JI-EE ATV BXL 100 Service Manual Download Page 49

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11. HYDRAULIC DISC BRAKE SYSTEM

11.1 TROUBLESHOOTING

11.4 REPLACE THE BRAKE HYDRAULIC OIL

11.2 REPLACE BRAKE DISC

11.5 REAR BRAKE ADJUSTMENT

11.3 REPLACE THE BRAKE SHOE

11.1 TROUBLESHOOTING

POOR BRAKE PERFORMANCE

★

Improper brake adjustment

★

Worn brake shoes

★

Brake linings oily, greasy or dirty

★

Worn brake cam

★

Worn brake drum

★

Brake arm serrations improperly engaged

★

Brake shoes worn at cam contact area

11.2 REPLACE BRAKE DISC

Remove the rear left tire

Unscrew the two bolts shown on the photo
and remove caliper.

Summary of Contents for ATV BXL 100

Page 1: ......

Page 2: ...INE FUEL SYSTEM 14 5 ENGINE LUBRICATION AND COOLING SYSTEM 18 6 ENGINE COMBUSTION SYSTEM 21 7 TRANSMISSION SYSTEM 25 8 FRONT WHEEL AND STEERING SYSTEM 29 9 REAR WHEEL SYSTEM 42 10 FENDERS AND EXHAUST PIPE 45 11 HYDRAULIC DISC SYSTEM 48 12 ELECTRICAL SYSTEM 53 13 TROUBLE SHOOTING 57 1 ...

Page 3: ... The battery electrolyte contains sulfuric acid Protect your eyes skin and clothing If you contact it flush thoroughly with water and call a doctor if electrolyte gets in your eyes 1 2 NOTES All information illustrations directions and specifications included in this publication are base on the latest product information available at the time of approval for printing JI EE Industry Co Ltd reserves...

Page 4: ...1 3 SERIAL NUMBER The frame serial number is stamped on the right side of the frame The engine serial number is stamped on the left side of the crankcase Frame serial number Engine serial number 3 ...

Page 5: ...k Starter Oil Pump Separate Supply 1 0 liter Automatic C V T V belt CHASSIS Overall Length 1600mm 62 9inch Overall Width 795mm 31 2inch Overall Height 1020mm 40 1inch Seat Height 700mm 27 5inch Wheel base 1020mm 40 1inch Ground Clearance 120mm 4 7inch Dry Weight 141kg Fuel Tank Capacity 6 5 0 2liter SUSPENSION Front Dual Absorber Swing arm Rear Single Absorber Swing arm BRAKES Front Drum Rear Hydr...

Page 6: ... Steering shaft bushing holder nut 24 30 17 7 22 1 Wheel rim bolt 18 25 13 3 18 4 Tie rod lock nut 35 43 25 8 31 7 King pin nut 30 40 22 1 29 5 Handlebar lower holder nut 40 48 29 5 35 4 Front wheel bolt 24 30 17 7 22 1 Front axle castle nut 40 60 30 45 Front brake arm nut 4 7 3 0 5 2 Rear brake arm nut 7 12 5 2 8 9 Rear axle castle nut 40 60 30 45 Rear wheel bolt 24 30 17 7 22 1 Exhaust muffler m...

Page 7: ... 0 8 kgf cm2 TOE IN 5 10 mm TORQUE VALUES SPARK PLUG TIE ROD LOCK NUT 25 30 N m 35 43 N m ENGINE OIL JASO FC Grade or same degree oil GEAR LUBRICATION OIL SAE 90 2 2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding conditions Riding in unusually dusty areas require more frequent servicing INITIAL SERVICE First week REGULAR SERVICE Every 30 operating d...

Page 8: ...pper end Lubricate the cable with commercially lubricant to prevent from premature wear 2 5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttle lever 2 6 AIR CLEANER Unscrew the air cleaner cover screws Pull out...

Page 9: ...ing washer attached thread the spark plug in by hand to prevent cross threading Tighten the spark plug with 25 30 N m 2 8 IDLE SPEED ADJUST SCREW Connect an engine speedometer Warm up the engine 10 minutes are enough Turn the idle speed adjust screw on the carburetor to obtain the idle speed Turn in clockwise will get higher speed Turn out counter clockwise will get lower speed IDLE SPEED 1800 100...

Page 10: ...E SYSTEM Inspect the front brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play of the brake lever at the end of the brake lever The standard of free play is 15 25 mm Inspect the rear brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play of the rear brake lever at the end of the lever T...

Page 11: ...es to indicate the axle center height Measure the distance between the marks Carefully move the vehicle back let the wheels have turned 180 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 measurements Toe in 5 10mm If the toe in is out of standard adjust it by changing the length of the tie rods...

Page 12: ...LT Gear oil needs to be changed every year There is a gear oil release bolt at the rear of engine Unscrew this release bolt and can let the dirty oil flow out The re add oil hole is on the engine case beside gearbox FILL OIL 11 ...

Page 13: ...NE REMOVAL Remove the seat and rear fender Chapter 10 Remove the spark plug cap from the spark plug Remove the rear tires first and than disassemble 2 REMOVE TAILPIPE 1 REMOVE REAR TIRE the exhaust pipe Caution When remove the tailpipe before be careful the temperature Please wear the gloves to avoid the heat from tailpipe Remove the drive chain cover This is under the chain Remove the drive chain...

Page 14: ...nger nuts are outside and one is inside Remove the engine from the left side of frame 3 3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal The torque of engine hanger bolt is 24 30 Nm Route the wires and cable in reverse order properly 13 ...

Page 15: ...LY UNPROPER ADJUSTMENT TO THE IDLE SPEED SCREW IGNITION MALFUNCTION FUEL AIR MIXTURE RATIO NOT GOOD AIR CLEANER DIRTY INSULATOR LEAKAGE FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE FUEL JET OF CARBURETOR CLOGGED FUEL TANK CAP BREATHING HOLE CLOGGED FUEL FILTER CLOGGED FUEL FLOWS IN THE TUBE UNSMOOTHLY FLOAT LEVEL IN CARBURETOR TOO LOW RICH MIXTURE FLOAT NEEDLE VALVE IN CARBURETOR FAULTY FLOAT...

Page 16: ...er Disconnect the fuel line and auto choke electric wire Unscrew the intake pipe mounting bolts at the carburetor then remove the carburetor Note Turn off the fuel pipe by turn the fuel cup below fuel tank to off position DISASSEMBLY Remove the carburetor cap Remove the throttle cable from the throttle valve while depressing the throttle valve spring Remove the needle clip retainer the jet needle ...

Page 17: ...m pin float and float needle valve Inspect the seat of the float needle valve for wear or damage Disassembly the idle jet main jet idle speed adjust screw and idle mixtures adjust screw Inspect all the jets and screws for wear or damage Clean the passages and jets with compressed air 16 ...

Page 18: ...verse order of disassembly THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle Install the jet needle into the throttle valve Assemble the throttle cable spring and the throttle valve Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor 17 ...

Page 19: ...antity is not enough this engine will be serious scratched and then this engine will stop even cannot work again When this engine is serious scratched you need to change the piston piston rings and cylinder together Also you need to check the combustion system and lubrication system carefully 5 3 OIL PUMP The quantity of oil that deliver out from oil pump increased by the engine speed and the carb...

Page 20: ...IN OIL TANK IS TOO LOW OIL TUBES WERE NOT FIXED WELL OIL HAS LEAKAGED FROM TUBE ENDS OIL TUBES WERE BROKEN OIL TUBES WERE CLOGGED OIL PUMP CANNOT WORK ALWAYS INSUFFICIENT OIL LEVEL EXTERNAL OIL LEAKS IN LUBRICATE OIL TANK WORN CYLINDE HEAD GASKET WORN PISTON RINGS 19 ...

Page 21: ...RN OUT HIGH COMPRESSION EXCESSSIVE CARBON BUILD UP ON PISTON HEAD OR IN COMBUSTION CHAMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD UP EXCESS SMOKE CYLINDER OR PISTON RINGS WORN OUT IMPROPER INSTALLATION OF PISTON RINGS PISTON OR CYLINDER WALL SCORED OR SCRATCHED OVERHEATING EXCESSIVE CARBON BUILD UP ON THE PISTON OR COMBUSTION CHAMBER ENGINE COOLING SYSTEM FAN CYLINDER ...

Page 22: ...the cylinder head Remove the cylinder carefully and then you can see the whole piston Remove one piston pin clip Remove the piston and piston pin Spread each piston ring and remove it by lifting up at a point just opposite the gap Note Don t let the clip drop into engine crankcase 6 3 CYLINDER AND PISTON INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder inner diameter at...

Page 23: ... 0 10 mm Insert each piston ring into the cylinder and measure the end gap Service limit 0 5 mm Measure the clearance between ring and groove Service limit 0 09 mm Measure the piston outer diameter at 10 mm high from the skirt s bottom Service limit 39 9 mm for 50cc engine 51 9 mm for 100cc engine 22 ...

Page 24: ... 04 mm for 100cc engine Measure the connecting rod small end inner diameter with an inside micrometer Service limit 14 06 mm for 50cc engine 15 06 mm for 100cc engine 6 4 INSTALLATION Install the piston rings with the marks facing up Do not damage the piston rings by spreading the ends too far Clean the cylinder gasket surface being careful not to drop any gasket material into the crankcase 23 ...

Page 25: ...exhaust pipe Do not align the piston pin clip end gap with the piston cutout Install a new cylinder gasket Apply a thin coat of engine oil to the piston rings and cylinder wall Install the cylinder compressing the piston rings Replace a new cylinder head gasket Install the cylinder head Tighten the cylinder mounting bolt The torque is 10 14N m 24 ...

Page 26: ...TRIC SELF STARTER MECHANISM 7 4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION 7 8 DISASSEMBLY AND CHECK OF C V T SYSTEM 7 1 TROUBLESHOOTING SCOOTER CAN NOT MOVE AFTER ENGINE START BELT WEARED FRONT PULLEY WEARED OR BROKEN LINING OF CLUTCH WEARED CAN NOT RUN AT HIGH SPEED BELT WEARED ROLLERS WEARED SPRING OF REAR PULLEY IS DISTORTED 7 2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 25 ...

Page 27: ...e drive pulley will be push to belt by the centrifugal force from six rollers Then the pitch circle of belt in drive pulley will be larger The belt at driven pulley is forced to move to the center of shaft then the radius of pitch circle is decreased The transmission ratio is therefore altered by the alteration of pitch circle s radius In the drawing H means high speed L means low speed 7 5 CONTIN...

Page 28: ...d and make the engine maintain smooth running with original revolution 7 6 GEAR BOX The torque received by the Drive shaft will be transmitted by the speed reduction of two sets to rear axle shaft The first gear ratio is 36 13 for 50cc engine 47 15 for 100cc engine The second gear ratio is 48 12 for 50cc engine 31 11 for 100cc engine DISASSEMBLE TRANSMISSION BOX Unscrew fixing nut of rear wheel ax...

Page 29: ...or can act only when the left hand brake is applied 7 8 DISASSEMBLY AND CHECK OF C V T SYSTEM Remove the engine clutch cover by unscrew the fixed bolts Check the belt for wear If necessary replace the belt Disassembly the front drive pulley check the six rollers for wear If necessary replace the rollers 28 ...

Page 30: ...ING OF FRONT WHEELS AND STEERING SYSTEM 8 5 FRONT BRAKES 8 2 TROUBLESHOOTING 8 6 SPEEDOMETER 8 3 HANDLEBAR 8 7 STEERING SYSTEM 8 4 FRONT WHEEL 8 1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM FRONT WHEEL FRONT BRAKE STEERING SYSTEM HANDLEBAR 29 ...

Page 31: ...RONT BRAKE DRUM BEARING BENT RIM AXLE NUT NOT TIGHTENED PROPERLY INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CABLE BENT TIE RODS WHEEL INSTALLED INCORRECTLY UNEQUAL TIRE PRESSURE BENT FRAME WORN SWING ARM PIVOT BUSHINGS BRAKE SHOES WORN WORN BRAKE DRUM IMPROPER BRAKE ADJUSTMENT LOOSE FRONT SUSPENSION FASTENERS BINDING SUSPENSION LINK FAULTY FRONT SWING ARM BUSHINGS IMPROPERLY INSTALLED FRONT SWING A...

Page 32: ...ture for adjustment tool 8 3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar Remove front brake cable Remove the couple of brake switch assy Remove engine switch housing on the left handle bar Remove rear brake cable Remove the bolts attaching the upper holder cover There are two bolts on top and another two bolts on the both sides 31 ...

Page 33: ... the L or R marks facing forward Tighten the forward bolts first and then tighten the rear bolts Install the handlebar upper holder s cover Install the switch housing aligning the boss with the hole Tighten the upper screw first then tighten the lower one Install the rear brake lever bracket aligning the boss with the hole Tighten the screw securely Aligning the split line of the throttle housing ...

Page 34: ...ten the four wheel castle nuts Torque 40 60 N m Remember put a cotter pin in the castle nut 8 5 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel Remove the brake drum Measure the brake lining thickness The minimum limit 1 5 mm If they are thinner than the minimum limit replace the brake linings Measure the brake drum inner diameter 86mm The maximum limit 86 mm 33 ...

Page 35: ...the bearings BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm Remove the brake panel from the knuckle Remove brake arm and cam Remove indicator plate and felt seal INSTALL BRAKE PANAL Apply grease to the brake cam and anchor pin and install the cam in the brake panel Soak the felt seal in the engine oil and install the seal on the brake cam 34 ...

Page 36: ...n the screws securely Position the brake shoes in their original locations and install the brake shoe spring Install the brake drum and front wheel Install the castle nut and cotter pin When finish all steps of above it must do some fine turnings on break system First tune the adjuster screws of brake distributor When the nuts tighten loosen it about two teeth Then tune the adjuster nuts of steeri...

Page 37: ...ere replaced or poor brake force The adjustment should be done The brake adjustment steps are below 1 Handlebar Brake Lever It should tune up the brake allot assembly first and then align the handlebar lever 2 Front Brake Tune the front brake up to normal and adjust the nut in the brake allots assembly 3 Finally Set the pedal brake to the position And use the above steps to adjust the whole brake ...

Page 38: ...SENSOR BROKEN DRUM MAGNET REMOVAL First disassemble the screws on top of the panel There are seven screws which locate on the top side and forward Then the panel just can be taking apart Second some cables just connect with the panel So let the those couplers are disassembled When those two were taken apart use open end tool to unscrew the screws on the back of panel So it can be checked and chang...

Page 39: ...is located on the back of wheel hub Use hexagon wrench to disassemble the nut LEFT FRONT BRAKES INSPECTION Remove the left front wheel Remove the brake drum Make sure the magnet steady in the drum Install front brake drum 38 ...

Page 40: ...ase use thickness gauge to make it be in place Tie the wires of speedometer with front brake cable 8 7 STEERING SYSTEM REMOVAL OF KINGPIN AND TIE ROD Remove the front wheels and brakes drum Remove the cotter pin on the kingpin Remove the four self lock nuts from the tie rod ball joints and take off the two tie rods Unscrew the bolt and remove the kingpin 39 ...

Page 41: ...he kingpin for damage or cracks STEERING SHAFT REMOVAL Remove the speedometer and handle bar cover see paragraph 8 1 Remove the front fender see paragraph 10 1 Unscrew the steering shaft fixed out below shaft Pull steering shaft carefully BUSHING INSPECTION Remove the steering shaft Remove the bushing from the shaft Inspect the bushing for damage or wear replace if necessary Measure the bushing in...

Page 42: ...y and quietly Also check that the bearing outer race fits in the holder Replace the bearing if necessary INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing Apply grease to the bushing Install the bushing holder and tighten the nuts Torque 24 30 N m Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 60 N m INSTALLATION OF TIE ROD In...

Page 43: ...9 REAR WHEEL SYSTEM 9 1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 9 3 DRIVE MECHANISM 9 2 TROUBLESHOOTING 9 4 INSTALLATION 9 1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 42 ...

Page 44: ...ELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY BRAKE DRAG INCORRECT BRAKE ADJUSTMENT STICKING BRAKE DISC STICKING BRAKE TUBE 9 3 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel first Then remove the drive chain cover Disassembly the chain retaining clips and master link Disassembly the driven sprocket axle and sprocket collar Check the driven sproc...

Page 45: ... smoothly and quietly Replace if necessary 9 4 INSTALLATION Add grease to the dust seal lips and install dust seals Assembly the rear axle and the driven sprocket Assembly the drive chain on the driven sprocket Assembly the master link and retaining clip Note the retaining clip direction Install the drive chain cover Assembly the chain under cover 44 ...

Page 46: ...PIPE INSTALLATION 10 1 FENDERS DRAWING 10 2 REAR FENDERS REMOVE First pull the Seat Fixer Assembly to take off the seat This seat fixer assembly is under the right side of the rear fender The next procedures of remove the rear fender is Unscrew the three bolts that connect in the back bumper and four in front The actual positions please see the fenders drawing 45 ...

Page 47: ...ews under the front fender just above front wheels Unscrew the two fixed screws beside the oil tank Unscrew the fuel tank cap Then the front fender can be remove Remove the seat by pulling the seat fixer assembly under the rear fender Remove the handle bar assembly headlight and handlebar cover Unscrew the hexagon screws which connect with footrest plate Unscrew the four screws which connect with ...

Page 48: ...nder and footrest plate before you take off the exhaust pipe Unscrew the two exhaust pipe bolts that fixed with engine Remove the exhaust pipe mounting bolts that fixed on the engine Remove the exhaust pipe carefully 10 6 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal Torque Exhaust muffler bolts 30 35 N m After installation make sure that there are no exhaust leaks 47 ...

Page 49: ...HE BRAKE SHOE 11 1 TROUBLESHOOTING POOR BRAKE PERFORMANCE Improper brake adjustment Worn brake shoes Brake linings oily greasy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 11 2 REPLACE BRAKE DISC Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper 48 ...

Page 50: ...e mounting seat of the disc Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm 11 3 REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown and remove caliper 49 ...

Page 51: ...e plate to the end Remove the brake shoe as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm Press the piston to the end prior to installation of PISTON brake shoe 50 ...

Page 52: ...il drain Fasten the bolt after the used oil being drained out completely Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup to avoid air get into brake system such like caliper and tube Unscrew the bolt to vent air from brake system Fasten the bolt if there isn t any air in the brake system 51 ...

Page 53: ...R When repairs some parts about rear brake system it must be tuned in handlebar master cylinder adjustment nut and rear brake First the adjustment nut of master cylinder should be tuned up to specification And than to tune up the nut on the handlebar the brake force must be in specification Be careful it will be filled with the brake oil in reservoir beforehand and then the wheel cylinder should d...

Page 54: ...LY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit CHARGING SYSTEM FAILURE LOOSE BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH ENGINE INTERMITTENT POWER LOOSE BATT...

Page 55: ...park plug cap in place STANDARD 7 4 12 kΩ 20 12 3 IGNITION TIMING The ignition advance is 17 3 before TDC The Capacitive Discharge Ignition CDI system is factory pre set and does not require adjustment 12 4 ALTERNATOR EXCITER COIL Remove the seat rear fender and front fender see chapter 10 Disconnect the exciter coil wire Measure the resistance between the yellow red wire and ground STANDER 460 70...

Page 56: ... or milk and call a physician 12 6 BATTERY INSPECTION Battery is under the seat you can see this battery beside oil tank on central Measure the battery voltage using a voltmeter VOLTAGE Fully charged 13 1 V Undercharged Below 12 0 V Warning When the battery voltage is below 11 0 V please don t use and replace it BATTERY REMOVAL Remove the seat and then you can see the battery Disconnect the negati...

Page 57: ...12 7 WIRING DIAGRAMS 56 ...

Page 58: ...ignition coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire disconnected Improperly adjusted air screw Improperly ignition timing Fuel air mixture ratio is too lean Carburetor flooded Improperly adjusted air screw Fuel air mixture ratio too rich Auto choke s...

Page 59: ...ternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch CHECK IGNITION TIMING 13 3 POOR PERFORMANCE AT HIGH SPEED N G CHECK IGNITION TIMING O K CHECK FUEL TUBE AT FUEL FLOW RESTRICTED CARBURETOR FUEL FLOWS FREELY REMOVE CARBURETOR CLOGGED CHECK FOR CLOGGED JETS NOT CLOGGED CHECK AIR CLEANER DIRTY FILTER...

Page 60: ... rings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn piston and cylinder Fuel air mixture ratio is lean Wrong type of fuel Ignition timing too advanced Excessive carbon deposited in Combustion chamber OVERHEATING FOULED OR DISCOLOED O K O K N G ENGINE SPE...

Page 61: ...mproperly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Improper wheel alignment Bent frame STEERING IS HEAVY ONE WHEEL IS WOBBLING VEHICLE PULLS TO ONE SIDE 60 ...

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