Manual de Taller ET 300

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
5-3 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
6-3 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
7-4 Cylinder And Piston Removal
7-5 Piston Ring Installation
7-6 Piston Installation
7-7 Cylinder Installation
8. V-BELT DRIVING SYSTEM
8-2 Maintenance Description
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
9-4 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
10-3 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
11-4 Disassembly Of Crankcase
11-5 Crankshaft Inspection
11-6 Assembly Of Crankcase
12. COOLING SYSTEM
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
14-3 Front Wheels
14-4 Hydraulic Brake
14-5 Suspension Adjustment
15. REAR WHEEL AND BRAKE SYSTEM
15-1 Parts Drawing
15-3 Remove Rear Wheel And Rear Brake
15-4 Swingarm & Rear Axle Holder
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
17-2 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.
Do not smoke or allow sparks or flames in your work area.
● 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
gets in your eyes.
● HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the
engine is run. Wear insulated gloves before handling these parts.
● USED ENGINE/GEAR OIL

Used engine oil and gear oil may cause skin disease if repeatedly contact with
the skin for long periods.
Keep out of reach of children.
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
Type 4 Stroke，Single Cylinder, Water cooled

Displacement 287.2c.c
Bore and Stroke 75 mm x 65 mm
Compression 10.0:1
Maximum Hp 20ps / 6500
Maximum Torque (Nm/rpm) 24.6 Nm / 5000
Carburetor
Ignition DC-CDI
Starting Electric
Lubrication Auto oil injection
Transmission Automatic (C.V.T. V-belt + Reverse)
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
The frame serial number is stamped on the front of the frame.

The engine serial number is stamped on the left side of the crankcase.
Frame serial number
8
1-5 Torque Values
STANDARD
● 5 mm bolt and nut 5 N.m (3.5 lbf.ft)
● 6 mm bolt and nut 10 N.m (7.2 lbf.ft)
● 8 mm bolt and nut 22 N.m (16 lbf.ft)
●10 mm bolt and nut 35 N.m (25 lbf.ft)
●12 mm bolt and nut 55 N.m (40 lbf.ft)
ENGINE
● Cylinder head nut 38 N.m (27.4 lbf.ft)
● Spark plug 12 N.m (8.9 lbf.ft)
● Cylinder head bolt 15 N.m (10.1 lbf.ft)
● Alternator bolt 8 N.m (5.9 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)
Nuts, Bolts Tightness

Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all
bolts and nuts on the frame are tightened securely.
Check all fixing pins, snap rings, hose clamp, and wire holders for security.
1.6 Special Tools
For Frame
1. Adjustable Hook Spencer

(E1105-LRA0-FT1)
Purpose: Adjusting of suspension
2. Ball Joint Puller(E0205-LRA0-FT1)
Purpose: Taking out the ball joint from front knuckle as repairing.
10
For Engine
1. TACKING ACG FLY WHEEL TOOL
(C1110-RB1-FT1)
2. COUNTER SHIFT IMPLEMENT (I1003-RB1-FT1)
3. ADJUST TAPPET IMPLEMENT
(A4721-HMA-FT1)
4. SLEEVE OF FABRICATING TRANSMISSION
SHAFT & OIL SEAL (I1202-RB1-FT1)
11
5. SLEEVE OF FABRICATING L CRANK & OIL
SEAL (I1201-HMA-FT1)
6. TAKING 6205 BRG. TOOL (I6150-6205-FT1)
7. 6205 BRG. KNOCK TOOL (I6150-6205-FT2)
8. L CRANK CASE COVER 6006 BRG. FABRICATING TOOL
(I6150-6006-FT1)
12
9. FABRICATING R CRANK CASE COVER 6201
BRG. TOOL (I6140-6201-FT1)
10. TAKING BRG. RB1 TOOL (I6150-RB1-FT1)
11. PNEUMATIC TAKING BRG. 6205 TOOL (I6150-6205-FT3)
12. TAKING TAPPET PIN TOOL (A4451-HMA-FT1)
13
13. ASSEMBLING DRIVE SHAFT TOOL
(B3411-RB1-FT1)
14. TAKING TRANSMISSION SHAFT BRG. 6305
TOOL (I6100-6305-FT1)
15. KNOCKING BRG.(6901) WATER PUMP IMPLEMENT

(I1001-KJ9-FT1)
14
16. KNOCKING WATER PUMP OIL SEAL IMPLEMENT (INSIDE)
(I1205-KF0-FT1 )
17. KNOCKING WATER PUMP OIL SEAL(IRON) IMPLEMENT

(A9217-H9A-FT1)
18. TAKING & LOCKING SPECIAL NUT 36MM SLEEVE

(I0202-HMA-FT1)
19. TAKING & FABRICATING IN. VALVE TOOL

(A4711-HMA-FT1)
15
20. TAKING BRG. 62040 LARGE-SIZE TOOL
(I6100-6204-FT3 )
21. ALL-PURPOSE FIXER (B2101-HMA-FT1)
22. KNOCKING BRG.(6204) IMPLEMENT

(I6100-6204-FT2)
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
2-1 Maintenance Data
SPECIFICATION
SPARK PLUG
SPARK PLUG GAP 0.8 mm
RECOMMENDED SPARK PLUGS NGK CR8E
THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1700±100 rpm
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.
300KM Every Every Every Every Notes

1 Month 3 Months 6 Months 1 Year 2 Years
Fuel Lines I I R
Throttle Operation I I
Air Filter I C R
Fuel Filter R
Spark Plug I I R
Drive Chain I, L Lubricate for every 1 month
Brake Shoes I
Brake System I I
Brake Fluid I R
Nuts, Bolts & Fasteners I
WHEEL/TIRES I I
Wheels I I
Steering System I I
Suspension System I I
C.V.T Drive belt I R
Transmission Oil R Replace for every 3,000km or 6 Months
Engine Oil R Replace for every 3,000km or 6 Months
Battery I I,C I,C
Oil Filter (Screen) C C
Valve Clearance I I
Coolant I I R
Cooling Fan I I
Carburetor (Idle Speed) I I
Choke I
Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary

C: Clean L: Lubricate R: Replace
2-3 Fuel Tube
Inspect the fuel lines for deterioration, damaging or

leakage and replace if necessary.
18
2-4 Throttle Operation
Inspect for smooth throttle lever full opening and automatic

full closing in all steering positions.
Inspect if there is no deterioration, damage or kink in the
throttle cable, replace it if necessary.
Check the throttle lever, free play is 5-10 mm at the tip of the
throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to prevent
premature wear. Throttle
2-5 Throttle Cable Adjustment
Slide the rubber cap of the adjuster off the throttle

Housing, loosen the lock nut and adjust the free play
of the throttle lever by turning the adjuster on the throttle housing.
Inspect the free play of the throttle lever.
2-6 Air Cleaner
Please remove the four hooks, and then disassemble

two screws inside the air cleaner case.
Pull out the air filter element from the air cleaner case.
Washing the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the every component into air cleaner in the reverse order
of removal.
Note: for more detail please check chapter 5-10
2-7 Spark Plug
This spark plug is located at the front of the engine.

Disconnect the spark plug cap and unscrew the spark plug.
Check the condition of spark plug electrodes wear.
19
Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
The spark plug gap shall keep in 0.8mm
With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading.
Tighten the spark plug with 1.0~1.2kgf-m
2-8 Idle Speed
Connect an engine speed meter.

Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. “Turn in” (clockwise) will
get higher speed. “Turn out” (counter clockwise) will get lower speed.
IDLE SPEED: 1700±100 rpm
2-9 Drive Chain
Stopping the ATV and shift the transmission into neutral(N) .

Measure the drive chain slack midway between the
sprockets.
Chain slack =15~25mm (5/8~1 inch)
Adjust the chain slack.

Loosen the lock nuts and turn drive chain adjusting nuts
until get the correct slack.
Tighten the axle holder bolts.
Torque = 90N.m (65 lbf.ft)
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.
Inspect the sprocket teeth, if it is excessive wearing or damaging,

please replace it.
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.
Front Brake lever free play is 15-25 mm.

Brake lever
Adjustable nut
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
Inspect the rear brake lever and cable for excessive

play or other damage. Adjustable nut
Replace or repair if necessary.
Measure the rear brake lever free play at the Parking On
end of the lever trip.
Rear Brake lever free play is 15-25 mm.
21 Adjustment
Brake level
NOTE:
y The second method to adjust brake level is under the driver
seat and rear brake component.
y In order to avoid a pre-load occurred between brake disk and

lining. After all adjusting of brake system are completed,
please check the small clearance between brake disk and
lining. Rear Brake
Adjustable nut
Front Brake
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
Parking Brake Adjustable nut
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.
*The standard of tire pressure is 0.26 kgf/cm2
2-12 Steering Shaft Holder Bushing

Remove the front fender first.
Remove the steering shaft holder and check the steering shaft bushing
for wears or damage.
If the bushing is worn or damaged, please change a new one.
Grease the steering shaft bushing and install the parts
in the reverse order of removal.
Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)
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.
Torque: 35-43 N.m
Lock Nuts
24
3. ENGINE REMOVE AND INSTALLATION
3-1 General Information 3-3 Engine Installation
3-2 Engine Removal
3.1 General Information
ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR

ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY
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.
There are some pictures to describe main step of removing engine.
Disconnect the wire connectors. There are three connectors for

carburetor auto-choke, starter motor and generator respectively.
Remove the drive chain cover.

Remove the drive chain retaining clip and master link,
and remove the drive chain.
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
Valve Rocker Arm
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
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
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20

Oil pump Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil strainer cap 1.5~3.0kgf-m
Engine oil drain 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
Low oil pressure

y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage
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.
Place an oil pan under the ATV, and remove oil

drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value：1.9~2.5kgf-m
4-5 Engine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value：1.5~3.0kgf-m Oil strainer cap
Add oil to crankcase (oil viscosity SAE 10W-30)

Recommended using King serial oil.
Engine oil capacity: 1200c.c. when replacing
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Oil strainer
O-ring
29
4-6 Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
Clip
Remove cir clip and take out oil pump driving

chain and sprocket.
Make sure that pump shaft can be rotated freely.

Remove 2 screws on the oil pump, and then
remove oil pump.
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
Check clearance between inner and outer rotors.

Limit: 0.20 mm
Check clearance between rotor side face and

pump body
Limit: 0.12 mm
Oil Pump Re-assembly

Pins
Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of
inner rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins
properly.
31
Tighten the oil pump screw. 1 screw
Roller
Oil Pump Installation

Install the oil pump, and then tighten screws.
Torque value：0.8~1.2kgf-m
Make sure that oil pump shaft can be rotated
freely.
2 screws
Clip
Install oil pump drive chain and sprocket, and

then install cir clip onto oil pump shaft.
Install starting gear and generator.

(Refer to chapter 10)
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
Make sure that the drain bolt washer can be re-used.

Add oil to specified quantity from the join hole.
Gear Oil Quantity: 650c.c. when replacing
Make sure that the join bolt washer can be re-used,

and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
Gear oil drain bolt

5. FUEL SYSTEM
5-1 Mechanism Diagram 5-6 Throttle Valve
5-2 Precautions In Operation 5-7 Float Chamber
5-3 Trouble Diagnosis 5-8 Adjustment Of Idle Speed
5-4 Carburetor Remove / Install 5-9 Fuel Tank
5-5 Air Cut-Off Valve 5-10 Air Cleaner
Fuel tank cap
Fuel unit
Fuel tank
Auto fuel cock
Carburetor
Fuel strainer
Inlet pipe
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
| Vacuum/air pressure pump

| Fuel level gauge
Specification of CARBURETOR
ITEM UA25A
Carburetor diameter Ø22mm
I.D. number PTG 050
Fuel level 14.8mm
Main injector # 110
Idle injector # 35
Idle speed 1700 ± 100rpm
Throttle lever clearance 1~3 mm
Air screw 2 turns

Poor engine start Mixture too lean
y No fuel in fuel tank y Clogged fuel injector
y Clogged fuel tube y Vacuum piston stick and closed
y Too much fuel in cylinder y Malfunction of float valve
y No spark from spark plug(malfunction of y Fuel level too low in float chamber
ignition system ) y Clogged fuel tank cap vent
y Clogged air cleaner y Clogged fuel filter
y Malfunction of carburetor chock y Obstructed fuel pipe
y Malfunction of throttle operation y Clogged air vent hose
y Air existing in intake system
Stall after started

y Malfunction of carburetor chock Mixture too rich
y Incorrect ignition timing y Clogged air injector
y Malfunction of carburetor y Malfunction of float valve
y Dirty engine oil y Fuel level too high in float chamber
y Air existing in intake system y Malfunction of carburetor chock
y Incorrect idle speed y Dirty air cleaner
Rough idle
y Malfunction of ignition system
y Incorrect idle speed
y Malfunction of carburetor
y Dirty fuel
Intermittently misfire as acceleration

Late ignition timing

y Malfunction of carburetor
Power insufficiency and fuel consuming

y Fuel system clogged
5-4 Carburetor Remove / Install
Removal
Drain out fuel in the float chamber.
Drain bolt
1 screw
Loosen the choke cable fixed iron sheet screw from

plate.
Remove the choke cable.
Choke cable
Disconnect the fuel hose. Vacuum pipe Fuel pipe

Release the clamp strip of air cleaner.
Remove the carburetor upper parts from the

carburetor.
Clamp
Release the 2 nuts of carburetor insulator, and then
remove the carburetor.
Installation
Install in reverse order of removal procedures.
2 nuts
5-5 Air Cut-Off Valve 2 screws
Disassembly
Remove 2 screws.
Remove air cut-off valve cover, spring and valve.
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.
Disconnect the throttle cable from the throttle valve

and remove the valve spring.
Throttle valve
Remove the fuel needle clamp and fuel needle.
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.
Tighten the carburetor upper part.

Adjust the free play of throttle valve cable.
5-7 Float Chamber
Disassembly
Remove 3 mounting screws and remove float
chamber cover.
Remove the fuel level plate, float pin, float and float 3 Screws
valve.
Float Float 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.
Clean jets with cleaning fluid. Then use compressed

air to blow the dirt off.
Blow carburetor body passages with compressed air.
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.
Checking fuel level

Float gauge
Caution Lock nut
y Check again to ensure float valve, float for

proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber
face is vertical to the main jet.
Fuel level: 14.8mm
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
Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let
engine runs in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that Stopper screw
emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 0,8~1.5%
HC: below 900ppm
Air adjustment screw

5-9 Fuel Tank 4 bolts
Fuel unit removal
Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).
Caution Coupler
․Do not bend the float arm of fuel unit
․Do not fill out too much fuel to fuel tank.
Fuel unit inspection (Refer to electrical equipment

chapter 17).
Fuel unit installation

Install the gauge in the reverse order of removal.
Caution
Fuel tube
Do not forget to install the gasket of fuel unit or
damage it.
Fuel tank removal

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender. Vacuum tube
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).
FRONT
Remove the fuel tube.
Remove the vacuum tube.
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.
Loosen the clamp strip of air cleaner, and then

remove the air cleaner vapor hose.
Remove the air cleaner (4 bolts).
Installation
Install the tank in the reverse order of removal.
Cleaning air cleaner element Clamp 4 bolts

Remove the air cleaner cover (4 catch hooks).
4 hooks
Remove element mounting screw.

Loosen the clamp strip of air cleaner element, and
then remove the air cleaner element.
Clean the element with non-flammable or high-flash
point solvent and then squeeze it for dry.
Caution
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and then Clamp 1 screw
squeeze it out. Install the element onto the element
seat and then install the air cleaner cover.
6. CYLINDER HEAD/VALVE
6-1 Mechanism Diagram 6-6 Valve Stem Replacement
6-2 Precautions In Operation 6-7 Valve Seat Inspection And Service
6-3 Troubleshooting
6-4 Cylinder Head Removal 6-10 Valve Clearance Adjustment
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
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.
Specification of CYLINDER HEAD

Item Standard Limit
Compression pressure 12±2 kg/cm2 ---
Intake 5.90 5.85
Camshaft Height of cam lobe
Exhaust 5.70 5.65
ID of valve rocker arm 11.982~12.000 12.080
Rocker arm
OD of valve rocker arm shaft 11.966~11.984 11.936
Intake 4.975~4.990 4.900
OD of valve stem
Exhaust 4.950~4.975 4.900
ID of valve guide 5.000~5.012 5.030
Clearance between Intake 0.010~0.037 0.080
valve stem and guide Exhaust 0.025~0.062 0.100
Valve
Free length of valve Intake 38.700 35.200
spring Exhaust 40.400 36.900
Valve seat width 3.400 4.000
Intake 0.10±0.02mm -
Valve clearance
Exhaust 0.15±0.02mm -
Tilt angle of cylinder head --- 0.050
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.
Low compression pressure

1. Valve
y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston ring worn out.
High compression pressure

y Too much carbon deposit on combustion chamber or piston head
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).
Remove 1 bolt of thermostat and then remove the

thermostat. Thermostat bolts
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Tensioner bolts
4 bolts Spark plug

Remove Air Injection system (AI) pipe mounting
bolts.
Remove spark plug.
Remove the side cover mounting blots of cylinder 3 bolts

head, and then take out the side cover.
Remove left crankcase cover, and turn the Timing mark
Turn the drive face, and align the timing mark on
the sprocket with that of cylinder head, piston is at
TDC position.
Remove cam sprocket bolts and then remove the 2 bolts
sprocket by prying chain out.
Cam shaft setting plate
Remove cam shaft setting plate (1 bolt).
Rocker arm shafts
Remove rocker arm shafts and rocker arms.

Special Service Tool:
Rocker arm and cam shaft puller
Rocker arm shaft and
cam shaft puller
Cam shafts
Remove cam shafts.

Rocker arm and cam shaft puller
Rocker arm
shaft and cam

Remove the 2 cylinder head mounting bolts from 4 Nuts
cylinder head right side, and then remove 4 nuts and

washers from cylinder head upper side.
Remove the cylinder head.
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.
Use a valve cotter remove & assembly tool to press

the valve spring, and then remove valves.
Valve cotter remove
and assembly tool
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.
Valve cotter remove & assembly tool
Exhaust valve Outer spring Cotter

Remove valve stem seals.
Valve stem seals
Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of cylinder

head.

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge and
thickness gauge.
Service limit: 0.5 mm
Camshaft
Inspect cam lobe height for damaged.
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.
Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm shaft
and cam rocker arm.
mm.
Calculate the clearance between the rocker arm shaft

and the rocker arm.
mm.
Valve spring free length

Measure the free length of intake and exhaust valve
springs.
Service limit:
Inner spring 35.00 mm
Outer spring 39.00 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 5.0 mm valve guide reamer
Before measuring the valve guide, clean carbon

deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner

diameters.
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.08 mm
EX→0.10 mm
Caution
If clearance between valve stem and valve guide

exceeded service limit, check whether the new
clearance that only replaces new valve guide is
within service limit or not. If so, replace valve
guide.
Correct it with reamer after replacement.

If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve

guide.
6-6 Valve Stem Replacement
Heat up cylinder head to 100~150 ℃ with heated Valve guide driver
plate or toaster. 5.0mm
Caution
y Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed
as heating it.
y Wear on a pair of glove to protect your hands
when operating.
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
y Check if new valve guide is deformation after

pressed it in.
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150℃.
Adjust the valve guide driver and let valve guide height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room
Valve guide reamer 5.0 mm
temperature, and then correct the new valve guide
with reamer.
Caution
y Using cutting oil when correcting valve guide

with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-7 Valve Seat Inspection And Service
Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other manual
grinding tool.
Caution
y Do not let emery enter into between valve stem and

valve guide.
y Clean up the emery after corrected, and apply with
engine oil onto contact faces of valve and valve seat.
Remove the valve and check its contact face.
Valve seat width
Caution
Replace the valve with new one if valve seal is

roughness, wear out, or incomplete contacted with
valve seat.
Valve seat inspection

Roughness
If the valve seat is too width, narrow or rough, corrects it.
Valve seat width

Service limit: 1.6mm
45°
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve seat

chamfer cutter.
Refer to operation manual of the valve seat chamfer
cutter.
Use 45° valve seat chamfer cutter to cut any rough or
Old valve seat width
uneven surface from valve seat.
Caution
After valve guide had been replaced, it has to be

ground with 45° valve seal chamfer cutter to 32°
correct its seat face.

Use 32° cutter to cut a quarter upper parts out.
Use 60° cutter to cut a quarter lower parts out.
Remove the cutter and check new valve seat.
Use 45° cutter to grind the valve seat to specified width. 60°
Caution
Make sure that all roughness and uneven faces 1.0mm

had been ground.
Grind valve seat again if necessary.
45°
Coat the valve seat surface with red paint.

Install the valve through valve guide until the valve
Contact surface too high
contacting with valve seat, slightly press down the valve
but do not rotate it so that a seal track will be created on
contact surface.
32°
Caution
The contact surfaces of valve and valve seat are

very important to the valve sealing capacity.
Contact surface too low Old valve seat width
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.

Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Valve spring retainer

Caution Valve stem seal
The closed coils of valve spring should face down Valve cotter
Inlet valve
to combustion chamber.
Valve spring
Exhaust valve
Use a valve cotter remove & assembly tool to press

the valve spring, and then remove valves.
Caution
In order to avoid damaging the valve stem and the

cylinder head, in the combustion chamber place a
rag between the valve spring remover/installer as
compressing the valve spring directly.
Valve cotter remove

Special Service Tool: and assembly tool
Valve cotter remove & assembly tool
Tap the valve stems gently with a plastic hammer to

make sure valve retainer and valve cotter is settled.
Caution
Place and hold cylinder head on to working table

so that can prevent from valve damaged.
Gasket
Clean up all residues and foreign materials onto the
matching surfaces of both cylinder and cylinder
head.
Install chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.
Caution
Do not damage the matching surfaces of cylinder

and cylinder head. Chain guide Dowel pins
Avoid residues of gasket or foreign materials

falling into crankcase as cleaning.
4 Nuts
Install 4 washers and tighten 4 nuts on the cylinder

head upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head right side.
Torque value:
Nut 3.6~4.0kgf-m 2 bolts
Bolt 1.0~1.4kgf-m
Install camshaft into cylinder head, and install

rocker arm, rocker arm shaft.
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
Make sure timing marks are matched.
3 bolts
Install cylinder head side cover (3 bolts).

Install thermostat (2 bolts).
Thermostat bolts
Loosen auto tensioner adjustment bolt and remove

bolt and spring.
Install tensioner and install spring and adjustment
bolt.
Tensioner adjustment bolt
Install cylinder cover (4 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
Caution
This model is equipped with more precision 4-valve

mechanism so its tighten torque can not be exceeded
standard value in order to avoid causing cylinder head
deformation, engine noise and leaking so that
motorcycle’s performance be effected.
Install the engine onto frame (refer chapter 5).

6-10 Valve Clearance Adjustment
Loosen Air Injection system (AI) pipe upper side bolt
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.
Valve clearance inspection and adjustment.

Check & adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.
Stop the engine after confirmed, and then install the
cylinder head cover and AI pipe.
Caution
y If lubricant does not flow to cylinder head, engine

components will be worn out seriously. Thus, it
must be confirmed.
y When checking lubricant flowing condition, run the
engine in idle speed. Do not accelerate engine
speed.
Contents
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
1.0~1.4kgf-m
0.8~1.2kgf-m
To this chapter contents

General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.
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

Low or Unstable Compression Pressure Smoking in Exhaust Pipe
y Cylinder or piston ring worn out y Piston or piston ring worn out
y Piston ring installation improperly
y Cylinder or piston damage
Knock or Noise Engine Overheat

y Cylinder or piston ring worn out y Carbon deposits on cylinder head top side
y Carbon deposits on cylinder head top-side y Cooling pipe clogged or not enough in coolant
y Piston pin hole and piston pin wear out flow
Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.
Cover the holes of crankcase and cam chain with

a piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.
Remove cylinder gasket and dowel pin. Dowel pins
Clean up all residues or foreign materials from

the two matching surfaces of cylinder and
crankcase.
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.
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.
Measure clearance between piston rings and

grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.
Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
Measure the outer diameter of piston pin.
Service Limit: 16.96 mm
Measure the inner diameter of connecting rod

small end.
Measure the inner diameter of piston pin hole.

Calculate clearance between piston pin and its
hole.
Measure piston outer diameter.

Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：75.380 mm
Compare measured value with service limit to

calculate the clearance between piston and
cylinder.
7-5 Piston Ring Installation

Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.
Top ring
nd
2 ring
Oil ring
Top groove
nd
2 groove
Oil groove
Clean up all residues and foreign materials on

the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
7-6 Piston Installation IN mark
Install piston and piston pin, and place the IN

marks on the piston top side forward to inlet
valve.
Install new piston pin clip.

Caution
Clip end gap
y Do not let the opening of piston pin clip align
with the piston cutout.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.
Cutout
7-7 Cylinder Installation

Install dowel pins and new gasket.
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.。
Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).
Coolant hose
8. V-BELT DRIVING SYSTEM
8-1 Mechanism Diagram 8-5 Drive Belt

8-2 Maintenance Description 8-6 Drive Face
8-3 Trouble Diagnosis 8-7 Clutch Outer/Driven Pulley
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
Torque value Special Service Tools

y Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000
y Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002
y Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100

Engine can be started but motorcycle can Insufficient horsepower or poor high
not be moved speed performance
1. Worn drive Belt 1. Worn drive belt
2. Worn drive face 2. Insufficient spring force of driven pulley
3. Worn or damaged clutch weight 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly
Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight
Clamp strips
Left crankcase cover removal
Release the 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover. (10 bolts)
Remove 2 dowel pin and gasket.
10 bolts
Left crankcase cover install

Install left crankcase cover in the reverse
procedures of removal.
Dowel pins
Starter drive pulley

Left cover plate
L bearing setting plate
Ratchet cover
Dowel pins
Left cover plate gasket
Starter drive pulley

L crank case cover gasket
Volute spring
L crank case cover

Starter grip
2 bolts
Left crankcase cover inspection
Remove 2 bolts to remove left crankcase cover
bearing setting plate.
9 bolts
Check bearing on left crankcase cover.

Rotate bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Remove the bearing 6006 with inner bearing

puller.
Tools number:SYM-6204025
Tools name: INNER BEARING PULLER.
Bearing 6006 install with special tool.

Tools number:SYM-1134600-HMA RB1 6006.
Tools name: L CRANK CASE COVER
BEARING INSTALL TOOL.
Disassembly
Remove 5 screws from l cover plate and remove l
cover plate.
5 screws
Remove 1 bolt from ratchet cover
1 bolt
Remove 2 starter ratchets and 2 ratchet springs

Remove starter drive pulley and volute spring
Caution
y If remove the volute spring from the l crank
cover then its has to be replaced.
Loosen the starter rope from the starter grip.
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
Universal holder Bearing stay collar

Hold clutch outer with universal holder, and
remove nut, bearing stay collar and clutch outer.
Caution
y Using special service tools for tightening or

loosening the nut.
y Fixed rear wheel or rear brake will damage
reduction gear system.
Push the drive belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive belt.
Remove the drive belt from the groove of driven
pulley.
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
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.
Install the driven pulley that has installed the belt

onto drive shaft.
On the drive belt another end to the movable drive
face.
Universal holder Bearing stay collar

Install the clutch outer and bearing stay collar.
Hold the clutch outer whit universal holder, and
then tighten nut to specified torque value.
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.
8-6 Drive Face Universal holder
Removal
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Remove movable drive face comp and drive face

Movable drive face
boss from crankshaft.
Crankshaft
Drive face boss
Remove ramp plate.

Ramp plate
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.
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.
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
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
Install ramp plate. Ramp plate
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.
Drive face boss
Movable drive face Drive face boss

Install movable drive face comp. onto crankshaft.
Crank shaft
Press down
Driven pulley installation
Press drive belt into pulley groove, and then pull
the belt onto drive shaft.
Drive belt
Install drive face, washer and nut.
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.
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.
Remove seal collar 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.
O-ring Guide pin Guide pin roller
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Inner
diameter
Clutch outer
Clutch lining
Clutch lining
Measure each clutch weight thickness. Replace
it if exceeds service limit.
Clutch weight
Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
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
Clutch weight Replacement

Spring Driving plate
Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.
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
Check if shock absorption rubber is damage or

Shock absorption rubber
deformation. Replace it if necessary.
Setting pin
Apply with grease onto setting pins.
Install new clutch weight onto setting pin and then

Shock absorption rubber
push to the specified location.
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.
Caution
Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity. Clutch weight
Install the spring into groove with pliers.

Spring
Install snap ring and mounting plate onto setting
pin.
Snap ring
Replacement of Driven Pulley Bearing

Remove inner bearing. Outer bearing
Clipper
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
Remove snap ring and then push bearing forward

to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Snap ring
Apply with specified oil.
Outer bearing
Install new inner bearing.
Caution Bearing end
y Its sealing end should be forwarded to outside

as bearing installation.
y Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of drive face.
Align oil seal lip with bearing, and then install the
Inner bearing
new oil seal (if necessary).
Installation of Clutch OUTER/Driven Pulley
Oil seal
Assembly
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.
Specified grease
O-ring
Install the movable driven face onto driven face.

Movable driven face Guide pin
Install the guide pin and guide pin roller. Oil seal
O-ring Guide pin Guide pin roller
Install the collar.
Collar
Install friction plate, spring and clutch weight into

clutch spring compressor, and press down the
assembly by turning manual lever until mounting Clutch nut wrench
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Install clutch outer/driven pulley and drive belt onto
drive shaft. Clutch spring compressor
9. FINAL DRIVING MECHANISM
9-1 Mechanism Diagram - Transmission 9-5 Inspection Of Mission Mechanism

Cover 9-6 Bearing Replacement
9-2 Precautions In operation 9-7 Re-assembly Of Final Driving
9-3 Trouble Diagnosis Mechanism
9-1 Mechanism Diagram - Transmission Cover

9-2 Precautions In operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 750c.c. (650c.c. when replacing)
Torque value
Gear box cover 2.6~3.0kgf-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

Engine can be started but motorcycle can
not be moved.
y Damaged drive gear
y Burnt out drive gear
y Damaged gear shift system
Noise
y Worn or burnt gear
y Worn gear
Gear oil leaks

y Excessive gear oil.
y Worn or damage oil seal
Remove gear change lever (1 bolt).
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
The socket bolt is provided with left turn

thread.
Socket bolt
Remove 2 bolts, and then remove the drive

sprocket fixing plate, drive chain and drive
sprocket.
2 bolts
Remove gear fill bolt. Fill bolt

Place an oil pan under the ATV, and remove gear
oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value:
Gear oil fill bolt 3.5~4.5kgf-m
Drain bolt
Remove gear box cover bolts (9 bolts) and then
remove the cover.
9 bolts
Remove shift drum catch ball, spring and bolt.
Shift drum fixed catch bolt
Shift drum
Remove shift spindle, shift fork shaft, shift fork

and shift drum.
Shift fork shaft and fork Shift spindle
Reverse shaft Drive shaft
Remove final shaft, counter shaft and reverse shaft.
Final shaft Counter shaft

Remove drive shaft bearing setting plate (1 bolt).
Bearing setting plate
Remove the drive shaft.

Special tool:
Shaft protector
Remove gasket and dowel pin.
Caution
y If non- essential do not remove the drive shaft
from the case upper side.
y If remove the drive shaft from the gear box,
then its bearing and oil seal has to be
replaced.
Oil seal Bearing

9-5 Inspection Of Mission Mechanism
Check if the shift spindle is wear or damage.
Check if the shift drum is wear or damage.
Check if the shift fork and shaft is wear or damage.
Check if the counter shaft is wear or damage.

Check if the reverse shaft is wear or damage.
Check if the final shaft and gear are burn, wear or

damage.
Gear box Drive shaft bearing
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
Caution Final shaft bearing

Gear box cover
y If remove the drive shaft from the crankcase
upper side, then its bearing has to be replaced.
Reverse shaft bearing Counter shaft bearing

9-6 Bearing Replacement
Caution Inner bearing puller
y Never install used bearings. Once bearing

removed, it has to be replaced with new one.
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
Install new final shaft, counter shaft and reverse

shaft bearings into left crankcase.
Special tool:
Bearing driver (6204)
Needle bearing driver (HK2016)
Clutch nut wrench Drive shaft and

seal install bush
Install new drive shaft bearings and baring driver

into left crankcase.
Drive shaft puller
Drive shaft and

seal install bush
Install the universal bearing puller and bearing

driver.
Turn the universal bearing puller to install drive
shaft bearing.
Special tool:
Universal bearing puller
Install drive shaft.
Special tool: Clutch nut wrench Drive shaft and
Drive shaft puller seal install bush
Drive shaft and oil seal install bush
Clutch nut wrench
Drive shaft 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).
Gear box side

Use inner bearing puller to remove the final shaft
needle bearing, gear shift shaft bearing and counter
shaft bearing from the cover inner side.
Special tool:
Cir clip
Remove cir clip of final shat out side bearing.

.
Special tool:
Inner bearing puller Inner bearing puller
Remove oil seal from gear box cover and discard
the seal
Install new bearing and bearing driver into gear Universal

box cover outer side. bearing puller
driver.
Bearing driver

shaft bearing.
Special tool: Universal
Bearing driver (6205) bearing puller
Bearing driver
Install new oil seal and bearing driver into gear Universal
box cover inner side. bearing puller
driver.
shaft oil seal.
Special tool:
9-7 Re-assembly Of Final Driving
Mechanism
Apply with grease onto the oil seal lip of final Oil seal
driving shaft.
Reverse shaft Drive shaft

Install counter shaft, reverse shaft and final shaft
onto gear box.
Final shaft Counter shaft
Shift drum
Install shift drum, shift fork and fork shaft onto

gear box.
Shift fork shaft and fork Shift spindle
Install shift drum fixed catch ball, spring and bolt

onto gear box.
Shift drum fixed catch bolt

Align the position mark on the shift spindle Position mark
sprocket with that of shift drum, and then install
shift spindle.
Dowel pins
Install dowel pins and new gasket.
9 bolts
Install gear box cover and bolts, and tighten.

Install the shift spindle bracket, drive chain

protector, speedometer gear box and gear change
lever.
Add gear oil.
Gear oil quantity: 750c.c.
10. ALTERNATOR/STARTING CLUTCH
10-1 Mechanism Diagram 10-6 Flywheel Removal
10-2 Precautions In Operation 10-7 Starting Clutch
10-3 Right Crankcase Cover Removal 10-8 Flywheel Installation
10-4 A.C.G. Set Removal 10-9 A.C.G. Set Installation
10-5 Right Cover Bearing 10-10 Right Crankcase Cover Installation
0.8~1.2kgf-m
1.0~1.4kgf-m
5.0~6.0kgf-m
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)
ID of starting clutch gear 25.026~25.045 25.100
OD of starting clutch gear 42.175~42.200 42.100
Torque value
Flywheel nut 5.0~6.0kgf-m
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.
Water pump cover bolts
10-4 A.C.G. Set Removal 2 screws

Remove 2 mounted screws from pulse generator
and then remove it.
Remove 3 screws from right crankcase cover and
then remove generator coil set.
3 screws
10-5 Right Cover Bearing

Inspection Cir clip
Rotate the bearing with finger to check if the
bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Remove the cir clip, and then remove bearing.

Special tool:
Check the oil seal for wear or damage. Replace it
if necessary.
Oil seal
Install a new one bearing (6201LU) by bearing

driver.
Special tool:
Bearing driver
Bearing driver
10-6 Flywheel Removal

Reduction gear Flywheel nut
Remove right crankcase cover.

Hold the flywheel by drive face with universal
holder.
Remove flywheel nut.
Special tool:
Universal Holder
Remove starter reduction gear and shaft.
Pull out flywheel with A.C.G. flywheel puller.
flywheel puller
Special tool:
A.C.G. Flywheel puller
Remove flywheel and starting driven gear.
10-7 Starting Clutch

Starting Clutch Inspection ID
Remove starting clutch driven gear.
Check the gear for wear or damage.
Measure the ID and OD of the starting clutch
driven gear.
Service Limit: ID: 25.1 mm
OD: 42.10 mm
OD
Check the starting reduction gear and shaft for

wear or damage.
Check each roller for wear or damage.

Install starting clutch driven gear onto one way
clutch.
Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction. (View
as shown in this figure.)
One way clutch removal Starting driven gear

Remove starting driven gear.
Remove 3 socket bolts, and then remove one way 3 socket bolts
clutch.
One way clutch
Starting driven gear

One way clutch Installation
Install the components in the reverse procedures 3 socket bolts
of removal.
Caution
Tape a tightening tape onto the thread of hexagon
bolt.
Starting driven gear

Install starting driven gear.
10-8 Flywheel Installation Groove
Align the key on crankshaft with the flywheel

groove, and then install the flywheel.
Hold the flywheel by drive face with universal

holder, and tighten flywheel nut.
Special tool:
Universal Holder
Install reduction gear shaft and reduction gear. Reduction gear
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
10-10 Right Crankcase Cover

Installation
Install dowel pin and new gasket.
Dowel pin
Remove water pump cover.

Install right crankcase cover onto the crankcase.
Note: Align the water pump shaft indent with the oil
pump shaft.
Install right crankcase cover (11 screws).
Install the dowel pin, new gasket and water pump 11 bolts
cover onto crankcase cover.
Water pump cover bolts

Connect water hoses to the right crankcase cover
and water pump cover.
11. CRANKCASE / CRANK
11-1 Mechanism Diagram 11-4 Disassembly Of Crankcase
11-2 General Information 11-5 Crankshaft Inspection
11-3 Trouble Diagnosis 11-6 Assembly Of Crankcase
1.0~1.4kgf-m
0.8~1.2kgf-m
0.8~1.2kgf-m
Eng. Oil drain bolt

3.5~4.5kgf-m
Operational precautions
y This Section concerns disassembly of the crankcase for repair purpose.
y Remove following components before disassembling crankcase.
－Engine remove Section 5
－Cylinder head Section 6
－Cylinder and piston Section 7
－Drive face and driven pulley Section 8
－AC generator/Start one way clutch Section 10
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

Engine noise
y Loose crankshaft bearing
y Loose crankshaft pin bearing
y Worn out piston pin and pin hole
11-4 Disassembly Of Crankcase
Tensioner
Remove the cam chain setting plate, and then
remove cam chain.
Loosen the pivot bolt and remove the tensioner.
Cam chain setting plate
Loosen 2 bolts on the right crankcase.
2 bolts
11 bolts
Loosen 11 bolts on the left crankcase.
Place right crankcase downward and left crankcase

up.
Tap the left crankcase with a plastic hammer to
remove it.
Caution
Care should be taken not to damage the contact
surfaces.
Remove balance shaft from right crankcase.
Balance shaft
Remove crankshaft from right crankcase.
Remove gasket and dowel pins.

Scrape gasket residues off the crankcase contact
surface.
Caution
Do not damage contact surface of the gasket.
It is better to moisten the gasket residue for easy
scrapping.
Drive out left crankcase oil seal.

11-5 Crankshaft Inspection
Use a thickness gauge to measure left and right
clearance of connecting rod big end.
Measure point for the crank big

end of the connecting rod.
Measure the clearance of the big end at the vertical

directions.
Place the crankshaft on a V-block, measure run-out

of the crankshaft.
90 mm 60 mm
Check crankshaft bearing

Use hand to crank the bearing to see it moves
freely, smoothly and noiseless.
Check the inner ring to see it links firmly on the
bearing.
If any roughness, noise and loose linkage are
detected, replace the bearing with new one.
Caution
The bearing shall be replaced in pair.
Special tool: outer bearing puller
Crank bearing
Check balance shaft bearing
Check bearings on right and left crankcase. Balance shaft bearings
Rotate each bearings inner ring with fingers.
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.
Special tool: Inner bearing puller
Bearing driver
11-6 Assembly Of Crankcase

Install wave washer into right crank bearing seat.
Wave washer
Install crank shaft on the right crankcase.
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
Install the left crankcase onto the right crankcase.
11 bolts
Tighten 11 bolts on the left crankcase.

Tighten 2 bolts on the right crankcase.

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
Install the tensioner and tighten the pivot bolt.

Torque value: 0.8 ~1.2kgf-m
Install the cam chain.
Install the cam chain setting plate.
Cam chain setting plate

12. COOLING SYSTEM
12-1 Mechanism Diagram 12-5 System Test
12-2 General Information 12-6 Radiator
12-3 Trouble Diagnosis 12-7 Water Pump
12-4 Trouble Diagnosis For Cooling System 12-8 Thermostat
Radiator filler cap
Reserve tank
By-pass pipe
To cylinder head
Coolant outlet pipe
Radiator
Cooling fan
Coolant inlet pipe
Thermostat
Thermo switch (fan)
Water pump
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.
y Refill the radiator with distilled water or specified additives.

y Add coolant to the reservoir.
y The cooling system can be serviced on the ATV.
y Never spill the coolant to the painted surface.
y Test the cooling system for any leakage after the repair.
y Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the water
thermometer.
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

The engine temperature is too high The engine temperature is too low
y The water thermometer and the temperature y The water thermometer and the temperature
sensor do not work properly. sensor malfunction.
y The thermostat is stuck to close. y The thermostat is stuck to open.
y Insufficient coolant.
y The water hose and jacket are clogged. Coolant is leaking
y Fan motor malfunction. y The water pump mechanical seal does not
y The filler cap of the radiator malfunction. function properly.
y The O ring is deteriorated.
y The water hose is broken or aged.
12-4 Trouble Diagnosis For Cooling System
The temperature indicated is too high
A. Stop and waiting for the

A1.Refill the radiator with
engine is completely N coolant then check for any Y
cooled down, open cap to Water leaking problem
leakage?
check the capacity of
coolant in radiator.
N
Y
B. Turn on main switch and N B-1. Measure thermo unit to N

check the water confirm voltage 6V↑? Replace thermo unit
temperature indicator
back to zero?
Y
Y
B-2. Inspect the circuits of Y
water temperature have Short or earth handle
short or earth?
N
Meter problem
C-1. Eng. stop and remove

C. Open radiator cap and N water pump cover, start
softly throttle, inspect Water pump repair
the motor to inspect pump
coolant have circulated? its rotation? N
Y Y
Water hose clogged
D. Close radiator cap,

measure thermo unit to N
confirm voltage reduced Replace thermo unit
comply with temperature
rise?
Next page
Preceding page
E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch

N N
and inspect cooling fan was to confirm voltage be Replace thermal switch
operating after the changed (12→0V)?
temperature gauge over 3
checks?
Y
Y
E-2. Connect cooling fan
F. Confirm the cooling fan was terminals with battery N
convulsion? Replace cooling fan
(12V) directly to inspect
its operation?
Y
Meter unusual Y
E-3. Keep eng. 3000~4000

rpm and inspect coolant
If circuit connects reverse flow into reserve tank
cooling fan will forward, after the temperature
correct and check again. gauge over 3 checks?
E-4. Remove thermostat from N

holder then heats it by Replace thermostat
water directly to check its
operation?
Y Refill with coolant then

check again
For bleed the air bubbles

completely, open radiator cap
Notice the water hose
and start engine while engine is
can’t any unsuitable
cool then press water hose
bend or twist and
softly by hand to bleeding.
bleed the air bubbles
Turn the throttle repeatedly
completely.
until the coolant surface
becomes stable.
12-5 System Test
Test on the filler cap

Hermetically seal the filler cap, apply water and pressure
to the filler cap. Replace it with new one if found failing to
maintain the specified pressure within a given time limit,
or the opening pressure is too high or too low. The
specified pressure shall be maintained at least for 6
seconds in the test
Relief pressure for the filler cap: 0.9-0.15 kgf/cm2 Pressure tester
Apply pressure to the radiator, engine and water hose to Filler cap
check for any leakage

Caution
Reserve tank cap
Pressure which is too high may damage the radiator.
Never use pressure which exceeds 1.05 kg/cm2.
If the system fails to maintain the specified pressure for at
least 6 seconds, repair or replace parts.
Change of coolant
Warning
Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down, otherwise, you may get scalded.
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.
Refilling system with coolant and bleeding the air bubbles.

y Run the engine, and remove by-pass pipe.
y Check by-pass hole whether has the air bubble to emit.
y If emits without the air bubble, only has the coolant to
flow out, then backflow pipe joint on, engine flameout.
y Remove radiator filler cap.
y Starts the engine, inspects does not have the air bubble
in the radiator coolant, also the coolant liquid level is
stable.
y Stop the engine. Add coolant to proper level if Drain bolt
necessary.
y Screw and tighten up the radiator filler cap.
By-pass pipe
Caution
In order to avoid the water tank rusting, please do
not use the unclear trade mark refrigerant.
Coolant recommended: SYM Bramax radiator agent.
Concentration: 50%
Check reserve tank
y Remove the front center cover, and then remove reserve
tank filler cap.
y Check the liquid level in the front fender right side. Add
coolant to proper level if too low.
y Reinstall the reserve tank filler cap. Upper
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
Filler pipe clamp

Remove coolant filler pipe.
Loosen the radiator 4 bolts.
Coolant inlet pipe
Remove coolant upper side pipes.
4 bolts
Coolant outlet pipe

Remove coolant outlet pipe.
Disconnect the couplers for the thermo switch and fan
motor, and then remove radiator and cooling fan.
Thermo switch coupler
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
Liquid packing must be applied to the

thermo switch before installing to
avoid damaging the radiator.
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
Check water pump seal / cooling system divulges

inspection
y Disassembles the refrigerant drain bolt, overflows little
buckles the N actually fluid, confirmed overflows the
refrigerant whether has the greasy dirt.
y Turns on lathe the engine oil gauge rule, the inspection
engine oil whether does have bleaches situation of the
emulsified.
If has the above two kind of interior to divulge the
Drain bolt
phenomenon, possibly for the water pump inner two seal
damages, the engine cooling system damages or the
cylinder and the cylinder head gasket damages, please first
dismantles the right crank case to say A confirms the
replacement water pump seal, if does not have the question
to take apart for overhaul cooling system of system again
the cylinder head, the cylinder.
Removal of water pump

Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen 4 bolts and remove the pump cover.
Loosen 9 bolts and remove the right cover.
Take off the gasket and dowel pins.
Turn pump rotor clockwise and remove.

Caution
The rotor is provided with left turn
thread.
Remove the cir clip from the right crankcase cover.

Remove the water pump shaft and the inner bearing.
Remove the outside bearing by inner bearing puller.
Rotate the inner ring of bearing, the bearing shall move
smoothly and quietly.
If the bearing does not rotate smoothly or produces a noise,
replace it with new one.
Special tool:
Check any wear and damage of the mechanical seal and Mechanical seal
inside seal.
Caution
The mechanical seal and inside
seal must be replaced as a unit.
Replacement of Mechanical Seal Water pump bearing

Remove the inside bearing by inner bearing puller. driver
Drive the mechanical seal and inner seal out of the right
crankcase.
Special tools:
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.
Install the mechanical seal onto the right crankcase.

Special tools:
Water pump mechanical
Water pump mechanical seal driver seal driver
Install the new inner seal onto the right crankcase.
Water pump oil seal
Special tools: driver (inner)
Water pump oil seal driver (inner)
Water pump bearing

Install a new outside bearing to the right crankcase cover. driver (6901)
Special tools:
Water pump bearing driver (6901)
Caution
Do not reuse old bearing. It must be
replaced with a new one once it has
been removed.
Inner bearing
Mount the water pump shaft and the inner bearing to the
right crankcase cover.
Water pump shaft
Install the cir clip to hold the inner bearing.

Install the seal washer into the rotor.
Caution
Washer must be replaced together with
the mechanical seal.
Water pump rotor

Install the rotor onto the water pump shaft and tighten.
Torque Value: 1.0~1.4kgf-m
Caution
The rotor is left thread.
Install the dowel pin and right cover gasket.

The rotation water pump rotor, causes the water pump
drive shaft scoop channel, aligns the oil pump drive shaft
flange, install the right crank case. (9 bolts)
Install the dowel pin and new gasket.

Install the water pump cover with 4 bolts.
12-8 Thermostat Temperature sensor By-pass pipe
Please refer to chapter 17 for inspection of temperature

sensor.
Removal
Drain out the coolant.
Remove the thermostat set. (2 bolts)
2 Bolts
Inspection
Visually inspect thermostat for any damage.
Place the thermostat into heated water to check its

operation.
Caution
Whenever the thermostat and the
thermometer are in contact to the wall of
heated water container
the reading displayed is incorrect. If the
valve of the thermostat remains open at
room temperature or the valve operation is
not corresponding to the temperature
change
then it must be replaced.
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
13-1 Parts Drawing 13-4 Throttle Housing

13-2 Troubleshooting 13-5 Steering System
13-3 Handlebar
13-1 Parts Drawing
Steering
Handle bar
HARD STEERING ★ Faulty tire

★ Steering shaft holder too tight
★ Insufficient tire pressure
★ Faulty steering shaft bushing
★ Damaged steering shaft bushing
FRONT WHEEL WOBBLING ★ Faulty tire

★ Worn front brake drum bearing
★ Bent rim
★ Axle nut not tightened properly
STEERS TO ONE SIDE ★ Bent tie rods

★ Wheel installed incorrectly
★ Unequal tire pressure
★ Bent frame
★ Worn swing arm pivot bushings
★ Incorrect wheel alignment
FRONT SUSPENSION NOISE ★ Loose front suspension fasteners

★ Binding suspension link
HARD SUSPENSION ★ Faulty front swing arm bushings

★ Improperly installed front swing arms
★ Bent front shock absorber swing rod
SOFT SUSPENSION ★ Weak front shock absorber springs

★ Worn or damage front swing arm bushings
13-3 Handlebar
REMOVAL
Remove the throttle housing by

two fixed screws.
Remove the throttle lever housing on the right

side handle bar.
Remove brake lever bracket assembly.
Screws
Remove the handle bar switch on the left handle bar.
Remove rear brake lever bracket assembly.
Screws Bolts
Remove the handle cover and instrument panel by four

screws at right and left side as shown in picture.
Screws
Remove the bolts attaching the handlebar upper holder.

Remove the handlebar.
INSTALLATION
Put the handlebar on the lower holders.
Make sure the handlebar punch marks match
with the top end of the handlebar of lower holders.
Install the handlebar upper holders with

the L or R marks facing forward.
Tighten the forward bolts first, and then tighten
the rear bolts.
Install the handlebar upper holder’s cover.
dot
Install the switch housing, aligning the small dot of the

handlebar.
Tighten the upper screw firstly, after that tighten
the lower one.
Install the rear brake lever bracket, aligning

the small dot of the handlebar.
Tighten the screw securely.
13-4 Throttle Housing
DISASSEMBLY
Loosen the screws on the throttle housing cover.
Remove throttle housing cover and gasket.
Disconnect throttle cable from the throttle arm
and remove from the throttle housing.
NOTE:
Assembly is in the reverse order of disassembly.
Screws
13-5 Steering System

When the steering shaft needs to be repaired, you need to remove three kinds of components: the tie-rods, front wheels
and hub assy. Following the steps to check these components, if broken please change the new one
Step 1
Tie-rod Inspection
9 Inspecting the tie-rod for damage or bending.
9 Inspecting the ball joint rubbers for damage, wearing or
deterioration.
Turn the ball joints with fingers. The ball joints should turn
smoothly and quietly.
Steering Shaft Removal

Remove the handle bar cover and handle bar.
(See Chapter 13-3)
Remove the front fender. (See Chapter 16-1)
Remove handlebar lower holder.
Loosen the steering shaft holder bolt and remove steering
shaft holder.
Take off the cotter pin below steering shaft.
Loosen the steering shaft fixed out below shaft.
Pull steering shaft carefully.
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.
Installation of Steering Shaft

Apply grease to the holder.
Install the holder and oil seal tighten with
the nuts.
Torque: 33 N.m (24 lbf-ft)
Install the steering shaft nut and tighten it.
This nut is under this steering shaft.
Torque: 50 N.m (37 lbf.ft)
14. FRONT WHEEL AND BRAKE SYSTEM
14-1 Parts Drawing 14-4 Hydraulic Brake

14-2 Troubleshooting 14-5 Suspension Adjustment
14-3 Front Wheels
14-1 Parts Drawing
FRONT WHEEL
FRONT BEAKE
HARD STEERING ★ Faulty tire

★ Insufficient tire pressure
FRONT WHEEL WOBBLING ★ Faulty tire

★ Worn front brake drum bearing
★ Bent rim
★ Axle nut not tightened properly
BRAKE DRAG ★ Incorrect brake adjustment

★ Sticking brake cable
STEERS TO ONE SIDE ★ Bent tie rods

★ Wheel installed incorrectly
★ Unequal tire pressure
★ Incorrect wheel alignment
POOR BRAKE PERFORMANCE ★ Brake shoes worn

★ Worn brake drum
★ Brake linings oily, greasy or dirty
★ Improper brake adjustment
14-3 Front Wheels
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
Install and tighten the four-wheel nuts

Torque: 24 N.m (17.7 lbf.ft) Wheel nuts
Remember put a cotter pin in the castle nut.
14-4 Hydraulic Brake
This type of brakes are applying in front of two wheels of
RA1
REMOVAL
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.
Please follow the next three steps of right pictures.
Loosen fours nuts as shown in picutre

Then take the wheel out.
you can find two bolts fixed at front hydraulic disk

component.
Loosen these two bolts and you can take out disk component.
Bolts
After disassembling the wheel, please inspect the disk plate.

If the disk plate needs to be changed, you have to loosen
castle nut to take wheel hub apart.
Before loosening castle nut, you have to remove cotter pin Wheel hub
Castle nut
Then using the power tools to take the screw out
from brake stopping plate. You can take the brake disc off.
When change brake shoe wear, you must push

the master piston to rearward.
After removal the front brake assembly, you must fabricate

in reverse sequence.
ADD BRAKE OIL
The brake oil tank is under the driver seat at right hand side.
Please check the brake oil level position at outside of tank.
To open the cap of brake oil tank, please turn “CCW”
direction.
Brake oil tank

Suspension system in this type of AVT can be adjustable its

hardness and softness (fig 1).
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.
How to use the “Adjustable Hook Spanner”
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
15-1 Parts Drawing
REAR WHEEL
REAR Wheel Axel

REAR BRAKE
Bad Brake Performance ★ Brake shoes are worn
★ Bad brake adjustment
★ Brake linings are oily, greasy or dirty
★ Brake drums are worn
★ Brake arm setting is improperly engage
Vibration or Wobble ★ Axle is not tightened well
★ Bent rim
★ Axle bearings are worn
★ Faulty tires
★ Rear axle bearing holder is faulty
Brake Drag ★ Incorrect brake adjustment
★ Sticking brake cam
★ Sticking brake cable
Hard Suspension ★ Bent damper rod
★ Faulty swing arm pivot bushings
Soft Suspension ★ Weak shock absorber damper
★ Weak shock absorber spring
15-3 Remove Rear Wheel And Rear Brake
To replace brake disk

The produce of removing the rear left tire is same as
removing front tire.
You need to loosen four nuts firstly.

Loosen two bolts to take out rear brake disk
as shown in picture.
Bolts
Loosen bolts and remove the brake disc

Check the thickness of disc and replace a new one
if the thickness less than 3mm
TO REPLACE THE BRAKE SHOE
To replace the brake shoe, please loosen this bolt as

shown in picture.
Bolt
Please push the plate back to take a shoe out as shown

in picture
Plate Piston
Eventually, you can take all brake shoe out the hub.
There are two kind of brake linings as shown in picture
TO REPLACE THE BRAKE HYDRAULIC OIL

Loosen the bolts and open the cover
Loosen the bolt and drain the used oil out.
Tighten the bolt after the used oil being drained out
completely
Bolt
Add the brake oil (Dot 3 or Dot 4)

Keep oil level at least half of the cup in order to avoid
air in the brake system.
Loosen the bolt to vent the air from brake system.

Tighten the bolt if there isn’t any air in the brake system
Tighten torque 40~70kgf-cm
Pull left brake lever slightly in order to extract air from

brake system
Fill the brake oil in the level shown on the cup
when no air comes out
Assemble the cover
15-4 Swingarm & Rear Axle Holder
This section is to introduce how to repair the swing-arm,

The following pictures are going to teach you how to
Install the swing-arm.
1. Put the swingarm at proper position as shown in

picture. Two hanger bolts will be used to hold the swing-arm
at right and left side. Hanger bolt Swingarm
2. Tighten a hanger bolt on the right side as shown in

picture.
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
4. Tighten the nut
NOTE: If you make a wrong assembly procedure, it will cause:
1. A damage of bearings
2. The main frame will be extended at the area of assembly swim arm (Unalignment).
Suspension system in this type of AVT can be adjustable its hardness

and softness (fig 1).
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.
How to use the “Adjustable Hook Spanner”
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
16-1 Fenders Drawing 16-3 Front Fender Removal

16-2 Rear Fenders Removal 16-4 Exhaust Pipe Removal
16-1 Fenders Drawing
EXHAUST PIPE (For all serials)

16-2 Rear Fenders Removal
There are two seat release bars located at the right
and left hand side of the seat. Please remove the seat
first.
Release Bar
Procedures of remove the rear fender:

Remove the rear rack.
1. Open the seat.
2. Loosen four bolts which connect the front fender and
rear fender.
3. Loosen three bolts, which connect the rear tender
and frame, these two bolts just below the seat.
Loosen the three screws which connect

with footrest plate.
Pull the rear fender backward.
So the rear fender can be removed.
Pull the seat handle up first.
Bolts
There are two screws on the top of seat compartment.
Please remove them.
Finally, you must remove the bolts on the footrest.

16-3 Front Fender Removal
To remove the front fender, there are sever trips to indicate

users how to remove it.
1. First picture shows there are two screw, loosen it.
Screws
Remove the mounting bolts from the front fender.
Please remove the two screws on the top of the headlight.

Then you can see there is a screw on the tip of the vehicle.
Please remove it.
There is a screw near the suspension as shown in picture.

Bolt
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.
Remove the exhaust pipe bolts mounting on the frame

below the seat.
Remove the exhaust pipe carefully.
Nuts Bolts
Bolt
EXHAUST PIPE INSTALLATION

Installation is the reverse order of removal.
Torque: Exhaust muffler bolts 30 N.m (22 lbf.ft)
CATUATION:
After installing, make sure that there are no exhaust leaks.
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
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
ENGINE INTERMITTENT POWER ★ LOOSE BATTERY CONNECTION

★ LOOSE CHARGING SYSTEM CONNECTION
STARTER MOTOR CAN NOT WORK ★ BATTERY SHORTAGE

★ FAULTY IGNITION SWITCH
★ LOOSE OR DISCONNECTED WIRE
ENGINE CAN NOT WORK ★ FAULTY IGNITION SYSTEM
★ ENGINE PROBLEMS
★ FAULTY ENGINE STOP SWITCH
HEAD LIGHT CAN NOT WORK ★ THE SWITCH DO NOT TURN TO “ON”
POSITION
★ THE LIGHT BULB WAS BROKEN, REPLACED

17-2 Ignition Coil
Remove the spark plug cap from the spark plug.
Disconnect the ignition coil primary wire.
Measure the primary coil resistance.
STANDARD: 0.1 - 0.3Ω(20℃)
Measure the secondary coil resistance with

the spark plug cap in place.
STANDARD : 7.4 – 12 kΩ(20℃)
17-3 Ignition Timing

The ignition advance is 15°± 3°/4000rpm
The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment.
17-4 Battery Information

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate
ventilation when charging or using the battery in an open area. The battery contains sulfuric acid
(Electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
Electrolyte is poisonous. If swallowed drink large quantities of water or milk and call a physician.
BATTERY VOLTAGE INSPECTION
Battery is under the seat. Measure the battery voltage by

using a multifunction electric meter.
VOLTAGE: Fully charged: 13.1 V

Undercharged: Below 12.0 V
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
Install the battery in the reverse order of removal.

After installing the battery, coat the terminals with
clean grease.
CHARGING
Firstly, connect the charged positive cable to the battery

positive terminal. Secondly, connect the charged negative cable to the
battery
negative terminal.
Using 0.9A-charging current about 11 hours. (Normal charging)
Or using 4A-charging current about 3 hour. (Quick charging)
Keep flames and sparks away from a battery being charged.
Quick charging should be limited to an emergency;
Normal charging is preferred.
17-5 Electric Starter

Information
If a battery has not work a period of time, the voltage may
reduce and may not provide enough power to starter motor.
If a battery is in a good condition, but engine can not be start.
Please go back to service.
TROUBLESHOOTING
Starter Motor Turns Slowly
Weak battery.
Poorly connected starter motor cable.
Failed starter motor.
Poorly connected battery ground cable.
Starter Motor Cannot Work

Engine stop switch at “off “position.
Gearshift bar is not at neutral position.
Check for a blown fuse near battery.
Make sure that the battery is fully charged and in good condition.
17-6 Light Bulbs Replacement

HEADLIGHT & Front Direction lights
To remove the headlight, please loosen three screws at

back of the headlight.
After loosen these three screws, users can find a connector.

Please disjoin the connector in order to replace an electrical
bulb conveniently and safely. The steps show on pictures.
Installation is in the reverse order of disassembly.
Head light
To replace the direction lights must loosen the screws
as shown in picture.
Screws Direction light
Front position light removes

There are two screws inside the cap.
Please disassemble first then push the cap upward.
You could replace the electrical bulb.
Front position light
Turn around the cap, you could see the connector.

Turn the seat to replace the electrical bulb.
TAILLIGHT
The taillight combines a position and a rear brake light.

Normally, when users switch the key to “ON” position, the
front
& rear position lights are always keep the light slightly.
Until a brake handlebar is depressed, the rear position light
become more light
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.
Please rotate the electrical bulb, and then it could be removed.
Screws
Rear Direction lights remove
The same disassembling procedure like front direction light.

Please use the pliers to remove the seat. Then the bubble
could be see and replaced.
Rear Brake Lights

17-7 Instrument Pane
The instrument panel includes fuel gauge, speed meter, water
Temperature gauge, right and left turn signal, trip do-meter,
and indicator camp. A LCD is used on ATV8E’s instrument panel
to display all driving information for users. Therefore, this is an
all-in-one instrument panel.
Instrument Panel REMOVAL

There is a cable and connector on the back of the
instrument panel. After removing instrument panel,
users can find out
an electrical connector which is connected with a driving
sensor at the back of the instrument panel.
The sensor is installed at the brake disk and a cable is tightened

on the left side of knuckle component as shown in pictures
Sensor
Cable
17-8 Wiring Diagram
18.TROUBLESHOOTING
18-1 Engine Can Not Work 18.4 Loss Power

18.2 Poor Performance At Low And Idle Speeds 18.5 Poor Handling
18.3 Poor Performance At High Speed
18-1 Engine Can Not Work

Possibility
N.G.
CHECK FUEL FLOW TO CARBURETOR
★ No fuel In fuel tank
★ Clogged float valve
O.K.
★ Clogged fuel tank cap breather hole
N.G. ★ Clogged at fuel tube
SPARK TEST
WEEK OR NO SPARK ★ Faulty spark plug
★ Fouled spark plug
★ Faulty CDI unit
★ Faulty alternator
★ Faulty engine stop switch
O.K. ★ Poorly connected ,broken or shorted wires
★ Broken or shorted ignition coil
★ Broken or shorted spark plug wire
★ Faulty pulse generator
N.G. ★ Faulty ignition switch
TEST CYLINDER COMPRESSION
LOW COMPRESSION ★ Worn cylinder and piston rings
★ Damaged cylinder head gasket
O.K.
ENGINE START BUT STOPS
START THE ENGING ★ Auto choke off or damaged
★ Auto choke power wire disconnected
★ Improperly adjusted air screw
ENGINE DOES NOT FIRE ★ Improperly ignition timing
★ Fuel / air mixture ratio is too lean
REMOVE AND INSPECT SPARK PLUG ★ Carburetor flooded

WET PLUG
★ Improperly adjusted air screw
★ Fuel / air mixture ratio too rich
★ Auto choke stuck or damaged
★ Air cleaner dirty
18.2 Poor Performance At Low And Idle Speeds
Possibility
N.G.
CHECK IGNITION TIMING
★ Faulty CDI unit or pulse generator
O.K.
CHECK carburetor N.G.

AIR SCREW ADJUSTMENT ★ Improperly adjusted air screw
O.K
CHECK FOR LEAKING N.G ★ Deteriorated insulator o-ring

INTAKE PIPE
★ Loose carburetor
O.K.
PERFORM SPARK TEST ★ Loose or disconnected ignition system wires

WEEK OR INTERMITTENT ★ Faulty ,carbon or wet fouled spark plug
SPARK
★ Faulty alternator
★ Faulty CDI unit
★ Faulty ignition switch
★ Faulty ignition coil
★ Broken or shorted spark plug wire
★ Faulty engine stop switch
18.3 Poor Performance At High Speed
Possibility
N.G.
CHECK IGNITION TIMING ★ Faulty CDI unit
O.K.
CHECK FUEL TUBE AT FUEL FLOW RESTRICTED

CARBURETOR ★ Lack of fuel in tank
★ Clogged fuel line
★ Clogged fuel valve
FUEL FLOWS FREELY ★ Logged fuel tank breather hole
REMOVE CARBURETOR CLOGGED

CHECK FOR CLOGGED JETS ★ Clean with high pressure air gun
NOT CLOGGED
CHECK AIR CLEANER DIRTY

FILTER ELEMENT ★ Clean the filter
18-4 Loss Power
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
ACCELERATE LIGHTY ★ Fuel / air mixture ratio too rich or lean

ENGINE SPEED DOES ★ Clogged in air cleaner
NOT INCREASE ★ Clogged in muffler
★ Restricted fuel flow
ENGINE SPEED INCREASE ★ Clogged fuel tank cap breather hole
N.G.
CHECK IGNITION TIMING ★ Faulty pulse generator
O.K. ★ Faulty CDI unit
TOO LOW
TEST CYLINDER COMPRESSION ★ Leaking head gasket
★ Worn cylinder and piston rings
O.K.
CLOGGED
CHECK CARBURETOR ★ Clean
O.K.
FOULED OR DISCOLOED
CHECK SPARK PLUG ★ Clean the spark plug
O.K. ★ Spark plug is incorrect heat range
CHECK FOR ENGINE OVERHEATING

OVERHEATING ★ Excessive carbon deposited in
Combustion chamber
★ Wrong type of fuel
O.K. ★ Fuel / air mixture ratio is lean
★ Use of poor quality fuel
ACCELERATE OR RUN KNOCKS
AT HIGH SPEED ★ worn piston and cylinder
★ Fuel / air mixture ratio is lean
★ Wrong type of fuel
★ Ignition timing too advanced
★ Excessive carbon deposited in
Combustion chamber
18-5 Poor Handling
Possibility
STEERING IS HEAVY
★ Damaged steering bearing
★ Damaged steering shaft bushing
ONE WHEEL IS WOBBLING
★ 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

Manual de Taller ET 300

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ET-300

Do not smoke or allow sparks or flames in your work area.

gets in your eyes.

engine is run. Wear insulated gloves before handling these parts.

● USED ENGINE/GEAR OIL

the skin for long periods.

Keep out of reach of children.

Type 4 Stroke，Single Cylinder, Water cooled

The frame serial number is stamped on the front of the frame.

Frame serial number

● 6 mm bolt and nut 10 N.m (7.2 lbf.ft)

● 8 mm bolt and nut 22 N.m (16 lbf.ft)

●10 mm bolt and nut 35 N.m (25 lbf.ft)

●12 mm bolt and nut 55 N.m (40 lbf.ft)

● Spark plug 12 N.m (8.9 lbf.ft)

● Cylinder head bolt 15 N.m (10.1 lbf.ft)

● Alternator bolt 8 N.m (5.9 lbf.ft)

Nuts, Bolts Tightness

1. Adjustable Hook Spencer

2. Ball Joint Puller(E0205-LRA0-FT1)

1. TACKING ACG FLY WHEEL TOOL

2. COUNTER SHIFT IMPLEMENT (I1003-RB1-FT1)

3. ADJUST TAPPET IMPLEMENT

4. SLEEVE OF FABRICATING TRANSMISSION

SHAFT & OIL SEAL (I1202-RB1-FT1)

6. TAKING 6205 BRG. TOOL (I6150-6205-FT1)

7. 6205 BRG. KNOCK TOOL (I6150-6205-FT2)

8. L CRANK CASE COVER 6006 BRG. FABRICATING TOOL

BRG. TOOL (I6140-6201-FT1)

10. TAKING BRG. RB1 TOOL (I6150-RB1-FT1)

11. PNEUMATIC TAKING BRG. 6205 TOOL (I6150-6205-FT3)

12. TAKING TAPPET PIN TOOL (A4451-HMA-FT1)

14. TAKING TRANSMISSION SHAFT BRG. 6305

15. KNOCKING BRG.(6901) WATER PUMP IMPLEMENT

17. KNOCKING WATER PUMP OIL SEAL(IRON) IMPLEMENT

18. TAKING & LOCKING SPECIAL NUT 36MM SLEEVE

19. TAKING & FABRICATING IN. VALVE TOOL

21. ALL-PURPOSE FIXER (B2101-HMA-FT1)

22. KNOCKING BRG.(6204) IMPLEMENT

2-1 Maintenance Data

300KM Every Every Every Every Notes

Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary

2-3 Fuel Tube

Inspect the fuel lines for deterioration, damaging or

Inspect for smooth throttle lever full opening and automatic

2-5 Throttle Cable Adjustment

Slide the rubber cap of the adjuster off the throttle

2-6 Air Cleaner

Please remove the four hooks, and then disassemble

2-7 Spark Plug

This spark plug is located at the front of the engine.

2-8 Idle Speed

Connect an engine speed meter.

2-9 Drive Chain

Stopping the ATV and shift the transmission into neutral(N) .

Chain slack =15~25mm (5/8~1 inch)

Adjust the chain slack.

Torque = 90N.m (65 lbf.ft)

Inspect the sprocket teeth, if it is excessive wearing or damaging,