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Warning

Caution

Warning

(

)

Installation

steps

steering

bar

Install

the

lower

holding

seat

①

steering

tube

②

and upper holding seat

③

When tightening the bolt of holding seat, make

ensure the even of clearance .

Attached:bolt torque:20Nm

2.Install the throttle grip unit

The

projection

①

throttle

grip

must

correspond

the

sunken

part

②

the

right

lever seat

when

installation

Correct installation of cable and wire is very

necessary for ensuring the safty operation of vehicle.

Refer to chapter 1“wiring diagram of vehicle”

3.Ajusting the free clearance of brake cable

4.Adjusting the toe-in of front wheel

5.Mounting front fedner, bumper, front luggage

carrier.

Содержание RT150ST-A

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 20: ...rease Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lubricating oil Lu...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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