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Chapter 6 Alternator/Electrical Equipment

VI-11

Headlight

BULB REPLACEMENT

Remove headlight panel. (280AS only)

Disconnect the headlight coupler.

Remove headlight bulb rubber dust seal.

Remove the bulb socket.

Remove the clip and replace the headlight bulb.

CAUTION

◦

Do not put finger prints on the headlight bulb,

they may create hot sports on the bulb.

◦

If you touch the bulb with your hands, clean it

with c cloth moistened with alcohol to prevent

its early failure.

◦

Do not try to replace the bulb with light ON.

Position the headlight bulb rubber dust seal.

NOTE

◦

Install the dust seal securely.

Speedometer

REMOVAL/INSTALLATION

Loosen two mounting bolts of speedometer

cover.

Disconnect speedometer connectors and

pull out the speedometer cover with

speedometer.

Loosen three speedometer mounting screws and

remove the speedometer.

Install the speedometer in the reverse order of

removal.

Dust Seal

Bulb Socket

Dust Seal

Содержание 2002 ATV-320 S

Страница 1: ...SERVICE MANUAL ATV 320 S U 2002 24 JUNE 30 2007 High Power Liquid Cooled Engine HER CHEE INDUSTRIAL CO LTD...

Страница 2: ...alified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manu...

Страница 3: ...r I 38 Chapter 2 Fuel System Carburetion Carburetor II 3 Fuel Tank II 7 Air Cleaner II 10 Exhaust System II 12 Chapter 3 Ignition and Starting System Ignition System III 1 Starting System III 4 Recoil...

Страница 4: ...he VIN Vehicle Identification Number is attached to the lower front right side of frame behind the frame number The engine serial number is stamped on the upper rear right crankcase The carburetor ide...

Страница 5: ...shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks z All items must use original parts pure...

Страница 6: ...rmed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority z Definition of signs The sign given in the Service Manual shall refer to the operation m...

Страница 7: ...6 0 008 0 25 0 010 Oil pump Rotor end clearance 0 04 0 09 0 002 0 004 0 12 0 005 TORQUE VALUES Oil drain plug 20 25 N m 15 18 ft lb Oil filter screen cap 18 22 N m 13 16 ft lb Transmission oil check b...

Страница 8: ...ring and filter screen and clean the filter screen After the oil has been completely drained be sure the O ring on the filter screen cap is in good condition and install the filter screen with the clo...

Страница 9: ...SPECTION Measure the pump body to outer rotor clearance Service Limit 0 25 mm 0 010 in Measure the outer rotor to inner rotor tip clearance Service Limit 0 20 mm 0 008 in Check the rotor to pump body...

Страница 10: ...ates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery especially while charging it SERVICE RULES 1 Use genuine ADLY or ADLY recommended parts and lubr...

Страница 11: ...bly 0 8 liter 0 85 US qt at change Transmission 0 6 liter 0 74 US qt at disassembly 0 5 liter 0 63 US qt at change Coolant capacity Engine and radiator 1 1 liter 1 16 US qt Reserve tank 0 3 liter 0 31...

Страница 12: ...ar selection rod then remove muffler ass y Disconnect coolant hose Disconnect spark plug and generator wire connector and coupler Disconnect blow by tube at cylinder head cover and crankcase Disconnec...

Страница 13: ...er engine mount Torque value 40 55 N m 29 40 ft lb B Front engine mount C Front engine bracket Torque value 40 55 N m 29 40 ft lb D Rear upper hanger plate Torque value 18 24 N m 13 16 ft lb E Rear en...

Страница 14: ...Chapter 1 Engine Transmission Gear I 5 Cylinder Head Cover 1 5 2 3 7 6 4 8 11 10 9 5 5 5 9...

Страница 15: ...Chapter 1 Engine Transmission Gear I 6 Cylinder Head 2 3 4 4 5 6 7 8 9 11 10 12 12 13 14 18...

Страница 16: ...Chapter 1 Engine Transmission Gear I 7 Camshaft Valve Cam...

Страница 17: ...Valve stem EX 4 955 4 970 0 1951 0 1957 4 90 0 193 Valve guide I D 5 00 5 012 0 1969 0 1973 5 03 0 198 IN 0 010 0 037 0 0004 0 0015 0 08 0 003 Stem to guide clearance EX 0 030 0 057 0 0012 0 0022 0 10...

Страница 18: ...Burned or bent valves Incorrect valve timing Broken valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Compression Too High Excessive carbon...

Страница 19: ...o keep it from falling to the crankcase Remove rocker arm cam shaft bearing holder plate mounting bolt and holder plate Remove rocker arm shaft by using a M6 bolt screw in shaft then pull out the shaf...

Страница 20: ...rocker arm ROCKER ARM INSPECTION Measure the rocker arm shaft O D Service Limit 16 96 mm 0 6677 in Measure the rocker arm bore I D Service Limit 17 04 mm 0 6709 in Turn the outer race of each rocker...

Страница 21: ...bolts Derail the cam chain from the cam sprocket teeth and remove the cam sprocket Remove the cylinder head base bolt Remove the four cylinder head cap nuts and four copper washer Remove the cylinder...

Страница 22: ...rrect reassembly Remove the valve stem seals Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head gasket surface NOTE Avoid damaging the gasket surfa...

Страница 23: ...lve movement in the guide and measure and record each valve stem O D Service Limit IN 4 9 mm 0 193 in EX 4 9 mm 0 193 in VALVE GUIDE NOTE Remove the guides to remove any carbon build up before checkin...

Страница 24: ...lve also NOTE Reface the valve seats whenever the valve guide are replace CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil then insert the valves into the valve guides Install new valve stem...

Страница 25: ...tall the carburetor insulator with two bolts and tighten the bolts CYLINDER HEAD INSTALLATION Install the dowel pins and a new gasket onto the cylinder Install the cylinder head onto the cylinder Inst...

Страница 26: ...and exhaust lobe Install intake and exhaust rocker arm to cylinder head Tighten the rocker arm camshaft bearing holder plate mounting bolt Push the cam chain adjuster push rod back into the adjuster...

Страница 27: ...index mark on the right crankcase cover to bring the position to TDC Top Dead Center on the compression stroke With the engine in this position all four valves can be checked Loosen the valve adjuste...

Страница 28: ...the cylinder head cover seal for any buckle or broken Replace a new one if necessary Coating engine oil on seal face before install Install the cylinder head cover to cylinder and tighten four 6mm hea...

Страница 29: ...Chapter 1 Engine Transmission Gear I 20 Cylinder Piston Crankshaft...

Страница 30: ...er clearance 0 010 0 040 0 0004 0 0016 0 10 0 004 Piston Piston ring Piston pin bore 17 002 17 008 0 6694 0 6696 17 04 0 671 Piston pin O D 16 994 17 000 0 6691 0 6693 16 96 0 668 Piston to piston rin...

Страница 31: ...er Remove the cylinder gasket and dowel pins Place rags in the crankcase openings Clean off any gasket material from the cylinder surface of the crankcase NOTE Gasket material will come off easier if...

Страница 32: ...PISTON PIN AND PISTON RING INSPECTION Measure the piston pin bore I D Service Limit 17 04 mm 0 6709 in Measure the piston pin O D Service Limit 16 96 mm 0 6677 in Calculate the piston pin to piston cl...

Страница 33: ...ston O D at a point 10 mm 0 4 in from the bottom and 90 to the piston pin bore Service Limit 75 90 mm 2 9882 in Compare this measurement against the service limit and calculate piston cylinder clearan...

Страница 34: ...gs should be installed with the markings facing up After installing the rings they should rotate freely without sticking PISTON INSTALLATION Install the piston and piston pin Position the piston IN ma...

Страница 35: ...h fresh engine oil Carefully lower the cylinder over the piston by compressing the piston rings one at a time CAUTION Do not force the cylinder over a ring you may damage the piston and piston rings L...

Страница 36: ...Chapter 1 Engine Transmission Gear I 27 Crankcase...

Страница 37: ...taching bolts Remove the crankcase with the left side crankcase down and remove the right crankcase CAUTION Never pry the crankcase mating surfaces apart Remove the gasket and dowel pins Remove the cr...

Страница 38: ...aring with your finger The bearings should turn smoothly and quietly Also check that the bearing inner race fits tightly in the crankshaft Replace the crankshaft assembly if the races do not turn smoo...

Страница 39: ...the left crankcase being careful not to damage the oil seal Install the dowel pins and a new gasket Place the crankcase over the crankshaft and onto the left crankcase Install the nine crankcase atta...

Страница 40: ...Chapter 1 Engine Transmission Gear I 31 Right Crankcase Cover...

Страница 41: ...hanical seal for wear or damage Turn the water pump shaft to check the bearing it should turn smoothly and quietly Inspect ignition pulse generator soldering and check the sealing rubber for any defic...

Страница 42: ...Chapter 1 Engine Transmission Gear I 33 Cooling system...

Страница 43: ...test 55 distilled water 45 ethylene glycol 32 26 50 distilled water 50 ethylene glycol 37 35 45 distilled water 55 ethylene glycol 44 5 48 Coolant capacity Radiator and engine Reserve tank Total syste...

Страница 44: ...The engine must cool before removing the radiator cap or severe scalding may result Remove the front light fender 280AS or front fender assy 280AU Remove the radiator cap Place a drain pan under the...

Страница 45: ...out from between core fins with low pressure air If insects etc are clogging the radiator wash them off with low pressure water REMOVEAL Remove the front light fender 280AS or front fender assy 280AU...

Страница 46: ...lly for damage Suspend the thermostat in heated water to check its operation NOTE If the thermostat or thermometer touches the pan you ll get a false reading Replace the thermostat if the valve stays...

Страница 47: ...Chapter 1 Engine Transmission Gear I 38 Left Crankcase Cover...

Страница 48: ...23 6 035 153 5 6 043 Driven face spring free length 114 8 4 520 110 0 4 33 Driven face O D 40 96 40 98 1 612 1 613 40 92 1 611 Moveable driven face I D 41 00 41 04 1 614 1 616 41 06 1 617 Weight rolle...

Страница 49: ...ts and remove the crankcase cover dowel pins and gasket Inspect the gasket for crankcase cover and replace it if necessary Install the left crankcase cover in the reverse order of removal Torque 8 12...

Страница 50: ...ces then set the drive belt on the drive pulley face collar Reinstall the drive pulley face and recoil dish hold the drive pulley and tighten the nut Torque 80 100 N m 58 72 ft lb Reinstall the left c...

Страница 51: ...e Limit 27 06 mm 1 065 in Check the drive face collar for wear or damage Measure the O D at the drive face sliding surface Service Limit 26 94 mm 1 061 in Check the driver face for wear or damage Meas...

Страница 52: ...h the spline side facing out Clean off any grease or oil from the drive pulley faces INSTALLATION Install the moveable drive face onto the crankshaft Install the drive belt Clean the drive pulley face...

Страница 53: ...rive pulley holder and remove the drive pulley nut and clutch outer Remove the driven pulley clutch assembly INSPECTION Check the clutch outer for wear or damage Measure the clutch outer I D Service L...

Страница 54: ...Chapter 1 Engine Transmission Gear I 45 Transmission...

Страница 55: ...S qt at change 0 6 liter 0 63 US qt at disassembly TORQUE VALUES Transmission case cover 6 mm 8 12 N m 6 9 ft lb 8 mm 20 24 N m 14 18 ft lb 10 mm 10 15 N m 7 11 ft lb Troubleshooting Engine starts but...

Страница 56: ...LY Drain the gear oil by loosen drain bolt Remove drive sprocket Remove shaft lever Loosen eight gearbox attaching bolts Remove right side gearbox cover dowel pins and gasket Remove gear shaft arm Rem...

Страница 57: ...rmal wear or broken teeth Inspect gear shaft arm for abnormal wear or broken teeth Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The...

Страница 58: ...ar shaft fork Install gear shift arm NOTE Aligned shift forks to shift drum groove gear shift arm to shift drum and shift drum retainer in correct position Install the dowel pins and a new gasket add...

Страница 59: ...area Do not smoke or allow flames or sparks in the work area When disassembling the fuel system parts note the location of the O ring and gasket Replace them with new ones if necessary on reassembly B...

Страница 60: ...h idle Faulty ignition system Incorrect idle speed Faulty carburetor Contaminated fuel Misfiring during acceleration Faulty ignition system Backfiring Faulty ignition system Faulty carburetor Poor per...

Страница 61: ...Chapter 2 Fuel System Carburetion II 3 3 CARBURETOR...

Страница 62: ...t damage jet needle on the throttle piston Disconnect the heater component on carburetor Disconnect the fuel tube from the carburetor Remove the carburetor Vacuum Chamber DISASSEMBLY Loosen the drain...

Страница 63: ...pect the float valve for grooves and nicks Inspect the operation of the float valve Blow open all passages with compressed air before assembling ASSEMBLY Clean main jet needle jet holder needle jet an...

Страница 64: ...arburetor Install the throttle cable Install the choke cable with choke piston Install the carburetor aligning the tab on the carburetor with the groove in the intake manifold and tighten the band scr...

Страница 65: ...Chapter 2 Fuel System Carburetion II 7 7 FUEL TANK...

Страница 66: ...dy FUEL VALVE INSPECTION Disconnect vacuum tube from fuel valve and fuel tube from carburetor Connect a commercially brake bleeder to vacuum tube then pump the brake bleeder Check the fuel flow thru f...

Страница 67: ...place if necessary Use a ohmmeter connect to gauge terminal to check the ohm reading from upper to lower float level of petrol gauge Ohm reading 10 90 Replace petrol gauge if the ohm reading is discon...

Страница 68: ...Chapter 2 Fuel System Carburetion II 10 10 AIR CLEANER ASSEMBLY...

Страница 69: ...e air filter assembly mounting clamp Remove the air filter element cover Drain the accumulated water or dust Clean the air cleaner case and filter element with compress air Inspect the filter element...

Страница 70: ...Chapter 2 Fuel System Carburetion II 12 12 EXHAUST SYSTEM...

Страница 71: ...hanger mounting bolts Pull back the muffler assembly for removal Bend the exhaust pipe front section to release pipe springs INSPECTION Check the exhaust pipe gasket replace it if necessary INSTALLATI...

Страница 72: ...1 k Ignition pulse generator at 20 68 50 170 TROUBLESHOOTING No spark at plug Poorly connected broken or shorted wire Between ignition pulse generator and ignition control module CDI Between CDI and i...

Страница 73: ...ance is out of the specification remove the spark plug cap from spark plug wire and measure the resistance of the secondary coil Resistance 3 7 4 5 k REMOVAL INSTALLATION Disconnect the ignition coil...

Страница 74: ...dy and a four pin gear position coupler INSPECTION Disconnect the CDI coupler and connectors and check each circuit according to the table below CIRCUIT COLOR CORRECT Ignition Puler Bu Y G 50 170 Bl Y...

Страница 75: ...r motor brush spring tension 680 920 g 1 49 2 03 lb 680 g 1 49 lb TROUBLESHOOTING Starter won t turn Burned out fuse Weak battery Poorly connected broken or shorted wire Faulty Ignition switch starter...

Страница 76: ...motor cable from the starter relay Disconnect starter relay terminal and remove the starter relay Connect an ohmmeter between the positive and starter motor terminal Connect the yellow red wire termin...

Страница 77: ...the starter motor INSTALLATION NOTE Before installing the starter motor check the operation by connecting the starter motor wire to the starter relay Install the starter motor in the reserve order of...

Страница 78: ...Chapter 3 Ignition and Starting System III 7 Recoil Backup Starting System...

Страница 79: ...e engine starting After engine start release the recoil haft the wire should return into the recoil body and the haft stay to it s original position NOTE If the recoil haft can t back to original posi...

Страница 80: ...an assistant will be required when removing panels to help avoid damaging the surface Once the visible fasteners have been removed try to lift off the panel as described but DO NOT FORCE the panel if...

Страница 81: ...Chapter 4 Frame Cover IV 2 FRAME BODY 320S...

Страница 82: ...Chapter 4 Frame Cover IV 3 FRAME BODY 320U...

Страница 83: ...Chapter 4 Frame Cover IV 4 BODY COVER SEAT 320S...

Страница 84: ...Chapter 4 Frame Cover IV 5 BODY COVER SEAT 320U...

Страница 85: ...ector Remove upper fender to frame mounting bolts and front to rear fender joint bolts Remove two lower mount bolts Remove tail light fender 320S Open the rear luggage box and remove the mounting bolt...

Страница 86: ...sconnect indicator light and main switch wire Remove L R side cover and front to rear joint bolts Remove speedometer cover and handle bar supporter then make handle bar freely for moving Remove fender...

Страница 87: ...bumper cover to bumper and headlight to bumper mounting bolts Remove fuel cap then remove fuel tank dash board NOTE Lock the fuel cap to fuel tank as soon as removed fuel tank dash board With an assi...

Страница 88: ...nstall the front carrier in the reverse order of removal NOTE Attached all four bolts first and after aligned the carrier tighten the bolts INSTALLATION Install the front carrier in the reverse order...

Страница 89: ...tighten the bolts INSTALLATION Install the front bumper in the reverse order of removal REAR BUMPER REMOVAL Remove the rear carrier Remove four bumper mounting bolts NOTE The right side front bolt al...

Страница 90: ...ll joint Upper 55 N m 40 ft lb Lower 55 N m 40 ft lb Front wheel hub nut 59 79 N m 43 58 ft lb Rear wheel hub nut 140 160 N m 101 116 ft lb Wheel nut 64 N m 17 22 ft lb Brake disk bolt 30 N m 22 ft lb...

Страница 91: ...Chapter 5 Wheels Tires Brakes V 2 HANDLE BAR...

Страница 92: ...Chapter 5 Wheels Tires Brakes V 3 STEERING MPH...

Страница 93: ...to lower holders and aligning the punch mark on the handlebar with the upper surfaces surface of the lower holders Install the handlebar upper holders and tighten four hex socket bolts Torque 24 30 N...

Страница 94: ...t nut Remove the steering shaft holder bolts Remove the steering shaft holder basket and pull out the steering from frame INSPECTION Inspect tie rod end mounting plate for wear or damage and replace i...

Страница 95: ...Chapter 5 Wheels Tires Brakes V 6 FRONT REAR WHEEL...

Страница 96: ...s or embedded object Check the front and rear wheels rim for trueness Service Limits Radial 2 0 mm 0 08in Axial 2 0 mm 0 08in Replace if the reading exceeds the service limit Measure the tread depth a...

Страница 97: ...sary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the outer race fits tightly in the hub Remove and discard the bearing if the races do not t...

Страница 98: ...Chapter 5 Wheels Tires Brakes V 9 FRONT SUSPENSION...

Страница 99: ...Chapter 5 Wheels Tires Brakes V 10 REAR SUSPENSION SWING ARM SUB ASS Y...

Страница 100: ...t Remove upper and lower a arm mounting bolts and remove a arm from vehicle frame INSPECTION Inspect ball joint rubber and joint for wear or damage Replace ball joint upper and lower at same time Insp...

Страница 101: ...t with brake line and parking brake cable aside the swing arm assemble Remove rocker arm to chassis mounting bolt Remove foot brake pedal Loosen the swing arm bolt and remove it Pull back the swing ar...

Страница 102: ...ER INSPECTION Check oil seal for broken or damage replace it if necessary Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Check the outer race fits ti...

Страница 103: ...Chapter 5 Wheels Tires Brakes V 14 HYDRAULIC BRAKE SYSTEM...

Страница 104: ...Chapter 5 Wheels Tires Brakes V 15 BRAKE CALIPER...

Страница 105: ...ATION ITEM STANDARD mm in SERVICE LIMIT mm in Front 4 0 0 16 3 0 0 14 Disc thickness Rear 4 0 0 16 3 5 0 14 Disc runout 0 3 0 012 Brake pad thickness 1 0 0 04 TORQUE VALUES Bleed valve 4 7 N m 3 5 ft...

Страница 106: ...AUTION Do not allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced...

Страница 107: ...els calipers then bleeding the rear brake shunt and caliper Add fluid when the fluid level in the master cylinder reservoir is low NOTE Check the fluid level often while bleeding the brakes to prevent...

Страница 108: ...queeze the brake lever and hold it down then open the bleed valve half turn and then close the valve NOTE Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever...

Страница 109: ...d pull out the bolts Push brake pads against caliper piston to let it back into the caliper bore then remove inner brake pad from caliper house Press caliper mounting plate toward bore side then push...

Страница 110: ...rovide enough room for the new pads to clear the disc Tighten the caliper mounting bolts Torque 30 N m 25 ft lb BRAKE DISC INSPECTION REMOVAL AND INSTALLATION INSPECTION Visually inspect the surface o...

Страница 111: ...of removal Tighten the disc retaining bolts Torque 43 N m 31 ft lb NOTE Used pre coating anti loosen bolts Rear disc removal installation Remove the left rear wheel hub Remove the rear caliper Remove...

Страница 112: ...bolt fixing nut and then turn in the adjust bolt until you can feel it touch the piston wall Turn out the adjust bolt half turn and hold the adjust bolt then tight the fixing nut NOTE Pull the parkin...

Страница 113: ...ne installed in the frame SPECIFICATION ITEM STANDARD mm in SERVICE LIMIT mm in Starter driven gear I D 22 026 22 045 0 8672 0 8679 22 10 0 870 Starter Driven gear O D 42 195 42 208 1 6612 1 6617 42 1...

Страница 114: ...Chapter 6 Alternator Electrical Equipment VI 2 Alternator Starter Gear...

Страница 115: ...water pump Remove the two pipe bolts two 8 mm oil pipe bolts 12 mm oil pipe bolt and washer then remove the pipe Disconnect the pulse generator and alternator wire connectors Disconnect the crankcase...

Страница 116: ...generator Remove the three stator attaching bolts and stator FLYWHEEL REMOVAL Remove the oil orifice from the end of the crankshaft Hold the flywheel with a flywheel holder and remove the flywheel nut...

Страница 117: ...AR INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limit I D 22 10 mm 0 870in O D 42 15 mm 1 659in Inspect the starter idle gear and s...

Страница 118: ...clutch into the one way clutch outer Install the one way clutch assembly to the flywheel and tighten with 6 mm socket bolts Torque 28 32 N m 21 24 ft lb NOTE Apply a locking agent to the socket bolt t...

Страница 119: ...l Install the oil orifice drive pin in the crankshaft Install the woodruff key into the crankshaft slot Install the flywheel onto the crankshaft aligning the key on the crankshaft with the groove in t...

Страница 120: ...is in position securely RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oi...

Страница 121: ...oil pipe bolts in the correct position If the 8 mm oil pipe bolts are interchanged engine damage may result NOTE Make sure that the sealing washer tab at the right crankcase cover faces the right cran...

Страница 122: ...If the bulb light there is a short to ground somewhere in that area probably where insulation has rubbed off a wire The same test can be performed on other components in the circuit including the swit...

Страница 123: ...touch the bulb with your hands clean it with c cloth moistened with alcohol to prevent its early failure Do not try to replace the bulb with light ON Position the headlight bulb rubber dust seal NOTE...

Страница 124: ...INSPECTION During the regulator normally function the alloy body of regulator will became heated Started the engine use your hand to touch the alloy body to check it s functional When engine is runnin...

Страница 125: ...Chapter 6 Alternator Electrical Equipment VI 13 Wire Diagram...

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