Eton VECTOR 250 - SERVICE Page 48 Service Manual Download | Manualshive

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48

Install cam chain on to sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket 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).

4 bolts

2 bolts

Timing mark

3 bolts

Tensioner adjustment bolt

Thermostat bolts

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Summary of Contents for VECTOR 250 - SERVICE

Page 1: ...ylinder HEAD Cylinder Valve 34 7 Cylinder Piston 50 8 V Belt driving system 58 9 Transmission 72 10 ACG Start one way clutch 84 11 Crankcase Crank 93 12 Cooling System 101 CHASSIS 13 Steering Suspensi...

Page 2: ...d 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 di...

Page 3: ...ll Length 1815mm Overall Width 1062mm Overall Height 1130mm Wheel base 1193mm Ground Clearance 150mm Dry Weight 225kg Fuel Tank Capacity 12L SUSPENSION Front Double A Arm Adjustable Shocks Rear Swing...

Page 4: ...RIAL 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 Side Frame serial number Engine serial number Frame seria...

Page 5: ...aft nut 50 N m 36 9 lbf ft Steering shaft holder bolt 33 N m 24 lbf ft Wheel rim bolt 18 N m 13 3 lbf ft Tie rod lock nut 35 N m 25 8 lbf ft King pin nut 40 N m 29 lbf ft Handlebar lower holder nut 40...

Page 6: ...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...

Page 7: ...for every 1 month 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 Rep...

Page 8: ...ber cap of the adjuster off the throttle Housing loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttl...

Page 9: ...nd to prevent crosses threading Tighten the spark plug with 12 19 N m 2 8 IDLE SPEED Connect an engine speed meter Warm up the engine 10 minutes are enough Turn the idle speed adjust screw on the carb...

Page 10: ...damaged Inspect the sprocket teeth if it is excessive wearing or damaging please replace it 2 10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage Replace or rep...

Page 11: ...t brake level is under the driver seat and rear brake component Because the brake system is different ones need to adjust it to reach a proper brake level 2 11 WHEELS AND TIRES Inspect the tire surfac...

Page 12: ...ering shaft holder and check the steering shaft bushing for wears or damage If the bushing is worn or damaged please change a new one Grease the steering shaft bushing and install the parts in the rev...

Page 13: ...e center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5 10mm If the toe in is out of standard adjust it by changing the length of th...

Page 14: ...t 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 rem...

Page 15: ...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 Hanger bo...

Page 16: ...roubleshooting 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...

Page 17: ...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...

Page 18: ...fter 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...

Page 19: ...p 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 oi...

Page 20: ...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 s...

Page 21: ...nd 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 sta...

Page 22: ...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 Star...

Page 23: ...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 F...

Page 24: ...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 disas...

Page 25: ...alfunction 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 in...

Page 26: ...ove 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...

Page 27: ...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 Assem...

Page 28: ...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...

Page 29: ...mage 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 incr...

Page 30: ...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...

Page 31: ...turns 1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1700 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key...

Page 32: ...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 fu...

Page 33: ...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 h...

Page 34: ...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...

Page 35: ...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...

Page 36: ...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...

Page 37: ...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...

Page 38: ...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 S...

Page 39: ...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...

Page 40: ...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 Ser...

Page 41: ...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 va...

Page 42: ...nce 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...

Page 43: ...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...

Page 44: ...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 co...

Page 45: ...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...

Page 46: ...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 sp...

Page 47: ...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 hea...

Page 48: ...sprocket 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...

Page 49: ...lign the timing mark on the cam sprocket with that of cylinder head piston is at TDC position Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clea...

Page 50: ...echanism 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 7 1 Mechanism Diagram...

Page 51: ...10 0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 16 970 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...

Page 52: ...nder 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 remov...

Page 53: ...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 o...

Page 54: ...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 distanc...

Page 55: ...carefully Place 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 th...

Page 56: ...6 Piston Installation 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 cli...

Page 57: ...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...

Page 58: ...TEM 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...

Page 59: ...990 40 930 ID of driven face 41 000 41 050 41 070 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...

Page 60: ...then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Clamp strips 9 b...

Page 61: ...Left crankcase cover inspection Release the 2 clamp strips of left crankcase cover ducts and then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Clamp strips 9 bol...

Page 62: ...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 Inspecti...

Page 63: ...ive 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...

Page 64: ...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...

Page 65: ...he outer diameter of movable drive face boss and replace it if it exceed service limit Service limit mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Servi...

Page 66: ...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...

Page 67: ...service 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 mov...

Page 68: ...the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing...

Page 69: ...n Replace it 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 bloc...

Page 70: ...de 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 for...

Page 71: ...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 nu...

Page 72: ...ansmission cover Final shaft Drive sprocket Reverse shaft Counter shaft Drive shaft Bearing 6304 Bearing 6205LLU Bearing 6204 Bearing 6305 Change switch Gasket Gear oil fill bolt 3 5 4 5kgf m Drive sh...

Page 73: ...ver 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...

Page 74: ...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...

Page 75: ...catch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft Shift drum Shift spindle Shift fork shaft and fork 9 bolt...

Page 76: ...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 beari...

Page 77: ...ection 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 wea...

Page 78: ...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...

Page 79: ...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 dri...

Page 80: ...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...

Page 81: ...ring puller to install 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 bearin...

Page 82: ...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 sha...

Page 83: ...tall 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...

Page 84: ...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 Crankc...

Page 85: ...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...

Page 86: ...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...

Page 87: ...g 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 flywh...

Page 88: ...ing 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 Li...

Page 89: ...gear 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 an...

Page 90: ...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 fa...

Page 91: ...e 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 R...

Page 92: ...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 co...

Page 93: ...93 11 CRANKCASE CRANK 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 94: ...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 Ve...

Page 95: ...emove 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 rem...

Page 96: ...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 f...

Page 97: ...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 a...

Page 98: ...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...

Page 99: ...and 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 Dow...

Page 100: ...ankcase 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 bol...

Page 101: ...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 inl...

Page 102: ...r 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 roto...

Page 103: ...mo 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 coo...

Page 104: ...y 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 c...

Page 105: ...pletely 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 Reinsta...

Page 106: ...levating 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...

Page 107: ...tor 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...

Page 108: ...firms 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...

Page 109: ...r 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...

Page 110: ...r 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 righ...

Page 111: ...ghten 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 o...

Page 112: ...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 c...

Page 113: ...113 13 STEERING AND SUSPENSION 13 1 PARTS DRAWING 13 2 TROUBLESHOOTING 13 3 HANDLENAR 13 4 THROTTLE HOUSING 13 5 STEERING SYSTEM 13 1 PARTS DRAWING STEERING...

Page 114: ...114 Handle bar...

Page 115: ...y 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 fro...

Page 116: ...ndle 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...

Page 117: ...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 th...

Page 118: ...ct throttle cable from the throttle arm and remove from the throttle housing NOTE Assembly is in the reverse order of disassembly 13 5 STEERING SYSTEM Removal of Kingpin and Tie rod Remove the front w...

Page 119: ...t 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 Steering Shaft Holder Inspecti...

Page 120: ...120 Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 N m 37 lbf ft...

Page 121: ...121 14 FRONT WHEEL AND BRAKE SYSTEM 14 1 PARTS DRAWING 14 2 TROUBLESHOOTING 14 3 FRONT WHEEL 14 4 HYDRAULIC BRAKE 14 5 SUSPENSION SYSTEM 14 1 PARTS DRAWING FRONT WHEEL FRONT BEAKE...

Page 122: ...ncorrectly 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 fr...

Page 123: ...placing a jack or other support under the frame Remove the front wheel nuts washer and wheels Please follow the next three steps of right pictures Loosen fours nuts as shown in picutre Then take the w...

Page 124: ...hub apart Before loosening castle nut you have to remove cotter pin Then using the power tools to take the screw out from brake stopping plate You can take the brake disc off When change brake shoe we...

Page 125: ...BRAKE 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...

Page 126: ...ion 1 You can raise the all ATV body up by using a repair platform The four wheel are in the free position you can easy to adjust the suspension 2 If you do not have any repair platform just using spe...

Page 127: ...127 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 AXLE HOLDER 15 1 PARTS DRAWING REAR WHEEL REAR Wheel Axel...

Page 128: ...128 REAR BRAKE...

Page 129: ...bearings 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 b...

Page 130: ...as shown in picture Loosen bolts and remove 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...

Page 131: ...n take all brake shoe out the hub There are two kind of brake linings as shown in picture TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open the cover Loosen the bolt and drain the used oil...

Page 132: ...ke 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 ai...

Page 133: ...ollowing pictures are going to teach you how to Install the swingarm 1 Put the swingarm at proper position as shown in picture Two hanger bolts will be used to hold the swingarm at right and left side...

Page 134: ...134 3 Screw another hanger bolt on the left side as shown in picture But do not tighten it Let the cross section of bolt and cross section of hole in the same plane 4 Tighten a nut Hanger bolt...

Page 135: ...nsion 1 You can raise the all ATV body up by using a repair platform The four wheel are in the free position you can easy to adjust the suspension 2 If you do not have any repair platform just using s...

Page 136: ...136 16 FENDERS AND EXHAUST PIPE 16 1 FENDRES 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 137: ...the rear rack 1 Open the seat 2 Loosen the four bolts which connect the front fender and rear fender 3 Loosen the two bolts which connect the rear tender and frame these two bolts just below the seat...

Page 138: ...138 There are two screws on the top of seat compartment Please remove them Next there are two screws on side of the tail Finally you must remove the bolts on the footrest Bolts Screw Bolts...

Page 139: ...it 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...

Page 140: ...seat rear fender and footrest plate before you take off the exhaust pipe Loosen the two exhaust pipe bolts that fixed on the engine Warning DO NOT service the exhaust pipe while they are hot Remove t...

Page 141: ...141 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 Bolt...

Page 142: ...ug 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...

Page 143: ...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 drin...

Page 144: ...ot work a period of time the voltage may reduce and may not provide enough power to starter motor If a battery is in a good condition but engine can not be start Please go back to service TROUBLESHOOT...

Page 145: ...n the connector in order to replace an electrical bulb conveniently and safely The steps show on pictures Installation is in the reverse order of disassembly Front Direction lights remove To replace t...

Page 146: ...e 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...

Page 147: ...o 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 Plea...

Page 148: ...or 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...

Page 149: ...149...

Page 150: ...150 12 8 WIRING DIAGRAM...

Page 151: ...nition 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...

Page 152: ...alternator 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...

Page 153: ...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 pi...

Page 154: ...mproperly 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 I...

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