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700ATV Maintenance Manual

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Содержание 700ATV

Страница 1: ...1 700ATV Maintenance Manual...

Страница 2: ...nt of engine 11 2 1 Inspection of cylinder head intake and exhaust valve 11 2 2 Inspection of spark Plug 12 2 3 Inspection of cylinder piston and piston ring 14 2 4 Inspection of crankshaft 17 2 5 Ins...

Страница 3: ...ase cover 33 3 6 Magneto 33 3 7 Oil pump 34 3 8 Clutch 35 3 9 Carburetor 36 3 9 1 Structure of carburetor 36 3 9 2 Inspection and adjustment of carburetor 37 4 Chassis 4 1 Steering operation system 39...

Страница 4: ...to and charging system 88 5 3 Battery 88 5 4 Lighting system 90 5 5 Meterand signal system 91 5 6 Electrical starting system 92 6 Appendix 93 6 1 Specification 93 6 2 Requirements for torque of fasten...

Страница 5: ...5 General Information 1 Description...

Страница 6: ...dentification code 1 1 1 Frame No The frame No is engraved in the right bottom of the supporting frame See Figure 1 1 Figure 1 1 1 1 2 Engine No The engine No is engraved in the right side of the engi...

Страница 7: ...ers 1 2 1 Oil filter detacher To fasten and detach the oil filter 1 2 2 Height gauge To gauge the height of various components 1 2 3 Vernier To measure the length of various components 1 2 4 Outside m...

Страница 8: ...internal diameter of a hole 1 2 6 Dial indicator To accurately measure a small distance 1 2 7 Torque Spanner To measure torque force 1 2 8 Feeler gauge To measure gap width 1 2 9 Multimeter To check...

Страница 9: ...valve clearance Adjust if necessary Sparkplug Check condition Adjust gap and clean Rep ace if necessary Air fiter element clean Replace if necessary Every20 40hours More often in wet of dusty areas C...

Страница 10: ...Check balance damage Repair if necessary Wheel bearing Check bearing assemblies for lossenss damage Replace if necessary Front and rear suspendion Check operation Correct if necessary Steering system...

Страница 11: ...ine until the pressure gauge stop rising The maximum reading would be greater than 0 7 0 9Mpa after starting for 4 6 times See figure 2 1 Figure 2 1 check the valve lash Note when adjust valve lash th...

Страница 12: ...check the lash between the valve stem by feeler gauge Valve clearance inlet and exhaust valve 0 05 0 08mm See figure 2 3 Figure 2 3 Loose the lock nut rotate the adjusting screw until it appears that...

Страница 13: ...the Spark Plug cap remove the spark plug by box key look over whether the spark plug insulator and electrode is damaged or sooting If so see figure 2 5 Figure 2 5 2 Check the spark clearance by feele...

Страница 14: ...ut of roundness 0 0035 0 005 cylinder degree of toruosity 0 04 0 06 external diameter of piston 101 95 101 97 101 92 bore diameter of piston pin hole 22 002 22 010 22 010 gap between piston pin and pi...

Страница 15: ...on of piston 2 Blast and abnormal noise 3 Abrasion of cylinder or piston Inspection of cylinder 1 Check whether the cylinder is damaged 2 Measure the bore diameter of cylinder at three spots 3 At the...

Страница 16: ...piston groove is cracked and abraded See figure 2 7 Figure 2 7 2 Insert piston ring into cylinder and measure the end gap repairing limit value the first ring the second ring 0 5mm See figure 2 8 Fig...

Страница 17: ...the external diameter of piston pin the gap between piston and piston pin repairing limit value 0 02mm See figure 2 11 Figure 2 11 2 4 Inspection of crankshaft heck that whether crank and connecting r...

Страница 18: ...figure 2 13 Figure 2 13 2 6 Inspection of carburetor 1 Inspect the idle of carburetor The engine speed should be 1500 150r min 10 minutes after starting at normal idle and will not misfire when brisk...

Страница 19: ...spection of air filter 1 Disassemble the air cleaner remove cartridge clean the cartridge with non flammable cleaning solvent and then make it dry Note Petrol is forbidden 2 Dip the air filter cartrid...

Страница 20: ...icle is oiled with lubricant of APISGSAE10W 40 APISGSAE10W 40 APISGSAE10W 40 APISGSAE10W 40 Others are forbidden capacity The capacity is 1 9L after disassembly and assembly 2 The capacity is 1 8L whe...

Страница 21: ...he oil case again Then unplug the dip stick and look whether oil level is lower than the indicator See figure 2 18 Note Ensure that the engine is landed by both four wheel in flat ground Figure 2 18 2...

Страница 22: ...valve Repairing limit value 2 0mm See figure 2 20 1 2 20 2 2 20 3 Figure 2 20 1 Figure 2 20 2 Figure 2 20 3 Measure the width of mating surfaces of valve If the mating surfaces is coarse corrode or ca...

Страница 23: ...nd valve guide Repairing limit value intake 0 12mm exhaust 0 14mm Note Eliminate carbon in the pipe before measuring If the pipe will be replaced grind the valve seat again 5 Inspection of valve and v...

Страница 24: ...ht of inlet valve spring 32 5mm squareness 0 10mm free height of exhaust valve spring 36 2mm squareness 0 10mm Figure 2 22 1 Figure 2 22 2 6 Examining lifting distance of breaker cam Measure the lengt...

Страница 25: ...worn out or damaged and whether the oil hole is blocked Note If there is a rocker arm to be replaced examine the peak of breaker cam measure the bore diameter of rocker arm Repairing limit value 12 03...

Страница 26: ...and hole 0 05mm See figure 2 25 Figure 2 25 3 3 3 3 disassembly of engine 3 3 3 3 1 1 1 1 cylinder head and block Unplug the intake pipe and spark plug Figure 2 26 1 2 26 2 Figure 2 26 1 Figure 2 26 2...

Страница 27: ...27 remove valve chain wheel Figure 2 27 2 Figure 2 27 1 Figure 2 27 2 remove lower rocker arm shaft See figure 2 28 Figure 2 28 Remove vision hole cover of left front cover See figure 2 29 Figure 2 29...

Страница 28: ...ylinder cover That is to say the piston of cylinder is at the top dead center Inspection of compression top dead center See figure 2 30 1 and figure 2 30 2 figure 2 30 1 figure 2 30 2 When inlet valve...

Страница 29: ...rms of cylinder head See figure 2 31 Figure 2 31 Remove chain tensioner adjuster See figure 2 32 Figure 2 32 remove the cylinder head Loosen the bolt by intersection manner before remove the bolt see...

Страница 30: ...er cotter sealed ring of cylinder headtensioner adjuster guide board See figure 2 34 Figure 2 34 remove cylinder block0 seal adjuster cotter sealed ring of cylinder head See figure 2 35 Figure 2 35 3...

Страница 31: ...piece of cleaning cloth to avoid the snap ring falling into the case See f See f See f See figure igure igure igure 2 2 2 2 3 3 3 36 6 6 6 Figure 2 36 remove piston pin and piston Clean the buckle of...

Страница 32: ...3 3 3 Manual starting mechanism Manual starting mechanism Manual starting mechanism Manual starting mechanism See figure 2 38 Figure 2 38 3 4 sensor Figure 2 39 3 5 left crankcase cover See figure 2 4...

Страница 33: ...stator coil remove the pluse coil Remove the stator with rotor stripper See figure 2 41 Figure 2 41 Remove the whitney key See figure 2 42 Figure 2 42 3 7 oil pump remove the bolt of oil pump cover Se...

Страница 34: ...34 remove right cover See figure 2 44 Figure 2 44 Remove the right support frame clutch pulley disc See figure 2 45 1 figure 2 45 2 figure 2 45 3 Figure 2 45 1 Figure 2 45 2...

Страница 35: ...ch clutch clutch remove the clutch Remove bolts See figure 2 46 Figure 2 46 Remove the clutch shoe block and clutch cover See figure 2 47 Figure 2 47 Check the wear condition of the clutch shoe block...

Страница 36: ...g 19 Fuel inlet valve component 20 High speed jet 21 Drain screw 22 idle metering air jet 23 Enriching Plunger component 24 Seal ring of external shaft cover 25 External shaft cover 26 Screw M4 8 27 S...

Страница 37: ...ated chamber cover 2 spring 3 piston valve remove permanent seat spring spring block oil needle remove pilot screw spring washer Note the pilot screw is set at maximum performance Before removing pilo...

Страница 38: ...uretor body float bowl oil passage gas fouling block cleaning chap damage replace the carburetor assembly cleaning steps check the float damaged replace check the float triangular needle triangular ne...

Страница 39: ...is damaged inject the petrol into valve Replace it when there is oil leakage check the main jet main jet pilot jet pilot screw 0 scrapers pilot jet bent worn out damaged replace gas fouling block blow...

Страница 40: ...ng of steering vertical column 6 supporting seal ring of steering vertical column 7 Supporting stent 8 hex bolt M8 60 9 stop reverse piece 10 Supporting Collar Sheath 11 cushion 14 32 4 12 Hexagon ope...

Страница 41: ...components 6 left switch components 4 1 1 4 1 1 4 1 1 4 1 1Disassembly inspection and assembly of Steering Disassembly inspection and assembly of Steering Disassembly inspection and assembly of Steer...

Страница 42: ...ring Bar Holder Figure 4 1 2 Figure 4 1 1 1 Hexagon Flange Bolt M8 30 2 Steering Bar Holder 3 Steering Bar Clip 3 Unplug all cables and connecting wires and remove the Steering Bar Figure 4 1 3 Figure...

Страница 43: ...groove nut M14 5 Remove the supporting brackets of the steering vertical column Figure 4 1 4 Figure 4 1 5 1 Supporting stent 2 Inner and outer supporting Bracket 3 safety cushion Figure 4 1 5 6 Remove...

Страница 44: ...ring Vertical Column 2 Bottom Seat 4 1 1 2 Inspection of steering vertical column components 1 Check whether the nut between the inner ball pin of tension rod and the Turning rocker arm is tightened F...

Страница 45: ...severe injury or death 3 check whether the tension rod is bended cracked or rusted In occasion of above problems please have the tension rod replaced Caution tension rod should not be repaired by wel...

Страница 46: ...4 1 1 3 Assembly of steering vertical column a Firstly fix the Turning rocker arms comp into the steering vertical column Then plug the steering vertical column into the bottom seat and fix it with M1...

Страница 47: ...vertical column onto the frame with hexagon flange bolt M8 60 2pcs supporting stent 1pcs inner and outer supporting bracket 2pcs stop reverse piece 1pcs and collar pipes 2pcs Figure 4 1 10 Fastening T...

Страница 48: ...6 Supporting ferrel 4 Fix the tension rod into the conical bore of the steering vertical column with tension rod components 2sets cushion 12 2pcs M10 hexagon open groove nuts 2pcs and cotter pins 3 2...

Страница 49: ...ring bar clip 4 1 2 3 Unplug all cables and wires and remove the steering bar Figure 4 1 3 4 1 2 2 Inspection of steering bar 1 Check any existing or potential crack on the steering bar In case of abo...

Страница 50: ...on of the inner surface must be less than 0 8mm Otherwise replace the steering bar clip 4 1 2 3 Assembly of the steering bar 1 Connect the steering bar clip and holder with the main frame by hexagon f...

Страница 51: ...branch seat 13 front disk brake pipe 14 rear brace of front hydraulic pipe 15 inner hex bolt M6 10 16 bolt of front hydraulic pipe 17 front hydraulic disk brake cushion 18 Hexagon Flange Bolts M6 25 1...

Страница 52: ...luid as was recommended by the manufactureFigure 4 2 1 Figure 4 2 1 to ensure the fluid level 1 Brake fluid box is higher than the minimum mark b Travel distance of the front brake lever should be kep...

Страница 53: ...must use DOT4 Brake Fluid e Periodical inspection of the wear condition of front disk brake plate is also necessary Disk brake plate must be replaced depending on its wear condition Figure 4 2 3 Cauti...

Страница 54: ...e and assembly of Front Disk Brake System 4 2 1 2 Disassembly of front disk brake plate 1 Removing the wheel component see Figure 4 2 4 1 front wheel hub 2 Hexagon open groove nut M30 3 cotter pin 3 2...

Страница 55: ...4 2 6 Figure 4 2 6 1 bottom seat of Disk Brake Pump 2 Disk Brake Pump unity 2 Remove the Front Fuel Pipe Brackets Figure4 2 7 Figure4 2 7 1 branch seat of Disk Brak Fuel Pipe 2 Hexagon Flange Bolts M...

Страница 56: ...ion distortion crack wear and other hidden defects 4 Check the Brake Plate Clip for distortion crack rust and stuck 5 Inspect the Brake Shoe for wear condition Brake shoe must be replaced when worn ou...

Страница 57: ...o the Front Wheel Hub with M8 Special Bolts 4pcs Figure 4 2 4 Caution grease the bolt with thread glue when fastening Fastening Torque of the Bolt 22N M 26N m 3 Fix the Front Wheel Hub onto the Front...

Страница 58: ...m Caution Do not operate the vehicle immediately after assembling the brake system Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating...

Страница 59: ...nspect the brake fluid box level on the right handlebar Should the fluid level falls under the minimum mark please refill the box with the same type of fluid as was recommended by the manufacturer Fig...

Страница 60: ...Pedal the process of abrading brake pad reducing the fluid level in the box Therefore periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid g Periodical inspection o...

Страница 61: ...n the disk brake plate must be replaced h Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection Method Fuel pipe must b...

Страница 62: ...12 Figure 4 2 12 1 Rear Disk Brake Clip 2 hexagon flange bolt M18 14 4 Remove Rear Disk Brake System 4 2 2 4 Disassembly of Rear Disk Brake Plate 1 remove rear wheel components Figure 4 2 13 2 Release...

Страница 63: ...smission shaftv 3 Remove the Rear Disk Brake Plate from Bottom Seat see Figure 4 2 15 Figure 4 2 15 1 Bottom Seat of Rear Disk Brake Plate 2 Rear Disk Brake Plate 4 2 2 5Inspection of Rear Brake Syste...

Страница 64: ...Shoe for wear condition Brake shoe must be replaced when worn out 1 Brake Shoe 6 Inspect the Brake Shoe for maximum wear distortion and crack in which case it must be replaced Maximum wear of Rear Dis...

Страница 65: ...30 Bolts 2pcs Fastening Torque 18 N m 22 N m 4 Mount Fluid Box of Rear Disk Brake onto the Frame with M Bolt 1pcs Fastening Torque 8 N m 12 N m 5 Mount Rear Disk Brake Pump onto the Frame with M Bolt...

Страница 66: ...ting before riding the vehicle 4 3 Wheel and Tyre 4 3 1 Preparation for maintenance of wheel 1 Inspect wear condition of the tyre Figure 4 2 16 2 Check if the Wheel Hub is worn out or damaged Figure 4...

Страница 67: ...laced 3 Check the joining condition of the tyre and wheel hub If the joint of tyre and wheel hub is loose replace the tyre immediately 4 Check the vibration of tyre wheel hub Figure 4 2 13 Vibration o...

Страница 68: ...cification and operation guide of Wheel Hub and Tyre Since wheels and tyres are crucial to the Figure 4 2 17 vehicle operation periodical inspection for tyre pressure and profile depth is necessary Sp...

Страница 69: ...pinning or lose of control Therefore please ensure the tyre pressure strictly complies with figures shown in the chart above Before operating the vehicle each time please check if profile depth of the...

Страница 70: ...shaft 3 fore bridge differential components 4 middle transmissionshaft components of fore bridge 5 L R turning joint front tank components 1 gear box assembly of front bridge 2 the right cover 3 the l...

Страница 71: ...32 differential adjusted washer 33 bolt M14X15 34 cooper gaske 14X2 35 vent piepe of drive case 36 clip of oil pipe 37 fore transimmision shaft 38 weak spring of fore transimmision shaft 39 dust proo...

Страница 72: ...ged properly 6 In case the choke is jammed it must be dredged with a needle If the problem is not solved replaced it 7 If there are defects on sensors it must be checked and maintained by a profession...

Страница 73: ...ked plesae have it replaced immediately 2 Check whether the ball is running smoothly If found loosen or stunk replace the transmissionshaft 3 Disassemble the transmissionshaft clean then install Cauti...

Страница 74: ...Figure 4 2 19 2 Inject 0 32L of GearLubricant of SAE 80 API GL 4 into fore bridge differential Then tighten the bolt Torque of the bolt 23N m 3 Fix the fore bridge differential onto the frame with hex...

Страница 75: ...r Bridge 4 4 2 1transmissioncase of rear bridge 1 rear bridge transmission case assembly 2 the left case 3 needle bearing 22BM3010 4 needle bearing 55BM6720A 5 cluster gear of rear bridge 6 needle bea...

Страница 76: ...16017 31 0 rings of rear bridge cover 32 rear adjuster washer 33 hexagon flange bolt M10X25 34 rear bridge oil change plug M14X15 35 cooper gasket 14 36 weak spring of rear bridge transimmision shaft...

Страница 77: ...chanism refer shift Mechanism refer shift Mechanism refer shift Mechanism refer to the picture of to the picture of to the picture of to the picture of gear gear gear gear shift Mechanism shift Mechan...

Страница 78: ...pletely declutch whether the gearshift is greased reliable whether the oil pipe of gear shift mechanism is blocked whether gear shift mechanism jams If these situation happens maintanance staff would...

Страница 79: ...dust proof cover of rear rocker arm 5 rear left upper rocker arm assembly 6 middle spacer sleeve of fore L R rocker arm 7 hexagon flange bolt M10 65 8 ust proof cover of rear rocker arm 9 rear left bo...

Страница 80: ...ker arm assembly 4 middle spacer sleeve of rocker arm 5 open groove nut M10 6 cotter pin 3 2 32 7 fore bottom left rocker arm assembly 8 fore bottom velocity joint assembly 9 stopper elastic ring for...

Страница 81: ...or problem A If the L R rocker arms swing easily we can test it from the following aspects whether the collar sheath is defective by pressuer and whether the Rubber Sheath is worn out or cracked B Che...

Страница 82: ...not be cracked Check whether these components are greased with butter and then tighten the up and down rocker arm assembly and L R fore dampers and ther components Fix the L R tension rods into hole...

Страница 83: ...heath 4 Check if the cotter pin on the assembly shaft of the rear damper is reliable Caution Disassemble rear damper and check if the damper and the connecting hole is bent or cracked In case of above...

Страница 84: ...12 White Green W G 29 Black White B W 13 White Red W R 30 White Blue W L 14 White Black W B 31 Yellow White Y W 15 Light Blue Lb 32 Green Blue G L 16 Light Green Lg 33 Purple V 17 Black Yellow B Y Tr...

Страница 85: ...85...

Страница 86: ...ug pollute or wear intermittence 2 high voltage bag high voltage lead wire insulated badness repalce replace electrification system 1 discharge self 2 uncharge or shortage charge 1 cover polluted or d...

Страница 87: ...ge to capacitance C at the same time spring coil produce spring signal provided to SCR as the turnon spring signal when reaching the ignition timing SCR turnon capacitance began to discharge at the el...

Страница 88: ...come into to being the pressure Through 3 lines Y yelloe output into the rectifier through rectifier into direct current pressure and output through R1 to charge the battery 5 3 Battery Under the fol...

Страница 89: ...y at a low temperature and dry place 5 Charge battery before fix it If battery without electrolyte it may cause the rectifier damaged And the electrolyte is venomous and dangerous As it contains vitri...

Страница 90: ...red green black flashing relay battery 12V 12Ah black brown blue red1 function switch 10A signal 25A Ignition 5A 2 4draver 25A frontlight biue black1 red red white red brown brown blue yelow red brown...

Страница 91: ...is function left and right turning lights will shine at the same time Meter meet an emergency the lamp is red do not shine Horn Switch yellow red light green function OFF function yellw red blue white...

Страница 92: ...m working process Turn on the start switch on the left handlebar the battery can supply power for the CDI Then the CDI supply power for the startor relay then the power from the battery can be sent to...

Страница 93: ...change a powerful battery or charge for it 3 If the startor motor can not work normally please check according to the 2 rule to see if it is not lubricated enough 6 Appendix 6 1 Specification 6 1 1 T...

Страница 94: ...tion Emergency brake hand operation Parking brake Engine hand operation Gear shift handle Wheel Hub Front Alloy Steel wheels Rear Alloy Steel wheels Tyre dimension Front 25x8 12 Vacuum Tyre Rear 25x10...

Страница 95: ...100r min Fuel type Unlead 90 Lubrication Pressure Splash Starting system Electric Start and hand recoil start Ignition C D I Drive train Axle Transmission CVT Belt drive r atio 5 0695 0 7679 L Drive r...

Страница 96: ...ic Battery 12V 21Ah Headlight 12V 35W 35W White light Front Indicator 12V 3W White light Rear Indicator 12V 5W Red light Brake light 12V 21W Red light Rear license plate light 12V 5W White light Turni...

Страница 97: ...rmance must be less than 13s 200m c curb top speed Crest speed must be less than 90km h the Crest speed of E mark must be less than 80km h d grade climbing Climbing cpacity must be greater than 22 e m...

Страница 98: ...o frequency interference must be conform to GB 14023 2006 l parking performance When using the parking brake on neutral the parking brake system must enable the vehicle motionless in both straight and...

Страница 99: ...ut on fore damper 35 45 Upper nut on rear damper 45 55 bottom nut on rear damper 45 55 Nut on upper rocker arm of the left 40 50 Nut on bottom rocker arm of the left 40 50 Nut on upper rocker arm of t...

Страница 100: ...tor to control the dash light earth connection 3 The function of the diode in this circuitry is that after parking and brake to actualize the electrial starting 4 The relay electrical source to provid...

Страница 101: ...101 L1 L2 30A CDI m m i n 1000 FUEL OVERRIDE...

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