Rato RT150ST-A Service Manual Download

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RT150ST-A SERVICE MANUAL

Chongqing Rato Power Co., Ltd.

RT150ST-A

维修手册

重庆润通动力有限公司

Summary of Contents for RT150ST-A

Page 1: ...RT150ST A SERVICE MANUAL Chongqing Rato Power Co Ltd RT150ST A...

Page 2: ...ntry vehicle If you don t have this knowledge when repairing cross country vehicle the condition of improper assembling and danger occurs after assembling are easily happened Proper operation and main...

Page 3: ...9 III ATV body 10 Section 6 Wiring diagram of ATV 11 Section 7 Requirements for torque of fastener 12 Section 8 Lubrication 13 I General torque specification 13 Section 9 Lubrication point and type o...

Page 4: ...ght lamp 31 Section 5 Maintainace and Adjustment of Engine 33 I Clean of air filter 33 II Inspection of spark plug 34 III Adjustment of idle speed 35 IV Adjusting ment of free clearance of throttle gr...

Page 5: ...r and Rear wheel fork 65 Chapter IV Electric Appliance 66 Section 1 Inspect switch 66 Section 2 Troubleshooting the ignition system failure 67 Section 3 Running of starting circuit 71 Section 4 Troubl...

Page 6: ...lencer 6 Rear fender 7 Front fender 8 Bumper 9 Left lever of rear brake 10 Left switch unit 11 Fuel tank cover 12 Throttle grip 13 Right lever of front brake Caution The ATV you purchased maybe slight...

Page 7: ...d for removing and assembling rotator of kick starter 6 Puller for crank mainly used for disassembling crank from crankcase 7 Puller for rocker shaft mainly used for removing rocker shaft 8 Compressin...

Page 8: ...ng instruments and meters can be selected with reference to the same type of vehicle speedometer of engine multimeter Ignition timing meter spark tester of spark plug barometer ignition checker measur...

Page 9: ...other mated components by normal running in together When assembling or replacing these components they should be in pairs 1 5 When disassembling the engine clean all the components and put in the tra...

Page 10: ...to replace all the locking washer shim and location pin After bolt or nut is fixed on the locking position be sure to bend and fix both ends of locking shim along head of bolt or di rection of nut 6...

Page 11: ...oosening bolt of terminal of big capacity battery don t let the wrench contact with en gine or other metal parts of vehicle body to avoid the electric shock 7 4 When connecting the wire of battery fir...

Page 12: ...inserting the joint it should be fixed then put in plastic coating after inserting In general multi head connector is plastic one and locking catch is designed When disas sembling the connector first...

Page 13: ...it liter lit liter kg mm kg cm2 Centigrade 7 233 86 794 0 0723 0 8679 2 205 0 03527 0 6214 0 6214 3 281 1 094 0 3937 0 3937 0 03527 0 06102 0 8799 0 2199 55 997 14 2234 9 5 32 ft lb in lb ft lb in lb...

Page 14: ...of spark plug C7HSA NGK Clearance of spark plug 0 6 0 7mm Type of clutch automatic Output Primary reduction system CVT Secondary reduction system Chain drive Output type Frame Bracket steel tube Cast...

Page 15: ...Size of tire Radial runout of rim Lateral swing of rim Type Type Material of rim Size of tire Radial runout of rim Lateral swing of rim Type Free play of brake lever left Free play of brake lever rig...

Page 16: ...11 Section 6 Electrical diagram of ATV...

Page 17: ...tandard Association In order to avoid the twist or unbalancing phe nomenon when locking screw please cross lock or londuit as per appointed orders When measuring torque force standard torque force tes...

Page 18: ...ation Pressure Splashing oil Standard Item Piston cylinder Piston pin Connecting rod Valve Automatic centrifugal clutch Crank Camshaft Rocker Bearing Sprocket chamber Branch valve Fine filter Spindle...

Page 19: ...hole Throttle rotating frame shaft and end section of throttle cable Connection bolt of rear wheel fork and frame rear wheel fork bearing Rubber sleeve and rear wheel fork Rear shock absorber bushing...

Page 20: ...rease Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lu...

Page 21: ...just it if necessary Check it there is crack or damage in gas tube Replace it if necessary Check the leakage Tighten it again if necessary Replace the gasket if necessary Clean Check the cracks or dam...

Page 22: ...f cushion By that you can disassemble the cushion 2 Installation Firstly insert the support lug on the front end of cushion into the spigot of frame then press down the rear part Pay attention to conf...

Page 23: ...istly 4 Take out the battery 5 Disassemble the rear fender 2 Installation Operate according to reverse procedure of Disassembly Pay attention to following points 1 Install Rear fender 2 Install Batter...

Page 24: ...nt fender 1 Disassembly 1 Place the vehicle on the horizontal ground 2 Disassembly the front carrier 3 Disassembly the bumper protective plate and bumper 4 Disassembly the front panel 5 Take off bolt...

Page 25: ...e Caution Place a cloth on the engine to absorb the splashed gasoline Warning The gasoline is inflammable Avoid to splash it on the hot engine 7 Remove the fuel tank 2 Installation Operate according t...

Page 26: ...ake the vehicle 2 Check Check the disk friction pad to see if it reaches the life span replace it whenever necessary II Adjustment of front brake Before adjusting check the wear degree of front brake...

Page 27: ...he tension of front brake cable Pick up the front wheel from ground and rotate the two front wheels and ensure the two front brake s brake force Rotate the adjusting screw clockwise or counterclockwis...

Page 28: ...otate the steering bar leftward and or rightward then roate from left to right lightly If the ball pin unit of steering tension rod have any vertical clearance replace it 4 Raise up the front end of t...

Page 29: ...left right tension rod Loosen the locking nuts at the end of left right tension rod Left right tension rods should turn the same turns left or right up to obtain in the specified toe in and make the...

Page 30: ...d replace it 3 Inspection Operation Shock the fornt rear shock absorbers up and down two times If it is not active in operation replace the component V Adjustment of rear shock absorber Adjustment of...

Page 31: ...Tire pressure 1 Recommended tire pressure 2 Front 20Kpa 0 20kg f cm 2 Rear 25Kpa 0 25kg f cm 2 The overlow tire pressure will cause the tire came out of the rim in bad driving condition The Min tire...

Page 32: ...in the tire pressure manoeter the readig of the meter will be not correct at the moment the second measurement should be conducted and the second measurment reading should be adpoted Uneven and Improp...

Page 33: ...can produce explosive gas so follow the following protection measures a Be sure to keep the ventilation when changing the battery b Keep it away from spark flame such as welding equipment burning cig...

Page 34: ...ctrode 7 Installment a Battery clamp plate b Cushion II Inspection of fuse Closet the main switch when checking or replacing the fuse otherwise it will cause the short circuit 1 Inspection steps Remov...

Page 35: ...s is not allowed to approach the lamp which is on and the lamp is very hot never touch it before cooling 6 installment Lamp new Be sure that the projective part on the lamp is engaged with the convex...

Page 36: ...side of the headlight with hand 5 Remvoal Lamp The inflammables is not allowed to approach the lamp which is on and the lamp is very hot never touch it before cooling 6 Installment Lamp new Headlight...

Page 37: ...the lamp is engaged with the comex groove on the light seat 8 Install the lens to the light seat 9 Installment Headlight Caution Install the rubber hole guard ring of the headlight connecting wire co...

Page 38: ...components Never start the engine without filter otherwise the piston and cylinder will be overworn 4 Inspection a Air filter core If damaged replace it 5 Clean of the foam filter core a Clean with no...

Page 39: ...g the engine 2 Remove the spark plug 3 Inspection of spark plug a Electrode Wear damaged replace b Insulator color Brown or light brown in normal condition If the color is clearly different check the...

Page 40: ...he free clearance of throttle grip is within 3 5mm otherwise readjust the idle speed IV Adjustment of free clearance of throttle grip First adjust the engine idle speed when adjusting throttle grip 1...

Page 41: ...t with improvement of driving skill never remove the adjusting screw of speed limitator b For the correct throttle grip operation never screw out the adjuster to exceed 12mm and adjust the free cleara...

Page 42: ...rod c Turn the adjusting screw by clockwise with valve adjusting spanner until the right clearance is gotten to Size of valve adjusting spanner 3mm code d Fix the adjusting screw to avoid turning and...

Page 43: ...ng of compressive force Inadequate compressive force will reduce the engine performance Before measuring compressive force Valve clearance should be adjusted first refer to Adjustment of valve clearan...

Page 44: ...ton ring throttle cylinderhead washer maybe be damaged Check if the cylinder head throttle surface or piston top end are carbon laydown Warning 39 d If the pressure is lower than the min value i Drop...

Page 45: ...SE CC SFSE SD etc X Replacement of engine oil and inspection of oil flow Engine oil can be used to lubricate clutch but don t use any chemical additive in machine oil because the additive can lead to...

Page 46: ...ilter cap with Oring rough filter and draining plug Before installing the draining plug mount Oring compress spring and fine filter and be ensure that their mounting order must be correct Mounting tor...

Page 47: ...Wear limit value of friction wafer Wear limit value of front brake hub Standard value Min value Max value Radia run out End face run act 42 I Disassembly 1 Pay attention to following points when disas...

Page 48: ...usting nut pin spring circlip spring and circlip 5 Remove the front brake cable and front brake air pipe 6 Disassemble brake shoe assy and front cover assy 7 Disasssemble Front brake arm Wear indicati...

Page 49: ...d Rim run out limit Radial run out 2 0mm in figure End face run out 2 0mm in figure 3 Check Tire surface If worn or damaged replace it Refer to Tire inspection of chapter2 Install the tire according t...

Page 50: ...e the brake shoe in set including brake shoe spring 6 Check Brake shoe tension spring If worn or damaged replace it 7 Measure Inner diameter of front brake hub as shown in figure If it does not confor...

Page 51: ...he oil seal with plain screwdriver place a cloth on the outer edge of oil seal to avoid damage D i s a s s e m b l e t h e b e a r i n g w i t h corresponding tool Assemble new bearing and oil seal ac...

Page 52: ...III Installation procedure The installation procedure is the riversal of Disassembly But pay attention to following points 1 Lubrication as shown in figure Dust proof seal Bearing Cam shaft Rotating p...

Page 53: ...ke cable with brake cover 6 Install as shown in figure Circlip Spring Circlip Spring Pin Adjusting nut 7 Install as shown in figure Front brake hub Gakset O ring Washer Slotted nut torque 70N m 8 Inst...

Page 54: ...55N m The rotation direction of front wheel A is the arrow direction marked on the tire 10 Adjustment Free clearance of front brake cable Refer to the Adjustment of front brake section fo chapter Two...

Page 55: ...e frame so as to lift the rear wheel and make the rear wheel leave the earth In order avoid the parts falling which will acuse danger during romoval process rest the vehcile firmly 3 Removal 1 Connect...

Page 56: ...thread and gear groure from damage do nut beat the rear wheel axle directly with hammer II Inspection steps 1 Inspection rear wheel 2 Measurement a Radial runout of rim b Tire surface 3 Inspection Rea...

Page 57: ...forcefully 7 Check 1 Rear brake suppont 2 If there is any crack or friction in the suppent replace it 8 Inspection 1 Bearing Rotate the rear wheel axle if the axle shakes left and right in the bearing...

Page 58: ...oval steps of steering bar 1 Removal Handle bar decration cover 2 Removal Front brake cable Remvoal Throttle grip assy 3 Removal After stopping the vehicle remove the rear brake assembly 4 Removal Ste...

Page 59: ...Removal Split pin Nut Tension rod When removing the tension rod end and steering ball pin from the steering vertical column welding assy and front seat assy of front brake with common bearing tension...

Page 60: ...spection Steering vertical column holder and seal ring If they are worn or damaged replace it 4 Inspection If the tension rod is bent or damaged If they are replace them 5 Correcting The displacement...

Page 61: ...n to the steering vertical column welding assy Connect D position to the front seat assy the front brake The connection nut A B can be tightened up only when the revealed thread length of two ends of...

Page 62: ...tion Never damage the seal ring when installing 4 Installment When installing the steering vertical column holder and steering vertical cotumn welding take them as unit In order to ensure the correct...

Page 63: ...new split pin 8 Tighting After mounting the washer nut split pin under the steering vertical column Nut torque 30Nm 9 Install Clip locking washer bolt Attached bolt torque 23Nm Always use new locking...

Page 64: ...20Nm 2 Install the throttle grip unit The projection of throttle grip must correspond to the sunken part on the right lever seat when installation Correct installation of cable and wire is very neces...

Page 65: ...n nut on the left right front seat assy and left right front seat assy 6 Check the free clearance of left right front wheel fork Inspection step a Check the parts of let right front wheel fork on the...

Page 66: ...s leakage replace it Check the universal joint If it is crack or damaged replace the front shock absorber Check spring if it is fatigue or damage r e p l a c e t h e f r o n t s h o c k a b s o r b e...

Page 67: ...pposit steps of Disassembly is the mounting steps The following must be paid attention when mounting 1 Lubricate the inner surface of bushing subassembly Lubrication oil is lithium base grease 2 Fix n...

Page 68: ...Mount Front shock absrober front shock absorber nut bolt under the front shock absorber Before fixing the front shock absorber nut Must ensuring the side plane of universal joint is limited by frame...

Page 69: ...t correct it by fixing the nut Must use new split pin 9 Mount front brake cap assy brake shoe assy front brake hub and front wheel Refer to installation of front wheel and front brake of this chapter...

Page 70: ...eakage if any replace it b If rear shock absorber is bent or damaged if any replace it c Pull the spring up and down to check if the spring fatiguer or damaged if any replace rear shock absorber 3 Tak...

Page 71: ...en inspecting the circuit Should turn on and off the switch many times when inspecting The manual explains how to inspect the switch The left figure indicate the wire end position of switch The vetica...

Page 72: ...value of charge coil 9 Circuit connection whole ignition system Remove following components before troubleshooting 1 Cushion 2 Front frame 3 Front fender Remark Power spark tester Ignition tester Poc...

Page 73: ...rance 0 6mm 0 24in Not conforming to specification or no spark Conforming to specification Ignition system has no problem conforming to specification Inspect if the resistance of spark plug conform to...

Page 74: ...alue of triggering coil Remove CDI magneto connector from clabe Connect the multitester 100 to wire end of triggering coil Multitester pen blue wire end Multitester pen blue wire end Inspect if the re...

Page 75: ...ge coil Multitester pen yellow green wire end Multitester pen yellow green wire end Coil resistance value At 20 68 F 450 550 Inspect if the resistance value conform to speci fication Not conforming to...

Page 76: ...switch Rear brake switch Neutral switch A To main switch B From main switch When the vehicle is in driving or reverse start and the rear brake is in idle start then the cut off relay will prevent sta...

Page 77: ...more 3 Starting motor Connect positive terminal of battery with cable fo starting motor by wire Inspect the running condition of starting motor Pocket multimeter No electrification Clean the battey t...

Page 78: ...ect if the power off relay is on The circuit is on 5 Starting relay Remove the connector of starting relay from cable Connect the multimeter 1 and battery 12V to terminal of power off relay Battery wi...

Page 79: ...Connect the whole starting system correctly Incorrect Incorrect Incorrect Incorrect Incorrect Correct Correct Correct Correct 7 Neutral switch 6 Main switch 8 Rear brake switch 9 Starting switch 10 C...

Page 80: ...0 028 in Remark Scrap the mica with square scraper to get proper dimension fit the reverser 4 Check Armature winding insolation power on Failure Replce starting motor Check procedure of armature wind...

Page 81: ...eplace whole device Length of brush 10mm 0 39 inches Range of wear 6mm 0 14 inches Brushing spring force 326 970g 3 2 3 8N 7 Check Oil sealing Bushing O ring Wear damage repalce it Installation of sta...

Page 82: ...itch 2 Battery Check battery condition Correct Pass 3 Charging voltage Connect engine techometer to the wire of spark plug Connect pocket tester DC20V to the battery Pocket multimeter White terminal P...

Page 83: ...White terminal Pocket multimeter White terminal Pocket multimeter White terminal Pocket multimeter White terminal Measure the resistance value of startor coil At 20 68 F 11 10 1 50 Meet specification...

Page 84: ...entire lighting system Pocket multimeter P N YU 03112 1 Safety Refer to Inspection of switch Pass 2 Battery Check the battery condition Voltage of open circuit Correct No electrification Replace fuse...

Page 85: ...switch is failure replace the switch of handle left Poor coupling Connect whole lighting system correctly 5 Coupling of wires Check the wire compling or whole lighting sys tem Correct Check the return...

Page 86: ...aillamp Multimeter blue terminal Multimeter black terminal Meet specification Adjust main switch to ON postion Adjust lamp switch to ON postion Check the voltage of blue wire in coupler of bulb socket...

Page 87: ...rrier Bumper 2 Remvoe Front panel Front fender Rear fender Right left main footrest 3 Oil draining Screw out oil draining screw plug Drain off the lubricating oil of the engine from the oil draining h...

Page 88: ...the gasoline of the carburetor float cabinet firstly Wrap the overflow pipe with cloth to absorb the splashed gasoline The gasoline is inflammable Pay attention not to splash the gasoline on hot engin...

Page 89: ...11 Disassembly of engine Remove the engine unit from lift side 9 Dismantle the engine connecting plate 10 Dismantle the driving sprocket II Disassembly of engine 84...

Page 90: ...1 Remove Cylinder head cover 2 Remove bolt shroud assy 3 Remove Spark plug 85...

Page 91: ...5 Remove Camshaft holder 4 Remove pipe comp inlet 6 Remove Bolt Camshaft assy 86...

Page 92: ...87 7 Remove Cylinder head Cylinder head gasket Location pin Oil seal Lower guide plate exhaust side 8 Remove Bolt Chain tensioner Gasket 9 Remove Cylinder body assy Location pin...

Page 93: ...10 Remove Circlip Piston pin Piston unit 11 Remove Motor unit start 12 Remove Left crankcase cover Gasket Pin 13 Remove Pulley set driven 88...

Page 94: ...14 Remove Pulley set drive 16 Remove Bolt Cover assy fan 15 Remove Transmission Belt 17 Remove Bolt Fan comp cooling 89...

Page 95: ...18 Remove Nut Fly wheel comp Stator comp 19 Remove Bolt Cover right crank case Gasket 20 Remove Bolt Crank case comp Right 21 Remove Shaft comp crank 90...

Page 96: ...22 Remove Bolt Cover mission Gear Shaft drive Shaft comp counter Gear find Circlip 91...

Page 97: ...ess of cylinder cover bottom face Recorrect the bottom face or replace if unqualified Flatness of cylinder bottom face is less than 0 10mm 0 004in 2 Intake and exhaust valve 1 Check Valve surface Valv...

Page 98: ...en valve rod and valve guide pipe Limit 0 010 0 037mm 0 004 0 0015 in 0 025 0 052mm 0 0010 0 0020 in 0 08mm 0 0031 in 0 10mm 0 0039 in When replacing the valve should replace the valve guide pipe and...

Page 99: ...d the valve race after installing valve guide pipe 4 Valve race 1 Clean Carbon deposit valve raue and value face 2 Check Valve seat ring Regrind the valve if it is exfoliation corroded 3 Measure Conta...

Page 100: ...tacting width is too wide If the contacting width is too wide too nar row or not in the middle it is necessary to recorrect valve race 4 Correct Valve race Use reamers of 30 45 and60 Rotate the reamer...

Page 101: ...uide pipe Grinding procedure of valve face Paint a layer of grinding powder Ensure no grinding power entering the clear ance between the valve and valve guide pipe Caution Caution Reamer assy of valve...

Page 102: ...irty on the valve face and valve race after every grinding 6 Measure the contacting width again after correcting and grinding Meassure the contacting width and position of valve and valve race again a...

Page 103: ...r part Oil seal of valve rod Valve Inner spring of valve Outer spring of valve Spring cover of valve Locking clip of valve Installing pressure of valve spring Inner spring intake exhaust When it is 30...

Page 104: ...y respectively Check the valve seal There should be no leak age on valve race 3 Regrinding procedure Remove components of the cylinder cover again Grind repeatedly with fine grinding powder Clean tota...

Page 105: ...Measure inner diameter of valve rocker hole Replace it if unqualified Outer diameter of rocker 11 985 11 991mm 0 4718 0 4721 in Measure the outer diameter of rocker shaft Replace it if unqualified In...

Page 106: ...uide plate intake side Replace it if it is worn or damaged Substract the outer diameter of rocker shaft from inner diameter of valve rocker hole to calculate the clearance Clearance between rocker hol...

Page 107: ...diameter gauge is the measuring position Remark Measure twice the inner diameter C of cyl inder from two directions vertical with each other in the same face Then find out average value 2 Check Flexi...

Page 108: ...cylinder and replace the piston and piston ring as a set at the same time 14 Piston ring and piston pin Piston ring 1 Measure Clearance between piston ring and ring groove Use feeler gauge If out of s...

Page 109: ...sed clearance of scraping place of oil ring assy if the clearance of scraping plate is bigger replace a set of oil ring Caution 0 03 0 07mm 0 12mm 0 001 0 003 in 0 005 in 0 02 0 06mm 0 12mm ring 0 008...

Page 110: ...fication replace it 3 Measurement Inner diameter of piston pin Out of specification replace it 4 Measurement Clearance between piston pin and piston pin hloe Clearance between piston pin and piston pi...

Page 111: ...out of specificaition replace it or repair it Runout amount of big head of connecting rod 0 010 0 025mm 0 0004 0 0010 in 2 Inspection Crankshaft bearing If there is some noise or not active in opera t...

Page 112: ...should be with in 1mm 0 04 in 16 Drive belt Check if the transmission belt worn or not and replace it whenever necessany 17 Shaft drive To check if the gears on the shaft worn or has any erack not an...

Page 113: ...place it 2 Inspection Oil seal If damaged or worn replace it 21 Circlip and washer Inspection Circlip Washer If damaged loose bent replace it 22 Crankcase 1 Clean crankcase with soft agent completely...

Page 114: ...arting plug 4 Air filter Core of air filter is clogged 2 Electric system 1 Spark plug Improper spark plug clearance standard clearance is 0 6 0 7mm Terminal is worn Spark plug is polluted wrong spark...

Page 115: ...dle and high speed performance Refer to starting trouble difficulty and poor idle speed performance section in this chapter 1 Carburetor Wrong needle valve position Main jet is clogged or loosened Fue...

Page 116: ...d oil VII Engine is overheat 1 Ignition system Improper spark plug clearance Wrong spark plug heating value CDI failure 2 Fuel system Main jet of carburetor is wrong Improper oil level Core of air fil...

Page 117: ...t rear wheel is too big 5 Frame Bend Damaged frame 6 Rear wheel fork Bearing or bushing is worn Rear wheel fork is bent or damaged X Lighting system 1 Head light is out of work buld is trouble Too big...

Page 118: ...Our group reserve the right to change structure dimension and parameter of the vehicle s parts without additional notice...

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