Manual de Taller ET 300
Manual de Taller ET 300
Manual de Taller ET 300
Service Manual
1
Contents
1. INFORMATION
1-1 Safety
1-2 Notes
1-3 Engine Specifications
1-4 Serial Number
1-5 Torque Values
1-6 Special Tools
2. MAINTENANCE
2-1 Maintenance Data
2-2 Maintenance Schedule
2-3 Fuel Tube
2-4 Throttle Operation
2-5 Throttle Cable Adjustment
2-6 Air Cleaner
2-7 Spark Plug
2-8 Idle Speed
2-9 Drive Chain
2-10 Brake System
2-11 Wheels And Tires
2-12 Steering Shaft Holder Bushing
2-13 Toe-In
3. ENGINE REMOVE AND INSTALLATION
3-1 General Information
3-2 Engine Removal
3-3 Engine Installation
4. LUBRICATION SYSTEM
4-1 Mechanism Diagram
4-2 Precautions In Operation
4-3 Troubleshooting
4-4 Engine Oil
4-5 Engine Oil Strainer Clean
4-6 Oil Pump
4-7 Gear Oil
5. FUEL SYSTEM
5-1 Mechanism Diagram
5-2 Precautions In Operation
5-3 Trouble 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
6. CYLINDER HEAD/VALVE
6-1 Mechanism Diagram
6-2 Precautions In Operation
6-3 Troubleshooting
6-4 Cylinder Head Removal
6-5 Cylinder 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
7. CYLINDER/PISTON
7-1 Mechanism Diagram
7-2 Precautions In Operation
7-3 Trouble Diagnosis
7-4 Cylinder And Piston Removal
7-5 Piston Ring Installation
7-6 Piston Installation
7-7 Cylinder Installation
8. V-BELT DRIVING SYSTEM
8-1 Mechanism Diagram
8-2 Maintenance Description
8-3 Trouble Diagnosis
8-4 Left Crankcase Cover
8-5 Drive Belt
8-6 Drive Face
8-7 Clutch Outer/Driven Pulley
9. FINAL DRIVING MECHANISM
9-1 Mechanism Diagram - Transmission Cover
9-2 Precautions In Operation
9-3 Trouble Diagnosis
9-4 Disassembly Of Transmission
9-5 Inspection Of Mission Mechanism
9-6 Bearing Replacement
9-7 Re-assembly Of Final Driving Mechanism
10. ALTERNATOR/STARTING CLUTCH
10-1 Mechanism Diagram
10-2 Precautions In Operation
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 Crankcase Cover Installation
11. CRANKCASE / CRANK
11-1 Mechanism Diagram
11-2 General Information
11-3 Trouble Diagnosis
11-4 Disassembly Of Crankcase
11-5 Crankshaft Inspection
11-6 Assembly Of Crankcase
12. COOLING SYSTEM
12-1 Mechanism Diagram
12-2 General Information
12-3 Trouble Diagnosis
12-4 Trouble Diagnosis For Cooling System
12-5 System Test
12-6 Radiator
12-7 Water Pump
12-8 Thermostat
13. STEERING AND SUSPENSION
13-1 Parts Drawing
13-2 Troubleshooting
13-3 Handlebar
13-4 Throttle Housing
13-5 Steering System
14. FRONT WHEEL AND BRAKE SYSTEM
14-1 Parts Drawing
14-2 Troubleshooting
14-3 Front Wheels
14-4 Hydraulic Brake
14-5 Suspension Adjustment
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
15-5 Suspension Adjustment
16. FENDERS AND EXHAUST PIPE
16-1 Fenders Drawing
16-2 Rear Fenders Removal
16-3 Front Fender Removal
16-4 Exhaust Pipe Removal
17. ELECTRICAL SYSTEM
17-1 Troubleshooting
17-2 Ignition Coil
17-3 Ignition Timing
17-4 Battery Information
17-5 Electric Starter
17-6 Light Bulbs Replacement
17-7 Instrument Pane
17-8 Wiring Diagram
18.TROUBLESHOOTING
18-1 Engine Can Not Work
18-2 Poor Performance At Low And Idle Speeds
18-3 Poor Performance At High Speed
18-4 Loss Power
18-5 Poor Handling
1. INFORMATION
1-1 Safety 1-4 Serial Number
1-2 Notes 1-5 Torque Values
1-3 Engine Specifications 1-6 Special Tools
1-1 Safety
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition.
● CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and lead to death.
● BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and
clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte
● HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the
1-2 Notes
All information, illustrations, directions and specifications included in this publication are base on the latest
product information available at the time of approval for printing.
JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and
without incurring any obligation whatever.
No part of this publication may be reproduced without written permission.
6
1-3 Engine Specifications
CHASSIS
Overall Length 1830mm
Overall Width 1040mm
Overall Height 1150mm
Wheel base 1190mm
Ground Clearance 150mm
Dry Weight 225Kg
Fuel Tank Capacity 12L
SUSPENSION
Front Double A-Arm & Adjustable
Rear Swing Arm & Adjustable Shock
BRAKES
Front Front Hydraulic Disc*2
Rear Rear Hydraulic Disc*1
TIRES
Front 21x7-10
Rear 22x10-10
PRESSURE【kgf/cm2】
Front 0.26
Rear 0.26
COLORING
Specifications subject to change without notice.
7
1-4 Serial Number
8
1-5 Torque Values
STANDARD
● 5 mm bolt and nut 5 N.m (3.5 lbf.ft)
ENGINE
● Cylinder head nut 38 N.m (27.4 lbf.ft)
FRAME
● Handlebar upper holder bolt 24 N.m (17.7 lbf.ft)
● Throttle housing cover screw 4 N.m (2.9 lbf.ft)
● Steering shaft 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 N.m (29.5 lbf.ft)
● Front wheel bolt 24 N.m (17.7 lbf.ft)
● Front axle castle nut 40-60 N.m (30-45 lbf.ft)
● Front brake arm nut 4 N.m (3.0 lbf.ft)
● Rear brake arm nut 7 N.m (5.2 lbf.ft)
● Rear axle castle nut 40-60 N.m (30-45 lbf.ft)
● Rear wheel bolt 24 N.m (17.7 lbf.ft)
● Exhaust muffler mounting bolt 30 N.m (22.1 lbf.ft)
● Engine hanger bolt 30 N.m ( 22 lbf.ft)
● Rear axle holder bolt 90 N.m (65 lbf.ft)
● Swing arm pivot nut 90 N.m (65 lbf.ft)
● Rear shock absorber mounting nut 45 N.m (33 lbf.ft)
Check all fixing pins, snap rings, hose clamp, and wire holders for security.
1.6 Special Tools
For Frame
Purpose: Taking out the ball joint from front knuckle as repairing.
10
For Engine
(C1110-RB1-FT1)
(A4721-HMA-FT1)
11
5. SLEEVE OF FABRICATING L CRANK & OIL
SEAL (I1201-HMA-FT1)
(I6150-6006-FT1)
12
9. FABRICATING R CRANK CASE COVER 6201
13
13. ASSEMBLING DRIVE SHAFT TOOL
(B3411-RB1-FT1)
TOOL (I6100-6305-FT1)
14
16. KNOCKING WATER PUMP OIL SEAL IMPLEMENT (INSIDE)
(I1205-KF0-FT1 )
15
20. TAKING BRG. 62040 LARGE-SIZE TOOL
(I6100-6204-FT3 )
16
2. MAINTENANCE
2-1 Maintenance Data 2-8 Idle Speed
2-2 Maintenance Schedule 2-9 Drive Chain
2-3 Fuel Tube 2-10 Brake System
2-4 Throttle Operation 2-11 Wheels And Tires
2-5 Throttle Cable Adjustment 2-12 Steering Shaft Holder Bushing
2-6 Air Cleaner 2-13 Toe-In
2-7 Spark Plug
SPECIFICATION
SPARK PLUG
SPARK PLUG GAP 0.8 mm
RECOMMENDED SPARK PLUGS NGK CR8E
THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1700±100 rpm
BRAKE LEVER FREE PLAY 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
TOE-IN 5±10 mm
TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL 1.4 Liter (1.2Liter for change)
GEAR LUBRICATION OIL 750cc (650cc for change)
17
2-2 Maintenance Schedule
The internal maintenance in the following table is based on average riding, normal conditions.
Riding in unusually dusty areas, require more frequent servicing.
18
2-4 Throttle Operation
When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator.
Please use special chain oil to lubricate the drive chain.
Clean the drive chain with kerosene and wipe it dry.
Inspect the drive chain for any possible wearing or damaging.
Replace the chain, if it is worn excessively or damaged.
20
2-10 Brake System
Inspect the front brake lever and cable for excessive play or other
damage.
Replace or repair if necessary.
Measure the brake lever free play at the end of the brake lever trip.
Parking Brake
Turn the parking brake to the left side is “parking off”, while
turn to right side is “parking on”. As you found out the
parking brake which has been decreased its brake ability, you
might screw the adjustable nut to modify the clearance of
brake shoe to the correct position. Also, another method of
adjustment of parking brake, please refer to next page.
Parking Off
21 Adjustment
Brake level
NOTE:
y The second method to adjust brake level is under the driver
seat and rear brake component.
Loosen the adjustable nut near the rear brake caliper. Screw the
adjustable bolt by hand with C.W. turn to the end, then back to a
quarter turn. Tighten the nut to complete the parking brake
adjustment.
Also, as you fount out the brake ability which is a bit insufficient,
you can screw the adjustable nut of parking Brake
22
2-11 Wheels And Tires
Inspect the tire surfaces for cuts, nails or other sharp objects.
Check the each tire surface at cold tire condition.
2-13 Toe-In
Keep the vehicle on level ground and the front wheels facing straight
ahead.
Mark the centers of the tires to indicate the axle center height.
Measure the distance between the marks.
Carefully to move the vehicle back, let the wheels turn 180 degree,
so the marks on the tires are aligned with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear measurements.
Toe-in: 5±10mm
23
If the toe-in is out of standard, adjust it by changing
the length of the tie-rods equally by turning the tie-rod
while holding the ball joint.
Tighten the lock nuts.
Lock Nuts
24
3. ENGINE REMOVE AND INSTALLATION
3-1 General Information 3-3 Engine Installation
3-2 Engine Removal
Before removing engine, you need to remove all of components such as seat, front and back fender,
fuel tube, exhaust pipe, carburetor cable and drive chain…etc. You can then see three hanger bolts which have
screwed on engine.
Loosen these three hanger bolts. You have succeeded to remove this engine.
Hanger bolt
25
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.
26
4. LUBRICATION SYSTEM
4-1 Mechanism Diagram 4-5 Engine Oil Strainer Clean
4-2 Precautions In Operation 4-6 Oil Pump
4-3 Troubleshooting 4-7 Gear Oil
4-4 Engine Oil
Press-In Lubrication
Cam Shaft
Oil Route
Spray Lubrication
Con-Rod
Oil Route
Spray Lubrication
Press-In Lubrication
Rotate Direction
Oil Pump
Oil Strainer
27
4-2 Precautions In Operation
General Information:
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1400 c.c.
Change: 1200c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)
單位:mm
Torque value
Torque value oil strainer cap 1.5~3.0kgf-m
Engine oil drain bolt 1.9~2.5kgf-m
Gear oil drain bolt 1.0~1.5kgf-m
Gear oil join bolt 1.0~1.5kgf-m
Oil pump connection bolt 0.8~1.2kgf-m
4-3 Troubleshooting
Low engine oil level Dirty oil
y Oil leaking y No oil change in periodical
y Valve guide or seat worn out y Cylinder head gasket damage
y Piston ring worn out y Piston ring worn out
28
4-4 Engine Oil
Turn off engine, and park the ATV in flat surface
with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Drain bolt
Caution
Drain oil as engine warmed up so that makes sure
oil can be drained smoothly and completely.
Oil strainer
O-ring
29
4-6 Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
Clip
2 screws
1 screw
Oil Pump Disassembly
Remove the screws on oil pump cover and
remove the cover.
Remove oil pump shaft roller and shaft.
Roller
30
Oil Pump Inspection
Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
31
Tighten the oil pump screw. 1 screw
Roller
2 screws
Clip
32
4-7 Gear Oil
Gear Oil Change Gear oil join bolt
Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.
Torque value: 1.0~1.5kgf-m
Fuel unit
Fuel tank
Carburetor
Fuel strainer
Inlet pipe
5-2 Precautions In Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.
Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
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 disassemble air cut valve arbitrarily.
Tool
Special service tools
Specification of CARBURETOR
ITEM UA25A
Carburetor diameter Ø22mm
Idle injector # 35
Rough idle
y Malfunction of ignition system
y Incorrect idle speed
y Malfunction of carburetor
y Dirty fuel
Drain bolt
1 screw
Choke cable
Installation
Install in reverse order of removal procedures.
2 nuts
5-5 Air Cut-Off Valve 2 screws
Disassembly
Remove 2 screws.
O-ring Spring
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.
Air cut-off valve Cover
Assembly
Install in reverse order of removal procedures.
5-6 Throttle Valve
Disassembly
Remove carburetor upper parts, and then remove
throttle valve and throttle cable.
Assembly
Place the fuel needle onto the throttle valve and clip it
with needle clamp.
Spring
Install the sealed cap, carburetor upper part, and
throttle valve spring.
Connect the throttle valve cable to the throttle valve. Needle clamp
Install the throttle valve into the carburetor body.
Fuel needle clip
Fuel needle
Throttle
cable
Caution
Align the groove inside the throttle valve with the
throttle stopper screw of the carburetor body.
Remove the fuel level plate, float pin, float and float 3 Screws
valve.
Inspection
Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve seat Fuel level plate Pin
face for wear, dirt.
Pin
Caution
In case of worn out or dirt, the float valve and
valve seat will not tightly close causing fuel level
to increase and as a result, fuel flooding. A worn
out or dirty float valve must be replaced with a
new a new one.
Float valve
Remove main jet, needle jet holder, needle jet, slow Needle jet holder
Main jet
jet and air adjustment screw.
Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
Needle jet Slow jet
the way down and note the number of turns.
y Does not turn adjust screw forcefully to avoid
damaging valve seat face.
Assembly
Install main jet, needle jet holder, needle jet, slow jet
and air adjustment screw.
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.
Installation of carburetor
Install carburetor in the reverse order of removal.
Following adjustments must be made after Throttle adjustment screw
installation.
․Throttle cable adjustment.
․Idle adjustment
5-8 Adjustment Of Idle Speed Ignition cable
Caution
y Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
y Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV warm up engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1700 ± 100 rpm
Caution Coupler
․Do not bend the float arm of fuel unit
․Do not fill out too much fuel to fuel tank.
Caution
Fuel tube
Do not forget to install the gasket of fuel unit or
damage it.
Remove fuel tank front and rear side 4 bolts, and then
remove fuel tank.
4 bolts
REAR
Installation
Install the tank in the reverse order of removal.
5-10 Air Cleaner Clamp
Removal
Loosen the clamp strip of air cleaner and carburetor,
and then remove the vapor hose.
Installation
Install the tank in the reverse order of removal.
1.0~1.4kgf-m
1.0~1.4kgf-m
3.6~4.0kgf-m
2.4~3.0kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m 1.0~1.2kgf-m
0.7~1.1kgf-m
1.0~1.4kgf-m
1.0~1.2kgf-m
6-2 Precautions In Operation
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
y Cylinder head service can be carried out when engine is in frame.
Torque Value
Cylinder head cover bolt 1.0~1.4kgf-m
Exhaust pipe stud bolt 2.4~3.0kgf-m
Cylinder head bolt 1.0~1.4kgf-m
Cylinder head Nut 3.6~4.0kgf-m
Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cylinder side cover bolt 1.0~1.4kgf-m
Cam sprocket bolt 1.0~1.4kgf-m
Tappet adjustment screw nut 0.7~1.1kgf-m
Spark plug 1.0~1.2kgf-m
Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-3 Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by
performing cylinder compression test and judging the abnormal noise generated.
Noise
y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Chain wear out or looseness
y Auto-tensioner wear out or damage
y Camshaft sprocket
y Rocker arm or rocker arm shaft wear out
6-4 Cylinder Head Removal
2 nuts
Remove engine. (Refer to chapter 5)
Remove the inlet pipe (2 nuts).
Tensioner bolts
Cam shafts
Rocker arm
2 bolts
Gasket
Remove cylinder head gasket and 2 dowel pins.
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Caution
Chain guide Dowel pins
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Caution
Inlet valve Inner spring Spring retainer
y In order to avoid loosing spring elasticity, do
not press the spring too much. Thus, press
length is based on the valve cotter in which can
be removed.
Special Service Tool:
Valve cotter remove & assembly tool
Caution
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.45mm
EX: Replacement when less than 34.30mm
Inspect the camshaft bearing for looseness or wear
out. If any damage, replace whole set of camshaft
and bearing.
Rocker Arm
Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?
Service Limit: Replace when it is less than 12.10
mm.
Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
Valve guide
Caution
Caution
Caution
Hold the cylinder head, and then press out old valve
guide from combustion chamber side.
Valve guide driver
Tool: Valve guide driver: 5.0 mm 5.0 mm
Caution
Caution
Caution
Caution
Caution
Use 45° cutter to grind the valve seat to specified width. 60°
Caution
45°
Caution
If the contact surface too high, grind the valve seat with
32° cutter.
Then, grind the valve seat to specified width.
If the contact surface too low, grind the valve seat with 60°
60° cutter.
Then, grind the valve seat to specified width.
After the valve seat ground, coat valve seat surface
with emery and then slightly press the ground
surface.
Clean up all emery coated onto cylinder and valve
after ground.
The closed coils of valve spring should face down Valve cotter
Inlet valve
to combustion chamber.
Valve spring
Exhaust valve
Caution
Caution
Caution
Install rocker arm pin mounting plate. Cam shaft setting plate
Install cam chain on to sprocket and align the Timing mark
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts. 2 bolts
Caution
3 bolts
Thermostat bolts
4 bolts
Install Air Injection system (AI) pipe. (4 bolts)
Install inlet pipe onto cylinder 4 bolts Spark plug
Install and tighten spark plug
Torque value: 1.0~2.0kgf-m
Caution
Caution
Checks and adjustment must be performed when
Timing mark
the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank.
Remove cylinder head cover.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T” 2 bolts
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.
Caution
7. CYLINDER/PISTON
7-1 Mechanism Diagram 7-5 Piston Ring Installation
7-2 Precautions In Operation 7-6 Piston Installation
7-3 Trouble Diagnosis 7-7 Cylinder Installation
7-4 Cylinder And Piston Removal
1.0~1.4kgf-m
0.8~1.2kgf-m
To this chapter contents
UA25A
Specification Unit:mm
Item Standard Limit
ID 74.995~75.015 75.100
Cylinder
Bend - 0.050
Clearance between piston Top ring 0.015~0.050 0.090
rings nd
2 ring 0.015~0.050 0.090
Top ring 0.150~0.300 0.500
nd
Piston/ Ring-end gap 2 ring 0.300~0.450 0.650
Piston ring Oil ring side rail 0.200~0.700 -
nd
OD of piston (2 ) 74.430~75.480 75.380
Clearance between piston and cylinder 0.010~0.040 0.100
ID of piston pin boss 17.002~17.008 17.020
OD of piston pin 16.994~17.000 16.960
Clearance between piston and piston pin 0.002~0.014 0.020
ID of connecting rod small-end 17.016~17.034 17.064
Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective
Top
in the cylinder.
Center
Service limit: 75.100 mm Bottom
Check cylinder if warp.
Service limit: 0.05 mm
Service limit:75.380 mm
Top ring
nd
2 ring
Oil ring
Top groove
nd
2 groove
Oil groove
To this chapter contents
Cutout
Dowel pins
Coat some engine oil to inside of cylinder, piston
and piston rings.
Care to be 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.。
Coolant hose
8. V-BELT DRIVING SYSTEM
8.5~10.5kgf-m
5.0~6.0kgf-m
5.0~6.0kgf-m
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
Item Standard value Limit
Driving belt width 24.000 mm 22.500 mm
OD of movable drive face boss 29.946~29.980 mm 29.926 mm
ID of movable drive face 30.000~30.040 mm 30.060 mm
OD of weight roller 19.500~20.000 mm 19.000 mm
ID of clutch outer 144.850~145.150 mm 145.450 mm
Thickness of clutch weight 6.000 mm 3.000 mm
Free length of driven pulley spring 102.400 mm 97.400 mm
OD of driven pulley boss 40.950~40.990 mm 40.930 mm
ID of driven face 41.000~41.050 mm 41.070 mm
Weight of weight roller 17.700~18.300 g 17.200 g
10 bolts
Dowel pins
Ratchet cover
Dowel pins
Volute spring
9 bolts
5 screws
1 bolt
Caution
y If remove the volute spring from the l crank
cover then its has to be replaced.
Installation
Install in reverse order of removal procedures
Caution
First before installing the drive pulley must
establish 2 1/2 of the pressures transferred to
pressure springs.
8-5 Drive Belt Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.
Special Tool:
Tool number : SYM-2210100
Tool name: universal holder
Caution
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
Service Limit: 22.5 mm
Replace the belt if exceeds the service limit.
Belt tooth
Caution
Width
y Using the genuine parts for replacement.
y The surfaces of drive belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.
Installation
Caution
z Pull out driven face to avoid it closing. Driven face
z Cannot oppress friction plate comp in order
to avoid creates the distortion or the
damage.
Install drive belt onto driven pulley.
Universal holder
Install the drive face, washer and drive face nut.
Hold drive face with universal holder, and then
tighten nut to specified torque value.
Torque value: 8.5~10.5kgf-m
8-6 Drive Face Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Crankshaft
Drive face boss
Remove weight rollers from movable drive face. Movable drive face
Weight roller
Inspection
Weight roller
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 19.0 mm
Weight: 17.2g
Check if drive face boss is worn or damaged and Movable drive face
replace it if necessary.
Measure the outer diameter of movable drive face
Drive face boss
boss, and replace it if it exceed service limit.
Service limit: 29.962 mm
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 30.060 mm
Reassembly/installation
Install weight rollers. Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Closure surface
Guide collar
8-10
With 4~5g grease spreads wipes drives in the
movable drive face axis hole.
Install drive face boss.
Caution
The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.
Crank shaft
Press down
Driven pulley installation
Press drive belt into pulley groove, and then pull
the belt onto drive shaft.
Drive belt
Caution
Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.
Hold drives face with universal holder.
Tighten nut to specified torque.
Torque value: 8.5~10.5kgf-m
Install left crankcase cover.
8-7 Clutch Outer/Driven Pulley
Clutch nut wrench
Disassembly
Remove drive belt, clutch outer and driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.
Caution
Do not press the compressor too much.
Clutch spring compressor
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
friction plate, clutch weight and spring from driven
pulley.
Collar
Remove guide pin, guide pin roller, and movable Movable driven face Guide pin
Seal
driven face, and then remove O-ring & oil seal
seat from movable driven face.
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 145.450 mm
Inner
diameter
Clutch outer
Clutch lining
Clutch lining
Measure each clutch weight thickness. Replace
it if exceeds service limit.
Service limit: 3.0 mm
Clutch weight
Free length
Driven pulley
Check following items:
y If both surfaces are damaged or worn.
y If guide pin groove is damaged or worn.
Driven face
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 40.93 mm
Inner diameter 41.07 mm
Movable driven face Guide pin groove
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Needle bearing
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Outer ball bearing
To this chapter contents
Caution
Some of models are equipped with one mounting
plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight
Caution
Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity. Clutch weight
Snap ring
Caution
y If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
y If the pulley equipped with ball bearing, it has to Inner needle
bearing
remove snap ring and then the bearing.
Snap ring
Outer bearing
Specified grease
O-ring
Collar
Torque value
Gear box cover 2.6~3.0kgf-m
Gear oil drain bolt 0.8~1.2kgf-m
Gear oil fill bolt 3.5~4.5kgf-m
Tools
Special tools
Bearing driver (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 puller: SYM-2341100
Inner bearing puller: SYM-6204002
Noise
y Worn or burnt gear
y Worn gear
1 bolt
Speedometer cable
Loosen speedometer cable mounting nut, and then
remove the cable.
Remove 3 bolts and remove drive chain protector.
Turn the socket bolt clockwise, and then remove 3 bolts
speedometer gear box.
Caution
Drain bolt
Remove gear box cover bolts (9 bolts) and then
remove the cover.
9 bolts
Shift drum
Caution
y If non- essential do not remove the drive shaft
from the case upper side.
y If remove the drive shaft from the gear box,
then its bearing and oil seal has to be
replaced.
Check bearings on gear box and gear box cover. Reverse shaft
Rotate each bearing’s inner ring with fingers. bearing
Check if bearings can be turned in smooth and
silent, and also check if 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. Counter shaft needle bearing
Final shaft bearing
Crankcase side
Remove drive shaft bearing setting plate, and then
remove drive shaft bearing from left crankcase
using following tools.
Remove reverse shaft bearing and counter shaft Bearing driver
bearing from left crankcase using following tools.
Remove drive shaft oil seal.
Special tool:
Inner bearing puller
Apply with grease onto new drive shaft oil seal lip, Drive shaft and
and then install the oil seal. seal install bush
Special tool:
Drive shaft and oil seal install bush
Install drive shaft bearing setting plate (1 bolt).
Cir clip
Bearing driver
Bearing driver
Install new oil seal and bearing driver into gear Universal
box cover inner side. bearing puller
Install the universal bearing puller and bearing
driver.
Turn the universal bearing puller to install drive
shaft oil seal.
Special tool:
Bearing driver (6205)
Universal bearing puller
9-7 Re-assembly Of Final Driving
Mechanism
Apply with grease onto the oil seal lip of final Oil seal
driving shaft.
Shift drum
Dowel pins
9 bolts
0.8~1.2kgf-m
1.0~1.4kgf-m
5.0~6.0kgf-m
10-2 Precautions In Operation
General information
y Refer to chapter 17: The troubleshooting and inspection of alternator
y Refer to chapter 17: The service procedures and precaution items of starter motor
Specification
Item Standard value (mm) Limit (mm)
Torque value
Flywheel nut 5.0~6.0kgf-m
Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive
8 mm bolts 0.8~1.2kgf-m
12 mm bolts 1.0~1.4kgf-m
Tools
Special tools
A.C.G. flywheel puller: SYM-3110A00
Universal holder: SYM-2210100
10-3 Right Crankcase Cover Removal
Remove left footrest. 11 bolts
Drain out the engine oil and coolant, and then
remove coolant hoses.
Remove water pump cover (4 bolts).
Remove 11 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.
3 screws
Bearing driver
OD
Remove 3 socket bolts, and then remove one way 3 socket bolts
clutch.
Wire 2 bolts
10-9 A.C.G. Set Installation
Install the A.C.G. coil set onto right crankcase
cover (3 screws).
Install pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed under
pulse generator.
3 screws
Dowel pin
1.0~1.4kgf-m
0.8~1.2kgf-m
0.8~1.2kgf-m
y In case it requires replacing the crankshaft bearing, the driving chain 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
Crankshaft
Vertical clearance of the big end of the connecting rod 0~0.008 0.050
Run-out 0.030 0.100
Torque value
Bolts for crankcase 0.8~1.2kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Cylinder stud bolt 1.0~1.4kgf-m
Tools
Special tools
L. crank shaft oil seal driver (27*42*7): SYM-1332100-HMA
2 bolts
11 bolts
90 mm 60 mm
Wave washer
Align the position mark on the balance shaft drive Position mark
gear with that of balance shaft driven gear, and then
install balance shaft onto right crankcase.
Install 2 dowel pins and new gasket.
Dowel pins
11 bolts
2 bolts
Clean the crankshaft.
Apply a layer of grease on the lip of oil seal, Puts on
the left crank shaft.
Install the oil seal in the left crankcase with care not to
damage the lip of the oil seal.
Oil seal
By oil seal driver (27×42×7), oil seal will knock into driver
located.
Special tool:
Oil seal driver (27×42×7)
Tensioner
Reserve tank
By-pass pipe
To cylinder head
Radiator
Cooling fan
Thermostat
Thermo switch (fan)
Water pump
12-2 General Information
General
Warning:
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant
may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the
engine is completely cooled down.
Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 850c.c.
Reservoir upper 420c.c.
Begins to activate at 82~95℃
Thermostat
Stroke: 0.05~3mm
Thermos switch (fan) Begins to activate at 98±3℃
Not-pressure: 107.7℃
Boiling point
Pressurized: 125.6℃
Torque Value
For water pump rotor 1.0~1.4kgf-m
Tools Requirement
Special tools
Water pump bearing driver (6901): SYM-9100100
Water pump oil seal driver (Inner): SYM-9120500-H9A
Water pump mechanical seal driver: SYM-1721700-H9A
Inner bearing puller: SYM-6204020
Y
B-2. Inspect the circuits of Y
water temperature have Short or earth handle
short or earth?
N
Meter problem
Y Y
Water hose clogged
Next page
Preceding page
Remove the front center cover, and then remove filler cap. Radiator filler cap
Place a water pan under the water pump; loosen the drain
bolt to drain out the coolant.
Reinstall the drain bolt.
Caution
The reserve tank liquid level coca too is not high, Lower
after avoids the water temperature elevating, 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 radiator clean using compressed air. If the radiator is
blocked by dirt, use low pressure water jet to clean it.
Care shall be taken when straightening the sink fan.
Removal
Place a water pan under the water pump; loosen the drain
bolt to drain out the coolant.
Drain bolt
4 bolts
Disassembly
Loosen the 3 bolts from the fan duct, and then remove the Cooling fan
fan duct. duct bolts x3
Loosen 3 screws from the fan motor, and take off the fan
motor. Cooling fan
Remove nut to remove the fan from fan motor. motor screws x3
Assembly
Install fan motor onto fan duct and insert the fan into the
motor shaft.
Apply a coat of the adhesive to the shaft thread of the
motor, and then install the washer and the lock nut. Thermo switch
Tighten the fan duct onto the radiator with 3 bolts. Please
refer to chapter 17 for the inspection of the thermo switch.
Caution Fan nut
Installation
Install the removed parts in the reverse order of removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.
12-7 Water Pump
Drive the mechanical seal and inner seal out of the right
crankcase.
Special tools:
Inner bearing puller
Water pump bearing driver
Caution
Replace a new mechanical seal after removing
it.
Mechanical seal
Apply a coat of sealant to the mating surfaces of the right
crankcase before installing the new mechanical seal.
Inner bearing
Mount the water pump shaft and the inner bearing to the
right crankcase cover.
Removal
Drain out the coolant.
Remove the thermostat set. (2 bolts)
2 Bolts
Inspection
Visually inspect thermostat for any damage.
Technical Data
Valve begins to open 82~95℃
Valve stroke 0.05 ~ 3mm
Installation
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out the air bubble (Page 12-5).
13. STEERING AND SUSPENSION
Steering
Handle bar
13-2 Troubleshooting
13-3 Handlebar
REMOVAL
Screws
Remove the handle bar switch on the left handle bar.
Remove rear brake lever bracket assembly.
Screws Bolts
Screws
dot
NOTE:
Assembly is in the reverse order of disassembly.
Screws
Step 2
Steering Shaft Holder Inspection
Remove the steering shaft.
Remove the bushing from the shaft.
Inspect the bushing for damage or wear, replace if necessary.
Measure the bushing inner diameter.
Maximum limit: Ø39.5 mm
Step 3
Steering Shaft Inspection
Inspect the steering shaft for damage or cracks.
FRONT WHEEL
FRONT BEAKE
14-2 Troubleshooting
REMOVAL
(The disassemble of front wheel system
in this serials are the same)
Raise the front wheels off the ground by placing a jack
or other support under the frame.
Remove the front wheel nuts, washer and wheels.
INSTALLATION
REMOVAL
Bolts
Castle nut
Then using the power tools to take the screw out
from brake stopping plate. You can take the brake disc off.
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.
1. You can raise the all ATV body up by using a repair platform.
The four wheels are in the free position, you can use special
tool (adjustable hook spanner, E1105-LRA0-FT1 ) to adjust
the suspension.
When you use the adjustable hook spanner, please depress the
slider (fig 2&3.) to a proper position.
Fig 1
Depress
Fig 2 Depress
Fig 3
15. REAR WHEEL AND BRAKE SYSTEM
15-1 Parts Drawing 15-3 Remove Rear Wheel And Rear Brake
15-2 Troubleshooting 15-4 Swingarm & Rear Axle Holder
15-5 Suspension Adjustment
REAR WHEEL
Bolts
Bolt
Plate Piston
Eventually, you can take all brake shoe out the hub.
Bolt
Hanger bolt
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.
Hanger bolt
1. A damage of bearings
2. The main frame will be extended at the area of assembly swim arm (Unalignment).
15-5 Suspension Adjustment
1. You can raise the all ATV body up by using a repair platform.
The four wheels are in the free position, you can use special tool
(adjustable hook spanner) to adjust the suspension.
When you use the adjustable hook spanner, please depress the slider (fig
2&3.) to a proper position. You can then adjust your ATV’s suspension
(fig 4). Fig 1
Press it
Fig 2
Fig 3
Fig 4
16. FENDERS AND EXHAUST PIPE
Release Bar
Screws
Screws
16-4 Exhaust Pipe Removal
You must wait at least 15 minutes after stopping the engine.
You need to remove the 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.
Nuts Bolts
Bolt
CATUATION:
After installing, make sure that there are no exhaust leaks.
17. ELECTRICAL SYSTEM
17-1 Troubleshooting 17-5 Electric Starter
17-2 Ignition Coil 17-6 Light Bulbs Replacement
17-3 Ignition Timing 17-7 Instrument Pane
17-4 Battery Information 17-8 Wiring Diagram
17-1 Troubleshooting
ENGINE STARTS BUT STOPS ★ IMPROPER IGNITION TIMING
★ FAULTY SPARK PLUG
NO SPARK AT PLUG ★ ENGINE STOP SWITCH AT “ OFF “ POSTION
★ GEARSHIFT BAR IS NOT AT NORMAL
POSITION
★ FAULTY IGNITION COIL
★ FAULTY GENERATOR
★ FAULTY CDI UNIT
★ POOLY CONNECTED:
Between CDI and ignition coil
Between alternator and CDI unit
Between CDI and engine stop switch
Between ignition coil and spark plug
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
★ IGNITION SECONDARY CIRCUIT
Faulty plug
Loosen contacted spark plug wire
★ IMPROPER IGNITION TIMING
Faulty generator
Faulty CDI unit
CHARGING SYSTEM FAILURE ★ LOOSE, BROKEN OR SHORTED WIRE
★ FAULTY ALTERNATOR
★ FAULTY IGNITION SWITCH
BATTERY REMOVAL
There are two main steps to teach you how to take out battery.
Open the seat, and then you can see the battery. Bolts
Disconnect the negative cable (Black - ) first and then the
positive cable (Red + ).
BATTERY INSTALLATION
TROUBLESHOOTING
Starter Motor Turns Slowly
Weak battery.
Poorly connected starter motor cable.
Failed starter motor.
Poorly connected battery ground cable.
Head light
To replace the direction lights must loosen the screws
as shown in picture.
TAILLIGHT
Taillight
Rear Brake lights remove
On the back of the brake light, you could see the cap.
There are two screws to fix this cap, loosen them can
open the cap.
Screws
Sensor
Cable
17-8 Wiring Diagram
18.TROUBLESHOOTING
Possibility
N.G.
CHECK IGNITION TIMING
★ Faulty CDI unit or pulse generator
O.K.
O.K
Possibility
N.G.
CHECK IGNITION TIMING ★ Faulty CDI unit
★ Faulty pulse generator
O.K.
NOT CLOGGED
Possibility
RAISE WHEELS OFF GROUND DOES NOT SPIN FREELY
AND SPIN BY HAND ★ Brake dragging
★ Drive chain too tight
SPIN FREELY ★ Damaged wheel bearing
★ Wheel bearing needs lubrication
PESSURE LOW CHECK
CHECK TIRE PRESSURE
TIRE ★ Punctured tire
★ Faulty tire valve
PRESSURE NORMAL
O.K.
FOULED OR DISCOLOED
CHECK SPARK PLUG ★ Clean the spark plug
O.K. ★ Spark plug is incorrect heat range
★ Bent rim
★ Improperly installed wheel hub
★ Excessive wheel bearing play
★ Bent swingarm
★ Bent frame
★ Swing arm pivot bushing excessively
★ Worn
VEHICLE PULLS TO ONE SIDE
★ Bent tie-rod
★ Incorrect tie-rod adjustment
★ Rear tie air pressure incorrect
★ Improper wheel alignment
★ Bent frame