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Eton VECTOR 250 - SERVICE, Руководство по обслуживанию

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59 

 

8-2 Maintenance Description 

 
Precautions in Operation 
General Information 

y

  Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. 

y

  Drive belt and drive pulley must be free of grease. 

 

Specification of V-BELT SYSTEM 

Item 

Standard value (mm) 

Limit (mm) 

Driving belt width 

24.000 

22.500 

OD of movable drive face boss 

29.946~29.980 

29.926 

ID of movable drive face 

30.000~30.040 

30.060 

OD of weight roller 

19.500~20.000 

19.000 

ID of clutch outer 

144.850~145.150 

145.450 

Thickness of clutch weight 

6.000 

3.000 

Free length of driven pulley spring 

102.400 

97.400 

OD of driven pulley boss 

40.950~40.990 

40.930 

ID of driven face 

41.000~41.050 

41.070 

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 plate nut: 5.0~6.0kgf-m 

 

Special Service Tools 

Clutch spring compressor: 

SYM-2301000

 

Inner bearing puller: 

SYM-6204002

 

Clutch nut wrench 39 x 41 mm: 

SYM-9020200

 

Universal holder: 

SYM-2210100

 

Bearing driver: 

SYM-9100100

 

 

8-3 Trouble Diagnosis 

Engine can be started but motorcycle can 
not be moved 

1. Worn drive Belt 

2. Worn drive face 

3. Worn or damaged clutch weight 

4. Broken driven pulley 

 

Shudder or misfire when driving 

1. Broken clutch weight   

2. Worn clutch weight 

Insufficient horsepower or poor high 
speed performance 

1. Worn drive belt 

2. Insufficient spring force of driven pulley 

3. Worn roller 

4. Driven pulley operation un-smoothly   

 

 

Содержание VECTOR 250 - SERVICE

Страница 1: ...ylinder HEAD Cylinder Valve 34 7 Cylinder Piston 50 8 V Belt driving system 58 9 Transmission 72 10 ACG Start one way clutch 84 11 Crankcase Crank 93 12 Cooling System 101 CHASSIS 13 Steering Suspensi...

Страница 2: ...d exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts USED ENGINE GEAR OIL Used engine oil and gear oil may cause skin di...

Страница 3: ...ll Length 1815mm Overall Width 1062mm Overall Height 1130mm Wheel base 1193mm Ground Clearance 150mm Dry Weight 225kg Fuel Tank Capacity 12L SUSPENSION Front Double A Arm Adjustable Shocks Rear Swing...

Страница 4: ...RIAL 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 Side Frame serial number Engine serial number Frame seria...

Страница 5: ...aft nut 50 N m 36 9 lbf ft Steering shaft holder bolt 33 N m 24 lbf ft Wheel rim bolt 18 N m 13 3 lbf ft Tie rod lock nut 35 N m 25 8 lbf ft King pin nut 40 N m 29 lbf ft Handlebar lower holder nut 40...

Страница 6: ...2 6 AIR CLEANER 2 13 TOE IN 2 7 SPARK PLUG 2 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...

Страница 7: ...for every 1 month 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 Rep...

Страница 8: ...ber cap of the adjuster off the throttle Housing loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttl...

Страница 9: ...nd to prevent crosses threading Tighten the spark plug with 12 19 N m 2 8 IDLE SPEED Connect an engine speed meter Warm up the engine 10 minutes are enough Turn the idle speed adjust screw on the carb...

Страница 10: ...damaged Inspect the sprocket teeth if it is excessive wearing or damaging please replace it 2 10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage Replace or rep...

Страница 11: ...t brake level is under the driver seat and rear brake component Because the brake system is different ones need to adjust it to reach a proper brake level 2 11 WHEELS AND TIRES Inspect the tire surfac...

Страница 12: ...ering shaft holder and check the steering shaft bushing for wears or damage If the bushing is worn or damaged please change a new one Grease the steering shaft bushing and install the parts in the rev...

Страница 13: ...e center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5 10mm If the toe in is out of standard adjust it by changing the length of th...

Страница 14: ...t 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 rem...

Страница 15: ...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 Hanger bo...

Страница 16: ...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 17: ...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 18: ...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 19: ...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 20: ...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 21: ...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 22: ...e 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 Star...

Страница 23: ...rouble 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 F...

Страница 24: ...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 disas...

Страница 25: ...alfunction 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 in...

Страница 26: ...ove 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...

Страница 27: ...ve 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 Assem...

Страница 28: ...ottle 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...

Страница 29: ...mage 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 level to incr...

Страница 30: ...d 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...

Страница 31: ...turns 1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1700 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key...

Страница 32: ...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 fu...

Страница 33: ...Remove 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 h...

Страница 34: ...nder 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...

Страница 35: ...012 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...

Страница 36: ...er 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 37: ...t 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 38: ...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 Special S...

Страница 39: ...and 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...

Страница 40: ...Head 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 Ser...

Страница 41: ...mm 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 va...

Страница 42: ...nce 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...

Страница 43: ...y 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 44: ...ve 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 co...

Страница 45: ...ve 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...

Страница 46: ...remove 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 sp...

Страница 47: ...and 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 hea...

Страница 48: ...sprocket 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...

Страница 49: ...lign the timing mark on the cam sprocket with that of cylinder head piston is at TDC position Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clea...

Страница 50: ...echanism Diagram 7 2 Precautions in Operation 7 3 Trouble Diagnosis 7 4 Cylinder and Piston Removal 7 5 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 1 Mechanism Diagram...

Страница 51: ...10 0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 16 970 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...

Страница 52: ...nder 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 remov...

Страница 53: ...ston 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 o...

Страница 54: ...eter 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 distanc...

Страница 55: ...carefully Place 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 th...

Страница 56: ...6 Piston Installation 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 cli...

Страница 57: ...taken 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...

Страница 58: ...TEM 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...

Страница 59: ...990 40 930 ID of driven face 41 000 41 050 41 070 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 plate nut 5 0 6...

Страница 60: ...then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Clamp strips 9 b...

Страница 61: ...Left crankcase cover inspection Release the 2 clamp strips of left crankcase cover ducts and then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Clamp strips 9 bol...

Страница 62: ...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 pulley Inspecti...

Страница 63: ...ive 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...

Страница 64: ...hen 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 65: ...he outer diameter of movable drive face boss and replace it if it exceed service limit Service limit mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Servi...

Страница 66: ...pulley 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 67: ...service 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 mov...

Страница 68: ...the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing...

Страница 69: ...n Replace it if 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 bloc...

Страница 70: ...de 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 for...

Страница 71: ...d 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 nu...

Страница 72: ...ansmission cover Final shaft Drive sprocket Reverse shaft Counter shaft Drive shaft Bearing 6304 Bearing 6205LLU Bearing 6204 Bearing 6305 Change switch Gasket Gear oil fill bolt 3 5 4 5kgf m Drive sh...

Страница 73: ...ver 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...

Страница 74: ...on 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...

Страница 75: ...catch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft Shift drum Shift spindle Shift fork shaft and fork 9 bolt...

Страница 76: ...Special 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 beari...

Страница 77: ...ection 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 wea...

Страница 78: ...bearing 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...

Страница 79: ...eal 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 dri...

Страница 80: ...stall 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...

Страница 81: ...ring puller to install 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 bearin...

Страница 82: ...nter 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 sha...

Страница 83: ...tall 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...

Страница 84: ...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 Crankc...

Страница 85: ...s 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...

Страница 86: ...val 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 87: ...g 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 flywh...

Страница 88: ...ing 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 Li...

Страница 89: ...gear 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 an...

Страница 90: ...bolt 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 fa...

Страница 91: ...e 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 R...

Страница 92: ...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 co...

Страница 93: ...93 11 CRANKCASE CRANK 11 1 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1 2kgf m 1 0 1 4kgf m 0 8 1 2kgf m...

Страница 94: ...hain 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 Ve...

Страница 95: ...emove 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 rem...

Страница 96: ...m 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 f...

Страница 97: ...he 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 a...

Страница 98: ...n 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 99: ...and 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 Dow...

Страница 100: ...ankcase 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 bol...

Страница 101: ...12 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 inl...

Страница 102: ...r 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 roto...

Страница 103: ...mo 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 coo...

Страница 104: ...y 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 c...

Страница 105: ...pletely 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 Reinsta...

Страница 106: ...levating 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...

Страница 107: ...tor 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...

Страница 108: ...firms 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...

Страница 109: ...r 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...

Страница 110: ...r 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 righ...

Страница 111: ...ghten 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 o...

Страница 112: ...the 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 c...

Страница 113: ...113 13 STEERING AND SUSPENSION 13 1 PARTS DRAWING 13 2 TROUBLESHOOTING 13 3 HANDLENAR 13 4 THROTTLE HOUSING 13 5 STEERING SYSTEM 13 1 PARTS DRAWING STEERING...

Страница 114: ...114 Handle bar...

Страница 115: ...y 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 fro...

Страница 116: ...ndle 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...

Страница 117: ...with 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 th...

Страница 118: ...ct throttle cable from the throttle arm and remove from the throttle housing NOTE Assembly is in the reverse order of disassembly 13 5 STEERING SYSTEM Removal of Kingpin and Tie rod Remove the front w...

Страница 119: ...t 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 Steering Shaft Holder Inspecti...

Страница 120: ...120 Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 N m 37 lbf ft...

Страница 121: ...121 14 FRONT WHEEL AND BRAKE SYSTEM 14 1 PARTS DRAWING 14 2 TROUBLESHOOTING 14 3 FRONT WHEEL 14 4 HYDRAULIC BRAKE 14 5 SUSPENSION SYSTEM 14 1 PARTS DRAWING FRONT WHEEL FRONT BEAKE...

Страница 122: ...ncorrectly 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 fr...

Страница 123: ...placing a jack or other support under the frame Remove the front wheel nuts washer and wheels Please follow the next three steps of right pictures Loosen fours nuts as shown in picutre Then take the w...

Страница 124: ...hub apart Before loosening castle nut you have to remove cotter pin Then using the power tools to take the screw out from brake stopping plate You can take the brake disc off When change brake shoe we...

Страница 125: ...BRAKE 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...

Страница 126: ...ion 1 You can raise the all ATV body up by using a repair platform The four wheel are in the free position you can easy to adjust the suspension 2 If you do not have any repair platform just using spe...

Страница 127: ...127 15 REAR 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 1 PARTS DRAWING REAR WHEEL REAR Wheel Axel...

Страница 128: ...128 REAR BRAKE...

Страница 129: ...bearings 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 b...

Страница 130: ...as shown in picture Loosen bolts and remove 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...

Страница 131: ...n take all brake shoe out the hub There are two kind of brake linings as shown in picture TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open the cover Loosen the bolt and drain the used oil...

Страница 132: ...ke system Loosen the bolt to vent the air from brake system Tighten the bolt if there isn t any air in the brake system Tighten torque 40 70kgf cm Pull left brake lever slightly in order to extract ai...

Страница 133: ...ollowing pictures are going to teach you how to Install the swingarm 1 Put the swingarm at proper position as shown in picture Two hanger bolts will be used to hold the swingarm at right and left side...

Страница 134: ...134 3 Screw another hanger bolt on the left side as shown in picture But do not tighten it Let the cross section of bolt and cross section of hole in the same plane 4 Tighten a nut Hanger bolt...

Страница 135: ...nsion 1 You can raise the all ATV body up by using a repair platform The four wheel are in the free position you can easy to adjust the suspension 2 If you do not have any repair platform just using s...

Страница 136: ...136 16 FENDERS AND EXHAUST PIPE 16 1 FENDRES 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 137: ...the 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...

Страница 138: ...138 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 139: ...it 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...

Страница 140: ...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 t...

Страница 141: ...141 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 142: ...ug 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...

Страница 143: ...ry 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 drin...

Страница 144: ...ot 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 TROUBLESHOOT...

Страница 145: ...n the connector in order to replace an electrical bulb conveniently and safely The steps show on pictures Installation is in the reverse order of disassembly Front Direction lights remove To replace t...

Страница 146: ...e cap you could see the connector Turn the seat to replace the electrical bulb TAILLIGHT The taillight combines a position and a rear brake light Normally when users switch the key to ON position the...

Страница 147: ...o fix this cap loosen them can open the cap Please rotate the electrical bulb and then it could be removed Rear Direction lights remove The same disassembling procedure like front direction light Plea...

Страница 148: ...or 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 out...

Страница 149: ...149...

Страница 150: ...150 12 8 WIRING DIAGRAM...

Страница 151: ...nition 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...

Страница 152: ...alternator 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...

Страница 153: ...rings 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 pi...

Страница 154: ...mproperly 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 I...

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