700ATV Maintenance Manual.
Contents
1. 99 Orr eC Ui UC dl LCM hos ataccnasin ess enssassoudsusent E 100 General Information 1 Description 1 1 Identification code 1 1 1 Frame No The frame No 1s engraved in the right bottom of the supporting frame See Figure 1 1 Figure 1 1 1 1 2 Engine No The engine No is engraved in the right side of the engine See figure 1 2 Figure 1 2 1 2 Special tools instruments and meters 1 2 1 Oil filter detacher To fasten and detach the oil filter 1 2 2 Height gauge To gauge the height of various components 1 2 3 Vernier an E 2 FEN com Lawowooas Ln g e BEES e 7 To measure the length of various components p E 1 2 4 Outside micrometer To accurately measure external diameter of a column 1 2 5 Inside micrometer To accurately measure internal diameter of a hole 1 2 6 Dial indicator To accurately measure a small distance 1 2 7 Torque Spanner To measure torque force 1 2 8 Feeler gauge To measure gap width 1 2 9 Multimeter To check electrical circuits and parts 1 2 10 Barometer To measure pressure of the tyre 1 2 11 Magneto drawing device To detach the magneto 1 2 12 Snap ring clampTo install and detach snap rings 1 3 Periodic maintenance chart es o o ROUTINE comes first ai gt 20 3 750 1 500 1 500 3 000 Check valve clearance Valves ae Adjust if necessary Check condition S2. dark dark dark dark f a a eo r5 green brown green brown O a M yellow yellow B gr een yellow green yellow green blue yellow2 red Dive N black1 b urpi E oil i ae temperature l_ battery indicator Q lotto oil light 12V 17M i fgit i ed orown fred _ yetow ron l 12V 12Ah S brown ounle Mne frea O temperature light light2 rearlight brakelight front left rearleft left switch V 18W right right right functionred1 brown LSet TAN L 12V 18W 12V 5W 21 turn turn turn black blue pay eae ere ran light light indicator 5 2 r light switch Gi 25A i 10A signal 25A frontlight black black black black J L whole safety box o black black black 12V 10W the key diagram of illumination system 9 59 Meterand signal system 90 Operation and working way 1 Headlight Headlight Switch function Oo yellow green O OF O 20 Q 2 Emergency light switch 3 Turing light switch function 9reen green function gray pager dar oes an eae gt Ss R QO OFF When using this function left and right turning lights will shine at the same time Meter LX meet an emergency the lamp is red do not shine 4 Horn Switch n yellw blue function hee pie function ed white PIVE re OoOO Ss O a io O OFF O 91
3. When press the button the horn will move But if without sound or with unclear sound or with little sound please check the problem according to the guide 5 6 Electrical starting system Starting Circuit LIW AMA a a o L B a B Starting system working process Turn on the start switch on the left handlebar the battery can supply power for the CDI Then the CDI supply power for the startor relay then the power from the battery can be sent to the startor motor through the startor relay and the startor motor works help the engine to work Note 1 When electrical starting please keep the battery with enough power and the time of pressing button will be within 92 55 seconds If longer time more than 5 seconds it may cause the damange of startor relay and the startor relay motor and may also cause the damage of the battery that it can not be charged or not charge enough 2 When starting if heard some noises from the startor relay the battery must be without enough power Please stop starting and change a powerful battery or charge for it 3 If the startor motor can not work normally please check according to the 2 rule to see if it is not lubricated enough 6 Appendix 6 1 Specification 6 1 1 Table of specification a Specification of vehicle Overall length 225 0mm Overall width 1210mm Overall he
4. b 22 03 0 035 3 Swirl the when spark plug and tighten to 18 20N m by box key then fix the spark plug cap when assembling 2 3 Inspection of cylinder piston and piston ring Camshaft lube is injected by a hole of engine body into cylinder so the hole must not jam It is necessary to fix the cushion and adjer without dust permeated into the crank case before assembly 14 diagnosing and eliminating of malfunction Emission of black smoke for abrasion of cylinder or piston 1 Cylinder piston of piston ring is worn out 2 The piston ring is not properly assembled 3 The piston or cylinder wall is scraped overheated 1 Excessive incrustation of piston 2 Blast and abnormal noise 3 Abrasion of cylinder or piston Inspection of cylinder 1 Check whether the cylinder is damaged 2 Measure the bore diameter of cylinder at three spots 3 At the top the middle and the bottom of the piston stroke And measure the bore diameter at directions of right angle intersection repairing limit value out of roundness 0 005 mm taper 0 005mm Inspection of piston and piston ring Measure the gap between piston ring and piston groove l unplug the piston ring Note It is forbidden to damaging the piston ring when assembling Check whether the piston and the piston groove is cracked and abraded See figure 2 7 Figure 2 7 2 Insert piston ring into cylinder and measure the end gap repai
5. Fastening Torque 22 N m 26 N m 6 Fix front wheel hub onto the front wheel shaft with cushion open groove nuts and cotter pins Fastening Torque 50 N m 60 N m 7 Assemble Front Wheel Components onto Front Wheel Hub with M10 Conical Nuts GB T802 4pcs Fastening Torque of Conical Nut 55 N m N m 65 Caution Do NOT operate the vehicle immediately after assembling the brake system Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid circulating before riding the vehicle 4 3 Wheel and Tyre 4 3 1 Preparation for maintenance of wheel 1 Inspect wear condition of the tyre Figure 4 2 16 2 Check if the Wheel Hub is worn out or damaged Figure 4 2 13 3 Check if the Wheel Hub is rusted or cracked Figure 4 2 16 4 Check if the conical nuts of the Wheel Hub are loosen or distorted 4 3 2 Disassembly inspection and assembly of wheel components 66 4 3 2 1 Disassembly of wheel components Remove M10 Conical Nuts 4pcs and detach the tyre Figure 4 2 13 4 3 2 2 Inspection of wheel components 1 Check if the wheel hub has any distortion rust crack or other potential defects If so please replace the wheel hub 2 Check if the tyre has reached its maximum wear condition in which case it should be replaced 3 Check the joining condition of the tyre and wheel hub If the joint of tyre and wheel hub is loose replace the tyre im
6. f F p Figure 4 1 10 1 hexagon flange bolt M8 6 2 Inner and outer supporting bracket 3 stop reverse piece 4 Supporting stent 5 Supporting Collar Sheath 6 Supporting ferrel 4 Fix the tension rod into the conical bore of the steering vertical column with tension rod components 2sets cushion p12 2pcs M10 hexagon open groove nuts 2pcs and cotter pins 3 2x 32 2pcs Figure 4 1 11 Fastening Torque 28N m Figure 4 1 11 1 Turning rocker arms comp 2 Cushion 10 3 Hexagon open groove nut M12 4 Cotter pin 3 2 X 32 48 4 1 2 Disassembly inspeciton and assembly of steering bar 4 1 2 1 Disassembly of steering bar 4 1 2 2 1 Remove all of the Plastic cover and Plastic oranments on Steering Bar Figure 4 1 1 2 Remove steering bar clip ht 4 1 2 3 Unplug all cables and wires and remove the steering bar Figure 4 1 3 Inspection of steering bar Check any existing or potential crack on the steering bar In case of above defects the steering bar must be replaced Figure 4 1 12 Figure 4 1 12 2 Altitude balance on each end of the steering bar must be less than 3mm otherwise replace the steering bar Figure 4 1 12 49 3 Check if there exists any slip thread crack or other defects on the fastening bolts in which case the bolts must be replaced 4 Check whether the steering bar clip is damaged Figure 4 1 12 Radial runout and wear condition of the inner surfac
7. 2 25 Figure 2 25 3 disassembly of engine 3 1 cylinder head and block Unplug the intake pipe and spark plug Figure 2 26 1 20D Figure 2 26 1 Figure 2 26 2 Remove cylinder valve cover cam chainwheel cover and Figure 2 27 1 26 remove valve chain wheel Figure 2 27 2 Figure 2 27 1 Figure 2 27 2 remove lower rocker arm shaft See figure 2 28 Figure 2 28 Remove vision hole cover of left front cover See figure 2 29 Figure 2 29 2I Alignment asjust these two symbols of the cam chain wheel to be at the same level with cylinder cover alignmentment of top dead center Rorate the crankshaft with T sleeve anti clockwise until these two symbols of the cam chain wheel to be at the same level with cylinder cover That is to say the piston of cylinder is at the top dead center Inspection of compression top dead center See figure 2 30 1 and figure 2 30 2 figure 2 30 1 figure 2 30 2 When inlet valve spring rise rotate the crankshaft until the T indicator on the magneto rotor to be at the same level with the center of vision hole cover of left front cover hat is to say the piston is at the compression top dead center and there are valve clearance in these four 28 rocker arms of cylinder head See figure 2 31 Figure 2 31 Remove chain tensioner adjuster See figure 2 32 Figure 2 32 remove the cylinder head Loosen the bolt by intersection mann
8. and down rocker arm assembly and L R fore dampers and ther components Fix the L R tension rods into hole by way of the trough of open groove nut with cotter pin 4 pes and make these tension rods bisection on feet 82 4 6 9 Inspection and Maintenance of rear Suspension 1 Inspection and Maintenance are similar to the fore Suspension 2 Check whether the assemble shaft of the rear damper is deformed in which case it must bu changed 3 Check the Collar Sheath and Rubber Sheath 4 Check if the cotter pin on the assembly shaft of the rear damper is reliable Caution Disassemble rear damper and check if the damper and the connecting hole is bent or cracked In case of above defects call for professional staff or replace the damper and then tighten the bolt Note self lock nut is necessary and the torque must be at a range of 45 55 N m 9 Electrical system Route color indication 1 Black B 18 Blue White L W 2 Red R 19 Blue Black L B 83 4 Green G 5 Orange O 6 White W 7 Gray Gr 8 Blue L 9 Brown Br 10 Dark Green Dg 11 Dark Red Dr 12 White Green W G 13 White Red W R 14 White Black W B 15 Light Blue Lb 16 Light Green Lg 17 Black Yellow B Y 20 Red Black R B 21 Red White R W 22 Green White G W 23 Brown White Br W 24 Brown Blue Br L 25 Red Brown R Br
9. brake plate 1 Removing the wheel component see Figure 4 2 4 1 front wheel hub 2 Hexagon open groove nut M30 3 cotter pin 3 2 32 4 cushion 5 taper nut M10 Figure 4 2 4 2 Sequently remove the cotter pins Open groove nuts cushion and front wheel hub from the front wheel shaft Figure 4 2 4 3 Remove the disk brake plate from the front wheel hub Figure 4 2 5 1 disk brake plate 54 2 Rront brake plate clip 4 2 1 3 Disassembly of the Front Disk Brake system 1 Remove the bottom seat of Disk Brake Pump and then remove the whole unity Figure 4 2 6 Figure 4 2 6 1 bottom seat of Disk Brake Pump 2 Disk Brake Pump unity 2 Remove the Front Fuel Pine Rrackets Fisure4 2 7 1 Figure4 2 7 1 branch seat of Disk Brak Fuel Pipe 2 Hexagon Flange Bolts M8 3 Detach the Plate Clip nut and remove the Plate Clip Figure4 2 3 4 Remove the Rront brake plate system Figure4 2 3 4 2 1 4lnspection of the Front Brake System 55 1 Check the Brake Fluid Box for crack leakage and other potential defects 2 Check Fastening Bolts of all Fuel Pipes for possible looseness or damage 3 Check all Fuel Pipes for deterioration distortion crack wear and other hidden defects 4 Check the Brake Plate Clip for distortion crack rust and stuck 5 Inspect the Brake Shoe for wear condition Brake shoe must be replaced when worn out Figure 4 2 8 Figure 4 2 8 1 Brake Shoe 6 I
10. cylinder valve cover vision hole cover the fuel tank and cushion See figure 2 4 Figure 2 4 2 2 Inspection of spark Plug 1 Unplug the Spark Plug cap remove the spark plug by box key look over whether the spark plug insulator and electrode is damaged or sooting If so see figure 2 5 Figure 2 5 2 Check the spark clearance 3m by feeler gauge whether it is between 0 6 0 7mm Or adjust the gap clean incrustation with spark plug cleaner and steel wire brush and check if the spark plug sealing washer Figure 2 6 Figure 2 6 cylinder Piston piston ring and piston pin connecting rod item bore diameter of cylinder taper out of roundness degree of toruosity external diameter of piston bore diameter of piston pin hole gap between piston pin and piston pin hole Piston ring end Top ring the clearance second ring gap between oilring piston ring top ring and piston the second groove ring gap between cylinder and piston external diameter of piston pin bore diameter Gap between small end of connecting rod and piston pin standard value mm p 102 102 03 0 0040 0 0035 0 04 p 101 95 6 101 97 b 22 002 6 22 010 0 007 0 020 0 25 0 40 0 3 0 9 0 3 0 07 0 02 0 06 0 03 0 08 p 219997921990 b 22 016 0 22 027 0 016 0 033 limit value mm 102 1 0 005 0 005 0 06 p 101 92 b 22 010 0 02 0 5 LZ 0 10 0 09 0 09 p 21 96
11. diameter Repairing limit value intake 5 95mm exhaust 5 95mm See figure 2 21 Fix valve into guide and look over the motion 23 Figure 2 21 Inspection of valve spring Measure the free height and squareness Repairing limit value intake and exhaust See figure 2 22 1 2 22 2 free height of inlet valve spring 32 5mm squareness 0 10mm free height of exhaust valve spring 36 2mm squareness 0 10mm Figure 2 22 1 Figure 2 22 2 6 Examining lifting distance of breaker cam Measure the length of fillet with micrometer and check If 1t is worn out Repairing limit value inlet lifting distance 5 73mm Exhaust lifting distance 6 53mm See figure 2 23 24 Figure 2 23 7 Check whether the crankshaft journal is worn out and measure the external diameter of crankshaft journal Repairing limit value o 22 939mm Inspection of rocker arm Check whether the rocker arm is worn out or damaged and whether the oil hole is blocked Note If there is a rocker arm to be replaced examine the peak of breaker cam measure the bore diameter of rocker arm Repairing limit value 612 038mm See figure 2 24 Figure 2 24 7 Inspection of rocker arm shaft Examine if the rocker arm if worn out or cracked Measure the external diameter of rocker arm shaft with micrometer Repairing limit value O11 96mm 25 The repairing limit value of clearance between rocker arm shaft and hole 0 05mm See figure
12. pilot screwd note the revolutions of screw in order to fix it back remove float chamber cover washer remove float pin float a7 triangular needle remove the cover nut 0 rings spring starting plunger pilot jet check the carburetor body float bowl oil passage gas fouling block gt cleaning chap damage gt replace the carburetor assembly cleaning steps check the float damaged gt replace check the float triangular needle triangular needle seat 0 rings filter gauze Damaged worn out block gt replace check the piston valve crack gt replace 38 diaphragm rupture gt replace piston valve oil stick bent worn out gt replace Note If the piston valve is damaged inject the petrol into valve Replace it when there is oil leakage check the main jet main jet pilot jet pilot screw 0 scrapers pilot jet bent worn out damaged gt replace gas fouling block gt blow with compressed air 4 Chassis 4 1 Steering operation system Structure of Steering Vertical Column 39 1 steering vertical column components 2 turning rocker arm components Js Steering Bar Clip 4 hexagon flange bolt M8 X35 5 inner and external bearing of steering vertical column 6 supporting seal ring of steering vertical column 7 Supporting stent 8 hex bolt M8X60 9 stop reverse piece 10 Supporting Collar Sheath 11 cushion l4 32x 4 12 Hexagon open groove nut M14 13 cotter pin 3 2X 32 14 tension rod assembly 1
13. replace the bearing and Yanggakdo 71 3 Check if the constant velocity joint 1s matched up well If not so or there is gear cracked and abnormal noise remove the constant velocity joint and align it 4 Check if there exists any slip thread or flaw on the Open groove nut 5 Disassemble the front tank and check whether the gears Is engaged properly 6 In case the choke is jammed it must be dredged with a needle If the problem is not solved replaced it 7 If there are defects on sensors it must be checked and maintained by a professional 8 Gears is fragile commondities in transmission system 4 4 1 2 Disassembly of fore bridge component 1 Detach the two front wheel parts 2 Removed front Disk Brake Clip cotter pin cushion and the front wheel hub Figure 4 2 20 YY IN 3 disassemble the fore bridge differential Figure 4 2 20 72 4 Take out the fore bridge from the frame 5 Release engine oil in the differential 6 Unplug the transmissionshaft from the differential Figure 4 2 19 4 4 1 3 Inspection and Maintenance of fore bridge 1 If the dust proof Rubber Sheath of the transmissionshaft is worn out or cracked plesae have it replaced immediately 2 Check whether the ball is running smoothly If found loosen or stunk replace the transmissionshaft 3 Disassemble the transmissionshaft clean then install Caution 1 The dust proof Rubber Sheath can not be touched by petrol an
14. 00r min 5500r min 13kW 5500r min 24kW 6000r min 6500r min 49N m 5000r min 27 5N m 4500r min 1400 100r min Unlead 90 Pressure Splash Electric Start and hand recoil start C D 1 Axle CVT Belt drive r 5 0695 0 7679 atio L Drive 5 3595 30 17 x 41 21 x ratio 24 18 H Drive 3 2230 26 21 x 41 21 x ratio 24 18 R Drive 3 8282 25 17 x 41 21 x ratio 24 18 Engine Drive 10 909 22415 ratio Wet automatic centrifugation Comply with GB11121 1995 standard Depending on regional weather condition 95 0il capacity Engine dry weight c Components Specification Carburetor Pattern Spark plug Speed meter Battery Headlight Front Indicator Rear Indicator Brake light Rear license plate light Turning light Rear reflector d Other specification Turning operation system Driving method choose either SAE 5W 40 or SAE te Die Tlkg PD42J Parallel Vacuum DR8EA Electronic 12V 21Ah 12V 12V 12V 12V 12V 35W 35W 3W SW 21W SW 10W White light White light Red light Red light White light Amber light Red light Hand operating steering bar 10W 30 Cold region SAE 20W 40 Warm region Two wheel four wheel drive 2W means two wheel drive 4W means four wheel drive 96 Rocker arms Front and Rear dual rocker arms Parking brake Mechanical Frame Steel pipe Magneto Rotate DC output Spark plug gap 0 6 0 7 mm Safety fuse 30A 6 1
15. 0X40 16 hex locknut 17 elastic cushion 18 hexagon flange bolt MIOX65 19 hex locknut M101 25 20 fore L R damper 21 hexagon flange bolt M10X50 22 hex locknut M101 25 23 cover of fore bottom left rocker arm 24 cover of fore bottom right rocker arm 25 hexagon flange bolt M6X12 26 holding plate nutM6 4 6 4 Disassembly Maintenace and Assembly of up and dowm rocker arm 1 Disassembly and Maintenace Collar Sheath cotter pin and damper may easy to occor problem A If the L R rocker arms swing easily we can test it from the following aspects whether the collar sheath 1s defective by pressuer and whether the Rubber Sheath 1s worn out or cracked B Check whether the cotter pin is reliable If not so replace it C The main problems and homologous maintenance are as following check whether the spring is split or the oil will spill out in which case the damper muse be replaced and test if the oil bowl is excellent without damage in different circumstances 2 Disassembly as the following picture Mount fore L R damper up and down rocker arm assembly onto the frame with Hexagon Flange Bolt M10 x65 8pcs M10 nuts 8pcs Hexagon Flange Bolt M10 x 50 4pcs and M10locknuts 4pcs to ensure a torque of 40 45Nm 81 Caution A These components should be greased with butter before assembly B The surface of components can not be cracked Check whether these components are greased with butter and then tighten the up
16. 2 Performance Requirement a Starting Performance Starting time must be less than 15s b Accelerating Performance Starting acceleration performance must be less than 14s 200m and overtaking acceleration performance must be less than 13s 200m c curb top speed Crest speed must be less than 90km h the Crest speed of E mark must be less than 80km h d grade climbing Climbing cpacity must be greater than 22 e minimum specific fuel consumption minimum specific fuel consumption should be less than 340g Kw h f reliability The reliable travelled distance is 6000km It may be tested by GB T 5374 1995 g durability The durability distance travelled distis 16000km It may be tested by GB T 5374 1995 h emission The emission limit must be conform to GB 14621 2002 and GB 14622 2002 97 a idle emissions CO lt 3 8 HC lt 800 ppm b mode emissions CO lt 7 0 g km HC lt 1 5g km NOx lt 0 4 g km i deceleration and stopping performance a braking distance lt 27m starting velocity is 60km h b braking deceleration must be greater than 5 88m s j noise The aon running noise must be less than 79dB A Static noise is 94dB A and the eagine speed is 2750mim k radio frequency interference The allowable radiation the loss of suppress of ignition system and the radio frequency interference must be conform to GB 14023 2006 1 parking performance When using the parking brake on neutral the parking brake system
17. 26 Yellow Red Y R 27 Green Red G R 28 Green Black G B 29 Black White B W 30 White Blue W L 31 Yellow White Y W 32 Green Blue G L 33 Purple V Troubleshooting and repair No electrification 1 First Check the safety 2 Second if the safety is good then check the battery whether it is power on 3 Finally check the switch lock and electric route whether they are bad Other troubleshooting and causations as follows 84 85 ignition system electrification system phenomena 1 no spark a y spark weak or sparkover intermittence 1 discharge self 2 uncharge or shortage charge 1 flash not bright or weak 1 switch lock Xcarve out a way or short circuit connection badness x line badness 2 CDI set X After electrify no noise from the CDI bonding 3 high voltage X high insulated badness Xhigh voltage lead carve out a way or short circuit 4 magneto voltage lead X signal loop and charge loop carve out a way or short circuit 1 spark plug x pollute or wear intermittence 2 high voltage bag Xhigh voltage lead wire insulated badness l cover polluted or drenched by rain l carve out a way or Short circuit caused by connected wire badness 2 rectifier damaged 3 baterry Xlower electrolyte electrode failure 1 the switch of flash lamp or emergency light contacted badness 2 lamp Xx filamen
18. 5 cushion 10 16 Hexagon open groove nut M10 17 cotter pin Components of Steering Bar 40 1 Steering Bar 2 steering Rubber Sheath 3 air duct door pull cable 4 oiler components 5 acceelerator pull cable components 6 left switch components 4 1 1Disassembly inspection and assembly of Steer ing Vertical Column 4 1 1 1Disassembly of Steering Vertical Column 4 1 Remove all of the Plastic cover and Plastic oranments on Steering Bar Figure 4 1 1 1 Front Mud Shield 2 Plastic Ornament 3 Rear Mud Shield 2 Remove Steering Bar Holder Figure 4 1 2 1 Hexagon Flange Bolt M8 x 30 2 Steering Bar Holder 3 Steering Bar Clip 3 Unplug all cables and connecting wires and remove the Steering Bar Figure 4 1 3 1 Connecting Wire 2 Rear Brake Cable 3 Front Brake Cable 4 Steering Bar 4 Remove the cotter pin Figure 4 1 3 Open groove nut and cushion at the bottom 42 of the Steering Vertical Column 1 cotter pin 3 2 x 32 2 cushiond14 x 32 x 4 3 Hexagon open groove nut M14 5 Remove the supporting brackets of the steering vertical column Figure 4 1 5 1 Supporting stent 2 Inner and outer supporting Bracket 3 safety cushion 6 Remove outer ball pin components on tension rod form turning joint Figure 4 1 6 1 Tension rod Figure 4 1 4 Figure 4 1 6 43 2 front right Yanggakdo 3 cotter pin 3 2 32 1 2 4 Hexagon open gro
19. Plate Caution 1 If the thickness of the disk brake plate is less than 2 5mm it must be replace 2 In occasion of crack or distortion the disk brake plate must be replaced h Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection Method Fuel pipe must be replace when worn out cracked or distorted 4 2 2 2 Disassembly Inspection and Assembly of Rear Disk Brake System 4 2 2 3 Disassembly of Rear Disk Brake System 61 1 detach Rear Disk Brake Pump from the Frame Figure 4 2 6 2 Remove Rear Disk Brake oil bowl from the Frame Figure 4 2 9 3 Release assembling Bolt M8 14 and detach the Rear Disk Brake Clip Figure 4 2 12 Figure 4 2 12 1 Rear Disk Brake Clip 2 hexagon flange bolt M18 x 14 4 Remove Rear Disk Brake System 4 2 2 4 Disassembly of Rear Disk Brake Plate 1 remove rear wheel components Figure 4 2 13 2 Release the transmission case components of rear bridge from the main frame Remove rear central transmission shaftv components Figure 4 2 14 Figure 4 2 13 1 Conical Nuts M10 2 Wheel Hu 3 Remove the Bottom Seat 62 of Rear Disk Brake Plate from the Rear Bridge Figure 4 2 14 Figure 4 2 14 1 hexagon flange bolt M10 x 115 2 rear transmission case 3 rear central transmission shaftv ji 2 3 Remove the Rear Disk Brake Plate from Bottom Seat se
20. TOOATV Maintenance Manual Catalogue General Information E 1 D ser Dti OAiicicicsacccisomiccicatadatennaatnbantarwneacaaranneeeubes x Fes MOGI LOI MOM COC aja e E E ESETE 6 Models Prane NOs arren tr rE S 6 Mi Mite eT IO INO a sticicoe Sacra De esas descr sessed E E ie O cl nraie atone 7 1 2 Special tools instruments and meters 1 1 3 Periodic maintenance ChAT vccoce cv cue sawonesondsevemdoavarwecat 9 ENE INe aooaa aaa E aaa EE EEE AA EEEE E n 11 2 Inspection and adjustment of engine 11 2 1 Inspection of cylinder head intake and OX NAUST VAY sesvecan aaie oia 11 2 2 Inspection of Spark PlUC vicatccticcunkarviiobaveiieiwokdonaenes 12 2 3 Inspection of cylinder piston and piston ring 14 24 ANS PECL LOM Ol Chan SNA lores ci tatwecicat ne dvesmvasnsepeecerale 17 Dest Me E E E E E E E 18 23 0 MS PECT LOM Ol Cat DU RC TON eserse eia ai 18 2d INSPEC HOM Ol arr PAT Cd tech cca tere cmt eee ie 19 Zuo dns Peer WOM Oi Ome We UCT oea ewes 20 2 9 Inspection of lubrication system cc cece ec ee eee 20 2 10 Lubrication of COINS pos gcse erscicn cree nace elects arena bodes bacon 21 2 11 Inspection of cylinder Nad cc cccertins densaicadecsoesieniaxes 21 Disassembly of ENGINe ccc cece cceccccccceeeeeeeeees 27 1 Cylinder head and FOO Cl auras ste Saas tie oeeelpeeecumisatnnaneatueak 21 2 Piston and connecting rod i e e cece e cece ccececcecece 31 3 Manual
21. again Then unplug the dip stick and look whether oil level is lower than the indicator See figure 2 18 Note Ensure that the engine is landed by both four wheel in flat ground Indicator of oil wy gt Figure 2 18 level 2 11 Inspection of cylinder head 1 Check whether the spark plug and valve seat is cracked and whether the cylinder head is out of shape Examine the flatness of cylinder head by flat or knife edge gauge and clearance gauge Repairing limit value 0 05mm See figure 2 19 21 Figure 2 19 2 Remove and examine the width of valve Repairing limit value 2 Omm pee figure 2 201 2 20 2 2 20 35 If the mating surfaces is coarse corrode or cannot contact with valve seat normally repalce it Figure 2 20 1 Figure 2 20 2 Figure 2 20 3 Measure the width of mating surfaces of valve 22 repairing limit value 1 5mm lf the valve seat is to wide or narrow or cracked grind it to ensure itmpermeabi ity 4 Measure bore diameter of valve guide with internal micrometer and special gauge At last calculate clearance between valve stem and valve guide Repairing limit value intake 0 12mm exhaust 0 14mm Note Eliminate carbon in the pipe before measuring If the pipe will be replaced grind the valve seat again 5 Inspection of valve and valve pipe Check whether the valve is bent burn or the valve stem is worn out Check the motion of valve and measure external
22. ar shift Mechanism refer to the picture of gear shift Mechanism 1 Check the mobility of gear shift handle If it is not working properly remove the gear shift Mechanism to check if the fork ball and spring is stuck in which case replace the defective component and try again The last way is to turn to the professional repairman 2 If there is lack in the gear shift mechanism adjust the nut of the fork to correct position and strengthen gear shift mechanism 3 Remove the gear shift mechanism and check whether the linking rod is cracked If so it should be changed 4 Check whether the bouncing spring of gear shift mechanism is intense enough 5 Check whether the gear is engaged correctly and whether there are tripstop or lack If these situation exists call for 11 the maintanance staff to test and repair it 6 If the gear can not be engaged we can test it from the following aspects whether the clutch can completely declutch whether the gearshift is greased reliable whether the oil pipe of gear shift mechanism is blocked whether gear shift mechanism jams If these Situation happens maintanance staff would come to test and repair it 4 6 Suspension 4 6 1components of rear Suspension l rear damper components 2 hexagon flange bolt M1050 3 locknutM10X 1 25 78 4 horizontal rear fin components 5 the right horizontal rear fin velocity joint 6 the left horizontal rear fin velocity joint 7 l
23. ator coil produce alternating current then induce electromotive force come into to being the pressure Through 3 lines Y yelloe output into the rectifier through rectifier into direct current pressure and output through R1 to charge the battery 5 3 Battery Under the following problems please change the battery 1 With long time charge but the pressure do not increase to a set value 2 At the bottom of case there is something dirty or electrode have become white or the case with a sulfate function 88 3 Electrode former scratched or scratched by press or insulation without work Pay attention when using ie 4 pA Long time out of using but without charge is not correct Too much charge so long time charge is not correct generally if battery empty the normal charge time hours Do not charge under a much higher pressure or electric current Keep battery at a low temperature and dry place Charge battery before fix it If battery without electrolyte it may cause the rectifier damaged And the electrolyte is venomous and dangerous As it contains vitriol it may cause burn accident Battery also contains explode gas so keep it far away spark and flame and cigarette When charge or using in house keep the air easy floating When work near the battery please take care of your eyes and keep kids away from the battery If under such accidents please deal with it as follows or ask for help from the doc
24. ch shoe block and clutch cover See figure 2 47 Check the wear condition of the clutch shoe block and clutch cover See figure 2 48 Figure 2 48 35 3 9 carburetor 3 9 1 structure of carburetor 1 carburetor assembly 2 011 needle component 3 Plunger spring 4 Big diaphragm 5 Plunger 6 Diaphragm circlip7 Screw on upper cover 8 Mixture ratio adjusting screw component 9 idle metering jet 10 High speed jet 11 Liner 12 Foam pipe 13 0 ring of foam pipe 14 Float 15 Screw M4X816 Float pin 17 Big screw 18 Float seal ring 19 Fuel inlet valve component 20 High speed jet 21 Drain screw 22 idle metering air jet 23 Enriching Plunger component 24 Seal ring of external shaft cover 25 External shaft cover 26 Screw M4X8 27 Suction pipe A 28 T plastic pipe 29 Suction pipe B 30 ACV valve diaphragm cover 31 Screw M4xX12 32 Suction pipe C 33 ACV valve diaphragm component 34 Fuel inlet pipe 35 Starting jet 36 Dust proof cover 37 Screw 38 Nut 39 acceelerator pull cablelocating dowel loop 40 adjusting screw component 41 Screw 42 Washer 43 Fixing clamp 44 Washer 45 Screw 46 clip 47 Robber pipe 36 48 Non return valve 49 Flood pipe 3 9 2 Inspection and adjusting he carburetor decomposition 1 Remove the evacuated chamber cover 2 spring 3 piston valve remove permanent seat Spring spring block oil needle remove pilot screw Spring washer Note the pilot screw is set at maximum performance Before removing
25. d diesel oil 2 The dust proof Rubber Sheath must not becracked for slight scratch may be damaged the Rubber Sheath 3 Inject 2 3 Lithium Lubrication into the bal I 4 Open the differential and inspect wear condition of 73 gear Shaft and cushion then replace the defective component 4 4 1 4 assembly of fore bridge component 1 Fix transmissionshaft onto fore bridge differential Figure 4 2 19 2 Inject 0 32L of GearLubricant of SAE 80 API GL 4 into fore bridge differential Then tighten the bolt Torque of the bolt 23N m 3 Fix the fore bridge differential onto the frame with hexagon flange bolt M10 x110 2pcs M10 nuts 2pcs cushion 10 2pcs Figure 4 2 21 Fastening Torque of the Bolt is 40 4 5N m Figure 4 2 21 1 hexagon flange bolt M10 x110 74 2 fore bridge case 4 4 2 Rear Bridge 4 4 2 1transmissioncase of rear bridge 1 rear bridge transmission case assembly 2 the left case needle bearing 55BM6720A 5 cluster gear of rear bridge 6 needle bearing 3 needle bearing 22BM3010 T rear disk brake seat 8 4 bX 15 oil seal 9 clamp sheath 10 O ring of rear drive gear 11 cushion 12 12 nutMl2X1 25 13 rear drive gear seat 14 rear adjuster cushion I 15 rear adjuster cushion Il 16 oiling plug 17 O rings of grease hole 18 hex bolt M8X35 19 cushion 8 20 hex bolt M8X25 21 cushion 8 22 zinc base alloy oil cap 23 case cover of rear bridge 24 i
26. e Figure 4 2 15 Figure 4 2 15 1 Bottom Seat of Rear Disk Brake Plate 2 Rear Disk Brake Plate 4 2 2 5Inspection of Rear Brake System 1 Check the Brake Fluid Box for crack leakage and other potential defects 2 Check Fastening Bolts of all Fuel Pipes for possible looseness or damage 63 3 Check all Fuel Pipes for deterioration distortion crack wear and other hidden defects 4 Check the Brake Plate Clip for distortion crack rust and stuck 5 Inspect the Disk Brake Shoe for wear condition Brake shoe must be replaced when worn out A 1 Brake Shoe 6 Inspect the Brake Shoe for maximum wear distortion and crack in which case it must be replaced Maximum wear of Rear Disk Brake Plate is less than 2 5mm 4 2 2 6 Assembly of Rear Brake System 1Fix Disk Brake Plate onto the Bottom Seat with Special M8 Bolts 6pcs Caution Grease the bolt with thread glue 64 when fastening Fastening Torque of bolt 22 N m 28N m 2 Mount the Bottom Seat of Rear Disk Brake Plate onto rear transmission case Then configure the rear central transmission shaft rear transmission case in turn See Figure 4 2 15 3 Mount the Disk Brake Clip onto rear transmission case with M10 x 30 Bolts 2pcs Fastening Torque 18 N m 22 N m 4 Mount Fluid Box of Rear Disk Brake onto the Frame with M Bolt pcs Fastening Torque 8 N m 12 N m 5 Mount Rear Disk Brake Pump onto the Frame with M Bolts 2pcs
27. e must be less than 0 8mm Otherwise replace the steering bar clip 4 1 2 3 Assembly of the steering bar 1 Connect the steering bar clip and holder with the main frame by hexagon flange bolts M8 30 4pcs and adjust the direction of brake cables on both left and right handlebar and clutch cable Figure 4 1 2 4 2 Brake System 4 2 1Front Disk Brake components 1 disk brake pump assembly 2 disk brake compressed bearing 3 disk brake oil bowl sealing washer 4 disk brake oil bowl cover 5 cross recess half countersunk head screw M5 X 12 6 disk brake pump seat 7 cross recess pan head screw M5X60 8 disk brake handle 9 hexagonal locknut M8 10 disk brake switch 11 disk brake handle bolt 12 disk brake oil pipe branch seat 13 front disk brake pipe 14 rear brace of front hydraulic pipe 15 inner hex bolt M6 x 10 16 bolt of front hydraulic pipe 17 front hydraulic disk brake cushion 18 Hexagon Flange Bolts M6X 25 19 Hexagon Flange Bolt M8X14 20 Hexagon Flange nutM8 21 rear brake piece 22 brake fluid Case 4 2 1 Preparation for inspection and maintenance of the front disk brake system l Brake system is crucial to the life safety of the operator and therefore must be periodically inspected and maintained The vehicle uses brake plate Please follow the tips of 51 inspection as below a Inspect the brake fluid box level on the right handlebar Should the fluid level falls under the minimum mark please r
28. efill the box with the same type of fluid as was recommended by the manufactureFigure 4 2 1 Figure 4 2 1 to ensure the fluid level 1 Brake fluid box is higher than the minimum mark b Travel distance of the front brake lever should be kept between 10mm l5mm Otherwise please adjust the screw to meet required travel distance Figure 4 2 2 Figure 4 2 2 1 Adjusting Screw c Inspect the elasticity of the brake handlebar 52 d Brake fluid will be automatically injected into the brake fuel pipe in the process of abrading brake pad reducing the fluid level in the box Therefore periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid e Periodical inspection of the wear condition of front disk brake plate is also necessary Disk brake plate must be replaced depending on its wear condition Figure 4 2 3 Caution 1 If the thickness of the disk brake plate is less than 1 5mm it must be replace 2 In occasion of crack or distortion the disk brake plate must be replaced Figure 4 2 3 1 Brake plate clip 2 Hexagon self lock nut M8 53 f Disk brake plate uses hydraulic pressure of the brake fluid Therefore fuel pipe must be periodically inspected and replaced Inspection Method Fuel pipe must be replace when worn out cracked or distorted 4 2 1 1 Disassembly inspection maintenance and assembly of Front Disk Brake System 4 2 1 2 Disassembly of front disk
29. er before remove the bolt see figure 2 33 29 Figure 2 33 remove adjuster cotter sealed rin of cylinder headtensioner adjuster guide board See figure 2 34 remove cylinder block0 seal adjuster cotter sealed ring of cylinder head See figure 2 35 Figure 2 35 3 2 piston and connecting rod 30 remove the piston snap ring Note block the crankcase breather with a piece of cleaning cloth to avoid the snap ring falling into the case See figure 2 36 Figure 2 36 remove piston pin and piston Clean the buckle of piston and piston pin hole to facilitate the removing of piston pin Note it is forbidden to knock the piston pin with a hammer See figure 2 37 Figure 2 37 31 3 3 Manual starting mechanism See figure 2 38 Figure 2 38 3 4 sensor Figure 2 3 5 left crankcase cover See figure 2 40 Figure 2 40 32 3 6 magneto remove the stator coil remove the pluse coil Remove the stator with rotor Stripper See figure 2 41 Figure 2 42 3 7 oil pump remove the bolt of oil pump cover See figure 2 43 Figure 2 43 33 remove right cover il See figure 2 44 Figure 2 44 Remove the right support frame clutch pulley disc See figure 2 45 1 figure 2 4 2 figure 2 45 3 Figure 2 45 1 Figure 2 45 2 34 Figure 2 45 3 3 8 clutch remove the clutch Remove bolts See figure 2 46 Figure 2 46 Remove the clut
30. f damaged Fittings and Check all chassis fittings and fastenrs fasteners Correct if necessary Lights and Check operation switches Adijust headinght beams Engine 2 Inspection and adjustment of engine 2 1 Inspection of cylinder head intake and exhaust 10 valve Preheat the engine then misfire and unplug the spark plug Fix pressure gauge into the hole open the choke and throttle handle and start for 4 6 times Note Giving a leakage check to the pressure gauge Rotate the engine until the pressure gauge stop rising The maximum reading would be greater than 0 7 0 9Mpa after starting for 4 6 times See figure 2 1 Figure 2 1 check the valve lash Note when adjust valve lash the engine must be cooled The tempreture should be less than 35 C Remove the seat cushion and fuel tank unplug the vision hole cover round the flywheel of magneto anti clockwise to aim T at the signal of fore cover on the left Note The piston must be fixed to the dead enter Figure 2 2 Figure 2 2 Remove cylinder valve cover check the lash between the valve stem by feeler gauge Valve clearance inlet and exhaust valve 0 05 0 08mm See figure 2 3 Figure 2 3 Loose the lock nut rotate the adjusting screw until it appears that the feeler gauge be pulled Then fasten the adjusting screw by valve adjuster tighten the lock nut and check the valve lash Afterword install the
31. ight 1225mm Wheel base 1365mm Wheel gauge 900mm Ground clearance 260mm Seat height 930mm Mini turning radius 2000mm Suspension Front Hydraulic spring swing arm Rear Hydraulic spring swing arm Braking pattern Front dual disk Rear single 93 Normal condition disk front and rear linkage Right foot left hand operation Braking pattern Front dual disk Rear single Primary Brake 1 disk front and rear linkage right E mark foot right hand operation Front dual disk Rear single Primary Brake 2 disk front and rear linkage right foot right hand operation Emergency brake hand operation Engine hand operation Gear shift handle Wheel Hub Front Alloy Steel wheels Rear Alloy Steel wheels Parking brake Tyre dimension Front 25x8 12 Vacuum Tyre Rear 25x10 12 Vacuum Tyre Tyre pressure Front 35kpa Rear 35kpa Fuel tank Vol ieee tect ae Dry weight 319kg Max loading weight 180kg G V W R 509kg Max loading weight 100kg EMARK Hitch Total weight including 609kg EMARK hitch b Engine specification Engine Model Brand HS1102MU HSUN Pattern Single cylinder water cool dual 94 Bore x Stroke Compression Ratio Volume Max power Max power E mark Rated power Max Torque Max Torque E mark Mini Idle speed Fuel type Lubrication Starting system Ignition Drive train Transmission Clutch Lubrication Crankcase exhaust four stroke 102mm x 84mm 9 2 1 686m1 25kW 50
32. ilter 1 Disassemble the air cleaner remove cartridge clean the cartridge with non flammable cleaning solvent and then make it dry Note Petrol is forbidden 2 Dip the air filter cartridge into 20 oil then take it out and squeeze the excessive oil assemble it orderly Impermeability is necessary See figure 2 15 figure 2 16 Figure 2 15 Figure 2 16 19 2 8 Inspection of oil filter Cleaning of lubricator oil strainer remove clarifier Figure 2 17 clean it to ensure a well work condition Then F 4 b x s 7 fix it up Note Clean the clarifier before injecting oil into crankcase Figure 2 17 2 9 Inspection of lubrication system Lubricant of engine the vehicle is oiled with lubricant of APISGSAE10W 40 Others are forbidden capacity The capacity is 1 9L after disassembly and assembly 2 The capacity is 1 8L when fueling up after drain Inspection of lubricant locate the dune buggy on the ground to lookover the capacity with dip stick If the level is lower than the bottom indicator fuel up with recommended lubricant to the upper indicator Inspection of oil pump flow of oil pump 20 measure clearance of the top of internal external rotor Limit value 0 20mm 2 10 Lubrication of engine Check the oil level start the engine and let it running for a fow minutes to make it heated and lubricated completely then misfire Unplug the dip stick to do cleaning and dip it into the oil case
33. irculating before riding the vehicle 4 2 2 Rear Brake System 4 2 2 1Preparation for inspection and maintenance of the Rear Brake System 58 a Brake system is crucial to the life safety of the Operator and therefore must be periodically inspected and maintained b Rear wheels of the vehicle use brake plates mechanized by a rear brake pedal Please follow the tips of inspection as below c Inspect the brake fluid box level on the right handlebar Should the fluid level falls under the minimum mark please refill the box with the same type of fluid as was recommended by the manufacturer Figure 4 2 9 to ensure the fluid level is higher than the minimum mark Figure 4 2 9 1 Minimum Mark d Travel distance of the Rear Brake Pedal should be kept between 20mm 30mm Otherwise please adjust the screw to meet required travel distance Figure 4 2 10 59 e Inspect the elasticity of the brake handlebar f Brake fluid will be automatically injected into the fuel pipe in Figure 4 2 10 1 Rear Brake Pedal the process of abrading brake pad reducing the fluid level in the box Therefore periodical inspection of the fluid level is necessary Caution must use DOT4 Brake Fluid g Periodical inspection of the wear condition of front disk brake plate is also necessary Disk brake plate must be replaced depending on its wear condition Figure 4 2 11 60 Figure 4 2 11 1 Disk Brake
34. mediately 4 Check the vibration of tyre wheel hub Figure 4 2 13 Vibration of assembled Tyre must be controlled within 3mm Otherwise please replace with new tyre Remove the tyre for vibration test of the wheel hub Should the vibration exceed 1 2mm the wheel hub must be replaced 5 Inspect the four conical bores on the wheel hub In occasion of angular distortion or wear the wheel hub must be replaced 4 3 2 3 Assembly of wheel 67 Attach wheel hub onto the wheel with M10 Conical ball Nuts 4pcs and dust proof cover 1pcs Caution assemble the wheel in correct direction shown as the arrow Front and Rear Wheels are not interchangeable Figure 4 2 17 4 3 2 Speicification and operation guide of Wheel Hub and Tyre Since wheels and tyres are crucial to the Figure 4 2 17 vehicle operation periodical inspection for tyre pressure and profile depth is necessary Specification of Wheel and Tyre Whee Hub Tyre kPa Tyre Dimens i on Dimens i on Pressure Front 12x6 25x8 12 35 aoo d e s Rear 12x8 25x10 12 35 ma o o o ow fs To ensure maximum security and longer life expectancy of the wheel please periodically inspect the tyre pressure and 68 profile depth Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle such as hard turning Excessive tyre pressure can also reduce the friction force be
35. must enable the vehicle motionless in both straight and reverse at a grade way of which the grade of slope is 18 and the adhesion coefficient between tyre and road must be greater than 0 7 m antisway angle The greatest antisway angle to the left and right at unladen or motionless must bu greater than 25 n distance headlamp performance p The dune buggy must be equipmented with distance headlamps that conform to GB 5948 1998 or GB 4599 94 q The main beam intensity of distance headlamp must reach a digree 98 of 8000cd 6 2 Requirements for torque of fastener Nut on upper rocker arm of the 40 50 left Nut on bottom rocker arm of the 40 50 left Nut on upper rocker arm of the 40 50 rignt Nut on bottomr rocker arm of 40 50 the rignt Nut connecting chain stay and 40 50 rocker support Nut on fore wheel ADD CO Nn l Ne 6 3 Electrical circuits the characteristic of the electrical circuits 1 Actualize the electrial starting when it is at N parking and brake 2 When it is in the H gear the H gear switch of the engine is on the ground the H gear is lighting by the CDI inner transistor to control the dash light earth connection 3 The function of the diode in this circuitry is that after parking and brake to actualize the electrial starting 4 The relay electrical source to provide the electricity through the CDI working it can protect the relay and to exte
36. nd the useful time 5 Use the pan fuse box each operating circuit is working independence and easy to service there is no connect with the inner cable and the functional line it is hard to emerge the dummy section 100 greenjgreen ted orange LAAJ AA AMARA A Gt uW tL 7 dark low ligh red red jue red light bit brov function redt ack yeto PINK an 9 V t
37. nner hex bolt M8X45 25 cooper gasket p8 26 flange nut M8 27 hexagon flange bolt M8X12 28 cooper gasket 8 29 90X 665 oil seal 30 deep groove ball bearing 16017 31 O rings of rear bridge cover 32 rear adjuster washerlll 33 hexagon flange bolt M10X25 34 rear bridge oil change plug M14X15 35 cooper gasket 14 36 weak spring of rear bridge transimmision shaft 37 rear bridge transimmision shaft 38 external clip 18 39 sheath of rear bridge transimmision shaft 40 external clip amp 18018 41 clip 42 fore dust proof cover of rear bridge transimmision shaft 43 rear dust proof cover of rear bridge transimmision shaft 44 bypass line The maintenance of rear bridge is identical to the fore bridge Please refer to the preceding contents 4 5 gear shift mechanism lle 3 PRESALE 1 gear shift 76 plastic screw of gear shift mechanism 4 dust proof cover of gear shift mechanism 5 dust proof cover thimble of gear shift mechanism 6 elocity joint robber sheath of gear shift mechanism 7 velocity joint of gear shift mechanism 8 hex nut anti M8 9 waste oil pipe thimble of gear shift mechanism 10 waste oil pipe of gear shift mechanism 11 waste oil pipe thimble of gear shift mechanism 12 waste oil pipe robber plug of gear shift mechanism 13 hex nut upright M8 14 connecting rod of gear shift mechanism 15 hex nut anti M8 16 gear shift controling 17 cushion 6 18 hex nut M636 4 5 lInspection and Maintenance of ge
38. nspect the Brake Shoe for maximum wear distortion and crack in which case it must be replaced Maximum wear of Rear Disk Brake Plate is less than 56 1 5mm 4 2 1 5 Assembly of Front Brake System 1 Use Fuel Pipe Brackets 2pcs and Hexagon Flange Bolts M8 16 2pcs to connect the Fuel Pipe Clip with both left and right Lower Front L R rocker armss Caution Fuel Pipe must avoid physical contact with other components in movement 2 Fix the Disk Brake Plate onto the Front Wheel Hub with M8 Special Bolts 4pcs Figure 4 2 4 Caution grease the bolt with thread glue when fastening Fastening Torque of the Bolt 22N M 26N m 3 Fix the Front Wheel Hub onto the Front Wheel Shaft with open groove nuts and cotter pins Figure 4 2 4 Fastening Torque of Open groove nut 5O N m 6ON m 4 Fix the Plate Clip onto Front Turning Joint with M8 Bolts 4pcs Fastening Torque 18 N m 22 N m 5 Assemble Front Wheel Components onto Front Wheel Hub with M10 Conical Nuts of GB T802 4pcs Figure 57 4 2 15 Fa stening Torque of Conical Nut 55 N m 40N m 6 Fix Front Disk Brake Pump onto the Right Handlebar with M5 60 hexagon bolts 2pcs Figure 4 2 16 astening Torque of the bolt is 10 N m 14 N m Caution Do not operate the vehicle immediately after assembling the brake system Please apply the Brake Lever several times to fully engage the Disk Brake Plate and have the Brake Fluid c
39. ocknutM12x 1 25 8 horizontal rear fin robber sheath 9 horizontal rear fin press plate 10 hexagon flange bolt M amp 8 amp x 14 4 6 2rear rocker arm 1 rear left upper rocker arm assembly 2 middle spacer sleeve of fore L R rocker arm 3 hexagon flange bolt M1065 4 dust proof cover of rear rocker arm 5 rear left upper rocker arm assembly 6 middle spacer sleeve of fore L R rocker arm 7 hexagon flange bolt M10 X65 8 ust proof cover of rear rocker arm 9 rear left bottom rocker arm assembly 10 middle spacer sleeve of fore L R rocker arm ll hexagon flange bolt M1065 12 rear left bottom rocker arm assembly 13 middle spacer sleeve of fore L R rocker arm 14 hexagon flange bolt M1065 15 hex locknut M10X1 25 16 cover of rear left bottom rocker arm 17 hexagon flange bolt M6X 12 18 cover of rear right bottom rocker arm 19 hexagon flange bolt M6X 12 79 4 6 3 front Suspension 5KM9100 B290 1 fore upper left rocker arm 2 middle spacer sleeve of fore L R rocker arm 3 fore upper right rocker arm assembly 4 middle spacer sleeve of rocker arm 5 open groove nut M10 6 cotter pin 3 2X 32 T fore bottom left rocker arm assembly 8 fore bottom velocity joint assembly 9 stopper elastic ring for shaft 10 middle spacer sleeve of fore L R rocker arm l1 fore bottom right rocker arm 12 fore bottom velocity joint assembly 80 13 stopper elastic ring for shaft 14 middle spacer sleeve for security 15 hexagon flange bolt M1
40. oe harabe functor biac sen titel actf iae feta state ftue bue a ee een ra ap ak 2008 O O E GOO hres fatal O O O G ress emergency oto Z ooto el OTO W bui lamp controller OJO om O rola OTTO O horn OO Blo O hautain O TENA dark ar green 1 O1 O oven OO rgen browh dark rae red Ibldck ts Ae brown ie gileen yellow Breen yellow ci L QIIO lack blue 4 Sey yellow reat blue brown blue Black lack ik a Pel legn foak edt yellow ieg an holm i fronlight ty EH 8 ji browk red AYT broln red browa red 2 g Z I gt speed at a5 e 2 sensor TaN ont red Ol 30A P g lt green 2 ird red M 1 white white white redl H gear gear a four wheel j H dri lour wheels kel tr te A black indicator indicator ea drive lock ai ean rta arking brake n ramp lamp lamp _indicatorlamp lamp lamp inditatortamp lcetor amp A fe 3 3 brake red AN cog DIED ES EDEDED EDE A Z switch ignition swich brown blue White lack hite preen whit blue cation Yelow back cs ru om y ned dea biak live E Lee rea E 3 Iblue red il _ pink rme 12V 214h A Ted al Battery brown lye p 7 j j j 7 blue yellow brown over Load safeguar Bean bre HP ao light blue black i black M yel wplye black L acl temoreture q detect ah lo black four Ired blue white drive Iblack motor T00ATV 101
41. ove nut M10 7 Pull out the components of the steering vertical column from the bottom seat Figure 4 1 7 pf a Figure 4 1 7 1 Steering Vertical Column 2 Bottom Seat 4 1 1 2 Inspection of steering vertical column components 1 Check whether the nut between the inner ball pin of tension rod and the Turning rocker arm is tightened Figure 4 1 8 In case of loosen or worn out tighten it with proper tools or replace with identical nuts Figure 4 1 8 Torque 32 36N m 1 Steering drop arm assembly 2 Hexagon open groove nutM10 44 3 cotter pin 3 2 32 4 Tension rod 2 Check whether the inner and outter ball pin of the tension rod is loosen or got stuck Figure 4 1 8 In occasion of above defects further inspection of the exact causation must be carried out and replace with new ball pin components Caution Continuous use of defective ball pin might cause severe Injury or death 3 check whether the tension rod is bended cracked or rusted In occasion of above problems please have the tension rod replaced Caution tension rod should not be repaired by welding 4 Check whether the hexagon open groove nut and cottor pin are intact No crack or flaw is allowed Figure 4 1 8 Those two components are crucial and should be replaced whenever there is a potential problem 5 Check whether the supporing bracket is firmly fixed to the steering vertical column Figure 4 1 5 Inspection me
42. parkplug Adjust gap and clean Rep ace if necessary clean Every20 40hours Air fiter element Replace if necessary More often in wet of dusty areas Checkandadjustidlespeed starteroperation Carburetor a Adjust if necessary Check breather hose for cracks of Crankcase damage breathersystem Replace if necessary Check for lecakage Exhaust system Tighten if necessany Replace gasket s if necessary Check fuel hose for cracks or damage Fuel line Replace if necessaly Replace Wamenginebefore draining Engine oil Engine oil filter i l Replace cartridge Final gear oil Check for oil leakage Replace eveny 12 months Differential gear oil Check operation fuid leakage See NOTE page 8 Correct if necessary Check operation Rear brake a Adjust if necessary Select lever safety Check operation system cable Adjust if necessary Check operation V belt Check for cracks or damage Check balance damage Wheel oe Repair if necessary Check bearing assemblies for lossenss Wheel bearing damage Replace if necessary Front and rear Check operation suspendion Correct if necessary Front brake eee ae Checkoperation Replace if damaged eering system Check toe in Adjust if necessaly Drive shaft universal Lubricate with lithium soap bassed joint grease Check operation Axle boots Replace i
43. r constant velocity joint assenbly 11 differential adjusted washer 12 M8X20 engine gearbox bolt 13 differential assembly 14 inner hex bolt M8X25 15 inner hex bolt M8X10 16 hexagon flange bolt MIO X25 17 clipusedin 66 18 5X80 cylindrical pin 19 engine gearbox assembly 20 adaptor 21 cog rack 22 fork 23 0 rings of engine gearbox 24 0 rings of front cover 25 deep groove ball bearing6007 26 deep groove ball bearing 6912 27 deep groove ball bearing 16007 28 needle bearingl5BM2112 29 M10X16 oil change bolt 30 10X1 5 cooper gasket 31 power divider coupling 32 differential adjusted washerII 33 bolt M14X15 34 cooper gaske p 14X2 35 vent piepe of drive case 36 clipofoil pipe 37 fore transimmision shaft 38 weak spring of fore transimmision shaft 39 dust proof cover of fore transimmision shaft 4 4 1 Disassembly inspection assembly of Rear Bridge components refer to the figure of fore Bridge fore case components 4 4 1 1 1 Check if the connection between wheel hub and the Bottom Seat of wheel hub is reliable and if there is any distortion on the Bottom Seat of wheel hub If there exists any such potential defects the Bottom Seat of wheel hub must be replaced immediately 2 Check if the Yanggakdo and its attachements are compatible well and if there is stagnation slosh and Crunch of the Yanggakdo bearing In case the bearing or Yanggakdo is flawed the fore bridge must be removed in the first instance then
44. ring limit value the first ring the second ring 0 5mm See figure 2 8 Figure 2 8 Measure the bore diameter of piston pin hole repairing limit value see figure 2 9 Figure 2 9 3 Measure the external diameter 10mm above the bottom of the piston skirt Extreme position the gap between cylinder and pistonrepairing limit value 0 1mm See figure 2 10 Figure 2 10 Measure the external diameter of piston pin the gap between piston and piston pin repairing limit value 0 02mm See figure 2 11 Figure 2 11 2 4 Inspection of crankshaft heck that whether crank and connecting rod can rotate without stuck and whether the clearance between crank and connecting rod is 0 5 0 6mm The hop of crank shaft should be 0 05mm If not so replace it See figure 2 12 1 figure 2 12 2 Figure 2 12 1 Figure 2 12 2 2 5 Inspection of clutch The wear condition of shoe block and friction plate See figure 2 13 Figure 2 13 2 6 Inspection of carburetor 1 Inspect the idle of carburetor The engine speed should be 1500 150r min 10 minutes after starting at normal idle and will not misfire when briskly accelerate If not so rotate the carburetor idle adjusting screw clockwise to rise the idle anti clockwise to lower When adjusting is unavailable check that if there is a jam in af j carburetor idle nozzle or a air leakage of intake pipe See figure 2 14 Figure 2 14 2 7 Inspection of air f
45. starting mechanism ccc ccc cece cee ccecees 32 BLA Se Tle a tac eve sees shave AAEE ac tee cess isto Stee a EN 32 6 MOC VO oo ocece sera recesaiarene adeno muerast dwn hccrts in docdimiasiee mwep ate nesate Beep aaewmeisesennts e ected 33 oS MO VN ins ast seth eel heeatcee AE etait eae eee aee a Atos 34 BOY UAC E RE EI awe E enauncin tore E mera nunee oa tees 35 9 1 Structure of carburetor sesesesesesseress o o oser 36 9 2 Inspection and adjustment of carburetor 37 Chassis 1 Steering operation SyStemM sssssessssereserere ee ess 39 gid Brake SYS VOM se cauteceducne chnecwssedoesmeceesigetennavaedonseiu eens S ao Neer and TITE eremu E AE we ange 67 z4 Transmission SyYStelli esciens e a woes 70 5 gear shift MECHAM Stites cvcncccoate wats daccaatensaenGnedeanes aust 11 s0 DUS PENS Olaranen EEO at a E a nate EEE 19 Electrical SVS COM vet nconcssnsvoniden ius oese s errre e ee eene 84 Jal Tonton SyS FON te hana a e loaca cane a 8 7 5 2 Magneto and charging SYS 6Miinccncbsacca d de vdasabeewavdaaes 88 ee ie Te ane ere ce ees eee E TE ets TTE IT E EE tel 88 5 4 Lighting SVS Cll coat dann cadematcaesewedetek we Ri sorrrre eee rere 90 5 5 Meterand signal SVST CM 2nctcnsveidodarsanteavetnetsreaeetes 91 5 0 Electrical starting SyYSteM sisscrsercsirii uresen t Sacaork 92 O ADDEN X enara AE E R 93 Sad 310 A IGE 1 Aik C dC TTE EE 93 6 2 Requirements for torque of fastener
46. t of damaged X the watt of lamp larger lamp or smaller than regulated wk repair wk repair XK replace K repalce K repalce K repalce K repalce replace water proof keep clean of the cover and repalce electrolyte we repair repalce entered distilled water replace X repair or replace replace replace cause measure remark 86 5 1 ignition system 0 i A N i C D1 sa A lL Ll 6 D A WR N WG a 1 The key diagram of ignition elements ignition elements Ignition pressure provided by magneto ignition coil through diode commutated by R red line input CDI capacitance discharge ignition charge to capacitance C at the same time spring coil produce spring signal provided to SCR as the turnon spring signal when reaching the ignition timing SCR turnon capacitance began to discharge at the elementary coil L1 caused instant lower pressure while at the secondary coil caused induce opressure its instant pressure up to 10000V sparkover at the clearance of sparkplug 0 6mm so the engine ignited charge system 87 The key diagram of charge elements 5 2 magneto and charge system the elements of charge When the engine running driven magnet rotor circumgyrate so on the st
47. thod 45 Assemble the steering vertical column to the main frame with supporting bracket and M8 bolts etc and rotate the steering bar to ensure the column is not stuck or swinging In occasion of above problems the supporting bracket must be replaced Rotating Torque of the steering vertical column 3 5N m 4 1 1 3 Assembly of steering vertical column a Firstly fix the Turning rocker arms comp into the steering vertical column Then plug the steering vertical column into the bottom seat and fix it with M14 open groove nut 1pcs 6 14X 36X4 cushion lpcs collar sheath 1pcs and 3 2X32 cotter pin 1pcs Figure 4 1 9 Fastening Torque of M14 open groove nut 70 80N m Caution before inserting the steering vertical column Into the bottom seat both upper and lower oil seals must be greased with lithium lubrication 46 Figure 4 1 9 1 Steering bottom seat 2 Cushion 3 Hexagon open groove nut M14 4 Cotter pin 3 232 2 Fix the steering vertical column onto the frame with hexagon flange bolt M8 60 2pcs supporting stent 1pcs inner and outer supporting bracket 2pcs stop reverse piece 1pcs and collar pipes 2pcs Figure 4 1 10 Fastening Torque of M8 60 Bolt 26 30N m Caution inner surface of the supporting brackets must be greased with lithium lubrication 47 sey 994 eeee0n a ARLEETETTTTETTETTET Pretec in ALAEI ENTEEEETEPENTEPRENN ANANASA Lae ti 4 ag
48. tors 89 l Exterior wash lots of cleaning water 2 Interior drink milk or water and then milk of magnesia or egg or rap oil and hospitalize as soon as possible 3 Eyes wash cleaning water at least 15 minutes and hospitalize as soon as possible 5 4 Lighting system H blue re pm function bex 7 seer 2 rtowleen one yow lay eam lon foron foron ngm ra flashin fast Jeo O g and 20 Oo O eee relay igt S oe swith OFF switch ua white i it green green dark dark gray brown Pa a Q Q black red brown green stating oo O urgnt OFO a o 4 switghOFF o turnning z white white white pwitch oO L OFF iik rectification horn green ark Yellow switch PS O blue red reen regulator brown black red1 front meter 12V 3W rear indicator 0 brake Q brake light black switch switch o __ blue white e a o starting O M button
49. tween the tyre and ground causing spinning or lose of control Therefore please ensure the tyre pressure strictly complies with figures shown in the chart above Before operating the vehicle each time please check if profile depth of the tyre is over worn which might result in Spinning instability lose of control and other potential security risk of the vehicle Caution Should the profile depth falls below 3mm please replace the tyre inmediatly Figure 4 2 18 Figure 4 2 18 4 4 Transmission System 4 4 1 Fore Bridge 69 moa TOMOTO Growce t Industries Inc Telephon ns eve oghtemoto uee Engine Family STN TK 100 2 SOA a Engine Description 990cc Liquid Cooled Carbureted Emission Control System TH OR SALE HIS VEHICLE MEETS J SEPAREGULATIONS FOR 2008 ATV s AND IS CERTIFIEDF 1 TES MALORNE TO OPERATE OH MEADED GASOLINE ot SPARKPLUG amp GAP 040 DLESPEED 980 oF Strom N SPECIFICATIONS AND T PAN 5 x isankan Figure 4 2 19 1 front wheel hub 2 L R transmissionshaft 3 fore bridge differential components 4 middle transmissionshaft components of fore bridge 5 L R turning joint front tank components 1 gear box assembly of front bridge 10 5 2 the right cover 5 drive gear of front bridge 3 the left case 4 cushion 70 6 front driving axis pin sleeve 7 MIOX1 25 flange locknut 8 O ring of front bridge drive gear f9 65X048o0il seal 10 oil seal of rea
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