SERVICE MANUAL - Sarner Trading AB
Contents
1. A i 3 i W EE Ne NNS ee a ae Center gear shift fork R L gear shift fork ae Pe IN ON Q NI 2 a F CY 4 Chapter Engine CRANKCASE CRANKSHAFT Remove of the crank shaft Disassembly Shaft comp assembly x The crankshaft assembly normally is not for Crank shaft assembly disassembly It will generate more problems if Radial ball bearing the L R cranks are disassembled Semi cycle key x The semi cycle key normally was took out when disassembly the flywheel Beware keep it Radial ball bearing in certain place to avoid lost Radial ball bearing Assembly 6 1 x Operation with sequence in reverse of disassembly Chapter Engine CRANKCASE CRANKSHAFT e Check the connecting rod side clearance with a feeler gauge The connecting rod side clearance limit is 0 80mm e Check the connecting rod radial clearance with a dial indicator The connecting rod big end radial clearance limit is 0 065mm e Place a V block on each side of the crankshaft A and measure run out at the ends B Chapter Engine CRANKCASE CRANKSHAFT e Check the connecting rod Working diameter limit Replace if over 17 10mm e Check the balancer gear and bearing journals for wear or damage e Use a special tool TLH3 01 to pull the crankshaft and push the left crankcase onto the crankshaft LUBRICATION SYSTEM TROUBLE DIAGNOSE Oil quantit2. Disassembly of Cylinder Piston Disassembly Cylinder WARNING Cylinder and gasket Don t knock the cooling fin 1 Hex flange bolt 2 Clean the gasket stick on crank case 2 Cylinder 1 Replace if necessary 3 Oil ring 1 Replace if deformed 4 Cylinder gasket 1 5 Dowel pin 2 Disassembly Piston WARNING 6 Piston pin clip 2 Dont knock the piston when remove the pin 7 Piston pin 1 Check the piston piston pin and piston rings 8 Piston ring set 1 Clean the carbon residual on ring and 9 Piston 1 ditch on piston Beware not to break or damage the piston rings Assembly x Operation with sequence in reverse of 9 gt 1 disassembly Chapter Engine CYLINDER PISTON Cam chain tensioner Removal e Loosen the cam chain tensioner sealing bolt and washer e The cam chain tensioner lifter shaft must be retracted and locked into place before removing the tensioner e Remove the tensioner mounting bolts and detach the tensioer from the cylinder block e Clean all old gasket material from the tensioner body and from its mating surface on the cylinder block Installation e Lubricate the friction surfaces of the components with moly based grease p e Install a new tensioner gasket on the we sa cylinder Po a e Cut the cable tie and remove the coat xe N 1 SY az hanger wire XO e Install the tensioner sealing bolt and a new sealing washer and tighten the Co sealing bolt to toque WN Disassembly of Piston e
3. General tools shall be used Poa ay New Replace by new items after dismounting Attention Dangerous and important operations Information for Preparation SPECIFICATION TYPE ATV 300XS LENGTH 1830 mm WIDTH 1160 mm 1180 mm 830 mm EIGHT EAT HEIGHT 1250 mm ET WEIGHT NGINE TYPE OOLING ISPLACEMENT ORExSTROKE Manuel 5 speed First gear 0 095 Second gear 0 139 TRANSMISSION Third gear 0 190 Forth gear 0 242 Fifth gear 0 299 al m m i OJ gt ep i Reverse gear 0 065 LUTCH TYPE NGINE OIL CHANGE NGINE IDLE SPEED ALVE CLEARANCE TARTING PARK PLUG PARK PLUS GAP GNITION Front Double A Arm with preload adjustable shock ica Rear Swing arm with preload adjustable shock RAKE ATTERY INAL DRIVE RONT TIRE EAR TIRE RONT BUMPER LOAD REAR BUMPER LOAD Information for Preparation LOCKING TORQUE The standard locking torque shall apply in case of no specification STANDARD TORQUE Torque kg m Torque kg m 6mm Bolt Nut 1 0 6 mm Screw 0 9 8mm Bolt Nut 6 mm Flange Bolt Nut 1 2 1 22 10mm Bolt Nut_ 3 5 Z mm Flange Bolt Nut 12mm Bolt Nut 5 5 8 mm Flange Bolt Nut 18mm Bolt Nut 15 0 10 mm Flange Bolt Nut 3 18mm Lock nut CHASSIS Locking Place Qty Dia mm Torque kg m Remark Engine mounting flange nut__ 4 8 oT _ Footrestflangebolt 6 B 7 ee oo Ts SS SS ENGINE korn kg m Breather separator Allen bolt sie
4. 1 Cylinder Head amp Valve l 3 Cylinder amp Piston l 10 Crankcase amp Crankshaft l 16 Transmission amp Gear l 17 Lubrication 23 Fuel System amp Carburetion Sri eae Il 3 Fuel Tanke ee ee eee Il 8 Ar Gleaner ree ee AEE Il 11 Exhaust System Il 13 Clutch and Starting System Clutch IIl 2 Starting System 1 4 Frame amp Cover Frame amp COVEN sireni en IV 2 Wheels Tyres amp Brakes Handlebar amp Steering V 2 Front amp Rear Wheel V 6 Suspension System V 9 Hydraulic Brake System V 14 Electrical Equipment Electrical Device VI 2 Wire Diagram VI 7 General Information MODEL IDENTIFICATION Engine No The frame serial number is stamped on the The engine serial number is stamped on the lower front right side of frame upper rear right crankcase Identification No The VIN Vehicle Identification Number is The carburetor ident
5. Reason of Trouble battery damage coil damage terminal damage YL wire damage Red wire damage regulator damage socket damage ACG damage GR wire broken socket damage regulator damage INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose Check and Adjust Reason of Trouble change spark plug and check again no sparking or sparking strong the previous spark plug damage weak I check spark plug cap ignition coil loosen I check C D I unit socket loosen check the terminal of C D I unit unimpeded l measure resistance check relate spare parts normal abnormal Pelee near Ft CIEE a E 4 main switch damage pulser coil damage normal abnormal coil damage lighten coil damage main switch damage socket joint connect abnormal l the previous coil damage CHECK AND ADJUST INFORMATION WARNNING Do not start the engine at a close zone because the exhaust gases from the engine including some noxious emission such as CO HC NOx etc that can result serious damage for health Strictly prohibit using any flammable thing in the working zone because that can rise fire easily ENGINE Spark Plug Gap 0 0 6 0 7mm _ _ _ o Pee CHASSIS Parking brake lever free play 10 20mm fF Left lever free play 5710mm _ __ _ _ J S Throttle free play 276mm _ ___ J S Torque of Front Rim Nut 14 kgm Torque of Rear Rim Nut 14kgm S o Detailed
6. The piston should have an IN mark on its crown that goes toward the intake side of the engine Chapter Engine CYLINDER PISTON e Wear eye protection and pry the cir clip out of its groove with a pointed tool e Push the piston pin part way out then pull it the rest of the way Inspection of Piston e Remove the top and second piston rings e Remove the upper oil ring side rail and expander then remove the lower side rail Warning Be ware not to scratch the piston during ring removal Chapter Engine CYLINDER PISTON e Measure the piston ring to groove clearance with a feeler gauge Working limit Top ring replace above 0 11mm 2 ring replace above 0 09 mm e Take off piston rings and put into the bottom of cylinder Note x Use piston to press the ring into cylinder e Measure the opening gap of the piston ring when pressed into cylinder Working limit Top ring replace above 0 5mm 2 ring replace above 0 5mm e Measure the hole of the piston pin Working limit Replace if inside diameter is over 17 04 mm e Measure outside diameter of piston pin Working limit Replace if under 16 96 mm Chapter Engine CYLINDER PISTON e Measure outside diameter of piston Note It s important to measure the outside diameter with vertical position The measure point is about 5mm away from the bottom Working limit Replace if under 73 9 mm Piston rings installat
7. out the cable from the clutch lever on top of right crankcase cover l Ay ay pee ASS FENN D N D ZZ A JN gt ke I LA Z R crankcase Gasket pin LUBRICATION SYSTEM Remove 2xM8 25mm hex flange bolts on master cylinder assembly This is to lower down the brake pedal for easier disassembly Release brake pedal reset spring Lift the vehicle from right side and flip over to left side Then remove the oil tube fix bolt on top of right crankcase cover X Beware not to lost the copper washers Remove the nylon insert bolt on reverse stopper lever LUBRICATION SYSTEM Remove 2xM6 12mm hex flange bolts together with the switch cover Un plug the contact switch connectors Attention Beware the light green wire is for the neutral signal the gray wire is for the reverse signal Remove 10xM6 32mm 1xM6 40mm_ and 1xM6 50mm hex flange bolts Put away all wires cables Slightly hit the right crankcase cover from side way and pull out to remove the cover LUBRICATION SYSTEM Remove the right crankcase cover gasket and beware not to lost the dowel pins Remove 4xM6 28mm hex bolts and 4 springs under the clutch lifter plate Hold the lifter plate together with the needle roller bearing Before remove the locknut punch out the lock section on the nut Remove the locknut and clutch center LUBRICATION SYSTEM Take off the clutch center Use reversed procedure to s
8. tire pressure specification please check the marking on tires Please follow the maintenance schedule to do the routine maintenance Service Interval R Replace Inspection check adjust and replace if necessary D Need some special tools or techniques suggest to be serviced on dealers site nspection parts System 1 2 Air cleaner element C park plug etrol filter Fuel tube alve clearance ngine oil ng oil filter screen ngine idle speed rive chain rake shoe wear Brake system lutch system uspension e tighten up bolts and nuts ire and Wheel teering system and shaft bearing Note 1 2 Note 2 Z O D 2 U V ervice Interval Initial Service 20 hours or 150km either earlier time for new vehicle Regular Check Every 100 hours or 1000km earlier time Regular Check Every 200 hours or 2000km earlier time NNO GO N Ss No Note 1 Used in dusty sandy snow area need to be inspected Note 2 Used in rainy muddy condition need to be inspected Note 3 Used after 50 hours or 500km need to be inspected Note 1 If the ATV is new then the motor oil have to replace at the first initial service 2 For safety reason we suggest the maintenance should be done at local service center 3 If the driving condition is very abominable such as rainy dust zone or heavy load that we suggest operating maintenance more frequency CHECK AND ADJUST PARKING BRAKE LEVER P
9. ARNING Don t knock cooling fin Hex flange bolt Intake manifold assembly Assembly x Operation with sequence in reverse of o gt 1 disassembly x Tie up nuts on cylinder head cover 2 3 times x Unscrew the bolts cross wise for 2 3 times Chapter Engine CYLINDER HEAD VALVE Disassembly the cylinder head a Disassembly Spark plug Hex flange bolt Hex flange bolt Hex flange bolt Hex flange bolt Hex flange bolt Hex flange bolt Plain washer Cylinder head cover assembly Hex acorn washer face nut Plain washer Hex socket bolt Dowel pin Cylinder head Cylinder head gasket 6x28 6x52 6x35 6x80 6x115 6x136 6 5x14x1 6 M10xP1 5 10x20x2 10x105xP1 25 8x12 PNMOARHOAH MH Ww 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Check the gasket if wear out or damaged Assembly x Operation with sequence in reverse of 15 1 disassembly Chapter Engine CYLINDER HEAD VALVE Remove the camshaft and valve Disassembly Dowel pin Rocker arm shaft comp Valve arm rocket assembly Valve cotter Valve spring assembly Inlet Exhaust valve Valve stem seal Hex flange bolt Camshaft sprocket Camshaft comp The dowel pins are located underneath the cylinder head cover Using 8mm bolt to pull out the shaft from R side OONDOOAaRWN _PpPFfABONN PY O Assembly x Operation with sequence in reverse of disassembly Chapter Engine CYLINDER HEAD VALVE e Ch
10. Hex socket flange bolt Cam chain tensioner mounting eye Hex flange bolt bolt 4 24 10 f o 14 2 0 Crankcase bolts Hex flange Bolt Cylinder base bolts ae a eee Cylinder head cover flange bolts 13 Hex flange Bolt Oil pipe bolts Gearshift return spring pin Gearshift drum shifter pin 6 6 36s pao 22 ued Cylinder head cap nuts 10 Hex acorn washer oe fl o e O 8 a ae Information for Preparation The following drawing that shows the disassembling situation of the cover parts for ATV 300XS J AU N INFORMATION FOR PERPARATION DIFFICULT START OR CANN T START Diagnose Check and Adjust loose the fuel release screw of caruretor and check if the fuel is inside of carburetor L fuel supply to carburetor is sufficient no fuel supply to carburetor i loosen the spark plug if connect with the spark cap and contact with the frame check the spark plug sparking no sparking or sparking weak emi i i Oe Ce SC j test the compression pressure compression pressure is normal compression pressure too low or no pressure follow the standard Stat up procedure and test again engine can not ignite engine can ignite but can not start loosen the spark plug and test spark plug is dry spark plug is wet continue Reason of Trouble fuel tank without gasoline tubing to carburetor b
11. M6x45 M6x65 a NN M6x12 Use rubber hammer slightly hit the gear to remove the crankcase Scratch off the gasket which between Crankcase gasket Right crankcase Dowel pin Hex flange bolt Plain washer Stud bolt Stud bolt 15 gt 1 Assembly MPO N a NY HS HS SS HS SS SS SS SS l crankcases and use new gasket after disassembly Do not damage the crankcase surrounding edge Check the oil seal is attrition or not M12x15 12 5x20x2 The stud bolts are not necessary to remove unless it s banded or defect Operation with sequence in reverse of disassembly Chapter Engine CRANKCASE CRANKSHAFT Disassembly of the transmission gear Disassembly Hex socket bolt Bearing setting plate Main shaft assembly Counter shaft assembly Reverse idle gear shaft Thrust washer Reverse idle gear Reverse idle gear bush Thrust washer OOnNOOFR WD Assembly 9 1 The gear assembly should pull out at the same time with drum shaft assembly Beware keep the washer and cir clip in original order The ball and needle bearings are located on crankcase Check the bearing is functioning well or not Be ware of the gear set sequence and assembly direction Operation with sequence in reverse of disassembly Chapter Engine CRANKCASE CRANKSHAFT Disassembly of the gear shaft mechanism Ke 7 Sian 3 Disassembly Gear shift arm assembly Shifter collar Hex flange bolt Guide plate Ro
12. SERVICE MANUAL ATV 300XS 2002 24 JULY 31 2007 High Power Engine HER CHEE INDUSTRIAL CO LTD Foreword This service manual contains information on servicing ATV 300XS This manual is written for use as a guideline only It is recommended that any mechanic with or without sufficient experience thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual For fully qualified mechanics this manual supplies service data necessary for repairs and maintenance It is highly recommended that a qualified mechanic regardless of technical level should study the service manual in full before attempting service on ATV 300XS All the data and diagrams provided in this service manual are valid at the time of publication Information may be updated without notice due to improvements or upgrades No quotation reproduction or reprint of the service manual as a whole or in part will be permitted without the express written consent from ADLY Motor sports CONTENTS General Information amp Lubrication Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 General Information F 4 Information for Preparation F 5 Check amp Adjust F 16 Engine Engine Removal amp Installation l
13. ark plug wire Alternator there pin connector Reverse and neutral switches Starter cable e Disconnect the reverse cable e Disconnect the clutch cable from the lifter arm and detach the cable from the bracket e Remove the drive sprocket cover remove the drive sprocket and pull the drive chain back so that it doesn t interfere with engine removal e Remove the engine mounting bolts nuts and brackets at the lower front and lower rear e Have an assistant help you lift the engine and remove it from the left side e Slowly lower the engine to a suitable working area NOTE Remove the external oil pipe on cylinder head cover for bigger clearance to remove the engine Chapter Engine Engine Remove and Installation INSTALLATION e Mounting the engine and tie up fixed nuts with standard locking torque Locking torque Fixed M10 nuts on bracket 4 0 kg m e Place a floor jack under the engine Again be sure to protect the engine from the jack head with a block of wood Lift the engine to align the mounting bolt holes then install the brackets bolts and nuts e The remainder of installation is the reverse of the removal steps with the following additions a Use new gaskets at all exhaust pipe connections b Adjust the clutch cable and the throttle cable c Fill the engine with oil Run the engine and check for leaks e Finish mounting the engine be sure to check the throttle cable tolerance Use reversed pro
14. cedure to setup the parts that has been removed NOTE x All cables and wiring has to be set into correct position Chapter Engine CYLINDER HEAD VALVE Fe AA A H a Ve CA KE Ce oN Y a SI lt A N XQ M TROUBLE DIAGNOSE Idle Speed not Stable Compression pressure too low Bad adjustment of valve clearance Valves banded or burn Valve timing not correct Damage of valve spring Sealing of valves and seats abnormal Leaking of cylinder head gasket Bottom of cylinder head damaged Wrong installation of spark plug Valve gap adjustment 0 08 mm Compression Pressure too high e Too much carbon residue inside combustion chamber Emission with White Smoke e Valves or valve guide attrition e Oil seal on valve attrition e Piston ring attrition Noise Bad adjustment of valve gap Valve burn or spring damaged Camshaft or rock arm attrition Attrition of cam chain guide comp Chapter Engine CYLINDER HEAD VALVE Attention of Operation Can be operated when engine installed on vehicle Must cleaning before operating avoiding dust enter the engine Remove the gasket dust stay on joint face Avoid to use screwdriver harm the joint face when remove the cylinder amp cylinder head Cleaning before check parts and smear motor oil appointed in sliding face before installing Remove Cylinder Head Disassembly Cap nut of exhaust pipe 8mm Exhaust pipe of front section Exhaust pipe gasket x W
15. de cylinder head working limit Replace if over 5 53 mm Cylinder head assembly e Install valve seal spring seat ote i JA d O 2 Fi x Install new valve seal after removed e Install valve into cylinder head with some lubrication oil on seal and spring seat AK e Install springs spring holder cotter and S N use special tool to assembly Note x Must use the special tool x Valve cotter sharp edge face toward cylinder head bottom Valve spring holder tool TLH3 03 PaE a TO AL WL QW A WS A e Use rubber hammer hit the valve top for E 2 3 times to have better contact ae between valve and cotter Chapter Engine CYLINDER HEAD VALVE Camshaft adjustment e After install the cylinder head it s necessary to setup the camshaft timing e Before put the timing chain on cam sprocket turn the T mark on ACG flywheel aim at the crankcase sign MEMO Chapter Engine CYLINDER PISTON TROUBLE DIAGNOSE Low compression pressure e Piston ring wear out burn or broken e Cylinder piston wear out or damaged Compression pressure too high e Piston or combustion chamber stocks with carbon material e Avoid to harm the cylinder inner surface and piston face Exhaust with white smoke e Piston ring wear out burn or broken e Cylinder piston wear out or damaged Piston noise e Piston cylinder or piston ring damaged e Piston pin and piston wear out
16. e oil level gauge Remove the oil release bolt underneath the engine and release the oil Install the oil release bolt Fill the engine oil Confirm the washer of the bolt whether damaged Engine oil quantity disassemble 2 0 Lit change 1 6 Lit Check all parts whether leaking after assembly DRIVE CHAIN Check the drive chain condition turn direction The drive chain should be check adjust and lubricate regularly Inspect the drive chain at a point on the lower run about halfway between the fix clip sprockets The free play of the drive chain should be between 20 30mm up and down CHECK AND ADJUST Inspect the front sprocket teeth for excessive wear mark sure there s no play in the sprocket When install the chain clip beware the clip direction BRAKE SYSTEM Parking brake and rear brake Check all the brake shoes If the brake shoes have any dint or wearing very serious then change it Check the play of brake lever normal play 10 20 mm lf the brake lever play is too much adjust the fix bolts on right brake lever Adjust bolt im Fix nut If the play of the rear brake over the normal value then adjust the adjusting nut of rear brake caliper on swing arm Adjusting nut must be aligned with pin any slight deviation may result in braking play change cause danger as brake applied STEERING Turn the steering handlebar from right side to left side to check the stee
17. eck the cam surface to see if it s wear out or damaged Working limit Replace if IN cam under 35 57 mm EX cam under 35 58 mm e Check the camshaft bearings to see if it s wear out or loose If its loose or wear out change whole set of camshaft e Check the rock arm and shaft e Check rock arm inside diameter Working Limit Replace if over 12 04mm e Check the rock arm shaft outside diameter Working Limit Replace if under 11 92mm Note x If the sliding face of rock arm wear out then check the cam surface of the cam shaft e Check the gap between rock arm and shaft Working Limit Replace if over 0 07 mm Remove valves Use valve spring holder tool to remove the spring holder cotter spring valve and seal Note Valve spring must use special tool to disassembly Parts removed have to place in certain order assembly in opposite order Valve spring holder tool TLH3 03 Chapter Engine CYLINDER HEAD VALVE Check cylinder head e Check the hole of spark plug and valve S guide to see if it s damaged E RR 7 p RE AA E A CRS Check valve spring free length Working limit Outer spring Replace under 39 8 mm Inner spring Replace under 37 8 mm IAI Check valve and valve guide e Check valve to see if its burned or banded e Check the movement between valve and guide is smooth or not Valve outside diameter working limit Replace under 5 45 mm 6 Valve guide insi
18. etup the parts that has been removed Attention Beware all dowel pins are located into the crankcase Replace new gasket of the right crankcase cover after disassemblv OIL PUMP Remove Remove the O ring from the oil pipe To detach the oil pipe from the crankcase remove these 2 bolts Carefully pull the oil pipe off the crankcase Remove this dowel pin and O ring from the oil pipe Remove the oil pump mounting bolts Use reversed procedure to setup the parts that has been removed LUBRICATION SYSTEM oil pump assembly 1 1 0il pump body 4 oil pump inner rotor 2 crank shaft pin 5 oil pump cover 3 0il pump outer rotor 6 driven gear Oil Pump Disassembling e Remove the snap ring and washer e Remove the pump cover bolts and separate the cover from the pump body e Remove the pump driven gear and shaft Remove the rotors wash all the components in solvent LUBRICATION SYSTEM Check e Check the gap between the pump body and outer rotor The gap limit is 0 25 mm e Check the gap between inner and outer rotor The gap limit is 0 2 mm e Check the gap between the rotors anda straightedge laid across the pump body The gap limit is 0 1 mm
19. g the timing light to check the ignition timing When the engine speed running at idle the F mark of flywheel should aim at the inspection hole CHECK AND ADJUST IGNITION TIMING Using the timing light to check the ignition timing Keep the engine speed about 4000 rpm if 2 mark lines on flywheel aim at center of inspection hole then the ignition timing is correct CYLINDER PRESSURE Remove the spark plug cap and spark plug Install the pressure gauge Rotate the throttle and press the electric start button The normal cylinder pressure is 12 14 kg cm2 If the cylinder pressure is too low then check the following items Valve leakage Valve gap is too tie Cylinder head gasket is damage Piston ring wear out Piston cylinder wear out If the cylinder pressure is too high then check the combustion chamber and the top face of piston whether with too much carbon residue CHECK AND ADJUST ENGINE OIL When you check the quantity of oil the Low High vehicle has to stay at the ground flat level Stop the engine and remove the oil level gauge Unscrew the engine oil filler cap from the right front corner of the engine and pull out the dipstick lf the oil level is stay within bottom mark of the gauge then the oil quantity is enough Refill the engine oil if it s too less The standard oil type is SAE 10W 40 Re install the oil level gauge Change the engine oil Take out th
20. ification number is attached to the lower front right side of stamped on the right side of the carburetor frame behind the frame number Information for Preparation ATTENTION ON OPERATION All washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted Q Q Q Locking of all screws nuts cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks All items must use original parts pure oil and greases Ad ly All service shall use special tools and general tools to repair All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated Information for Preparation ATTENTION ON OPERATION Certified lubricants in cans shall be used on all the elements to be lubricated a F After assembly performance of all elements shall be duly checked and the locking shall be duly verified Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation ih OIL Lubrication by designated lubricant O EU GREASE Lubrication by grease Special Tool Parts on which special tools shall be used General Tool
21. ion e Each ring should be greased with oil arning Do not scratch piston and do not band piston rings The mark on piston ring must face up Be sure the rings rotate freely after install into piston Piston installation e Clean the gasket stick on top of crankcase e Install piston piston pin and clips arning The IN mark on top of cylinder must aim at the intake valve direction x Piston pin clip must not drop into crankcase Use cloth to seal the crankcase Check the piston clips is located in fix position Chapter Engine CYLINDER PISTON Cylinder Installation e Put the dowel pins and gasket on top of crankcase e Cylinder inside surface piston and piston rings must be greased with oil e Beware of the pressure from piston ring when install into cylinder arning Be careful not to damage or band the piston ring The opening section of piston rings should not be the same with piston pin and set into 120 to each other e Fit the cylinder into correct position top rng VLD second ring Chapter Engine CRANKCASE CRANKSHAFT TROUBLE DIAGNOSE Engine noise e Loose of crankshaft bearings e Loose of bearings inside crankshaft connecting rod Disassembly of the crankcase Disassembly Hex flange bolt Breather tube clamp Clutch wire receiver Oil filter screen Hex socket flange bolt Breather plate Breather plate gasket Left crankcase M6x35
22. iver Rotate the flywheel and keep the T line aim at the centerline of the inspection hole Measure valve clearance with a feeler gauge of the specified thickness To adjust the valve clearance loosen the locknut and turn the adjuster Attention xx When you adjusting the valve don t invert the crankshaft otherwise cannot adjust the exhaust valve Valve gap check and adjust Valve gap IN 0 08 mm EX 0 12 mm Loose the fixed nut and rotating the adjusting nut reach to the proper gap Tie up the fixing nut and check the gap again Using the valve gap tool to adjust the valve gap CHECK AND ADJUST ADJUSTING IDLE SPEED Engine idle speed adjustment has to do Connect with the rom meter then starting the engine Before adjusting the idle speed make sure the spark plug gap is correct Also turn the handlebars from left to right and note whether the idle speed changes If it does the throttle cable may be incorrectly routed Be sure to correct this problem before proceeding Warning Use screw driver to adjust the idle speed to avoid injury Adjust the idle speed adjust screw reach to the normal idle speed The idle speed is about 1400 100 rpm IGNITION TIMING The ignition system of this ATV is controlled by C D I unit thus don t need to adjust anything If the ignition timing isn t correct then checking the ignition system whether normally Remove the 14 mmA C G cap Usin
23. locking float chamber tubing blocking fuel filter blocking fuel cup blocking air in fuel tank blocking spark plug grimy or damage C D I damage main switch damage AGG fulser coil damage high tension coil damage AGG lighting coil damage valve set damage cylinder piston piston ring damage cylinder gasket leakage valve burn valve timing is not correct valve gap is too tight or no gap start clutch damage ignition timing is not correct carburetor fuel adjust screw isn t correct intake manifold sucking air fuel level of carburetor is too high throttle open angle is too wide INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH LOST POWER Diagnose engine speed goes up ignite timing is correct valve gap is correct compression pressure is normal no blocking engine speed can t goes up fully ignite timing isn t correct valve gap isn t correct compression pressure is too low blocking spark plug normal spark plug stain oil quantity oil quantity is is normal too rich normal abnormal normal over heat continue Check and Adjust Cl SO 7 start engine and go up speed slight adjusting ignite timing test compression pressure check carburetor blocking loosen spark plug and check e a a Ce Ce check the oil quantiity in crankcase is too rich or dirty increase engine speed or continue turning athigh Reason of T
24. mage spark plug cable damage eee to main switch damage check A C G A C G damage system end INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH HIGH SPEED Diagnose normal normal no blocking valve timing is correct normal end abnormal abnormal blocking valve timing isn t correct spring broken or elastic deformation Check and Adjust check fuel cup supply normal check and adjust valve timing Reason of Trouble C D I damage ACG pulse coil damage adjusting isn t correct valve seat damage fule filter blocking air hole of fuel tank blocking fuel cup damage fuel in tank is not sufficient cleaning camshaft gear mark position is not correct spring damage INFORMATION FOR PREPARATION CHARGE ABNORMAL Diagnose Check and Adjust ay ae a ne ee eS eg ee 7 start engine and measure voltage of both terminal on battery voltage of battery voltage of battery can t go up is normal measure the resistance of ACG coil measure value normal too high battery have voltage battery have not voltage check socket of regulator loosen normal abnormal over charge Sere ea ee AE check the voltage between regulator and frame main switch at ON main switch at ON SSS SS the battery have the battery have no voltage voltage ne a ts ee gg 7 check the socket of regulator a ee E EEE normal socket loosen
25. ring operation Be sure the wiring and cable does not affect the steering handle CHECK AND ADJUST FIXING OF NUTS AND BOLTS Check the fixing nuts bolts on all parts to see if the nuts bolts loosen then tie up with certain locking torque SUSPENSION Front Hold the brake lever and push the handlebar Check the fork movement and other parts if is loose or oil leaking Rear Check the damping of rear suspension Check the suspension bush function normally Inspect all suspension fasteners before riding TIRE RIM Check the tires whether have any nail broken etc Check tire pressure with a gauge that will read accurately at the low pressure used in ATV tires The tire pressure can be very depends on different operation condition Please check the mark on tire for operation pressure tolerance CHECK AND ADJUST Check the shaft and nut of front wheel whether loosen Check the nut of rear wheel whether loosen Locking Torque Front wheel 18mm nut 14 kg m Rear wheel 18mm nut 14 kg m Chapter Engine ENGINE REMOVE AND INSTALLATION ENGINE REMOVAL e Drain the engine oil e Remove the seat and the left right footpad assembly e Remove the body front fender assembly e Disconnect the negative battery cable e Disconnect the crankcase breather tube from cylinder head cover and on cylinder e Remove the carburetor e Remove the exhaust system e Label and disconnect the following wires Sp
26. rouble air cleaner blocking fuel supply isn t smooth air hole of air tank blocking exhaust pipe blocking manual choke stay on fuel cup damage C D I damage pulser coil damage valve gap adjusting isn t correct valve seat over abrade valve seat damage cylinder piston abrade cylinder gasket leakage valve timing isn t correct cleaning carburetor cleaning the stain spark plug type isn t correct oil flowing is too rich oil flowing is too lean oil doesn t circulate oil tubing blocking oil supply is too lean cylinder piston abrade mixutre gases is too lean carbon residue in combustion chamber is too much ignition timing is too earily fuel isn t good clutch plate sliding mixutre gases is too lean carbon residue in combustion chamber is too much ignition timing is too earily fuel isn t good INFORMATION FOR PREPARATION REVOLUTION NOT STABLE LOW R P M Diagnose Check and Adjust Reason of Trouble C D I damage normal abnormal pulser coil damage Were eget en ea adjust the carburetor fuel adjuste screw fuel mixture too lean Drees adjusting isn t adjusting is correct J 5 locking N correct fuel mixture too rich loosing screw gasket damage no sucking air sucking air the screw of carburetor is loosen loosen spark plug connecct with spark cap and contract with frame eee eee ee i check the spark plug spark damage or stain sparking C D I damage re ee i ae A C G da
27. tor assembly Bushing Bearing holder plate Shift pin Shift drum center Hex flange bolt Gear shift drum stopper assembly Hex socket bolt Hex washer face bolt Neutral switch rotor comp Reverse stopper cam comp Hex flange bolt Reverse shift stopper comp Gear shift fork assembly Gear shift spindle comp Hex socket bolt Gear shift drum assembly Assembly x Operation with sequence in reverse of disassembly x Parts from sequence 1 to 11 are removed during previous L crankcase disassembly x Parts from sequence 12 to 17 are removed during previous R crankcase disassembly OOnNO OF WD x Check the tolerance between the forks and drum i l N e Nean NO S NO S SS SS IM 21 1 x Apply oil during assembly Chapter Engine CRANKCASE DISASSEMBLY GEAR SHIFT MECHANISM e Check the small spring locates on the gearshift arm to see if it s too loose or not e Check the stopper plate is loose or not e Check the roller guide Working diameter limit Replace if under 5 7mm e Check the inside diameter of the forks Working diameter limit Replace if over 13 04mm e Check the outside diameter of the forks Working diameter limit Replace if over 12 96mm e Check the fork ear thickness applied to gear shaft area Working diameter limit Replace if under 4 50mm e Check the shift drum grooves for wear especially at the points Xx a ON l fof Nene N fl a
28. ull the right brake lever will perform brake function Push the locking will lock the brake The main adjusting nut for throttle play is located under the handle bar Loose the fixed nut and adjust the play nut to proper position The throttle lever control bolt is located the throttle base Loose the fixed nut and adjust the screw to The throttle lever free play 2 6 mm get proper position CHECK AND ADJUST SPARK PLUG Pull to remove the spark plug cap Use tools come with the vehicle to remove the spark plug If the spark plug grimy or with carbon residue then using the copper brush to clean it Spark plug specification DR8EA Resistance Check the gap of spark plug Gap 0 6 0 7 mm AIR CLEANER Remove the seat Pull to open 4 clips on air cleaner cover and remove the cover Take out the air filter Check the filter whether is dirty or damaged If it s dirty or damaged then clean it or change a new one Attention Clean the element and frame in a high flash point solvent squeeze the solvent out of the foam and let the guide and element dry completely Check period If the ATV often driving at the rainy or abominable surroundings please check the filter more frequently CHECK AND ADJUST VALVE ADJUSTING Attention When you check or adjust the valve do it when the engine temperature is low below 35 C Remove the timing hole plug and the crankshaft hole plug with screwdr
29. y reduced Engine burn e Normal consumption e No oil pressure or pressure too low e Oil leaking e Oil thoroughfare blocking e Piston ring wear out or installed wrong e Oil type incorrect e Valve seal wear out ENGINE OIL amp FILTER Oil quantity x When you check the oil quantity the vehicle has to stand on flat ground Starting the engine about 2 3 min then stop it After 2 3 min check the oil quantity Remove the oil level gauge and check if the oil level under the lower limit then adds the standard oil to upper limit of gauge Oil Exchange The motor oil will flow more easily if the engine is warm The oil release bolt is under crankcase Locking torque 1 5 kg m Remove the right crankcase cover to check and clean the oil filter Replace new filter if it s damaged Adding the proper oil quantity Engine disassembly 2 0L Oil change 1 6L Check the engine oil whether leaking If not then starting the engine at idle speed for few minutes and checking the oil level again LUBRICATION SYSTEM CLUTCH Remove Remove the seat and body cover see 3 1 3 2 Remove 2x10mm Hex flange bolts on left step bar foot peg and 2 Pan Philips bolts on the rear foot fender Remove foot peg and fender together Take off 12 bolts on R crankcase cover and remove the cover Remove the gasket and 2 dowel pins Release the clutch cable fix nut from the left side of the engine Pull
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