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7-7 Cylinder Installation

Install dowel pins and new gasket

Coat some engine oil to inside of cylinder,

piston and piston rings.

Care to be taken when installing piston into

cylinder. Press piston rings in one by one as

installation.

Caution

Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).

Do not push piston into cylinder
forcefully because piston and piston
rings will be damaged

Coolant hose

Summary of Contents for ATV300

Page 1: ...INE 4 LubricationSystem 15 5 FuelSystem 19 6 CylinderHEAD CylinderValve 30 7 Cylinder Piston 46 8 V Beltdrivingsystem 54 9 ACG Startonewayclutch 67 10 CoolingSystem 76 CHASSIS 11 SteeringSuspension 84...

Page 2: ...HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts USED ENGINE GEAR OIL Used engine oil and gear o...

Page 3: ...65 COLORING Specifications subject to change without notice Compression 10 5 1 OutputPower 14KW 6000rpm Maximum Torque Nm rpm 22 3 Nm 5500rpm Carburetor Vacuum film Ignition TCI Starting Electric Lub...

Page 4: ...ing your vehicle identification date in your operation and maintenance manual and on a sheet that you should keep in a safe place separately from the vehicle The VIN No A is stamped on the central fra...

Page 5: ...ft Rear brake arm nut 7 N m 5 2 lbf ft Rear axle castle nut 40 60 N m 30 45 lbf ft Rear wheel bolt 24 N m 17 7 lbf ft Exhaust muffler mounting bolt 30 N m 22 1 lbf ft Engine hanger bolt 30 N m 22 lbf...

Page 6: ...ING SYSTEM 2 6 AIR CLEANER 2 12 TOE IN 2 7 SPARK PLUG 2 1 MAINTENANCE DATA SPECIFICATION SPARK PLUG SPARK PLUG GAP 0 6 0 8 mm RECOMMENDED SPARK PLUGS NGK DR8EA THROTTLE LEVER FREE PLAY 2 5 mm IDLE SPE...

Page 7: ...12000 Everyday check before riding Crankcaselube R R R R R R R I Lube filter C C C C Air filter Clean filter every 2000 3000 km change it when necessary Spark plug Initial 1000km and Clean every 3000...

Page 8: ...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 thro...

Page 9: ...en the spark plug with 12 19 N m 2 8 IDLE SPEED Connect an engine speed meter Warm up the engine 10 minutes are enough Turn the idle speed adjust screw B on the carburetor to obtain the idle speed Tur...

Page 10: ...ause the brake system is different ones need to adjust it to reach a proper brake level 2 10 WHEELS AND TIRES Inspect the tire surfaces for cuts nails or other sharp objects Check the each tire surfac...

Page 11: ...moval Torque steering shaft holder bolt 33 N m 24 lbf ft 2 12 TOE IN Keep the vehicle on level ground and the front wheels facing straight ahead Mark the centers of the tires to indicate the axle cent...

Page 12: ...12 If the toe in is out of standard adjust it by changing the length of the tie rods equally by turning the tie rod while holding the ball joint Tighten the lock nuts Torque 35 43 N m...

Page 13: ...ed to remove all of components such as seat front and back fender fuel tube exhaust pipe carburetor cable and drive shafts etc You can then see three hanger bolts which have screwed on engine Loosen t...

Page 14: ...14 3 3 ENGINE INSTALLATION The Engine installation is essentially in the reverse order of removal The torque of engine hanger bolt is 30 N m Route the wires and cable in reverse order properly...

Page 15: ...15 4 LUBRICATION SYSTEM 4 1 Mechanism Diagram 4 2 Precautions in Operation 4 3 Troubleshooting 4 4 Engine Oil 4 5 Engine Oil Strainer Clean 4 6 Gear Oil 4 1 Mechanism Diagram...

Page 16: ...iner cap 1 5 3 0kgf m Engine oil drain bolt 1 9 2 5kgf m Gear oil drain bolt 1 0 1 5kgf m Gear oil join bolt 1 0 1 5kgf m Oil pump connection bolt 0 8 1 2kgf m 4 3 Troubleshooting Low engine oil level...

Page 17: ...fter drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m 4 5 Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check...

Page 18: ...e drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Star...

Page 19: ...Diagram 5 2 Precautions in Operation 5 3 Trouble Diagnosis 5 4 Carburetor Remove Install 5 5 Air Cut Off Valve 5 6 Throttle Valve 5 7 Float Chamber 5 8 Adjustment of Idle Speed 5 9 Fuel Tank 5 10 Air...

Page 20: ...ke unstable drive ability When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual ga...

Page 21: ...ed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insuff...

Page 22: ...nect the fuel hose Release the clamp strip of air cleaner Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the carburetor Installation I...

Page 23: ...23 5 5 Air Cut Off Valve Disassembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Assembly Install in reverse order of removal procedures...

Page 24: ...e fuel needle clamp and fuel needle Assembly Place the fuel needle onto the throttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect...

Page 25: ...nd valve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt Caution Caution In case of worn out or dirt the float valve and valve seat will not tightly clos...

Page 26: ...adjustments must be made after installation Throttle cable adjustment Idle adjustment Set the air adjustment screw in according to number of turns noted before it was removed Take care not to damage...

Page 27: ...d turns 1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1500 100 rpm Connect the hose of exhaust analyzer to exhaust Front end Press test k...

Page 28: ...nstallation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fuel tank...

Page 29: ...lement Remove the air cleaner cover 6 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammab...

Page 30: ...Operation 6 3 Troubleshooting 6 4 Cylinder Head Removal 6 5 Cylinder Head Inspection 6 6 Valve Stem Replacement 6 7 Valve Seat Inspection and Service 6 8 Cylinder Head Reassembly 6 9 Cylinder Head In...

Page 31: ...xhaus t Guide seat Clearance between valve stem and guide Intake Exhaus t Free length of valve spring Valve seat width Tilt angle of cylinder head 0 05 Torque Value Cylinder head cover bolt 1 0 1 4kgf...

Page 32: ...lve Improper valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure...

Page 33: ...t of thermostat and then remove the thermostat Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove the side cover mounting...

Page 34: ...linder head piston is at TDC position Remove cam sprocket bolts and then remove the sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special...

Page 35: ...se a valve cotter remove assembly tool to press the valve spring and then remove valves Caution Special Service Tool Valve cotter remove assembly tool Do not damage the matching surfaces of cylinder a...

Page 36: ...ve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 5 mm Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 34...

Page 37: ...mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust va...

Page 38: ...it IN 0 08 mm EX 0 10 mm Caution Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too Caution Before measuring the valve...

Page 39: ...erature and then correct the new valve guide with reamer Caution Correct valve seat and clean up all metal residues from cylinder head Tool Valve guide reamer 5 0 mm Do not let torch heat cylinder hea...

Page 40: ...n valve seat has to be ground with valve seat chamfer cutter Refer to operation manual of the valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve s...

Page 41: ...that a seal track will be created on contact surface Caution If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too...

Page 42: ...ress the valve spring and then remove valves Caution Special Service Tool Valve cotter remove assembly tool Tap the valve stems gently with a plastic hammer to make sure valve retainer and valve cotte...

Page 43: ...urfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tig...

Page 44: ...e with camshaft bolt hole Tighten the sprocket mounting bolts 50 Caution Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and s...

Page 45: ...er valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 10 0 02 mm EX 0 15 0 02 mm Install the cylinder head side cover Star...

Page 46: ...PISTON 7 1 Mechanism Diagram 7 2 Precautions in Operation 7 3 Trouble Diagnosis 7 4 Cylinder and Piston Removal 7 5 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 1 Mech...

Page 47: ...er ID of piston pin boss OD of piston pin Clearance between piston and piston pin ID of connecting rod small end 7 3 Trouble Diagnosis Low or Unstable Compression Pressure Smoking in Exhaust Pipe Cyli...

Page 48: ...iston Remove cylinder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Inspection Check if the inner diameter of cylinde...

Page 49: ...ston rings Check if the piston rings are damaged or its grooves are worn Caution Place piston rings respective into cylinder below 20 mm of cylinder top In order to keep the piston rings in horizontal...

Page 50: ...eter of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution Service limit 71 00 mm Compare measured v...

Page 51: ...stall the piston ring onto piston carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwa...

Page 52: ...iston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution Soap the residues into solvent so that the residues can be removed more easily Do not...

Page 53: ...n and piston rings Care to be taken when installing piston into cylinder Press piston rings in one by one as installation Caution Install coolant hose onto cylinder Install cylinder head refer to Chap...

Page 54: ...8 V BELT DRIVING SYSTEM 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 8 1 Mechanism Diag...

Page 55: ...Tools Drive face nut 8 5 10 5kgf m Clutch spring compressor SYM 2301000 Clutch outer nut 5 0 6 0kgf m Inner bearing puller SYM 6204002 Drive plate nut 5 0 6 0kgf m Clutch nut wrench 39 x 41 mm SYM 90...

Page 56: ...moval Release the 2 clamp strips of left crankcase cover ducts and then remove the ducts Remove left crankcase cover 10 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left cr...

Page 57: ...emove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diagram shown Servi...

Page 58: ...ter whit universal holder and then tighten nut to specified torque value Torque value 5 0 6 0kgf m Install the drive face washer and drive face nut Hold drive face with universal holder and then tight...

Page 59: ...hen remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Universal...

Page 60: ...Measure the outer diameter of movable drive face boss and replace it if it exceed service limit Service limit mm Measure the inner diameter of movable drive face and replace it if it exceed service l...

Page 61: ...ulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution Hold drives face with universal holder Tighten nut to specified torque Torque value 8 5 10 5kgf m Install...

Page 62: ...then remove mounting nut with special service tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remo...

Page 63: ...orn components Measure the outer diameter of driven face and the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm...

Page 64: ...if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block should not...

Page 65: ...all new inner bearing Caution Install snap ring into the groove of drive face Align oil seal lip with bearing and then install the new oil seal if necessary If the inner bearing equipped with oil seal...

Page 66: ...e pin and guide pin roller Install the collar Install friction plate spring and clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that...

Page 67: ...recautions in Operation 9 3 Right Crankcase Cover Removal 9 4 A C G Set Removal 9 5 Right Cover Bearing 9 6 Flywheel Removal 9 7 Starting Clutch 9 8 Flywheel Installation 9 9 A C G Set Installation 9...

Page 68: ...of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 5 0 6 0kgf m St...

Page 69: ...and gasket 9 4 A C G Set Removal Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set 9 5 Right Cover Bearing I...

Page 70: ...89 Install a new one bearing 6201LU by bearing driver Special tool Bearing driver 9 6 Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with un...

Page 71: ...l and starting driven gear 9 7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch driven gear...

Page 72: ...flywheel and rotate starting clutch gear The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting...

Page 73: ...nstall starting driven gear 9 8 Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face with universal holder and tight...

Page 74: ...nerator 2 screws Tie the wire harness securely onto the indent of crankcase Caution 9 10 Right Crankcase Cover Installation Install dowel pin and new gasket Remove water pump cover Install right crank...

Page 75: ...75 Install right crankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover...

Page 76: ...76 10 COOLING SYSTEM 10 1 Mechanism Diagram 10 2 General Information 10 3 Trouble Diagnosis 10 4 Trouble Diagnosis for Cooling System 10 5 System Test 10 6 Radiator 10 1 Mechanism Diagram...

Page 77: ...city of coolant Engine radiator Reservoir upper c c c c Thermostat Begins to activate at 82 95 Stroke 0 05 3mm Thermos switch fan Begins to activate at 88 3 Boiling point Not pressure 107 7 Pressurize...

Page 78: ...coolant The water hose and jacket are clogged Fan motor malfunction The filler cap of the radiator malfunction The engine temperature is too low The water thermometer and the temperature sensor malfu...

Page 79: ...79 10 4 Trouble Diagnosis for Cooling System...

Page 80: ...80...

Page 81: ...hange of coolant Warning Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall the drain bolt Refilli...

Page 82: ...iator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radiator clean using compressed air If the radiator is blocked by dirt...

Page 83: ...embly Install fan motor onto fan duct and insert the fan into the motor shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan...

Page 84: ...84 11 STEERING AND SUSPENSION 11 1 PARTS DRAWING 11 2 TROUBLESHOOTING 11 3 HANDLENAR 11 4 THROTTLE HOUSING 11 5 STEERING SYSTEM 11 1 PARTS DRAWING...

Page 85: ...e pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment FRONT SUSPENSION NOISE Loose front suspension fasteners Binding suspension link HARD SUSPENSION Faulty front swing arm bus...

Page 86: ...dle bar Remove rear brake lever bracket assembly Remove the handle cover and instrument panel by four screws at right and left side as shown in picture Remove the bolts attaching the handlebar upper h...

Page 87: ...s with 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 small dot of t...

Page 88: ...n the reverse order of disassembly 11 5 STEERING SYSTEM Removal of Kingpin and Tie rod Remove the front wheels and hub assy Remove the four self lock nuts from the tie rod ball joints and take off the...

Page 89: ...ing Shaft Holder Inspection Remove the steering shaft Remove the bushing from the shaft Inspect the bushing for damage or wear replace if necessary Measure the bushing inner diameter Maximum limit 22...

Page 90: ...90 12 FRONT WHEEL AND BRAKE SYSTEM 12 1 PARTS DRAWING 12 2 TROUBLESHOOTING 12 3 FRONT WHEEL 12 4 HYDRAULIC BRAKE 12 5 SUSPENSION SYSTEM 12 1 PARTS DRAWING FRONT WHEEL BRAKE...

Page 91: ...tire pressure Incorrect wheel alignment POOR BRAKE PERFORMANCE Brake shoes worn Worn brake drum Brake linings oily greasy or dirty Improper brake adjustment 12 3 FRONT WHEELS REMOVAL The disassemble...

Page 92: ...next three steps of right pictures Loosen fours nuts as shown in picutre Then take the wheel out you can find two bolts fixed at front hydraulic disk component Loosen these two bolts and you can take...

Page 93: ...hoe wear you must push the master piston to rearward After removal the front brake assembly you must fabricate in reverse sequence ADD BRAKE OIL The brake oil tank is under the driver seat at right ha...

Page 94: ...on 1 You can raise the all ATV body up by using a repair platform The four wheel are in the free position you can easy to adjust the suspension 2 If you do not have any repair platform just using spec...

Page 95: ...95 13 REAR WHEELAND BRAKE SYSTEM 13 1 PARTS DRAWING REAR WHEEL FR RR AXLE 13 1 PARTS DRAWING 13 2 TROUBLESHOOTING 13 3 Suspension adjustment...

Page 96: ...adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bushings Soft Suspension Weak shock absorber damper Weak shock absorber spring 13 3 Suspension...

Page 97: ...l and spark plug Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty...

Page 98: ...ettes away Provide adequate ventilation when charging or using the battery in an open area The battery contains sulfuric acid Electrolyte Contact with skin or eyes may cause severe burns Wear protecti...

Page 99: ...ing is preferred 14 5 ELECTRIC STARTER Information If a battery has not work a period of time the voltage may reduce and may not provide enough power to starter motor If a battery is in a good conditi...

Page 100: ...nnector in order to replace an electrical bulb conveniently and safely The steps show on pictures Installation is in the reverse order of disassembly Front Direction lights remove To replace the direc...

Page 101: ...ombines a position and a rear brake light Normally when users switch the key to ON position the front rear position lights are always keep the light slightly Until a brake handlebar is depressed the r...

Page 102: ...amp A LCD is used on ATV8E s instrument panel to display all driving information for users Therefore this is an all in one instrument panel Instrument Panel REMOVAL There is a cable and connector on t...

Page 103: ...103...

Page 104: ...e flashing Switch to middle position turn indicators off WARNING Please make sure use turn signal while turning or changing lanes It cannot stop automatically back it to original position after using...

Page 105: ...in MPH 2 left turning indicator 3 High light indicator 4 Low light indicator 5 Right turning indicator 6 temperature indicator 7 Fuel indicator 8 Four wheel drive two wheel drive indicator 9 Mileage...

Page 106: ...106 Fuse 1 2 3 4 5 6 1 Ignition system fuse 10 A 2 Fan system fuse 10A 3 light system fuse 15 A 4 charging system fuse 15A 5 Auxiliary DC jack fuse 10 A 6 Auxiliary DC jack fuse 15 A...

Page 107: ...107 15 TROUBLESHOOTING 15 1 ENGINE CAN NOT WORK 15 2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 15 3 POOR PERFORMANCE AT HIGH SPEED 15 4 LOSS POWER 15 5 POOR HANDLING 15 1 ENGINE CAN NOT WORK...

Page 108: ...108 15 2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 15 3 POOR PERFORMANCE AT HIGH SPEED...

Page 109: ...109 15 4 LOSS POWER...

Page 110: ...110 15 5 POOR HANDLING...

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Summary of Contents for ATV300

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KEEWAY ATV300, User Manual, Page: 53 / 110

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Summary of Contents for ATV300

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