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3. ENGINE REMOVE AND INSTALLATION

3-1 General Information 3-3 Engine Installation
3-2 Engine Removal

3.1 General Information

ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR
ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY

3-2 Engine Removal

Before removing engine, you need to remove all of components such as seat, front and back fender,

fuel tube, exhaust pipe, carburetor cable and drive chain…etc. You can then see three hanger bolts which have

screwed on engine.

Loosen these three hanger bolts. You have succeeded to remove this engine.

There are some pictures to describe main step of removing engine.

Disconnect the wire connectors. There are three connectors for

carburetor auto-choke, starter motor and generator respectively.

Remove the drive chain cover.

Remove the drive chain retaining clip and master link,

and remove the drive chain.

Hanger bolt

Содержание ATV8F - SERVICE

Страница 1: ...1 VECTOR 300 Service Manual...

Страница 2: ...res 2 12 Steering Shaft Holder Bushing 2 13 Toe In 3 ENGINE REMOVE AND INSTALLATION 3 1 General Information 3 2 Engine Removal 3 3 Engine Installation 4 LUBRICATION SYSTEM 4 1 Mechanism Diagram 4 2 Pr...

Страница 3: ...SYSTEM 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 9 FINALDRIVING MECHANISM 9 1 Mecha...

Страница 4: ...ostat 13 STEERING AND SUSPENSION 13 1 Parts Drawing 13 2 Troubleshooting 13 3 Handlebar 13 4 Throttle Housing 13 5 Steering System 14 FRONT WHEEL AND BRAKE SYSTEM 14 1 Parts Drawing 14 2 Troubleshooti...

Страница 5: ...g 17 4 Battery Information 17 5 Electric Starter 17 6 Light Bulbs Replacement 17 7 Instrument Pane 18 TROUBLESHOOTING 18 1 Engine Can Not Work 18 2 Poor Performance At Low And Idle Speeds 18 3 Poor Pe...

Страница 6: ...er and call a doctor if electrolyte gets in your eyes HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these...

Страница 7: ...n Transmission Automatic C V T V belt Reverse CHASSIS Overall Length 1815mm Overall Width 1062mm Overall Height 1130mm Wheel base 1193mm Ground Clearance 150mm Dry Weight 225Kg Fuel Tank Capacity 12L...

Страница 8: ...8 1 4 Serial Number The frame serial number is stamped on the front of the frame The engine serial number is stamped on the left side of the crankcase Frame serial number...

Страница 9: ...n nut 40 N m 29 lbf ft Handlebar lower holder nut 40 N m 29 5 lbf ft Front wheel bolt 24 N m 17 7 lbf ft Front axle castle nut 40 60 N m 30 45 lbf ft Front brake arm nut 4 N m 3 0 lbf ft Rear brake ar...

Страница 10: ...1 6 Special Tools For Frame 1 Adjustable Hook Spencer E1105 LRA0 FT1 Purpose Adjusting of suspension 2 Ball Joint Puller E0205 LRA0 FT1 Purpose Taking out the ball joint from front knuckle as repairi...

Страница 11: ...1 For Engine 1 TACKING ACG FLY WHEEL TOOL C1110 RB1 FT1 2 COUNTER SHIFT IMPLEMENT I1003 RB1 FT1 3 ADJUST TAPPET IMPLEMENT A4721 HMA FT1 4 SLEEVE OF FABRICATING TRANSMISSION SHAFT OIL SEAL I1202 RB1 FT...

Страница 12: ...12 5 SLEEVE OF FABRICATING L CRANK OIL SEAL I1201 HMA FT1 6 TAKING 6205 BRG TOOL I6150 6205 FT1 7 6205 BRG KNOCK TOOL I6150 6205 FT2 8 L CRANK CASE COVER 6006 BRG FABRICATING TOOL I6150 6006 FT1...

Страница 13: ...13 9 FABRICATING R CRANK CASE COVER 6201 BRG TOOL I6140 6201 FT1 10 TAKING BRG RB1 TOOL I6150 RB1 FT1 11 PNEUMATIC TAKING BRG 6205 TOOL I6150 6205 FT3 12 TAKING TAPPET PIN TOOL A4451 HMA FT1...

Страница 14: ...13 ASSEMBLING DRIVE SHAFT TOOL B3411 RB1 FT1 14 TAKING TRANSMISSION SHAFT BRG 6305 TOOL I6100 6305 FT1 15 KNOCKING BRG 6901 WATER PUMP IMPLEMENT I1001 KJ9 FT1 14...

Страница 15: ...ATER PUMP OIL SEAL IMPLEMENT INSIDE I1205 KF0 FT1 17 KNOCKING WATER PUMP OIL SEAL IRON IMPLEMENT A9217 H9A FT1 18 TAKING LOCKING SPECIAL NUT 36MM SLEEVE I0202 HMA FT1 19 TAKING FABRICATING IN VALVE TO...

Страница 16: ...16 20 TAKING BRG 62040 LARGE SIZE TOOL I6100 6204 FT3 21 ALL PURPOSE FIXER B2101 HMA FT1 22 KNOCKING BRG 6204 IMPLEMENT I6100 6204 FT2...

Страница 17: ...1 Maintenance Data SPECIFICATION SPARK PLUG SPARK PLUG GAP 0 8 mm RECOMMENDED SPARK PLUGS NGK CR8E THROTTLE LEVER FREE PLAY 5 10 mm IDLE SPEED 1700 100 rpm BRAKE LEVER FREE PLAY 15 25 mm DRIVE CHAIN S...

Страница 18: ...th Brake Shoes I Brake System I I Brake Fluid I R Nuts Bolts Fasteners I WHEEL TIRES I I Wheels I I Steering System I I Suspension System I I C V T Drive belt I R Transmission Oil R Replace for every...

Страница 19: ...play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttle lever 2 6 Air Cleaner Please remove the four hooks and then disassemble two screws ins...

Страница 20: ...se will get lower speed IDLE SPEED 1700 100 rpm 2 9 Drive Chain Stopping the ATV and shift the transmission into neutral N Measure the drive chain slack midway between the sprockets Chain slack 15 25m...

Страница 21: ...he parking brake which has been decreased its brake ability you might screw the adjustable nut to modify the clearance of brake shoe to the correct position Also another method of adjustment of parkin...

Страница 22: ...the small clearance between brake disk and lining Loosen the adjustable nut near the rear brake caliper Screw the adjustable bolt by hand with C W turn to the end then back to a quarter turn Tighten t...

Страница 23: ...ange a new one Grease the steering shaft bushing and install the parts in the reverse order of removal Torque steering shaft holder bolt 33 N m 24 lbf ft 2 13 Toe In Keep the vehicle on level ground a...

Страница 24: ...24 If the toe in is out of standard adjust it by changing the length of the tie rods equally by turning the tie rod while holding the ball joint Tighten the lock nuts Torque 35 43 N m Lock Nuts...

Страница 25: ...s seat front and back fender fuel tube exhaust pipe carburetor cable and drive chain etc You can then see three hanger bolts which have screwed on engine Loosen these three hanger bolts You have succe...

Страница 26: ...26 3 3 Engine Installation The Engine installation is essentially in the reverse order of removal The torque of engine hanger bolt is 30 N m Route the wires and cable in reverse order properly...

Страница 27: ...roubleshooting 4 4 Engine Oil 4 5 Engine Oil Strainer Clean 4 6 Oil Pump 4 7 Gear Oil 4 1 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In...

Страница 28: ...0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 5 3 0kgf m Engine oil drain...

Страница 29: ...fter drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m 4 5 Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check...

Страница 30: ...p and take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oi...

Страница 31: ...and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving s...

Страница 32: ...nd then tighten screws Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install sta...

Страница 33: ...drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Start...

Страница 34: ...ouble Diagnosis 5 4 Carburetor Remove Install 5 5 Air Cut Off Valve 5 6 Throttle Valve 5 7 Float Chamber 5 8 Adjustment Of Idle Speed 5 9 Fuel Tank 5 10 Air Cleaner 5 1 Mechanism Diagram Carburetor Fu...

Страница 35: ...y When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly y There is a drain screw in the float chamber for draining residual gasoline y Do not disass...

Страница 36: ...function of carburetor y Dirty fuel Intermittently misfire as acceleration y Malfunction of ignition system Late ignition timing y Malfunction of ignition system y Malfunction of carburetor Power insu...

Страница 37: ...e the choke cable Disconnect the fuel hose Release the clamp strip of air cleaner Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the c...

Страница 38: ...e Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assemb...

Страница 39: ...ttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into t...

Страница 40: ...ve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt Caution In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel...

Страница 41: ...air adjustment screw Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking fuel level Caution y Check a...

Страница 42: ...Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle valve stopper screw and let engi...

Страница 43: ...unit installation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fue...

Страница 44: ...emove the air cleaner cover 4 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or hi...

Страница 45: ...der Head Inspection 6 6 Valve Stem Replacement 6 7 Valve Seat Inspection And Service 6 8 Cylinder Head Reassembly 6 9 Cylinder Head Installation 6 10 Valve Clearance Adjustment 6 1 Mechanism Diagram 0...

Страница 46: ...12 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Intake 38 700 35 200 Free length of valve spring Exhaust 40 400 36 900 Valve seat width 3 400 4 000 I...

Страница 47: ...r valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure...

Страница 48: ...Remove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove spark plug Remove...

Страница 49: ...then remove the sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller Remove cam shafts Spec...

Страница 50: ...nd cylinder head y Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution y I...

Страница 51: ...ead Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 5 mm Camshaft Inspect cam lobe height for damaged Serv...

Страница 52: ...m Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valv...

Страница 53: ...e between the valve stem and valve guide Service Limit IN 0 08 mm EX 0 10 mm Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only re...

Страница 54: ...When pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side...

Страница 55: ...e seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limit 1 6mm Check the con...

Страница 56: ...e seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve s...

Страница 57: ...emove assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spr...

Страница 58: ...nd cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head...

Страница 59: ...rocket mounting bolts Caution Make sure timing marks are matched Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and spring In...

Страница 60: ...0 2 0kgf m Caution This model is equipped with more precision 4 valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation engine nois...

Страница 61: ...t piston is placed at TDC position in compression stroke Caution Do not turn the bolt in C C W direction to prevent from camshaft bolt looseness Valve clearance inspection and adjustment Check adjust...

Страница 62: ...s 0 8 1 2kgf m 1 0 1 4kgf m 7 CYLINDER PISTON 7 1 Mechanism Diagram 7 2 Precautions In Operation 7 3 Trouble Diagnosis 7 4 Cylinder And Piston Removal 7 5 Piston Ring Installation 7 6 Piston Installat...

Страница 63: ...0 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod small end 17 016 17...

Страница 64: ...cylinder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be...

Страница 65: ...ton rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of...

Страница 66: ...ter of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance...

Страница 67: ...e the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that all piston...

Страница 68: ...allation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution y Do not let the opening of piston pin clip align with t...

Страница 69: ...aken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install c...

Страница 70: ...M 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 8 1 Mechanism Diagram 5 0 6 0kgf m 5 0 6...

Страница 71: ...40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive pl...

Страница 72: ...bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Dowel pins Clamp strips 10 bolts Left cover plate Ratchet cover Dowel...

Страница 73: ...smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Remove the bearing 6006 with inner be...

Страница 74: ...Disassembly Remove 5 screws from l cover plate and remove l cover plate Remove 1 bolt from ratchet cover Remove 2 starter ratchets and 2 ratchet springs 5 screws 1 bolt...

Страница 75: ...ing from the l crank cover then its has to be replaced Loosen the starter rope from the starter grip Installation Install in reverse order of removal procedures Caution First before installing the dri...

Страница 76: ...belt into belt groove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven...

Страница 77: ...e shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque va...

Страница 78: ...en remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft...

Страница 79: ...outer diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit S...

Страница 80: ...ulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution Make sure that two sides of pulley surfaces have to be free of...

Страница 81: ...ice tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and movable...

Страница 82: ...the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner bearing...

Страница 83: ...f necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block should not b...

Страница 84: ...of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution y Its sealing end should be forwa...

Страница 85: ...clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut...

Страница 86: ...Transmission Cover 9 2 Precautions In operation 9 3 Trouble Diagnosis 9 4 Disassembly Of Transmission 9 5 Inspection Of Mission Mechanism 9 6 Bearing Replacement 9 7 Re assembly Of Final Driving Mech...

Страница 87: ...r 6204 SYM 9110400 Bearing driver 6205LLU SYM 9100400 HMA Bearing driver 6305 SYM 9100400 RB1 Needle bearing driver HK2016 SYM 9100300 RB1 Drive shaft and oil seal driver SYM 9120200 HMA Drive shaft p...

Страница 88: ...n The socket bolt is provided with left turn thread Remove 2 bolts and then remove the drive sprocket fixing plate drive chain and drive sprocket Remove gear fill bolt Place an oil pan under the ATV a...

Страница 89: ...catch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft 9 bolts Shift drum fixed catch bolt Shift drum Shift spind...

Страница 90: ...pecial tool Shaft protector Remove gasket and dowel pin Caution y If non essential do not remove the drive shaft from the case upper side y If remove the drive shaft from the gear box then its bearing...

Страница 91: ...tion Of Mission Mechanism Check if the shift spindle is wear or damage Check if the shift drum is wear or damage Check if the shift fork and shaft is wear or damage Check if the counter shaft is wear...

Страница 92: ...earing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Caution y If r...

Страница 93: ...al Special tool Inner bearing puller Install new final shaft counter shaft and reverse shaft bearings into left crankcase Special tool Bearing driver 6204 Needle bearing driver HK2016 Install new driv...

Страница 94: ...tall bush Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the c...

Страница 95: ...all drive shaft bearing Special tool Bearing driver 6205 Universal bearing puller Install new oil seal and bearing driver into gear box cover inner side Install the universal bearing puller and bearin...

Страница 96: ...ter shaft reverse shaft and final shaft onto gear box Install shift drum shift fork and fork shaft onto gear box Install shift drum fixed catch ball spring and bolt onto gear box Oil seal Reverse shaf...

Страница 97: ...ll shift spindle Install dowel pins and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Install the shift spindle bracket drive chain protector speedometer gear box a...

Страница 98: ...10 3 Right Crankcase Cover Removal 10 4 A C G Set Removal 10 5 Right Cover Bearing 10 6 Flywheel Removal 10 7 Starting Clutch 10 8 Flywheel Installation 10 9 A C G Set Installation 10 10 Right Crankca...

Страница 99: ...of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 5 0 6 0kgf m S...

Страница 100: ...al Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set 10 5 Right Cover Bearing Inspection Rotate the bearing...

Страница 101: ...6201LU by bearing driver Special tool Bearing driver 10 6 Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with universal holder Remove flywhee...

Страница 102: ...g driven gear 10 7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch driven gear Service Limi...

Страница 103: ...ar The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting driven gear Remove 3 socket bolts and...

Страница 104: ...olt Torque value 1 0 1 4kgf m Install starting driven gear 10 8 Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face...

Страница 105: ...wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator 10 10 Right Crankcase Cover Installation Install dowel pin and new gasket Rem...

Страница 106: ...right crankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover 11 bolts Water pump cov...

Страница 107: ...Diagram 11 2 General Information 11 3 Trouble Diagnosis 11 4 Disassembly Of Crankcase 11 5 Crankshaft Inspection 11 6 Assembly Of Crankcase 11 1 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1...

Страница 108: ...ain of engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Specification Unit mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Ver...

Страница 109: ...ove the tensioner Loosen 2 bolts on the right crankcase Loosen 11 bolts on the left crankcase Place right crankcase downward and left crankcase up Tap the left crankcase with a plastic hammer to remov...

Страница 110: ...right crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue fo...

Страница 111: ...e crankshaft Service limit 0 10 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If an...

Страница 112: ...is uneven noising or loose bearing mounted then replace it Special tool Inner bearing puller Bearing driver 11 6 Assembly Of Crankcase Install wave washer into right crank bearing seat Install crank...

Страница 113: ...d new gasket Install the left crankcase onto the right crankcase Tighten 11 bolts on the left crankcase Torque value 0 8 1 2kgf m Tighten 2 bolts on the right crankcase Torque value 0 8 1 2kgf m Dowel...

Страница 114: ...kcase with care not to damage the lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Oil seal driver 27 42 7 Install the tensioner and tighten the pivot bolt...

Страница 115: ...2 4 Trouble Diagnosis For Cooling System 12 5 System Test 12 6 Radiator 12 7 Water Pump 12 8 Thermostat 12 1 Mechanism Diagram Radiator filler cap Radiator Reserve tank Thermo switch fan Coolant inlet...

Страница 116: ...850c c 420c c Thermostat Begins to activate at 82 95 Stroke 0 05 3mm Thermos switch fan Begins to activate at 98 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump rotor...

Страница 117: ...unit Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coola...

Страница 118: ...until the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then che...

Страница 119: ...etely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Reinstall...

Страница 120: ...vating in the cooling system the refrigerant backflow floods 12 6 Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow r...

Страница 121: ...r shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please refer to chapter 17 for th...

Страница 122: ...rms the replacement water pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain bolt t...

Страница 123: ...seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of t...

Страница 124: ...Special tools Water pump bearing driver 6901 Caution Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right...

Страница 125: ...ten Torque Value 1 0 1 4kgf m Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil...

Страница 126: ...he thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not cor...

Страница 127: ...13 STEERING AND SUSPENSION 13 1 Parts Drawing 13 2 Troubleshooting 13 3 Handlebar 13 4 Throttle Housing 13 5 Steering System 13 1 Parts Drawing Steering Handle bar...

Страница 128: ...Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment Loose front suspension fasteners Binding suspension link Faulty front...

Страница 129: ...le bar Remove rear brake lever bracket assembly Remove the handle cover and instrument panel by four screws at right and left side as shown in picture Remove the bolts attaching the handlebar upper ho...

Страница 130: ...ith the L or R marks facing forward Tighten the forward bolts first and then tighten the rear bolts Install the handlebar upper holder s cover Install the switch housing aligning the small dot of the...

Страница 131: ...rom the throttle arm and remove from the throttle housing NOTE Assembly is in the reverse order of disassembly 13 5 Steering System When the steering shaft needs to be repaired you need to remove thre...

Страница 132: ...ft holder bolt and remove steering shaft holder Take off the cotter pin below steering shaft Loosen the steering shaft fixed out below shaft Pull steering shaft carefully Step 2 Steering Shaft Holder...

Страница 133: ...Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 N m 37 lbf ft...

Страница 134: ...14 FRONT WHEEL AND BRAKE SYSTEM 14 1 Parts Drawing 14 2 Troubleshooting 14 3 Front Wheels 14 4 Hydraulic Brake 14 5 Suspension Adjustment 14 1 Parts Drawing FRONT WHEEL FRONT BEAKE...

Страница 135: ...orrectly Unequal tire pressure Incorrect wheel alignment Brake shoes worn Worn brake drum Brake linings oily greasy or dirty Improper brake adjustment 14 3 Front Wheels REMOVAL The disassemble of fron...

Страница 136: ...sher and wheels Please follow the next three steps of right pictures Loosen fours nuts as shown in picutre Then take the wheel out you can find two bolts fixed at front hydraulic disk component Loosen...

Страница 137: ...the power tools to take the screw out from brake stopping plate You can take the brake disc off When change brake shoe wear you must push the master piston to rearward After removal the front brake a...

Страница 138: ...AKE OIL The brake oil tank is under the driver seat at right hand side Please check the brake oil level position at outside of tank To open the cap of brake oil tank please turn CCW direction Brake oi...

Страница 139: ...ATV body up by using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner E1105 LRA0 FT1 to adjust the suspension How to use the Adjustable Hook...

Страница 140: ...R WHEEL AND BRAKE SYSTEM 15 1 Parts Drawing 15 2 Troubleshooting 15 3 Remove Rear Wheel And Rear Brake 15 4 Swingarm Rear Axle Holder 15 5 Suspension Adjustment 15 1 Parts Drawing REAR WHEEL REAR Whee...

Страница 141: ...REAR BRAKE...

Страница 142: ...arings are worn Faulty tires Rear axle bearing holder is faulty Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bus...

Страница 143: ...ove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE To replace the brake shoe please loosen this bolt as shown in picture Plea...

Страница 144: ...oil being drained out completely Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup in order to avoid air in the brake system Loosen the bolt to vent the air from brake system Ti...

Страница 145: ...lowing pictures are going to teach you how to Install the swing arm 1 Put the swingarm at proper position as shown in picture Two hanger bolts will be used to hold the swing arm at right and left side...

Страница 146: ...hten it Let the cross section of bolt and cross section of hole in the same plane nearly 4 Tighten the nut NOTE If you make a wrong assembly procedure it will cause 1 A damage of bearings 2 The main f...

Страница 147: ...using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner to adjust the suspension How to use the Adjustable Hook Spanner When you use the adjus...

Страница 148: ...16 FENDERS AND EXHAUST PIPE 16 1 Fenders Drawing 16 3 Front Fender Removal 16 2 Rear Fenders Removal 16 4 Exhaust Pipe Removal 16 1 Fenders Drawing EXHAUST PIPE For all serials...

Страница 149: ...he rear rack 1 Open the seat 2 Loosen the four bolts which connect the front fender and rear fender 3 Loosen the two bolts which connect the rear tender and frame these two bolts just below the seat L...

Страница 150: ...There are two screws on the top of seat compartment Please remove them Next there are two screws on side of the tail Finally you must remove the bolts on the footrest Bolts Screw Bolts...

Страница 151: ...1 First picture shows there are two screw loosen it Remove the mounting bolts from the front fender Please remove the two screws on the top of the headlight Then you can see there is a screw on the t...

Страница 152: ...seat rear fender and footrest plate before you take off the exhaust pipe Loosen the two exhaust pipe bolts that fixed on the engine Warning DO NOT service the exhaust pipe while they are hot Remove th...

Страница 153: ...EXHAUST PIPE INSTALLATION Installation is the reverse order of removal Torque Exhaust muffler bolts 30 N m 22 lbf ft CATUATION After installing make sure that there are no exhaust leaks Bolt...

Страница 154: ...Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IG...

Страница 155: ...in an open area The battery contains sulfuric acid Electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous If swallowed drink...

Страница 156: ...s not work a period of time the voltage may reduce and may not provide enough power to starter motor If a battery is in a good condition but engine can not be start Please go back to service TROUBLESH...

Страница 157: ...bly TAILLIGHT The taillight combines a position and a rear brake light Normally when users switch the key to ON position the front rear position lights are always keep the light slightly Until a brake...

Страница 158: ...ulb and then it could be removed Rear Direction lights remove The same disassembling procedure like front direction light Please use the pliers to remove the seat Then the bubble could be see and repl...

Страница 159: ...for users Therefore this is an all in one instrument panel Instrument Panel REMOVAL There is a cable and connector on the back of the instrument panel After removing instrument panel users can find ou...

Страница 160: ...Cable...

Страница 161: ...17 8 Wiring Diagram...

Страница 162: ...tion coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire di...

Страница 163: ...ternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch 18 3 Poor Performance At High Speed N G CHECK IG...

Страница 164: ...ings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn pist...

Страница 165: ...roperly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Imp...

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