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5. REMOVAL OF ENGINE, TRANSMISSION SYSTEM AND GEARSHIFT

5-1

Inspection Information……………5-1 Removal and Installation of Front and Rear
Engine Removal and Installation…5-2 axle……………………………………5-5

Removal and Installation of Gearshift…5-7

Inspection Information

Note:

●

When removal Engine, please use jack to support the bodywork. Don’t damnify the

frame, body of Engine, bolt and cable etc.

●

Please blind up the frame when removal the engine.

●

Don’t removal engine from the bodywork when operating as follows:

—OIL PUMP
—CARBURETOR, AIR FILTER.
—COVER, CYLINDER HEAD,CYLINDER HEAD,CYLINDER,CAMSHAFT.
—CVT SYSTEM, CVT COVER.
—GEARBOX.
—RIGHT SIDE COVER, AC MAGNETO,WATE PUMP.
—PISTON

﹑

PISTON RING, PISTON PIN.

●

Following operation require removal of engine from vehicle:

—CRANKCASE

Tightening torque:

Engine front rear mounting bolt

（

M12

）：

45

～

50N.m

Engine front rear mounting bolt

（

M8

）：

23

～

25N·m

Engine rear upper bracket mounting bolt

（

M12

）:

45

～

50N·m

Engine rear upper bracket mounting bolt

（

M8

）:

23

～

25N·m

5

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Summary of Contents for 500ATV

Page 1: ...Service Manual 500ATV 500ATV 2 4 4 ...

Page 2: ...contains an introductory de scription of procedures for inspection maintenance overhaul disassembly assembly removal and installation of com ponents and parts troubleshooting and service data together with illu strations of our ATV Model 500ATV and 500ATV 2 CONTENTS Vehicle Service Information 1 Vehicle Body Muffler 2 Inspection Adjustment 3 Cooling System 4 Removal and Installation of Engine 5 Re...

Page 3: ...ety Proper service and maintenance are essential to the customer is safety and the reliability of the vehicle Any error or oversight while servicing a vehicle can result in faulty operation damage to the vehicle or injury to others For Your Safety Because this manual is intended for the professional service technician we do not provide warnings about many basic shop safety practices e g Hot parts ...

Page 4: ...l help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventilation whenever you run the engine Burns from hot parts or coolant Let the engine and exhaust system cool before working in those areas Injury from moving parts If the instruction tells you to run the engine be sure your hands fingers and clothing are out of the way Gasoline vapo...

Page 5: ...ided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen Vehicle Identification Number 500ATV LCXGSTS1 Vehicle Identification Number 500ATV 2 LCXMSTS1 Engine Number Carburetor XY192 Engine Number EFI XY192 A NOTE The vehicle identification number is used to identify your machine 1 ...

Page 6: ...equal shaft Carburetor type Combustion Chamber Type Triangle Valve Driving Type SOHC Chain Drive Bore stroke 92 75mm 3 62 2 95 in Compression ratio 10 2 1 Lubrication Type Pressure and splash lubricating type Maximal power 25Kw 6000 rpm EEC model less than 15kw Max torque 42N M 4000 rpm EEC model 24N M 4000 rpm Lowest fuel consuming rate g Kw h 280g Kw h Idling speed r min 1400 100 Starting system...

Page 7: ...st Out dimension 716 x 516 x 536 Net weight 72 5kg Output type front and rear shaft output Engine Shaft running direction counter clockwise from back of engine Air Filter type Paper element filter Type Vacuum Diaphragm type KEIHIN AW6A Fuel Device Carburetor Diameter of mixing valve 40mm Type Wet auto centrifugal Clutch Operation mode Automatic CVT Parking Gear shifting Gears Shi ft Low Gear High ...

Page 8: ...Datasheet Lubricating device Item Standard Service limit Volume when replacing 2500ml Engine Oil Capacity Full capacity 12000ml Recommended Oil see original Specially for 4 stroke motorcycle SAE 10W 40 20W 50 Substitutes must be used in the following range API type SE or SF grade SAE type Choose from the left chart according to the environmental temperature Gap between inner and outer rotors 0 02 ...

Page 9: ...ml Coolant capacity Standard Density 45 Opening pressure of radiator cap 108kpa 1 1kgf cm2 Temperature valve open 72 2ºC Temperature valve full open 88ºC Thermostat Overall lift 3 5 4 5mm Front Rear Wheel Item Standard Service Limit Vertical 1 0mm 2 0mm Play of wheel rim Horizontal 1 0mm 2 0mm Groove 3 0mm Front Wheel Tire Pressure 7 0 2PSI 47 1 5KPa Vertical 1 0mm 2 0mm Play of wheel rim Horizont...

Page 10: ...controlled parallel connected regulated voltage Capacity 12V18Ah Fully charged 12 8V Terminal point voltage Insufficient charge 11 8V Standard 0 9A 5 10H Battery Charging current time Quick 4A 1H Ignition system Item Standard Ignition CDI ignition Type BKR6E NGK Optional K6RTC Spark Plug Spark plug gap 0 6 0 8mm Ignition timing Max advanced angle 43 3500r min Ignition Above 200V Peak voltage Pulse...

Page 11: ...DER HEAD OIL STRAINER CAMSHAFT M6 20 10 12 CVT COVER LEFT LOWER M6 18 10 13 GEAR POSITION SENSOR SHEAVE DRUM ASSY HANDLE ASSY M6 16 12 14 SHEAVE DRUM ASSY THERMOSTAT TEMPERATURE SWITCH M6 10 12 15 MAGNETO STATOR M5 12 6 16 GEARSHIFT SPRING M14 26 30 17 PRIMARY SHEAVE ASSY M12 160 80 18 CYLINDER M10 78 65 19 CYLINDER M10 70 65 20 HEAD CYLINDER ASSY M10 190 70 21 DRAIN BOLT M10 16 30 22 SECONDARY SH...

Page 12: ...ASE M6 85 10 33 CRANKCASE M6 92 10 34 THERMOSTAT TEMPERATURE SWITCH M14 12 30 35 CVT COVER LEFT LOWER M6 12 10 36 COVER SHIFT SHAFT M6 139 10 37 COVER SHIFT SHAFT M6 28 10 38 FLANGE OUTPUT M16 300 M5 4 5 6 M6 8 12 39 Other Bolts M8 18 25 ...

Page 13: ...3 25N m 12 BOLT FRONT REAR DRIVE SHAFT 8 M8 22 23 25N m 13 BOLT FRONT BRAKE MASTER CYLINDER 4 M8 20 23 25N m 14 BOLT REAR BRAKE DISC GUARD 2 M10 60 45 50N m 15 BOLT REAR BRAKE MASTER CYLINDER 2 M10 20 45 50N m 16 BOLT FRONT REAR BRAKE DISC 12 M8 16 23 25N m 17 NUT BRAKE PEDAL 1 M10 1 25 45 50N m 18 BOLT MASTER CYLINDER PEDAL BRAKE 2 M6 30 10 12N m 19 NUT FRONT REAR ARM ANG FRAME 12 M10 1 25 45 50N...

Page 14: ... liquid Category Specification Capacity Remark Fuel RQ 93or upper grade lead free gasoline 22L Content of fuel box Lubricating oil engine Gear box SAE15W 40 SF 2500ml change oil 2600ml change filter Lubricating oil front main driver First 0 33L change 0 28 Lubricating oil Rear main driver SAE 85W 90 GL 5 First 0 30L change0 25 Brake liquid GB1083 JG3 1 1L Engine coolant Distilled water Glycol 1 1 ...

Page 15: ...ndicator light switch 3 Low beams High beams turning switch 4 Turning light switch 5 Horn switch 6 Start switch 7 Engine stop switch 8 Starter choke 9 Drive select lever 10 Winch switch 11 4WD 4WD Lock 12 4WD 2WD 13 Throttle lever 14 Main switch 15 Auxiliary DC jack 12V 120W 10A 1 ...

Page 16: ...1 SERVICE INFORMATION 1 14 ...

Page 17: ...1 SERVICE INFORMATION 1 15 1 ...

Page 18: ...1 SERVICE INFORMATION 1 16 ...

Page 19: ...e work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove and Install muffler after it is fully cold This chapter is on the disassembly and installation of rack visible parts exhaust pipe Muffler and fuel tank Hoses cables and wiring should be routed properly Replace the gasket with...

Page 20: ...verse the removal procedure for Installation FRONT BUMPER Remove Remove four bolts 4 Remove bumper Installation Reverse the removal procedure for Installation SEAT Remove Pull upward seat buckle Lift and push seat backward Installation Press upward seat buckle Press seat forward and down Note Make sure that the seat is firmly installed ...

Page 21: ...emove rear Rack Installation Reverse the removal procedure for Installation REAR BUMPER Remove Remove two bolts 4 Remove rear bumper Installation Reverse the removal procedure for Installation HANDLEBAR COVER Remove Remove two bolts 5 Remove handlebar cover Installation Reverse the removal procedure for Installation 2 ...

Page 22: ... Remove Remove Seat 2 2 Remove Bolt 1 for left side panel and store box cover Remove Bolt 2 for left side panel and front cover L Remove Bolt 3 for left side panel and footrest board L Installation Reverse the removal procedure of installation ...

Page 23: ... for right side panel and store box cover Remove Bolt 2 for left side panel and footrest board R Installation Reverse the removal procedure of installation LEFT FOOTREST BOARD Remove Remove left side panel 2 4 Remove bolt 3 nuts for front cover L Remove bolt 4 nuts for rear cover 2 ...

Page 24: ...tion Reverse the removal procedure of installation RIGHT FOOTREST BOARD Remove Remove right side panel 2 5 Remove bolt 1 nuts for front cover R Remove bolt 2 nuts for rear cover Remove bolt 3 Remove right footrest board Installation Reverse the removal procedure of installation ...

Page 25: ... the removal procedure of installation REAR COVER ASSEMBLY DISASSEMBLY INSTALLATION 1 TAILLIGHT ASSEMBLY L 2 TAILLIGHT ASSEMBLY R 3 NUT CLIP M6 4 WASHER φ6 5 SCREW M6 16 6 LICENSE PLATE LIGHT 7 SCREW TAP ST4 2 16 8 WASHER φ6 9 REAR REFLECTOR 10 NUT CLIP M6 11 NUT FLANGE M5 12 SCREW M6 16 13 WASHER RUBBER 14 COVER LEFT LINE RR 15 COVER RIGHT LINE RR 16 EXPANSION SCREW M8 20 17 COVER TAIL LIGHT 18 R...

Page 26: ...t 4 Remove connector of ignition switch Remove connector of power output Remove store box cover Installation Reverse the removal procedure of installation FRONT COVER ASSEMBLY Remove Remove seat 2 2 Remove front Rack 2 2 Remove front bumper 2 2 Remove left side panel 2 4 Remove right side panel 2 5 Remove store box cover 2 8 Remove bolt 1 ...

Page 27: ...R ASSEMBLY 2 WASHER φ5 3 NUT FLANGE M5 4 COVER WATER TANK 5 SCREW M6 16 6 NUT CLIP M6 7 WASHER RUBBER 8 BATTERY COVER 9 EXPANSION SCREW M8 20 10 COVER LEFT LINE FR 11 COVER RIGHT LINE FR 12 FRONT COVER L 13 FRONT COVER R 14 SCREW M6 16 15 COVER RADIATOR 16 COVER VENT GRILLE 17 HEADLIGHT UNIT L 18 HEADLIGHT UNIT R 19 WASHER φ5 φ15 1 20 SCREW M5 10 21 HEADLIGHT L FENDER 22 HEADLIGHT R FENDER 23 SCRE...

Page 28: ...1 Nut 2 for exhaust pipe elbow Remove Nut1 Nut 2 Remove Remove bolt 1 Remove bolt 2 Remove muffler Remove exhaust pipe Installation Reverse the removal procedure of installation FRONT LEFT RIGHT WHEEL ASSEMBLY Remove Remove cap of wheel center rubber Remove nut 3 Remove front left right wheel assembly Installation Reverse the removal procedure of installation ...

Page 29: ...is highly flammable therefore smoke and fire are strictly forbidden in the work place Special attention should also be paid to sparks Gasoline may also be explosive when it is vaporized so operation should be done in a well ventilated place Remove Remove rear cover assembly 2 7 Remove rear right wheel assembly 2 11 Remove bolt 1 Remove bolt 2 Remove rear right absorber Disconnect connectors of fue...

Page 30: ...ON 1 FUEL TANK 2 PIPE FUEL 3 FUEL SENSOR 4 FUEL FILTER 5 FUEL PUMP 6 CAP FUEL TANK 7 CUSHION RUBBER φ25 8 CUSHION RUBBER φ20 9 WASHER φ8 10 BOLT FLANGE M8 20 11 SCREW M5 10 12 WASHER φ5 13 BOLT FLANGE M6 16 14 HOSE VACUUM φ5 15 FUEL HOSE φ5 16 FUEL HOSE φ5 17 CLAMP φ8 18 CUSHION RUBBER φ55 19 HOSE THREE JOINT 20 HOSE VACUUM φ4 21 CLAMP φ10 22 FUEL HOSE φ5 23 NUT FLANGE M6 ...

Page 31: ...15 19 Bolt16 20 Bolt17 GUARD PLATE IRON DISASSEMBLY INSTALLATION Note Guard plate middle front Guard plate middle Guard plate middle rear guard plate rear and guard plate tail are located at the bottom of vehicle The maintenance person should have to work under the vehicle bottom when disassembling the above parts For safety purpose make sure that the vehicle should be firmly parked 1 Bolt 1 2 Bol...

Page 32: ...2 Vehicle body Muffler 2 14 Visible Parts ...

Page 33: ...engine is just stopped Careless contact may cause serious burn Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done after the engine is just stopped Gasoline is highly flammable smoking is strictly forbidden in the work place Keep alert on the electrical sparks Besides vaporized gasoline is highly explosive so work should be done in a well ventilated place Be caref...

Page 34: ...y be required on vehicles that are used in severe conditions Km Initial 250 Every 1000 Every 2000 Interval Item Hours Initial 20 Every 50 Every 100 Remarks Valve clearance I I IN 0 08 0 10 EX 0 08 0 10 Idle Speed I I I 1400 100r min I Spark plug R Every 6000km No carbon deposit Gap 0 6 0 8mm Air Filter C C R every 20000km Fuel Hose carburetor I Clutch I R every 4 year Drive Belt I R Oil Filter R R...

Page 35: ...brake disc Brake disc damage and wear Replace when the thickness of front brake disc is less than 3 5mm rear brake less than 3 5mm Tire pressure Front tire 47kPa 7 0 2PSI Rear tire 47kPa 7 0 2PSI Chap and damage Groove depth and abnormal wear No wear indication on the surface of tire the remained depth of groove should not be less than 3mm Loosened wheel nut and axle Sway of front wheel bearing Dr...

Page 36: ...d Looseness of joint parts Drive Train Final shaft Drive shaft Sway of Spline Spark plug Ignition Device Ignition timing Battery Terminal Joint Electrical System Wiring Looseness and damage of joints Fuel leakage Fuel device Throttle Coolant level Engine Cooling system Coolant leakage ...

Page 37: ...ion Alarm and lock device Function Instruments Function Looseness or damage caused by improper installation Exhaust pipe and muffler Function of muffler Frame Looseness and or damage Others Lubrication grease of frame parts Abnormal parts which can be determined when driving Make sure if there is any abnormal with relative parts 3 ...

Page 38: ...ring stem for further check Park the vehicle on level place slowly turn the handlebar left and right to see if it can turn freely In case there is any hindrance check if it is from the main cable assembly or other cables If no check the steering tie rod end and check if the steering stem bearing is damaged Note Make sure the steering can be operated freely An accident may occur if the handlebar is...

Page 39: ... and rubber parts Keep the fluid away from these parts Slightly turn the handlebar left and right till the master cylinder is in horizontal then remove the fluid reservoir cap Brake Disc Brake Pad Wear of brake pad Check the brake pad wears from the mark as indicated Replace the brake pad if the wear has reached position of wear limit trough Note The brake pad must be replaced with a whole set Che...

Page 40: ...wheel is tightened and check whether it sways Not tighten enough Tighten it Sway Replace the rocker arm Front Toe in size Park the vehicle on level place measure the front toe in Toe in B A 0 10mm Toe in out of the range Adjust the locknut of tie rod Note After the toe in has been adjusted slowly run the vehicle to check whether the direction of vehicle can be controlled by handlebar ...

Page 41: ... and may cause deflected wear of the tires Specified pressure tire 500ATV Front wheel Rear wheel Pressure 47kPa 7 0 2PSI 47kPa 7 0 2PSI Tires sizes 25 8 12 25 10 12 500ATV 2 Front wheel Rear wheel Pressure 47kPa 7 0 2PSI 47kPa 7 0 2PSI Tires sizes 26 9 14 26 11 14 Tire Tread Check the tire tread Tread Height if 3mm then Replace with new tires Note When the tread height is less than 3mm the tire sh...

Page 42: ...Wheel Bearing Lift the front wheel Make sure there is loading on the vehicle Shake the wheel in axial direction for any sway In case of any sway Disassemble the front wheel and check the bearing Suspension System Park the vehicle on lever place press the vehicle several times up and down as illustrated on the right In case of any rocking or abnormal noise check whether there is any oil leakage fro...

Page 43: ... ring in direction b Gear Shifting Shift the gear to check for flexibility and gear engagement Adjust the gearshift rod if necessary Release the lock nut to adjust the length of gearshift rod Fuel Device Status of the fuel system Remove the seat 2 2 Remove rear cover 2 7 Check the fuel hose for any aging or damage Aged or damaged fuel hose Replace Check if there is cracks or bending with the vacuu...

Page 44: ...till stickiness with the throttle Replace with a new throttle cable if the specified free play could not be acquired by adjusting the regulator or if there is still stickiness with the throttle Adjusting the Speed Limiter The speed limiter is to limit the opening of throttle Check the maximum length of limiter screw thread Maximum screw thread a 12mm Adjust with a cross driver Note For beginners t...

Page 45: ...s into eyes rinse with plenty of water and go to consult the doctor In case of swallowing the coolant induce vomit and consult the doctor Keep the coolant in a safe place and away from reach of children Coolant level Coolant might reduce due to natural evaporation Check the coolant level regularly Note Coolant can prevent rust and resist freeze Ordinary water may cause engine rust or cracks in win...

Page 46: ...r leakage In case of any leakage disassemble and do further check Refer to Chapter 4 Check the radiator hose for aging damages or cracks The rubber hose will naturally get aged after a period of service time The aged hose may get cracked when the cooling system is heated Nip the hose with fingers and check if there are any tiny cracks In case of any abnormal replace with a new hose Check the clamp...

Page 47: ...Store the coolant properly and keep it away from reach of children Check radiator fins for mud block and or damage Correct the bent fins Clean off the mud With water and compressed air Replace with a new one if the damaged fin area reached 20 The overhauling of the water pump can be done without removing the engine Add coolant through reservoir tank Do not open the radiator cap except when disasse...

Page 48: ...ged radiator fin Coolant is not enough Faulty or malfunction of fan motor No rise or slow rise of water temperature Faulty thermostat thermostat is not closed Faulty circuit of water temperature display Coolant leakage Faulty water seal O rings are aged damaged or improperly sealed Washers are aged damaged or improperly sealed Improper installation of pipes or hoses Pipes and or hoses are aged dam...

Page 49: ...mpurities Inspection of radiator cap Note Open the radiator cap after the coolant is fully cooled Remove Remove bolt 1 and battery panel Remove radiator cap counter clockwise Note Apply coolant on the sealing surface of radiator cap before attaching the tester to the radiator cap Install the radiator cap tester to the radiator cap Apply the specified pressure radiator cap opening pressure for 6 se...

Page 50: ...ashes in your eyes thoroughly wash your eyes with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomit immediately and see a physician Store the coolant properly and keep it away from reach of children Note Mix the coolant undiluted with soft water according to the temperature 5 lower than t...

Page 51: ...n coolant After drainage assemble with a new seal gasket drain bolt and tighten Reservoir Tank Remove Remove seat 2 2 Remove front cover assembly 2 8 Remove 2 mounting bolts Remove water hose of reservoir tank Remove reservoir tank discharge coolant Flush reservoir tank Install reservoir tank 4 ...

Page 52: ...lant level when the vehicle is on an even ground Air Discharge Discharge the air from cooling system according to the following steps 1 Remove drain bolt 4 5 discharge air and install it 2 Start the engine and run it several minutes at idle speed 3 Quickly increase throttle 3 4 times to discharge air from cooling system 4 Add coolant till filling port 5 Repeat step 2 3 till no more coolant can be ...

Page 53: ...4 COOLING SYSTEM 4 7 Cooling System Chart 4 ...

Page 54: ...RADIATOR 1 2 17902 5010 RESERVOIR TANK 1 3 9852 223205 CLAMP 22 32 4 4 17812 5010 WATER HOSE φ20 φ28 500 1 5 17813 5010 WATER HOSE φ20 φ28 760 1 6 9852 080003 CLAMP φ8 1 7 17811 5010 WATER HOSE 1 8 GB T 5787 M6 16 BOLT FLANGE M6 16 2 9 GB T 5787 M6 25 BOLT FLANGE M6 25 2 10 17110 5010 RADIATOR FAN 1 11 9852 100003 CLAMP φ10 1 ...

Page 55: ...blind up the frame when removal the engine Don t removal engine from the bodywork when operating as follows OIL PUMP CARBURETOR AIR FILTER COVER CYLINDER HEAD CYLINDER HEAD CYLINDER CAMSHAFT CVT SYSTEM CVT COVER GEARBOX RIGHT SIDE COVER AC MAGNETO WATE PUMP PISTON PISTON RING PISTON PIN Following operation require removal of engine from vehicle CRANKCASE Tightening torque Engine front rear mountin...

Page 56: ...c parts Chapter 2 Remove air filter Remove exhaust pipe and muffler Chapter 2 Remove hoop Remove water inlet hose of engine Remove bolt 1 Remove gear shift rod A Remove hoop Remove water outlet hose of engine Remove connectors of magneto connector of CDI pickup coil connector magneto connector connector of gear sensor connector of cathode as illustrated on the right ...

Page 57: ...GINE TRANSMISSION SYSTEM AND GEARSHIFT 5 3 Remove spark plug Separate jacket of starter relay remove nut remove anode cable of starter relay Remove clamp of air inlet duct for CVT Remove carburetor Remove air filter 5 ...

Page 58: ...5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT 5 4 Remove clamp of air outlet duct for CVT Remove muffler 2 10 Remove gearshift 5 7 Remove fixing bolt of engine ...

Page 59: ... Axle Support the vehicle with jack make sure the vehicle will not fall Remove Plastic parts for frame Chapter 2 Front and rear wheels and arms Chapter 8 Air filter engine service chapter Carburetor engine service chapter Engine Rear brake caliper 9 4 1 FRONT AXLE 2 REAR AXLE 3 FRONT DRIVE SHAFT 4 REAR DRIVE SHAFT 5 REAR BRAKE DISC 6 REAR BRAKE DISC GUARD 7 BOLT FLANGE M10 1 25 120 8 BOLT FLANGE M...

Page 60: ...5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT 5 6 Remove bolt and nut fixed in the frame of front axle Remove bolt and nut fixed in the frame of Rear axle ...

Page 61: ... 50N m Bolt torque of Rear axle M8 45 50N m Bolt torque of Rear axle M10 45 50N m Bolt torque of Front and Rear drive shaft 23 25N m Gearshift Disassembly Remove seat 2 6 Remove plastic cover gearshift 2 7 Remove Bolt Remove shift of gearshift fixed in engine Remove Bolt of Gearshift by fixed in Bodywork Remove Gearshift Installation Reverse the removal procedure for installation Make sure that ge...

Page 62: ...5 REMOVAL OF ENGINE TRANSMISSION SYSTEM AND GEARSHIFT 5 8 GEARSHIFT SYSTEM ASSEMBLY DISASSEMBLY INSTALLATION Please reference to 500ATV Parts catalog ...

Page 63: ...6 Engine Removal Inspection Installation 6 1 Wu Yang 500 CC engine maintenance manual 6 ...

Page 64: ...rictly observe in order to reduce personnel casualties prevent maintenance and repairing the improper damage to the engine or the after repair engines still don t safe These warning and note is not unnecessary that s very important Because of the failure to abide by the maintenance program caused by the dangerous consequences not all this manual and a warning The manual of procedure recommended to...

Page 65: ...or the above the engine explains the it down and the inspection repair and reassemble program In order to be able to secure fast and accurate operation of these steps you must first learn to read the manual and other any maintenance materials Content Title Chapters Essential information 00 Engine 01 6 ...

Page 66: ...on 6 11 How to use the manual Subject areas z This handbook contains all the necessary operation and maintenance procedures All procedures are classified into five kinds of basic operation detach attach Dissembling assembly replace check up adjust z Omitted by checking vehicles will be able to complete the simple operation for example remove install parts use top up the vehicles thousands of clean...

Page 67: ...ommended Coolant 35 antifreeze corrosion resistant high boiling point coolant Warning Coolant is poisonous Never drink it Store it properly Caution DO NOT mix coolant with that of other engines Fuel symbols z There are eight symbols are marked lubricating oil grease fluid and sealants and SST or equivalent tools of usage Such signs that the use of maintenance process method or the party of the mat...

Page 68: ... in serious injury or death Be careful z Be careful that if the neglect this tip can lead to vehicles or parts damaged Attention z Pay attention to provide help to accomplish a specific code added information standard z Specification for inspection or adjustment of the scope of the operation license bound z The lower provisions for inspection or adjust the operation can t more than limit and limit...

Page 69: ...ove should be in all parts do not affect its function or appearance place do mark remember to area don t easy to assemble In the process of split down and the check z Remove the parts should be carefully check whether there is so disabled deformation damage and other problems Components placed z All the parts should be removed had placed so that to group outfit z Need to replace parts and need to ...

Page 70: ...orque and the whole value standard data z The following parts disassembly the application of new thing after replace oil seal washer Type O sealing ring lock washer cotter Nylon Nut z According to the different position Should be in some specific part application or and mat of sealants If daub the sealants so should be in the installation parts before hard sealants so as to avoid leakage Should be...

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Page 73: ...6 Engine Removal Inspection Installation 6 11 Engine information 6 ...

Page 74: ...lywheel assembly 6 61 Technology parameters 6 70 Maintenance tools 6 73 Engine overhaul warnings Warning z In the lab long term contact with the oil make mice produce skin cancer The work finished please immediately use soap and water to wash to protect your skin z The proper service and repair process is important security operators and the safety and reliability of the vehicle z Don t deal with ...

Page 75: ...side Use special lubricants and sealants and grease Make sure all part of clean lubrication for restructuring they when specified The use of special tools according to the service manual Place and shop disassemble parts for the correct assembly respectively Use original parts or their equivalence since 1 CVT part remove check According to the list of instructions on the order 1 Hexagon flange bolt...

Page 76: ...el and driven wheels on the flange bolts 1 3 Remove the CVT active wheel as shown in figure 1 3 1 With specialized tools twist intothe CVT active wheel sliding shaft inside with pneumatic board tightened the specialized tools will be active round out the top Note 1 A special tool to twist in place in order to avoid sliding axis will be threaded damage ...

Page 77: ...ure CVT active wheel dial the come out even with driven pulley and belt off together 1 6 As shown in figure remove three M6 18 hex flange bolts and five M6 12 countersunk head screws then remove the left box nakedness 1 7 CVT belt examination 1 7 1 The belt can t have crack such as a crack will need to change 1 7 2 The width of the CVT belt examination 6 ...

Page 78: ... width 29 4 31 mm minimum width 28 2 mm 1 7 3 CVT belt length inspection Standard width 1016 5 1025 7 mm Maximal length 1050mm 1 8 Active round of inspection 1 8 1 Drive wheel back spring length Standard length 65 1 8 2 Drive wheel back spring verticality ...

Page 79: ...Sliding mat wear degrees 1 8 4 Roller wear degree 1 8 5 Centrifugal piece of wear degrees 1 8 6 bush of wear degree 1 9 CVT Driven pulley examination 1 9 1 Driven pulley damping twist spring length and vertical degree 1 9 2 Buffer piece of wear degrees 6 ...

Page 80: ...ng joints dish 23 spring washer 6mm 7 Hex flange surface nut M16 24 Washer Φ6 19 1 5 8 washerΦ16 Φ32 2 25 Shift gears pulled move 9 The flywheel assembly see Z 02 flywheel split 26 The pipe clip 10 flat key 27 exhalent siphon 11 Beyond the clutch assembly 28 Hexagon flange bolts M6 28 12 Hexagon flange bolts M6 25 29 water pump cover 13 cable clamp 30 Pump cover gasket 14 Coil fixed a combination ...

Page 81: ...19 2 1 As shown in figure remove the right cover hex flange bolts 2 2 As shown in figure remove the right cover Hex flange bolts 2 3 Turn the handwheel chronological make the flywheel scribed line and coil fixed a carved on the line alignment 6 ...

Page 82: ...ded on the flywheel dial is taken 2 6 Have the remove the flywheel 2 6 1 With specialized tools into the flywheel remove screw of screw hole and by pneumatic wrench tighten the special tools will flywheel ejector matters need attention 2 6 2 Special tools for three bolt twist into depth to consistent and try to twist the end ...

Page 83: ...21 2 6 3 In no pneumatic wrench to work with only when a fixed flywheel to will pull out of the flywheel 2 7 As shown in figure remove magneto five hexagonal bolt 2 8 As shown in figure with a screwdriver pry out the crankshaft on flat to key 6 ...

Page 84: ...6 Engine Removal Inspection Installation 6 22 2 9 As shown in figure with both hands captures magneto will coil fixed a dial out 2 10 As shown in figure remove shift shaft hex bolt on the cover ...

Page 85: ...ver bolts removed with glue like light striking the shift shaft cover to that of the case apart 2 12 As shown in figure remove hexagonal bolt remove the shift shaft and change shift gears clicked 2 13 As shown in figure remove the pipe clip will feed line dial out 6 ...

Page 86: ...ction Installation 6 24 2 14 As shown in figure remove water pump on the cover hexagonal bolt the pump cover taken down 2 15 As shown in figure remove cover type shape nuts 2 16 As shown in figure remove water pump impeller ...

Page 87: ...1 Hexagon flange boltsM6 30 5 O ringΦ2 Φ24 8 2 Hexagon flange boltsM5 12 6 O ringΦ2 Φ129 5 3 Coil assembly 7 Oil seal Φ 25 Φ 38 7 see Z 03 oil split explain 4 The supplied pan head screwsM5 8 8 Coil fixed a 2 18 Magneto check As shown in figure magneto wire if there is broken 6 ...

Page 88: ...bing remove check According to the list of instructions on the order 1 Hexagon flange boltsM6 28 6 Tubing boltM12 30 2 Tubing boltM12 43 7 oil inlet 3 Tubing boltM10 28 8 copper washerΦ10 Φ18 1 5 4 The tubing A 9 copper washerΦ12 18 1 5 5 The tubing B ...

Page 89: ... Cove 11 spring washer 3 Cylinder head gasket 12 Timing driven sprocket 4 Hexagon flange boltsM6 25 13 Hexagon flange boltsM10 190 5 The chain regulator assembly 14 washerΦ25 Φ10 5 2 6 The chain adjustment control gasket 15 Hexagon flange boltsM6 28 7 Hexagon flange boltsM6 20 16 Cylinder head combination 8 Cylinder head side cover 17 Cylinder head of cushion 9 The cylinder head side cover gasket ...

Page 90: ...figure remove the intake pipe piece the supplied pan head screws take down the carburetor 4 2 As shown in figure cylinder head cover remove the hexagonal bolt take down cylinder head cove 4 3 As shown in figure remove hex bolt on the side cover off the side cover ...

Page 91: ...e remove tensioning device on the bolts of tensioning device take spring 4 5 As shown in figure remove tensioning device two 4 6 hexagonal bolt tensioning device take ontology 4 7 As shown in figure remove the sprocket driven the hexagonal bolt take down the sprocket 6 ...

Page 92: ...ine Removal Inspection Installation 6 30 4 8 As shown in figure disassembly of cylinder head four hexagonal bolt 4 8 As shown in figure with glue knock like the cylinder head side parts of cylinder head off ...

Page 93: ...htlyM6 17 13 camshaft 3 rockshaft 14 LOCK CLAMP 4 Inlet rocker assembly 15 Valve bearing plate see Z 04 lock clamps valve cap dish that split 5 copper washerΦ22 Φ28 0 2 16 valve springΦ3 2 Φ23 42 6 Exhaust rocker combination 17 intake valve 7 Hexagon flange boltsM6 20 18 exhaust valve 8 thermostat housing 19 valve oil seal 9 Thermostat 20 spark plug 10 Hexagon flange boltsM6 20 21 Cylinder head co...

Page 94: ...ercome valve spring tension making the lock clip from bearing the position of the valve plate with magnets will lock clip suck out 4 9 2 Rocker check 4 2 1 Rocker standard thickness 29 95 30 00 mm 4 9 3 With the rocker aperture standard 22 22 021 mm If the test result is greater than the standard requirements the rocker replacement ...

Page 95: ...cal degree 1 The valve spring rotating week at the location of the maximum clearance to A measurements If more than specifications range the replacement valve spring 2 Valve spring vertical degree 1 95 mm 4 9 6 valve check 1 Measurement valve head contact width If it is not within the scope of specifications please use 45 valve seat cutter trim valve seat ring and reforming valve interface standar...

Page 96: ...aft diameter standards 21 73 21 84 mm If the test result is less than standard requirements the replacement lock shaft 4 11 Camshaft check Check the camshaft inlet CAM and CAM face whether exhaust pitting or potholes defect if have replace the camshaft 1 Inlet CAM standard height 32 769 mm min height 32 659 mm ...

Page 97: ... standard outside diameter 37 946 37 960 mm Such as measuring results less than rating then replace the camshaft 4 12 Cylinder head check 1 The cylinder head flatness check As shown in figure six direction cylinder head top surface of measuring flatness The cylinder head flatness standards 0 03 mm If not within this then replace the cylinder head The cylinder head valve seat inspection and mainten...

Page 98: ...ns on the order 1 Chain guide a 7 wrist pin 2 Hexagon flange boltsM10 78 8 piston assembly 3 Hexagon flange boltsM6 28 9 locating pinΦ15 12 4 cylinder combination 10 Tension rod bolt 5 cylinder head gasket 11 Chain tension rod 6 C form block circle 12 timing chain 5 1As shown in figure remove cylinder four hexagonal bolt ...

Page 99: ...ure card ring plier take down the piston pin CARDS ring and then taking off the piston pin and the piston 5 4Inspection of the cylinder In the top surface with a 61 5 mm place not the X and Y directions measuring cylinder diameters If it is not within the scope of the provisions then replace the cylinder block Standard cylinder size limit 92 000 92 025 6 ...

Page 100: ...clearance between the piston ring groove If more than specification limits please the piston piston piston pin as a whole to change The first line of gas ring standard clearance 0 02 0 06 mm The second way gas ring standard clearance 0 015 0 06 mm maximum clearance 0 11 mm 2 As shown by hand to insert the cylinder piston through the live plug push into the bottom of the piston stroke 3 The gap wit...

Page 101: ...ring the outer diameter of piston pin If more than specification limits please the piston piston piston pin as a whole to change 2 The piston pin outside diameter standards 22 998 22 994 mm Timing chain examination 5 7 The chain guide a and the chain of tension bar examination 1 The chain tension rod and guide a and chain engage face worn grooves the replacement of the stem guide a tension 6 ...

Page 102: ...ording to the list of instructions on the order 1 Hexagon flange bolts M6 85 5 Hexagon flange bolts M8 90 2 Hexagon flange bolts M6 95 6 Right case components 3 Hexagon flange bolts M6 105 7 Left the components 4 Hexagon flange bolts M10 78 6 1 As shown on the right engine decomposition bolt ...

Page 103: ...As shown in figure on the left with copper rod knock output flanges and axial shaft out or so the decomposition 6 3 As shown in figure or so the decomposition 7 The removal decomposition right check According to the list of instructions on the order 6 ...

Page 104: ...that split 7 1 As shown in figure the drive shaft remove directly from the right by hand on it out 7 2 As shown in figure reverse gear shaft removal the reverse axial driven shaft direction tilt hands caught in reverse axis tilt out tooth surface 7 3 As shown in figure driven shaft deputy shaft and shift drum remove a hand grasp on the driven shaft components active bevel gear and the other a hand...

Page 105: ...sh bearing whether card bearing radial clearance is too large if have replace bearing 2 6001 Bearing radial clearance standards 0 011 0 025 mm 3 6304 Bearing radial clearance standards 0 013 0 028 mm 7 5 Right crankshaft case check up 1 the diameter standard 72 000 72 025 mm 2 the Maximum diameter 72 080 mm 6 ...

Page 106: ...aft block decomposition remove check According to the list of instructions on the order 1 With the lock flange surface nut M16 6 Driven shaft block 2 washerΦ16 Φ32 2 7 C form block circle 3 Axle drive bevel pinion 8 Bridge driven gear 4 Hexagon flange bolts M6 22 9 driven shaft 5 Bearing plate ...

Page 107: ...ctive bevel gear check Check the cone tooth gear tooth surface crack point or corrosion so the defects such as a crack pitting serious change is active bevel gear 8 3 The driven shaft block bearing inspection Use hand turn sluggish bearing whether card bearing radial clearance is too large if have replace bearing 6305Bearing radial clearance standards 0 013 0 028 mm 6 ...

Page 108: ...of 1 9 washerΦ26 Φ35 1 5 C form block circle 10 countershaft 9 1wheel gear check up 9 1 1 Check the vice shaft gear tooth surface five have crack pitting corrosion defects such as a crack pitting the serious gear replacement or vice axis 9 1 2The reverse gear components and low gear components contains copper sets such as copper set of severe worn within the prescribed scope is replaced copper or ...

Page 109: ...aring cover 5 Hexagon flange boltsM6 45 20 Hexagon flange boltsM6 22 6 Hexagon flange boltsM6 50 21 front bearing retainer 7 Oil pump assembly 22 ball bearing6205 8 Hexagon flange boltsM6 16 23 output shaft 9 Oil absorption plate assemblies 24 drivenbevel gear 10 filler opening gasket 25 Bevel gear positioning sets 11 Points oil cover plate MATS 26 ball bearing 6207 12 Points oil cover plate 27 Fl...

Page 110: ...ft cabinet remove with rubber hammer pump driven gear tapping oil the oil pump driven gear pump shaft from removed 10 3 Turn will the crankshaft and balance axis make the crankshaft and balanced shaft jilt piece of stagger 10 4 Will the left upright with tongbang striking the crankshaft neck off balance and crankshaft axis ...

Page 111: ...gine Removal Inspection Installation 6 49 10 5 The output axis of the flange constructed remove 10 6 The left of the bearing inspection 10 7 the diameter standard of the left crankshaft hole 80 000 80 025 6 ...

Page 112: ...standard of the left crankshaft hole 77 40 77 45mm The max depth 77 65 10 9 Check the oil pump Oil pump ontology rotor aperture standards 40 68 40 72 10 10 The oil pump rotor diameter standards 40 45 40 49 10 11 The oil pump rotor thickness standards 8 980 8 995 ...

Page 113: ...12 the depth standard of the Oil pump rotor hole 9 030 9 045 10 13 the gap between the outer rotor and the inner Rotor 10 14 the gap between the connect rod and the crankshaft 0 25 0 45 10 15 the diameter of the connect rod small side 23 010 23 030 6 ...

Page 114: ...Φ18 1 5 26 Points oil cover plate MATS 6 Hexagon flange bolts M12 12 torsion 30N m 27 Points oil cover plate 7 ball bearing 6207 28 Oil pump assembly See also Oil pump assembly explain 8 Bevel gear positioning sets 29 Hexagon flange bolts M6 45 torsion 10N m 9 output shaft 30 Hexagon flange bolts M6 50 torsion 10N m 10 Bevel gear positioning sets 31 filter opening gasket 11 driven bevel gear 32 Oi...

Page 115: ...assembly instructions 19 O ringΦ2 5 Φ67 40 dowel pinΦ12 18 20 Hexagon flange bolts M8 28 torsion 25N m 41 Oil pump driven gear 21 Output shaft flange constructed 11 1 Oil pump assembly instructions As shown in figure machine oil fixed bolt diagonal points to two to three times after preloaded on tight The oil pump shaft rotation with time to be flexible 11 2 As shown in figure will pack the cranks...

Page 116: ...balanced shaft after striking tongbang end main shaft put in place 11 5 As shown in figure crankshaft balance of shaft active teeth and balance on the driven shaft tooth marks to is 11 6 As shown in figure oil pump driven gear pump shaft load of are pin hole with glue stick after tapping gear gear from move put in place ...

Page 117: ...o the list as shown in the assembly sequence 1 washer Φ15 Φ36 2 6 reverse gear shaft see the reverse shaft assembly instructions 2 Shift drum assembly 7 Hexagon flange bolts M8 32 torsion 30N m 3 washer Φ32 Φ40 2 8 drive shaft 9 O ringΦ2 Φ10 4 Deputy shaft combina see vice shaft assem instructions 5 The driven shaft combina see from the shaft assem instructions see Z 09 outfit that 6 ...

Page 118: ...re shows flange surface nut torque to300 N m 1 Driven shaft block 6 C form block circle 2 Bearing plate 7 Axle drive bevel pinion 3 Hexagon flange boltsM6 22 torsion10N m 8 washerΦ16 Φ32 2 4 driven shaft 9 Flange facingnutM16 torsion300N m 5 Bridge driven gear ...

Page 119: ...ts 8 washerΦ23 5 Φ33 1 4 washerΦ26 Φ35 1 5 9 Into reverse components 5 Bridge active tooth 10 Sliding set of 2 C archives circle to assembly in position Washer assembly sequence can t be wrong at the same time after all gear assembly to flexible rotation Z 09Assembly instructions 12 4Shift drum assembly deputy shaft combination and driven shafts combination as shown in the cabinet together right 2...

Page 120: ...y sequence 1 Hexagon flange boltsM8 90 torsion25N 6 Shift positioning spring 2 Hexagon flange boltsM6 105torsion10N 7 Hexagon flange boltsM14 26 torsion30N m 3 Hexagon flange boltsM6 85 torsion10N 8 Al washerΦ6 Φ12 1 5 4 Hexagon flange boltsM6 95 torsion10N 9 oil seal Φ 12 Φ 25 7 see Z 10 installa instructions 5 Shift positioning steel ballsSR4 5 10 water seal See Z 11 installation instructions Cl...

Page 121: ...the flange bolts lock first diagonal tighten which in turn lock 4 Close box lock bolts crankshaft examined the output shaft and shift drum of the drive shaft rotation is flexible 1 2 3 4 5 As shown in figure respectively with 6 his hands on the part about before and 7 after pressure or so housing With the right to knock tongbang ends about closed box 6 ...

Page 122: ...6 Engine Removal Inspection Installation 6 60 Bolts on the diagonal lock points secondary tighten Oil pump oil seal type with specialized tools The water seal type with specialized tools ...

Page 123: ...tructions 4 O ringΦ2 5 Φ15 16 wrist pin 5 Coil fixed a combination See a pack of coil fixed description 17 C form block circle 6 cable clamp 18 locating pinΦ15 12 7 Hexagon flange boltsM6 25 torsion10N m 19 head gasket 8 flat key 20 Cylinder combination See the cylinder assembly instructions 9 FLYWHEEL ASSY 21 Hexagon flange boltsM6 28 t i 10N 10 washerΦ16 Φ32 2 22 Hexagon flange boltsM10 76 t i 6...

Page 124: ...own in the assembly sequence 1 Coil fixed seat 5 O ringΦ2 Φ24 8 2 O ringΦ2 Φ129 5 6 Hexagon flange boltsM6 30 torsion10N m 3 oil sealΦ25 Φ38 7 7 Hexagon flange boltsM5 12 torsion6N m 4 Coil assembly 8 The supplied pan head screwsM5 8 torsion6N m Flat key assembly instructions The flywheel assembly instructions ...

Page 125: ...6 Engine Removal Inspection Installation 6 63 The piston assembly instructions Cylinder assembly instructions Cylinder bolt assembly instructions 6 ...

Page 126: ...6 Engine Removal Inspection Installation 6 64 The cylinder head assembly instructions Timing chain assembly instructions ...

Page 127: ...at 12 Hexagon flange boltsM6 20 torsion 10N m 4 Hexagon flange boltsM6 28 torsion 10N m 13 Cylinder head gasket 5 washerΦ25 Φ10 5 2 14 Cylinder head 6 Hexagon flange boltsM10 190 torsion 70N m 15 Hexagon flange boltsM6 28 torsion 10N m 7 Timing driven sprocket 16 The chain adjustment control gasket 8 spring washer 17 The chain regulator assembly 9 Hexagon flange boltsM6 22 torsion 10N m 18 Hexagon...

Page 128: ...Φ2 Φ43 5 valve springΦ3 2 Φ23 42 Valve spring assembly instruction 16 Camshaft cover 6 Valve bearing plate 17 Hexagon flange bolts M6 20 torsion 10N m 7 LOCK CLAM see Z 12 bearing plate w installation instructions 18 Thermostat 8 CAMSHAFT ASSY INTAKE The camshaft assembly instructions 19 Thermostat Cover components 9 air suction rocker arm combination 20 Hexagon flange bolts M6 20 torsion 10N m 10...

Page 129: ...0 4 water Pump cover gasket 15 Shift shaft cover gasket 5 water pump cover 16 Shift shaft cover 6 Hexagon flange boltsM6 28 torsion10N m 17 Hexagon flange boltsM6 139 torsion10N m 7 exhalent siphon 18 Hexagon flange boltsM6 28 torsion10N m 8 The pipe clip 19 locating pinΦ6 12 9 Shift gears pulled move 20 Right box gasket 10 washerΦ6 Φ19 1 5 21 Right box combination 11 spring washer 6mm 22 Hexagon ...

Page 130: ...et 6 The tubing A 2 Tubing bolt M12 30 torsion 35N m 7 Tubing bolt M10 28 torsion 35N m 3 copper packingΦ12 18 1 5 8 Tubing bolt M12 43 torsion 35N m 4 copper packingΦ10 Φ18 1 5 9 Hexagon flange bolts M6 28 torsion 10N m 5 The tubing B 10 oil sealΦ25 Φ47 13 ...

Page 131: ... torsion 10N m 14 Steps mat 5 drive shaft clapboard down 15 Hexagon flange bolts M10 160 torsion 80N m 6 Left the box cover Lower body 16 Steps mat 7 Drive shaft clapboard up 17 Hexagon flange bolts M10 100 torsion 80N m 8 The countersunk head screws M6 12 torsion 10N m 18 Left the box cover Upper body 9 Crankshaft clapboard 19 Hexagon flange bolts M6 32 torsion 10N m 10 Hexagon flange bolts M6 18...

Page 132: ...e stem diameter mm in minimum EX 26 90 IN 6 standard EX 6 IN 5 95 The valve stem to between guide mm in minimum EX 5 95 IN 101 standard EX 101 IN 100 8 Valve length mm in minimum EX 100 8 IN 6 Valve intraductal diameter mm in standard EX 6 IN 50 guide stretch length mm in standard EX 50 IN 0 85 Valve heads edge thickness mm in minimum EX 0 85 IN 8 The valve seat contact height mm in standard EX 8 ...

Page 133: ...in maximum 0 10 Diameter of the cylinder in the 92 mm in diameter measuring cylinder 1 65 in below the surface mm in standard 92 Minimum maximum aperture tolerances mm in 0 025 0 piston Piston Dia mm in standard 92 standard 0 02 0 04 The piston to the cylinder clearance mm in maximum 0 05 packing ring Compression ring on 0 10 Compression ring in 0 35 standard Oil ring 0 35 Compression ring on 0 25...

Page 134: ...onnecting rod Spindle neck diameter mm in standard 35 standard 0 015 0 033 Spindle neck bearing free gap mm in maximum 0 10 The main journal cylindricity mm in maximum 0 005 The main bearing size mm in standard 6307 left 6207 right crank pin neck diameter mm in standard 34 Crank pin not round mm in maximum 0 0025 standard 0 4 The crankshaft axial clearance mm in maximum 0 7 bolt standard 190 The c...

Page 135: ...7 CARBURETOR 7 1 Carburetor Removal 7 2 Inspection 7 3 Measurement and Adjustment 7 4 Carburetor Assembly 7 5 Carburetor Installation 7 6 Carburetor Parameters 7 6 7 ...

Page 136: ...B ASSY 10HC A73E 0000 13 Main Jet MJ 99101 939 1380 140 2 TOP COMP 1030 906 2100 15 STAR JET 99101 939 0600 4 SPG 1290 880 2000 17 FV COMP 16155 ZG8 L100 5 SPG SEAT 1229 801 7000 17 1 CLIP 0405 019 1000 6 JN N425 PCA00 19 GASKET 0901 814 6000 7 VACCUME PISTON 20 S J N424 25B35 40 8 S S COMP 1034 868 2500 12 N J 16164 NN1 0030 12 1 NJH N413 03C00 ...

Page 137: ...ng for damage Damage Replace Check valve seat needle valve O ring for damage abnormal wear or dirt Damage or wear or dirty Replace Check piston valve for scratches abnormal wear or damage Scratches wear or damage Replace Check diaphragm for tears Tears Replace Check vacuum chamber cover spring for damage or cracks Damage or cracks Replace Note Valve set needle valve should be replaced as a set 7 ...

Page 138: ...d air Insert piston valve into carburetor body and check the free movement Check free movement of throttle valve Replace With a new one if it s stuck 3 Measurement and Adjustment Keep the carburetor in a upside down position Measure distance a from the mating surface of float chamber without gasket to the top of float Float Height 10 1mm Note The float arm should rest on the needle valve Do not co...

Page 139: ...fuel level gauge with drain pipe Tool Fuel Level Gauge Loosen drain screw Keep fuel level gauge vertical next to the float chamber line and read the fuel level a Fuel Level 3 5 0 5mm If the fuel level is not within the specification adjust the fuel level Remove carburetor Check valve seat and needle valve If either of valve seat or needle valve is worn replace both If both are fine adjust float he...

Page 140: ...er carburetor drain hose fuel inlet hose 6 Carburetor Parameters Type KEIHIN AW6A Aperture No 07G0 Throat size mm 40mm Pilot r min 1400 r min 100 r min Float height mm 10 1 Fuel level mm 3 5 0 5 Main jet MJ 99101 939 1380 140 Main air jet MAJ N424 25B35 40 Jet needle JN N425 PCA00 Needle jet NJ 16164 NN1 0030 Note Align the installation mark of carburetor and carburetor joint ...

Page 141: ... on the wheel Avoid any damage to the wheel When removing tire use the special tire lever and rim protector Maintenance Standard Item Standard Service Limit Longitudinal 0 8mm 2 0mm Rim Vibration Lateral 0 8mm 2 0mm Remained groove 3 0mm 7 0 2PSI 47 1 5KPa Tire Tire pressure 7 0 2PSI 47 1 5 KPa Front brake Free play brake lever 0mm Tightening Torque Nut Tie rod 45 50 N m Lock nut steering stem 23 ...

Page 142: ...el bearing Vibration of Front Wheel Wheel rim distorted Faulty wheel bearing Faulty tire Improper balance of wheels Improper tightening of wheel axle Wheel Cannot Turn Freely Faulty wheel bearing Front wheel axle is bended Brake drag Front Suspension is Too Soft Weakened front shock absorbers Tire pressure is too low Front Suspension is Too Hard Front shock absorber is bended Tire pressure is too ...

Page 143: ...y Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Assembly Press rim into wheel Install rim on the wheel hub Tightening Torque Bolt Wheel Hub 30 35 N m Front Wheel Hub Disassembly Remove Front wheel 8 3 Front brake caliper 8 4 Rim axle nut Brake disc and wheel hub 4 bolts from front brake disc Wheel hub Installation Reverse the removal proce...

Page 144: ...Removal Remove Front wheel 8 3 2 bolts from front knuckle Front brake caliper Inspection Check brake caliper for cracks and tightening parts for oil leakage Replace if any Installation Reverse the removal procedure for installation Tightening Torque Fixing Bolt Brake Caliper 23 25N m ...

Page 145: ...er Cylinder Disassembly Remove Bolt 1 Bolt 2 Separate front brake master cylinder from handlebar Do not remove front brake master cylinder from vehicle unless when replacing master cylinder assembly NOTE Do not hang master cylinder on braking hose Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position and...

Page 146: ...OTE Do not put the master cylinder upside down to avoid possible entrance of air into brake system Keep the master cylinder in the installation position and fix it to the frame Refer to Chapter 1 for proper routing of brake hose Check brake efficiency after installation Brake Hose T Pipe Remove Front cover assembly 2 8 Bolt 3 Front right absorber T Pipe Installation Reverse the removal procedure f...

Page 147: ... of the vehicle Park the vehicle on a level ground and securely support front part of the vehicle Removal Remove Front wheel 8 3 Front wheel hub 8 3 Front brake caliper 8 4 Bolt1 nut 1 Bolt2 nut2 for front left arm upper Bolt3 nut 3 for front left arm Lower Bolt4 nut 4 for front left arm Lower Remove slotted nut Remove tie rod Remove front left suspension 8 ...

Page 148: ... BUSH φ10 5 φ16 23 15 BOLT FLANGE M10 1 25 40 16 FRONT SHOCK ABSORBER 17 FRONT LEFT ARM UPPER 18 FRONT RIGHT ARM UPPER 19 NUT M12 1 25 20 CIRCLIP 34 21 JOINT ARM BALL 22 PIN SPLIT 2 5 25 23 INNER HEX SCREW M10 160 24 BOLT FLANGE M10 1 25 45 25 SCREW M6 16 26 WIRE CLAMP 27 SCREW M6 12 FRONT KNUCKLE DISASSEMBLY INSTALLATION 1 FRONT LEFT DRIVER SHAFT 2 FRONT RIGHT DRIVER SHAFT 3 NUT M12 1 25 4 JOINT ...

Page 149: ... 3 35 3 SCREW CAP DRIVE AXLETREE M20 1 5 4 NUT WHEEL M10 1 25 5 VALVE RIM 6 RIM FR WHEEL 12 6 7 FRONT TIRE 25 8 12 8 HUB FR WHEEL 9 BOLT WHEEL M10 35 1 25 10 HUB FR WHEEL 11 FRONT BRAKE DISC 12 BOLT BRAKE DISC M8 16 13 MUDGUARD L FR BRAKE DISC 14 MUDGUARD R FR BRAKE DISC 15 BOLT FLANGE M8 12 16 DUST SEAL φ22 5 φ26 5 10 8 ...

Page 150: ...ont Left Lower Arm Refer to Front Left Upper Arm Front Left Lower Arm for removal disassembly inspection and installation of other suspension arms Front Right Arm Disassembly Remove Front right absorber 8 8 Bolt 23 and Nut 10 Bolt 6 and Nut 10 Bolt 6 and Nut 10 Remove wheel brake caliper and wheel hub before removing absorber Remove tie rod before removing bolts Pull out front right knuckle from f...

Page 151: ...ty Drive Shaft of front axle only does not require removal of front suspension Remove Front wheel 8 3 Front left brake caliper 8 4 Front left wheel hub 8 3 Check dust boot Damaged dust boot Replace Shake constant velocity drive shaft check the agility of rzeppa universal joint free turning of bearing and any gap between rzeppa constant velocity joint and spline Stagnated turning noise gap with spl...

Page 152: ... cover Remove handlebar cover 2 3 Remove store box cover 2 8 Installation Reverse the removal procedure for installation Right Handlebar Switch Remove Front cover assembly 2 8 Right handlebar switch connector 2 bolts Right handlebar switch Installation Install right handlebar switch 8 15 ...

Page 153: ...Mirror Disassembly Turn counter clockwise and loosen nut Remove left rear view mirror by turning it counter clockwise Note Left rear view mirror is right threaded Turn counter clockwise for removal Turn clockwise and loosen nut Remove right rear view mirror by turning it clockwise Note Right rear view mirror is left threaded Turn clockwise for removal Installation Reverse the removal procedure for...

Page 154: ... fixing bolts Handlebar Installation Reverse the removal procedure for installation Tightening Torque 20 30N m 2 0 3 0kgf m Note Main cable throttle cable brake hose cable wiring should be routed properly Installation of Throttle Cable Remove 3 screws Right handlebar top cover Install Throttle cable Right handlebar switch top cover ...

Page 155: ...f left handlebar switch with positioning hole on handlebar Tighten with screw 1 and 2 from under Insert connector of left handlebar switch into socket of main cable Installation of Right Handlebar Switch Tighten with bolt 1 and 2 from under Insert connector of right handlebar switch into socket of main cable 8 ...

Page 156: ...d right grips Install guard of handle grip Tighten the bolt NOTE Before applying adhesive wipe off grease or Oil on the handlebar surface with a lacquer thinner Installation of Master Cylinder Keep the UP mark on master cylinder upward Install master cylinder Tighten the screw NOTE Main cable throttle cable brake hose and wiring should be routed properly Install Rear view mirror 8 13 ...

Page 157: ...R STEERING STEM 3 BUSH STEERING 4 SHAFT STEERING 5 NUT M10 1 25L 6 JOINT TIE ROD L 7 PIN COTTER 3 35 8 ARM STEERING 9 WASHER φ14 φ28 2 10 NUT CASTLE M14 1 5 11 PIN COTTER 2 5 25 12 TIE ROD ASSY 13 JOINT TIE ROD 14 NUT M10 1 25 15 NUT M10 1 25 16 WASHER φ10 φ20 2 17 SPRING WASHER φ10 18 TIE ROD 8 ...

Page 158: ...teering stem flat with a flat screwdriver and hammer Remove Bolt 1 and Bolt 2 Steering stem bushing Cotter pin Tie rod nut and washer Press down steering tie rod and separate from steering stem Remove fixing bolt of steering stem Lift steering stem with handlebar from vehicle Installation Reverse the removal procedure for installation NOTE Check steering after installation 3 3 Main cables and wire...

Page 159: ...oil seal from frame with special tool Special tools Bearing removal tool set Rotor puller Removal tool shaft Removal tool hammer Installation Reverse the removal procedure for installation Special tools Tool Bearing Race Tool shaft Note Use special tools for installation of bearing Reverse the removal procedure for installation of the steering system NOTE Check steering after installation 8 ...

Page 160: ...ible damage to the wheels When removing tire from rim use special tire lever and rim protector to avoid damage to the rim Overhaul standard Item Standard Limit Longitudinal 2 0mm Rim vibration Horizontal 2 0mm Remained Tire Tread 1 6mm Tire pressure front 7 0 2PSI 47 1 5KPa Rear wheel Tire Tire pressure rear 7 0 2PSI 47 1 5KPa Rear brake Brake lever Free Play 10 15mm Tightening torque Rear wheel a...

Page 161: ...balance Improper tightening of wheel axle nut Loosened wheel nut Rear shock absorber is too soft Weak spring Oil leakage from rear shock absorber Rear shock absorber is too hard Bent rear shock absorber Tire pressure is too high Poor brake efficiency Improper brake adjustment Stained brake pad or brake disk Worn or damaged brake pad 9 ...

Page 162: ...ecessary Slowly turn the wheel measure the rim vibration with a dial gauge Service limit Axial 2 0mm Radial 2 0mm Installation Refer to front wheel installation 8 3 Wheel hub removal Remove rear wheel 9 3 Remove nut of front wheel axle Remove wheel hub Installation Reverse the removal procedure for installation Tightening torque Rim Axle Nut 180 200N m ...

Page 163: ...e Installation Reverse the removal procedure for installation Note Refer to Chapter 1 for brake hose routing Rear Brake Disc Remove Rear right wheel 9 3 Remove rear right suspension Rear drive shaft Rear brake caliper 9 4 Rear brake disc 8 3 Inspection Brake Disc Thickness 3mm Replace Installation Reverse the steps of removal for installation Note Refer to Chapter 1 for brake hose routing 9 ...

Page 164: ...NSTALLATION 1 REAR LEFT GUARD 2 REAR RIGHT GUARD 3 SCREW M6 16 4 BOLT FLANGE M10 1 25 70 5 DUST CAP 6 CENTER SPACER 7 BUSH ARM 8 NUT FLANGE M10 1 25 9 ARM SET L RR LOWER 10 ARM SET R RR LOWER 11 BOLT FLANGE M10 1 25 210 12 DUST SEAL 16 24 4 13 BEARING K16 22 12 14 CENTER SPACER 15 BOLT FLANGE M10 1 25 40 16 REAR SHOCK ABSORBER 17 INNER HEX SCREW M10 1 25 90 18 CENTER SPACER 19 ARM SET RR UPPER 20 ...

Page 165: ... CAP PIVOT 6 BUSH RR KNUCKLE 7 COLLAR RR KNUCKLE 8 KNUCKLE SET L RR 9 KNUCKLE SET R RR 10 KNUCKLE SET L RR 11 KNUCKLE SET R RR STABILIZER BAR DISASSEMBLY INSTALLATION 1 STABILIZER BAR 2 STABILIZER BAR 3 CENTER SPACER 4 RUBBER SUPPORT 5 HOLDER STABILIZER 6 BOLT FLANGE M8 16 7 LINK SET RR STABILIZER 8 PIN SPLIT 2 5 25 9 NUT M10 1 25 10 WASHER φ10 φ20 2 9 ...

Page 166: ...sorbers Maintenance of rear absorbers only does not require removal of rear suspension Remove the following parts for rear right shock absorber 15 Bolt 8 Nut 20 Bolt 8 Nut Remove rear right shock absorber Installation Reverse the removal procedure for installation Rear Right Arm Refer to front right Arm in Chapter 8 for the removal inspection and installation of Rear Right Arm Rear Left Suspension...

Page 167: ... Type Torque N m Remark Fornt axle bolt 6 M8 1 25 25 20 Screw 2 M4 22 10 Screw 2 M5 15 10 Screw 1 M6 16 12 Screw 3 M6 25 13 Screw 1 M12 10 15 Front screw 1 M12 1 5 70 Glue Bolt 6 M10 1 25 20 35 Front axle bolt 1 M18 1 25 8 20 Bolt 1 M10 1 25 12 25 Bearing Retainer 1 M65 2 0HL 60 Rear axle bolt 2 M10 1 25 25 35 Rear axle bolt 6 M8 1 25 25 20 Nut 1 M12 1 25 70 Bolt 4 M8 25 25 Bearing Retainer 1 M65 ...

Page 168: ...re abnormal sound a Abnormal sounds during accelerating decelerating have little to do with engine working but possibly with gear worn b Constant abnormal sounds during accelerating or decelerating might be cause by gear clearance wrongly adjusted during assembling Note Wrong assembly or adjustment of the front or rear axle will aggravate gear worn and block c Slight sounds will be noticed during ...

Page 169: ... 1 12 FRONT AXLE RIGHT CASE 1 3 O RING ф16 5 ф2 5 1 13 BEARING 16007 1 4 BOLT M18 1 5 10 1 14 CIRCLIP 62 1 5 O RING ф15 5 ф1 5 1 15 O RING ф160 ф3 1 6 SPEED SENSOR 1 16 ALUNINUM PAD ф18 ф10 1 5 1 7 BOLT FLANGE M6 16 1 17 BOLT FLANGE M10 1 25 12 1 8 ALUNINUM PAD ф18 ф10 1 5 1 18 OIL SEAL 25 40 7 1 9 JOINT BREATHER PIPE M10 1 25 10 1 19 BOLT FLANGE M8 1 25 25 6 10 NEEDLE BEARING NA5903 1 10 ...

Page 170: ... 15 NUT M8 1 4 O RING ф16 5 ф2 5 1 16 BOLT FLANGE M10 1 25 25 2 5 BOLT FLANGE M18 1 5 8 1 17 BOLT FLANGE M8 25 6 6 OIL SEAL 65 90 10 1 18 NEEDLE BEARING NA5903 1 7 ALUNINUM PAD 10 18 2 1 19 BEVEL GEAR BEARING HOUSING 1 8 BOLT M10 1 25 12 1 20 O RING ф63 ф3 1 9 REAR AXLE SIDE COVER 1 21 ADJUST WASHER thickness 0 5mm 1 10 BEARING 16017 1 22 OIL SEAL 35 55 8 1 11 O RING ф150 ф3 0 1 23 BOLT FLANGE M8 ...

Page 171: ... 1 3 WASHER ф53 ф39 5 1 1 15 DRIVE CLUTCH 1 4 LEFT HALF AXLE GEAR Z 16 1 16 DRIVE CLUTCH COVER 1 5 PIN 4 30 1 17 FRONGT AXLE FORK 1 6 PLANT GEAR Z 10 2 18 FORK SHAFT ф10 ф80 1 7 PLANT GEAR SHAFT 15 87 1 19 SCREW M12 10 1 8 RIGHT HALF AXLE GEAR Z 16 1 20 FORK SPRING 15 ф3 5 ф0 5 1 9 ADJUST WASHER D ф58 ф48 0 2 1 21 STEEL BALL SR2 1 10 DIFFERENTIAL CASE 1 11 SPRING PAD 10 6 12 HEXAGONHEADED BOLT M10...

Page 172: ...QTY Ref No Description QTY 1 DRIVEN BEVEL GEAR FRONT ASLE LEVOROTARY Z 33 1 6 BEARING RETAINER M65 2 0HL 1 2 BEARING 6008 P6 1 7 COUPLER 14T 1 3 ADJUST WASHER B φ 54 ф 66 0 2 1 8 WASHER φ12 ф30 4 1 4 DRIVE PINION GEAR DEXTRAL 9T 1 9 NUT FLANGE M12 1 25 1 5 BEARING TM6305 1 ...

Page 173: ...TY 1 DRIVEN BEVEL GEAR REAR ASLE DEXTRAL Z 33 1 6 BEARING RETAINER M65 2 0HL 1 2 ADJUST WASHER E φ67 ф55 0 8 1 7 BEARING TM6305 1 3 NEEDLE BEARING K556120 1 8 COUPLER REAR AXLE 1 4 ADJUST WASHER G φ 100 ф 86 0 2 1 9 WASHER 12 30 4 1 5 DRIVE BEVEL GEAR LEVOROTARY Z 9 1 10 NUT FLANGE M12 1 25 1 10 ...

Page 174: ...f No Description QTY 1 GEAR MOTOR 1 9 WASHER φ8 ф4 1 3 2 RING 1 10 SPRING PAD 4 3 3 DOWEL PIN φ8 10 2 11 HEX NUT 3 4 BOLT FLANGE M6 25 3 12 CONTACT COVER 1 5 CONNTACT COMPONENTS 1 13 WASHER φ8 ф4 1 2 6 GASKET 1 14 SPRING PAD 2 7 SCREW 2 15 SCREW M4 22 2 8 CONTACT WIRE 1 16 DIFFERENTIAL CONTROLLER 1 ...

Page 175: ...ylndrical surface of front axle and oil seal lips Replace broken parts if necessary z Check drive pinion gear and differential gear inspect worn surface Replace broken if necessary z Check driven gears surface gear center differential bracket differential wearing situation on the differential gear assembly Replace parts if necessary z Check inside and outside spline washer wearing status in front ...

Page 176: ...il seal bearing and drive clutch assembly 24 Use screw thread fastening glue z Front differential gear case cover assembly Note Use engine oil for oil seal or bearing assembly z Differential gear assembly M10 1 25 20 Tightening torque35Nm Note Use engine for bearing and dif ferential gear Use proper washer to make gear working freely Adjust washer thickness 0 2 0 3 0 4 0 5 1 0 ...

Page 177: ...ce between drive pinion gear and differential gear Drive bevel gear clearance measurement Install sup port tools tightening bolts M10 1 25 put up dial indicator make sure 21 mm is between measuring point and support tools Turn support tools counter clock and read the data Standard 0 10 0 25 Adjust washer thickness 0 1 0 2 0 3 0 4 0 5 1 0 b Shift fork and drive clutch assembly should be against tig...

Page 178: ...LE 10 12 c Use special equipment or vehicle control circuit into two stroke position M6 25 before gear motor assembly d Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle ...

Page 179: ...rning stability rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required z Check rear axle if bearing clearance is normal turning status rollway stell ball neddle bearing as well Replace bearing if necessary Special tools are required z Check worn status of drive bevel gear and ring gear rear axle Replace if necessary z Check oil seal lips o ring shape Repl...

Page 180: ...sing 6 thickness c Inspect installing clearance by check ing bevel gear clearance Standard 0 1 0 2 e Keep installing point bearing clear ance 0 1 0 2 by choosing 8 thickness d Drive bevel gear clearance measure ment illustration see above Install measuring tools tightening torque M14 1 25 60 Put up dial indicator and make sure distance from indicator point tomeasuringtoolcenteris22mm Counter clock...

Page 181: ...10 FRONT REAR AXLE 10 15 f Adjust item 29 as illustrated and make sure its end and back clearance of drive gear is 0 3 0 6 Tighten item 31 10 ...

Page 182: ...ging System Layout 11 1 Inspection of Charging System 11 5 Overhaul Info 11 2 Rectifier Regulator 11 6 Troubleshooting 11 3 Inspection of AC Magneto 11 8 Battery 11 4 Layout for Electricity Equipment in Vehicle 11 9 Charging System Layout ...

Page 183: ...ng and do not open the electrolyte cover Note Replace if the battery service life expired Keep the ignition switch OFF when removing electrical parts Disconnect the negative connection of battery if it is stored on the vehicle Fast charging is not recommended as it may reduce the battery life If battery is repeatedly charged and discharged fully fully charged and fully discharged it may cause dama...

Page 184: ...stance of charging coil 20 0 2 0 3Ω Rectifier Type 3 phase loop rectification controllable parallel connection regulated voltage battery 12V18Ah Current Leakage Less than 1mA Fully charged 12 8v Voltage between terminals Insufficient charge Less than 11 8V Standard 0 9A 5 10hours Battery Charge current time Fast charge 4A 60minutes ...

Page 185: ...tion Install cap firmly on the positive pole after installation Inspection Measure voltage between battery terminals and check test status Complete test 12 8V Insufficient test 11 8V Insufficient charge Recharge Note When recharging after normal charging measure the voltage between terminals after 30 minutes Measuring immediately after recharging will not gain the correct test due to the sharp vol...

Page 186: ...fully charged battery Keep ignition switch at OFF position Connect voltmeter between battery s terminals after engine is started and warmed up Note Avoid short circuit when measuring Over voltage may be generated when removing or joining the battery terminals with switch ON and will damage the multimeter and the electrical parts Operation should be done with ignition switch OFF Use a fully charged...

Page 187: ...t by shifting from the high to the low range Do not turn on the ignition switch when measuring the current Current Leakage less than 1mA When current leakage is higher than specified limit there is fault with the return circuit Disconnect terminals and connectors while measuring current to check out the faults Rectifier Regulator System inspection Note Inspection can be done without removing the A...

Page 188: ...ation Reverse the removal procedure for installation Note Wires hoses and cables should be routed properly Charpter1 Regulator Rectifier Measure the resistance between the terminals using a multimeter If any of the resistance is not within the specified value replace the regulator rectifier NOTE If the multimeter reads under 1 4V when the probes are not connected replace the multimeter battery ...

Page 189: ...within specified value Check that the generator core is insulated Set multimeter at 1 10Ω Generator Coil Resistance 0 1 0 4Ω Yellow Yellow Insulate Resistance 12 22KΩ Yellow Earthing wire Generator Non load Performance Start engine run it at 5000r min Measure AC voltage between three lead wires of generator with multimeter Replace the generator if the voltage is lower than the specified value Set ...

Page 190: ...11 BATTERY CHARGING SYSTEM 11 9 Layout for All Electricity Equipment in Vehicle ...

Page 191: ...to CDI In addition over voltage may be generated on CDI and cause damage to return circuit when removing or joining the connectors and terminals with switch ON Always shut the ignition switch when overhauling Most of the failures of ignition system are caused by faulty contacts between connectors and terminals Check all the connections for any faults before overhauling Select spark plug of proper ...

Page 192: ...12 IGNITION SYSTEM 12 2 Ignition System Diagram ...

Page 193: ...or it is obstructed between negative pole and thread or positive pole and input end 2 Faulty spark includes no spark and weak spark Inspect the following aspects if there is no spark 1 Inspect ignition coil with multimeter or measurement in the following steps 1 Measure primary bobbin resistance usually it is about 1Ω 2 Measure secondary bobbin resistance usually it is about 4 2K 3 Measure damp re...

Page 194: ...asure after all the wires are correctly connected Inspection should be done when the spark plug and spark plug cap are properly installed If the spark plug is removed the peak voltage will rise Remove the store box cover 2 8 Keep spark plug in the cylinder head install quali fied spark plug on the spark plug cap and earth the engine Open rubber cover of ignition coil keep the ignition wire connect...

Page 195: ...ttery fuse 30A Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 11 If the battery is bad Clean the battery terminals Recharge or replace the battery Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 6 If the spark plug is in bad condition or it is not the ...

Page 196: ...h for continuity Refer to CHECKING THE SWITCHES If the main switch is bad Replace the main switch Engine stop button Check the engine stop button for continuity Refer to CHECKING THE SWITCHES If the engine stop button is bad Replace the left handlebar switch ...

Page 197: ... attached by the magnet of rotor Be careful not to hurt the fingers when removing Loosen bolt remove AC magneto stator and pickup pickup resistance 110 130Ω Installation Reverse the removal procedure for installation Ignition Coil Remove magneto cover Remove spark plug cap from spark plug Engine Service Loosen bolt and remove ignition coil Installation Reverse the removal procedure for installatio...

Page 198: ...SSY 2 BOLT FLANGE 3 CLUTCH STARTER ASSY 4 LIMIT BUSH HANDLE 5 HANDLE ASSY 6 COVER HANDLE 7 SPRING COIL 8 SHEAVE DRUM ASSY 9 ROPE 10 PAWL 11 PAWL SPRING 12 SPRING 13 FRICTION PLATE 14 SPRING WASHER 15 BOLT FLANGE 16 STARTER PULLY 17 BOLT FLANGE 18 BOLT FLANGE ...

Page 199: ...lace If the commutator is discolored polish with a sand paper and clean with a clean and dry cloth If there is undercut scrape out insulator B and make its distance between A as d d 1 5mm Armature Coil Check for continuity between each segment and between each segment and armature shaft using a multimeter If there is no continuity between the segments or there is continuity between segments and sh...

Page 200: ...12 IGNITION SYSTEM 12 10 Layout for Ignition System Equipment in Vehicle ...

Page 201: ...rmation of glass face and damage to bulb Pay attention to the following when replacing the bulb Do not replace the bulb when it is turned on Keep ignition switch in the OFF position and replace after the bulb is cooled down Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface Clean the glass with a clean rag dipped in alcohol or isoamyl acetate in case of any oil st...

Page 202: ...13 Lighting Instruments Switches 13 2 Troubleshooting Head Light Cannot Turn On Broken fuse Open circuit with main cable Burnt Bulb Faulty Switch ...

Page 203: ... bulb Oil stains on the glass surface may cause break of bulb Clean the stained surface with alcohol or isoamyl acetate Make sure that the three pins of the bulb should be in line with the three positioning holes in the socket when replacing the bulb Bulb specification 12V 35 35W Reverse the removal procedure for installation After replacing the bulb adjust headlight beam Inspection of Headlight T...

Page 204: ... light bulb Bulb Specification 12V 21 5W Reverse the removal procedure for installation Front Turning Indicator Bulbs Remove headlight 10 5 Remove dust cover of front turning indicator bulb Replace front turning light bulbs Bulb Specification 12V 10W Rear Turning Indicator Bulbs Remove socket of rear turning indicator bulb Replace rear turning indicator bulbs Bulb Specification 12V 10W Reverse the...

Page 205: ...adlight fender Fixing bolt of headlight headlight connector Headlight Disconnect headlight connector Reverse the removal procedure for installation Note Be careful not to damage main cable when assembling After replacing adjust the headlight beam Note Main cables and wires should be routed properly 13 ...

Page 206: ... continuity Means proper continuity Remove Remove store box cover 2 8 Disconnect connector of ignition switch Remove ignition switch Reverse the removal procedure for installation Handlebar Switch Remove front top cover 2 4 Disconnect left and right handlebar switches Check according to the following table the continuity of the terminals Low beams High beams turn switch and light switch Start Swit...

Page 207: ...e 8 12 or 8 13 Brake Light Switch Disconnect brake light switch connector and check terminators for continuity Hold the brake lever Continuity Release the brake lever No continuity No continuity Replace brake light switch Horn Inspection Remove front cover 2 8 Disconnect horn Connect with a fully charged 12V battery and check if the horn sounds Faulty Horn Replace 13 ...

Page 208: ...allation Meter Run the vehicle at low speed and check if the speed indicator moves Faulty speedometer Replace Removal and Installation Remove front cover 2 8 Disconnect dashboard wire connector Remove fixing nut and remove meter as illustrated on the right Reverse the removal procedure for installation Note Main cables and wires shall be routed properly ...

Page 209: ...d locate the float position and check if it conforms to the fuel gauge reading Non conformity check main cable for damage or short circuit Check fuel sensor and fuel gauge Remove fuel sensor connector Connect multimeter between connector terminals Shake float with hand and measure the resistance of float at different positions Connection Terminal Upper Yellow White Green 3 10Ω 20 Lower Yellow Whit...

Page 210: ...on hole of fuel tank Fuel sensor should be fitted properly No fuel leakage is allowed Connect connector of horn Inspection of Fuel Gauge Switch on power supply and check if fuel level gauge functions normally If fuel gauge works normally Reverse the removal procedure for installation ...

Page 211: ...d do not raise temperature sharply The thermometer should not contact the vessel bottom Disassembly Remove right side panel 2 7 Disconnect and remove transducer Put the transducer into a vessel with coolant slowly heat up the liquid and measure the transducer resistance Temperature Resistance 50 138 170Ω 80 48 56Ω 100 24 30Ω 120 14 18Ω Transducer out of range Replace Install transducer Connect wat...

Page 212: ...13 Lighting Instruments Switches 13 12 500ATV Circuit Diagram ...

Page 213: ...14 Troubleshooting 14 1 1 Engine Common Failure Diagnosis 14 2 2 Carburetor 14 5 3 Cooling System Radiator 14 6 4 Ignition System 14 6 14 ...

Page 214: ...needle valve 4 Clogged fuel hose 5 Clogged fuel filter Transfer is not in Neutral position Replace Replace Replace Repair or Replace Tighten Check electrical part Adjust Adjust Clean or Replace Clean and dry or replace Replace Replace Replace Replace Clean or Replace Clean or Replace Replace Replace Clean or Replace Set to Neutral position Engine stalls easily or has unstable Idle speed 1 Improper...

Page 215: ... Engine lacks power 1 Improper valve clearance 2 Weak valve spring 3 Improper valve timing 4 Worn cylinder 5 Worn piston ring 6 Improper valve seating 7 Fouled spark plug 8 Improper spark plug gap 9 Clogged carburetor jet 10 Improper fuel level in fuel chamber 11 Dirty air filter 12 Worn rocker arm or rocker arm shaft 13 Air leakage from air intake pipe 14 Excessive engine oil Adjust Adjust Adjust...

Page 216: ...eplace chain sprocket Repair or replace Noise from Clutch 1 Worn or damaged crankshaft spline 2 Worn inner race spline Replace crankshaft Replace inner race Noise from Crankshaft 1 Rattling bearing 2 Worn or burnt crank pin bearing 3 Excessive thrust clearance Replace Replace Replace Noise from CVT 1 Worn or slipping drive belt 2 Worn rollers in primary sheave Replace Replace Engine is noisy Noise...

Page 217: ...t Adjust Idling or low speed trouble 1 Clogged slow jet 2 Clogged slow jet passage 3 Clogged air intake 4 Clogged bypass port 5 Starter plunger not fully closed 6 Improper set of idle screw 7 Improper float height Clean Clean Clean Clean Adjust Adjust Adjust Medium or high speed trouble 1 Clogged main jet 2 Clogged main air jet 3 Clogged needle jet 4 Faulty throttle valve 5 Clogged fuel filter 6 I...

Page 218: ...Faulty thermoswitch 2 Extremely cold weather 3 Faulty thermostat Clean Discharge air and add coolant Check and replace Replace Replace Check and or replace Replace Put on radiator cover Replace 4 Ignition System Complaint Symptom and Possible Causes Remedy No Sparking or Weak Sparking 1 Faulty CDI 2 Faulty spark plug 3 Faulty Generator 4 Insufficient battery voltage 5 Faulty ignition coil 6 Faulty...

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