valve removal 01 lock the fuel cap and fuel clock on OFF Fig 3 50 02 loosen the screw Fig 3 51 03 disconnect the fuel horse Fig 3 5...

Page 47: ...46 ...

Page 48: ...g hole cap on L crankcase Fig 3 57 02 use the ignition timing light to check ignition timing Fig 5 59 03 the correct ignition timing at idle speed mark on F in flywheel CAUTION THE CDI IGNITION TIMING IS NOT ADJUSTABLE IF TIMING IS INCORRECT CHECK THE IGNITION SYSTEM 3 31 3 Cylinder compression Fig 3 60 01 warn up engine few min and then stop engine 02 remove the spark plug and insert the compress...

Page 49: ...48 ...

Page 50: ...ve inspection 13 Fuel tanks and fuel valve installation 14 Air cleaner cleaning 4 02 LUBRICATION SYSTEM NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING Q A 1 Engine oil 2 Oil pump oil filter rotor removal 3 Oil pump disassembly and inspection 4 Oil pump reassembly and installation 4 03 ENGINE REMOVAL INSTALLATION NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING Q A 1 Engine removal 2 Engine install...

Page 51: ...n 8 L crankcase cover installation 9 Starter motor installation 4 07 CLUTCH GEAR SHIFT MECHANISM NOTE SERVICE INFORMATION NOTE PROBLEMS SHOOTING Q A 1 R crankcase cover removal 2 Clutch removal 3 Clutch inspection 4 Gear shift mechanism removal 5 Gear shift inspection and installation 6 R crankcase cover installation 4 O8 CRANKCASE CRANKSHAFT TRANSMISSION STARTER SPINDLE NOTE SERVICE INFORMATION N...

Page 52: ...YSTEM AND CARBURETION BRIEFING 01 Dutch 03 Seal of air cleaner cover 05 Element of air cleaner 07 Fuel tank 09 Carburettor 02 Cleaner cover 04 Plate of element sec 06 Side cover 08 Fuel hose 10 Joint of air cleaner ...

Page 53: ...por or gasoline in eyes go to doctor immediately 2 If gasoline spills on skin wash with soap and water If gasoline spills on clothing be changed clothes WARNING 2 POTENTIAL HAZARD IMPROPER CARE WHEN REFUELLING AWARENESS 2 Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If fuel tank is overfilled fuel could spill out due to heat from the engine or the sun SOLUT...

Page 54: ...harcoal canister Q A Engine lacks power clogged air cleaner faulty carburettor faulty ignition system Q A Rich mixture float level too low clogged air jets clogged air cleaner worn throttle needle Q A Misfiring during acceleration faulty ignition system faulty carburettor faulty accelerating pump faulty charcoal canister Q A Backfiring carburettor fuel level too low improperly adjusted carburettor...

Page 55: ...the float valve seat for any wear or damage 03 inspect the float for damage or fuel inside the float 4 1 4 Jets air screw throttle screw removal Fig 4 8 4 9 01 remove the main slow jet 1 and jet holder 2 Fig 4 8 02 remove the air screw 1 and throttle stop screw 2 Fig 4 9 CAUTION 1 BE CAREFUL NOT TO DAMAGE THE JETS AND JET HOLDER DURING THE REMOVAL BEFORE REMOVAL TURN THE THROTTLE STOP AND AIR SCRE...

Page 56: ...55 ...

Page 57: ...ber 4 1 8 Carburettor installation Fig 4 05 4 06 01 use slow compressed air through all passages before install 02 tighten the 2 locknuts and air cleaner connector band screw torque 0 8 1 2 kg m 4 l 9 Throttle valve installation Fig 4 1 4 2 4 3 4 4 The procedure reverses the removal steps 01 install the jet needle into the throttle valve and secure with the needle retainer Jet needle notch 4th Not...

Page 58: ...ar 1ST CAUTION BE SURE TO PERFORM THE INITIAL MAINTENANCE FOR CHANGING ENGINE OIL A QUALIFIED SYNTHETIC 4 STROKE OIL IS STRONGLY RECOMMENDED CLEANING ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION THE DRAWING OF LUBRICATION SYSTEM FOLLOWS DIRECTION AS 02 oil pump ...

Page 59: ...AINTENANCE FOR CHANGING ENGINE OIL A QUALIFIED SYNTHETIC 4 STROKE OIL IS STRONGLY RECOMMENDED CLEANING ENGINE OIL FILTER AFTER 1ST 20HRS OR 100KM OPERATION 4 STROKE ENGINE OIL VISCOSITY SAB 10W 40 A QUALIFIED SYNTHETIC OIL IS STRONGLY RECOMMENDED 4 STROKE ENGINE OIL IS A MAJOR FACTOR AFFECTING THE ENGINE PERFORMANCE AND SERVICE LIFE PERIODIC INSPECTION ADJUSTMENT AND LUBRICATION WILL KEEP ATV IN T...

Page 60: ...p disassembly and inspection 01 remove the 2 screws Fig 4 18 02 measure the clearance of pump body to outer rotor Fig 4 19 service limit 0 20mm 03 measure the clearance of inner rotor to outer rotor Fig 4 20 service limit 0 02mm 04 Measure the clearance of rotor end to pump body Fig 4 21 service limit 0 15mm 4 2 4 Oil pump reassembly and installation Fig 4 22 The procedure reverses the removal ste...

Page 61: ...60 ...

Page 62: ...T 2 4 3 0 KGM 4 EXHAUST PIPE JOINT LOCK NUT 0 8 1 2 KGM 4 3 1 Engine removal Be sure to turn off the fuel clock Fig 4 23 01 remove the carburettor Fig 4 24 02 disconnect the clutch cable Fig 4 25 4 26 03 remove the exhaust pipe Fig 4 27 4 28 4 29 4 30 03 remove the spark plug cap Fig 4 31 04 turn the fuel cap off and disconnect the fuel cube 05 disconnect the generator wire connector Fig 4 32 WARN...

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Page 64: ...throttle operation 02 clutch lever free play adjustment and 03 drive chain adjustment CAUTION WHEN INSTALLING THE ENGINE DO NOT DAMAGE THE BOLT THREAD AND ROUTE THE WIRES AND CABLES PROPERLY WARNING 1 SERVICING AN ENGINE WHILE IT IS RUNNING AWARENESS 1 Hoc surface or moving parts can harm people Electrical components can be damaged SOLUTION 1 Turn off the engine when performing maintenance unless ...

Page 65: ...64 ...

Page 66: ...adjusting 09 retainer valve spring 11 spring valve outer 13 seat valve spring inner 15 insulator carburettor 17 valve IN 19 o ring 02 gasket head cover 04 rocker arm holder 06 nut tapping adjuster 08 cotter 10 spring valve inner 12 seal valve stem 14 seat valve spring outer 16 head cylinder 18 valve EX ...

Page 67: ...T 2 3 2 8 KGM 3 CAM FOLLOWER BOLT 1 5 2 0 KGM 4 ROCKER ARM BOLT 1 5 2 0 KGM ITEM 01 Valve clearance cold engine 02 Cylinder compression 03 Cylinder head war page 04 Rocker arm clearance 05 Rock arm shaft clearance 06 Valve seat angle 07 valve stem O D 08 Valve guide I D 09 Valve stem guide clearance STANDARD MM 10 14 Kg cm2 0 05 or less 0 05 0 1 0 05 0 1 0 05 0 25 0 05 0 25 0 013 0 46 0 13 0 46 80...

Page 68: ...and rocker arm Worn camshaft or cam follower Worn valve guide 4 4 1 Cylinder head cover removal Fig 4 42 01 remove the 3 bolts attaching on cylinder head cover 02 remove the cylinder head 03 check the cylinder head cover o ring replace it if damage 4 4 2 Rock arm set removal fig 4 42 4 42A 01 remove the 3 bolts 02 remove the rock arm set 03 measure L R rocker am clearances a standard 0 05 0 25mm C...

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Page 70: ...47 service limit IN less than 5 42mm for replace 1 EX less than 5 40mm for replace 2 08 clean any carbon from valve guide and measure the guide I D Fig 4 48 4 49 service limit IN more than 5 505mm for replace EX more than 5 525mm for replace 09 apply engine oil to new o rings and install them into new valve guides Then drive in the new valve guides 10 ream the new valve guides Fig 4 50 11 clean th...

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Page 72: ...07 install the dowel pins 1 and new gasket 2 onto the cylinder Fig 4 53 08 install the cylinder head 09 install the push bar guide plate and 4 cylinder head lock nut 11 tighten the cylinder head lock nuts diagonally torque 2 3 2 8 kg m 12 install cam follower bolts copper washer then tighten bolt torque 1 8 2 3 kg m 13 install the 2 push bars 14 install the rocker arm set bolts and copper washers ...

Page 73: ...72 ...

Page 74: ...73 4 5 CYLINDER PISTON BRIEFING 01 gasket cylinder head 03 gasket cylinder 05 follower cam 07 piston ring 09 piston pin 02 cylinder 04 washer wave 12 3 21 0 2 06 shaft caw follower 08 circlip 10 piston ...

Page 75: ...rance 2nd 0 5 0 75 0 45 0 7 0 5 0 75 0 8 1 05 02 Ring end gap top clearance 2nd side rail oil ring 0 15 0 35 0 1 0 3 0 15 0 35 0 1 0 3 0 2 0 5 0 3 0 9 03 Piston O D 125 150 56 45 56 48 61 97 61 99 04 Piston O D measure location 10mm from bottom of piston skirt 05 Piston Cyl 125 clearance 150 0 01 0 075 0 005 0 065 06 Pis Pin hole I D 15 002 15 008 15 012 or more 0 135 or more 0 125 or less 56 3 or...

Page 76: ...tion 01 remove the piston pin clip Be sure put a towels under piston to prevent the clip drops 1 into the crankcase Fig 4 56 02 clean any gasket material from cylinder surface Fig 4 57 03 press the piston pin out of the piston and remove the piston 04 inspect the piston piston pin and piston rings 05 remove piston rings Do not damage rings set Fig 4 53 05 remove carbon deposits in the piston ring ...

Page 77: ...76 ...

Page 78: ...LUES MEASURED AT THE 3 LEVELS IN X OR Y DIRECTION IS SUBJECT TO MAX VALUE CALCULATED SERVICE LIMIT OF CYLINDRICITY MORE THAN 0 05MM REPLACE 05 inspect the top of the cylinder for warp Fig 4 66 service limit less than 0 05mm replace 06 measure the connecting rod small end I D Fig 4 67 service limit more than 15 032 replace 07 check the cam follower contact face for ear or electrode position peeling...

Page 79: ...78 ...

Page 80: ...ton piston pin and piston pin clip The piston IN mark is located on intake valve side Be sure to put a towels in the crankcase to prevent piston pin clip falling into Fig 4 73 4 5 6 Cylinder installation The installation should follow the reverse order of removal 01 install the 12mm washer wave washer into the groove 02 install the cam follower and cam follower shaft 03 apply engine oil on the cam...

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Page 82: ... crankcase 05 bearing needle 07 gear reduction 09 cap L crankcase cover 11 camshaft 13 shaft starter gear 15 washer l7 outer starter 19 gear starting clutch 02 stertor 04 camper wire harness 06 shaft reduction gear 08 cover reduction gear 10 o ring 12 bearing needle 14 Shaft cam gear 16 o ring 18 flywheel ...

Page 83: ... starting improperly tightened flywheel lock bolt Q A Starter clutch slips worn starter clutch roller faulty starter clutch roller or spring worn starter gear shaft O D Q A Starring noise worn reduction gear worn starter gear worn starter clutch roller faulty reduction pinion shaft bearing STANDARD MM 125 150 ITEMS 9 972 9 987 10 031 10 056 9 973 9 984 10 19 10 205 10 031 10 056 22 021 22 042 01 R...

Page 84: ...g 4 77 4 78 01 disconnect the neutral light switch wire 02 remove the L crankcase cover bolts 03 remove the L crankcase cover and two dowel pinions 04 clean off all gasket 05 remove the reduction pinion 1 Fig 4 81 4 6 3 Generator removal 01 remove the flywheel lock bolt Fig 4 79 02 remove the flywheel Fig 4 79 4 6 4 Starter clutch removal and inspection 01 remove the bolt 1 on starter gear set 2 F...

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Page 86: ...he 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 install...

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Page 88: ...ressure 05 plate clutch 07 circlip 09 plate clutch lifter 11 pin clutch lifter guide 13 spindle gear shift 15 spring shaft drum stop 02 washer spline 04 disc clutch friction 06 center clutch 08 spring clutch 10 bearing 12 rod clutch lifter 14 cam gear shift 16 stopper gear shift ...

Page 89: ...ear shift spindle or damaged transmission drum grooves worn or deformed gear shift plate faulty gear shift cam stopper Q A Clutch won t operate vehicle run slowly excessive free play bent clutch plate Q A Too much pressure on clutch lever kinked twisted or damaged clutch cable or damaged clutch lifter Q A Clutch does not operate smoothly improper clutch outer groove Q A Gear tripping faulty gear s...

Page 90: ...ove the spring clutch anger clutch friction disks and plates Fig 4 57 05 remove the thrust washer 1 outer clutch and outer guide Fig 4 9S 4 7 3 Clutch Inspection 01 check the clutch tension spring to make sure each clutch tension spring free length a Fig 4 99 service limit less than 34 20mm replace 02 check the clutch friction disc to make sure thickness a Fig 4 100 service limit 2 60mm 03 check c...

Page 91: ...90 ...

Page 92: ... make sure the stopper operation 09 tighten the bolt torque 0 8 1 2 kg m 10 install the gear shift spindle and washer Be sure the return spring aligns with the crankcase tab 11 install the outer clutch and thrust washer Be sure thrust washer chamfered side facing up 12 install the clutch 13 staffer the clutch friction disks and clutch plates and put them on the clutch center 14 install the clutch ...

Page 93: ...92 ...

Page 94: ...der clutch wire 03 counter shaft 05 main shaft 07 fork R gear shaft 09 fork L gear shaft 11 rotor neutral switch 13 L crankcase 15 spring 02 R crankcase 04 bearing 06 gear shift fork 08 fork center gear shaft 10 drum gear shaft 12 crankshaft 14 oil filter 16 oil filter cap ...

Page 95: ...93 5 0 12 12 018 11 97 11 984 4 43 or less 12 058 or more 11 936 or less ESTÁNDAR MM SERVICE LIMIT MM 01 Left 02 Right ITEMS 12 985 12 965 20 959 20 98 12 915 or less 20 919 or less ESTÁNDAR MM 01 Gear I D M start M 4th M 5th S start S 1st S 2nd S 2nd 02 Main Shaft L crank Start 4th 5th 03 Counter R crank Shaft O D L crank 1st gear 2nd gear 3rd gear ITEMS 20 02 20 041 20 20 021 20 02 20 041 20 01 ...

Page 96: ...dowel pins 2 be sure don t lose the gear shift spindle washer Fig 4 222 4 8 2 Transmission system removal and inspection 01 remove the transmission fork shaft and transmission forks 2 Fig 4 113 4 114 02 remove the transmission drum 1 Fig 4 115 03 inspect each transmission fork for bending or damage Fig 4 116 04 measure each transmission fork claw thickness service limit less than 4 43mm replace 05...

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Page 98: ...e counter 2nd more than 22 081mm replace 03 measure each shaft collar I D Fig 4 120 4 121 countershaft starter idle gear more 16 85mm replace countershaft 1st gear more 19 00mm replace 04 measure each shaft collar O D Fig 4 122 countershaft starter idle gear less 19 55mm replace countershaft 1st gear less 19 55mm rep ace 05 check the main shaft and countershaft for any wear and damage 06 measure m...

Page 99: ...98 ...

Page 100: ...less than 15 95mm replace B less than 19 95mm replace C less than 12 85mm replace 4 8 6 Bearing inspection and replacement 01 check the main shaft and countershaft bearings for smooth tuning Fig 4 125 02 replace the bearings with new ones if bearing do not turn smoothly quietly or if they fit loosely in the case 03 if the countershaft needle bearing in the L crankcase is nosy or has excessive free...

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Page 102: ...be installed more easily by tuning on neutral light cooper piece on transmission drum toward cylinder 06 install the mid transmission fork to main shaft 3rd gear 07 install the fork guide pin into the transmission drum groove 08 install the L transmission fork to the countershaft 5th gear 09 install the fork guide pin into the transmission drum groove 10 install the transmission fork shaft CAUTION...

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Page 104: ...ke fluid change refilling 2 Brake shoe disc master cylinder inspection 3 Installation brake shoe disc master cylinder 5 04 STEELING SYSTEM 1 Removal 2 Inspection 3 Installation 5 05 FRONT SHOCK ABSORBER AND FRONT ARM 1 Removal 2 Inspection shock absorber 3 Inspection steering knuckle 4 Inspection front arm 5 Installation 5 06 REAR SHOCK ABSORBER AND SWING ARM 1 Removal R shock 2 Inspection and rem...

Page 105: ...1 FROM WHEEL AND FRONT BRAKE BRIEFING 01 lever camshaft 03 camshaft 05 o ring 07 tire 09 hub 11 washer 13 oil seal 02 plate brake shoe 04 brake shoe set 06 spacer bearing 08 wheel 10 collar 12 indicator plate ...

Page 106: ... wear indicator plate 1 Fig 5 08 13 remove the camshaft 3 Place an aligning mark next to the punched mark on the camshaft lever before remove that it car be reinstalled in the same position Fig 5 08 5 1 2 Inspection Fig 5 09 I 01 check the wheel any cracks bends warpage replace 02 measure the wheel run out replace Fig 5 09 service limit radial 1 2 0 mm 0 08 in lateral 2 2 0 mm 0 08 in WARNING AFTE...

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Page 108: ... edge to protect edge Fig 5 13 03 remove the bearing 3 using a general bearing puller Fig 5 12 04 install the new bearing and oil seal by revering the previous steps It may use a socket 4 matches the outside diameter of the race of the bearing and oil seal Fig 5 14 CAUTION DO NOT STRIKE THE CENTER RACE 5 OR BALLS 6 OF BEARING CONTACT SHOULD BE MADE ONLY WITH THE OUTER RACE 7 FIG 5 14 5 1 4 Brake s...

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Page 110: ...he slot on the camshaft Fig 5 18 04 install brake shoe plate and be sure the boss on the knuckle correctly engages with the locating slot on the brake shoe plate Fig 5 19 05 on Fig 5 20 tighten 1 bolt brake cam lever torque 0 9 kg m 2 nut front wheel hub torque 7 0 kg m 3 nuts front wheel torque 4 5 kg m 06 install the new cotter pin 1 Fig 5 21 CAUTION 1 DO NOT LOOSEN THE WHEEL HUB AFTER TORQUE TI...

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Page 112: ...111 5 2 REAR WHEEL AND REAR AXLE BRIEFING 01 axle 03 hub 05 sprocket driven 40T 07 nut hexagon 09 collar wheel 11 wheel 02 spacer 04 collar sprocket axle 06 chain 08 washer lock 10 tire ...

Page 113: ...ut 1 Fig 5 24 04 elevate the rear wheel by placing a stand under frame Fig 5 24 05 remove rear wheels 2 Fig 5 24 06 remove cotter pin 1 wheel hub nut 2 Fig 5 25 07 remove plate washer 3 wheel hub 4 Fig 5 25 08 loosen rear axle outer nut 1 Fig 5 26 09 loosen rear axle inner nut 2 Fig 5 26 10 Tighten rear axle inner nut 1 of 1 8 clockwise turn 2 Fig 5 27 ...

Page 114: ...ess parking brake lever or brake pedal when the caliper if out the disc Fig 5 31 21 remove the rear axle Fig 5 32 Fig 5 32a Fig 5 32b CAUTION 1 NEVER DIRECTLY TAP THE AXLE END WITH A HAMMER WHICH WILL CAUSES DAMAGE TO THE AXLES THREAD 1 AND SPLINE 2 FIG 5 33 2 INSTALL THE WHEEL BOSS 3 AND SUITABLE SOCKET 4 ON THE AXLES END TO PROTECT THE THREAD AND SPLINE FROM DAMAGE FIG 5 33 21 take out wire clip...

Page 115: ...114 ...

Page 116: ...mit 1 5mm 0 06 in 11 inspect rear axle hub 1 for any cracks or bend replace Fig 5 40 12 inspect bearing 1 for any play in axles hub or turns roughly replace Fig 5 41 13 inspect oil seats 2 for any wear or damage replace 5 2 3 Rear axle hub bearing and oil seal replacement steps 01 clean the outside of the rear axle 02 remove the oil seal 1 by using a flat head screw driver and place a wood block 2...

Page 117: ...116 ...

Page 118: ...ER WHICH WILL CAUSES DAMAGE TO THE AXLES THREAD AND SPLINE 2 INSTALL THE WHEEL BOSS AND SUITABLE SOCKET ON THE AXLES END TO PROTECT THE THREAD AND SPLINE FROM DAMAGE 07 install caliper torque 2 8 kg m 08 install sprocket hub 09 install rear axle inner nut 10 install rear axle outer nut 11 drive chain On this step the rear axle nut should not be screwed on 12 install under guard torque 2 3 kg m 13 ...

Page 119: ...rely 22 tighten rear wheel nut torque 4 5 kg m 23 replace the parking brake 24 adjust drive chain slack refer to part 3 25 drive chain slack 30 40mmd l8 1 57 in 25 tighten rear axle hub upper nut torque 5 0 kg m 26 tighten rear axle hub lower nut torque 5 0 kg m 5 2 5 Rear axles nut tighten steps 01 apply the bone or locking agent on rear axle nuts threads 02 1st tighten the inner rear axles nut o...

Page 120: ...119 5 3 REAR DISC BRAKE BRIEFING 01 master cylinder 03 brake pad caliper 05 bracket caliper 07 disc 09 hose 02 brake hose 04 caliper 06 bracket disc 08 brake fluid reservoir ...

Page 121: ...k nut 1 to draw the existing brake fluid out Fig 5 46 03 fill the new brake fluid into tank Be sure no air on hose 1 Fig 5 47 04 use only recommended brake fluid DOT 3 or DOT 4 only Fig 5 48 05 after re fill brake fluid place the brake lever several times and loosen the bleed valve lock nut to bleed air out CAUTION 1 NEVER ALLOW FOREIGN MATERIALS DIRT WATER ENTER THE BRAKE FLUID RESERVOIR 2 BRAKE ...

Page 122: ...cylinder Reverse the removal procedure 01 install the brake shoe into caliper 02 install the master cylinder 03 install disc to brake hub torque 2 8 kg m 04 lubricate the rear axles splines lightweight lithium soap base grace 0 5 Install under guard torque 2 3 kg m 06 install the caliper new gasket cover 07 install wheel hub 08 install the R wheel 09 adjust the parking brake under apply the rear b...

Page 123: ...122 ...

Page 124: ...123 5 4 STEELING SYSTEM BRIEFING 01 blot flange 03 plug taper 05 holder handle lower 07 joint universal 09 bracket 11 tie rod 02 holder handle upper 04 steering 06 washer 08 collar 10 washer lock ...

Page 125: ... 5 4 1 Removal 01 remove handlebar cover Fig 5 55 02 disconnect fuel breather hose 03 remove the L and R lever holder Fig 5 56 5 57 04 remove the front cover 1 Fig 5 58 05 disconnect main switch 1 neutral 2 front lamp leads 3 ...

Page 126: ...r 3 Fig 5 61 09 remove cotter pins 1 nuts 2 and tie rods 3 Fig 5 62 10 remove cotter pins 1 nut steering column 2 and washer 3 Fig 5 63 11 straighten lock washer tabs 1 Fig 5 64 12 remove bolts 2 lock washer 3 cable holder 4 Fig 5 64 13 remove bearing 1 oil seals 2 collars 3 Fig 5 65 14 remove steering column 1 Fig 5 66 ...

Page 127: ...126 ...

Page 128: ...ig 5 71 08 adjust L R tie rod length and rod end angle under 1 loosen the locknuts 1 Fig 5 72 2 adjust the tie rod length by turning both tie rod ends tie rod length 321mm 12 6 in 3 set rod end 2 on knuckle arm side in an angle where the indentation surface 3 of the tie rod is parallel to the rod end shaft 4 and then tighten the locknut Fig 5 73 torque 3 0 kg m 4 set other rod end 5 on steering co...

Page 129: ...128 ...

Page 130: ... kg m 07 bend the lock washer tab along the bolt flats 08 tighten the steering column torque 3 0 kg m 09 install new cotter pin 10 put L R tie rods rod end mark is facing up knuckle arm 11 tight en tie rod nuts torque 2 5 kg m 12 install new cotter pin 13 tighten handlebar holder bolts Be sure the upper handlebar mark 1 face co front Tighten the bolts 2 on the from side of handlebar holder and the...

Page 131: ...130 5 5 FRONT SHOCK ABSORBER AND FRONT ARMS BRIEFING 01 shaft pivot 03 bush solid 05 upper arm 07 collar lower 09 shock absorber 02 cover thrust 04 collar 06 nipple grease 08 lower arm ...

Page 132: ...nt arm brackets 1 of the frame Any bent cracked damage repair or replace 2 check the tightening torque of the front arm upper lower securing nuts 2 torque F arm upper and lower 3 0 kg n 3 check the front arms upper and lower free play A by moving it from side to side Any play noticeable replace the inner collar bushings and thrusts covers as a set 4 check the front arms upper and lower vertical mo...

Page 133: ...132 ...

Page 134: ...8 01 any cracks bends damage replace 02 do not try to straighten a bent arm that will dangerously weaken the arm 03 check collar free play any loose replace inner collar and bushing as a set Fig 5 89 5 91 04 insert the inner collar into front arm and check free play 05 inspect thrust cover 1 and bussing 2 for any wear damage replace Fig 5 90 06 check ball joint movement for any exits free play rep...

Page 135: ...134 ...

Page 136: ...he thrust cover Fig 5 94 use lightweight lithium soap base grease 05 tighten steering knuckle nuts torque 4 8 kg m 06 tighten knuckle arm bolts torque 3 8 kg m 07 connect tie rod to knuckle arm 08 lubricate front shock absorber bushing 1 Fig 5 95 use lightweight lithium soap base grease 09 tighten front shock absorber nuts 2 torque 4 5 kg m 10 tighten front shock absorber bolts torque 2 6 kg T 11 ...

Page 137: ...NG ARM BRIEFING 01 Shaft pivot 03 Washers 05 Bush 07 O ring 09 Seal guard 11 Under guard 13 Shock absorber 15 Pin clevis 02 Cover thrust 04 Oil seal 06 Bearing needle roller 08 Spacer 10 Rear arm 12 Support chain 14 Bolt 16 Cover thrust ...

Page 138: ...STEPS FIG 5 96 GAS PRESSURE MUST BE RELEASED BEFORE DISPOSING OF SHOCK ABSORBER BY DRILLING 1 A 2 3MM 0 08 O L2IN A HOLE THROUGH GAS CHAMBER WALL AT A POINT 25 30MM 1 0 1 2 IN FROM BOTTOM END OF GAS CHAMBER BE SURE TO WEAR EYE PROTECTION TO PREVENT EYE DAMAGE FROM ESCAPING GAS OR METAL CHIPS 5 6 1 Removal 0 1 place the ATV on a level place 02 elevate the rear wheel by placing a stand under frame 0...

Page 139: ...138 ...

Page 140: ...07 06 remove the L side washer 2 oil seal 3 Fig 5 107 07 remove the R and L inner collars 4 spacer 5 Fig 5 107 08 remove the L thrust cover protector 6 Fig 5 107 09 inspect the swing arm set 7 for any crack bend damage replace Fig 5 107 10 inspect the pivot shaft 1 by roll the axle on a flat surface on any bends replace Be sure do not try to straighten a bend axles which will cause a weak pivot sh...

Page 141: ...140 ...

Page 142: ...wing arm pivot shaft nut torque 8 5 kg m 03 check swing arm side play 04 check swing arm vertical movement 05 lubricate shock absorber bushings 1 Fig 5 121 5 122 torque 2 5 kg m 06 install new cotter pin 07 install chain tensioner 08 install rear axle hub with rear axle 09 install chain guide and chain assembly 10 install under guard and caliper 11 install rear wheel 12 adjust drive chain slack re...

Page 143: ...142 ...

Page 144: ...e rear wheels by placing suitable stand under frame 06 remove the L rear wheel 1 07 remove the under guard 1 Fig 5 116 08 loosen rear ales hub upper nut 1 and then lower hub nut 2 Fig 5 117 09 loosen chain tensioner adjusters 3 Fig 5 117 10 remove clip 1 plate 2 master link 3 and drive chain 4 Fig 5 118 11 remove drive sprocket Fig 5 114 12 remove chain guide Fig 5 116 13 remove chain guide roller...

Page 145: ...144 ...

Page 146: ...5 125A 01 straighten the lock washer 1 tabs and remove the driven sprocket 2 02 install a new driven sprocket and lock washers torque 2 4 kg m 03 bend the lock washer tabs along the nut flats 5 7 4 Installation reverse the 5 7 1 procedure and follows points as Fig 5 121 01 lubricate Molybdenum disulfide grease inner surface collar 02 tighten chain guide roller bolts torque 0 9 kg m 03 install driv...

Page 147: ...146 ...

Page 148: ...ng inspection open circuit voltage 4 Charging 5 Performance test 6 Limit voltage test 7 A C Generator removal and inspection 8 Regulator Rectifier 6 04 STARTING SYSTEM NOTE SERVICE INFORMATION NOTE TROUBLE SHOOTING Q A 1 Starter motor removal 2 Disassembly and inspection 3 Starter motor housing continuity check 4 Brush inspection 5 Assembly 6 Starter relay inspection 7 Starter motor installation 6...

Page 149: ...AL ELECTRIC SYSTEM BRIEFING 01 neutral light 03 fuse 15A 250V 05 earth cable 07 plug cap 09 main switch 11 starter relay 02 wire harness 04 battery YUASA YTX7A BS 06 ignition coil 08 rectifier regulator 10 C D I ...

Page 150: ...ector has a lock lock it at the correct position Be checked if there is any loose wire Fig 6 05 06 Before connecting a terminal check for damaged terminal cover or loose negative terminal Fig 6 06 07 insert the terminal completely Check the terminal cover for proper coverage Do not make the terminal cover opening face up Fig 6 07 08 Secure wire harnesses to the frame with their respective wire ban...

Page 151: ...150 ...

Page 152: ...vers are used to protect the wire harnesses they shall be installed securely Fig 6 16 17 Do not break the sheath of the wire If a wire or harness has a broken sheath it can be repaired by wrapping it with a protective tape or replacing it 18 After routing check that the wire harnesses are not twisted or kinked Fig 6 17 19 wire harnesses routed along the handlebar should not be pulled tight have ex...

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 155: ...rimary side Pulse coil max Voltage Exciter coil max voltage ITEM Standard type Hot type Cold type F mark 15 2 or 1 400 rpm Primary coil Secondary with plug cap Coil with plug cap resistance 20c resistance 20c DR 8EA NGK DR 7EA NGK DR 9EA NGK 0 6 0 7 mm Max aligning angle 33 2 a 3 900 rpm 0 2 0 3 Ohm 7 6 8 6 K 3 2 4 8 K 50 60 Ohm 100 120 Ohm 140 V min 1 5 V 300 rpm min 300 10 000 rpm 400 V max ...

Page 156: ...TESTING INSTRUMENTS ELECTRIC TESTER TIMING LIGHT AND TACHOMETER NOTE TROUBLESHOOTING Q A Engine stalls immediately after it starts Weak spark Improper ignition timing Faulty CDI unit 0 A No spark at plug Faulty ignition switch Poorly connected broken or shorted wire on 1 between pulse coil CDI unit and ignition coil 2 between exciter coil and CDI unit 3 between CDI unit and ignition coil 4 between...

Page 157: ...ance between the spark plug wire and the primary coil terminal Fig 6 21A Resistance 3 2 4 8 OHM without plug cap CAUTION THIS TEST IS FOR REFERENCE ONLY ACCURATE TEST SHOULD BE PERFORMED WITH A CDI TESTER 03 measure the spark plug cap s resistance Remove the spark plug cap 1 and measure the spark plug s resistance Fig 6 22 6 23 Resistance 4 2 5 8 OHM 04 performance test with a CDI tester If the sp...

Page 158: ...READINGS USE ELECTRIC TESTER FOR TESTING 6 2 4 OPTTON Test with a CDI tester reference NOTE REFERENCE OF CDI TESTER OPERATE THE CDI TESTER FOLLOWING THE MANUFACTURER S OPERARION MANUAL CONNECT THE SPECIAL CONNECTOR TO THE CDI COUPLER AND CDT TESTER Switch Range C D I Good C D I Faulty 1 OFF 2 P 3 EXT 4 ON1 5 ON2 if the CDI unit is faulty replace with a new one 6 2 5 Pulse Coil Inspection Fig 6 27 ...

Page 159: ...158 ...

Page 160: ...159 6 3 CHARGING SYSTEM BRIEFING 01 AC generator 03 battery YUASA YTX7A BS 02 rectifier regulator ...

Page 161: ...RGING BATTERY 4 WHEN INSPECTING THE A C GENERATOR USE AN ELECTRIC TESTER 5 ROUTE THE CHARGING SYSTEM WIRES PROPERLY TO AVOID SHORTED WIRE DUE TO WIRES BEING TWISTED OR KINKED 6 TORQUE VALUE 1 A C GENERATOR STARTER 0 8 1 2 KG M 2 A C GENERATOR ROTOR 5 5 6 5 KG RO 7 SPECIAL TOOLS 1 FLYWHEEL HOLDER 2 FLYWHEEL PULLER 8 TESTING INSTRUMENTS ELECTRIC TESTER Battery capacity Electrolyte specific gravity C...

Page 162: ...eak battery Loose battery connect ion terminal Charging system failure Faulty regulator rectifier Q A Intermittent power Loose battery cable connection Loose charging system connection Loose lighting system connection Q A Charging system failure Loose broken or shorted wire or connector Faulty regulator rectifier Faulty A C generator ...

Page 163: ...en battery charged the terminals Full Charge 13 1V on a voltmeter Undercharged 12 3V on a voltmeter Fig 6 29A 6 3 4 Charging 01 connect the charger positive cable to the battery positive terminal 02 connect the charger negative cable to the battery negative terminal CAUTION KEEP FLAMES AND SPARKS AWAY FROM A CHARGING BATTERY TURN THE POWER ON OFF AT THE CHARGER NOT AT THE BATTERY TERMINALS 10 PREV...

Page 164: ...ge 14 7 0 4V use a tachometer for operation 6 3 7 A C Generator removal and inspection Fig 6 30 01 disconnect the A C generator s wires 02 measure the resistance wires Resistance 0 2 0 3 OHM CAUTION DO NOT CONNECT THE A C GENERATOR S WIRES TO GROUND 6 3 8 Regulator Rectifier Fig 6 31 6 32 6 33 01 remove the front cover 02 remove the regulator rectifier screw 1 and disconnect the regulator rectifie...

Page 165: ...164 ...

Page 166: ...165 6 4 STARTING SYSTEM BRIEFING 01 starter motor 03 start button 02 starter relay ...

Page 167: ...E 1 STARTER MOTOR BOLT 0 3 0 4 KG M 2 STARTER CLUTCH LOOK NUT 1 2 KG M 4 SPECIAL TOOLS 1 FLYWHEEL HOLDER 2 FLYWHEEL PULLER 3 COMMON TOOLS NOTE TROUBLESHOOTING Q A Q A Starter won t turn Fuse burned out Weak battery Faulty ignition switch Faulty starter clutch Faulty starter relay Loose wire connection Faulty starter motor Q A Lack of Power Weak battery Loose wire connection Foreign matter stuck in...

Page 168: ... continuity check between individual commutator segment and armature shaft There should be no continuity 6 4 3 Starter motor housing continuity check Fig 6 39 01 Check and make sure that there is no continuity between the wire terminal and the brushes replace if necessary 6 4 4 Brush inspection Fig 6 40 01 measure the length of each brush a Service Limit 8 5mm replace if below 02 check for continu...

Page 169: ...168 ...

Page 170: ...arter button 03 The starter relay is normal to hear a clicking sound If there is no clicking sound Fig 6 41 1 Inspect the starter real voltage 2 Inspect the starter relay ground circuit 3 Check for continuity between the starter relay wires Fig 6 42 04 Connect the starter relay wires to a 12V battery Fig 6 42A 05 Connect the starter motor terminals to an electric tester and check for continuity be...

Page 171: ...170 ...

Page 172: ...171 6 5 LIGHTS INSTRUMENTS SWITCHES BRIEFING 01 head light 03 neutral light 05 engine stop switch 02 main switch 04 taillight 06 Hi Lo beam switch ...

Page 173: ...ic tester also contains a voltmeter which can be used to measure the voltage 5 Different bulbs have different specifications When replacing use a new bulb of the same specification 6 The continuity check can be made without removing the switch from vehicle NOTE TROUBLESHOOTING Q A Q A Light does not come on Burnt bulb Faulty ignition or light switch Fuse burned out Dead battery or loose battery wi...

Page 174: ...hts AC generator wire Fig 6 47 06 removal the stop taillight Fig 6 48 07 replace the bulb Fig 6 49 be follows bulb specification 08 check the stop taillight Fig 6 50 NOTE IN THE NEUTRAL POSITION THE GREEN INDICATOR LIGHT WILL GO ON AND THE IGNITION SWITCH SHOULD BE AT ON 1 OR ON 2 POSITION NOTE OPTION THE SCOP LIGHT L R SINGLE LIGHT FLASHER ARE THE DEVICES FOR CERTAIN AREA REGULATION DETAILS REFER...

Page 175: ...174 ...

Page 176: ...switches 1 Fig 6 54 01 check the start button 2 Fig 6 55 02 check the engine stop switch 3 Fig 6 56 03 check the Hi Lo beam switch 4 Fig 6 57 NOTE LO POSITION IS FOR LOW BEAM AND FCAILLIGHT HI POSITION IS FOR HIGH BEAM AND TAILLIGHT CAUTION DO NOT PUSH STARTER BUTTON MORE THAN FOUR SECONDS EACH TIME WHICH WILL CAUSE THE STARTER OVERHEAT AND DAMAGE THE STARTER DURING ENGINE RUNNING DO NOT PRESS STA...

Page 177: ...176 ...

Page 178: ...CH 5 IGN COIL 6 SPARK PLUG 7 STARTER RELAY 8 FUSH 9 RECT REGU 10 BATTERY 11 STARTER 12 MAGNETO 13 C D I UNIT 14 TAIL LIGHT B BLACK L BLUE G GREEN Y YELLOW R RED W WHITE P PINK BR BROWN L W BLUE WHITE G W GREEN WHITE B R BLACK RED Y R YELLOW RED B Y BLACK YELLOW B W BLACK WHITE LG R LIGHT GREEN RED ...

Page 179: ... engine lacks power 7 4 Poor performance at high speed 7 5 Poor charging battery over discharge or overcharge 7 6 Spark plug has no function 7 7 F or R Brake Performance Poorly 7 8 Shock absorber Malfunction 7 9 Instable Handling NOTE STANDARD MOTOR CORP IS CONTINUALLY STRIVING TO IMPROVE BY TAKING MODIFICATION OR SIGNIFICANT CHANGES ON ALL MODELS ALL NECESSARY FURTHER INFORMATION WILL BE AVAILABL...

Page 180: ...containing water of foreign material B Fuel does reach carburettor refer 7 1 2 7 1 2 Remove the spark plug and install it into spark plug cap to test spark by connecting it to the engine ground A Weak or no spark 1 Faulty spark plug 2 Fouled spark plug 3 Faulty GDI unit 4 Faulty pulse coil 5 Faulty exciter coil 6 Faulty ignition switch 7 Broken or shorted ignition coil B Good spark refer to 7 1 3 ...

Page 181: ...air cleaner B Dry spark plug 7 2 POOR PERFORMANCE ESPECIALLY AT LOW AND IDLE SPEED 7 2 1 Check ignition timing A Incorrect 1 Faulty GDI unit 2 Faulty pulse coil B Correct refer to 7 2 2 7 2 2 Check carburettor air screw adjustment A Incorrectly adjusted 1 Mixture too lean Turn screw in 2 Mixture too rich Turn screw out B Correctly adjusted refer to 7 2 3 7 2 3 Check carburettor gasket for air leak...

Page 182: ...tor 2 Damaged or cracked vacuum tube 3 Clogged air vent hole B Good 7 3 POOR PERFORMANCE ENGINE LACKS POWER 7 3 1 Start the engine and accelerate lightly A Engine speed does not increase sufficiently 1 Clogged air cleaner 2 Restricted fuel flow 3 Clogged fuel tank cap breather hole 4 Clogged exhaust muffler 5 Carburettor fuel level too low 6 Clogged carburettor high speed fuel passage B Engine spe...

Page 183: ...ead gasket 4 Incorrect valve timing B Normal refer to 7 3 5 7 3 5 Checking carburettor for clogging A Clogged 1 Clean and unclog B Not clogged refer to 7 3 6 7 3 6 Remove the spark plug for check A Fouled or discolored 1 Fouled spark plug 2 Incorrect valve timing B Not fouled or discolored refer to 7 3 7 7 3 7 Check crankcase for excessive or dirty engine oil A Excessive oil 1 Oil level too high 2...

Page 184: ...Worn cylinder and piston 2 Mixture too lean 3 Poor quality fuel 4 Excessive carbon build up in combustion chamber 5 Ignition timing too advanced B Not overheating refer to 7 3 10 7 3 10 Accelerate or run at high speed A Engine knocks 1 Excessive carbon build up in combustion chamber 2 Poor quality fuel 3 Slipping clutch 4 Mixture too lean 5 ignition timing too advanced B Engine does not knock ...

Page 185: ...r to 7 4 3 7 4 3 Check fuel filter for fuel supply A Abnormal 1 No fuel in fuel tank 2 Clogged fuel filter 3 Clogged fuel tank cap breather hole B Normal refer to 7 4 4 7 4 4 Check carburettor for clogged jets A Clogged 1 Clean B Not Clogged refer to 7 4 5 7 4 5 Check valve timing adjustment A Incorrect 1 Cam sprocket aligning marks not aligned B Correct refer to 7 4 6 7 4 6 Check valve return spr...

Page 186: ...ocket red wire to and frame body to Measure the voltage between them A Battery has no voltage 1 Broken red wire B Battery has voltage 7 5 4 Check the regulator rectifier coupler for loose connection A Abnormal 1 Faulty regulator rectifier 2 Poorly connected coupler B Normal 1 Faulty A C Generator 7 5 5 Connect the regulator rectifier black wire to and frame body to Measure the voltage between them...

Page 187: ...ly connected coupler Normal refer to 7 6 4 7 6 4 Check for continuity and measure the resistance between the CDI unit wire coupler terminals A Abnormal refer to 7 6 4 B Normal refer to 7 6 5 Be Checked related parts A Abnormal 1 Faulty ignition switch 2 Faulty exciter coil 3 Faulty pulse coil 4 Faulty ignition coil B Normal 1 Broken wire harness 2 Loose coupler connection 7 6 5 Check the CDI unit ...

Page 188: ...spring or 7 oily or grassy brake shoe or 8 oily or grassy brake drum or 9 brake cable broken 7 7 2 R brake poor Check 1 brake pad wear out or 2 brake disc bent or wear out or 3 fatigue damage return spring or 4 damage ratchet or 5 oily or grassy brake disc or 6 oily or grassy brake pad or 7 brake horse broken or 8 brake fluid leaking 7 8 SHOCK ABSORBER MALFUNCTION Check 1 bent or damaged damper ro...

Page 189: ...ide 2 incorrect tire pressure 3 unevenly worn tires 7 9 4 check wheels for any 1 incorrect wheel balance 2 deformed wheel 3 loose bearing 4 bent or loose wheel axle 5 excessive wheel run out 7 9 5 check frame for any 1 twisted 2 damaged frame 3 improperly installed bearing race 7 9 6 check swing arm for any 1 worn bearing or bush 2 bent or damaged 7 9 7 check rear shock absorber 1 fatigued spring ...

Page 190: ...arter operation check fuel hose routing and ensure that clamps are in proper position check engine oil 4 stroke level check for proper routing and free play on throttle brake clutch check operation check operation free play fluid level check parking brake operation Drive chain check1free play check tire pressure and wheel run out check wheel nut torque check turning operation check operation check...

Page 191: ... Corp Sports Quads 125 150 170 250cc SK 125 150 170 250cc double light STGs l25 l50 l70 250cc double light separate front fender BL 125 150 170 250cc single light STGb l25 150 l70 250cc single light separate front fender ...

Page 192: ...ONLY DIFFERENCE ON BLAST BL MODEL IS FRONT LAMP COVER AND FRONT LAMP SET WHERE WITH THE E MARK LAMP REGULATION 01 Remove the front cover as introduction 02 Put new bulb and secure it in place with the bulb holder 03 Reinstall the headlight back see the picture attachment procedure for page 4 4 NOTE Service Information for Fuel System and Carburetion Main Jet 150 cc en 102 170 cc en 108 Slow Jet 15...

Page 193: ...NT TIRE PRESSURE SPECIFICATION THAT SHOULD BE PROVIDED BY EACH AREA IMPORTER ONLY CAUTION THE ON ROAD ATVS WILL HAVE SOME DIFFERENT IDENTIFICATION NUMBER ID PLATE OR WARNING LABEL CAUTION THE ON ROAD ATVS WILL HAVE SOME DIFFERENT PAPER OF DOCUMENTS WITH THE VEHICLE THAT SHOULD BE PROVIDED BY EACH AREA IMPORTER ONLY CAUTION THE ON ROAD ATVS MAYBE ALLOW MORE THAN SINGLE RIDER HOWEVER IT IS NOT RECOM...

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