Explorer Patriot 430 Service Manual Download

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Measure the outer diameter of piston pin.

Service Limit: 16.96 mm

Measure the inner diameter of connecting rod
small end.

Service Limit: 20.065mm

Measure the inner diameter of piston pin hole.

Service Limit: 20.02 mm

Calculate clearance between piston pin and
its hole.

Service Limit: 0.02 mm

Measure piston outer diameter

Caution

The measurement position is 8 mm distance
from piston bottom side, and 90° to piston pin.

Service limit

᧶

85.850 mm

Compare measured value with service limit to
calculate the clearance between piston and
cylinder.

5. Piston Ring Installation

Summary of Contents for Patriot 430

Page 1: ...SERVICE MANUAL PATRIOT 430...

Page 2: ...tions and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV EXP PATRIOT 430 ATV...

Page 3: ...ection and adjustment Chapter 1 includes general information and trouble diagnosis Chapter 2 includes service maintenance information and special tools manual Chapter 3 11 includes engine and driving...

Page 4: ...3 SERIAL NUMBER Frame number Engine number Home page Contents...

Page 5: ...7 8 CYLINDER PISTON 7 8 1 8 14 V BELT DRIVING SYSTEM 8 9 1 9 12 FINAL DRIVING MECHANISM 9 10 1 10 10 ALTERNATOR STARTINGCLUTCH 10 11 1 11 8 CRANKSHAFT CRANKCASE 11 12 1 12 12 COOLING SYSTEM 12 13 1 1...

Page 6: ...aution Means that equipment damages may result if procedures are not followed Engine oil Limits to use SAE 10W 40 API SG class oil Warranty will not cover the damage that caused by not apply with the...

Page 7: ...with soap and water right after contacting Keep the used oil beyond reach of children Hot components Caution Components of the engine and exhaust system can become extremely hot after engine running T...

Page 8: ...ying Caution Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system Brake fluid Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the p...

Page 9: ...ols Metric bolts nuts and screws are not interchangeable with the English system using wrong tools and fasteners may damage this vehicle Clean the outside of the parts or the cover before removing it...

Page 10: ...from inside out Loosen the small fasteners first If the bigger ones are loosen first small fasteners may receive too much stress Store complex components such as transmission parts in the proper asse...

Page 11: ...mension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 t...

Page 12: ...ends for tightening the clamps Connector Rubber and plastic boots should be properly reinstalled to the original correct positions as designed The tool should be pressed against two inner and outer b...

Page 13: ...on for installed parts is in correct and properly Make sure service safety for each other when conducting by two persons Do not let parts fall down Before battery removal operation it has to remove th...

Page 14: ...e connected firstly And the two posts of battery have to be greased after connected the cables Make sure that the battery post caps are located in properly after the battery posts had been serviced If...

Page 15: ...acing up Do not pull the wires as removing a connector or wires Hold the connector body Make sure if the connector pins are bent extruded or loosen Insert the connector completely If there are two loc...

Page 16: ...es and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses Wire band and wire h...

Page 17: ...ing components as routing the harness Keep wire harnesses far away from the hot parts Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws Route h...

Page 18: ...oughly clean the surface where tape is to be applied Secure the rubber boot firmly as applying it on wire harness Never use wires or harnesses which insulation has been broken Wrap electrical tape aro...

Page 19: ...ar should not be pulled too tight or have excessive slack be rubbed against or interfere with adjacent or surrounding parts in all steering position Before operating a test instrument operator should...

Page 20: ...19 With sand paper to clean rust on connector pins terminals if found And then conduct connection operation later...

Page 21: ...otal Weight Rear 246kg Weight Dimension Total 476 kg Secondary Reduction Gear Shaft Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reductio...

Page 22: ...pet adjustment screw nut Spark plug Tensioner lifter bolt Carburetor insulator bolt Oil pump screw Water pump impeller Engine left cover bolt Engine oil draining bolt Engine oil strainer cap Mission d...

Page 23: ...stle nut Rear wheel nut Engine hanger nut Drive gear bolt Driven gear nut Front Rear suspension arm bolt Front Rear suspension arm nut Brake lever bolt Brake hose bolt Brake caliper bolt Air bleed val...

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Page 28: ...27 7 Lubrication Points...

Page 29: ...28 2 2 GREASE GREASE Drive shaft Acceleration cable Front rear lever pivot Speedometer gear Wheel bearing...

Page 30: ...arburetor Idle Speed Adjustment 2 7 9 Ignition System 2 8 10 Cylinder Compression Pressure 2 8 11 Drive Belt 2 9 12 Brake System Disk Brake 2 10 13 Brake Light Switch Starting Inhibitor 2 11 14 Headli...

Page 31: ...oolant Reservoir upper 800 c c Clearance of throttle valve 1 3 mm Type NGK CR7E Spark plug Gap 0 7 0 8 mm F Mark in idling speed BTDC 20 1500 rpm Full timing advanced BTDC 51 6200 rpm Idling speed 180...

Page 32: ...el hoses and connectors I I 23 Valve clearance I I 24 Lines connections in cooling I I A 25 Coolant I I R Code I Inspection cleaning and adjustment R Replacement C cleaning replaced if necessary L Lub...

Page 33: ...ion is not smooth Measure the throttle lever free play in its flange part Remove rubber boot loosen fixing nut and then adjust it by turning the adjustment screw Tighten the fixing nut and check accel...

Page 34: ...hole Remove spark plug Measure spark plug gap Spark plug gap 0 8 mm Carefully bend ground electrode of the plug to adjust the gap if necessary Hold spark plug washer and install the spark plug by scr...

Page 35: ...on the camshaft sprocket aligns with cylinder head mark so that 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 lo...

Page 36: ...cified idle speed 1500 100 rpm 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 va...

Page 37: ...eck CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found 10 Cylinder Compression Pressure Warm up engine Turn off the engine Remove the trunk Remove the central co...

Page 38: ...right crankcase cover vapor hose Remove 14 bolts of the engine left side cover and the cover Check if the belt is crack or worn out Replace the belt if necessary or in accord with the periodical maint...

Page 39: ...spread out if operate the lever Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents...

Page 40: ...nt refer chapter 14 Make sure the brake lining condition Replace the lining pads if the brake lining wear limitation groove close to the brake disc Caution Do not operate the brake lever after the cli...

Page 41: ...clutch operation If the ATV is in forward moving and shaking check clutch condition Replace it 16 Suspension Warning Do not ride the ATV with poor suspension Looseness wear or damage suspension will m...

Page 42: ...ed with nails stones or other materials Appointed tire pressure Tire pressure 5psi Off road recommended Check if front and rear tires pressure is in normal Measure tire thread depth from tire central...

Page 43: ...739 Remover PARTS NO 440651 PARTS NO 440652 PARTS NAME Bearing 924384 Remover PARTS NAME Bearing 924182 Remover PARTS NO 440653 PARTS NO 440654 PARTS NAME Bearing 924382 Remover PARTS NAME Transmissio...

Page 44: ...TS NO 440660 PARTS NAME Flywheel Remover PARTS NAME Chain Wheel 924360 Installer Washer 924718 Installer PARTS NO 440661 PARTS NO 440662 PARTS NAME Piston Rod Connecting PARTS NAME Cylinder Head Valve...

Page 45: ...4146 Holder PARTS NO 440667 PARTS NO 440668 PARTS NAME Cylinder Head Valve and Spring PARTS NAME Universal Joint Head Installer Remover 924646 Installer PARTS NO 440669 PARTS NO 440670 PARTS NAME Chai...

Page 46: ...enance operation for the engine oil pump and gear oil replacement Specifications Engine oil quantityDisassembly 3500 c c Filter change 3200 c c Change 3000 c c Oil viscosity SAE 10W 40 Torque value To...

Page 47: ...Oil leaking Valve guide or seat worn out Piston ring worn out Low oil pressure Low engine oil level Clogged in strainer circuits or pipes Oil pump damage Dirty oil No oil change in periodical Cylinde...

Page 48: ...olt Torquevalue 2 4kgf m 5 Engine Oil Strainer Clean Drain engine oil out Remove oil strainer cap Clean oil strainer Check if O ring can be re used Install oil strainer cap Torque value 1 0 1 2 kgf m...

Page 49: ...t hand threads Remove the snap ring Remove the washer Remove the oil pump driver gear Remove the pin Remove the washer Make sure that pump shaft can be rotated freely Remove 3 screws on the oil pump a...

Page 50: ...ner 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 drivin...

Page 51: ...Installation Install the oil pump and then tighten 3 screws Torque 1 0 kgf m Make sure that oil pump shaft can be rotated freely Install the washer Install the pin Install the oil driven gear Install...

Page 52: ...ttle Valve 4 6 7 Float Chamber 4 7 8 Adjustment of Idle Speed 4 9 9 Fuel Tank 4 10 10 Air Cleaner 4 11 1 Mechanism Diagram 4H 2 Precautions in Operation General Information Warning Gasoline is a low i...

Page 53: ...embly There is a drain screw in the float chamber for draining residual gasoline Do not disassemble air cut valve arbitrarily Specification ITEM BSR33 Carburetor diameter 33mm I D number 33_77 Fuel le...

Page 54: ...ed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insuff...

Page 55: ...e carburetor clamp screws Loosen the carburetor side cap 3 screws Remove cap Disconnect the throttle cable Remove the starter cable Remove the carburetor Installation Install in reverse order of remov...

Page 56: ...rews spring and valve 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...

Page 57: ...56 6 Throttle Valve Disassembly Remove carburetor top comp Remove the spring holder needle set jet and piston valve Remove the cable adjuster assy 2 screws Cable adjuster assy...

Page 58: ...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 fue...

Page 59: ...holder needle jet slow jet and air adjustment screw Caution Be care not to damage jets and air adjustment screw Before removing adjustment screw turn it all the way down and note the number of turns...

Page 60: ...rns Standard turns 3 turns 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 Pres...

Page 61: ...lation 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 upper cover and center c...

Page 62: ...ks 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...

Page 63: ...be serviced as engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutch Crankcase RH cover Clutch h...

Page 64: ...Remove battery negative post Remove battery positive post Remove side cover and the footrest refer chapter 13 Remove starter motor wire Remove the spark plug cap Disconnect A C Generator wire coupler...

Page 65: ...64 Remove 2 nuts and then remove exhaust pipe Remove 2 bolts and then remove the exhaust muffler Remove the fuel hose Remove the air cleaner 2 Nuts Fuel hose Air cleaner...

Page 66: ...65 Remove the carburetor Remove the gearshift lever Remove the gearshift mud Remove the speedometer cable...

Page 67: ...e the front and rear tube Remove coolant inlet hoses Remove coolant outlet hose and by pass pipe Remove 2 bolts and remove the front differential plate 2 bolts Plate Water hoses clamp Outlet hose By p...

Page 68: ...67 3 Engine installation Remove the front differential 2 bolts Remove the rear differential 3 bolts Remove the engine mounting bolts and nuts Remove the engine from the left side 3 bolts 3 screws...

Page 69: ...erse order of engine removal Torque value 70 N m Caution The engine mounting nuts are self locking once the nut was been removed it is no longer of any use Be sure to use new nuts For every time engin...

Page 70: ...differential and rear gear box flange coupling bolt 83 N m Install the new gasket Install muffler Pay attention don t damage the connector Tighten the exhaust pipe nuts specified torque 25 N m Connec...

Page 71: ...70 Muffler mounting bolt 12 N m Tighten the muffler bolts specified torque 29 N m...

Page 72: ...1 4 Engine Disassembly Remove starter motor wire Remove the spark plug cap Remove the thermostat Remove the spring bolt and remove the cam chain pensioner adjuster assy Remove the engine oil pipe bolt...

Page 73: ...72 Remove the recoil starter Remove the valve timing check plug Turn the crankshaft and let the T D C line on The rotor with index mark...

Page 74: ...leshooting 6 3 4 Cylinder Head Removal 6 4 5 Cylinder Head Inspection 6 7 6 Valve Stem Replacement 6 10 7 Valve Seat Inspection and Service 6 11 8 Cylinder Head Reassembly 6 13 9 Cylinder Head Install...

Page 75: ...tions in Operation General Information This chapter is contained maintenance and service for cylinder head valve and camshaft as well as rocker arm Cylinder head service can be carried out when engine...

Page 76: ...length of valve Inner 36 32 5 spring outer 39 5 36 0 Valve seat width 1 600 Intake 0 10 s 0 02mm Valve clearance Exhaust 0 15 s 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cove...

Page 77: ...e Improper valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure T...

Page 78: ...move 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 spark plug Re...

Page 79: ...le cam 6 bolt Remove cam sprocket bolts and then remove The sprocket by prying chain out Remove cam chain tensioner and hole bolt Remove cam shafts Remove Rocker arm and cam shaft puller 3 bolts 6 bol...

Page 80: ...linder and cylinder head 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 Cauti...

Page 81: ...Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Servic...

Page 82: ...mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10mm Valve spring free length Measure the free length of intake and exhaust val...

Page 83: ...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 r...

Page 84: ...hen pressing in the new valve guide cylinder head still have to be kept in100 150 Adjust the valve guide driver and let valve guide height within 13 mm Press in new valve guide from rocker arm side To...

Page 85: ...e with a new one if valve 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 wide Service li...

Page 86: ...he valve through valve guide until the valve contacting with valve 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 s...

Page 87: ...ring should face down to combustion chamber Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder...

Page 88: ...r foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 bolts on the cylinder head upper side and then tighten 4 cylinder head nuts to the specified torque 2 M6 2 M8 Cyl...

Page 89: ...k washer so that it is covering the locating pin Bend up the washer tongue positively to lock bolts Align the line A on the generator rotor with the Index mark B on the crankcase Loosen auto tensioner...

Page 90: ...Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjust...

Page 91: ...ism Diagram 7 1 2 Precautions in Operation 7 2 3 Trouble Shooting 7 2 4 Cylinder and Piston Removal 7 3 5 Piston Ring Installation 7 6 6 Piston Installation 7 7 7 Cylinder Installation 7 7 1 Mechanism...

Page 92: ...der 0 04 0 058 0 120 Piston Piston ring ID of piston pin boss 20 001 20 006 20 020 OD of piston pin 19 996 20 000 19 960 Clearance between piston and pin 0 001 0 010 0 020 ID of connecting rod small e...

Page 93: ...der gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be removed...

Page 94: ...ton 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...

Page 95: ...pin hole Service Limit 20 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 8 mm distance from piston bo...

Page 96: ...ring onto piston carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings in installation All marks on the piston rings must be forwarded to up side...

Page 97: ...ly 6 Piston Installation Install piston and piston pin and place the marks on the piston top side forward to exhaust valve Install new piston pin clip Caution Do not let the opening of piston pin clip...

Page 98: ...aken 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 c...

Page 99: ...ism Diagram 7 1 2 Precautions in Operation 7 2 3 Trouble Shooting 7 2 4 Cylinder and Piston Removal 7 3 5 Piston Ring Installation 7 6 6 Piston Installation 7 7 7 Cylinder Installation 7 7 1 Mechanism...

Page 100: ...der 0 04 0 058 0 120 Piston Piston ring ID of piston pin boss 20 001 20 006 20 020 OD of piston pin 19 996 20 000 19 960 Clearance between piston and pin 0 001 0 010 0 020 ID of connecting rod small e...

Page 101: ...der gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be removed...

Page 102: ...ton 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...

Page 103: ...pin hole Service Limit 20 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 8 mm distance from piston bo...

Page 104: ...ring onto piston carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings in installation All marks on the piston rings must be forwarded to up side...

Page 105: ...ly 6 Piston Installation Install piston and piston pin and place the marks on the piston top side forward to exhaust valve Install new piston pin clip Caution Do not let the opening of piston pin clip...

Page 106: ...aken 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 c...

Page 107: ...1 Mechanism 8 1 2 Maintenance Description 8 2 3 Troubleshooting 8 2 4 Clutch Cover 8 3 5 Drive Belt 8 5 6 Drive Face 8 7 7 Clutch Outer Driven Pulley 8 10 1 Mechanism Diagram...

Page 108: ...boss 44 965 44 985 mm 40 935 mm ID of driven face 45 000 45 035 mm 45 600 mm Weight of weight roller 13 300 13 700 g 12 800 g Torque value Drive face nut 10 12kgf m Clutch outer nut 10 12 0kgf m Drive...

Page 109: ...the 2 clamp strips of clutch cover ducts and then remove the ducts Remove clutch cover 14 bolts Remove 2 dowel pin and gasket Clutch cover install Install left clutch cover in the reverse procedures...

Page 110: ...h cover Rotate bearing s Inner ring with fingers Check if bearings can be turned in smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noi...

Page 111: ...o 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 I...

Page 112: ...led the belt onto drive shaft On the drive belt another end to the movable drive face Install the clutch outer Hold the clutch outer whit universal holder and then tighten nut to specified torque valu...

Page 113: ...d then 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 Univers...

Page 114: ...er diameter of movable drive face boss and replace it if it exceed service limit Service limit 26 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Serv...

Page 115: ...ion By 2 screw Press drive belt into pulley groove and then pull the belt onto drive shaft Install movable drive face and nut Loosen the 2 screw Caution Make sure that two sides of pulley surfaces hav...

Page 116: ...pressor onto bench vise and then remove mounting nut with special service tool Release the clutch spring compressor and remove movable driven sheave and spring from driven pulley Remove seal collar fr...

Page 117: ...If both surfaces are damaged or worn If guide pin groove is damaged or worn Replace damaged or worn components Measure the outer diameter of driven face and the inner diameter of movable driven face R...

Page 118: ...n plate spring and into clutch spring compressor and press down the assembly by turning manual lever unit mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting...

Page 119: ...the driven output rear shaft and front shaft Remove the c ring from the universal joint assy Remove the driven output front shaft with a chisel Remove the joint parts Using a vise let the driven outp...

Page 120: ...with a chisel Remove the nut Remove the bearing by tapping with the hammer and tool Remove the universal joint assy Remove the parts Rear universal joint disassembly Remove the c ring from the univer...

Page 121: ...vise held the driven output rear shaft and remove the nut Unlock the nut with a chisel Remove the NTT form Driven output front shaft When reassemble with a new nut Must be replaced the new bearing and...

Page 122: ...with a chisel Using a vise held the driven output front shaft and remove the nut Remove the washer driven bevel gear and bearing Remove the parts Replace the new nut for reassemble Must be replaced th...

Page 123: ...show Insert the bearing to the joint and turning the joint If excessive play is noted must be replace the new bearing Reassemble the driven output rear shaft and front shaft In the reverse order of d...

Page 124: ...shaft Before reassembly thoroughly clean all parts with solvent Using a vise hold the bevel gear Tighten the new nut to the specified torque Stake the nut with a punch Apply gease to the bearing and s...

Page 125: ...been adjusted and checked Put the bearing rings and shaft in the crankcase Position the bearing pin to the pin grooves in the crankcase Check the gear backlash and tooth contact correctl Tooth face co...

Page 126: ...justed or checked Install the new c ring by tapping and hammer copper After reassembling the universal joint assy Check the joint assy Movement smoothly If movement have a large resistance Tapping the...

Page 127: ...ear teeth and lubricate the teeth with engine oil Tighten the drive bevel gear nut and rear out put shaft nut to the specified torque Rear output shaft nut 100 N M 10 0 kgf m Drive bevel gear nut 100...

Page 128: ...ssembling CAUTION Be sure keep the drive belt drive face and driven face away from any greasy matter Install the output shaft assembly with a plastic mallet Install the shim drive bevel gear and washe...

Page 129: ...earing into the groove of the crankcase TRANSFER GEARSHIFT Install the transfer related parts Install the spacer spring shaft and reverse idle gear Install the washer CRANKCASE Clean R and L crankcase...

Page 130: ...C G Set removal 10 3 11 Left Cover Bearing 10 3 12 Flywheel Removal 10 4 13 Starting Clutch 10 5 14 Flywheel Installation 10 7 15 A C G Set Installation 10 8 16 Left Crankcase Cover Installation 10 8...

Page 131: ...cedures and precaution items of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 29 OD of starting clutch gear 52 548 52 445 Torque Flywheel nut 10 12kgf m Starti...

Page 132: ...n and gasket 4 A C G Set Removal Remove 3 mounted screws from pulse generator and then remove it Remove 3 screws from left crankcase cover and then remove generator coil set 5 Left Cover Bearing Inspe...

Page 133: ...one bearing 16005 by bearing driver 6 Flywheel Removal Remove left crankcase cover Remove starter reduction gear and shaft Pull out flywheel with A C G flywheel puller Special tool A C G Flywheel pul...

Page 134: ...ear Service Limit ID 29 mm OD 52 54 mm Check the starting reduction gear and shaft for wear or damage Check each roller for wear or damage Install starting clutch driven gear onto one way clutch Hold...

Page 135: ...move one way clutch One way clutch Installation Install the components in the reverse procedures of removal Caution Tape a tightening tape onto the thread of hexagon bolt Torque value 3 0 3 5kgf m Sta...

Page 136: ...with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tighten flywheel nut Torque vale 10 0 12 0kgf m Special tool Universal Holder Install r...

Page 137: ...ly onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator 10 Left Crankcase Cover Installation Install dowel pin and new gasket Remove water pump cover In...

Page 138: ...Install left crankcase cover 15 screws Install the dowel pin new gasket and water pump cover onto left crankcase cover 15 bolts Water pump bolts...

Page 139: ...L CASE R CASE...

Page 140: ...l seal with the special tool Bearing installer set 440655 CAUTION Change the new oil seal to prevent oil leakage NOTE Be sure the stamped mark on the oil seal faces outside OIL SEPARATOR When installi...

Page 141: ...Install the bearing NOTE Be sure The sealed cover of the bearing must face outside Install the chuck Bearing NOTE When installing the Bearing chuck apply a small quantity of Loctite 262TM Thread lock...

Page 142: ...E BELT COVER Remove the snap ring with the snap ring pliers NOTE If any damage the bearing replace the new one Remove the bearing REASSEMBLY Install the bearing Install the snap ring with snap ring pl...

Page 143: ...pressure value 25N M 2 5kgf m Using an shaped tool to check the oil pressure valve operation If the piston does not operate replace the new one ASSEMBLY Remove the generator stator Remove the oil seal...

Page 144: ...grease to the bearing O ring and oil seal lip Install the oil seal NOTE When installing the oil seals be sure the stamped mark on the oil seal faces outside Apply a small quantity of Loctite 262TM Thr...

Page 145: ...ASSEMBLY After removing the nut take out the recoil starter related parts from the housing WARNING When removing the plastics disc Wear eye and hand protection because the spring may quickly unwind an...

Page 146: ...the reel with the spiral spring end 3 Hook the rope onto the hook part 4 of the reel turn thereel clockwise 5 times with the rope Install the ratchet related parts NOTE Apply the shaft and ratchet wit...

Page 147: ...ent Front fork oil seal installer 440655 Apply a small quantity of Loctite 262TM Thread locker to the thread and install and the gearshift cam stopper BALANCER Install the balancershaft Install the ke...

Page 148: ...Apply Loctite 510 Flange sealant to the mating surface of the left crankcase L CASE R CASE...

Page 149: ...shaft rotate smoothly Fit the clamp to the bolt Check the each shaft rotates smoothly after the crankcase bolts have been tightend OIL PUMP Install the oil pump Install the washer and pin Install the...

Page 150: ...pump drive gear bolt to the specified torque Oil pump drive bolt 50 N m 5 0 kgf m Rotor holder 440665 CAM CHAIN Install the cam chain CLUTCH SHOE Install the clutch shoe assembly Apply Loctite 262TM...

Page 151: ...ng NEUTRAL SWITCH Install the springs and switch contacts Install the neutral switch CLUTCH CASE Install the dowel pins and put the new gasket Tighten the clutch case bolts Install the collar OUTSIDE...

Page 152: ...IVEN FACE AND DRIVE BELT Install the drive belt between the movable driven face and fixed driven face by tapping with a plastic mallet CAUTION The drive belt contact surface of the driven face should...

Page 153: ...is seated in and both the drive and driven faces check the belt without slip CLUTCH COVER Install the dowel pins and new gasket Install the clutch cover OIL FILTER Apply engine oil lightly to the O r...

Page 154: ...ears as shon Install the water pump gears with special tool Install the wash Bearing installer set 440660 Install the water pump gears and tighe the nut NOTE Make sure the crankshaft can turning smoot...

Page 155: ...Be sure the one way clutch on the crankshaft is fitted into the generator rotor properly Tighten the generator rotor nut to the specified torque with the special tool Generator rotor nut 160 N m 16 0...

Page 156: ...earshift shaft Install the gearshift shaft by aligning the punched mark with the center of the cam driven gear STARTER DRIVEN GEAR IDLE GEAR Install the starter idle gear and driver gear LEFT CRANKCAS...

Page 157: ...he clamp to the bolt SPEEDOMETER GEARBOX Fit a new gasket and install the speedometer gearbox WATER PUMP Check the water pump shaft position with water pump gear shat Apply engine oil on the O ring of...

Page 158: ...ARTER CUP Apply engine oil to the O ring and lip of the oil seal Install the starter cup Tighten the starter cup nut by using a suitable bar Starter cup nut 35 N m 3 5 kgf m Cup Starter installer 4406...

Page 159: ...cooling system for any leakage after the repair Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the water thermometer Technical Specification Item Spe...

Page 160: ...lant The water hose and jacket are clogged Fan motor malfunction The filler cap of the radiator malfunction The engine temperature is too low The water thermometer and the temperature sensor malfuncti...

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Page 163: ...tem unless the engine is completely 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 d...

Page 164: ...perature of the cooling system 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...

Page 165: ...o fan duct and insert the fan into the motor 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 wit...

Page 166: ...eplacement 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 o...

Page 167: ...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 corre...

Page 168: ...intenance 13 2 3 Front handle cover Meter cover 13 3 4 Front center cover 13 4 5 Upper center cover 13 4 6 Footrest 13 5 7 R L side cover 13 5 8 Front fender 13 6 9 Rear fender 13 7 10 Front bumper co...

Page 169: ...assembly or disassembly operation Never injure hooks molded on the body covers Align the buckles on the guards with slot on the covers Make sure that each hook is properly installed during the assembl...

Page 170: ...screws from meter cover and then remove front handle cover Loosen 2 bolts from meter stay Remove couplers of meter Disassembly Remove 4 screws and 2 nuts Installation Install in reverse order of remo...

Page 171: ...emble first then push the cap upward and then remove front center cover Installation Install in reverse order of removal procedures 5 Fuel tank cover Remove Remove seat Loosen 4 screws and then remove...

Page 172: ...t with rear fender both side and then remove footrest cover These 4 bolts on the right and left footrests Installation Install in reverse order of removal procedures 7 R L side cover Remove Loosen the...

Page 173: ...er Loosen the screws which connect to footrest and side cover each side 9 screws Loosen the 4 screws which connect the front fender right and left side then remove front winker and headlight coupler R...

Page 174: ...attery and C D I on rear fender Caution Loose battery screw from polar side never connect polar and negative with any electric object Remove R L Tail light coupler and R L position lamp coupler Loosen...

Page 175: ...se order of removal procedures Caution Please put the shift lever in the N position bracket that welded in the frame when take off the body cover and running the engine in N position Warning It will b...

Page 176: ...3 4 Front Wheel 14 4 5 Front Wheel Hub 14 4 6 Disk Brake System Inspection 14 7 7 Adding Brake Fluid 14 8 8 Brake fluid replacement Air bleed 14 9 9 Front Brake Caliper 14 10 10 Brake Disk 14 11 11 F...

Page 177: ...or rubber parts to avoid damage Check the operation of the brake system before riding Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the t...

Page 178: ...Dirty lining 2 Deformed brake disk 3 Poor brake caliper installation 4 Imbalance brake disk or wheel Steers to one side 1 Bent tie rods 2 Wheel installed incorrectly 3 Unequal tire pressure 4 Incorrec...

Page 179: ...me Remove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 50 N m 5 Front Wheel Hub Removal Remove front brake caliper 2 bolts Remove...

Page 180: ...pection Install the front brake disk to the wheel hub Install wheel hub and brake disk on to knuckle Install wheel hub washer and tighten the wheel hub nut Torque 80 N m Install cotter pin Install fro...

Page 181: ...ake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk Caution Check the front brake lining must be removed front wheel first Park the ATV on a level ground and...

Page 182: ...not surpass the upper limit spilled brake fluid on painted surfaces plastic or rubber components may result in damages Remove the master cylinder cap and diaphragm Add high quality brake fluid uses on...

Page 183: ...drain valve when finishing the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system a...

Page 184: ...e brake disk Brake lining replacement Remove two guide pins Compress caliper mounting plate and then remove brake linings Install new linings and tighten the guide pins Installation Install the brake...

Page 185: ...tos ingredient cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it 11 Front Brake Master Cylinder Master Cylinder Removal Caution Do n...

Page 186: ...on if its measured value exceeds Allowable limit 13 945 mm Master Cylinder Assembly Caution It is necessary to replace the whole set comprising piston spring piston cup and cir clip Make sure there is...

Page 187: ...nnect brake hoses with 2 new washers Tighten the brake hose bolt to the specified torque value Torque 23 N m Make sure the hose is installed correctly Install all wires hoses and components and avoid...

Page 188: ...18 Operation Precautions 15 2 19 Trouble Diagnosis 15 2 20 Steering Handle 15 3 21 Steering Shaft 15 5 22 Steering Tie Rod 15 6 23 Knuckle 15 7 24 Front Cushion 15 8 25 Suspension Arm 15 9 26 Toe In...

Page 189: ...ft bushing Damaged steering shaft bushing Front wheel wobbling Faulty tire Worn front knucle bearing Bent rim Axle nut not tightened properly Steers to one side Bent tie rods Wheel installed incorrect...

Page 190: ...emove front brake master cylinder Caution Do not let foreign materials enter into the cylinder Remove 2 screws and then remove throttle hosing holder and throttle hosing Loosen the socket bolts for th...

Page 191: ...switch and choke cable Remove switch wire band Remove handle mounting bolt and then remove the handle upper holder handle Installation Install in reverse order of removal procedures Torque Handlebar...

Page 192: ...then remove steering shaft holder nut fixed plate pressed plate and steering shaft Inspection Check wear of damage and replace it if necessary Measure the holder inner diameter Maximum limit 39 5 mm...

Page 193: ...he ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Installation Install the ball joint with adjustment groove on...

Page 194: ...e upper and under ball joints by ball joint driver Remove the knuckle Special Tool Ball joint driver Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking Installatio...

Page 195: ...Remove front cushion under bolt nut and remove the bolt Remove front cushion upper bolt nut and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque Front cus...

Page 196: ...er suspension arm Loosen under suspension arm nuts remove swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bending Installation Insta...

Page 197: ...back let the wheels turn 180 degree so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measurement...

Page 198: ...s 16 3 4 Rear Wheel 16 4 5 Rear Wheel Axle 16 5 6 Disk Brake System Inspection 16 6 7 Adding Brake Fluid 16 7 8 Brake Fluid Replacement Air Bleed 16 8 9 Rear Brake Caliper 16 9 10 Brake disk 16 10 11...

Page 199: ...the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 4 000 3 500 Fr...

Page 200: ...brake lever Blocked brake system Poor brake caliper Blocked brake pipe Seized worn master cylinder piston Bent brake lever Uneven brake Dirty brake lining disk Poor wheel alignment Clogged brake hose...

Page 201: ...al Raise the rear wheels off ground by placing a jack or other support under the frame Remove the rear wheel nuts and the remove rear wheel Installation Install the rear wheel and tighten the nuts Tor...

Page 202: ...heel shaft connecter washet and tighten the wheel shaft connecter nut Torque 100 N m Install cotter pin Remove rear wheel knuckle 2 bolts R L Installation Install rear wheel knuckle and tighten the bo...

Page 203: ...brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk Caution Check the rear brake lining must be remove rear wheel first Park the ATV on a level ground and...

Page 204: ...do not surpass the upper limit spilled brake fluid on painted surfaces plastic or rubber components may result in their damages Remove the brake fluid cap and diaphragm Add high quality brake fluid us...

Page 205: ...the brake system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightl...

Page 206: ...dition Replace the linings if the brake linings wear limitation groove close to the brake disk Installation Install the brake caliper and tighten the attaching bolts securely Torque 39 N m Caution Use...

Page 207: ...rm upper 1 bolts R L Installation Install the rear arm upper and tighten the bolt Torque 70 N m Removal the rear arm lower 2 bolts R L Installation Install the rear arm lower and tighten the bolts Tor...

Page 208: ...tighten the bolts Torque 28 N m Removal the rear brake disk 4 bolts Installation Install the rear brake disk and tighten the bolts Torque 25 N m Removal the rear differential 3 bolts Installation Ins...

Page 209: ...air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner to clean it 11 Rear Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials ent...

Page 210: ...r socket bolts and the master cylinder Disassembly Remove the rubber boot Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master Cylinder In...

Page 211: ...aution Never install cup lip in the opposite direction Make sure the cir clip is seated securely in the groove Install the rubber boot into groove properly Master Cylinder Install Caution Improper rou...

Page 212: ...st be remove push rod pin first Loosen lock nut and turn adjustment nut and push rod bracket to adjust brake free play Install fluid hose and clamp Connect brake hoses with 2 new washers Tighten the b...

Page 213: ...cushion under bolt Remove rear cushion upper bolt and then remove rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Ti...

Page 214: ...agnosis 17 3 5 Battery 17 4 6 Charging System 17 5 7 Ignition System 17 8 8 Starting System 17 10 9 Meters 17 12 10 Light Bulb 17 13 11 Switch Horn 17 16 12 Fuel Unit 17 19 13 Cooling Fan Thermo Switc...

Page 215: ...ter y To recharge the battery remove the battery from rack without removing ventilation caps y Unless in emergency never rapid charge the battery y The voltage must be checked with the voltmeter while...

Page 216: ...out of work Intermittent power supply The connector of the charging system becomes loose Poor connection of the battery cable Poor connection or short circuit of the discharging system Poor connection...

Page 217: ...ger to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1 4A 9 0A Charging time 5 10H 1H Warning Keep flame...

Page 218: ...leakage test set the current range at the largest scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse Do not turn the main s...

Page 219: ...er Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current...

Page 220: ...es the condition Item Check Points Standard Value Main switch Connection R B Battery voltage ON Battery connection R G Battery voltage Charging coil Y Y 0 17 0 8 If the readings measured are not norma...

Page 221: ...ck the following connectors as indicated in the table at the harness side Item Points to check Result Main switch turn to ON position B W B Battery voltage Pulse generator G W L Y 50 170 Primary circu...

Page 222: ...e resistance between the spark plug and the primary winding Standard resistance With no cap 15 0 10 With cap 20 0 10 K Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if n...

Page 223: ...ive cable terminal of the battery Disconnect the cable positive terminal from the relay Disconnect the positive cable of the starter motor Disconnect the coupler of the relay Connect an ohmmeter to th...

Page 224: ...the cable negative terminal then the cable positive terminal Remove starter motor cable Loosen the lock bolts and remove the starter motor Installation of Starter motor Install in reverse order of rem...

Page 225: ...l Remove 4 screws from meter cover and then remove front handle cover Loosen 2 bolts from meter stay Remove couplers of meter Remove 4 screws and 2 nuts and then remove speedometer 4 screws 2 bolts 2...

Page 226: ...ary Hight light H1 12V 55W Low light H7 12V 55W Caution Never touch the bulb with finger which will create a heat point Clean the fingerprint left on the bulb with alcohol Install the bulb of the head...

Page 227: ...light Bulb Pull out the front winker light bulb seat Replace with new front winker light bulb 12V 10W Replacing Bulb of Position Light Pull out the position light bulb seat Replace with new position...

Page 228: ...the taillight and rear winker light bulb connectors by CCW Replace with new taillight bulb 12V 16W Replacing Bulb of License Light Turn the license light bulb connectors by CCW Replace with new licens...

Page 229: ...the coupler of the main switch Push out the main switch Align the main switch stopper with the meter cover groove and install main switch Install the main switch coupler Handle switches Disconnect th...

Page 230: ...Headlight Switch Winker switch Horn switch Hazard switch Head light switch Winker switch Horn switch Hazard switch...

Page 231: ...tch if damaged Rear Brake Switch While grasp the brake lever firmly the terminals of white black and green yellow of the brake should have continuity Replace the switch if damaged Horn Remove the horn...

Page 232: ...he E position the resistance measured shall be as follows Position Resistance E Empty 97 5 107 5 F Full 4 1 Connect the wiring to the fuel unit and the ohmmeter as shown Connect the fuel unit coupler...

Page 233: ...e thermo switch in the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at r...

Page 234: ...Caution Engine oil should be used as a heating medium as the test temperature must be higher than 100 Contacting the container wall by the thermometer and the thermo unit may result in wrong readings...

Page 235: ...1 Electrical Diagram 18 1...

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