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CHAPTER 3A ENGINE

260/ 300 / 400 cc ATV SERVICE MANUAL09.0

CHAPTER 3 ENGINE PAGE. 3A- 65

Order

Job name/Part name

Q’ty

Remarks

8

9

10

Impeller shaft

O-ring

O-ring

1

1

1

Refer to “WATER PUMPINSTALLATION”
section.

Reverse the removal procedure for installation.

NOTE:

z

It is not necessary to disassemble the water

pump, unless there is an abnormality such as
excessive change in coolant temperature and/
or level, discoloration of coolant, or milky
transmission oil.

z

If necessary, replace water pump as an

assembly.

INSPECTION

1. Inspect:

z

Impeller shaft

Wear/damage

→

Replace.

Fur deposits

→

Clean.

2. Inspect:

z

Impeller shaft gear

Wear/damage

→

Replace.

3. Inspect:

z

Mechanical seal

c

Damage/worn/wear

→

Replace.

WATER PUMP INSTALLATION

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Summary of Contents for 2004 ATV 260

Page 1: ...0 2 ATV400 2B Attachment Delphi Small Engine Management System Service Manual WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearanc...

Page 2: ...ld use discretion as to how much disassembly is needed to correct any given condition All references to left and right side of the vehicle are from the operator s perspective when seated in a normal r...

Page 3: ...Engine CHAPTER3B 50 80 Engine CHAPTER3C 100 125 150 200Engine CHAPTER4A Chassis CHAPTER4B Chassis Youth mini ATV CHAPTER5 Final Drive CHAPTER6 Transmission CHAPTER7 Brakes CHAPTER8 Electrical CHAPTER9...

Page 4: ...contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Exhaust system components are very hot during and after use of ATV Never s...

Page 5: ...RMATION WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts infor...

Page 6: ...e for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals and O rings when overhauling the eng...

Page 7: ...tester NOTE z If there is no continuity clean the terminals z Be sure to perform the steps 1 to 7 listed above when checking the wire harness z Use the tester on the connector as shown WARNING Never r...

Page 8: ...ION TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 6214 0 6214...

Page 9: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER ATV 260 300 400 2 400 2B Mini Youth...

Page 10: ...09 0 CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS Note The on road equipments rear view mirror turn lights etc are not Standard Equipment for USA 2004 2005 DEMON Special Edition Anniversary Mini...

Page 11: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 7 ATV 260 300 05 Model ATV 260 300...

Page 12: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 8 Demon ATV 260 300 Europe Mini Youth...

Page 13: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 9 Special Edition Anniversary B Type 260 300...

Page 14: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 10 B Type 150 200 ATV 400 2...

Page 15: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 11 ATV 400 2B ATV 520...

Page 16: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 12 ATV 520 B...

Page 17: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 09 0 CHAPTER 1 GENERAL PAGE 1 13 NOTES...

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Page 36: ...e and replace in pairs especially in SDX300 model z The use of non standard size or type tires may affect ATV handling and cause machine damage especially in SDX300 model TIRE TREAD DEPTH Always repla...

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Page 38: ...rtoFrame MacPherson 15 18 21 25 LT NutM8BindingFrontAbsorberandFrontAbsorber Strutbody MacPherson 15 21 LT BoltM8AttachingFrontCalipertoFrontAbsorber Strutbody 18 25 LT BoltM8AttachingUpperSteeringCla...

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Page 40: ...T 3 2 2 IDLING SPEED ADJUSTMENT 3 2 3 SPARK PLUG INSPECTION 3 2 4 COMPRESSION PRESSURE 3 2 5 ENGINE OIL LEVEL INSPECTION 3 2 6 COOLANT LEVEL INSPECTION 3 3 CYLINDER HEAD 3 4 CAMSHAFT AND ROCKER ARMS 3...

Page 41: ...ntake A B C Exhaust A B C Camshaft runout limit 36 545 36 645 mm 30 021 30 121 mm 6 524 mm 36 547 36 647 mm 30 067 30 167 mm 6 48 mm 36 45 mm 29 92 mm 36 45 mm 29 97 mm 0 03m m Cam chain Cam chain typ...

Page 42: ...1 mm 1 6 mm 1 6 mm Valve spring Free length Inner IN EX Outer INEX Set length valve closed Inner IN EX Outer IN EX Com pressed pressure Inner IN EX Outer IN EX Tilt limit Inner IN EX Outer IN EX 38 1...

Page 43: ...30 mm 0 04 0 08 mm Taper 0 30 0 45 mm 0 03 0 07 mm 0 2 0 7 mm 0 45 mm 0 12 mm 0 7 mm 0 12 mm Piston rings Top ring Type End gap installed Side clearance installed 2nd ring Type End gap installed Side...

Page 44: ...buretor Type I D mark Ventuly outside diameter Main jet M J Jet needle M A J Throttle valve size J N Pilot air jet Th V Needle jet P A J 1 Pilot outlet N J Pilot jet P O Bypass B P Pilot screw P S Val...

Page 45: ...th height thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 260 300 288 238 42 mm 400 360 246 68 m 110 140kPa 1 1 1 4kg cm 2 1 1 1 4bar 2...

Page 46: ...eck supporting Oil pump Oil pump cover Drain plug Carburetor joint Carburetorjointandcarburetor Fuel pump Exhaust pipe assembly Crankcase left and right Drain bolt Oil filer Crankcase cover left Magne...

Page 47: ...Bolt M 6 2 12 1 2 Timing check plug P lug M 16 1 8 0 8 One way clutch _ M 8 3 30 3 0 Clutch housing Bolt M 14 1 60 6 0 Grease stopper Primary sheave _ M 4 4 3 0 3 Primary fixed sheave _ M 14 1 60 6 0...

Page 48: ...se cover 2 Remove zSpark plug z Valve cover intake side zValve cover exhaust side 3 Remove zTiming check plug 4 Measure zValve clearance Out of specification Adjust Valve clearance cold 260 300 Intake...

Page 49: ...ving and tighten the locknut zMeasure the valve clearance zIf the clearance is incorrect repeat above steps until specified clearance is obtained 7 Install zValve cover intake side c zO ringd 8 Instal...

Page 50: ...urning out Idling speed is decreased 3 2 3SPARK PLUG INSPECTION 1 Remove z Spark plug cap z Spark plug CAUTION Before removing the spark plug use compressed air to blow away any dirt accumulated in th...

Page 51: ...zValve clearance Out of specification Adjust Refer to CALCE CLEARANCE ADJUSTMENT section 2 Start the engine and let it warm up for several minutes 3 Turn off the engine 4 Remove zSpark plug Before re...

Page 52: ...ir Compression pressure at sea level Standard 1 400 kPa 14Kg cm2 14 bar Minimum 1 120 kP a 11 2 kg cm 2 11 2 bar Measurement steps zCrank the engine with the throttle wide open until reading on the co...

Page 53: ...lutch slippage zBe sure no foreign material enters the crankcase 4 Start the engine and let it warm up for a few minutes 5 Turn off the engine NOTE Wait a few minutes until the oil settles before insp...

Page 54: ...e zStart the engine after solving the problem s and recheck the oil pressure zTighten the oil check bolt to specification CAUTION zStart the engine and check the oil pressure with the oil check bolt l...

Page 55: ...rvoir tank of its coolant 3 Remove zDrain bolt c zRadiator cap WARNING Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure...

Page 56: ...nect zHose reservoir tank 8 Fill zRadiator to specified levelc Fill the coolant slowly until the coolant comes out from the head hose zReservoir tank to maximum level a Recommended coolant High qualit...

Page 57: ...engine parts Use only distilled water if soft water is not available zIf you use tap water make sure it is soft water zDo not use water containing impurities or oil zTake care that no coolant splashe...

Page 58: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 19 3 3CYLINDER HEAD...

Page 59: ...joint Joint O ring 1 1 2 1 1 1 1 2 Remove the parts in order Refer to CARBURETOR section 9 10 11 12 13 14 15 16 17 18 19 20 Crankcase cover Plug O ring Cam sprocket cover O ring Valve cover intake sid...

Page 60: ...and align the I mark c with the cylinder head match mark d when the piston is at TDC on the compression 2 Loosen zBolt c 3 Remove zTiming chain tensioner assembly zTiming chain tensioner gasket 4 Rem...

Page 61: ...inder head warpage Less than 0 03 mm Warpage measurement and resurfacement steps zPlace a straight edge and a feeler gauge across the cylinder head zMeasure the warpage If the warpage is out of specif...

Page 62: ...ecial instruction zFit the timing chain onto the cam sprocket and install the cam sprocket on the camshaft NOTE zWhen installing the cam sprocket keep the timing chain as tense as possible on the exha...

Page 63: ...tensioner rod f all the way in zInstall the tensioner with a new gasket gonto the cylinder zInstall the springs d and cap bolt c zTighten the bolt with gasket to the specified torque Bolt chain tensio...

Page 64: ...emoval Cylinder head Lock washer 1 Remove the parts in order Refer to CYLINDER HEAD section 2 Plate 1 Refer to ROCKER ARM AND ROCKER 3 Rocker arm shaft intake 1 4 Rocker arm shaft exhaust 1 SHAFT REMO...

Page 65: ...lobes Pitting Scratches Blue discoloration Re place 2 Measure zCam lobes length a and b Out of specification Replace Cam lobes length Intake a 36 545 36 645 mm Lim it 36 45 mm b 30 021 30 121 mm Lim...

Page 66: ...meter A of the rocker arm holes Out of specification Replace Inside diameter rocker arm 12 000 12 018mm Lim it 12 030 mm z Measure the outside diameter B of the rocker arm shafts Out of specification...

Page 67: ...Install the rocker arm shaft exhaust completely pushed in 5 Install zRocker arm c zRocker arm shaft d intake NOTE Intake Insert the guide shaft 8 mm e into the stud bolt hole in the cylinder head to t...

Page 68: ...rocker arm shaft Valve cotters Spring retainer Valve spring inner Valve spring Outer Valve intake Valve exhaust Valve guide Spring seat 4 2 2 2 1 1 2 2 Remove the parts in order Refer to CYLINDER HEAD...

Page 69: ...Do not compress so much as to avoid damage to the valve spring VALVE AND VALVE SPRINGS INSPECTION 1 Measure zValve stem diameter Out of specification Replace Valve stem diameter Intake 5 975 5 990mm...

Page 70: ...r Out of specification Replace Valve guide inside diameter Intake 6 000 6 012 mm Limit 6 05mm Exhaust 6 000 6 012 mm Limit 6 05 mm 7 Measure Stem to guide clearance Valve guide inside diameter Valve s...

Page 71: ...idth Where the valve seat and valve face made contact blueing will have been removed zIf the valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced 4 Lap zValve...

Page 72: ...b to the valve face zInstall the valve into the cylinder head zPress the valve through the valve guide and onto the valve seat to make a clear pattern zMeasure the valve seat with c again VALVES AND V...

Page 73: ...34 4 Instal zValve cotters c NOTE Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment d 5 Secure the valve cotters onto the valve stem by tappin...

Page 74: ...t 1 section 2 O ring 2 3 Timing chain guide exhaust side 1 Refer to PISTON RINGS 4 Cylinder 1 PISTON AND CYLINDER INSTALLATION section 5 Dowel pin 2 6 Cylinder gasket 1 7 Piston pin circlip 2 Refer to...

Page 75: ...When removing the piston ring open the end gap of the ring by fingers and push up the other side of the ring CYLINDER INSPECTION 1 Measure zCylinder bore Out of specification Rebore or replace NOTE zM...

Page 76: ...ton to cylinder clearance Piston to cylinder clearance Cylinder bore Piston skirt diameter Refer to CYLINDER section for cylinder bore measurement Out of specification Replace the piston and piston ri...

Page 77: ...imit 0 12mm 2nd ring 0 03 0 07mm Limit 0 12mm 2 Position zPiston ring into the cylinder NOTE Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore 1 5 0mm...

Page 78: ...ton c zPiston pin d zPiston pin clip e NEW NOTE zApply engine oil to the piston pins zThe mark a on the piston must face the exhaust side of the cylinder zBefore installing the piston pin clip cover t...

Page 79: ...ubricate zPiston outer surface zPiston ring zCylinder inner surface Engine oil 6 Install zCylinder NOTE zInstall the cylinder with one hand while com pressing the piston rings with the other hand zPas...

Page 80: ...ONDARY PRIMARY SHEAVE CRANKCASE COVER LEFT Order Job name Part name Q ty Remarks Crankcase cover left removal Remove the parts in order 1 Crankcase cover left 1 2 1 3 Hose clamp B 1 4 Joint B 1 5 Air...

Page 81: ...efer to PRIMARY SHEA VE 2 Primary fixed sheave 1 REMOVAL section 3 Nut 1 Refer to SECONDARY SHEAVE 4 Clutch housing 1 AND V BELT REMOVAL 5 Clutch assembly 1 section 6 V belt 1 Refer to SECONDARY SHEAV...

Page 82: ...mbly Disassemble the parts in order 1 Nut 1 2 Clutch carrier 1 Refer to SECONDARY SHEAVE 3 Clutch shoe spring 3 DISASSEMBLY section 4 Compression spring 1 5 Spring seat 1 Refer to SECONDARY SHEAVE 6 G...

Page 83: ...SHEAVE AND V BELT REMOVAL 1 Remove zNut c secondary sheave zClutch housing d NOTE Loosen the nut secondary sheave while holding the clutch housing with the sheave holdere 2 Remove zNut c clutch carrie...

Page 84: ...r f diameter 30mm thickness 2 3mm CLUTCH INSPECTION 1 Measure zClutch shoe thickness Scratches Glaze using coarse sandpaper Wear Damage Replace Clutch shoe thickness 3 0mm Limit 2 0mm NOTE zAfter usin...

Page 85: ...smooth operation zSecondary sliding sheave smooth operation 2 Inspect zTorque cam groove c Wear Damage Replace 3 Inspect zGuide pin d Wear Damage Replace PRIMARY SHEAVE ASSEMEBLY 1 Clean zPrimary slid...

Page 86: ...sliding sheave c inner surface grease nipple groove and oil seals z Lightweight lithium soap base grease to the bearings oil seals and inner surface of the secondary fixed sheave d 2 Install zSecondar...

Page 87: ...e and clutch spring holder arm f and compress the spring CAUTION Use the spacer h 30mm thickness 2 3mm 6 Install zV belt c zClutch assembly d NOTE Install the V bet with clutch assembly to the primar...

Page 88: ...PAGE 3A 49 8 Install zClutch housing c zNut clutch housing d NOTE Tighten the nut clutch housing using the sheave holder e 9 Set zV belt c NOTE Move the V belt to minimum diameter of the primary sheav...

Page 89: ...ty Remarks Magneto cover and stator coil removal Drain the engine oil 1 Couplers A C magneto lead 2 2 Exhaust pipe 1 3 Exhaust pipe gasket 1 4 Magneto cover 1 5 Gasket magneto cover 1 6 Dowel pins 2...

Page 90: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 51 A C MAGNETO AND STARTER CLUTCH...

Page 91: ...MAGNETO ROTOR REMOVAL 1 Remove zNut c rotor zPlain washerd NOTE zLoosen the nut rotor cwhile holding the rotor with a sheave holdere zDo not allow sheave the holder touch to the projection on the roto...

Page 92: ...e starter clutch and the starter wheel gear should be engaged zIf not the starter clutch is faulty Replace it zWhen turning the starter wheel gear counter clockwise it should turn freely zIf not the s...

Page 93: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 54 3 Tighten zNut rotor c NOTE Tighten the nut rotor c while holding the magneto rotord with a sheave holdere...

Page 94: ...name Part name Q ty Remarks Oil pump removal Remove the parts in order A C magneto Refer to A C MAGNETO AND STARTER 1 Cover 1 CLUTCH section 2 Pump driven gear 1 3 Dowel pin 1 4 Oil pump assembly 1 5...

Page 95: ...asure z Tip clearance between the inner rotor c and the outer rotord zSide clearance between the outer rotor d and the pump housing e zHousing and rotor clearance between the pump housing e and the ro...

Page 96: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 57 3 10CRANKCASE AND CRANKSHAFT...

Page 97: ...y primary sheave A C magneto and starter clutch Oil pump Water pump Rear wheel Bolt O ring 1 1 Remove the parts in the order Refer to ENGINE REMOVAL section Refer to CYLINDER HEAD section Refer to CYL...

Page 98: ...REMOVAL INSTALLATION section Reverse the removal procedure for installation CRANKSHAFT REMOVAL 1 Remove zCrankshaft assembly zTiming chain NOTE zBefore removing the crankshaft assembly remove the tim...

Page 99: ...Crank width 59 95 60 00 mm 4 Inspect zCrankshaft sprocket c Wear Damage Replace crankshaft zBearing d Wear Crack Damage Replace crankshaft zPump drive gear e Wear Damage Replace crankshaft 5 Inspect...

Page 100: ...00 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 61 3 Install zDowel pins zTiming chain c NOTE Install the timing chain not to be seen through the crankshaft hole a on the crankcase left d 3 11CO...

Page 101: ...r 1 7 Radiator cap 1 8 Radiator filler neck 1 Reverse the removal procedure for installation INSPECTION 1 Inspect zRadiator c Obstruction Blow out with compressed air through the rear of the radiator...

Page 102: ...4kg cm2 1 1 1 4 bar Measurement steps zAttach the radiator cap tester cand adapter d to the radiator cap e zApply the specified pressure for 10 seconds and make sure there is no pressure drop 4 Inspe...

Page 103: ...p removal Remove the parts in order Drain the coolant Refer to COOLANT REPLACEMENT section A C magneto Refer to A C MAGNETO AND STARTER CLUTCH section 1 lmpeller shaft gear 1 2 Dowel pin plain washer...

Page 104: ...NOTE zIt is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant temperature and or level discoloration of coolant or milky transmission oil z...

Page 105: ...ot smear any oils or grease on the ring side of the mechanical seal 3 Inspect zMechanical sea slip ring side c Inspect the slip ring side of the mechanical seal and the impeller d for level installati...

Page 106: ...ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 67 zHousing cover 7 Install zShaftc Align the slot on the impeller shaft with the projection on the shaft when installing 3 11 3T...

Page 107: ...removal procedure for installation INSTALLATION 1 Inspect zThermostatic valve Valve does not open at 70 5 73 5 Replace Inspection steps zSuspend the thermostatic valve in a vessel zPlace a reliable t...

Page 108: ...e area where refueling is performed or where gasoline is stored If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing i...

Page 109: ...ke unit leads to the 12V battery for 5 minutes zConnect pipe to the starter and blow it with the mouth etc Possible Replace auto choke unit Impossible Good condition z Remove auto choke unit leads to...

Page 110: ...n valve Wear Replace Check the jet needle for stepped wear Check the vacuum piston for wear or damage Check the diaphragm for holes deterioration or damage Check the vacuum piston for smooth operation...

Page 111: ...he tip of the float valve where it contacts the valve seat for stepped wear or contamination check the operation of the float valve 15 Remove zPilot jet Check the pilot jet for wear or damage Clean th...

Page 112: ...ot screw set Turn the pilot screw in and carefully count the number of turn until it seats lightly Make a note of this to use as a reference when reinstalling the pilot screw AIR CUT OFF VALVE 19 Remo...

Page 113: ...3A 74 23 Inspection zCompressing spring Distortion Replace zDiaphragm Wear Replace 24 Reverse the removal procedure for installation 3 12CARBURETOR ATV400 2 ATV400 2B 1 Remove zFuel hose 2 Remove zMan...

Page 114: ...SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 75 5 Remove zCarburetor assy 6 Remove zCover 7 Remove zDiaphragm spring zPiston valve 8 Inspect zJet needle Wear Replace zPiston valve Wear Replace 9 Remove...

Page 115: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 76 10 Inspect zNeedle valve Wear Replace 11 Remove zIdling jet 12 Remove zPilot jet 13 Remove zMain jet...

Page 116: ...3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 77 14 Remove zMain nozzle 15 Remove zMixture adjusting screw 16 Remove zNut zThrottle valve mounting arm zTorsion bar spring z...

Page 117: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 78 17 Remove zScrews zThrottle valve mounting bracket 18 Reverse the removal procedure for installation...

Page 118: ...CHAPTER 3A ENGINE 260 300 400 cc ATV SERVICE MANUAL09 0 CHAPTER 3 ENGINE PAGE 3A 79 NOTES...

Page 119: ...ter system 3 2 4 Camshaft assembly 3 9 1 Installation information 3 3 The cylinder and the piston 3 9 2 Starter Motor 3 3 1 Important points 3 9 3 Starter pinion 3 3 2 Removing the cylinder 3 10 Magne...

Page 120: ...e gap IN 0 04 0 06mm Throttle free play 2 6mm EX 0 04 0 06mm Spark plug gap 0 6 0 7mm Idling speed 1900 190rpm Spark plug type NGK C7HSA Engine oil quantity LD A7TC Normal range 0 8L 3 1 2 Air Filter...

Page 121: ...Always check and adjustment with engine temperature lower than 35 95 Remove cylinder head cover Rotate cooling fan to camshaft locate mark at top dead center aligning magneto fly wheel T mark with ma...

Page 122: ...n system if ignition time is incorrect Dismount right body cover Remove ignition timing inspection plus Check ignition timing using timing light Crankcase mark must be aligned with mark F on flywheel...

Page 123: ...It is good that oil level just under regulation screw bolt hole add gear oil when oil level is too low Gear oil recommended SEA 15W 40SE Build up gear oil regulator screw bolt Confirm packing washer...

Page 124: ...head When measuring parts to determine wear wash the parts with solvent and dry them in order to get accurate measurements When disassembling the valve components keep them in order and reinstall the...

Page 125: ...seat reamer 26mm Reamer damping fixture 5mm Special tools Valve spring compressor accessories Valve gap regulatory spanner Valve guide screwdriver Valve guide reamer Trouble diagnosis Confirm poor op...

Page 126: ...t and spring Use the kick start lever to turn engine slowly until T mark on flywheel lines up with indicator on crankcase and check position of camshaft to find if both valves are closed The hole in t...

Page 127: ...N 25 681mm below change EX 25 524mm below change Check surface of cam lobes for weary surface break down scuffing or cracking Check camshaft and bearing for loose fit or damage If any excessive wear o...

Page 128: ...amshaft rocker arm Inner diameter of camshaft rocker arm Used limit 10 10mm change if worn larger Outer diameter of camshaft rocker arm bearing Used limit 9 91mm change if worn larger The gap between...

Page 129: ...lve spring compressor to take off lock clip supporter valve spring and valve Place parts in a sequence after disassembling and assemble at a reverse process Clean carbon deposit from combustion chambe...

Page 130: ...alve guide is blocked Measure every valve stem outer diameter Used limit below 4 9mm change Remove carbon deposit from valve guide using a reamer Special tools Rotate reamer is proper direction and do...

Page 131: ...and dust Special tools Valve guide pipe reamer Valve seat checking and correcting Valve seat checking Get rid of carbon deposit from combustion chamber and valves Spread emery on seat surface between...

Page 132: ...cutting Do not polish or cut excessively Cut primary surface with 45 cutting head Chamfer inner edge with 32 cutting head Chamfer outer edge with 60 cutting head Correct inner surface by 60 chamfered...

Page 133: ...ut emery into valve and valve guide pipe when polishing Spread red inkpad on 45 seat surface and confirm if the centre of contact surface of valve is even after correcting Building up of cylinder head...

Page 134: ...mshaft assembly Install camshaft fixed seat Assemble rocker arm and rocker shaft Make alignment between shaft end and hole of camshaft seat when valve rocker shaft is assemblied Assembling of camshaft...

Page 135: ...two fixed bolts Thirdly put spring into camshaft chain regulator Finally assemble O ring and fixed bolt Press down regulator master jaw and drive down driving bar when camshaft chain regulator is ass...

Page 136: ...criterion Item Normal Size Max Service Allowance ID 50cc 39 39 01 39 10 ID 80cc 47 47 01 47 10 Distortion 0 05 Cylindricity 0 05 Cylinder Out of roundness 0 05 the top ring 0 015 0 055 0 09 Clearance...

Page 137: ...e exhaust pipe Knocking noise by the piston The piston ring worn damaged The cylinder the piston or the piston ring worn The piston cylinder worn or damaged The piston pin and piston hole worn 3 3 2 R...

Page 138: ...on ring end gap in bore Max service allowance Replace when it goes beyond 0 45mm Measure the ID of the piston pin hole Max service allowance Replace when it goes beyond 13 04mm Measure the OD of the p...

Page 139: ...beyond 0 1mm The difference between X and Y directions is out of roundness The cylindricity is the ID difference between X and Y directions measuring at three positions upper middle and lower The larg...

Page 140: ...g end gaps at 120 Lubricate the piston and rings liberally with engine oil Install the chain guide lever of the cam Attention Make sure that the guide lever enters the notch of the cylinder 3 3 4 Asse...

Page 141: ...the crankcase Lubricate the inner surface of the cylinder the piston and the piston ring with engine oil When assembling the piston rings they must be compressed into the cylinder Attention Don t dam...

Page 142: ...ve units are not allowed any oil if there is any remove it to minimize the slip between the belt and the drive units Tech Criterion Unit mm Item Normal Size Max Service Allowance ID of the driving pul...

Page 143: ...driving belt worn The driving plate broken Power can t develop fully The brake lining worn or broken The driving belt worn The spring of the clutch assembly fractured Distortion of the driven belt sp...

Page 144: ...together Remove the starting pivot and the return spring Detach the starting pivot sleeve Checking the starting pivot Check if the pivot and the gear are worn Check if there is any softness of the sta...

Page 145: ...haft of the driven gear Replace any parts showing excessive or unusual wear 3 4 3 Installing the starting assembly Install the starting pivot sleeve and the return spring to the crankcase cover As sho...

Page 146: ...left crankcase then install the clip 3 4 4 The driving belt Detach the left crankcase cover Checking Check if the driving belt is cracked frayed or abnormal wear Measure the width of the belt Max serv...

Page 147: ...lley the starting ratchet and 12mm washer The install and tighten the nut Torque 45N m 33ft lbs Attention During assembly be sure to align the splints of the driving unit is correct ratchet with those...

Page 148: ...Measure the OD of the driving pulley sleeve Max service allowance Replace when it is below 19 9mm 3 4 6 Assembling the driving pulley Install driving pulley sleeve and the driving pulley on the crank...

Page 149: ...it in the opposite sequence of removal 3 4 7 The clutch transmission pulley Removing the clutch transmission pulley Remove the driving pulley Then use a spanner wrench to hold the clutch housing to s...

Page 150: ...ansmission pulley assembly then take out the o ring and the oil seal Checking the clutch transmission pulley Check the wear of the clutch housing Measure the ID of the clutch housing Max service allow...

Page 151: ...k the wear of the transmission pulley Measure the ID of the pulley Max service allowance Replace when it goes beyond 34 06mm Check if the guide rolling pin is excessively worn or unevenly worn Replace...

Page 152: ...bearing keeping the mark side up The clutch transmission Pulley assembly Assemble the transmission pulley guide pin and oil seal Install the sealing cover of the collar Assemble the transmission pulle...

Page 153: ...ling the clutch transmission pulley Put the driving belt onto the clutch transmission pulley then onto the driving shaft Assembly the clutch housing Use a spanner wrench to hold the housing then insta...

Page 154: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 36 3 5 The final transmission assembly 3 5 1 Instructions...

Page 155: ...ide lever for the bearing driver 12mm Bearing driver Trouble shooting The scooter doesn t run after the engine starting The transmission gear failed The driving belt worn or broken The clutch failed D...

Page 156: ...mbly Check if countershaft gear is worn or damaged Check if the final transmission gear is burn or damaged Check if the bearing in the left crankcase and the oil seal are worn damaged Check if the dri...

Page 157: ...the clutch main shaft Then remove the oil seal of the shaft Heat the final transmission gearbox to 120 to remove the bearing Drive the new bearing into the final transmission gearbox Install the new...

Page 158: ...ill it with the gear oil Designated gear oil SEA 15W 40SE Volume of the gearbox Filling 0 12L Changing 0 10L Screw up the oil screw and tighten it Torque 17 23N m 12 5 17ft lbs Start the engine to che...

Page 159: ...ore taking the crankcase apart Remove the following The cylinder head The cylinder the piston The driving plate the driven plate AC generator The carburetor the air filter The starting motor The oil p...

Page 160: ...lack The crankshaft pin bearing getting loose 3 6 2 Dismantling the crankcase Detach the bolt of the chain adjusting guide lever of the cam and remove the lever Remove assembly Bolt of the crankcase D...

Page 161: ...urfaces Attention Be sure not to scratch the joint surfaces Remove the oil seal from the left crankcase Remove the oil seal from the right crankcase 3 6 3 The crankshaft Measure the left and right cle...

Page 162: ...oes beyond 0 05mm Measure the run out of the crankshaft Max service allowance Replace when it goes beyond 0 10mm Check if there is any abnormal noise and looseness when the crankshaft bearing revolves...

Page 163: ...to let the chain damaged the oil seal Put the new locating pin and gasket onto the left crankcase Attention Keep the left crankcase downward to assemble with the right crankcase Tighten the bolts of t...

Page 164: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 46 Attention Be sure to put the O ring into the groove 3 7 Lubricating system...

Page 165: ...APTER 3B ENGINE PAGE 3B 47 3 7 1 Over all engine requirements Special attention Use proper Motor oil SAE 15W 40SE Use only clean fresh oil Do not rebuild oil pump Replace with a new pump when needed C...

Page 166: ...ck oil with scooter parked on level ground on center stand put motorcycle on the plain place when oil volume is checked run engine for two or three minutes and stop After 2 3 minutes check oil level C...

Page 167: ...rotor Remove stator pulse coil Remove 8 bolts of right crankshaft case cover and take off crankshaft case cover Remove washer and fixed pin Remove the fixed nut of gear in oil pump Take off gear of oi...

Page 168: ...p body and external rotator Used limited 0 12mm 0 005inch Check the gap between inner rotator and external rotator Used limited 0 12mm 0 005inch Check the gap between surface of rotator and body Used...

Page 169: ...3B 51 Assemble pump cover and tighten screws Installation First put two O rings at oil pump seat Put oil pump in crankshaft case First add oil to pump and then assembly Tighten three fixed screws Inst...

Page 170: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 52 Assemble right crankshaft case cover tighten 8 screws Assemble pulse coil and stator and rotor Install fan and cover...

Page 171: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 53 3 8 Carburetor...

Page 172: ...use a quality fuel stabilizer to prevent deterioration of the fuel and damage to the carburetor Repairing material Specification standard valve Carburetor Constant velocity CVK Venturi Bore 18mm Fuel...

Page 173: ...Misfire under acceleration Poor spark Air mixture screw too lean Bad accelerator pump 3 8 2 Disassembly of carburetor Disconnect cable connector for auto chock Loosen carb drain screw and drain fuel...

Page 174: ...k pin and seat for wear Replace if necessary Place auto choke in mounting location and press down firmly Put lock ring in position and fasten screw Air cut off valve Disassembling Disassemble two scre...

Page 175: ...ver Remove spring diaphragm piston Remove needle and slide Take special care to not or damage diaphragm replace if damaged Checking Check pin for wear and replace if necessary Assembling Install pisto...

Page 176: ...nd fuel volume control screw Be careful not to break fuel jets and control screw Count the turns when removing the fuel volume control screw When reinstalling jets and screws do not over tighten Clean...

Page 177: ...seat and main jet into the bottom of the carburetor housing Set the fuel level in the bowl by adjusting the fuel regulation screw The standard setting is 2 turns or 1 4 turn Assemble the float valve f...

Page 178: ...Checking Check acceleration pump plate for cracks or hardening of the rubber Replace if necessary Check for blocked fuel passages Clean by high pressure air Reverse steps to reassemble Take special c...

Page 179: ...e auto choke to the proper connection on the main wiring harness After starting the engine set the idle speed using the idle adjusting screw Carburetor Adjustment It is generally not necessary to adju...

Page 180: ...If needed readjust the mixture screw to help stabilize idle performance 3 9 Starter system 3 9 1Installation information Operation point The starter motor can be removed without disassembly of the en...

Page 181: ...Starter motor reversal Poor or faulty cable connections Battery discharged Faulty starter motor 3 9 2 Starter motor removal Never work on starter motor until main switch is turned off battery ground...

Page 182: ...d the armature shaft Check starter motor housing conductivity Be sure there is no conduction current between the cable terminal and starter motor housing Check conductivity between the lead terminal a...

Page 183: ...Engage motor housing with that of front bracket Install two housing bolts When engaging the housing with front bracket install the armature first hold the armature shaft and then install the housing i...

Page 184: ...te or light grease Do not use heavy grease This will limit the fast movement of the starter pinion INSTALLATION Apply a light film of grease to the gears and install the starter pinion by reversing th...

Page 185: ...flywheel Detach the fix nuts of the flywheel Use a spanner wrench hold fly wheel while removing the retaining nut Use a fly wheel puller to remover the flywheel Remove and save the key Detach the stat...

Page 186: ...bber sleeve of the magneto wire Clean the cone part of the crankshaft and of the flywheel Be sure to lay the locating key of the flywheel into the keyway on the crankshaft precisely Point the groove o...

Page 187: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 69 Universal solid wrench Set up the cooling fan Torque 9N m Install the fan cover and securely tighten fastness...

Page 188: ...as reference point in tests Record coil resistance tests REFERENCE STANDARD item Standard value Specific spark plug NGK C7HSA LD A7TC spark plug gap 0 6 0 7mm spark plug angle Maximum advance in F po...

Page 189: ...ent multi meter are used If the pointer on the dial flickers and finally stops at in testing it should be regarded as normal Because the capacitor in the CDI module is charged while being tested and i...

Page 190: ...In faulty condition Sparking abnormally 3 11 5 MAGNETO Pickup Coil Inspection This test is to be conducted with the stator mounted in the engine Remove the cover Disconnect the magneto Test the picku...

Page 191: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 73 align within 2 with the engine revolving at a speed of 1500rpm The spark advance angle should be 13 1 1500r min...

Page 192: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL09 0 CHAPTER 3B ENGINE PAGE 3B 74 NOTES...

Page 193: ...STMENT 3 3 1 Air filter 3 3 2 Spark plug 3 3 3 Valve clearance adjustment 3 3 4 Carburetor idle adjustment 3 3 5 Transmission oil inspection for MINI ATV100 150 3 3 6 Transmission oil inspection for B...

Page 194: ...Keep all parts away from any source of fire 3 2 REPLACEMENT PARTS 3 2 1 Gaskets oil seals and o rings 1 Replace all gaskets seals and O rings when overhauling the engine All gasket surfaces oil seal l...

Page 195: ...e filter in soapy water and dry it 5 Reinstall pre filter over main filter Replace main filter as required 6 Reinstall filter into air box and tighten screw 3 3 2 Spark plug 1 Remove spark plug 2 Chec...

Page 196: ...utes 2 Turn the idling adjusting screw in or out until specified idling speed is obtained 3 Idling speed specification 1700 170rpm 4 If the idling speed is unstable or it is not smooth when accelerati...

Page 197: ...ment 450ml 3 3 7 Crankcase oil inspection 8 Stand the engine on a level surface 9 Have the engine run at idle speed for several minutes Inspect the oil level after the engine is turned off 2 3 minutes...

Page 198: ...over 2 Remove camshaft chain pensioner screw and then O ring 3 Lock camshaft chain pensioner by turning it clockwise 4 Rotate fan to have the mark on the camshaft chain in an upward position which is...

Page 199: ...ntake and exhaust cam damage Replace when intake valve below 25 75mm exhaust valve below 25 41mm 9 Check camshaft bearing for looseness and wear and tear and sprocket for abnormal wear If so replace a...

Page 200: ...asure the inside diameter of rocker arm shaft hole in camshaft holder Limit 10 10mm 4 Measure the inside diameter of rocker arm hole Limit 10 10mm 5 Measure the diameter of rocker arm shaft Limit 9 91...

Page 201: ...t must not be reused 7 Take out valve seat lock plate spring oil seal and valve by using a compressor 8 Clean off carbon deposits in the combustion chamber 9 Check spark plug valve guide and their sur...

Page 202: ...ce 16 Measure valve guide inside diameter Limit Intake 5 08mm exhaust 5 10mm Install cylinder head in the reverse order of removal 3 4 2 Cylinder body piston and piston ring 1 Remove cylinder body 2 R...

Page 203: ...carbon deposits from the piston ring grooves and rings NOTE Be sure to keep the piston ring undamaged 5 Position piston ring Measure the gap between piston ring and ring groove Limit first ring 0 09mm...

Page 204: ...r scratches and wear Measure cylinder inside diameter from and angle of 90 to piston pin and in upper middle and lower three positions cylinder diameter limit 47 1 mm 100cc 52 5 mm 125cc 57 1mm 150cc...

Page 205: ...50 200 SERVICE MANUAL09 0 CHAPTER 3C ENGINE PAGE 3C 13 3 Take out V belt 4 Check belt for cracks wear scaling or chipping 5 Measure V belt width limit 19 0mm 6 Remove sliding sheave 7 Remove movable c...

Page 206: ...PAGE 3C 14 9 Check weights wear 10 Measure weight outside diameter Limit 17 44mm 11 Measure sliding sheave inside diameter Limit 24 06mm 12 Check collar wear Measure collar outside diameter Limit 23...

Page 207: ...09 0 CHAPTER 3C ENGINE PAGE 3C 15 15 Check spacer wear Measure its thickness Limit 1 5mm 16 Remove clutch assembly 17 Remove clutch locknut 18 Take out secondary fixed sheave and sliding sheave 19 Mea...

Page 208: ...all them in the reverse order of removal NOTE Never smear grease to the V belt secondary sheave and clutch 3 4 4Transmission for MINI ATV100 150 1 Remove drain cock to drain transmission oil 2 Remove...

Page 209: ...l it in the reverse order of removal And add sufficient oil 3 4 5 Transmission for B type 150 200 3 4 5 1 Transmission Disassembly 1 Remove transmission case drain plug located on the front cover and...

Page 210: ...APTER 3C ENGINE PAGE 3C 18 4 Remove input shaft forward reverse shaft middle shaft and shift fork as an assembly 5 Remove bearing and helical gear 6 Remove pinion shaft retainer plate and pinion shaft...

Page 211: ...surfaces are clean and dry and shafts are fully seated in the transmission case Apply silicon glue to mating surfaces 3 Reinstall cover and torque bolts in a cross pattern in 3 steps to 14 5 ft lbs 20...

Page 212: ...switch Apply Loctite TM 242 blue to screw threads and torque screws to 13 16 in lbs 1 5 1 9 Nm 3 4 5 3 TROUBLE SHOOTING CHECKLIST Check the following items when shifting difficulty is encountered zIdl...

Page 213: ...PAGE 3C 21 3 4 6 Crankcase and crankshaft 13 Remove chain guide fixing bolt to take out chain 14 Remove driven gear from crankshaft and inspect gear for wear 15 Remove crankcase fixing bolts and separ...

Page 214: ...n crankcase contact face NOTE Make sure the contact faces are not scratched to avoid oil leakage 19 Remove oil seal from crankcase Inspect oil seal for wear 20 Measure connecting rod big end side clea...

Page 215: ...case oil before crankcase removal 3 4 7 Magneto 1 Remove magneto cover fixing bolts and screws to dismount magneto cover Inspect cover for damage and cracks 2 Remove 4 fixing bolts to take out fan Ins...

Page 216: ...urning the starter wheel gear counterclockwise it should turn freely When turning the starter wheel gear clockwise it should be engaged 4 Inspect clutch wheel gear for abnormal wear If so replace it w...

Page 217: ...replace 10 Measure idle gear shaft orifice inside diameter Limit 10 05mm 11 Measure idle gear shaft outside diameter Limit 9 94mm Install them in the reverse order of removal 3 4 9 Oil pump 1 Remove b...

Page 218: ...ump inner and outer rotors for abnormal wear If so replace the oil pump assembly 7 Fasten oil pump with screws after assembling Install oil pump in the reverse order of removal NOTE Be sure to point t...

Page 219: ...to bring about a fire 4 Inspect auto choke unit Connect yellow auto choke unit lead to the positive pole of a battery and green lead to the negative pole Some 5 minutes later connect a pipe to idle po...

Page 220: ...pect spring for distortion and diaphragm for damage If that is the case replace as a set Install in the reverse order of removal NOTE Make sure the slot on the air pressure diaphragm is in alignment w...

Page 221: ...fuel bowl float and needle valve 14 Inspect needle valve and valve seat for damage and blockage NOTE If the needle valve is damaged or blocked the air tightness between the valve and valve seat is not...

Page 222: ...r and in alignment with the main jet The standard fuel level is 18 5mm After inspection fit the lid on the float chamber and install the carburetor NOTE Generally fuel level adjusting screw has alread...

Page 223: ...r head bolt M6 9 Oil filter screen cover bolt M30 15 Exhaust pipe nut M6 9 Camshaft seat nut M8 20 Valve adjuster locknut M5 9 Cam chain tensioner bolt M6 10 Transmission case drain bolt M8 19 Clutch...

Page 224: ...rk plug heat range is correct Using incorrect spark plug will result in improper engine operation or spark plug damage Peak voltage is used as reference point in tests Record coil resistance tests REF...

Page 225: ...nition coil Faulty CDI unit No or Intermittent High Tension Voltage Faulty Ignition coil 3 7 3 CDI INSPECTION Disconnect the CDI module from the wire harness Test resistance of the terminals with an m...

Page 226: ...if necessary Test the primary coil resistance the standard value of which should be 0 1 1 0 Test the secondary coil resistance from spark plug cap negative terminals the standard value of which shoul...

Page 227: ...Coil Inspection for MINI ATV100 150 Test the charging coil resistance between the black red and the green lead terminals whose standard value is 450 550 Spark Advance Angle Inspection Since CDI is us...

Page 228: ...CHAPTER 3C ENGINE 100 125 150 200 SERVICE MANUAL09 0 CHAPTER 3C ENGINE PAGE 3C 36 NOTES...

Page 229: ...e ATV400 2 ATV400 2B WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spar...

Page 230: ...ft Replace if worn Discard hardware 6 Insert A arm shaft into new A arm 7 Install new A arm assembly onto vehicle frame Apply Loctite 242 to screw threads and Install new bolts Torque new bolts to 30...

Page 231: ...E Tighten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground WARNING DO NOT reuse old bolts Seri...

Page 232: ...er roll and install seal in each side of swing arm asm 3 Apply Loctite 242 to R H swing arm pivot 4 Tighten swing arm pivot until both are engaged in tapered roll 5 Adjust right side swing arm pivot i...

Page 233: ...pivot assembly 4 Remove coil spring and collapse strut body 5 Remove two pinch bolts from strut body 6 Remove strut body 7 Install front shock cartridge until bottomed in strut casting 8 Install pinc...

Page 234: ...ve screws and ball joint mounting bracket 7 Using ball joint cup removal installation toolkit remove ball joint cup from strut housing Refer to photos at right zInstall puller guide 1 zThread bolt 2 w...

Page 235: ...CHASSIS PAGE 4A 7 4 5 STEERING POST ASSEMBLY Note 1 Hand tighten the crown nut of the steering post 2 Align cotter pin hole 3 Install cotter pin Bend both ends of cotter pin around nut in opposite dir...

Page 236: ...CHAPTER 4A CHASSIS ATV 260 300 400 and B Type ATV400 2 400 2B ATV SERVICE MANUAL 09 0 CHAPTER 4 A CHASSIS PAGE 4A 8 NOTES...

Page 237: ...V for Europe 50 100 125 150 WARNING The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model f...

Page 238: ...achine under frame area Removal the bolts 4 Remove the front wheel Inspect all wheels for runout and damage FRONT HUB REMOVAL 1 Remove the wheel as described above 2 Remove the RUBBER CAP 22 and cotte...

Page 239: ...ith end of seal bore Do not damage the surface of the seal Coat the lip with special grease NOTE Drive the bearing 6002Z in first Reverse the wheel and hub removal procedure for installation DRUM BRAK...

Page 240: ...USHING 1 4 GREASE FITTING 5 GREASE FITTING CAP 6 BUSHING 2 7 NUT M10X1 25 8 A ARM PIVOT SHAFT CAP 9 COTTER PIN2 5X20 10 A ARM RITGHT 11 BOLT M10X1 25X48 12 A ARM RUBBER BUSHING 13 CASTLE NUT M10X1 25...

Page 241: ...support machine under frame area Removal the bolts 4 Removal the wheel Inspection Inspect all wheels for runout and damage Installation Reverse the wheel removal procedure for installation DRIVE CHAIN...

Page 242: ...ain as a set 3 Replace guards if damaged 4 Slide the pin portion of the master link 3 in to each end of chain to be connected 5 Slide the side plate 2 portion of the master link on to the pins 6 Slide...

Page 243: ...ain 10 Apply proper type spray on chain lubricant thoroughly inside and outside plates and rollers of chain Move ATV as needed to access entire chain FINAL DRIVE Removal 1 Remove wheels chain as descr...

Page 244: ...only for 50 80 23 BOLT M6X10 24 RUBBER STICK 25 BRACKET 26 RUBBER CAP 27 RIM REAR 28 PLUG 29 BOLT M10X1 25X28 1 Remove the RUBBER CAP 26 and cotter pin 2 Loosen and removal the CASTLE NUT 3 and washer...

Page 245: ...erse the rest procedure for installation till the hub 5 Screw in the left side castle nut and align the hole to the notch of the nut Install the right side castle nut and securely tighten the nut inst...

Page 246: ...spection Inspect the SWING ARM PIVOT BUSHINGs and the SWING ARM PIVOT shaft for nicks scratches or damage Replace if necessary Installation Reverse the removal procedure for installation Note Install...

Page 247: ...CHAPTER 4B CHASSIS ATV SERVICE MANUAL09 0 CHAPTER 4 CHASSIS PAGE 4B 11 NOTES...

Page 248: ...EMBLY 5 4 FRONT HUB INSTALLATION 2WD 5 5 FRONT DRIVE AXLE INNER AND OUTER CV JOINT REMAVAL INSPECTION 4X4 5 6 FRONT DRIVE AXLE INSTALLATION 4X4 5 7 FRONT DRIVE AXLE DISASSEMBLY INSPECTION 4X4 5 8 FRON...

Page 249: ...f the nut or bolt are reduced or destroyed during removal 5 2 FRONT HUB DISASSEMBLY INSPECTION 1 Elevate front end and safely support machine under footrest frame area CAUTION Serious injury may resul...

Page 250: ...erious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearings and seals 2 Check bearings for side play...

Page 251: ...rive or press one new bearing in to hub using a bearing driver 2WD 2 Drive or press the other bearing into hub until seated against the hub shoulder 2WD 3 Coat the new bearing with grease 2WD 4 Coat t...

Page 252: ...Tighten nut slightly if necessary to align cotter pin holes 6 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of Spindle in different directions 7 Install hub cap 8...

Page 253: ...B INSTALLATION ATV150 200 260 300 1 Inspect spindle seal on strut and bearing surface for wear or damage 2 Apple grease to spindle and bearing 3 Install spindle into strut 4 Install bearing to spindle...

Page 254: ...E 5 7 8 Install hub 9 Install bearing 30205 on spindle 10 Install washer and spindle nut Torque spindle nut to 160 170 inch lbs 18 19N m while rotating hub continuously back off nut 1 2 turn and rotat...

Page 255: ...lay 16 Install brake caliper using new bolts Apply Loctite 242 blue to threads Tighten bolts to specified torque CAUTION Always use new brake caliper mounting bolts upon assembly 12 Install wheel and...

Page 256: ...ideways between inner and outer race 5 Inspect bearing housing for scratches wear or damage Replace housing if damaged 5 5 FRONT DRIVE AXLE INNER AND OUTER CV JOINT REMAVAL INSPECTION 4X4 NOTE The out...

Page 257: ...tect the casting pop the in inner CV joint out from the front differential INSPECTION NOTE The boots are subjected to a lot of abuse if the vehicle is ridden in rough terrain If the boots are damage a...

Page 258: ...aft stopper ring has locked into the front differential side gear groove 4 Carefully install the outer CV joint spindle into the strut install the front hub and wheel 5 Install the ball joint on the A...

Page 259: ...r INNER CV JOINT INSPECTION 1 Clean the bearing assembly in solvent and thoroughly dry 2 Inspect the steel balls bearing case and the bearing race for wear or damage 3 Check for wear or damage to the...

Page 260: ...replace the drive axle Check the movement of the joint NOTE Inner CV joint must be replaced with the bearing as an assembly 5 8 FRONT DRIVE AXLE ASSEMBLY 4X4 1 The rubber boots are not identical and m...

Page 261: ...ybdenum disulfide grease to the bearing assembly Work the grease in between the balls the race and the case Make sure all voids are filled with grease 9 Apply a liberal amount of molybdenum disulfide...

Page 262: ...in designed position 17 Secure all large boot bands Bend down the tab on the boot band and secure the tab with the locking clip and tap them with a plastic hammer Make sure they are locked in place 1...

Page 263: ...ts 15 Remove axle tube s bolts from rear gear case and remove the right side tube 16 Slide axle through rear gearcase to the right enough to allow the axle tube to slip off between axle and swing arm...

Page 264: ...torque bolts to 20 ft lbs 25 Nm Anchor the brake hoses to the swing arm asm using the hold down clamp Install wheel hub large flat washer Install cone nuts with domed side facing outward Torque axle n...

Page 265: ...and retain for re assembly 5 Remove and discard the output cover seal and O ring 6 Remove input cover and O ring Remove pinion shaft assembly Inspect pinion gear for chipped broken or missing teeth Re...

Page 266: ...p ring and apply Loctite 242 to threads Tighten lock nut to specification 6 Install pinion shaft and input cover plate with new o ring and torque bolts to 14 ft lbs Cover Bolts Torque 14ft lbs 20 Nm 7...

Page 267: ...test the ATV carefully and thoroughly after front gearcase and differential service for vehicle maneuvers and operation Mount the front gear case assembly to Torque Test Jig The input shaft must be f...

Page 268: ...dispose of used oil 2 Remove bolts and selector cover 3 Remove screws and selector switch from the selector cover 4 Remove bolt washer spring and detent ball from the selector cover 5 Remove seal was...

Page 269: ...TV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 22 8 Remove selector fork splined dog and input shaft 9 Remove bearing and seal 10 Remove gear screws pinion shaft retainer plate and pinion shaft 11 Rem...

Page 270: ...s for wear cracks chips or broken teeth Inspect engagement dogs and detent ball housing replace if edges are rounded Inspect casting for crack Inspect bearings for smooth operation Check for excessive...

Page 271: ...RTANT New seals should be installed after the transmission is completely assembled 5 Install input shaft splined dog selector fork 6 Install selector rail gear and pins 7 Apply LocTiteTM 518 to mating...

Page 272: ...o mating surfaces reinstall left cover and torque bolts 14ft lbs 20Nm 13 Install new seals 5 19 FRONT DIFFRENTIAL DISASSEMBLY INSPECTION 1 Remove bolts and bevel crownwheel 2 Remove bolts and differen...

Page 273: ...ATV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 26 4 Remove bolts and differential cap B 5 Remove spring seat springs outer single clutch plate differential plat outer double clutch plate bevel gear...

Page 274: ...or wear cracks chips or broken teeth Inspect inner and outer splines on the spider gears and friction plates replace if edges are rounded Inspect casting for crack Inspect axletree for smooth operatio...

Page 275: ...l bevel gear gear axle washer outer double clutch plate differential plate outer single clutch plate springs spring seat 3 Install differential cap A 4 Check the preload clearance Clearance 1 2 1 5mm...

Page 276: ...seat 7 Install differential cap B 8 Check the preload clearance Clearance 1 2 1 5mm Out of specification change spring seat spring replace clutch plate as necessary 9 Apply LoctiteTM 271 red to screw...

Page 277: ...LODED VIEW TROUBLE SHOOTING Symptom Gears won t stay in position when shift 2WD 4WD Solution Increase the preload to indent ball by turning the grub screw or change a new spring Note Make sure not to...

Page 278: ...31 DIFFERENTIAL CENTRE EXPLODED VIEW 5 21 REAR FRONT PROP SHAFT REMOVAL Using roll pin remover remove the roll pin from prop shaft Slide the prop shaft back and away from the gear case The swing arm...

Page 279: ...CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 09 0 CHAPTER 5 FINAL DRIVE 5 32 NOTES...

Page 280: ...l of each ATV model for spare parts information and service PLEASE SEE CHARPTER 3B IN THIS MANUAL FOR THE TRANSMISSION OF YOUTH MINI ATV 50 80 CHARPTER 3C FOR MINI ATV100 150 AND B TYPE 150 200 6 1 GE...

Page 281: ...caution 1 Clamp shifter housing lightly in a soft jawed vice Using a cross pattern loosen each of the four screw s holding the cover to the shifter housing Loosen each screw only a few turns then pro...

Page 282: ...o cut or tear O ring in the process NOTE The LH slide has two short notches and the R H side has one short and one long notch The slides must be replaced in the proper channels for the shifter to func...

Page 283: ...an prevent proper adjustment of the other rod Remove necessary components to gain access to shift linkage rod ends 1 Inspect shift linkage tie rod ends and pivot bushings and replace if worn or damage...

Page 284: ...he rod end jam nuts securely while holding the rod end The jam nuts must be tightened with both front and rear rod ends parallel to each other If jam nuts are properly tightened the rod should rotate...

Page 285: ...ts M 10x1 25x70 13 Remove transmission from frame and remove drive shaft 2 brackets between the engine and transmission 6 7 ENGINE AND TRANSMSSION INSTALL Transmission 1 Position transmission in frame...

Page 286: ...ers are in correct position 7 Install rear inside cover components on transmission in new model there is no removable rear inside cover 8 Link engine and transmission together with engine mount jig ce...

Page 287: ...tches IMPORTANT The gear position indicator switches must be removed prior to disassembly 3 Remove the transmission cover bolts 4 Carefully remove the cover with a soft face hammer tap on the cover bo...

Page 288: ...hrust button 10 Remove shafts as an assembly 11 Clean all components and inspect for wear 12 Inspect engagement dogs of gears and replace if edges are rounded 13 Inspect gear teeth for wear cracks chi...

Page 289: ...e front only for 4X4 and rear output shafts 3 a 4X4 Install front and rear output shafts with chain as an assembly 3 b 2X4 Install rear output shaft 4 Before installing the cover make sure the sealing...

Page 290: ...and torque screws to 8 ft lb 12Nm 10 Assemble shafts with chain and shift forks 11 Carefully install high reverse shaft assembly and gear cluster as a unit into their respective bearing case areas Ta...

Page 291: ...zIdle speed adjustment zTransmission oil type quality zDriven clutch CVT deflection zLoose fasteners on rod ends zLoose fasteners on gear shift box zWorn rod ends clevis pins or pivot arm bushings zLi...

Page 292: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09 0 CHAPTER 6 TRANSMISSION PAGE 6 13 2X4 TRANSMISSION EXPLODED VIEW...

Page 293: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09 0 CHAPTER 6 TRANSMISSION PAGE 6 14 4X4 TRANSMISSION EXPLODED VIEW...

Page 294: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 09 0 CHAPTER 6 TRANSMISSION PAGE 6 15 NOTES...

Page 295: ...ter 4B for Assembling information about Drum Brake of Youth Mini ATV 7 1 SPECIFICATIONS 7 2 TORQUE 7 3 BRAKE SYSTEM SERVICE NOTES 7 4 BURNISHING PROCEDURE 7 5 FLUID REPLACEMENT BLEEDING PROCEDURE 7 6...

Page 296: ...4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051m m Brake Disc Run out 0 005 0 12 7m m 7 2 TORQUE Item Torque ft lbs except where noted Torque Nm Front Caliper Mounting Bolts 18...

Page 297: ...s use the following procedure 1 Choose an area large enough to safely accelerate the ATV to 50 km h 30 mph and to brake to a stop 2 Using hi gear accelerate to 50 km h 30 mph then compress brake lever...

Page 298: ...place the other end in a clean container Be sure the hose fits tightly on the fitting NOTE Fluid may be forced from supply port when brake lever is pumped Place diaphragm in reservoir to prevent spill...

Page 299: ...f sight glass is clear fluid level is too low 13 Install diaphragm cover and screws Tighten screws to specification 14 Field test machine at low speed before putting into service Check for proper brak...

Page 300: ...are worn replace lever and test the parking performance if any locking problem exists Replace the master cylinder as an assembly NOTE Mechanics parking brake is equipped for new Europe model INSTALLAT...

Page 301: ...d back into caliper Remove excess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 6 Measure the thickness of the pad material Replac...

Page 302: ...disc for nicks scratches or damage 2 Measure the disc thickness at 8 different points around the pad contact surface using a 0 1 micrometer and a dial indicator Replace disc if worn beyond service lim...

Page 303: ...caliper as an assembly if any problem exists INSTALLATION 1 Install caliper on hub strut Apply Loctite 242 to screw threads and Install new bolts Front Caliper Mounting Bolt Torque 18 ft lbs 25 Nm 2 I...

Page 304: ...ad spacer NOTE Do not over spread this spring pin a part farther than necessary to remove it 4 Clean 5 Measure the thickness of the pad friction material Replace pads if worn beyond the service limit...

Page 305: ...face of caliper for nicks scratches or damage and replace if necessary 6 Install brake pads in caliper body with friction material facing each other with the spacer between the pads Install retaining...

Page 306: ...ariance Service Limit 0 002 0 051mm difference between measurements Brake Disc Runout Service Lim it 0 005 0 127 mm REMOVAL REPLACEMENT 1 Removal wheel hub and caliper 2 Remove bolts and disc from the...

Page 307: ...CHAPTER 7 BRAKES ATV SERVICE MANUAL 09 0 CHAPTER 7 BRAKES PAGE 7 13 NOTES...

Page 308: ...8 3 IGNITION SYSTEM 8 4 CHARGING SYSTEM 8 5 ELECTRICS STARTING SYSTEM 8 6 COOLING SYSTEM 8 7 LIGHTING SYSTEM 8 8 REVERSE LIMIT SYSTEM 8 9 GEAR POSITION INDICATOR SWITCH TEST 8 10 SPEEDOMETER SYSTEM 8...

Page 309: ...TV 2 Remove the bulb socket with the wire harness from the backside of the lens unit by turn the socket CCW 3 Remove the bulb from the bulb socket carefully 4 Replace the bulb with a new one 12V 35W 3...

Page 310: ...rly in the three slots install the clip as shown in the fig and connect the cable plug to the conducting strip 4 Change the bulb HEADLIGHT ADJUSTMENT 1 The headlight beam can be adjusted vertically al...

Page 311: ...ise is to lower the beam To turn the two adjusting screws counterclockwise is to heighten the beam TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 From the rear of the taillight remove two screws holding lens...

Page 312: ...battery acid on anyone close to it If battery acid gets on anyone wash the affected area with large quantities of cool water and seek immediate medical attention To ensure maximum service life and per...

Page 313: ...e tablespoon baking soda Rinse with clean water and dry thoroughly 2 Reinstall battery attaching positive red cable first and then the negative black cable 3 Install clear battery vent tube from vehic...

Page 314: ...e test for 15 seconds During this cranking period the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 or higher and the cranking voltage drops below 9 5 volts during...

Page 315: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL PAGE 8 8 CIRCUIT DIAGRAM...

Page 316: ...lug cap resistance entire ignition system 6 Ignition coil 1 Fuse NO CONTINUITY Check switches Replace the fuse CONTINUITY 2 Battery INCORRECT z Clean battery terminals z Recharge or replace the batter...

Page 317: ...imum spark gap 6mm 0 24 in OUT OF SPECIFICATION OR NO SPARK 5 Spark plug cap resistance Tester lead Spark plug sidec Tester lead High tension cord side d zRemover the spark plug cap zConnect the pocke...

Page 318: ...l z Check if the primary coil has the specified resistance Tester lead Pink Terminal Tester lead B Y Terminal Primary coil resistance 3 6 4 8 20 Tester lead Spark plug lead Tester lead Pink Terminal z...

Page 319: ...Check the pickup coil has the specified resistance OUT OF SPECIFICATION Replace the pickup coil Primary coil resistance 168 252 20 MEETS SPECIFICATION 8 Main switch NO CONTINUITY CHECK SWITCHES Repla...

Page 320: ...h the engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable Check for current draw with the key off if the draw is excessive lo...

Page 321: ...RRECT Clean battery terminals Recharge or replace the battery 3 Charging voltage Connect the engine tachometer to the spark plug lead zConnect the pocket tester DC20V to the battery Test lead Battery...

Page 322: ...tester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 5 0 8 20 OUT OF SPECITICATION Replace the stator coil...

Page 323: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 16 8 5 ELECTRICS STARTING SYSTEM DIAGRAM...

Page 324: ...ear brake switch 9 starter switch 10 wiring connection entire starting system 1 fuse refer to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BA...

Page 325: ...must have the equivalent capacity as that of the battery lead or more otherwise it may burn This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity CONTINUI...

Page 326: ...h 7 Engine stop switch NO CONTINUITY Replace the handlebar switch 8 Front rear brake switch CHECKING SWITCHES NO CONTINUITY Replace the brake switch 9 Starter switch CHECKING SWITCHES NO CONTINUITY Re...

Page 327: ...NUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 20 8 6 COOLING SYSTEM IF THE FAN MOTOR FAILS TO TURN Procedure Check 1 Fuse Main Fan 2 Battery 4 Fan motor inspection 3 Main switch 5 Thermo switch 6 Wiri...

Page 328: ...CHECK SWITCHES NO CONTINUITY Replace the main switch 4 Fan motor inspection 1 Connect the battery to the fan motor Battery lead Green Blue terminal c Battery lead Green ground d Check the fan motor op...

Page 329: ...mperatures while heating the coolant with the temperature gauge WARNING zHandle the thermo switch with special care Never subject it to strong shocks or allow it to be dropped Should it be dropped it...

Page 330: ...ll keep rising The heat alarm unit operates the moment the temperature reaches 115 5 with the buzzer sounding and the signal flashing Stop the engine now to have the circuit fixed Procedure Check 1 Fu...

Page 331: ...om of the heated vessel Coolant temperature Resistance 80 47 5 56 8 100 26 2 29 3 OUT OF SPECIFICATION Replace the thermo unit MEETS SPECIFICATION 8 Voltage zConnect the pocket tester DC20V to the Tem...

Page 332: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 25 8 7 LIGHTING SYSTEM FOR USA MODEL...

Page 333: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 26 FOR EUROPE MODEL...

Page 334: ...er to CHECKING SWITCHES section NO CONTINUITY Replace the fuse 2 Battery Check the battery condition Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT Clean battery terminals Recharge or repl...

Page 335: ...O CONTINUITY Replace the bulb and or bulb socket 2 Voltage Connect the pocket tester DC20V to the headlight and high beam indicator light couplers A When the dimmer switch is on low beam B When dimmer...

Page 336: ...bulb socket CONTINUITY 2 Voltage Connect the pocket tester DC20V to the bulb socket connector Tester lead Black terminal c Tester lead Green terminal d Turn the main switch to on Turn the lights switc...

Page 337: ...E LIMIT SYSTEM The limit set for the speed limiter by the manufacturer is 13 15 km h which can be reset in accordance with the user s practice Turning the adjusting bolt clockwise is to increase the s...

Page 338: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 31 8 9 GEAR POSITION INDICATOR SWITCH TEST Switch table...

Page 339: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 32 Switch schematic...

Page 340: ...in Technical Parameter for sensor Item Code Vol value Unit Operating voltage Vcc 5 20 V Operating current Icc 15 mA Low voltage output Vol 0 4 V Hight voltage output Voh Vcc 1 V Operating distance D 1...

Page 341: ...Item Code Vol value Unit Operating voltage Vcc 5 20 V Operating current Icc 15 mA Operating distance D 1mm D 8mm mm The following is the graphic illustration for sensor installation 1 OIL SEAL 4 THE C...

Page 342: ...ight 7 Engine rpm meter 2 High beam indicator light 8 9 The odometer 3 Turn indicator light 10 Engine working hour counter 4 Reverse indicator light 11 2WD 4WD indicator 5 Speedometer A km mile select...

Page 343: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 36 HANDLE SWITCH SCHEMATIC FOR USA MODEL 2004 model 2005 model HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL...

Page 344: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 37 400ATV 2 400ATV 2B HANDLE SWITCH SCHEMATIC FOR USA MODEL 400ATV 2 400ATV 2B HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL...

Page 345: ...Install a new seal rubber onto the fuel level sensor Install the retainer plate onto the sensor by aligning the tab with the grove Install the sensor into the fuel tank while aligning the grove in th...

Page 346: ...ould come on If the fuel gauge does not function properly check the fuel level sensor If the fuel level sensor is OK replace the LCD Meter Fuel level Sensor Inspection Disconnect the fuel level sensor...

Page 347: ...en to the Controller Controller lights the 4WD indicator 5 If the Splined Dog is not in right position 4WD won t engage this information will be given to the Sensor by the Magneto on the Selector Plat...

Page 348: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 41 Fig 2 Fig 3 Page from owner s manual...

Page 349: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 42 Fig 4...

Page 350: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 43 8 14 WIRING DIAGR...

Page 351: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 44...

Page 352: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 45...

Page 353: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 46...

Page 354: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 47...

Page 355: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 48...

Page 356: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 49...

Page 357: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 50...

Page 358: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 51...

Page 359: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 52...

Page 360: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 53...

Page 361: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 09 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 54...

Page 362: ...ATV SERVICE MANUAL EUROPE 09 0 PN F010102A01 ATV 09 0 F010102A01...

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