SMC Networks ATV100 Service Manual Download Page 42

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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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