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4.2.1.5 Assembly of Front Brake System

1.Use Fuel Pipe Brackets (2pcs) and Hexagon Flange

Bolts M8*16 (2pcs) to connect the Fuel Pipe Clip with

both left and right Lower Front L/R rocker armss.

Caution: Fuel Pipe must avoid physical contact

with other components in movement.

2、Fix the Disk Brake Plate onto the Front Wheel Hub

with M8 Special Bolts (4pcs) (Figure 4-2-4)

Caution: grease the bolt with thread glue when

fastening.Fastening Torque of the Bolt:

22N.m-26N.m

3、 Fix the Front Wheel Hub onto the Front Wheel Shaft

with open-groove nuts and cotter pins. (Figure 4-2-4)

Fastening Torque of Open-groove nut:

50N.m—60N.m

4、 Fix the Plate Clip onto Front Turning Joint with

M8 Bolts (4pcs)

Fastening Torque: 18 N.m--22 N.m

5、Assemble Front Wheel Components onto Front Wheel

Hub with M10 Conical Nuts of GB/T802 (4pcs) (Figure

4-2-15)

Summary of Contents for HS500ATV-2

Page 1: ...1 500ATV 2 Maintenance Manual...

Page 2: ...nt of engine 11 2 1 Inspection of cylinder head intake and exhaust valve 11 2 2 Inspection of spark Plug 12 2 3 Inspection of cylinder piston and piston ring 14 2 4 Inspection of crankshaft 17 2 5 Ins...

Page 3: ...case cover 33 3 6 Magneto 33 3 7 Oil pump 34 3 8 Clutch 35 3 9 Carburetor 36 3 9 1 Structure of carburetor 36 3 9 2 Inspection and adjustment of carburetor 37 4 Chassis 4 1 Steering operation system 3...

Page 4: ...to and charging system 88 5 3 Battery 88 5 4 Lighting system 90 5 5 Meterand signal system 91 5 6 Electrical starting system 92 6 Appendix 93 6 1 Specification 93 6 2 Requirements for torque of fasten...

Page 5: ...5 General Information 1 Description...

Page 6: ...6...

Page 7: ...ntification code 1 1 1 Frame No The frame No is engraved in the right bottom of the supporting frame See Figure 1 1 1 1 1 1 2 Engine NO The engine No is engraved in the right side of the engine See fi...

Page 8: ...tach the oil filter 1 2 2 Height gauge To gauge the height of various components 1 2 3 Vernier To measure the length of various components 1 2 4 Outside micrometer To accurately measure external diame...

Page 9: ...ure a small distance 1 2 7 Torque Spanner To measure torque force 1 2 8 Feeler gauge To measure gap width 1 2 9 Multimeter To check electrical circuits and parts 1 2 10 Barometer To measure pressure o...

Page 10: ...lean Replace if necessary Every20 40hours More often in wet of dusty areas Carburetor Checkandadjustidlespeed starteroperation Adjust if necessary Crankcase breathersystem Check breather hose for crac...

Page 11: ...tion Replace if damaged Check toe in Adjust if necessaly Drive shaft universal joint Lubricate with lithium soap bassed grease Axle boots Check operation Replace if damaged Fittings and fasteners Chec...

Page 12: ...earance Note when adjust valve clearance the engine must be cooled The tempreture should be less than 35 Remove the seat cushion and fuel tank unplug the vision hole cover round the flywheel of magnet...

Page 13: ...8mm See figure 2 3 Figure 2 3 Loose the lock nut rotate the adjusting screw until it appears that the feeler gauge be pulled Then fasten the adjusting screw by valve adjuster tighten the lock nut and...

Page 14: ...ther the spark plug insulator and electrode is damaged or sooting If so see figure 2 5 Figure 2 5 1 Check the spark clearance by feeler gauge whether it is between 0 6 0 7mm Or adjust the gap clean in...

Page 15: ...15 3 Swirl the spark plug and tighten to 18 20N m by spanner then fix the spark plug cap when assembling 2 1 3 cylinder piston piston ring Specification...

Page 16: ...40 0 005 out of roundness 0 0035 0 005 cylinder degree of warp 0 04 0 10 Outside diameter of piston 84 47 84 45 84 35 84 25 Inner diameter of piston pin hole 20 002 20 01 20 05 20 1 gap between piston...

Page 17: ...irections of right angle intersection repairing limit value 0 05 mm out of roundness 0 005 mm 0 05mm taper 0 005mm Inspection of piston and piston ring 1 Measure the gap between piston ring and piston...

Page 18: ...ert piston ring into cylinder and measure the end gap repairing limit value the first ring the second ring 0 5mm See figure 2 10 Figure 2 10 Measure the bore diameter of piston pin hole repairing limi...

Page 19: ...of the piston skirt Extreme position the gap between cylinder and piston repairing limit value 0 1mm See figure 2 12 1 Figure 2 12 7 Measure the external diameter of piston pin the gap between piston...

Page 20: ...heck that whether crank and connecting rod can rotate without stuck and whether the clearance between crank and connecting rod is 0 5 0 6mm The hop of crank shaft should be 0 05mm If not so replace it...

Page 21: ...of carburetor The engine speed should be 1500 150r min 10 minutes after starting at normal idle and will not misfire when briskly accelerate If not so rotate the carburetor idle adjusting screw clockw...

Page 22: ...e it dry Note Petrol is forbidden 2 Dip the air filter element into 20 oil then take it out and squeeze the excessive oil assemble it orderly Impermeability is necessary See figure 2 17 Figure 2 17 2...

Page 23: ...0 APISGSAE10W 40 APISGSAE10W 40 Others are forbidden The capacity is 1 9L after disassembly and assembly 2 The capacity is 1 8L when fueling up after drain Inspection of oil pump flow of oil pump L mi...

Page 24: ...e Unplug the dip stick to do cleaning and dip it into the oil case again Then unplug the dip stick and look whether oil level is lower than the indicator See figure 2 20 Note Ensure that the engine is...

Page 25: ...gauge and clearance gauge Repairing limit value 0 05mm See figure 2 21 Figure 2 21 2 Remove and examine the width of valve Repairing limit value 2 0mm See figure 2 21 1 2 21 2 2 21 3 Figure 2 21 1 Fig...

Page 26: ...ometer and special gauge At last calculate clearance between valve stem and valve guide Repairing limit value intake 0 12mm exhaust 0 14mm Note eliminate carbon in the pipe before measuring If the pip...

Page 27: ...figure 2 23 1 2 23 2 free height of external spring 43mm squareness 0 8mm free height of inner pring 39 5mm squareness0 8mm Figure 2 23 1 Figure 2 23 2 6 Examining lifting distance of cam Measure the...

Page 28: ...t or damaged and whether the oil hole is blocked Note If there is a rocker arm to be replaced examine the peak of cam measure the bore diameter of rocker arm 12 0 038mm 0 020mm Repairing limit value 1...

Page 29: ...th micrometer Repairing limit value 12 051 0 067 0 The repairing limit value of clearance between rocker arm shaft and hole 0 09mm See figure 2 26 Figure 2 26 3 1 3 1 3 1 3 1 disassembly of engine 3 1...

Page 30: ...ylinder valve cover cam sprocket cover and remove timing sprocket Figure 2 28 1 Figure 2 28 2 remove lower rocker arm shaft See figure 2 29 1 Figure 2 29 1 Remove vision hole cover of left front cover...

Page 31: ...chain wheel to be at the same level with the symbol on cylinder cover that is to say the piston of cylinder is at the top dead center Inspection of compression top dead center When the 1 indicator on...

Page 32: ...nti clockwise and repeat the above mentioned steps See figure 2 31 1 Figure 2 31 1 Remove chain tensioner adjuster See figure 2 32 Figure 2 32 remove the cylinder head Loosen the bolt by intersection...

Page 33: ...33 Figure 2 33 remove dowel pin cushion cylinder head chain guide board See figure 2 34 Figure 2 34...

Page 34: ...ure 2 35 Figure 2 Figure 2 Figure 2 Figure 2 3 3 3 35 5 5 5 3 1 2 3 1 2 3 1 2 3 1 2 piston and connecting rod remove the piston circlip Note block the crankcase breather with a piece of cleaning cloth...

Page 35: ...ton pin hole to facilitate the removing of piston pin Note it is forbidden to knock the piston pin with a hammer See figure 2 37 Figure 2 37 3 1 3 3 1 3 3 1 3 3 1 3 remove pull out hand start assy See...

Page 36: ...crankshaft case cover See figure 2 40 Figure 2 40 3 1 6 3 1 6 3 1 6 3 1 6 magneto remove the stator coil remove the pluse coil Remove the stator with rotor stripper See figure 2 41 Figure 2 41 Remove...

Page 37: ...37 Figure 2 42 3 1 7 3 1 7 3 1 7 3 1 7 oil pump remove the bolt of oil pump cover See figure 2 43 Figure 2 43 remove right cover See figure 2 44...

Page 38: ...cket clutch pulley disc See figure 2 45 1 figure 2 45 2 figure 2 45 3 Figure 2 45 1 Figure 2 45 2 F F F Figure 2 igure 2 igure 2 igure 2 45 45 45 45 3 3 3 3 3 3 3 3 1 8 1 8 1 8 1 8 clutch remove the c...

Page 39: ...39 Figure 2 46 Remove the clutch shoe block and clutch cover See figure 2 47 Figure 2 47 Check the wear condition of the clutch shoe block and clutch cover See figure 2 48 Figure 2 48...

Page 40: ...40 3 9 carburetor 3 9 1 structure of carburetor...

Page 41: ...15 F12 0000 main spray nozzle 1 17 16116 F12 0000 screw upper cover 2 18 16117 F12 0000 air measure hole idle speed 1 19 16118 F12 0000 rubber tube fuel drain 1 20 16119 F12 0000 screw M4 10 3 21 1612...

Page 42: ...42 3 2 2 Inspection and adjusting carburetor decomposition Remove the evacuated chamber cover 1 spring 2 piston valve remove permanent seat spring spring seat oil needle...

Page 43: ...emove pilot screw spring washer 0 rings Note The pilot screw is set at maximum performance Before removing pilot screwed note the revolutions of screw in order to fix it back remove pontoon chamber co...

Page 44: ...44 shim remove pontoon pin pontoon triangular needle remove the cover nut 0 rings spring starting plunger pilot jet...

Page 45: ...45 check the carburetor body pontoon chamber oil passage gas fouling block cleaning chap damage replace the carburetor assy cleaning steps check the pontoon damaged replace...

Page 46: ...riangular needle seat 0 rings filter net Damaged worn out block replace check the piston valve crack replace diaphragm rupture replace piston valve oil needle bent worn out replace Note If the piston...

Page 47: ...47 valve Replace it when there is oil leakage check the main jet main jet pilot jet pilot screw 0 ring pilot jet bent worn out damaged replace gas fouling block blow with compressed air...

Page 48: ...lip 4 hexagon flange bolt M8 35 5 inner and external bearing of steering vertical column 6 supporting seal ring of steering vertical column 7 Supporting stent 8 hex bolt M8 60 9 stop reverse piece 10...

Page 49: ...49 Components of Steering Bar 1 Steering Bar 2 steering Rubber Sheath 3 air duct door pull cable 4 oiler components 5 acceelerator pull cable components 6 left switch components...

Page 50: ...eering Vertical Column 1 Remove all of the Plastic cover and Plastic oranments on Steering Bar Figure 4 1 1 1 Front Mud Shield 2 Plastic Ornament 3 Rear Mud Shield 2 Remove Steering Bar Holder Figure...

Page 51: ...1 cotter pin 3 2 32 2 cushion 14 32 4 3 Hexagon open groove nut M14 5 Remove the supporting brackets of the steering vertical column Figure 4 1 4 Figure 4 1 5 1 Supporting stent 2 Inner and outer supp...

Page 52: ...m the bottom seat Figure 4 1 7 Figure 4 1 7 1 Steering Vertical Column 2 Bottom Seat 4 1 1 2 Inspection of steering vertical column components 1 Check whether the nut between the inner ball pin of ten...

Page 53: ...components Caution Continuous use of defective ball pin might cause severe injury or death 3 check whether the tension rod is bended cracked or rusted In occasion of above problems please have the ten...

Page 54: ...otating Torque of the steering vertical column 3 5N m 4 1 1 3 Assembly of steering vertical column a Firstly fix the Turning rocker arms comp into the steering vertical column Then plug the steering v...

Page 55: ...32 2 Fix the steering vertical column onto the frame with hexagon flange bolt M8 60 2pcs supporting stent 1pcs inner and outer supporting bracket 2pcs stop reverse piece 1pcs and collar pipes 2pcs Fi...

Page 56: ...piece 4 Supporting stent 5 Supporting Collar Sheath 6 Supporting ferrel 4 Fix the tension rod into the conical bore of the steering vertical column with tension rod components 2sets cushion 12 2pcs M1...

Page 57: ...embly of steering bar 1 Remove all of the Plastic cover and Plastic oranments on Steering Bar Figure 4 1 1 2 Remove steering bar clip 4 1 2 3 Unplug all cables and wires and remove the steering bar Fi...

Page 58: ...bolts must be replaced 4 Check whether the steering bar clip is damaged Figure 4 1 12 Radial runout and wear condition of the inner surface must be less than 0 8mm Otherwise replace the steering bar c...

Page 59: ...ross recess pan head screw M5 60 8 disk brake handle 9 hexagonal locknut M8 10 disk brake switch 11 disk brake handle bolt 12 disk brake oil pipe branch seat 13 front disk brake pipe 14 rear brace of...

Page 60: ...x level on the right handlebar Should the fluid level falls under the minimum mark please refill the box with the same type of fluid as was recommended by the manufactureFigure 4 2 1 Figure 4 2 1 to e...

Page 61: ...rake pad reducing the fluid level in the box Therefore periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid e Periodical inspection of the wear condition of front di...

Page 62: ...gon self lock nut M8 f Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection Method Fuel pipe must be replace when worn...

Page 63: ...on 5 taper nut M10 2 Sequently remove the cotter pins open groove nuts cushion and front wheel hub from the front wheel shaft Figure 4 2 4 3 Remove the disk brake plate from the front wheel hub Figure...

Page 64: ...p 2 Disk Brake Pump unity 2 Remove the Front Fuel Pipe Brackets Figure4 2 7 Figure4 2 7 1 branch seat of Disk Brak Fuel Pipe 2 Hexagon Flange Bolts M8 3 Detach the Plate Clip nut and remove the Plate...

Page 65: ...distortion crack wear and other hidden defects 4 Check the Brake Plate Clip for distortion crack rust and stuck 5 Inspect the Brake Shoe for wear condition Brake shoe must be replaced when worn out F...

Page 66: ...Front Wheel Hub with M8 Special Bolts 4pcs Figure 4 2 4 Caution grease the bolt with thread glue when fastening Fastening Torque of the Bolt 22N m 26N m 3 Fix the Front Wheel Hub onto the Front Wheel...

Page 67: ...ehicle immediately after assembling the brake system Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating before riding the vehicle 4 2...

Page 68: ...handlebar Should the fluid level falls under the minimum mark please refill the box with the same type of fluid as was recommended by the manufacturer Figure 4 2 9 to ensure the fluid level is higher...

Page 69: ...ocess of abrading brake pad reducing the fluid level in the box Therefore periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid g Periodical inspection of the wear co...

Page 70: ...n the disk brake plate must be replaced h Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection Method Fuel pipe must b...

Page 71: ...12 Figure 4 2 12 1 Rear Disk Brake Clip 2 hexagon flange bolt M18 14 4 Remove Rear Disk Brake System 4 2 2 4 Disassembly of Rear Disk Brake Plate 1 remove rear wheel components Figure 4 2 13 2 Release...

Page 72: ...smission shaftv 3 Remove the Rear Disk Brake Plate from Bottom Seat see Figure 4 2 15 Figure 4 2 15 1 Bottom Seat of Rear Disk Brake Plate 2 Rear Disk Brake Plate 4 2 2 5Inspection of Rear Brake Syste...

Page 73: ...Shoe for wear condition Brake shoe must be replaced when worn out 1 Brake Shoe 6 Inspect the Brake Shoe for maximum wear distortion and crack in which case it must be replaced Maximum wear of Rear Dis...

Page 74: ...0 30 Bolts 2pcs Fastening Torque 18 N m 22 N m 4 Mount Fluid Box of Rear Disk Brake onto the Frame with M Bolt 1pcs Fastening Torque 8 N m 12N m 5 Mount Rear Disk Brake Pump onto the Frame with M Bolt...

Page 75: ...ting before riding the vehicle 4 3 Wheel and Tyre 4 3 1 Preparation for maintenance of wheel 1 Inspect wear condition of the tyre Figure 4 2 16 2 Check if the Wheel Hub is worn out or damaged Figure 4...

Page 76: ...laced 3 Check the joining condition of the tyre and wheel hub If the joint of tyre and wheel hub is loose replace the tyre immediately 4 Check the vibration of tyre wheel hub Figure 4 2 13 Vibration o...

Page 77: ...cification and operation guide of Wheel Hub and Tyre Since wheels and tyres are crucial to the Figure 4 2 17 vehicle operation periodical inspection for tyre pressure and profile depth is necessary Sp...

Page 78: ...or lose of control Therefore please ensure the tyre pressure strictly complies with figures shown in the chart above Before operating the vehicle each time please check if profile depth of the tyre i...

Page 79: ...L R transmissionshaft 3 fore bridge differential components 4 middle transmissionshaft components of fore bridge 5 L R turning joint front tank components 1 gear box assembly of front bridge 2 the ri...

Page 80: ...power divider coupling 32 differential adjusted washer 33 bolt M14X15 34 cooper gaske 14X2 35 vent piepe of drive case 36 clip of oil pipe 37 fore transimmision shaft 38 weak spring of fore transimmis...

Page 81: ...nd check whether the gears Is engaged properly 6 In case the choke is jammed it must be dredged with a needle If the problem is not solved replaced it 7 If there are defects on sensors it must be chec...

Page 82: ...bber Sheath of the transmissionshaft is worn out or cracked plesae have it replaced immediately 2 Check whether the ball is running smoothly If found loosen or stunk replace the transmissionshaft 3 Di...

Page 83: ...sionshaft onto fore bridge differential Figure 4 2 19 2 Inject 0 32L of GearLubricant of SAE 80 API GL 4 into fore bridge differential Then tighten the bolt Torque of the bolt 23N m 3 Fix the fore bri...

Page 84: ...84 1 hexagon flange bolt M10 110 2 fore bridge case 4 4 2 Rear Bridge 4 4 2 1transmissioncase of rear bridge...

Page 85: ...per gasket 8 26 flange nut M8 27 hexagon flange bolt M8X12 28 cooper gasket 8 29 90X 65 oil seal 30 deep groove ball bearing 16017 31 0 rings of rear bridge cover 32 rear adjuster washer 33 hexagon fl...

Page 86: ...f gear shift Mechanism refer Inspection and Maintenance of gear shift Mechanism refer Inspection and Maintenance of gear shift Mechanism refer to the picture of gear shift Mechanism to the picture of...

Page 87: ...e can test it from the following aspects whether the clutch can completely declutch whether the gearshift is greased reliable whether the oil pipe of gear shift mechanism is blocked whether gear shift...

Page 88: ...arm 3 hexagon flange bolt M10 65 4 dust proof cover of rear rocker arm 5 rear left upper rocker arm assembly 6 middle spacer sleeve of fore L R rocker arm 7 hexagon flange bolt M10 65 8 ust proof cov...

Page 89: ...er arm 2 middle spacer sleeve of fore L R rocker arm 3 fore upper right rocker arm assembly 4 middle spacer sleeve of rocker arm 5 open groove nut M10 6 cotter pin 3 2 32 7 fore bottom left rocker arm...

Page 90: ...nd dowm rocker arm 1 Disassembly and Maintenace Collar Sheath cotter pin and damper may easy to occor problem A If the L R rocker arms swing easily we can test it from the following aspects whether th...

Page 91: ...rface of components can not be cracked Check whether these components are greased with butter and then tighten the up and down rocker arm assembly and L R fore dampers and ther components Fix the L R...

Page 92: ...pin on the assembly shaft of the rear damper is reliable Caution Disassemble rear damper and check if the damper and the connecting hole is bent or cracked In case of above defects call for professio...

Page 93: ...ck White B W 13 White Red W R 30 White Blue W L 14 White Black W B 31 Yellow White Y W 15 Light Blue Lb 32 Green Blue G L 16 Light Green Lg 33 Purple V 17 Black Yellow B Y Troubleshooting and repair N...

Page 94: ...wear intermittence 2 high voltage bag high voltage lead wire insulated badness repalce replace electrification system 1 discharge self 2 uncharge or shortage charge 1 cover polluted or drenched by rai...

Page 95: ...on charge to capacitance C at the same time spring coil produce spring signal provided to SCR as the turnon spring signal when reaching the ignition timing SCR turnon capacitance began to discharge at...

Page 96: ...current then induce electromotive force come into to being the pressure Through 3 lines Y yelloe output into the rectifier through rectifier into direct current pressure and output through R1 to charg...

Page 97: ...Do not charge under a much higher pressure or electric current 4 Keep battery at a low temperature and dry place 5 Charge battery before fix it If battery without electrolyte it may cause the rectifie...

Page 98: ...rown green red green black flashing relay battery 12V 12Ah black brown blue red1 function switch 10A signal 25A Ignition 5A 2 4draver 25A frontlight biue black1 red red white red brown brown blue yelo...

Page 99: ...Turing light switch When using this function left and right turning lights will shine at the same time Meter meet an emergency the lamp is red do not shine Horn Switch yellow red light green function...

Page 100: ...6 Electrical starting system Starting Circuit Starting system working process Turn on the start switch on the left handlebar the battery can supply power for the CDI Then the CDI supply power for the...

Page 101: ...ot charge enough 2 When starting if heard some noises from the startor relay the battery must be without enough power Please stop starting and change a powerful battery or charge for it 3 If the start...

Page 102: ...Primary Brake 1 E mark Front dual disk Rear single disk front and rear linkage right foot right hand operation Emergency brake Front dual disk Rear single disk front and rear linkage right foot right...

Page 103: ...stroke Bore Stroke 84 5mm 84mm Compression Ratio 9 4 1 Volume 471ml Max power 17kW 5000r min 5500r min E mark Max power E mark 14 2kW 5500r min Rated power 16kW 4500r min 5000r min Max Torque 35N m 5...

Page 104: ...on Crankcase Comply with GB11121 1995 standard Depending on regional weather condition choose either SAE 5W 40 or SAE 10W 30 Cold region SAE 20W 40 Warm region Oil capacity 1 9L Engine dry weight 68kg...

Page 105: ...ating steering bar Driving method Two wheel four wheel drive 2W means two wheel drive 4W means four wheel drive Shaft arms Front and Rear dual shaft arms Parking brake Mechanical Frame Steel pipe Magn...

Page 106: ...00KM The testing method carries on according to GB T4570 1995 h Exhaustion The pollutant limiting value should conform to GB 14621 2002 the GB14622 2002 reques a idle speed discharges CO 3 8 HC 800 pp...

Page 107: ...er two directions maintains static fixed is motionless meantime between many to 5min m The side leans the steady constant angle The multipurpose vehicle under the idling the static condition and right...

Page 108: ...45 55 Nut on upper rocker arm of the left 40 50 Nut on bottom rocker arm of the left 40 50 Nut on upper rocker arm of the rignt 40 50 Nut on bottomr rocker arm of the rignt 40 50 Suspension nut 35 45...

Page 109: ...109 OVERRIDE FUEL m mi n1000 CDI 30A L2 L1...

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