SMC Networks ATV100 Service Manual Download Page 13

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1-0

The
valu

5m
6m
8m
10m
12m

Spa

Cyl

Cyl
Air
Air

Fan
Oil
Car
Car
Air

Inta

Oil
Oil

Gea
Cra
cas
L.R

Kic
Idle

One

Clu

Exh
Muf
Pro

A.C

Gea

05. Tool T

e torque va

ues for not

Standard

Item

m Bolt, Nu
m Bolt, Nu
m Bolt, Nu

mm Bolt, N
mm Bolt, N

Engine To

ark Plug

inder head

Shroud
Shroud co

n Bolt

pump bolt

rburetor up
rburetor flo

cleaner fix

ake bolt (re

plug cap
drop bolt (

ar box bolt

ankcase co
se)

R Crankcas

k Nut

e gear plate

e way clutc

utch

utch carrier

haust Pipe

ffler bolt

otector, mu

C. Generato

gnet (A.C.

ar shifting

Torque v

alues listed

listed in th

Toque Va

ut
ut
ut

Nut
Nut

orque

Item

d/cylinder s

d nut

over

pper bolt

oat bolt
xing bolt

eed valve)

(drain bolt)

over bolt (tr

se bolt

e bolt

ch bolt

(cylinder s

uffler

or nut (flyw

G. coil) sc

lever nut

SMC

value set

in table ar

he table.

alue

Torqu

0
0
1
3
5

stud bolt

)

ransmissio

side)

wheel/rotor

rew

MC ATV50

tting

re for more

e Value (k

0.45~0.60
0.80~1.20
1.80~2.00
3.00~4.00
5.00~6.00

Q’

1
4
4
3
1

4
2
2
4
2

4
1
1
6

6
1
2
1

1
1
2
2
2

1
2
1

0/100 Se

e important

kg-m)

5m
6m
6m
8m
10m

’ty

Thre

1
4
4
3
1

4
2
2
4
2

4
1
1
6

6
1
2
1

1
1
2
2
2

1
2
1

14
07
07
06

05
04
04

06
14
08
06
11

06
06
06
10

10
28
06
08
06

10
06
06

Service M

t tighten to

Item

m Screw
m Screw
m Screw
m Screw

mm Screw

ead Dia.

mm)

4*1.22
7*1.00
7*1.00
6*1.00

6.0

6*1.00

5*0.8
4*0.7
4*0.7

6*1.00

6*1.00
4*1.50
8*1.25
6*1.00

*1.00

6*1.00
6*1.00
6*1.00
0*1.25

0*1.00
8*1.00
6*1.00
8*1.25
6*1.00

0*1.25
6*1.00
6*1.00

Manual

Chapte

rque value

Torque

(kg

1.5~
1.4~
1.3~
0.5~
0.1~

0.5~
0.3~

0.15~

0.7~

0.7~
0.2~
1.5~
0.7~
0.7~

0.7~
0.7~
0.6~
2.5~

3.5~

0.7~
2.2~
0.7~

3.8~
1.0~

er 1 Gen

es. Please

orque Valu

0.45~0
1.00~1
0.70~1
2.00~3
3.50~4

e Value

g-m)

~2.0
~2.0
~1.5
~0.8
~0.2

~0.8
~0.5
~0.25

~1.0

~1.0
~0.4
~2.0
~1.0
~1.0

~1.0
~1.0
~1.0
~3.5

~4.5

~1.0
~3.0
~1.0

~4.2
~1.6

eral Inform

see standa

ue (kg-m)

0.60
1.40
1.10
3.00
4.50

sugges

2.0

1.0

1.4
0.7
0.2

0.7
0.4
0.2
0.2
0.9

1.1
0.3
1.8
1.2
1.2

1.2
0.9
0.8

4.0

3.0

0.9
2.6
0.9

3.8

0.8

12 -

mation

ard

All manuals and user guides at all-guides.com

Summary of Contents for ATV100

Page 1: ...SERVICE MANUAL CF5 UR5 UR0 ATV 50 100 ATV with F N R 3 in 1 engine Standard Motor Corporation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 2: ...do an this man l informat added to serious in equipment e SAE 2 y will not c ne oil ase is reco erials are ed thium soa h a new pa mended bra s 0 100 Se on of SMC please rea y repair ins ual to ind ti...

Page 3: ...on oi wash your f children xhaust syst he engine h insulated ases Flam cid electro or skin If you get ba ital to see e drink a l mediately g each of ch 0 100 Se our own your own s ce is well ve ou hav...

Page 4: ...gh d air Pay s cleaning a MC ATV50 ush to clea dust flying cause disor stic or rub ed parts fo hildren parts and SMC ATV ty service remove an g the parts n parts dam only metric sh system or the cove...

Page 5: ...able to pre eriorated w allation to m which has ut Loosen ay receive ch as trans them toge abel the as o avoid the of the impo ed in correc should be ts metal se s for assem other be s Insert the bolt...

Page 6: ...ace In thi orce on bo oth of thes MC ATV50 he groove e manufac n which the or burrs tha asket or sea dstone if th fuel vacuu ey can go t below the e ld be prop s designed essed again age may re s case...

Page 7: ...able sho ord tery have to ost caps ar ition of ch ogen gas a herefore a en handling ntilated are sparks or ging or han 0 100 Se ified lubrica alled parts when cond s to remov pen end wr t circuit an c...

Page 8: ...res as rem onnector b connector ctor comple onnector si d in prope nector is co ompletely MC ATV50 ECTROLYT ctrolyte as CONTAC 15 minutes r or milk fo medical at t the cause tor it locke t moving a co...

Page 9: ...ss h es against t arness con ng the har s far away es to avoid oid the proj MC ATV50 check if t ses to the f o that only have to be the weld o ntact with r rness from the h sharp edg jected end 0 100...

Page 10: ...lean rust o duct conne MC ATV50 neither pul es with elec er Thoroug as applying which insu round the d wire harnes en twisted he handleb erfere with ment opera test in acc on connect ection ope 0 100...

Page 11: ...V 10W 4 SMC s TV50 CVT 5mm 1028m 5mm Mass 142 Air Cooled orizontal mm fuel by oil p M 16 18mm R7HS x 1 starter Kick Wheel Magn Factory defa Engine Oil S element T Automatic selector fun 2T ve 428 88 0...

Page 12: ...4 SMC TV100 CV 5mm 1028m 5mm Mass 144 Air Cooled orizontal m fuel by oil p M 16 18mm R7HS x 1 starter Kick Wheel Magn Factory defa Engine Oil element utomatic wit ift selector f 2T ve 428 88 0 12L 41...

Page 13: ...ue k 0 45 0 60 0 80 1 20 1 80 2 00 3 00 4 00 5 00 6 00 Q on r 1 4 4 3 1 4 2 2 4 2 4 1 1 6 1 6 1 2 1 1 1 2 2 2 1 2 1 0 100 Se e important kg m 5m 6m 6m 8m 10m ty Thre m 1 4 4 3 1 4 2 2 4 2 4 1 1 6 1 6...

Page 14: ...me and handl upper low e pper arm g column upper bolt t IN t EX ame MC ATV50 Q e e bar wer 2 1 4 2 2 4 4 2 8 2 8 4 1 1 1 4 4 4 1 1 1 4 1 2 2 2 0 100 Se ty Thre 2 1 4 2 2 4 4 2 8 2 8 4 1 1 1 4 4 4 1 1...

Page 15: ...1 0 A E 06 Troub Engine do bles Diag oes not sta SMC nosis art MC ATV50 0 100 Se Service M Manual Chapte er 1 Gen eral Inform 14 mation All manuals and user guides at all guides com...

Page 16: ...po oor perform oor perform SMC mance at mance at MC ATV50 low and id high spee 0 100 Se dle speed ed Service M Manual Chapte er 1 Gen eral Inform 15 mation All manuals and user guides at all guides co...

Page 17: ...D P Poor Perfo ormance SMC MC ATV50 0 100 Se Service M Manual Chapte er 1 Gen eral Inform 16 mation All manuals and user guides at all guides com...

Page 18: ...A P Poor Steer ring SMC MC ATV50 0 100 Se Service M Manual Chapte er 1 Gen eral Inform 17 mation All manuals and user guides at all guides com...

Page 19: ...Disk B witch St dle ghtness a of Oil Capacity ine Oil r Oil throttle valv Ty Ga r free play static timing speed F R essure ery C ATV 50 ce Sched nt brake Brake arting In Pressur ve ype ap Front Rear...

Page 20: ...brake free pl brake or ear ear Brake Fl ge Check heck for dam Bearing amage Pressure Bush fastene ubricant eering Knuck belt weight r Clutch in age C ATV 50 ce Sched d and reco ATV at the the hours o...

Page 21: ...every 1000 dusty rain d med more ated a high V Re char ntenance a urs move carb s lower tha m the perio a periodic m ead to poor 0 100 S ectrical Syst I I I ustment ary y local dea 0 KM drive days 2...

Page 22: ...fixin eration ope 6 mm Cleaner the LH foo size type 3 screws f d then rem e element w h point solv with new o SMC es el cock an amage be with new o oil hose be p if any det il leaking C ne if neces on...

Page 23: ...n adjustm be performe at needed d check an after engin h that oper or 10 minu the engine Idle adjus get higher e Turn out engine and til around 1 le speed rpm SMC acid organ cleaning e stall the ele h...

Page 24: ...ed by spec ommercial e the drive he drive ch dry the drive c age e the chain aged drive sproc ear or dam SMC n ack 10 25mm ack s 4 pcs o n rear swin st the drive g nut uitable sla Chain ain becom ved...

Page 25: ...free play o e lever Th he rear bra e play or ot if necessa free play o e pedal SMC m drum b ake lever a or other d necessary of the brak The stand e brake fo ake and co ther dama ry of the rear he st...

Page 26: ...ak on e brake fluid brake fluid change e rubber ca er a transpar e drain valv cuum draw l brake flui ome clear he drain va Brake Fl uid to UPP ded brake f brake flu SMC m Disk B n apply by front 2 an...

Page 27: ...rake lin irst essary to re e brake lini ds Replac he brake lin ds if the br oove close ate the bra g removed der to main brake pad SMC brake fluid system or r nd brake le he button s o activate rking...

Page 28: ...n the fro times to ch f it is dama rebound e relative p all nuts an pension own the re times to ch f it is dama rebound e relative p SMC Switch S h is to light u cal starter c rake applyi ease throttl...

Page 29: ...s smoo el Tire e check sh surface is erials ire pressu oad recom t and rear thread de tire if the d 5 mm 0 mm s Bolts T odical mai al Maintena nuts on th ng pins sn ders for se SMC ndle bles if they t...

Page 30: ...g the lengt ng the tie r ghten the lo 43 N m R OIL ds to be ch ear oil relea s release b oil hole is o box Gear Oil 12L SMC level grou g straight a of the tires ight nce betwe e vehicle b ed 180 so gn...

Page 31: ...Not te SMC C ATV 50 0 100 S Service M C Manual Chapter 2 Maintenan 2 nce Informa 27 ation All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 32: ...nect e oil capacity SMC n Operat ngine lation n Operat n e supported an be servic elt clutch a ump and st bolt ng bolt tion nut Item y C ATV 50 tion tion with specia ced as engi and movabl art one way...

Page 33: ...v the R and he air clea 4 pan head cap and re the 10 pan er side un ay side an SMC val d in the co ustment in ustion syst ear carrier lever on th elease the arrier if any and batte y cord gative term...

Page 34: ...l p and oil hos he cylinde the deflect he cylinder SMC est stay a n each R a nd then rem cover s each R an ove out the ch on R an en remove oling shro he air shro head screw then remo pump cab se from...

Page 35: ...ue n bolt 2 6 out the exh e drive cha ut the bolts te the sprock SMC pipe prote screw st protecto tch spri witch sprin witch t muffler a ge nuts on lt 0 9kg ging flange ecting with 6kg m 26N haust muf...

Page 36: ...the A C ness ect the star ct the spee se sen the fixi crankcase out the spe ue r cable bolt SMC rk plug ca nition coil s head fuel oil ho k to off pos uretor loos n bolt at bo After fuel be se on the...

Page 37: ...gine ect the eng out the en e air clean the 2 fixing e he air clea or remove the ue olt 0 9kg m SMC hifting leve from the sh move the ge holder gine hange gine from t ner g screw on ner air duc e air...

Page 38: ...ake ue eed valve he start mo the 2 fixing ect the eart d remove o ue olt 1 3kg m SMC tor in connect tor retor pipe and r ket bolts reed valv bolt 1 1kg otor g bolts th cord 10 out the star m 13Nm C AT...

Page 39: ...of engin gine in the ul when rem end or twis wires have t nce with no SMC lation ne hanger reverse pr moving an st the wires to be route ormal layou C ATV 50 parts for a rocedures d installing s and t...

Page 40: ...NO OTE SMC C ATV 50 0 100 S Service M Manual Chapte er 3 Engin 3 e Removal 36 l All manuals and user guides at all guides com...

Page 41: ...ir Cl 01 Mech anism D autions in ble Shoo TANK uretor e Reed V leaner hanism D SM iagram n Operat ting Valve Diagram MC ATV 5 tion 5 100 Se ervice M 3 3 3 40 4 4 4 Manual Chapte 7 38 39 0 40 42 43 er...

Page 42: ...dle clearan ice tools pressure p uge SM n Operat tion n point and e when wo ottle cable ng fuel syst rew in the f ce pump MC ATV 5 tion d explosive orking with Damaged tem parts float cham 5 100 Se e...

Page 43: ...e rati er dirty n leakage k cap breat ure of carbureto k cap breat s in the tub el in carbur piston stick re edle valve i el too high n carbureto er element tly misfi on of igniti SM ting ylinder rk p...

Page 44: ...a k the fuel h or fuel lea ock and ca on e reverse w uretor L e air cleaner e 2 air clean se air duct clam air cleaner the fuel line intake clam the fuel pipe k to off po SM nd rear fen overs switch t...

Page 45: ...je e into the t tle cable s alve groove he carburet ust screws t chamber amber cov loat arm p ilot jet ma dle speed and screw olvent and ir with com the float ne r upside do en the plan e gasket a mm...

Page 46: ...justing scre urns 00 rpm y starter er is open de of the s m hose to into the ho ger opens If closed hoke unit l utes m hose to into the h lace the au oses auto uretor val Valve ket bolts on ake and re...

Page 47: ...fixin the air and m carburet on the air c cleaner co aner eleme aner elem gently but solvent o t twist the If damaged oil to the e et but not d nt assemb acid organiz rse order of e 0 9 mgf MC ATV 5 l...

Page 48: ...No otes SM MC ATV 5 5 100 Se ervice M Manual Chapte er 4 Fuel S 4 System 44 All manuals and user guides at all guides com...

Page 49: ...ate the p mix with th and foam SMC iagram n Operat ting ystem Diagram drives the p plunger sha he mixture cover the c C ATV 50 tion pump gear aft in oil pu of air fuel cylinder in 0 100 S rs of oil pu...

Page 50: ...rings SMC n Operat ly to engin d and then hed you n the combu ting PLY TO E ank is too l ed well m tube end n ed Air bub WORK oil level n lubricant d gasket C ATV 50 tion e is very im n this engin ne...

Page 51: ...the cla il out hose ove the thro ove the scr e oil pump n no need m crankca ove the spa nnect the o the electric shaft SMC op cover f oor panel hapter 3 pler of oil g hose from o olts on the ection nk...

Page 52: ...and pist e air coolin er air shrou SMC being pum ase check t bble or clog ew oil pump mp onto th tighten the gears are e hose from air bubble out hose ical starter mp and co l pump a out hose to ark p...

Page 53: ...No otes SMC C ATV 50 0 100 S Service M Manual Chapter r 5 Oil lubr 4 ricant Syste 49 em All manuals and user guides at all guides com...

Page 54: ...anism D autions in bleshoot der Pist inspecti der Pisto hanism D SMC iagram n Operat ing ton Ring ion on Ring i Diagram C ATV 50 tion gs Remo installati 0 100 S oval ion Service M Manual Chapte 50 51...

Page 55: ...groove e of the mou ston ring OD of p e between p OD of pis piston pin ho ing ket leaking ped or crac ings worn build up on worn out build up ings worn n of piston wall scored build up on tem fan c or...

Page 56: ...lind s or foreign surfaces o SMC Piston Ri ter 3 for en e the engin rench to re ng nuts fro ve the cylin ket der careful whole pisto on pin clip n pin pisto cting rod sm der gasket n materials of cyli...

Page 57: ...o fla to screw nuts by tur ction wrench to he crankca SMC solvent so t oved more on ring lubr g up at a po into engin der stud bo ange nuts in a little b rn each by remove ou ase C ATV 50 that the eas...

Page 58: ...cylin evels in X 0 05 mm d 0 03 mm the cylinde e for warp eler gauge it 0 10 mm each piston er and mea it 0 10 mm SMC ction spection er head if a with new if n residues the combu er head co use 0 03 m...

Page 59: ...100cc e re the pisto pin outer d iameter se or 50cc en or 100cc e ervice limit for 50cc e for 100cc re the con diameter w meter it mm for 50 mm for 10 SMC arance betw m on outer d m the skirt s gine...

Page 60: ...d cylinde essing the ce a new cy the cylinde n the cylind is 10 14N SMC ton Ring olt onto cra m rings with t damage t ends too f er gasket s op any gas se o inside of d install th piston pin ton with...

Page 61: ...Not te SMC C ATV 50 0 100 S Service M Manual Chapte er 6 Cylind 5 der Head V 57 Valves All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 62: ...is se Cover ving Fac Pulley As n of the F iagram combinatio n change th rease the l force from ve pulley w o move to t is decreas d by the alte H means SMC ATV tion r e MDF ssy Fr Drive on of autom he...

Page 63: ...4 5kgf m nut 4 0kgf ice Tools compress ench der ble Diagn n be start e Belt e face amaged cl iven pulley r misfire utch weigh ch weight t horsepo e belt nt spring fo er lley operat S Descript eration...

Page 64: ...ve by remo with fan M he driven p nd belt ve belt for y width of dr t 14 6 mm belt if excee genuine pa ces of drive SMC e Cover ver remov cover bolts d gasket ver instal ver in the r cover bolt e clu...

Page 65: ...co mp and ch oller ollers are to s of centrif are worn o ce will be a or damage h roller s ou service lim 14 50 mm SMC or dirt before riving Fa ngine spee face by ce ressed and minum fan i e face It...

Page 66: ...insid mit 112 3m using the s cles with a eight k the clutch ce limit ight lining t mit 1 0mm k the clutch g if crack o set if neces SMC second ut on the c ch weight a ve and fix s sheave an check the...

Page 67: ...e er bearing ce it if nece bearing is Replace it if e of inner k if the bear silent aring outer d Replace n Pulley s ng oil ring ace with n install to th ave pulley ass y sor and wr clutch weig th spe...

Page 68: ...NO OTE SMC C ATV 50 0 100 S Service M Manual Chapte er 7 CVT d 6 riving Syst 64 tem All manuals and user guides at all guides com...

Page 69: ...bolt 1 3k e bolt 0 8k SM Descript tch Start rting Mot iagram with electric k start by s ft side of c Descript n of one way kgf m 13N kgf m 8Nm MC ATV tion t clutch tor cal starter pindle gea crankcas...

Page 70: ...plate utch ass y ter boss an h of idle ge Chips Rou one way c B and che clutch shou ed when tur ce with new shaft on th ft should be or move arts if wea C JMAX 70 Clutch ce please MDF assy w and remo...

Page 71: ...ect the eart and remove n e motor fu motor can e gear end damage with new s ry on y of start m art motor g respond m or bolt 1 SMC start clutch ch in rever bearing ins all the idle g ar plate wit rque...

Page 72: ...for starting arter by loo hen pull ou on spindle over e gear bos ring and t y rts if wear ound rebou pring with c and spindle e left crank fixing clip a o the crank er pinion ge olt 0 9kgf C JMAX 70 c...

Page 73: ...NO OTE SMC C JMAX 70 700 ATV S Service C Manual Chapter 8 E l Engine Sta 6 arting Syste 69 em All manuals and user guides at all guides com...

Page 74: ...01 Mech anism D tenance N Generato ump and kshaft anism D SMC iagram Notice or Assy oil pum Diagram C ATV 50 mp drive g 0 100 S Chapt gear Service M ter 9 A C G Manual Generator 70 71 72 73 75 Oil Pu...

Page 75: ...G flywhe versal hold ankshaft pu ankshaft ins tenance e ng bolt xing bolt bolt t e bolt per bolt s eel puller der uller staller SMC Notice C ATV 50 0 7kgf m 0 7kgf m 3 8 kgf m 0 8kgf m 0 4kgf m 1 2kg...

Page 76: ...eal remove th e the gasket SMC or Assy oling shrou emoval ws on the e cooling fa nge nut an l screw the use wrenc le push bo side of cra WOODRUF ts on the s l rubber on he Stator A t C ATV 50 d refer...

Page 77: ...ke SMC ithium soa ble through mbly ly 0 8 kg y r and nut olding tool n flywheel t Nm an onto flyw m d oil pum erator Assy 9 03 s remove th p on the oil e out the oi C ATV 50 p base on h the crank f m...

Page 78: ...oil pump a teeth of the mage Repla soap base pump driv Pin an erse way o Make sur C ATV 50 n the teeth if W assy if e oil pump d ace it if grease on ve driven nd oil pump of disassem re the gear 0 100...

Page 79: ...rate tool f he tool but llel with the oosen one he tool clockwise a aft then se nkcase W hammer to r crankcase above to rankcase rankshaft es and thic A 37 90 0 03mm end side y F 0 4 lace with n check...

Page 80: ...nd while tur alling tool w t installing ly bottoms utside of L oil seal on e base greas nd seal driv C ATV 50 ft and to ea e the oil se with engin ng tool to t kcase hole p dead cen rning the n with t...

Page 81: ...aft Installin the R cran crankcase nkcase ase holdin m aft operati e the repair apply greas oil seal topper plat m Reed valve m C ATV 50 mount spa to the ma ng tool to t nkcase hole e onto g screws on...

Page 82: ...NO OTE SMC C ATV 50 0 100 S Chapt Service M ter 9 A C G Manual Generator Oil Pump C 7 Crankshaft 78 t All manuals and user guides at all guides com...

Page 83: ...m ntenance uble Diag nsmissio nsmissio ring Rep nsmissio chanism SMC e Notice gnosis n Disass n Inspec lacemen n Reass Diagram C ATV 50 sembly ction nt embly m 0 100 S Service M 79 80 80 81 82 83 83 M...

Page 84: ...r seat ve axle cov ols er ing driver and oil seal puller g puller uble Dia n be starte ed drive ge ut drive gea ed gear sh r burnt gea ear aks ve gear oil r damage o SMC e Notice disassembl ponents be...

Page 85: ...he flange n ear shift ca he 11 screw cover and t on case co he gasket a e SMC n Disasse er removal olt on the b and then dr out the oil meter gea ase cover b e bolt wash ring steel b nut and gea am a...

Page 86: ...t drive gear xle assemb der and id ometer ge e bolt from idle gear p mage n Gear In of main ax the dog cl ansmission k if smooth haft shift f C ATV 50 l ve axle fin ear shift ca top of bly and shif dl...

Page 87: ...seal remo earing rem o replace th allation o gear shift primary dr main axle ork with do SMC e Trans ge bolt on rive axle co l seal if oil on the left over turn a ugh feeling on the drive ng or dama r...

Page 88: ...gf m 12Nm drive axle h bolts gf m 12N gear shiftin gear shift le nd then tig gear box o bolt 0 3 SMC cam with ge dowel pin o e shaft wit ion gear co m cover with Nm ng lever an ever for F N hten the b...

Page 89: ...NO OTE SMC C ATV 50 0 100 S Service M Manual Chapter 10 0 Transmis ssion Gears 85 s All manuals and user guides at all guides com...

Page 90: ...All manuals and user guides at all guides com...

Page 91: ...All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 92: ...All manuals and user guides at all guides com...

Page 93: ...All manuals and user guides at all guides com...

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