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CHAPTER 3A ENGINE

260/ 300 cc ATV SERVICE MANUAL07.0

CHAPTER 3 ENGINE PAGE. 3A- 52

3.10CRANKCASE AND CRANKSHAFT

Order

Job name/ Part name

Q'ty

Remarks

1
2

Crankcase and crankshaft

removal

Engine removal
Cylinder head
Cylinder, and piston

V-belt, clutch, secondary/ 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 "CYLINDER AND PISTION"
section.
Refer to "V BELT, CLUTCH AND
SECONDARY/ PRIMARY SHEAVE"section.
Refer to "A.C. MAGNETO AND
STARTER CLUTCH" section.
Refer to "OIL PUMP" section.
Refer to "WATER PUMP" section.

Refer to "REAR WHEEL AND REAR
BRAKE" section.

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Summary of Contents for 2005 ATV 260

Page 1: ...e ATV 260 300 2x4 4x4 Youth ATV 50 80 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 A...

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: ...ion CHAPTER2 Maintenance CHAPTER3A 260 300 Engine CHAPTER3B 50 80 Engine CHAPTER3C 100 125 150 200Engine CHAPTER4A Chassis CHAPTER4B Chassis Youth mini ATV CHAPTER5 Final Drive CHAPTER6 Transmission C...

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 07 0 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N AND ENGINE SERIAL NUMBER ATV 260 300 Mini Youth...

Page 10: ...TV SERVICE MANUAL 07 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...

Page 11: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 07 0 CHAPTER 1 GENERAL PAGE 1 7 ATV 260 300 05 Model ATV 260 300...

Page 12: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 07 0 CHAPTER 1 GENERAL PAGE 1 8 Demon ATV 260 300 Europe Mini Youth...

Page 13: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 07 0 CHAPTER 1 GENERAL PAGE 1 9 Special Edition Anniversary B Type 260 300...

Page 14: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 07 0 CHAPTER 1 GENERAL PAGE 1 10 B Type 150 200...

Page 15: ...CHAPTER 1 GENERALINFORMATION ATV SERVICE MANUAL 07 0 CHAPTER 1 GENERAL PAGE 1 11 NOTES...

Page 16: ...ons maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 FUEL SYSTEM...

Page 17: ...ns and an average vehicle speed of approximately 16km h 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Insp...

Page 18: ...hly I change annually Battery Terminals 10 Monthly I C Battery fluid level 10 Monthly I DL Brake pad wear 2 Weekly I 10 Monthly C Gear case Oil 150 annually R Engine Cylinder Head and Cylinder Base Fa...

Page 19: ...months I T if necessary Spark Plug 100 hrs 12 months I R if necessary DL Ignition Timing 100 hrs 12 months I Adjust as needed DL Fuel System 100 hrs 12 months Check for leaks at tank cap lines fuel v...

Page 20: ...system only 2 Weekly I C L Adjust or and replace if necessary LUBRICANT AND FLUID Item Lube Rec Method Frequency 1 Engine Oil SAE 15W 40 SE Add to proper level on dipstick Check level daily 2 Brake F...

Page 21: ...ease Monthly or 20 hours 14 Throttle Cable Grease M Grease inspect and replace it if necessary Monthly or 20 hours 15 Rear prop shaft U joint Grease Locate fittings and grease Every 3 months or 50 hou...

Page 22: ...ecomes stiff or after washing 5 Hours are based on 10 mph 16Km h average 2 2 FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refue...

Page 23: ...ately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousne...

Page 24: ...y two years FUEL FILTER The fuel filter should be replaced in accordance with the Periodic Maintenance Chart or whenever sediment is visible in the filter 1 Shut off fuel supply at fuel valve 2 Remove...

Page 25: ...onnecting the fuel line refill the fuel tank and turn the fuel valve ON and check that there is no fuel leaking WARNING Always pay attention to the fittings of the plastic gas tank during fuel lines s...

Page 26: ...Measure from string to rim at front and rear of rim Rear rim measurement A should be 1 16 to 1 8 1 5 to 3 mm more than front rim measurement B NOTE The steering post arm frog can be used as an indicat...

Page 27: ...friction pads for wear damage and looseness zCheck surface condition of the disc BRAKE PAD INSPECTION zPads should be changed when friction material is worn to 3 64 1mm HOSE FITTING INSPECTION Check...

Page 28: ...nal manner following the procedure outlined in the Brake chapter FOOT BRAKE TESTING The foot brake should be checked for proper adjustment Support the rear wheels off the ground While turning the rear...

Page 29: ...against the adjusters 5 Make sure the rear wheels turns freely without dragging 6 Turn the adjustor the one on the lever and apply the lever While adjusting it is important you apply the lever back a...

Page 30: ...10mm the limit is 110 5mm z Measure the brake drum inside diameter a Drum Brake Checking Although the front brake has been adjusted at the factory the brake should be checked for proper operation The...

Page 31: ...ke adjustment at the middle of the cables adjuster jam nuts NOTE Apply the front brake a number of times to ensure the wheels lock and the brake light illuminate properly 4 Make sure the right and lef...

Page 32: ...ange of travel Check all front suspension components for wear or damage Inspect from strut cartridges for leakage Shock spring preload can not be adjusted replace if necessary REAR SUSPENSION Compress...

Page 33: ...nd under the footrest frame 4 Remove the wheel nuts and remove the wheel WHEEL INSTALLATION 1 With the transmission in gear and the parking Brake locked place the wheel in the correct Position on the...

Page 34: ...riginal equipment size and type and replace in pairs especially in 4X4 model z The use of non standard size or type tires may affect ATV handling and cause machine damage especially in 4X4 model TIRE...

Page 35: ...e schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter ATV 260 300 and B Type Item Torque Ft Lb Torque Nm Remarks EARLYDESIGN HandlebarClampNutM6...

Page 36: ...bsorbertoFrame 15 18 21 25 LT NutM8BindingFrontAbsorberandFrontAbsorber Strutbody 15 21 LT BoltM8AttachingFrontCalipertoFrontAbsorber Strutbody 18 25 LT BoltM8AttachingUpperSteeringClamptoFrame 12 16...

Page 37: ...CHAPTER 2 MAINTENANCE ATV SERVICE MANUA 07 0 CHAPTER 2 MAINTENANCE PAGE 2 22 NOTES...

Page 38: ...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 5 VAL...

Page 39: ...mm 0 03m m Cam chain Cam chain type No of links DID SC A 0404ASDH 104 Rocker arm rocker armshaft Rocker arm inside diameter Rocker shaft outside diameter Rocker arm to rocker arm shaft clearance 12 00...

Page 40: ...36 93 mm 30 1 mm 31 6 mm 7 8 9 0 kg 37 22 42 83 kg 361 mm 35 0 mm 2 5 1 7mm 2 5 1 7mm Piston Piston to cylinder clearance Piston size D Measuring point H Piston pin bore inside diameter Piston pin ou...

Page 41: ...h 22 6 mm 21 0 mm Carburetor 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...

Page 42: ...r Type Width height thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Cooling fin with electric fan 288 238 42 mm 110 140kPa 1 1 1 4kg cm 2 1 1 1 4bar 2 L 0 35 L Thermo...

Page 43: ...k 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 Magnet...

Page 44: ...olt 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 C...

Page 45: ...asure zValve clearance Out of specification Adjust Valve clearance cold Intake valve 0 08 0 12m m Exhaust valve 0 16 0 20mm Measurement steps zRotate the primary fixed sheave counterclockwise to align...

Page 46: ...T 1 Start the engine and let it warm up for several minutes 2 Attach z Inductive tachometer to the spark plug lead 3 Check zEngine idling speed Out of specification Adjust Engine idling speed 1 350 1...

Page 47: ...zSpark plug type Incorrect Replace Standard spark plug DR8EA NGK 2 Inspect zElectrode c Wear damage Replace zInsulator d Abnormal color Replace Normal color is a medium to light tan color 3 Clean zSp...

Page 48: ...g well to prevent it from falling into the cylinder 5 Attach zCompression gaugec 6 Measure zCompression pressure If it exceeds the maximum pressure allowed Inspect the cylinder head valve surfaces and...

Page 49: ...oil level Oil level should be between maximum and minimum marks 2 Oil level is below the minimum mark Add oil up to the proper lever RECOMMENDED ENGINE OIL Refer to the chart for selection of the oil...

Page 50: ...plug f zOil filer plug NOTE Check the drain plug O ring If damaged replace it with a new one 5 Fill zCrankcase Oil quantity 1 4L 6 Check zEngine oil level Refer to ENGINE OIL LEVEL INSPECTION section...

Page 51: ...low the LOWER level line Add soft water tap water up to the proper level CAUTION Hard water or salt water is harmful to engine parts Use only distilled water if soft water is not available If you use...

Page 52: ...wise toward the detent This allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it NOTE zRemove the radiator cap a...

Page 53: ...th water and then with soap and water If coolant is swallowed Vomit immediately and see a physician CAUTION zHard water or salt water is harmful to engine parts Use only distilled water if soft water...

Page 54: ...0 300 cc ATV SERVICE MANUAL07 0 CHAPTER 3 ENGINE PAGE 3A 17 Wait a few minutes until the coolant settles before inspecting the coolant level 13 Install Remain parts 3 3CYLINDER HEAD Order Job name Par...

Page 55: ...arts 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 side O ring Valve cover exhaust side O ring Timing...

Page 56: ...r assembly zTiming chain tensioner gasket 4 Remove zBreather plate d zCam sprocket zTiming chain NOTE zFasten a safety w ire to the timing chain to prevent it from falling into the crankcase zRemove t...

Page 57: ...figure eight sanding patten NOTE Rotate the cylinder head several times for an even resurfacement CYINDER HEAD INSTALLATION 1 Install zGasket cylinder head NEW zDowel pins zCylinder head NOTE zApply e...

Page 58: ...shaft Dam age or improper valve timing will result zWhile holding the camshaft temporarily tighten the bolts zRemove the safety wire from the timing chain 4 Install zBreather plate c zPlane washer d...

Page 59: ...ob name Part name Q ty Remarks 1 Cam shaft and rocker arms removal 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 Rocke...

Page 60: ...INSPECTION 1 Inspect zCam 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...

Page 61: ...iameter 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 specificatio...

Page 62: ...er 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 the rocker arm sh...

Page 63: ...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 section Refer to ROCKER ARM SHAFT AN...

Page 64: ...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 Limit 5 94mm Exhaust 5 960 5...

Page 65: ...cification 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 stem diameter...

Page 66: ...If the valve seat is too wide too narrow or the seat is not centered the valve seat must be replaced 4 Lap zValve face zValve seat NOTE After replacing the valve seat valve and valve guide the valve s...

Page 67: ...the valve guide and onto the valve seat to make a clear pattern zMeasure the valve seat with c again VALVES AND VALVE SPRINGS INSTALLATION 1 Deburr zValve stem end Use an oilstone to smooth the stem...

Page 68: ...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 tapping lightly with a p...

Page 69: ...ain 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 PISTON AND 8 Piston pin 1 PISTON...

Page 70: ...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 zMeasure the cylinder bore with a cylinde...

Page 71: ...earance 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 rings as a set Pisto...

Page 72: ...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 3 Measure zEnd gap zOut of s...

Page 73: ...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 the crankcase opening with a...

Page 74: ...ricate 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 zPass...

Page 75: ...DARY 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 st...

Page 76: ...er 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 SHEAVE...

Page 77: ...ly 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 Gui...

Page 78: ...EAVE 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 carrier...

Page 79: ...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 using...

Page 80: ...g 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 sliding sheave face c zPrimary fixed s...

Page 81: ...r surface of the secondary fixed sheave d 2 Install zSecondary sliding sheave c NOTE Install the secondary sliding sheave cusing the oil seal guide d to the secondary fixed sheavee 3 Install zGuide pi...

Page 82: ...ase to the V belt secondary sheave and clutch 7 Install zNut c clutch carrier NOTE Tighten the nut clutch carrier using the locknut wrench e while holding the clutch carrier with the rotor holder d 8...

Page 83: ...y 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 7...

Page 84: ...ty Remarks 1 2 3 4 5 6 A C magneto and starter clutch removal Rotor Shaft idle gear Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear 1 1 1 1 1 1 Remove the parts in order Re...

Page 85: ...necessary one holding bolt may be turned out slightly to adjust the flywheel puller s position CAUTION Cover the crankshaft end with the box wrench for protection STARTER DRIVE GEAR INSPECTION 1 Inspe...

Page 86: ...starter wheel gearc then install the woodruff keyd 2 Install z Rotor c z Plain washer NOTE zClean the tapered portion of the crankshaft and the rotor hub zWhen installing the magneto rotor make sure...

Page 87: ...ame 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 G...

Page 88: ...ure 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 roto...

Page 89: ...tch secondary 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...

Page 90: ...me Q ty Remarks 3 4 5 6 7 8 9 10 Timing chain guide intake Crankcase right Dowel pin Crankshaft assembly Timing chain Crankcase left Oil seal Oil seal 1 1 2 1 1 1 1 Refer to CRANKSHAFT INSTALLATION se...

Page 91: ...sprocket the crankshaft cannot be removed CRANKSHAFT INSPECTION 1 Measure zCrankshaft runout Out of specification Replace crankshaft and or bearing NOTE Measure the crankshaft runout with the cranksh...

Page 92: ...5 Inspect zCrankshaft journal Clogged Blow out the journal with compressed air CRANKCASE INSTALLATION 1 Clean all the gasket mating surface and crankcase mating surface thoroughly 2 Apply zSealant on...

Page 93: ...rt name Q ty Remarks Radiator removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Fan motor leads 2 2 Thermo switch leads 2 3 hose radiator 1 4 Outlet hose radia...

Page 94: ...zRadiator hoses zRadiator pipes Cracks damage Replace 3 Measure zRadiator cap opening pressure zRadiator cap opens at a pressure below the specified pressure Replace Radiator cap opening pressure 110...

Page 95: ...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 1 1 3 Shaf...

Page 96: ...cc ATV SERVICE MANUAL07 0 CHAPTER 3 ENGINE PAGE 3A 59 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 proced...

Page 97: ...damage Replace Fur deposits Clean 2 Inspect zImpeller shaft gear Wear damage Replace 3 Inspect zMechanical seal c Damage worn wear Replace WATER PUMP INSTALLATION 1 Install zMechanical seal c NEW Ins...

Page 98: ...W Installation steps zApply a small amount of grease to the impeller shaft tip zInstall the impeller shaft while turning it Use care so that the oil seal is not damaged or the spring does not slip off...

Page 99: ...emarks Thermostat removal Drain the coolant Remove the parts in order Refer to COOLANT REPLACEMENT section 1 Clip 1 2 Hose 1 3 Hose clamp 1 4 Inlet hose radiator 1 5 Thermostatic cover 1 Refer to THER...

Page 100: ...ometer in water z Observe the thermometer while continually stirring the water cThermostatic valve dVessel eThermometer fWater A CLOSE B OPEN NOTE The thermostatic valve is sealed and its setting requ...

Page 101: ...tart the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Never drain the float bowl when the...

Page 102: ...3A 65 the mouth etc Possible Good condition Impossible Replace auto choke unit 7 Remove zBlot zAuto choke unit 8 Auto choke unit inspection zPiston zJet needle Wear Replace 9 Install zAuto choke unit...

Page 103: ...OAT AND JETS 13 Remove zFloat chamber WARNING Never drain the float bowl when the engine and the exhaust system are hot Severe burns may result zFloat zNeedle valve 14 Inspection zNeedle valve Wear Re...

Page 104: ...zMain nozzle Check the main nozzle for wear or damage Clean the main nozzle with cleaning solvent and blow this open with compressed air 18 Remove zPilot screw set Turn the pilot screw in and careful...

Page 105: ...n Replace zDiaphragm Wear Replace 21 Reverse the removal procedure for installation ACCERERATING PUMP 22 Remove zCover Check the vacuum piston for wear or damage 23 Inspection zCompressing spring Dist...

Page 106: ...CHAPTER 3A ENGINE 260 300 cc ATV SERVICE MANUAL07 0 CHAPTER 3 ENGINE PAGE 3A 69 NOTES...

Page 107: ...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 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...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 137: ...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 138: ...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 139: ...y 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 as necessary Replacing the transmis...

Page 140: ...clutch transmission Pulley assembly Assemble the transmission pulley guide pin and oil seal Install the sealing cover of the collar Assemble the transmission pulley disk and the spring to the clutch...

Page 141: ...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 142: ...hanging 0 1L Tool Special tool Bearing pulling set 12mm Bearing pulling set 15mm Sleeve shaft for assembling the crankshaft Sleeve lever for assembling the crankshaft Common tool Bearing outer race dr...

Page 143: ...g loose Oil leakage Too much oil The oil seal broken 3 5 2 Dismantling the final transmission assembly Remove the left crankcase cover Remove the driven pulley of the clutch Drain the oil out of the f...

Page 144: ...cover Remove the oil seal on the final transmission shaft Heat the final transmission gearbox to 120 to remove the bearing Drive in the new bearing to the final transmission cover Oil leakage Too muc...

Page 145: ...untershaft install the locating pin and the new gasket Put on the final gearbox cover Tighten the bolts of the final gearbox cover Assemble the clutch driving pulley disk After assembling fill it with...

Page 146: ...e following work before 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 star...

Page 147: ...ng slack 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 crankca...

Page 148: ...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 149: ...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 150: ...he 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 the crankcase Torque 9N m 6...

Page 151: ...R 3B ENGINE PAGE 3B 45 3 7 Lubricating system 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...

Page 152: ...reen Oil volume check 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 minute...

Page 153: ...tor Remove alternator 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 pu...

Page 154: ...en oil pump 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...

Page 155: ...3B 49 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 156: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL07 0 CHAPTER 3B ENGINE PAGE 3B 50 Assemble right crankshaft case cover tighten 8 screws Assemble pulse coil and stator and rotor Install fan and cover...

Page 157: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL07 0 CHAPTER 3B ENGINE PAGE 3B 51 3 8 Carburetor...

Page 158: ...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 159: ...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 160: ...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 161: ...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 162: ...and control screw Count the turns when removing the fuel volume control screw When reinstalling jets and screws do not over tighten Clean jets with solvent and compressed air Clean body of carburetor...

Page 163: ...n screw The standard setting is 2 turns or 1 4 turn Assemble the float valve float and float pin to the bottom of the carburetor using the retainer pin Check the operation of the float and valve All p...

Page 164: ...retor Securely tighten the clamp screw to fix the carburetor in place Do not over tighten the screws as this can cause damage to the manifold Attach the inlet pipe to the rear of the carburetor and ti...

Page 165: ...ndard setting is 2 turns out 1 4 turn To set this position run the engine until warm and allow it to idle Turn the screw in or out a little at a time and measure the idle RPM The correct setting is ac...

Page 166: ...urn Starter motor turns over slowly Fuse broken Battery discharged Battery discharged Poor or faulty cable connections Faulty main switch Starter motor gear seized by a foreign object Faulty starter c...

Page 167: ...hem if necessary Clean attached metal particles from the commutator surfaces Measure the resistance between each contact surface of the components Make sure there is no conduction current between each...

Page 168: ...h ends sliding surfaces of armature shaft Install armature in front bracket Make sure the surfaces between the brush and armature are not damaged Be sure the dust cover lip is not damaged by the armat...

Page 169: ...inion operates properly Check the gears and bearing for wear or damage Check for extensions of driver gear Check for spring return of driver gear Clean assembly with solvent and lube with dry graphite...

Page 170: ...g fan Use a universal solid wrench to secure the 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...

Page 171: ...bs Set up the rubber 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 Po...

Page 172: ...APTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL07 0 CHAPTER 3B ENGINE PAGE 3B 66 Universal tool Universal solid wrench Set up the cooling fan Torque 9N m Install the fan cover and securely tighten fastne...

Page 173: ...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 174: ...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 175: ...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 176: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL07 0 CHAPTER 3B ENGINE PAGE 3B 70 align within 2 with the engine revolving at a speed of 1500rpm The spark advance angle should be 13 1 1500r min...

Page 177: ...CHAPTER 3B ENGINE 50cc 80cc ATV SERVICE MANUAL07 0 CHAPTER 3B ENGINE PAGE 3B 71 NOTES...

Page 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ...50 200 SERVICE MANUAL07 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 191: ...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 192: ...07 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 193: ...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 194: ...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 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...CHAPTER 3C ENGINE 100 125 150 200 SERVICE MANUAL07 0 CHAPTER 3C ENGINE PAGE 3C 36 NOTES...

Page 214: ...ARNING 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 information an...

Page 215: ...rn 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 ft lbs 41 4 Nm W...

Page 216: ...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 Serious injury...

Page 217: ...earing taper 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 a...

Page 218: ...emove 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 pinch bolts with clamp...

Page 219: ...all 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 with nut 3 onto...

Page 220: ...GE 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 directions 4...

Page 221: ...CHAPTER 4A CHASSIS ATV 260 300 and B Type ATV SERVICE MANUAL 07 0 CHAPTER 4 A CHASSIS PAGE 4A 8 NOTES...

Page 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ...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 229: ...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 230: ...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 231: ...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 232: ...CHAPTER 4B CHASSIS ATV SERVICE MANUAL07 0 CHAPTER 4 CHASSIS PAGE 4B 11 NOTES...

Page 233: ...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 FRONT DRIV...

Page 234: ...machine under footrest frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure Wear eye protection when removing bearin...

Page 235: ...UB ASSEMBLY 1 Drive 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 grea...

Page 236: ...DRIVE 5 4 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 5 Install spacer on spi...

Page 237: ...stall 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 rotate the hub several turns...

Page 238: ...tate smoothly without binding or rough spots or side play 16 Install brake caliper using new bolts Apply Loctite 242 blue to threads Tighten bolts to specified torque CAUTION Always use new brake cali...

Page 239: ...UTION To avoid damage to the front differential oil seal hold the front drive shaft horizontal and straight out from the front differential during removal 3 Hold the drive shaft straight out 4 Place a...

Page 240: ...al hold the front drive shaft horizontal and straight into the strut during installation 1 Hold the drive shaft straight in from the front differential 2 Push the drive shaft straight into the front d...

Page 241: ...CV off the drive axle and discard the boot band A it cannot be reused 8 If the outboard boot requires replacement perform the following a Open the clamps on both boot bands A and B on the outer CV jo...

Page 242: ...ust be replaced 11 Inspect the exterior of the inner CV joint for cracks or damage replace if necessary Check the movement of the joint for excessive play or noise by moving the drive axle in a circul...

Page 243: ...l balls into their receptacles in the bearing case c Pack the bearing assembly with molybdenum disulfide grease This will help hold the steel balls in place 6 Position the bearing assembly with the sm...

Page 244: ...e small boot band onto the boot Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer Make sure they are locked in place 16 Install the large...

Page 245: ...rear of the ATV CAUTION 7 Serious injury could occur if machine tips or falls 8 Remove wheels 9 Remove hubs 10 Remove brake hose clamp and brake shield s 11 Remove rear brake caliper s and support it...

Page 246: ...wing arm asm bolts and torque to 59 67 ft lbs 80 90Nm 7 Torque axle tube bolts in a cross pattern to 60 ft lbs 80 Nm 8 Re install skid plate and torque bolts to 25 ft lbs 34Nm Install new greased o ri...

Page 247: ...ning ring and seals reversing steps of rear axle bearing removal 2 Torque brake caliper rear hub nut and rear wheel nuts to specifications 5 14 REAR GEARCASE DISASSEMBLY 1 Drain and properly dispose o...

Page 248: ...otating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smoothly and quietly with no detectable up and down movement and minimal movement side to side 5 Cl...

Page 249: ...g Always field 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 s...

Page 250: ...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 251: ...TV SERVICE MANUAL 07 0 CHAPTER 5 FINAL DRIVE 5 19 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 252: ...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 253: ...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 254: ...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 255: ...ATV SERVICE MANUAL 07 0 CHAPTER 5 FINAL DRIVE 5 23 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 256: ...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 257: ...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 258: ...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 259: ...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 260: ...28 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 261: ...CHAPTER 5 FINAL DRIVE ATV SERVICE MANUAL 07 0 CHAPTER 5 FINAL DRIVE 5 29 NOTES...

Page 262: ...ch 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 GEAR SHIF...

Page 263: ...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 264: ...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 265: ...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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ...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 272: ...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 273: ...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 274: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 13 2X4 TRANSMISSION EXPLODED VIEW...

Page 275: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 14 4X4 TRANSMISSION EXPLODED VIEW...

Page 276: ...CHAPTER 6 TRANSMISSION ATV SERVICE MANUAL 07 0 CHAPTER 6 TRANSMISSION PAGE 6 15 NOTES...

Page 277: ...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 278: ...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 279: ...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 280: ...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 281: ...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 282: ...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 283: ...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 284: ...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 285: ...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 286: ...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 287: ...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 288: ...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 289: ...CHAPTER 7 BRAKES ATV SERVICE MANUAL 07 0 CHAPTER 7 BRAKES PAGE 7 13 NOTES...

Page 290: ...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 291: ...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 292: ...ght beam can be adjusted vertically all models and horizontally except the light on handlebar 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 3 Measure the...

Page 293: ...s to heighten the beam TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 From the rear of the taillight remove two screws holding lens cover in place and remove lens cover 2 Remove lamp and replace it with reco...

Page 294: ...al service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery must be fully charged before use 1 Remove vent plug from vent fitting 2 Fi...

Page 295: ...ted to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity...

Page 296: ...erminal board or connections wet corroded z Poor ignition coil ground e g coil mount loose or corroded z Faulty stator measure resistance of all ignition related windings zIncorrect wiring inspect col...

Page 297: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL PAGE 8 8 CIRCUIT DIAGRAM...

Page 298: ...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 299: ...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 300: ...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 301: ...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 302: ...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 303: ...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 304: ...tester X1 to the stator coil Tester lead yellow terminal Tester lead yellow terminal Measure the stator coil resistance Stator coil resistance 0 8 1 0 20 OUT OF SPECITICATION Replace the stator coil...

Page 305: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 16 8 5 ELECTRICS STARTING SYSTEM DIAGRAM...

Page 306: ...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 307: ...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 308: ...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 309: ...NUAL 07 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 310: ...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 311: ...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 312: ...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 313: ...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 314: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 25 8 7 LIGHTING SYSTEM FOR USA MODEL...

Page 315: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 26 FOR EUROPE MODEL...

Page 316: ...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 317: ...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 318: ...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 319: ...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 320: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 31 8 9 GEAR POSITION INDICATOR SWITCH TEST Switch table...

Page 321: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 32 Switch schematic...

Page 322: ...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 323: ...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 324: ...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 325: ...ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 36 HANDLE SWITCH SCHEMATIC FOR USA MODEL 2004 model 2005 model HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL 8 12 FUEL GAUGE FUEL LEV...

Page 326: ...al 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 the plate with the...

Page 327: ...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 328: ...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 329: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 40 Fig 2 Fig 3 Page from owner s manual...

Page 330: ...CHAPTER 8 ELECTRICAL ATV SERVICE MANUAL 07 0 CHAPTER 8 ELECTRICAL CTRICAL PAGE 8 41 Fig 4 8 14 WIRING DIAGRAM...

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Page 340: ...ATV SERVICE MANUAL 07 0 NOTES...

Page 341: ...9B 9 939397 93...

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