HER CHEE 2002 ATV-320 S Service Manual Download

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Chapter 1 Engine, Transmission & Gear

I-5

Cylinder Head Cover

Summary of Contents for 2002 ATV-320 S

Page 1: ...SERVICE MANUAL ATV 320 S U 2002 24 JUNE 30 2007 High Power Liquid Cooled Engine HER CHEE INDUSTRIAL CO LTD...

Page 2: ...alified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manu...

Page 3: ...r I 38 Chapter 2 Fuel System Carburetion Carburetor II 3 Fuel Tank II 7 Air Cleaner II 10 Exhaust System II 12 Chapter 3 Ignition and Starting System Ignition System III 1 Starting System III 4 Recoil...

Page 4: ...he VIN Vehicle Identification Number is attached to the lower front right side of frame behind the frame number The engine serial number is stamped on the upper rear right crankcase The carburetor ide...

Page 5: ...shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks z All items must use original parts pure...

Page 6: ...rmed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority z Definition of signs The sign given in the Service Manual shall refer to the operation m...

Page 7: ...6 0 008 0 25 0 010 Oil pump Rotor end clearance 0 04 0 09 0 002 0 004 0 12 0 005 TORQUE VALUES Oil drain plug 20 25 N m 15 18 ft lb Oil filter screen cap 18 22 N m 13 16 ft lb Transmission oil check b...

Page 8: ...ring and filter screen and clean the filter screen After the oil has been completely drained be sure the O ring on the filter screen cap is in good condition and install the filter screen with the clo...

Page 9: ...SPECTION Measure the pump body to outer rotor clearance Service Limit 0 25 mm 0 010 in Measure the outer rotor to inner rotor tip clearance Service Limit 0 20 mm 0 008 in Check the rotor to pump body...

Page 10: ...ates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it SERVICE RULES 1 Use genuine ADLY or ADLY recommended parts and lubr...

Page 11: ...bly 0 8 liter 0 85 US qt at change Transmission 0 6 liter 0 74 US qt at disassembly 0 5 liter 0 63 US qt at change Coolant capacity Engine and radiator 1 1 liter 1 16 US qt Reserve tank 0 3 liter 0 31...

Page 12: ...ar selection rod then remove muffler ass y Disconnect coolant hose Disconnect spark plug and generator wire connector and coupler Disconnect blow by tube at cylinder head cover and crankcase Disconnec...

Page 13: ...er engine mount Torque value 40 55 N m 29 40 ft lb B Front engine mount C Front engine bracket Torque value 40 55 N m 29 40 ft lb D Rear upper hanger plate Torque value 18 24 N m 13 16 ft lb E Rear en...

Page 14: ...Chapter 1 Engine Transmission Gear I 5 Cylinder Head Cover 1 5 2 3 7 6 4 8 11 10 9 5 5 5 9...

Page 15: ...Chapter 1 Engine Transmission Gear I 6 Cylinder Head 2 3 4 4 5 6 7 8 9 11 10 12 12 13 14 18...

Page 16: ...Chapter 1 Engine Transmission Gear I 7 Camshaft Valve Cam...

Page 17: ...Valve stem EX 4 955 4 970 0 1951 0 1957 4 90 0 193 Valve guide I D 5 00 5 012 0 1969 0 1973 5 03 0 198 IN 0 010 0 037 0 0004 0 0015 0 08 0 003 Stem to guide clearance EX 0 030 0 057 0 0012 0 0022 0 10...

Page 18: ...Burned or bent valves Incorrect valve timing Broken valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Compression Too High Excessive carbon...

Page 19: ...o keep it from falling to the crankcase Remove rocker arm cam shaft bearing holder plate mounting bolt and holder plate Remove rocker arm shaft by using a M6 bolt screw in shaft then pull out the shaf...

Page 20: ...rocker arm ROCKER ARM INSPECTION Measure the rocker arm shaft O D Service Limit 16 96 mm 0 6677 in Measure the rocker arm bore I D Service Limit 17 04 mm 0 6709 in Turn the outer race of each rocker...

Page 21: ...bolts Derail the cam chain from the cam sprocket teeth and remove the cam sprocket Remove the cylinder head base bolt Remove the four cylinder head cap nuts and four copper washer Remove the cylinder...

Page 22: ...rrect reassembly Remove the valve stem seals Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head gasket surface NOTE Avoid damaging the gasket surfa...

Page 23: ...lve movement in the guide and measure and record each valve stem O D Service Limit IN 4 9 mm 0 193 in EX 4 9 mm 0 193 in VALVE GUIDE NOTE Remove the guides to remove any carbon build up before checkin...

Page 24: ...lve also NOTE Reface the valve seats whenever the valve guide are replace CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil then insert the valves into the valve guides Install new valve stem...

Page 25: ...tall the carburetor insulator with two bolts and tighten the bolts CYLINDER HEAD INSTALLATION Install the dowel pins and a new gasket onto the cylinder Install the cylinder head onto the cylinder Inst...

Page 26: ...and exhaust lobe Install intake and exhaust rocker arm to cylinder head Tighten the rocker arm camshaft bearing holder plate mounting bolt Push the cam chain adjuster push rod back into the adjuster...

Page 27: ...index mark on the right crankcase cover to bring the position to TDC Top Dead Center on the compression stroke With the engine in this position all four valves can be checked Loosen the valve adjuste...

Page 28: ...the cylinder head cover seal for any buckle or broken Replace a new one if necessary Coating engine oil on seal face before install Install the cylinder head cover to cylinder and tighten four 6mm hea...

Page 29: ...Chapter 1 Engine Transmission Gear I 20 Cylinder Piston Crankshaft...

Page 30: ...er clearance 0 010 0 040 0 0004 0 0016 0 10 0 004 Piston Piston ring Piston pin bore 17 002 17 008 0 6694 0 6696 17 04 0 671 Piston pin O D 16 994 17 000 0 6691 0 6693 16 96 0 668 Piston to piston rin...

Page 31: ...er Remove the cylinder gasket and dowel pins Place rags in the crankcase openings Clean off any gasket material from the cylinder surface of the crankcase NOTE Gasket material will come off easier if...

Page 32: ...PISTON PIN AND PISTON RING INSPECTION Measure the piston pin bore I D Service Limit 17 04 mm 0 6709 in Measure the piston pin O D Service Limit 16 96 mm 0 6677 in Calculate the piston pin to piston cl...

Page 33: ...ston O D at a point 10 mm 0 4 in from the bottom and 90 to the piston pin bore Service Limit 75 90 mm 2 9882 in Compare this measurement against the service limit and calculate piston cylinder clearan...

Page 34: ...gs should be installed with the markings facing up After installing the rings they should rotate freely without sticking PISTON INSTALLATION Install the piston and piston pin Position the piston IN ma...

Page 35: ...h fresh engine oil Carefully lower the cylinder over the piston by compressing the piston rings one at a time CAUTION Do not force the cylinder over a ring you may damage the piston and piston rings L...

Page 36: ...Chapter 1 Engine Transmission Gear I 27 Crankcase...

Page 37: ...taching bolts Remove the crankcase with the left side crankcase down and remove the right crankcase CAUTION Never pry the crankcase mating surfaces apart Remove the gasket and dowel pins Remove the cr...

Page 38: ...aring with your finger The bearings should turn smoothly and quietly Also check that the bearing inner race fits tightly in the crankshaft Replace the crankshaft assembly if the races do not turn smoo...

Page 39: ...the left crankcase being careful not to damage the oil seal Install the dowel pins and a new gasket Place the crankcase over the crankshaft and onto the left crankcase Install the nine crankcase atta...

Page 40: ...Chapter 1 Engine Transmission Gear I 31 Right Crankcase Cover...

Page 41: ...hanical seal for wear or damage Turn the water pump shaft to check the bearing it should turn smoothly and quietly Inspect ignition pulse generator soldering and check the sealing rubber for any defic...

Page 42: ...Chapter 1 Engine Transmission Gear I 33 Cooling system...

Page 43: ...test 55 distilled water 45 ethylene glycol 32 26 50 distilled water 50 ethylene glycol 37 35 45 distilled water 55 ethylene glycol 44 5 48 Coolant capacity Radiator and engine Reserve tank Total syste...

Page 44: ...The engine must cool before removing the radiator cap or severe scalding may result Remove the front light fender 280AS or front fender assy 280AU Remove the radiator cap Place a drain pan under the...

Page 45: ...out from between core fins with low pressure air If insects etc are clogging the radiator wash them off with low pressure water REMOVEAL Remove the front light fender 280AS or front fender assy 280AU...

Page 46: ...lly for damage Suspend the thermostat in heated water to check its operation NOTE If the thermostat or thermometer touches the pan you ll get a false reading Replace the thermostat if the valve stays...

Page 47: ...Chapter 1 Engine Transmission Gear I 38 Left Crankcase Cover...

Page 48: ...23 6 035 153 5 6 043 Driven face spring free length 114 8 4 520 110 0 4 33 Driven face O D 40 96 40 98 1 612 1 613 40 92 1 611 Moveable driven face I D 41 00 41 04 1 614 1 616 41 06 1 617 Weight rolle...

Page 49: ...ts and remove the crankcase cover dowel pins and gasket Inspect the gasket for crankcase cover and replace it if necessary Install the left crankcase cover in the reverse order of removal Torque 8 12...

Page 50: ...ces then set the drive belt on the drive pulley face collar Reinstall the drive pulley face and recoil dish hold the drive pulley and tighten the nut Torque 80 100 N m 58 72 ft lb Reinstall the left c...

Page 51: ...e Limit 27 06 mm 1 065 in Check the drive face collar for wear or damage Measure the O D at the drive face sliding surface Service Limit 26 94 mm 1 061 in Check the driver face for wear or damage Meas...

Page 52: ...h the spline side facing out Clean off any grease or oil from the drive pulley faces INSTALLATION Install the moveable drive face onto the crankshaft Install the drive belt Clean the drive pulley face...

Page 53: ...rive pulley holder and remove the drive pulley nut and clutch outer Remove the driven pulley clutch assembly INSPECTION Check the clutch outer for wear or damage Measure the clutch outer I D Service L...

Page 54: ...Chapter 1 Engine Transmission Gear I 45 Transmission...

Page 55: ...S qt at change 0 6 liter 0 63 US qt at disassembly TORQUE VALUES Transmission case cover 6 mm 8 12 N m 6 9 ft lb 8 mm 20 24 N m 14 18 ft lb 10 mm 10 15 N m 7 11 ft lb Troubleshooting Engine starts but...

Page 56: ...LY Drain the gear oil by loosen drain bolt Remove drive sprocket Remove shaft lever Loosen eight gearbox attaching bolts Remove right side gearbox cover dowel pins and gasket Remove gear shaft arm Rem...

Page 57: ...rmal wear or broken teeth Inspect gear shaft arm for abnormal wear or broken teeth Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The...

Page 58: ...ar shaft fork Install gear shift arm NOTE Aligned shift forks to shift drum groove gear shift arm to shift drum and shift drum retainer in correct position Install the dowel pins and a new gasket add...

Page 59: ...area Do not smoke or allow flames or sparks in the work area When disassembling the fuel system parts note the location of the O ring and gasket Replace them with new ones if necessary on reassembly B...

Page 60: ...h idle Faulty ignition system Incorrect idle speed Faulty carburetor Contaminated fuel Misfiring during acceleration Faulty ignition system Backfiring Faulty ignition system Faulty carburetor Poor per...

Page 61: ...Chapter 2 Fuel System Carburetion II 3 3 CARBURETOR...

Page 62: ...t damage jet needle on the throttle piston Disconnect the heater component on carburetor Disconnect the fuel tube from the carburetor Remove the carburetor Vacuum Chamber DISASSEMBLY Loosen the drain...

Page 63: ...pect the float valve for grooves and nicks Inspect the operation of the float valve Blow open all passages with compressed air before assembling ASSEMBLY Clean main jet needle jet holder needle jet an...

Page 64: ...arburetor Install the throttle cable Install the choke cable with choke piston Install the carburetor aligning the tab on the carburetor with the groove in the intake manifold and tighten the band scr...

Page 65: ...Chapter 2 Fuel System Carburetion II 7 7 FUEL TANK...

Page 66: ...dy FUEL VALVE INSPECTION Disconnect vacuum tube from fuel valve and fuel tube from carburetor Connect a commercially brake bleeder to vacuum tube then pump the brake bleeder Check the fuel flow thru f...

Page 67: ...place if necessary Use a ohmmeter connect to gauge terminal to check the ohm reading from upper to lower float level of petrol gauge Ohm reading 10 90 Replace petrol gauge if the ohm reading is discon...

Page 68: ...Chapter 2 Fuel System Carburetion II 10 10 AIR CLEANER ASSEMBLY...

Page 69: ...e air filter assembly mounting clamp Remove the air filter element cover Drain the accumulated water or dust Clean the air cleaner case and filter element with compress air Inspect the filter element...

Page 70: ...Chapter 2 Fuel System Carburetion II 12 12 EXHAUST SYSTEM...

Page 71: ...hanger mounting bolts Pull back the muffler assembly for removal Bend the exhaust pipe front section to release pipe springs INSPECTION Check the exhaust pipe gasket replace it if necessary INSTALLATI...

Page 72: ...1 k Ignition pulse generator at 20 68 50 170 TROUBLESHOOTING No spark at plug Poorly connected broken or shorted wire Between ignition pulse generator and ignition control module CDI Between CDI and i...

Page 73: ...ance is out of the specification remove the spark plug cap from spark plug wire and measure the resistance of the secondary coil Resistance 3 7 4 5 k REMOVAL INSTALLATION Disconnect the ignition coil...

Page 74: ...dy and a four pin gear position coupler INSPECTION Disconnect the CDI coupler and connectors and check each circuit according to the table below CIRCUIT COLOR CORRECT Ignition Puler Bu Y G 50 170 Bl Y...

Page 75: ...r motor brush spring tension 680 920 g 1 49 2 03 lb 680 g 1 49 lb TROUBLESHOOTING Starter won t turn Burned out fuse Weak battery Poorly connected broken or shorted wire Faulty Ignition switch starter...

Page 76: ...motor cable from the starter relay Disconnect starter relay terminal and remove the starter relay Connect an ohmmeter between the positive and starter motor terminal Connect the yellow red wire termin...

Page 77: ...the starter motor INSTALLATION NOTE Before installing the starter motor check the operation by connecting the starter motor wire to the starter relay Install the starter motor in the reserve order of...

Page 78: ...Chapter 3 Ignition and Starting System III 7 Recoil Backup Starting System...

Page 79: ...e engine starting After engine start release the recoil haft the wire should return into the recoil body and the haft stay to it s original position NOTE If the recoil haft can t back to original posi...

Page 80: ...an assistant will be required when removing panels to help avoid damaging the surface Once the visible fasteners have been removed try to lift off the panel as described but DO NOT FORCE the panel if...

Page 81: ...Chapter 4 Frame Cover IV 2 FRAME BODY 320S...

Page 82: ...Chapter 4 Frame Cover IV 3 FRAME BODY 320U...

Page 83: ...Chapter 4 Frame Cover IV 4 BODY COVER SEAT 320S...

Page 84: ...Chapter 4 Frame Cover IV 5 BODY COVER SEAT 320U...

Page 85: ...ector Remove upper fender to frame mounting bolts and front to rear fender joint bolts Remove two lower mount bolts Remove tail light fender 320S Open the rear luggage box and remove the mounting bolt...

Page 86: ...sconnect indicator light and main switch wire Remove L R side cover and front to rear joint bolts Remove speedometer cover and handle bar supporter then make handle bar freely for moving Remove fender...

Page 87: ...bumper cover to bumper and headlight to bumper mounting bolts Remove fuel cap then remove fuel tank dash board NOTE Lock the fuel cap to fuel tank as soon as removed fuel tank dash board With an assi...

Page 88: ...nstall the front carrier in the reverse order of removal NOTE Attached all four bolts first and after aligned the carrier tighten the bolts INSTALLATION Install the front carrier in the reverse order...

Page 89: ...tighten the bolts INSTALLATION Install the front bumper in the reverse order of removal REAR BUMPER REMOVAL Remove the rear carrier Remove four bumper mounting bolts NOTE The right side front bolt al...

Page 90: ...ll joint Upper 55 N m 40 ft lb Lower 55 N m 40 ft lb Front wheel hub nut 59 79 N m 43 58 ft lb Rear wheel hub nut 140 160 N m 101 116 ft lb Wheel nut 64 N m 17 22 ft lb Brake disk bolt 30 N m 22 ft lb...

Page 91: ...Chapter 5 Wheels Tires Brakes V 2 HANDLE BAR...

Page 92: ...Chapter 5 Wheels Tires Brakes V 3 STEERING MPH...

Page 93: ...to lower holders and aligning the punch mark on the handlebar with the upper surfaces surface of the lower holders Install the handlebar upper holders and tighten four hex socket bolts Torque 24 30 N...

Page 94: ...t nut Remove the steering shaft holder bolts Remove the steering shaft holder basket and pull out the steering from frame INSPECTION Inspect tie rod end mounting plate for wear or damage and replace i...

Page 95: ...Chapter 5 Wheels Tires Brakes V 6 FRONT REAR WHEEL...

Page 96: ...s or embedded object Check the front and rear wheels rim for trueness Service Limits Radial 2 0 mm 0 08in Axial 2 0 mm 0 08in Replace if the reading exceeds the service limit Measure the tread depth a...

Page 97: ...sary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the outer race fits tightly in the hub Remove and discard the bearing if the races do not t...

Page 98: ...Chapter 5 Wheels Tires Brakes V 9 FRONT SUSPENSION...

Page 99: ...Chapter 5 Wheels Tires Brakes V 10 REAR SUSPENSION SWING ARM SUB ASS Y...

Page 100: ...t Remove upper and lower a arm mounting bolts and remove a arm from vehicle frame INSPECTION Inspect ball joint rubber and joint for wear or damage Replace ball joint upper and lower at same time Insp...

Page 101: ...t with brake line and parking brake cable aside the swing arm assemble Remove rocker arm to chassis mounting bolt Remove foot brake pedal Loosen the swing arm bolt and remove it Pull back the swing ar...

Page 102: ...ER INSPECTION Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the outer race fits ti...

Page 103: ...Chapter 5 Wheels Tires Brakes V 14 HYDRAULIC BRAKE SYSTEM...

Page 104: ...Chapter 5 Wheels Tires Brakes V 15 BRAKE CALIPER...

Page 105: ...ATION ITEM STANDARD mm in SERVICE LIMIT mm in Front 4 0 0 16 3 0 0 14 Disc thickness Rear 4 0 0 16 3 5 0 14 Disc runout 0 3 0 012 Brake pad thickness 1 0 0 04 TORQUE VALUES Bleed valve 4 7 N m 3 5 ft...

Page 106: ...AUTION Do not allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced...

Page 107: ...els calipers then bleeding the rear brake shunt and caliper Add fluid when the fluid level in the master cylinder reservoir is low NOTE Check the fluid level often while bleeding the brakes to prevent...

Page 108: ...queeze the brake lever and hold it down then open the bleed valve half turn and then close the valve NOTE Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever...

Page 109: ...d pull out the bolts Push brake pads against caliper piston to let it back into the caliper bore then remove inner brake pad from caliper house Press caliper mounting plate toward bore side then push...

Page 110: ...rovide enough room for the new pads to clear the disc Tighten the caliper mounting bolts Torque 30 N m 25 ft lb BRAKE DISC INSPECTION REMOVAL AND INSTALLATION INSPECTION Visually inspect the surface o...

Page 111: ...of removal Tighten the disc retaining bolts Torque 43 N m 31 ft lb NOTE Used pre coating anti loosen bolts Rear disc removal installation Remove the left rear wheel hub Remove the rear caliper Remove...

Page 112: ...bolt fixing nut and then turn in the adjust bolt until you can feel it touch the piston wall Turn out the adjust bolt half turn and hold the adjust bolt then tight the fixing nut NOTE Pull the parkin...

Page 113: ...ne installed in the frame SPECIFICATION ITEM STANDARD mm in SERVICE LIMIT mm in Starter driven gear I D 22 026 22 045 0 8672 0 8679 22 10 0 870 Starter Driven gear O D 42 195 42 208 1 6612 1 6617 42 1...

Page 114: ...Chapter 6 Alternator Electrical Equipment VI 2 Alternator Starter Gear...

Page 115: ...water pump Remove the two pipe bolts two 8 mm oil pipe bolts 12 mm oil pipe bolt and washer then remove the pipe Disconnect the pulse generator and alternator wire connectors Disconnect the crankcase...

Page 116: ...generator Remove the three stator attaching bolts and stator FLYWHEEL REMOVAL Remove the oil orifice from the end of the crankshaft Hold the flywheel with a flywheel holder and remove the flywheel nut...

Page 117: ...AR INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limit I D 22 10 mm 0 870in O D 42 15 mm 1 659in Inspect the starter idle gear and s...

Page 118: ...clutch into the one way clutch outer Install the one way clutch assembly to the flywheel and tighten with 6 mm socket bolts Torque 28 32 N m 21 24 ft lb NOTE Apply a locking agent to the socket bolt t...

Page 119: ...l Install the oil orifice drive pin in the crankshaft Install the woodruff key into the crankshaft slot Install the flywheel onto the crankshaft aligning the key on the crankshaft with the groove in t...

Page 120: ...is in position securely RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oi...

Page 121: ...oil pipe bolts in the correct position If the 8 mm oil pipe bolts are interchanged engine damage may result NOTE Make sure that the sealing washer tab at the right crankcase cover faces the right cran...

Page 122: ...If the bulb light there is a short to ground somewhere in that area probably where insulation has rubbed off a wire The same test can be performed on other components in the circuit including the swit...

Page 123: ...touch the bulb with your hands clean it with c cloth moistened with alcohol to prevent its early failure Do not try to replace the bulb with light ON Position the headlight bulb rubber dust seal NOTE...

Page 124: ...INSPECTION During the regulator normally function the alloy body of regulator will became heated Started the engine use your hand to touch the alloy body to check it s functional When engine is runnin...

Page 125: ...Chapter 6 Alternator Electrical Equipment VI 13 Wire Diagram...

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HER CHEE 2002 ATV-320 S, Service Manual

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Summary of Contents for 2002 ATV-320 S

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