Hsun hs700atv Maintenance Manual Download Page 72

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4.Check if there exists any slip thread or flaw on the open-groove

nut .

5..Disassemble the front tank and 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 checked and

maintained by a professional.

8. Gears are fragile commodities in transmission system.

4.4.1.2 Disassembly of fore bridge component:

1.Detach the two front wheel parts.

2.Removed front Disk Brake Clip, cotter pin, cushion and the

front wheel hub. (Figure 4-2-20)

Figure 4-2-20

3.Disassemble the fore bridge differential( Figure 4-2-20)

、

Take out the fore bridge from the frame

、

Release engine oil in the differential

、

Unplug the transmission shaft from the differential (Figure

4-2-19)

Summary of Contents for hs700atv

Page 1: ...1 700ATV Maintenance Manual ...

Page 2: ...ent 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 Inspection of clutch 18 2 6 Inspection of carburetor 18 2 7 Inspection of air filter 19 2 8 Inspection of oil filter 20 2 9 Inspection of lubrication system 20 2 10 Lubrication of engine 21 2 11 Inspect...

Page 3: ...ft crankcase 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 39 4 2 Brake system 51 4 3 Wheels and tires 67 4 4 Transmission system 70 4 5 gearshiftmechanism 77 4 6 Suspension 79 5 Electrical system 84 ...

Page 4: ...eto 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 fastener 99 6 3 Electrical circuits 100 ...

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

Page 6: ...6 1 1 Identification code 1 1 1 Frame No The frame No is engraved in the right bottom of the supporting frame See Figure 1 1 Figure 1 1 ...

Page 7: ...ne See figure 1 2 Figure 1 2 1 2 Special tools instruments and meters 1 2 1 Oil filter detacher To fasten and detach 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 ...

Page 8: ...ide micrometer To accurately measure internal diameter of a hole 1 2 6 Dial indicator To accurately measure 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 ...

Page 9: ...2 400 4 800 mi 200 750 1 500 1 500 3 000 ITEM ROUTINE Whicheve comes first hours 20 75 150 150 300 Valves Check valve clearance Adjust if necessary Sparkplug Check condition Adjust gap and clean Rep ace if necessary Air fiter element clean Replace if necessary Every20 40hours More often in wet of dusty areas Carburetor Checkandadjustidlespeed starteroperation Adjust if necessary Crankcase breather...

Page 10: ...nebefore draining Engine oil filter cartridge Replace Engine oil strainer Clean Final gear oil Differential gear oil Check for oil leakage Replace eveny 12 months Front brake Check operation fuid leakage See NOTE page 8 Correct if necessary Rear brake Check operation Adjust if necessary Select lever safety system cable Check operation Adjust if necessary V belt Check operation Check for cracks or ...

Page 11: ...if necessary Steering system Checkoperation 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 Check all chassis fittings and fastenrs Correct if necessary Lights and switches Check operation Adijust headinght beams ...

Page 12: ...tle handle and start for 4 6 times Note Giving a leakage check to the pressure gauge Rotate the engine until the pressure gauge stop rising The maximum reading would be greater than 0 7 0 9Mpa after starting for 4 6 times See figure 2 1 Figure 2 1 check the valve lash Note when adjust valve lash the engine must be cooled The tempreture should be less than 35 Remove the seat cushion and fuel tank u...

Page 13: ...ck the lash between the valve stem by feeler gauge Valve clearance inlet and exhaust valve 0 05 0 08mm 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 check the valve lash Afterword install the cylinder valve cover vision hole cover the fuel tank and c...

Page 14: ...ver whether the spark plug insulator and electrode is damaged or sooting If so see figure 2 5 Figure 2 5 2 Check the spark clearance by feeler gauge whether it is between 0 6 0 7mm Or adjust the gap clean incrustation with spark plug cleaner and steel wire brush and check if the spark plug sealing washer Figure 2 6 Figure 2 6 ...

Page 15: ... roundness 0 0035 0 005 cylinder degree of toruosity 0 04 0 06 external diameter of piston 101 95 101 97 101 92 bore diameter of piston pin hole 22 002 22 010 22 010 gap between piston pin and piston pin hole 0 007 0 020 0 02 Piston ring end clearance Top ring the second ring 0 25 0 40 0 5 oilring 0 3 0 9 1 2 top ring 0 3 0 07 0 10 gap between piston ring and piston groove the second ring 0 02 0 0...

Page 16: ...last and abnormal noise 3 Abrasion of cylinder or piston Inspection of cylinder 1 Check whether the cylinder is damaged 2 Measure the bore diameter of cylinder at three spots 3 At the top the middle and the bottom of the piston stroke And measure the bore diameter at directions of right angle intersection repairing limit value out of roundness 0 005 mm taper 0 005mm Inspection of piston and piston...

Page 17: ...e piston groove is cracked and abraded See figure 2 7 Figure 2 7 2 Insert piston ring into cylinder and measure the end gap repairing limit value the first ring the second ring 0 5mm See figure 2 8 Figure 2 8 Measure the bore diameter of piston pin hole repairing limit value see figure 2 9 Figure 2 9 ...

Page 18: ... the external diameter of piston pin the gap between piston and piston pin repairing limit value 0 02mm See figure 2 11 Figure 2 11 2 4 Inspection of crankshaft 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 See figure 2 12 1 figure 2 12 2 ...

Page 19: ...ct the idle 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 clockwise to rise the idle anti clockwise to lower When adjusting is unavailable check that if there is a jam in carburetor idle nozzle or a air leakage of intake pipe ...

Page 20: ...is forbidden 2 Dip the air filter cartridge into 20 oil then take it out and squeeze the excessive oil assemble it orderly Impermeability is necessary See figure 2 15 figure 2 16 Figure 2 15 Figure 2 16 2 8 Inspection of oil filter Cleaning of lubricator oil strainer remove clarifier Figure 2 17 clean it to ensure a well work condition Then fix it up Note Clean the clarifier before injecting oil ...

Page 21: ...ookover the capacity with dip stick If the level is lower than the bottom indicator fuel up with recommended lubricant to the upper indicator Inspection of oil pump flow of oil pump r min 1000 2000 3000 L min 3 78 7 43 10 89 measure clearance of the top of internal external rotor Limit value 0 20mm 2 10 Lubrication of engine Check the oil level start the engine and let it running for a fow minutes...

Page 22: ...n of cylinder head 1 Check whether the spark plug and valve seat is cracked and whether the cylinder head is out of shape Examine the flatness of cylinder head by flat or knife edge gauge and clearance gauge Repairing limit value 0 05mm See figure 2 19 Figure 2 19 2 Remove and examine the width of valve Repairing limit value 2 0mm See figure 2 20 1 2 20 2 2 20 3 Indicator of oil level ...

Page 23: ...m If the valve seat is to wide or narrow or cracked grind it to ensure impermeability 4 Measure bore diameter of valve guide with internal micrometer and special gauge At last calculate clearance between valve stem and valve If the mating surfaces is coarse corrode or cannot contact with valve seat normally repalce it ...

Page 24: ...ve stem is worn out Check the motion of valve and measure external diameter Repairing limit value intake 5 95mm exhaust 5 95mm See figure 2 21 Fix valve into guide and look over the motion Figure 2 21 Inspection of valve spring Measure the free height and squareness Repairing limit value intake and exhaust See figure 2 22 1 2 22 2 free height of inlet valve spring 32 5mm squareness 0 10mm free hei...

Page 25: ...ing limit value inlet lifting distance 5 73mm Exhaust lifting distance 6 53mm See figure 2 23 Figure 2 23 7 Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal Repairing limit value 22 939mm Inspection of rocker arm Check whether the rocker arm is worn out or damaged and whether the oil hole is blocked ...

Page 26: ...ring limit value 12 038mm See figure 2 24 Figure 2 24 7 Inspection of rocker arm shaft Examine if the rocker arm if worn out or cracked Measure the external diameter of rocker arm shaft with micrometer Repairing limit value 11 96mm The repairing limit value of clearance between rocker arm shaft and hole 0 05mm See figure 2 25 ...

Page 27: ...cylinder head and block Unplug the intake pipe and spark plug Figure 2 26 1 2 26 2 Figure 2 26 1 Figure 2 26 2 Remove cylinder valve cover cam chainwheel cover and Figure 2 27 1 remove valve chain wheel Figure 2 27 2 Figure 2 27 1 Figure 2 27 2 ...

Page 28: ...ignment asjust these two symbols of the cam chain wheel to be at the same level with cylinder cover alignmentment of top dead center Rorate the crankshaft with T sleeve anti clockwise until these two symbols of the cam chain wheel to be at the same level with cylinder cover That is to say the piston of cylinder is at the top dead center ...

Page 29: ...e crankshaft until the T indicator on the magneto rotor to be at the same level with the center of vision hole cover of left front cover That is to say the piston is at the compression top dead center and there are valve clearance in these four rocker arms of cylinder head See figure 2 31 Figure 2 31 Remove chain tensioner adjuster See figure 2 32 ...

Page 30: ... by intersection manner before remove the bolt see figure 2 33 Figure 2 33 remove adjuster cotter sealed ring of cylinder headtensioner adjuster guide board See figure 2 34 Figure 2 34 remove cylinder block0 seal adjuster cotter sealed ring of cylinder head ...

Page 31: ...breather with a piece of cleaning cloth to avoid the snap ring falling into the case See figure 2 36 Figure 2 36 remove piston pin and piston Clean the buckle of piston and piston 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 ...

Page 32: ...32 3 3 Manual starting mechanism See figure 2 38 Figure 2 38 3 4 sensor Figure 2 39 3 5 left crankcase cover See figure 2 40 Figure 2 40 3 6 magneto remove the stator coil ...

Page 33: ...Remove the stator with rotor stripper See figure 2 41 Figure 2 41 Remove the whitney key See figure 2 42 Figure 2 42 3 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 34: ...2 44 Remove the right support frame clutch pulley disc See figure 2 45 1 figure 2 45 2 figure 2 45 3 Figure 2 45 1 Figure 2 45 2 Figure 2 45 3 3 8 clutch remove the clutch Remove bolts See figure 2 46 Figure 2 46 ...

Page 35: ...ve 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 3 9 carburetor 3 9 1 structure of carburetor ...

Page 36: ...r component 24 Seal ring of external shaft cover 25 External shaft cover 26 Screw M4 8 27 Suction pipe A 28 T plastic pipe 29 Suction pipe B 30 ACV valve diaphragm cover 31 Screw M4 12 32 Suction pipe C 33 ACV valve diaphragm component 34 Fuel inlet pipe 35 Starting jet 36 Dust proof cover 37 Screw 38 Nut 39 acceelerator pull cablelocating dowel loop 40 adjusting screw component 41 Screw 42 Washer...

Page 37: ... screw is set at maximum performance Before removing pilot screwd note the revolutions of screw in order to fix it back remove float chamber cover washer remove float pin float triangular needle remove the cover nut 0 rings spring starting plunger pilot jet check the carburetor body ...

Page 38: ...check the float triangular needle triangular needle seat 0 rings filter gauze Damaged worn out block replace check the piston valve crack replace diaphragm rupture replace piston valve oil stick bent worn out replace Note If the piston valve is damaged inject the petrol into valve Replace it when there is oil leakage check the main jet main jet ...

Page 39: ...39 pilot jet pilot screw 0 scrapers pilot jet bent worn out damaged replace gas fouling block blow with compressed air 4 Chassis 4 1 Steering operation system Structure of Steering Vertical Column ...

Page 40: ...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 Supporting Collar Sheath 11 cushionф14 ф32 4 12 Hexagon open groove nut M14 13 cotter pin 3 2 32 14 tension rod assembly 15 cushionф10 16 Hexagon open groove nut M10 17 cotter pin ...

Page 41: ...41 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 ...

Page 42: ...c 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 4 1 2 Figure 4 1 1 1 Hexagon Flange Bolt M8 30 2 Steering Bar Holder 3 Steering Bar Clip 3 Unplug all cables and connecting wires and remove the Steering Bar Figure 4 1 3 Figure 4 1 2 1 Connecting Wire 2 Rear Brake Cable ...

Page 43: ...ical Column Figure 4 1 4 1 cotter pin 3 2 32 2 cushionф14 ф32 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 supporting Bracket 3 safety cushion Figure 4 1 5 6 Remove outer ball pin components on tension rod form turning joint ...

Page 44: ...components of the steering vertical column from 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 tension rod and the Turning rocker arm is tightened Figure 4 1 8 In case of loosen or worn out ...

Page 45: ... and replace with new ball pin 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 tension rod replaced Caution tension rod should not be repaired by welding 4 Check whether the hexagon open groove nut and cottor pin are intact No crack or flaw is allowed...

Page 46: ...g 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 vertical column into the bottom seat and fix it with M14 open groove nut 1pcs 14 36 4 cushion 1pcs collar sheath 1pcs and 3 2 32 cotter pin 1pcs Figure 4 1 9 Fastening Torque of M14 open groove nut 70 80N m Caution before insertin...

Page 47: ... 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 Figure 4 1 10 Fastening Torque of M8 60 Bolt 26 30N m Caution inner surface of the supporting brackets must be greased with lithium lubrication ...

Page 48: ...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 cushion12 2pcs M10 hexagon open groove nuts 2pcs and cotter pins 3 2 32 2pcs Figure 4 1 11 Fastening Torque 28N m Figure 4 1 11 1 Turning rocker arms comp ...

Page 49: ... Plastic oranments on Steering Bar Figure 4 1 1 2 Remove steering bar clip 附图4 1 2 3 Unplug all cables and wires and remove the steering bar Figure 4 1 3 4 1 2 2 Inspection of steering bar 1 Check any existing or potential crack on the steering bar In case of above defects the steering bar must be replaced Figure 4 1 12 Figure 4 1 12 2 Altitude balance on each end of the steering bar must be less ...

Page 50: ...Radial runout and wear condition of the inner surface must be less than 0 8mm Otherwise replace the steering bar clip 4 1 2 3 Assembly of the steering bar 1 Connect the steering bar clip and holder with the main frame by hexagon flange bolts M8 30 4pcs and adjust the direction of brake cables on both left and right handlebar and clutch cable Figure 4 1 2 Fastening Torque of the M8 30 Bolt is 26 30...

Page 51: ...xagonal 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 front hydraulic pipe 15 inner hex bolt栓 M6 10 16 bolt of front hydraulic pipe 17 front hydraulic disk brake cushion 18 Hexagon Flange Bolts M6 25 19 Hexagon Flange Bolt M8 14 20 Hexagon Flange nutM8 21 rear brake piece 22 brake fluid case 4 2 1 Preparation ...

Page 52: ...l 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 ensure the fluid level 1 Brake fluid box is higher than the minimum mark b Travel distance of the front brake lever should be kept between 10mm 15mm Otherwise please adjust the screw to meet required travel ...

Page 53: ...e periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid e Periodical inspection of the wear condition of front disk brake plate is also necessary Disk brake plate must be replaced depending on its wear condition Figure 4 2 3 Caution 1 If the thickness of the disk brake plate is less than 1 5mm it must be replace 2 In occasion of crack or distortion the disk brake ...

Page 54: ...rted 4 2 1 1 Disassembly inspection maintenance and assembly of Front Disk Brake System 4 2 1 2 Disassembly of front disk brake plate 1 Removing the wheel component see Figure 4 2 4 1 front wheel hub 2 Hexagon open groove nut M30 3 cotter pin 3 2 32 4 cushion 5 taper nut M10 Figure 4 2 4 2 Sequently remove the cotter pins open groove nuts cushion and front wheel hub from the front wheel shaft Figu...

Page 55: ... and then remove the whole unity Figure 4 2 6 Figure 4 2 6 1 bottom seat of Disk Brake Pump 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 Clip Figure4 2 3 4 Remove the Rront brake plate system Figure4 2 3 ...

Page 56: ...el Pipes for deterioration 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 Figure 4 2 8 Figure 4 2 8 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 Disk Brake Plate i...

Page 57: ...to 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 50 N m 60N m 4 Fix the Plate Clip onto Front Turning Joint with M8 Bolts 4pcs Fastening Torque 18 N ...

Page 58: ...ng Torque of the bolt is 10 N m 14 N m Caution Do not operate the vehicle 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 2 Rear Brake System 4 2 2 1Preparation for inspection and maintenance of the Rear Brake System ...

Page 59: ...t the brake fluid box 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 manufacturer Figure 4 2 9 to ensure the fluid level is higher than the minimum mark Figure 4 2 9 Figure 4 2 9 1 Minimum Mark d Travel distance of the Rear Brake Pedal should be kept between 20mm 30mm Otherwise please adju...

Page 60: ...e Pedal the process 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 condition of front disk brake plate is also necessary Disk brake plate must be replaced depending on its wear condition Figure 4 2 11 ...

Page 61: ...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 out cracked or distorted 4 2 2 2 Disassembly Inspection and Assembly of Rear Disk Brake System 4 2 2 3 Disassembly of Rear Disk Brake System 1 detach Rear Disk Brake Pump from the Frame Figure 4 2 6 2 Remove Rear Disk Brake oil bowl from t...

Page 62: ...ake System 4 2 2 4 Disassembly of Rear Disk Brake Plate 1 remove rear wheel components Figure 4 2 13 2 Release the transmission case components of rear bridge from the main frame Remove rear central transmission shaftv components Figure 4 2 14 Figure 4 2 13 1 Conical Nuts M10 2 Wheel Hub 3 Remove the Bottom Seat of Rear Disk Brake Plate from the Rear Bridge Figure 4 2 14 ...

Page 63: ...om Seat of Rear Disk Brake Plate 2 Rear Disk Brake Plate 4 2 2 5Inspection of Rear Brake System 1 Check the Brake Fluid Box for crack leakage and other potential defects 2 Check Fastening Bolts of all Fuel Pipes for possible looseness or damage 3 Check all Fuel Pipes for deterioration distortion crack wear and other hidden defects 4 Check the Brake Plate Clip for distortion crack rust and stuck ...

Page 64: ...and crack in which case it must be replaced Maximum wear of Rear Disk Brake Plate is less than 2 5mm 4 2 2 6 Assembly of Rear Brake System 1Fix Disk Brake Plate onto the Bottom Seat with Special M8 Bolts 6pcs Caution Grease the bolt with thread glue when fastening Fastening Torque of bolt 22 N m 28N m 2 Mount the Bottom Seat of Rear Disk Brake Plate onto rear ...

Page 65: ...ount Rear Disk Brake Pump onto the Frame with M Bolts 2pcs Fastening Torque 22 N m 26 N m 6 Fix front wheel hub onto the front wheel shaft with cushion open groove nuts and cotter pins Fastening Torque 50 N m 60 N m 7 Assemble Front Wheel Components onto Front Wheel Hub with M10 Conical Nuts GB T802 4pcs Fastening Torque of Conical Nut 55 N m N m Caution Do NOT operate the vehicle immediately afte...

Page 66: ...Wheel Hub is rusted or cracked Figure 4 2 16 4 Check if the conical nuts of the Wheel Hub Are loose or distorted 4 3 2 Disassembly inspection and assembly of wheel components 4 3 2 1 Disassembly of wheel components Remove M10 Conical Nuts 4pcs and detach the tire Figure 4 2 13 4 3 2 2 Inspection of wheel components 1 Check if the wheel hub has any distortion rust crack or other potential defects I...

Page 67: ...erwise please replace with new tire Remove the tire for vibration test of the wheel hub Should the vibration exceed 1 2mm the wheel hub must be replaced 5 Inspect the four conical bores on the wheel hub In occasion of angular distortion or wear the wheel hub must be replaced 4 3 2 3 Assembly of wheel Attach wheel hub onto the wheel with M10 Conical ball Nuts 4pcs and dust proof cover 1pcs Fastenin...

Page 68: ...mum security and longer life expectancy of the wheel please periodically inspect the tire pressure and profile depth Insufficient tire pressure can result in not only intensified wearing of the tire but also instability during the course of operating the vehicle such as hard turning Excessive tire pressure can also reduce the friction force between the tire and ground causing spinning or lose of c...

Page 69: ... the vehicle Caution Should the profile depth falls below 3mm please replace the tire immediately Figure 4 2 18 Figure 4 2 18 Figure 4 2 18 4 4 Transmission System 4 4 1 Fore Bridge Figure 4 2 19 1 front wheel hub 2 L R transmission shaft 3 fore bridge differential components 4 middle transmission shaft components of fore bridge ...

Page 70: ... 10 oil seal of rear constant velocity joint assembly 11 differential adjusted washer 12 M8X20 engine gearbox bolt 13 differential assembly 14 inner hex bolt M8X25 15 inner hex bolt M8X10 16 hexagon flange bolt M10 25 17 clip used in66 18 5X80 cylindrical pin 19 engine gearbox assembly 20 adaptor 21 cog rack 22 fork 23 0 rings of engine gearbox 24 0 rings of front cover 25 deep groove ball bearing...

Page 71: ... connection between wheel hub and the Bottom Seat of wheel hub is reliable and if there is any distortion on the Bottom Seat of wheel hub If there exists any such potential defects the Bottom Seat of wheel hub must be replaced immediately 2 Check if the differential and its attachments are compatible well and if there is stagnation slosh and Crunch of the Differential bearing In case the bearing o...

Page 72: ...must be checked and maintained by a professional 8 Gears are fragile commodities in transmission system 4 4 1 2 Disassembly of fore bridge component 1 Detach the two front wheel parts 2 Removed front Disk Brake Clip cotter pin cushion and the front wheel hub Figure 4 2 20 Figure 4 2 20 3 Disassemble the fore bridge differential Figure 4 2 20 4 Take out the fore bridge from the frame 5 Release engi...

Page 73: ...ust proof Rubber Sheath can not be touched by petrol and diesel oil 2 The dust proof Rubber Sheath must not be cracked for slight scratch may be damaged the Rubber Sheath 3 Inject 2 3 Lithium Lubrication into the ball 4 Open the differential and inspect wear condition of gear shaft and cushion then replace the defective component 4 4 1 4 assembly of fore bridge component 1 Fix transmission shaft o...

Page 74: ...ial onto the frame with hexagon flange bolt M10 110 2pcs M10 nuts 2pcs cushion 10 2pcs Figure 4 2 21 Fastening Torque of the Bolt is 40 45N m Figure 4 2 21 1 hexagon flange bolt M10 110 2 fore bridge case 4 4 2 Rear Bridge 4 4 2 1transmissioncase of rear bridge ...

Page 75: ...rear drive gear seat 14 rear adjuster cushion 15 rear adjuster cushion 16 oiling plug 17 0 rings of grease hole 18 hex bolt M8X35 19 cushion8 20 hex bolt M8X25 21 cushion8 22 zinc base alloy oil cap 23 case cover of rear bridge 24 inner hex bolt M8X45 25 cooper gasket8 26 flange nut M8 27 hexagon flange bolt M8X12 28 cooper gasket8 29 90X65 oil seal 30 deep groove ball bearing 16017 31 0 rings of ...

Page 76: ...e maintenance of rear bridge is identical to the fore bridge Please refer to the preceding contents 4 5 gear shift mechanism 1 gear shift mechanism assembly 2 gear shift mechanism handle 3 plastic screw of gear shift mechanism 4 dust proof cover of gear shift mechanism 5 dust proof cover thimble of gear shift mechanism 6 elocity joint robber sheath of gear shift mechanism 7 velocity joint of gear ...

Page 77: ...l repairman 2 If there is lack in the gear shift mechanism adjust the nut of the fork to correct position and strengthen gear shift mechanism 3 Remove the gear shift mechanism and check whether the linking rod is cracked If so it should be changed 4 Check whether the bouncing spring of gear shift mechanism is intense enough 5 Check whether the gear is engaged correctly and whether there are tripst...

Page 78: ... damper components 2 hexagon flange bolt M10 50 3 locknutM10 1 25 4 horizontal rear fin components 5 the right horizontal rear fin velocity joint 6 the left horizontal rear fin velocity joint 7 locknutM12 1 25 8 horizontal rear fin robber sheath 9 horizontal rear fin press plate 10 hexagon flange bolt M8 14 4 6 2rear rocker arm ...

Page 79: ...lange bolt M10 65 8 ust proof cover of rear rocker arm 9 rear left bottom rocker arm assembly 10 middle spacer sleeve of fore L R rocker arm 11 hexagon flange bolt M10 65 12 rear left bottom rocker arm assembly 13 middle spacer sleeve of fore L R rocker arm 14 hexagon flange bolt M10 65 15 hex locknut M10 1 25 16 cover of rear left bottom rocker arm 17 hexagon flange bolt M6 12 18 cover of rear ri...

Page 80: ...ker 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 assembly 8 fore bottom velocity joint assembly ...

Page 81: ...6 4 Disassembly Maintenace and Assembly of up and 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 the collar sheath is defective by pressuer and whether the Rubber Sheath is worn out or cracked B Check whether the cotter pin is reliable If not so replac...

Page 82: ... be greased with butter before assembly B The surface 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 tension rods into hole by way of the trough of open groove nut with cotter pin 4 pcs and make these tension rods bisection on feet ...

Page 83: ...Collar Sheath and Rubber Sheath 4 Check if the cotter 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 professional staff or replace the damper and then tighten the bolt Note self lock nut is necessary and the torque must be at a range of 45 55 N m 5 Electric...

Page 84: ...Dark Red Dr 28 Green Black G B 12 White Green W G 29 Black 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 No electrification 1 First Check the safety 2 Second if the safety is good then check the battery whether it is power on 3 Finally check the swit...

Page 85: ...85 ...

Page 86: ...igh voltage lead wire insulated badness repalce replace electrification system 1 discharge self 2 uncharge or shortage charge 1 cover polluted or drenched by rain 1 carve out a way or short circuit caused by connected wire badness 2 rectifier damaged 3 baterry lower electrolyte electrode failure water proof keep clean of the cover and repalce electrolyte repair repalce entered distilled water repl...

Page 87: ...rge 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 the elementary coil L1 caused instant lower pressure while at the secondary coil caused induce pressure its instant pressure up to 10000V sparkover at the clearance of sparkplug 0 6mm so the engine ignited...

Page 88: ...yelloe output into the rectifier through rectifier into direct current pressure and output through R1 to charge the battery 5 3 Battery Under the following problems please change the battery 1 With long time charge but the pressure do not increase to a set value 2 At the bottom of case there is something dirty or electrode have become white or the case with a sulfate function 3 Electrode former sc...

Page 89: ...nd dangerous As it contains vitriol it may cause burn accident Battery also contains explode gas so keep it far away spark and flame and cigarette When charge or using in house keep the air easy floating When work near the battery please take care of your eyes and keep kids away from the battery If under such accidents please deal with it as follows or ask for help from the doctors 1 Exterior wash...

Page 90: ...ction switch 10A signal 25A Ignition 5A 2 4draver 25A frontlight biue black1 red red white red brown brown blue yelow red brown blue white M M B 15A black red1 yellow yellow green blue yellow2 green yellow 12V 18W black 12V 1 7W oil temperature switch front light1 purple front left right turn light 12V 18W 12V 5W 21W 12V 10W front light2 rearlight brakelight starting button dark green dark green d...

Page 91: ... do not shine ４ Horn Switch When press the button the horn will move But if without sound or with unclear sound or with little sound please check the problem according to the guide 5 6 Electrical starting system Starting Circuit yellow red light green function O FF function yellw red blue white biue green black green red function function O FF gray nigger brown dark green ...

Page 92: ...tery with enough power and the time of pressing button will be within 55 seconds If longer time more than 5 seconds it may cause the damange of startor relay and the startor relay motor and may also cause the damage of the battery that it can not be charged or not charge enough 2 When starting if heard some noises from the startor relay the battery must be without enough power Please stop starting...

Page 93: ...Braking pattern Normal condition Front dual disk Rear single disk front and rear linkage Right foot left hand operation Braking pattern Primary Brake 1 E mark Front dual disk Rear single disk front and rear linkage right foot right hand operation Primary Brake 2 Front dual disk Rear single disk front and rear linkage right foot right hand operation Emergency brake hand operation Parking brake Engi...

Page 94: ...d HS1102MU HSUN Pattern Single cylinder water cool dual exhaust four stroke Bore Stroke 102mm 84mm Compression Ratio 9 2 1 Volume 686ml Max power 25kW 5000r min 5500r min Max power E mark 13kW 5500r min Rated power 24kW 6000r min 6500r min Max Torque 49N m 5000r min Max Torque E mark 27 5N m 4500r min Mini Idle speed 1400 100r min Fuel type Unlead 90 Lubrication Pressure Splash Starting system Ele...

Page 95: ...n Lubrication 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 71kg c Components Specification Carburetor PD42J Pattern Parallel Vacuum Spark plug DR8EA Speed meter Electronic Battery 12V 21Ah Headlight 12V 35W 35W White light Front Indicator 12V 3W White ...

Page 96: ...e Rocker arms Front and Rear dual rocker arms Parking brake Mechanical Frame Steel pipe Magneto Rotate DC output Spark plug gap 0 6 0 7 mm Safety fuse 30A 6 1 2 Performance Requirement a Starting Performance Starting time must be less than 15s b Accelerating Performance Starting acceleration performance must be less than 14s 200m and overtaking acceleration performance must be less than 13s 200m c...

Page 97: ...8 HC 800 ppm b mode emissions CO 7 0 g km HC 1 5g km NOx 0 4 g km i deceleration and stopping performance a braking distance 27m starting velocity is 60km h b braking deceleration must be greater than 5 88m s2 j noise The aon running noise must be less than 79dB A Static noise is 94dB A and the eagine speed is 2750mim2 k radio frequency interference The allowable radiation the loss of suppress of ...

Page 98: ... with distance headlamps that conform to GB 5948 1998 or GB 4599 94 q The main beam intensity of distance headlamp must reach a digree of 8000cd 6 2 Requirements for torque of fastener fastening parts N m torque pillar 35 45 nut on chain stay 45 50 Upper nut on fore damper 35 45 bottom nut on fore damper 35 45 Upper nut on rear damper 45 55 bottom nut on rear damper 45 55 Nut on upper rocker arm o...

Page 99: ...he engine is on the ground the H gear is lighting by the CDI inner transistor to control the dash light earth connection 3 The function of the diode in this circuitry is that after parking and brake to actualize the electrial starting 4 The relay electrical source to provide the electricity through the CDI working it can protect the relay and to extend the useful time 5 Use the pan fuse box each o...

Page 100: ...100 L1 L2 30A C D I m mi n 100 0 FU E L O V E R R I D E ...

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