ATV +Service+Manual

2009 ATV
SERVICE MANUAL EUROPE 09.0

PN. F010102A01
ATV
Mini
50/80/100/150 B-Type 150/200, 2x4 260/300, 2x4/ 4x4 ATV520 ATV400-2 ATV400-2B Attachment: Delphi Small
Manual
Model 2004 2005 Special Edition - Anniversary 2x4 4x4
260/300
Engine Management System Service
WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
General
Information Maintenance Engine Chassis Final Drive Transmission Brakes Electrical
Foreword
This manual is designed primarily for use by the ATV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary importance. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures. Keep this manual available for reference in the shop area. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. At the time of publication all information contained in this manual was technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. We constantly refine and improve its products, all materials and specifications are subject to change without notice. This ATVs publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information:
WARNING Indicates a potential hazard which will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV.. CAUTION Indicates a potential hazard which may result in personal injury or death or damage to the machine. NOTE The word NOTE in this manual will alert you to key information or instructions.
CONTENTS
CHAPTER1 General Information CHAPTER2 .Maintenance CHAPTER3A..260 300 400 Engine CHAPTER3B...50 80 Engine CHAPTER3C. . 100 125 150 200Engine CHAPTER4A..Chassis CHAPTER4B..Chassis (Youth/ mini ATV) CHAPTER5.Final Drive CHAPTER6.Transmission CHAPTER7Brakes CHAPTER8..Electrical CHAPTER9.520 Maintenance Attachment: Delphi Small Engine Management System Service Manual
WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Always keep alert and wear protection.. Exhaust system components are very hot during and after use of ATV. Never service when the engine is warm or hot. Escaping steam from cooling system or hot oil from the machine can cause severe burns. The engine must be cool before service. Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention and wear protection.
CHAPTER 1 GENERALINFORMATION
ATV SERVICE MANUAL 09.0
CHAPTER 1 GENERAL INFORMATION

1.1 IMPORTANT INFORMATION 1.2 V.I.N AND ENGINE SERIAL NUMBER 1.3 VEHICLE DIMENSIONS
CHAPTER 1
GENERAL
PAGE. 1- 1
1.1 IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated part must always be reused or replaced as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. REPLACEMENT PARTS Use only genuine parts for all replacements. Use recommended oil and grease for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. GASKETS,OIL SEALS AND O-RINGS 1. Replace all gaskets seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS Replace all lock washers/plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification.
BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. oil seal CAUTION: Do not use compressed air to spin the bearings dry. This will damage the bearing surfaces. Bearing
CIRCLIPS 1. Check all circlips carefully before reassembly.

CHAPTER 1 GENERAL PAGE. 1- 2
Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip , make sure that the sharp-edged corner is positioned opposite the thrust it receives. See sectional view. Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin and reinset the terminal into the connector. 6. Connect: Connector NOTE: The two connectors click together. 7. Check for continuity with a tester. NOTE: If there is no continuity, clean the terminals. Be sure to perform the steps 1 to 7 listed above when checking the wire harness. Use the tester on the connector as shown.
WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Always keep alert and wear protection.. Exhaust system components are very hot during and after use of ATV. Never service when the engine is warm or hot. Escaping steam from cooling system or hot oil from the machine can cause severe burns. The engine must be cool before service. Crate of the ATV and parts in the ATV maybe have sharp edge, always pay attention and wear protection.
CHAPTER 1
GENERAL
PAGE. 1- 3
CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULIPLIER IMP **mm x 0. 3937 = **in **cm x 0.03937 = **in
CONVERSION TABLE METRIC TO IMP Known Multiplier 7.233 mkg 86.794 mkg 0.0723 cmkg 0.8679 cmkg kg 2.205 g 0.03527 km/h 0.6214 km 0.6214 m 3.281 m 1.094 cm 0.3927 mm 0.03927 3 0.03527 cc(cm ) 0.06102 cc(cm3) lit(liter) 0.8799 lit(liter) 0.2199 55.997 kg/mm 2 14.2234 kg/cm Centigrade 9/5()+32
Torque
Weight Distance
Volume/ Capacity
Miscellaneous
Result ftlb Inlb ftlb Inlb lb oz mph mi ft yd in in oz(IMP liq.) cuin qt (IMP liq.) gal(IMP liq.) lb/in psi(lb/in2 ) Fahrenheit(F)
CHAPTER 1
GENERAL
PAGE. 1- 4
CHAPTER 1 GENERALINFORMATION 1.2 V.I.N AND ENGINE SERIAL NUMBER

ATV 260 / 300 / 400-2 /400-2B
Mini / Youth
CHAPTER 1
GENERAL
PAGE. 1- 5
CHAPTER 1 GENERALINFORMATION 1.3 VEHICLE DIMENSIONS
2004
2005
DEMON
Special Edition - Anniversary
Mini / Youth
B-Type
ATV400-2
ATV400-2B
520ATV
520ATV-B
Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA.
CHAPTER 1 GENERAL PAGE. 1- 6
ATV 260 / 300
05 Model ATV 260 / 300
CHAPTER 1
GENERAL
PAGE. 1- 7
Demon ATV 260 / 300 Europe
Mini / Youth
CHAPTER 1
GENERAL
PAGE. 1- 8
Special Edition - Anniversary
B-Type 260/ 300
CHAPTER 1
GENERAL
PAGE. 1- 9
B-Type 150/ 200
ATV 400-2
CHAPTER 1
GENERAL
PAGE. 1- 10
ATV 400-2B
ATV 520
CHAPTER 1
GENERAL
PAGE. 1- 11
ATV 520-B
CHAPTER 1
GENERAL
PAGE. 1- 12
CHAPTER 1 GENERALINFORMATION NOTES
CHAPTER 1
GENERAL
PAGE. 1- 13
CHAPTER 2 MAINTENANCE
CAUTION: If wheels are improperly installed it could affect Vehicle handling and tire wear.
ATV SERVICE MANUA 09.0
Tire Pressure Inspection Front 260/300 4PSI (270.5KPa) B-Type 150 / 200 Youth/ Mini 400ATV-2 400ATV-2B 5PSI 35KPa 5PSI 35KPa Rear 4PSI (27 0.5KPa)
2.7 TIRE PRESSURE

TIRE INSPECTION CAUTION : Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Improper tire inflation may affect ATV maneuverability. When replacing a tire always use original equipment size and type and replace in pairs, especially in SDX300 model. The use of non- standard size or type tires may affect ATV handling and cause machine damage, especially in SDX300 model. TIRE TREAD DEPTH Always replace tires when tread depth is worn to 1/8" (3mm ) or less.
WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8" (3mm ) or less.
CHAPTER 2
MAINTENANCE
PAGE. 2- 19
CHAPTER 2 MAINTENANCE
EARLY DESIGN* Bolt M10 Attaching A-Arm and Frame MANTENANCE-FREE PIVOT DESIGN Bolt M12 Attaching A-Arm and Frame Nut M10X1.25 Attaching A-Arm to Ball Joint Stud Screw M6 Attaching Ball Joint Mounting Bracket to Front Absorber Strut body (MacPherson) Swing Arm Pivot Left Swing Arm Pivot Right Threaded Pivot Nut (for swing arm) Nut M14X1.5 Attaching Front Absorber to Frame (MacPherson) Nut M8 Binding Front Absorber and Front Absorber Strut body (MacPherson) Bolt M8 Attaching Front Caliper to Front Absorber Strut body Bolt M8 Attaching Upper Steering Clamp to Frame Nut M8 Attaching Lower Steering Bearing Retainer to Frame Nut M10X1.25 Attaching Front Wheel to Front Wheel Hub Front Drive Axle Nut Screw M8 Attaching Front Brake Disc to Front Wheel Hub Nut M10X1.25 Attaching Rear Brake Disc to Rear Brake Rear Axle Nut M20X2 (for swing arm) Rear Hub Retaining Nut M20X1 (for IRS) Nut M10X1.25 Attaching Rear Caliper to Axle Tube Bolt M12x30 Attaching Axle Tube and Swing arm to Rear Gear-box Bolt M12x35 Attaching Axle Tube to Swing arm LT*---Apply Loctite 242 18 22-25 80 101 18 60 60-66 15-18 15 18 12 12 20 37-44 22-25 8 14 120 120 165 50-60 30-35 11 19 165 30 41
ATV SERVICE MANUA 09.0
LT* Only ATV 260 early model LT*
LT* Refer to SWING ARM ASSEMBLY INSTALLATION 4.2 SWING ARMCHAPTER 4A CHASSIS LT* LT* LT*
21-25 21 25 16 16 27 Refer to FRONT HUB INSTALLATION 25 30-35 110.6 137 25 80 80-90
LT* LT*
LT*
CHAPTER 2
MAINTENANCE
PAGE. 2- 21
CHAPTER 3A ENGINE 260/ 300 / 400 cc
ATV SERVICE MANUAL09.0
CHAPTER
3.1 MAINTENANCE SPECIFICATIONS 3.1.1 SPECIFICATIONS 3.1.2 TIGHTENING TORQUES
3 A ENGINE
260cc / 300 cc /400 cc
3.2 PARTS INSPECTION AND SERVICE 3.2.1 VALVE CLEARANCE ADJUSTMENT 3.2.2 IDLING SPEED ADJUSTMENT 3.2.3 SPARK PLUG INSPECTION 3.2.4 COMPRESSION PRESSURE 3.2.5 ENGINE OIL LEVEL INSPECTION 3.2.6 COOLANT LEVEL INSPECTION 3.3 CYLINDER HEAD 3.4 CAMSHAFT AND ROCKER ARMS 3.5 VALVES AND VALVE SPRINGS 3.6 CYLINDER AND PISTON 3.7 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE 3.8 A.C. MAGNETO AND STARTER CLUTCH 3.9 OIL PUMP 3.10 CRANKCASE AND CRANKSHAFT 3.11 COOLING SYSTEM 3.11.1 RADIATOR 3.11.2 WATER PUMP 3.11.3 THERMOSTAT 3.12CARBURETOR
CHAPTER 3 ENGINE PAGE. 3A1
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.1 MAINTENANCE SPECIFICATIONS

3.1.1SPECIFICATIONS Item Cylinder head : Warp limit. Cylinder: Bore size Out of round limit Camshaft: Cam dimensions Intake "A" "B" "C" Exhaust "A" "B" "C" Camshaft runout limit Cam chain: Cam chain type/No. of links Rocker arm /rocker armshaft: Rocker arm inside diameter Rocker shaft outside diameter Rocker arm - to- rocker arm shaft clearance Valve, Valve seat, Valve guide: Valve clearance (cold) IN EX Valve dimensions 0.08-0.12 mm 0.16-0.20 mm Standard
Limit 0.03 mm
260:70.000- 70.014 mm 300:72.500- 72.514 mm 400: 80.000- 80.014 mm
260:70.025 mm 300;72.525 mm 400:80.025mm
0.03 mm
36 .545- 36 .645 mm 30.021-30.121 mm 6.524 mm 36 .547- 36 .647 mm 30 .067- 30.167 mm 6.48 mm ..
36 .45 mm 29.92 mm 36 .45 mm 29 .97 mm 0.03m m
260/300: DID SC.A-0404A SDH/104 400:DID SC.A-0404A SDH/108 12 .000- 12 .018 mm 11.981- 11.991 mm 0.009- 0.012 mm 12 .03 mm 11.95 mm
CHAPTER 3 ENGINE
PAGE. 3A-

"A" head diameter "B" face width "C " seat width "D" margin thickness Stem outside diameter Guide inside diameter IN EX IN EX IN EX IN EX IN EX IN EX 33.9-34.1mm 28.4-28.6mm 3.394-3 .960mm 3.394-3.960 mm 0.9-1.1mm 0.9-1.1 mm 0.8-1.2 mm 0.8-1.2 mm 5.975- 5.990 mm 5.960-5.975 mm 6.000- 6.012 mm 6.000- 6.012 mm
5.94 mm 5.92 mm 6.05 mm 6.05 mm
Item Stem-to-guide clearance Stem runout limit
IN EX IN
Valve seat width EX Valve spring : Free length (Inner) IN/EX (Outer) INEX Set length (valve closed) (Inner) IN/EX (Outer) IN/EX Com pressed pressure (Inner) IN/EX (Outer) IN/EX Tilt limit (Inner) IN/EX (Outer) IN/EX Piston: Piston to cylinder clearance Piston size "D" Measuring point "H" Piston pin bore inside diameter Piston pin outside diameter Piston: Piston to cylinder clearance Piston size "D" Measuring point "H" Piston pin bore inside diameter Piston pin outside diameter
Standard 0.010- 0.037 mm 0.025-0.052 mm 0.9-1.1 mm 0 .9-1.1 mm 38.1 mm 36.93 mm 30.1 mm 31.6 mm 7 .8- 9.0 kg 37.22-42 .83 kg 260 /300: 0.02 - 0.04 mm 260;69.965-69.980 mm 300;72.465-72.480 mm 5mm 17.004-17.015 mm 16 .991-17 .000 mm 400: 0.02 - 0.049mm 79.965-79.980 mm 5mm 18.004-18.015 mm 17 .991-18 .000 mm
Limit 0.08 mm 0.1 mm 0.01 mm 1.6 mm 1.6 mm 361 mm 35.0 mm 2.5/1.7mm 2.5/1.7mm 0.15m m 17.045 mm 16 .975 mm 0.15m m
18.045 mm 17 .975 mm
PAGE. 3A3
CHAPTER 3 ENGINE

Piston rings : Top ring : Type End gap (installed) Side clearance (installed ) 2nd ring : Type End gap (installed) Side clearance Oil ring : End gap (installed) Piston rings : Top ring : Type End gap (installed) Side clearance (installed ) 2nd ring : Type End gap (installed) Side clearance Oil ring : End gap (installed) Crankshaft: 260 /300: Barrel 0.15- 0 .30 mm 0.04- 0.08 mm Taper 0 .30- 0 .45 mm 0.03 - 0.07 mm 0 .2- 0.7 mm 400: Barrel 0.2-0.35 mm 0.03-0.065 mm Taper 0.28-0.48 mm 0.02-0.052 mm 0. 15-0.4 mm
0 .45 mm 0 .12 mm 0.7 mm 0.12 mm
0.5 mm 0.1 mm 0.73 mm 0.1 mm
Crank width "A" Runout limit "C " Big end side clearance "D"
59.95-60.00 mm 0.03 mm 0.35- 0.85 mm
CHAPTER 3 ENGINE
PAGE. 3A-

Item Automatic centrifugal clutch: Clutch shoe thickness Clutch hosing inside diameter Clutch shoe spring free length W eight outside diameter Clutch- in revolution 3.0 mm 135 mm 2 8.1 mm 20 mm 2 ,100- 2,700 r/m in Standard
Limit
2.0 mm 135 .5 mm 19 .5 mm
V-belt: V-belt width Carburetor: Type I.D. mark Ventuly outside diameter Main jet Jet needle Throttle valve size Pilot air jet Needle jet Pilot outlet Pilot jet Bypass Pilot screw Valve seat size Starter jet 1 Starter jet 2 Float height Engine idle speed Intake vacuum Oil pump: Type Tip clearance Side clearance Housing and rotor clearance Trochoid type 0.1- 0 .34 mm 0.013- 0.03 6 mm 0 .04- 0.09 mm 0 .4 mm 0 .15 mm 0 .15 mm 22.6 mm 21.0 mm
(M .J) (M .A.J) (J.N) (Th .V) (P.A.J.1) (N.J) (P.O) (B.P) (P.S) (V.S) (G.S.1) (G.S.2) (F.H)
CVK 1000-L06-0000 T VH- 052D 30 # 128 N7AJ 10 1.2 2.1 0.95 # 38 0.7x4 1*3/8 1.2 # 42 0 .9 3.0 1,350-1,650 r/m in 220-260 mmHg
CHAPTER 3 ENGINE
PAGE. 3A-

Item Radiator: Type Width/height/thickness Radiator cap opening pressure Radiator capacity Reservoir tank capacity Thermostatic valve: Valve opening temperature Valve full open temperature Valve full open lift Standard
Limit
Cooling fin with electric fan 260 /300: 288/238/42 mm 400: 360/246/68 m
110-140kPa (1.1-1.4kg/cm 2,
1.1-1.4bar) 2L 0 .35 L
70 .5- 73 .5 85 3 mm
CHAPTER 3 ENGINE
PAGE. 3A-
3.1.2TIGHTENING TORQUES Part to be tightened Part name Thread size M6 M8 M12 M6 M8 M6 M6 M16 M6 M6 M10 M6 M8 M6 M6 M6 M6 M5 M6 M3 M 35 M6 M6 M6 M8 M6 M8 M 14 M6 M6 Qty 1 2 1 2 4 2 5 1 2 2 1 2 1 1 3 2 2 1 2 1 1 2 2 2 2 9 1 1 10 10 Tightening Torque N.m m.kg 10 13 18 10 22 10 10 80 14 8 60 10 8 10 10 7 10 5 7 1 32 10 10 10 20 10 22 3 10 10 1.0 1.3 1.8 1.0 2 .2 1.0 1.0 8.0 1.4 0 .8 6.0 1.0 0.8 1.0 1.0 0.7 1.0 0 .5 0.7 0.1 3 .2 1.0 1.0 1.0 2.0 1.0 2 .2 0 .3 1.0 1.0 Remarks
Oil check bolt _ Exhaust pipe stud bolt _ Spark plug _ Cam sprocket cover Bolt Cylinder head and cylinder Nut Cylinder head and cylinder Bolt (Cam chain side) Valve cover Bolt Rotor Nut Valve adjuster locknut Nut Cam shaft bearing stopper Bolt Cam sprocket Bolt Cam chain tensioner (Body) Bolt (Plug) Bolt Guide stopper 2 Bolt Water pump housing cover Bolt Hose joint _ Thermostatic valve cover Bolt Filer neck supporting Bolt Oil pump Screw Oil pump cover Bolt Drain plug Bolt Carburetor joint Bolt Carburetor joint and carburetor Bolt Fuel pump _ Exhaust pipe assembly Nut Crankcase (left and right) Bolt Drain bolt Bolt Oil filer Bolt Crankcase cover (left) Bolt Magnet cover _
CHAPTER 3 ENGINE
PAGE. 3A-
Part to be tightened
Part name Thread size
Qty
Tightening torque Nm m.kg 1.2 0 .8 3.0 6.0 0 .3 6.0 9.0 0.7 0.7 1.0 2 .3 0 .8
Remarks
Cover (oil pump) Timing check plug One way clutch Clutch housing Grease stopper (Primary sheave) Primary fixed sheave Clutch carrier assembly Stator Pick up coil Starter motor Thermo switch Thermo unit
Bolt P lug _ Bolt _ _ _ _ _ Bolt _ _
M6 M 16 M8 M 14 M4 M 14 M 36 M5 M5 M6 M 16 P t1/8
2 1 3 1 4 1 1 3 2 2 1 1
12 8 30 60 3 60 90 7 7 10 23 8
CHAPTER 3 ENGINE
PAGE. 3A-
3.2 PARTS INSPECTION AND SERVICE

3.2.1VALVE CLEARANCE ADJUSTMENT NOTE: Valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression. 1. Remove : Crankcase cover 2. Remove : Spark plug Valve cover (intake side) Valve cover (exhaust side) 3. Remove: Timing check plug 4.Measure: Valve clearance Out of specification Adjust. Valve clearance (cold): 260 / 300: Intake valve 0.08- 0.12m m Exhaust valve 0.16- 0 .20mm 400: Intake valve 0.08- 0.12m m Exhaust valve 0.13- 0.16mm Measurement steps: Rotate the primary fixed sheave counterclockwise to align the slit a on the rotor with the stationary pointer b on the crankcover 1 when the piston is Top Dead Center (TDC). Measure the valve clearance by using a feeler gauge. 6. Adjust Valve clearance
CHAPTER 3 ENGINE
PAGE. 3A-

Adjustment steps: Loosen the locknut Turn the adjuster in or out with the valve adjusting tool until specified clearance is obtained .
Turning in Valve clearance is decreased Turning out Valve clearance is increased Hold the adjuster to prevent it from moving and tighten the locknut.
Measure the valve clearance. If the clearance is incorrect, repeat above steps until specified clearance is obtained. 7. Install: Valve cover (intake side) O-ring 8 . Install: Valve cover(exhaust side) O-ring Spark plug Timing check window screw Crankcase cover
8N.m( 0.8m.kg)
3.2.2 IDLING SPEED ADJUSTMENT 1. Start the engine and let it warm up for several minutes. 2 . Attach : Inductive tachometer to the spark plug lead. 3. Check: Engine idling speed Out of specification Adjust. Engine idling speed: 1,350-1,650 r/min
CHAPTER 3 ENGINE PAGE. 3A- 10

4. Adjust: Engine idle speed Adjustment steps: Turn the pilot screw until it is lightly seated. Turn the pilot screw out by the specified number of turns. Pilot screw: 1 3/8 turn out Turn the throttle stop screw in or out until the specified idling speed is obtained. Turning in Idling speed is increased. Turning out Idling speed is decreased. 3.2.3SPARK PLUG INSPECTION 1.Remove : Spark plug cap Spark plug
CAUTION:
Before removing the spark plug, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinder. 1. Check: Spark plug type Incorrect Replace. Standard spark plug: DR8EA (NGK) 2.Inspect: Electrode Wear/ damage Replace. Insulator Abnormal color Replace. Normal color is a medium - to- light tan color. 3.Clean: Spark plug (with spark plug cleaner or wire brush) 4.Measure: Spark plug gap (with a wire gauge) Out of specification Adjust gap.
CHAPTER 3 ENGINE PAGE. 3A11

Spark plug gap : 0.6-0.7 mm 6. Install: Spark plug NOTE: Before installing a spark plug, clean the Gasket surface and plug surface.
3.2.4COMPRESSION PRESSURE MEASUREMENT NOTE : Insufficient compression pressure will result in performance loss. 1. Check: Valve clearance Out of specification Adjust. Refer to CALCE CLEARANCE ADJUSTMENT section. 2. Start the engine and let it warm up for several minutes. 3. Turn off the engine. 4. Remove: Spark plug Before removing the spark plug, use com pressed air to blow away any dirt accumulated in the spark plug well to prevent it from falling into the cylinder. 5. Attach: Compression gauge 6. Measure: Compression pressure If it exceeds the maximum pressure allowed Inspect the cylinder head, valve surfaces and piston crown for carbon deposits.

If it is below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again. Follow the table below. Compression pressure (With oil applied into cylinder) Reading Diagnosis Higher than Worn or damaged pistons without oil Possible defective ring (s), Same as valves, without oil cylinder head gasket or Piston Repair. Compression pressure(at sea level): Standard: 1,400 kPa (14Kg/cm2, 14 bar) Minimum : 1,120 kP a (11.2 kg /cm 2, 11.2 bar) Measurement steps : Crank the engine with the throttle wide open until reading on the compression gauge stabilizes. WARNING : Before cranking the engine, ground all spark plug leads to prevent sparking. 8. Install: Spark plug 3.2.5ENGINE OIL LEVEL INSPECTION 1. Start the engine and let it warm up for a few minutes . 2. Turn off the engine. 3. Inspect: (Do not thread dipstick in) Engine oil level Oil level should be between maximum and minimum marks 2 . Oil level is below the minimum mark Add oil up to the proper lever.
CHAPTER 3 ENGINE
PAGE. 3A- 13

RECOMMENDED ENGINE OIL Refer to the chart for selection of the oils suited to the atmospheric temperature. API STANDARD: API SE or higher grade CAUTION: Do not put in any chemical additives or use oils with a grade of CD or higher. Be sure not to use oils labeled "ENERGY CONSERVING I" or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. Be sure no foreign material enters the crankcase. 4. Start the engine and let it warm up for a few minutes. 5. Turn off the engine. NOTE: Wait a few minutes until the oil settles before inspecting the oil level. ENGINE OIL REPLACEMENT 1. Start the engine and let it warm up for several minutes . 2. Turn off the engine and place an oil pan under the engine. 3. Remove : Oil filer plug Drain plug Compression spring Oil strainer O-ring Drain the crankcase of its oil. 4. Install: O-ring NEW Compression spring Oil strainer Drain plug Oil filer plug NOTE : Check the drain plug O-ring. If damaged, replace it with a new one.
CHAPTER 3 ENGINE
PAGE. 3A- 14

5. Fill: Crankcase Oil quantity: 1.4L 6. Check: Engine oil level Refer to "ENGINE OIL LEVEL INSPECTION" section ENGINE OIL PRESSURE INSPECTION Inspection steps: Slightly loosen the oil check bolt Start the engine and keep it idling until the oil begins to seep from the oil check bolt. If no oil comes out after one minute, turn the engine off so it will not seize. Check oil passages and oil pump for dam age or leakage. Start the engine after solving the problem (s), and recheck the oil pressure. Tighten the oil check bolt to specification.
CAUTION: Start the engine and check the oil pressure with the oil check bolt loosened. Do not apply at high speeds more than specified when checking the pressure. NOTE: Wipe any spilled oil off the engine. 3.2.6COOLANT LEVEL INSPECTION Inspect: Coolant level Coolant level should be between the a b maximum and minimum marks. Coolant level is below the "LOWER " level line Add soft water (tap water) up to the proper level. CAUTION: Hard water or salt water is harmful to engine parts. Use only distilled water if soft water is not available. If you use tap water, make sure it is soft water.

1. Start the engine and let it warm up for several minutes. 2. Turn off the engine and inspect the coolant level again. NOTE: Wait a few minutes until the coolant settles before inspecting the coolant level. COOLANTRE PLACE MENT 1. Remove: Front cover of ATV plastic body work. Seat. 2. Remove: Hose (reservoir tank) Drain the reservoir tank of its coolant. 3. Remove: Drain bolt Radiator cap
WARNING: Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap. Slowly rotate the cap counterclockwise toward the detent. This allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. NOTE: Remove the radiator cap after removing the drain bolt.
CHAPTER 3 ENGINE
PAGE. 3A- 16

4. Clean: Radiator Fill soft water into the filer neck support (reservoir tank). 5. Install: Gasket NEW Drain bolt 6. Loosen: Hose
7. Connect: Hose (reservoir tank) 8. Fill: Radiator ( to specified level ) Fill the coolant slowly, until the coolant comes out from the head hose. Reservoir tank a ( to maximum level ) Recommended coolant: High quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminum engine. Coolant and water (soft water) : Mixed ratio: min50% /max50% follow the instruction of the coolant Total amount: 2L Reservoir tank capacity: 0.35L
CHAPTER 3 ENGINE
PAGE. 3A- 17

Handling notes for coolant: Coolant is potentially harmful and should be handled with special care. WARNING: splashes in your eyes: Thoroughly wash your eyes with water and consult a doctor. If coolant splashes on your clothes: Quickly wash it away with water and then with soap and water. If coolant is swallowed: Vomit immediately and see a physician. CAUTION: Hard water or salt water is harmful to engine parts. Use only distilled water if soft water is not available. If you use tap water, make sure it is soft water. Do not use water containing impurities or oil. Take care that no coolant splashes onto painted surfaces. If it does, wash them immediately with water. Do not mix different types of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines. 9. Tighten: Hose Fill the coolant slowly to the specified level. 10. Install: Radiator cap 11. Start the engine and let it warm up for several minutes. 12. Stop the engine and inspect the level. NOTE: Wait a few minutes until the coolant settles before inspecting the coolant level. 13. Install: Remain parts.
CHAPTER 3 ENGINE
PAGE. 3A- 18
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.3CYLINDER HEAD
CHAPTER 3 ENGINE
PAGE. 3A- 19

Order Job name / Part name Cylinder head removal Drain the coolant. Side panel Footrest board Carburetor 1 2 3 4 5 6 7 8 Thermo unit lead Plug cap Crankcase breather hose Outlet hose (cylinder head) Breather hose (crankcase) Carburetor joint Joint O-ring 1 1 2 1 1 1 1 2 9 10 11 12 13 14 Crankcase cover Plug/O-ring Cam sprocket cover/O-ring Valve cover (intake side)/O-ring Valve side)/O-ring Timing chain tensioner assembly 15 16 17 18 19 20 Timing chain tensioner gasket Breather plate Cam sprocket/Timing chain Cylinder head Cylinder head gasket Dowel pin cover (exhaust 1 1/1 1/1 1/1 1/1 1 1 1 1/1 1 1 2 Q ty
Remarks Remove the parts in order.
Refer to "CARBURETOR" section .
Refer to "CYLINDER HEAD REMOVAL AND INSTALLATION" section. Reverse the removal procedure for installation.
CHAPTER 3 ENGINE
PAGE. 3A- 20

CYLINDER HEAD REMOVAL 1. Align: a "I" mark on the rotor b (with stationary pointer on the crankcase cover ) NOTE: If any special mark found, contact the ATV manufacture via the agent for the parts and special instruction.
NOTE: Turn the primary sheave counterclockwise with c a wrench and align the "I" mark with the d cylinder head match mark when the piston is at TDC on the compression
2. Loosen: Bolt 3. Remove: Timing chain tensioner assembly Timing chain tensioner gasket 4. Remove: Breather plate Cam sprocket Timing chain NOTE: Fasten a safety w ire to the timing chain to prevent it from falling into the crankcase. Remove the bolt while holding the rotor mounting bolt with a wrench. 5. Remove: Cylinder head NOTE: Loosen the nuts in their proper loosening sequence. Start by loosening each nut 1/2 turn until all are loose.
CHAPTER 3 ENGINE
PAGE. 3A- 21

CYLINDER HEAD INSPECTION: 1. Eliminate: Carbon deposits (from combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: Spark plug threads Valve seats 2. Inspect: Cylinder head Scratches/damage Replace. 3. Measure: Cylinder head warpage Out of secification Resurface . Cylinder head warpage : Less than 0.03 mm
Warpage measurement and resurfacement steps: Place a straight edge and a feeler gauge across the cylinder head. Measure the warpage. If the warpage is out of specification, resurface the cylinder head. Place a 400 ~ 600 grit wet abrasive pape on the surface plate, and resurface the head using a figure eight sanding patten. NOTE: Rotate the cylinder head several times for an even resurfacement. CYINDER HEAD INSTALLATION 1. Install: Gasket (cylinder head) NEW Dowel pins Cylinder head NOTE: Apply engine oil onto the nut threads. Tighten the nuts in a crisscross pattern.
CHAPTER 3 ENGINE
PAGE. 3A- 22

2. Tighten: Nuts (cylinder head) Bolts (cylinder) 3. Install: Cam sprocket Timing chain Installing steps : Turn the primary sheave counterclockwise until a the TDC mark matches the stationary pointer b . c Align the "I" mark on the cam sprocket with d the stationary pointer on the cylinder head. NOTE: If any special mark found, contact the ATV manufacture via the agent for the parts and special instruction. Fit the timing chain onto the cam sprocket and install the cam sprocket on the camshaft. NOTE: When installing the cam sprocket, keep the timing chain as tense as possible on the exhaust side. c Align the match mark on the cam sprocket d with the stationary pointer on the cylinder head. Align the pin on the cam shaft with the slot in the cam sprocket. CAUTION: Do not turn the crankshaft during installation of the cam shaft. Dam age or improper valve timing will result. While holding the camshaft, temporarily tighten the bolts . Remove the safety wire from the timing chain. 4. Install: Breather plate Plane washer 5. Install: Timing chain tensioner
CHAPTER 3 ENGINE
PAGE. 3A- 23

Installing steps: Remove the tensioner cap bolt and springs . Release the timing chain tensioner one-w ay cam and push the tensioner rod all the way in. Install the tensioner with a new gasket onto the cylinder. Install the springs and cap bolt . Tighten the bolt (with gasket) to the specified torque . Bolt (chain tensioner) Cap bolt (timing chain tensioner) 6. Tighten: Bolt (cam sprocket) 7. Check: Valve timing Out of alignment Adjust. 8. Check: Valve clearance Out of specification Adjust. Refer to the "VALVE ADJUSTMENT"section.
CLEARANCE
CHAPTER 3 ENGINE
PAGE. 3A- 24
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.4CAMSHAFT AND ROCKER ARMS
Order
1 2 3 4 5 6 7 8 9
Job name / Part name Cam shaft and rocker arms removal Cylinder head Lock washer Plate Rocker arm shaft (intake) Rocker arm shaft (exhaust) Rocker arm Camshaft Locknut Adjuster O-ring
Q ty
Remarks Remove the parts in order. Refer to "CYLINDER HEAD" section.
1 1 1 1 2 1 2 2 1 Refer to "ROCKER ARM AND ROCKER SHAFT REMOVAL AND INSTALLATION" section.. Refer to "CAMSHAFT INSTALLATION" section .
Reverse the removal procedure for installation
CHAPTER 3 ENGINE
PAGE. 3A- 25

ROCKER ARM AND ROCKER SHAFTRE MOVAL 1. Remove: Rocker arm shaft (intake) Rocker arm shaft (exhaust) ARM
NOTE: Attach a rocker arm shaft puller bolt and weight to the rocker arm shaft and slide out the shaft. CAM SHAFT INSPECTION 1. Inspect: Cam lobes Pitting/Scratches/Blue discoloration place .
Re-
2. Measure: a b Cam lobes length and Out of specification Replace. Cam lobes length: Intake: a 36 .545- 36 .645 mm <Lim it: 36.45 mm> b 30.021-30.121 mm <Lim it: 29.92 mm> Exhaust: a 36 .547- 36 .647 mm <Lim it: 36.45 mm> b 30.067- 30.167 mm <Lim it: 29.97 mm> 3. Inspect: Cam shaft oil passage Stuffed Blow out compressed air.
oil
passage
with
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION 1. Inspect: Cam lobe contact surface Adjuster surface Wear/Pitting/Scratches/Blue discoloration Replace.
Inspection steps: Inspect the two contact areas on the rocker arms for signs of unusual wear. Rocker arm shaft hole. Cam-lobe contact surface. Excessive wear Replace. Inspect the surface condition of the rocker arm shafts. Pitting/scratches/blue discoloration Replace or check lubrication. Measure the inside diameter A of the rocker arm holes. Out of specification Replace. Inside diameter (rocker arm ): 12.000- 12.018mm < Lim it: 12.030 mm > Measure the outside diameter B of the rocker arm shafts. Out of specification Replace. Outside diameter(rocker arm shaft): 11.981-11.991 mm <Limit: 11.95 mm> CAMSHAFT AND ROCKER ARM INSTALLATION 1. Lubricate: Cam shaft Camshaft: Molybdenum disulfide oil Camshaft bearing: Engine oil 2. Install: Plate Lockwasher Bolt
NEW
NOTE: Bend the lockwasher tabs along the bolt
falts.
3. Apply: Molybdenum disulfide oil onto the rocker arm and rocker arm shaft. Molybdenum disulfide oil
4. Install: Rocker arm Rocker arm shaft
(exhaust)
NOTE: Exhaust: Install the rocker arm shaft (exhaust) completely pushed in. 5. Install: Rocker arm Rocker arm shaft
(intake)
NOTE: Intake: Insert the guide shaft (8 mm) into the stud bolt hole in the cylinder head to the rocker arm shaft (intake).
CAUTION: Do not confuse the installation direction of rocker arm shaft. Be sure to install the threaded part facing outward.
CHAPTER 3 ENGINE
PAGE. 3A- 28
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.5VALVES AND VALVE SPRINGS
Order
Job name / Part name Valves and valve springs removal Cylinder head Rocker arm , rocker arm shaft
Q ty
Remarks Remove the parts in order. Refer to "CYLINDER HEAD " section . Refer to "ROCKER ARM SHAFT AND ROCKER ARMS" section. Refer to "VALVES AND VALVE SPRINGS REMOVAL/INSTALLATION" section.
1 2 3 4 5 6 7 8
Valve cotters Spring retainer Valve spring (inner) Valve spring (Outer) Valve (intake) Valve (exhaust) Valve guide Spring seat
4 2 2 2 1 1 2 2
Refer to "VALVES AND VALVE SPRINGS INSTALLATION" section
Reverse the removal procedure for installation
CHAPTER 3 ENGINE
PAGE. 3A- 29

VALVES AND VALVE SPRINGS REMOVAL 1. Remove: Valve cotters NOTE: Attach a valve spring compressor and attachment between the valve spring retainer and cylinder head to remove the valve cotters. CAUTION: Do not compress so much as to avoid damage to the valve spring. VALVE AND VALVE SPRINGS INSPECTION 1. Measure: Valve stem diameter Out of specification Replace. Valve stem diameter: Intake: 5.975-5.990mm <Limit: 5.94mm> Exhaust: 5.960-5.975mm <Limit: 5.92mm> 2. Measure: Runout (valve stem ) Out of specification Replace. Runout limit: 0.01 mm
3. Measure: Free length (valve spring) Out of specification Replace. Valve spring free length: Inner spring: 38.1 mm <Limit: 36.1mm> Outer spring: 36.93 mm <Limit: 35.0mm>
CHAPTER 3 ENGINE
PAGE. 3A- 30
4. Measure: Spring tilt Out of specification Replace. Spring tilt limit: 1.7mm (2.5) 5. Inspect: Spring contact face Wear/Pitting/Scratches Replace. 6. Measure: Valve guide inside diameter Out of specification Replace. Valve guide inside diameter: Intake: 6.000-6.012 mm <Limit: 6.05mm> Exhaust: 6.000-6.012 mm <Limit: 6.05 mm> 7. Measure: Stem-to guide clearance= Valve guide inside diameterValve stem diameter Out of specification guide. Replace the valve
Stem-to-guide clearance limit: Intake: 0.08 mm Exhaust: 0.10 mm
VALVE SEATS INSPECTION 1. Eliminate: Carbon deposits (from the valve face and valve seat) 2. Inspect: Valve seats Pitting/wear Reface the valve seat.
3. Measure: a Valve seat width Out of specification Reface the valve seat. Valve seat width: Intake: 0.9-1.1mm <Limit:1.6mm> Exhaust: 0.9-1.1mm <Limit:1.6mm> Measurement step: Apply Mechanics blueing dye (Dykem) to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be replaced. 4. Lap: Valve face Valve seat NOTE: After replacing the valve seat, valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: a Apply a coarse lapping com pound to the valve face. CAUTION: Do not let compound enter the gap between the valve stem and the guide. Apply molybdenum disulfide oil to the valve stem. Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off al com pound.

NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Make sure to clean off all compound from the valve face and valve seat after every lapping operation.
b Apply Mechanics blueing dye (Dykem) to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. c Measure the valve seat with again.
VALVES AND VALVE SPRINGS INSTALLATION 1. Deburr: Valve stem end Use an oilstone to smooth the stem end. 2. Apply: Molybdenum disulfide oil (onto the valve stem and oil seal ) Molybdenum disulfide oil 3. Install: Valve spring seat Valve stem seal NEW Valve (into the cylinder head) Valve spring (under) Valve spring (outer) Spring retainer NOTE: a Install the valve spring with the larger pitch facing upwards. b Smaller pitch
4. Instal: Valve cotters NOTE: Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment .
5. Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood. CAUTION: Do not hit so much as to damage the valve.
CHAPTER 3 ENGINE
PAGE. 3A- 34
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.6CYLINDER AND PISTON
Order
Job name / Part name Cylinder and piston removal
Q ty
1 2 3 4 5 6 7 8 9 10 11 12
Cylinder head Joint O-ring Timing chain guide (exhaust side) Cylinder Dowel pin Cylinder gasket Piston pin circlip Piston pin Piston Piston ring (top) Piston ring (2nd) Side rail/Spacer
1 2 1 1 2 1 2 1 1 1 1 2/1
Refer to " CYLINDER HEAD " section . Refer to " PISTON RINGS, PISTON AND CYLINDER INSTALLATION" section.
Refer to "PISTON AND PISTON RINGS REMOVAL" section . Refer to "PISTON RINGS, PISTON AND CYLINDER INSTALLATION " section . Reverse the removal procedure for installation .
PISTON AND PISTON RINGS REMOVAL 1. Remove: Piston pin circlip Piston pin Piston NOTE: Before removing the piston pin circlip, cover the crankcase opening with a clean tow el or rag to prevent the circlip from falling into the crankcase cavity. 2. Remove: Top ring 2nd ring Oil ring NOTE: When removing the piston ring, open the end gap of the ring by fingers, and push up the other side of the ring. CYLINDER INSPECTION 1. Measure: Cylinder bore Out of specification Rebore or replace. NOTE: Measure the cylinder bore with a cylinder bore gauge. Measure the cylinder bore in parallel to and a right angle to the crankshaft. Then, find the average of the measurements. Cylinder bore: 260;70.000- 70.014mm 300;72.500- 72.514mm < Limit:260;70.025mm300;72.525> < Difference limit between A,B and C :0.03m m > 2. Measure: Warpage Out of specification Replace. Cylinder warpage limit: 0.03mm
CHAPTER 3 ENGINE
PAGE. 3A- 36

PISTON AND PISTON PIN INSPECTION 1. Measure: Piston skirt diameter Out of specification Replace . a 5.0mm from the piston bottom edge. Valve skirt diameter: 260; 69.965-69.980 mm 300; 72.465-72.480 mm Oversize (2) 260; 69.5 mm300; 72.0 mm Oversize (4) 260;70.0 mm260;72.5 mm 2. Calculate: Piston-to-cylinder clearance Piston-to-cylinder clearance= Cylinder bore-Piston skirt diameter Refer to CYLINDER section for cylinder bore measurement. Out of specification Replace the piston and piston rings as a set. Piston-to-cylinder clearance: 0.02-0.04mm 3. Measure: Piston pin bore diameter Out of specification Replace. Piston pin bore diameter: 17.004-17.015mm <Limit:17.045mm> 4. Measure: Piston pin outside diameter Out of specification Replace. Piston pin bore diameter: 16.991-17.000mm <Limit:16.975mm> 5. Inspect: Piston pin Blue discoloration/groove Clean or replace.
CHAPTER 3 ENGINE
PAGE. 3A- 37
PISTON RINGS INSPECTION 1. Measure: 1 Side clearance Out of specification Replace the piston and the piston rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance. Side clearance (piston ring): Top ring: 0.04- 0.08m m <Limit: 0.12mm> 2nd ring: 0.03 - 0.07mm <Limit: 0.12mm> 2.Position: Piston ring into the cylinder NOTE : Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore.
1 5.0mm
3. Measure: End gap Out of specification Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil ring. If the oil ring rails show excessive gap, replace all three rings. End gap: Top ring: 0.15-0.30mm <Limit:0.45mm> 2nd ring: 0.30-0.45mm <Limit:0.70m m> Oil ring: 0.20-0.70mm PISTON RINGS, PISTON AND CYLINDER INSTALLATION 1. Install: Top ring 2nd ring

Side rails (oil ring) Expander spacer (oil ring)
NOTE: Make sure to install the piston rings so that the manufacturers m arks or numbers are located on the upper side of the rings. Lubricate the pistons and piston rings liberally with engine oil.
2.Install: Piston Piston pin Piston pin clip
NEW
NOTE: Apply engine oil to the piston pins. a The " " mark on the piston must face the exhaust side of the cylinder. Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. Make sure to install each piston in its respective cylinder. 3. Install: Gasket (cylinder) NEW Dowel pins 4. Position: Piston rings NOTE: Offset the piston ring end gaps as shown.
a b c d
Top ring end Oil ring end (lower) Oil ring end (upper) 2nd ring end
5. Lubricate: Piston outer surface Piston ring Cylinder inner surface
Engine oil
6. Install: Cylinder NOTE: Install the cylinder with one hand while com pressing the piston rings with the other hand. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
CHAPTER 3 ENGINE
PAGE. 3A- 40
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.7V-BELT,CLUTCH AND SECONDARY/PRIMARY SHEAVE

CRANKCASE COVER (LEFT)
Order
Job name / Part name Crankcase cover (left) removal
Q ty
1 2 3 4 5 6 7 8
Crankcase cover (left) Hose clamp B Joint B Air strainer B Hose clamp A Joint A Air strainer A
1 1 1 1 1 1 1 1
Reverse the removal procedure for installation .
CHAPTER 3 ENGINE
PAGE. 3A- 41

PRIMARY SHEAVE
*Apply molybdenum disulfide grease
Order
Job name / Part name V-belt, clutch and secondary/ primary sheave removal Nut/Plain washer Primary fixed sheave Nut Clutch housing Clutch assembly V-belt Primary sliding sheave Collar Primary sheave cap Cam Weight Slider Spacer Oil seal
Q ty
Remarks Remove the parts in order
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1/1 1 1 1 1 1 1 1 1 1 8 4 4 1
Refer to "PRIMARY SHEA VE REMOVAL" section. Refer to "SECONDARY SHEAVE AND V-BELT REMOVAL" section. Refer to "SECONDARY SHEAVE INSTALLATION" section. Refer to "PRIMARY SHEAVE ASSEMBLY" section. Refer to "PRIMARY SHEAVE ASSEMBLY" section. Reverse the removal Procedure for installation.

SECONDARY SHEAVE
**Apply lightweight lithium-soap base grease
Order
Job name / Part name Secondary sheave disassembly
Q ty
Remarks Disassemble the parts in order.
1 2 3 4 5 6 7 8 9 10
Nut Clutch carrier Clutch shoe spring Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave
1 1 3 1 1 4 1 2 2 1
Refer to "SECONDARY SHEAVE DISASSEMBLY" section. Refer to "SECONDARY SHEAVE INSTALLATION " section . Refer to "SECONDARY SHEAVE INSTALLATION" section.
Reverse the disassembly procedure for assembly.
CHAPTER 3 ENGINE
PAGE. 3A- 43

PRIMARY SHEAVE REMOVAL 1. Remove: Nut (primary sheave) Plate washer Primary fixed sheave NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder .
SECONDARY SHEAVE AND V-BELT REMOVAL 1. Remove: Nut (secondary sheave) Clutch housing NOTE: Loosen the nut (secondary sheave) while holding the clutch housing with the sheave holder .
2. Remove: Nut (clutch carrier) CAUTION: Do not remove the nut (clutch carrier) yet. NOTE: Loosen the nut (clutch carrier) one turn using the locknut wrench while holding the clutch carrier with the rotor holder . 3. Remove: Clutch assembly V-belt NOTE: Remove the V-belt from the primary sheave side with clutch assembly.
CHAPTER 3 ENGINE
PAGE. 3A- 44
SECONDARY SHEAVE DISASSEMBLY 1. Remove: Nut (secondary sheave) NOTE: Loosen the nut while attaching the clutch spring compressor and clutch spring holder arm and release the compressed spring after removing the nut. CAUTION: Use the spacer (diameter:30mm thickness: 2-3mm). CLUTCH INSPECTION 1.Measure: Clutch shoe thickness Scratches Glaze using coarse sandpaper. Wear /Damage Replace Clutch shoe thickness: 3.0mm <Limit:2.0mm> NOTE: After using the sandpaper, clean off the polished particles. Inspect the other clutch shoes. Replace all three as a set.
V-BELT INSPECTION 1.Inspect: V-belt Cracks/Wear /Scaling /Chipping Replace. Oil/Grease Check primary sheave and secondary sheave. 2. Measure: V-belt width Out of specification Replace V-belt width: 22.6mm (Limit:21.0mm)
CHAPTER 3 ENGINE
PAGE. 3A- 45
WEIGHT INSPECTION 1. Inspect: Weight minimum outside diameter Cracks/Wear /Scaling /Chipping Replace. Out of specification Replace Weight out side diameter: 20.0 mm <Limit: 19.5mm>
SECOMDARY SHEAVE INSPECTION 1. Inspect: Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation 2. Inspect: Torque cam groove Wear /Damage Replace. 3. Inspect: Guide pin Wear /Damage Replace.
PRIMARY SHEAVE ASSEMEBLY 1. Clean: Primary sliding sheave face Primary fixed sheave face Collar Weight Primary sliding sheave cam face NOTE: Remove any excess grease. 2. Install: Weight Collar NOTE: Apply molybdenum disulfide grease to all of the outside of the weight and install. Apply lightweight lithium-soap base grease to the inside of the collar.
CHAPTER 3 ENGINE
PAGE. 3A- 46

3. Install: Spacer Slider Cam Primary sliding sheave cap.
SECOMDARY SHEAVE INSTALLATION 1. Apply: Lightweight lithium-soap base grease (to the secondary sliding sheave inner surface, grease nipple groove, and oil seals) Lightweight lithium-soap base grease (to the bearings, oil seals and inner surface of the secondary fixed sheave )
2. Install: Secondary sliding sheave NOTE: Install the secondary sliding sheave using the oil seal guide to the secondary fixed sheave .
3. Install: Guide pin
4. Apply: Lightweight lithium-soap base grease (to the guide pin sliding groove , and oil seal NEW
CHAPTER 3 ENGINE
PAGE. 3A- 47

5. Install: Secondary sheave complete Compression spring Clutch carrier NOTE: Temporarily tighten the nut while attaching the clutch spring holder and clutch spring holder arm and compress the spring.
CAUTION: Use the spacer
(30mm, thickness: 2-3mm).
6. Install: V-belt Clutch assembly NOTE: Install the V-bet with clutch assembly to the primary sheave side. CAUTION: Never smear grease to the V-belt, secondary sheave and clutch.
7. Install: Nut (clutch carrier) NOTE: Tighten the nut (clutch carrier), using the locknut wrench while holding the clutch carrier with the rotor holder
CHAPTER 3 ENGINE
PAGE. 3A- 48

8. Install: Clutch housing Nut (clutch housing) NOTE: Tighten the nut (clutch housing),using the sheave holder ).
9. Set: V- belt NOTE: Move the V-belt to minimum diameter of the primary sheave , maximum diameter of the secondary sheave and make the V-belt tense.
CHAPTER 3 ENGINE
PAGE. 3A- 49
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.8A.C. MAGNETO AND STARTER CLUTCH
MAGNETO COVER AND STATOR COIL
Order
Job name/ Part name Magneto cover and stator coil removal Drain the engine oil. Couplers (A.C. magneto lead) Exhaust pipe Exhaust pipe gasket Magneto cover Gasket (magneto cover) Dowel pins Stator coil Pick up coil
Q'ty
Remarks Remove the parts in order. Refer to "ENGINE OIL REPLACEMENT" section. NOTE: Disconnect the couplers.
1 2 3 4 5 6 7 8
2 1 1 1 1 2 1 1
Reverse the removal procedure for installation.

A. C. MAGNETO AND STARTER CLUTCH
CHAPTER 3 ENGINE
PAGE. 3A- 51
Order
Job name/ Part name A.C. magneto and starter clutch removal Rotor Shaft (idle gear) Idler gear Starter one way clutch assembly Woodruff key Starter wheel gear
Q'ty
1 2 3 4 5 6
1 1 1 1 1 1
Refer to "A.C. MAGNETO ROTOR REMOVAL /INSTALLATION" section.
Refer to "ROTOR INSTALLATION" section. Reverse the removal procedure for installation.
A.C. MAGNETO ROTOR REMOVAL 1. Remove: Nut (rotor) Plain washer NOTE: Loosen the nut (rotor) while holding the rotor with a sheave holder . Do not allow sheave the holder touch to the projection on the rotor. 2. Remove: Rotor Woodruff key NOTE: Remove the rotor using the flywheel puller. Center the flywheel puller over the rotor. Make sure after installing the holding bolts that the clearance between the flywheel puller and the rotor is the same everywhere. If necessary, one holding bolt may be turned out slightly to adjust the flywheel puller's position. CAUTION: Cover the crankshaft end with the box wrench for protection.
STARTER DRIVE GEAR INSPECTION


1. Inspect: Starter idle gear teeth Starter drive gear teeth Starter wheel gear teeth Burrs /chips /roughness /wear Replace. 2. Check: Starter clutch operation Push the dowel pins to the arrow direction. Unsmooth operation Replace. Checking steps: Hold the starter clutch. When turning the starter wheel gear clockwise, the starter clutch and the starter wheel gear should be engaged. If not, the starter clutch is faulty. Replace it. When turning the starter wheel gear counter clockwise, it should turn freely. If not, the starter clutch is faulty. Replace it.
A.C. MAGNETO ROTOR INSTALLATION 1. Install: Starter wheel gear . Woodruff key
NOTE: Install the starter wheel gear , then install the woodruff key .
2. Install: Rotor Plain washer
NOTE: Clean the tapered portion of the crankshaft and the rotor hub. When installing the magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft.
CHAPTER 3 ENGINE
PAGE. 3A- 53

3.Tighten: Nut(rotor) NOTE: Tighten the nut (rotor) while holding the magneto rotor with a sheave holder .
CHAPTER 3 ENGINE
PAGE. 3A- 54
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.9OIL PUMP
Order
Job name/ Part name Oil pump removal A.C. magneto Cover Pump driven gear Dowel pin Oil pump assembly Gasket Impeller shaft gear Dowel Pin Shaft
Q'ty
Remarks Remove the parts in order. Refer to "A.C. MAGNETO AND STARTER CLUTCH" section.
1 2 3 4 5 6 7 8
1 1 1 1 1 1 1 1
Reverse the removal procedure for installation.
CHAPTER 3 ENGINE
PAGE. 3A- 55

OIL PUMP INSPECTION 1. Inspect: Drive gear (oil pump) Pump housing Pump housing cover Wear /cracks/ damage Replace. 2. Measure: Tip clearance (between the inner rotor and the outer rotor ) Side clearance (between the outer rotor and the pump housing ) Housing and rotor clearance (between the pump housing and the rotors ) Out of specification Replace the oil pump assembly. Tip clearance : A 0.10-0.34 mm <Limit: 0.40mm> B Side clearance : 0.013-0.036mm <Limit:0.15mm> Housing and rotor clearance : C 0.04-0.09 mm <Limit: 0.15mm>
CHAPTER 3 ENGINE
PAGE. 3A- 56
CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.10CRANKCASE AND CRANKSHAFT
CHAPTER 3 ENGINE
PAGE. 3A- 57

Order Job name/ Part name Crankcase and crankshaft removal Engine removal Cylinder head Cylinder, and piston V-belt, clutch, secondary/ primary sheave A.C. magneto and starter clutch Oil pump Water pump Rear wheel Bolt O- ring Q'ty
Remarks Remove the parts in the order. Refer to "ENGINE REMOVAL" section. Refer to "CYLINDER HEAD" section. Refer to "CYLINDER AND PISTION" section. Refer to "V BELT, CLUTCH AND SECONDARY/ PRIMARY SHEAVE"section. Refer to "A.C. MAGNETO AND STARTER CLUTCH" section. Refer to "OIL PUMP" section. Refer to "WATER PUMP" section.
1 2
1 1
Refer to "REAR WHEEL AND REAR BRAKE" section.
CHAPTER 3 ENGINE
PAGE. 3A- 58

Order 3 4 Job name/ Part name Timing chain guide (intake) Crankcase (right) Q'ty 1 1
Remarks
Refer to "CRANKSHAFT INSTALLATION" section.
5 6 7 8 9 10
Dowel pin Crankshaft assembly Timing chain Crankcase (left) Oil seal Oil seal
2 1 1 1 1 Refer to "CRANKSHAFT REMOVAL/ INSTALLATION" section.
Reverse the removal procedure for installation. CRANKSHAFT REMOVAL 1. Remove: Crankshaft assembly Timing chain
NOTE: Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. If the timing chain hooks to the crankshaft sprocket, the crankshaft cannot be removed. CRANKSHAFT INSPECTION 1. Measure: Crankshaft runout Out of specification Replace and/or bearing. NOTE: Measure the crankshaft runout crankshaft assembly running slowly. Runout limit: 0.03 mm
crankshaft
with
the
CHAPTER 3 ENGINE
PAGE. 3A- 59

2. Measure: Big end side clearance Out of specification Replace big bearing, crank pin and/or connecting rod. Big end side clearance: 0.35-0.85 mm
end
3. Measure: Crank width Out of specification Replace crankshaft. Crank width: 59.95-60.00 mm
4. Inspect: Crankshaft sprocket Wear/ Damage Replace crankshaft. Bearing Wear/ Crack /Damage Replace crankshaft. Pump drive gear Wear/ Damage Replace crankshaft.
5. Inspect: Crankshaft journal Clogged Blow compressed air.
out
the
journal
with
CRANKCASE INSTALLATION 1. Clean all the gasket mating surface and crankcase mating surface thoroughly. 2. Apply: Sealant (onto the crankcase mating surfaces) NOTE: DO NOT ALLOW any sealant to come into contact with the oil gallery.

3. Install: Dowel pins Timing chain NOTE: Install the timing chain not to be seen through a the crankshaft hole on the crankcase (left) .
3.11COOLING SYSTEM
3.11.1RADIATOR
CHAPTER 3 ENGINE
PAGE. 3A- 61

Order Job name/ Part name Radiator removal Drain the coolant. Q'ty
Remarks Remove the parts in order. Refer to "COOLANT REPLACEMENT" section.
1 2 3 4 5 6 7 8
Fan motor leads Thermo switch leads hose (radiator) Outlet hose (radiator) Inlet hose (radiator) Radiator Radiator cap Radiator filler neck
2 2 1 1 1 1 1 1 Reverse the installation. removal procedure for
INSPECTION 1. Inspect: Radiator Obstruction Blow out with compressed air through the rear of the radiator. Flattened fins Repair or replace. If flattened over the 20% of radiator fin, repair or replace the radiator.
CAUTION: Use only specified adhesive to repair the radiator. 2. Inspect: Radiator hoses Radiator pipes Cracks/damage Replace.
3. Measure: Radiator cap opening pressure Radiator cap opens at a pressure below the specified pressure Replace.
CHAPTER 3 ENGINE
PAGE. 3A- 62

Radiator cap opening pressure: 110-140kPa (1.1-1.4kg/cm2 , 1.1-1.4 bar) Measurement steps: Attach the radiator cap tester and adapter to the radiator cap . Apply the specified pressure for 10 seconds, and make sure there is no pressure drop. 4. Inspect: Fan motor assembly Damage Replace. Malfunction Check and repair. Refer to "COOLING SYSTEM ". 5. Inspect: Pipes Cracks/damage Replace.
CHAPTER 3 ENGINE
PAGE. 3A- 63

3.11.2WATER PUMP
Order
Job name/ Part name Water pump removal Drain the coolant. A.C. magneto
Q'ty
Remarks Remove the parts in order. Refer to "COOLANT REPLACEMENT" section. Refer to "A.C. MAGNETO AND STARTER CLUTCH" section.
1 2 3 4 5 6 7
lmpeller shaft gear Dowel pin/plain washer Shaft Outlet hose (radiator) Housing cover Housing cover gasket Water pump housing
1 1/1 1 Refer to "WATER PUMP INSTALLATION" 1 section. 1 1 1 1
CHAPTER 3 ENGINE
PAGE. 3A- 64
Order 8 9 10
Job name/Part name Impeller shaft O-ring O-ring
Qty 1 1 1
Remarks Refer to WATER PUMPINSTALLATION section. Reverse the removal procedure for installation.
NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant temperature and/ or level, discoloration of coolant, or milky transmission oil. If necessary, replace water pump as an assembly. INSPECTION 1. Inspect: Impeller shaft Wear/damage Replace. Fur deposits Clean. 2. Inspect: Impeller shaft gear Wear/damage Replace.
3. Inspect: Mechanical seal Damage/worn/wear Replace.
WATER PUMP INSTALLATION


1. Install: Mechanical seal NEW
Installation steps: Apply the bond to the outside of the mechanical seal. Install the mechanical seal by using the mechanical seal installer and middle shaft bearing driver 2. Install: Mechanical seal NEW Apply coolant to the outside of the mechanical seal before installing. NOTE: Do not smear any oils or grease on the ring side of the mechanical seal. 3. Inspect: Mechanical sea , slip ring side Inspect the slip ring side of the mechanical seal and the impeller for level installation. Incorrect level Reinstall.
4. Install: Impeller shaft Circ lip NEW Installation steps: Apply a small amount of grease to the impeller shaft tip. Install the impeller shaft while turning it. Use care so that the oil seal is not damaged or the spring does not slip off its position. NOTE: After installing the impeller shaft, check it for smooth rotation. 5.Install: O-ring NEW
6. Install: Water pump housing


Housing cover 7. Install: Shaft Align the slot on the impeller shaft with the projection on the shaft when installing.
3.11.3THERMOSTAT
CHAPTER 3 ENGINE
PAGE. 3A- 67

Order Job name/ Part name Thermostat removal Drain the coolant Q'ty
Remarks Remove the parts in order. Refer to section. "COOLANT REPLACEMENT"
1 2 3 4 5 6
Clip Hose Hose clamp Inlet hose (radiator) Thermostatic cover Thermostatic valve
1 1 1 1 1 1
Refer to "THERMOSTAT INSTALLATION" section. Reverse the removal procedure for installation.
INSTALLATION 1. Inspect: Thermostatic valve Valve does not open at 70.5-73.5Replace. Inspection steps: Suspend the thermostatic valve in a vessel. Place a reliable thermometer in water. Observe the thermometer, while continually stirring the water. Thermostatic valve Vessel Thermometer Water A CLOSE B OPEN NOTE: The thermostatic valve is sealed and its setting requires specialized work. If its accuracy is in doubt, replace. A faulty unit could cause serious over-heating or over cooling. 2.Inspect: Thermostatic cover Cracks /damage Replace.
CHAPTER 3 ENGINE
PAGE. 3A- 68

INSTALLATION 1. Install: Thermostatic valve Thermostatic cover
3.12CARBURETOR ATV260/300 WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. Never drain the float bowl when the engine is hot. Severe burns may result.
CARBURETOR REMOVEL
1. Remove: Auto choke lead coupler 2. Remove: Fuel hose
CHAPTER 3 ENGINE
PAGE. 3A- 69

3. Remove: Nut Throttle cable 4.Lossen: Bolt Bolt 5. Remove: Carburetor assy
CARBURETOR DISASSEMBLY/ INSPECTION

6.Auto choke inspection (Ambient temperature lower than 45) Connect auto choke unit leads to the battery for 5 minutes. Connect pipe to the starter, and blow it the mouth etc. PossibleReplace auto choke unit. ImpossibleGood condition. Remove auto choke unit leads to the battery for 30 minutes. Connect pipe to the starter, and blow it the mouth etc. PossibleGood condition. ImpossibleReplace auto choke unit. 7. Remove: Blot Auto choke unit 12V with
12V with
8. Auto choke unit inspection: Piston Jet needle WearReplace. 9.Install: Auto choke unit
CHAPTER 3 ENGINE
PAGE. 3A- 70
VACUUM CHAMBER
10.Remove: Cover
11.Remove: Diaphragm spring Piston valve
12.Inspection: Jet needle WearReplace. Piston valve WearReplace. Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for holes, deterioration or damage. Check the vacuum piston for smooth operation up and down in the carburetor body.
FLOAT AND JETS

13.Remove: Float chamber WARNING Never drain the float bowl when the engine and the exhaust system are hot. Severe burns may result. Float Needle valve
14.Inspection: Needle valve WearReplace. Check the float valve and valve seat for scoring scratches, clogging or damage. check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination. check the operation of the float valve.
15.Remove: Pilot jet Check the pilot jet for wear or damage. Clean the pilot jet with cleaning solvent and blow this open with compressed air.
16.Remove: Main jet Check the main jet for wear or damage. Clean the main jet with cleaning solvent and blow this open with compressed air.
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PAGE. 3A- 72
17.Remove: Main nozzle Check the main nozzle for wear or damage. Clean the main nozzle with cleaning solvent and blow this open with compressed air.
18.Remove: Pilot screw set Turn the pilot screw in and carefully count the number of turn until it seats lightly. Make a note of this to use as a reference when reinstalling the pilot screw.
AIR CUT-OFF VALVE

19.Remove: Cover Compressing spring Diaphragm 20.Inspection: Compressing spring DistortionReplace. Diaphragm WearReplace. 21. Reverse installation. the removal procedure for
ACCERERATING PUMP
22.Remove: Cover Check the vacuum piston for wear or damage.
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PAGE. 3A- 73
23.Inspection: Compressing spring DistortionReplace. Diaphragm WearReplace. 24. Reverse installation. the removal procedure for
3.12CARBURETOR(ATV400-2/ATV400-2B) 1. Remove: Fuel hose 2. Remove: Manual enriching starter rope 3. Remove: Nut Throttle cable 4.Lossen: Bolt Bolt
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PAGE. 3A- 74

5. Remove: Carburetor assy 6.Remove: Cover
7.Remove: Diaphragm spring Piston valve
8.Inspect: Jet needle WearReplace. Piston valve WearReplace.
9.Remove: Float chamber Float Needle valve
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PAGE. 3A- 75

10.Inspect: Needle valve WearReplace.
11.Remove: Idling jet
12.Remove: Pilot jet
13.Remove: Main jet
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PAGE. 3A- 76
14.Remove: Main nozzle
15.Remove Mixture adjusting screw
16. Remove Nut Throttle valve mounting arm Torsion-bar spring Gasket
CHAPTER 3 ENGINE
PAGE. 3A- 77

17.Remove Screws& Throttle valve mounting bracket
18. Reverse installation.
the
removal
procedure
for
CHAPTER 3 ENGINE
PAGE. 3A- 78
CHAPTER 3A ENGINE 260/ 300 / 400 cc NOTES
CHAPTER 3 ENGINE
PAGE. 3A- 79
CHAPTER 3B ENGINE 50cc/80cc

3.1 Scheduled Maintenance
3.1.1 General information 3.1.2 Air Filter 3.1.3 Spark plug 3.1.4 Valve Adjustment 3.1.5 Carburetor idle speed 3.1.6 Ignition time 3.1.7 Cylinder pressure 3.1.8 Final reduction gear oil checking 3.1.9 Transmission belt
3.6 The crankcase the crankshaft

3.6.1 Important points 3.6.2 Dismantling the crankcase 3.6.3 The crankshaft 3.6.4 Assembling the crankcase
3.7 Lubricating system

3.7.1 Over all engine requirements 3.7.2 Engine oil / filter screen 3.7.3 Oil pump
3.8 Carburetor
3.8.1 General Information: 3.8.2 Disassembly of carburetor 3.8.3 Assembly of carburetor
3.2 Cylinder headValve

3.2.1 Important information 3.2.2 Disassembling of camshaft 3.2.3 Disassembly of cylinder head 3.2.4 Camshaft assembly
3.9 Starter system

3.9.1 Installation information 3.9.2 Starter Motor 3.9.3 Starter pinion
3.3 The cylinder and the piston

3.3.1 Important points 3.3.2 Removing the cylinder 3.3.3 Removing the piston 3.3.4 Assembling the piston 3.3.5 Assembling the cylinder
3.10 Magneto
3.10.1 Dismantling: 3.10.2 Assembling
3.11 Ignition System
3.4 Driving belt device the starting lever

3.4.1 Important points 3.4.2 The left crankcase cover detaching 3.4.3 Installing the starting assembly 3.4.4 The driving belt 3.4.5 The driving pulley dismounting 3.4.6 Assembling the driving pulley 3.4.7 The clutch/transmission pulley
3.5 The final transmission assembly

3.5.1 Instructions 3.5.2 Dismantling the final transmission assembly 3.5.3 Detach the final transmission gearbox cover 3.5.4 Assembling the final gear set
CHAPTER 3B ENGINE
PAGE 3B - 1 -

3.1 Scheduled Maintenance
3.1.1General information Warning Always make sure it is well-ventilated around before the engine starts. Never start the engine in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Valve gap: IN:0.04-0.06mm Specifications Throttle free play:2-6mm EX: 0.04-0.06mm Idling speed:1900190rpm Spark plug gap:0.6-0.7mm Spark plug type: NGK:C7HSA Engine oil quantity: LD: A7TC Normal range:0.8L 3.1.2 Air Filter Filter Replacement Remove air filter cap fix screw and remove air filter cap. Check filter for dirt or damage. Replace as necessary. Do not attempt to clean the filter element.
Replacing Frequency More frequency replacement is required if vehicle is driven on dusty roads or in rain. Make sure Air Filter Cover is securely in place.
3.1.3Spark plug Remove spark plug. Check spark plug for burning, dirt or deposit. Clean it with a spark-plug cleaner or steel brush in case of dirt or carbon deposit.
CHAPTER 3B ENGINE
PAGE 3B - 2 -

Specified spark plug: NGK:C7HSA LD: A7TC Check spark plug gap: 0.6-0.7mm Check plug for dirt, carbon build-up, cracking of insulator.
3.1.4 Valve Adjustment Always check and adjustment with engine temperature lower than 35(95) Remove cylinder head cover.
Rotate cooling fan to camshaft locate mark at top dead-center, aligning magneto fly wheel T mark with mark on crankcase.
Valve gap checking and adjustment Valve gap: IN:0.04-0.06mm EX: 0.04-0.06mm To adjust valve gap, loosen jam nut and rotate adjusting nut. Valve adjustment wrench Be sure to check valve gap again after locking jam nut.
CHAPTER 3B ENGINE
PAGE 3B - 3 -

3.1.5 Carburetor idle speed Idle adjustment should be made with the engine warmed up. Remove cover After the engine warms up, connect it to an engine revolution counter. Adjust idle screw until specified revolution is obtained. Minimum idling stabilized speed:1900 190rpm Readjust the screw if idle speed is not steady or fuel cannot be properly applied. 3.1.6 Ignition time Equipped with CDI, there is no need for ignition setting. Check ignition system if ignition time is incorrect. Dismount right body cover. Remove ignition timing inspection plus.
Check ignition timing, using timing light. Crankcase mark must be aligned with mark F on flywheel while engine is at idle speed. The timing should advance as the RPM is increased. The timing mark should align with the crankcase mark at 3000 RPM. 3.1.7 Cylinder pressure Measure cylinder pressure with the engine warmed up. Remove spark plug Install a cylinder pressure gauge. With throttle fully open, start starter motor to measure cylinder pressure. Compression pressure:15kg/cm2-600rpm If the pressure is excessively low, check for following: Valve leakage Valve gap too tight Cylinder head gasket damaged Piston ring worn
CHAPTER 3B ENGINE PAGE 3B - 4 -

Piston or cylinder worn Check combustion chamber and piston top for excessive carbon deposit if compression pressure is too high. 3.1.8 Final reduction gear oil checking Checking oil volume, build up main foot rest so that build up body becomes vertical on plain ground. Dismount gear oil adjusting bolt after stopping engine. It is good that oil level just under regulation screw bolt hole, add gear oil when oil level is too low. Gear oil recommended: SEA 15W/40SE Build up gear oil regulator screw bolt. Confirm packing washer broken or not. Changing gear oil Remove gear oil adjusting bolt and drain oil. Confirm packing washer broken or not. Add gear oil recommended: gear oil capacity:0.12L Bolt torque:19N.m(14ft.lbs) Check if there is any leakage after work.
3.1.9 Transmission belt Detach the left crankcase cover Check whether there is wear and tear of transmission belt. Change with new one when necessary or timely maintenance.
CHAPTER 3B ENGINE
PAGE 3B - 5 -

3.2 Cylinder headValve
3.2.1 Important information

When working on the cylinder head and valve train, always use engine oil to lubricate sliding parts when assembling. Never assembly dry parts into the valve train. The camshaft is lubricated by engine oil supplied via an oil passage in the cylinder head. Make sure this passage is clean and open when you reassemble the head. When measuring parts to determine wear, wash the parts with solvent and dry them in order to get accurate measurements. When disassembling the valve components, keep them in order, and reinstall them in the reverse order.
Standards
item Valve gap (cold) Cylinder head compressed pressure Cylinder head surface twisting Camshaft convert angle height Valve rocker diameter arm inner IN EX IN EX IN EX IN EX 25.749 25.55 10.0-10.022 10.0-10.022 9.972-9.987 9.972-9.987 1.0 1.0
CHAPTER 3B ENGINE
Standard value IN EX 0.04-0.06 0.04-0.06 15kg/cm -600rpm

2
Used limit 0.05 25.681 25.524 10.10 10.10 9.91 9.91 1.8 1.8
PAGE 3B - 6 -
Valve rocker arm bearing outer diameter Valve seat angle

Valve bar outer diameter Valve guide diameter pipe inner IN EX IN EX IN EX Inner spring Outer spring 4.975-4.990 4.955-4.970 5.0-5.012 5.0-5.012 0.010-0.037 0.030-0.057 30.5 33.5
4.9 4.9 5.3 5.3 0.08 0.10 26.1 30.5
Gap between valve bar and guide pipe Valve spring
Torque Value
Camshaft bolt Valve gap adjusting screw cap 20N.m 15 ft .lbs 8N. m 6 ft .lbs lubricate threads with oil
Tools:
General tools Valve spring compressor Valve seat reamer 24.5mm Valve seat reamer 25mm Valve seat reamer 22mm Valve seat reamer 26mm Reamer damping fixture 5mm Special tools Valve spring compressor accessories Valve gap regulatory spanner Valve guide screwdriver Valve guide reamer 45 IN/EX Plane reamer 30 IN Plane reamer 32 EX Plane reamer 60 IN/ EX
Trouble diagnosis
Confirm poor operation of cylinder head by measuring pressure or by noise produced by engine upper end.
Slow speed hitch

too low compression pressure bad valve gap burning or curving of valve bad valve timing broken valve spring bad valve seat leakage of cylinder head gasket cylinder head surface warping or cracking bad spark plug
White smoke from exhaust pipe

wearing of valve guide broken oil seal
Abnormal noise
bad valve gap broken or burning of valve or valve spring wearing and breaking of camshaft wearing of inner chain adjusting plate wearing of camshaft and valve rocker arm
Too high compressed pressure

too much carbon build-up in combustion chamber
CHAPTER 3B ENGINE
PAGE 3B - 7 -

3.2.2 Disassembling of camshaft
Remove four bolts and two nuts and take off cylinder head cover.
Disassemble tension seal bolt and spring.
Use the kick start lever to turn engine slowly until T mark on flywheel lines up with indicator on crankcase and check position of camshaft to find if both valves are closed. The hole in the cam gear should be away from the engine, if this is not correct rotate the crank one revolution to achieve this alignment.
Remove four bolts and remove camshaft fixed seat. Remove rocker arms and pivots.
CHAPTER 3B ENGINE
PAGE 3B - 8 -

Remove camshaft gear from camshaft chain. Remove camshaft.
Check camshaft Check cam lift. Use limit :IN: 25.681mm below change EX:25.524mm below change Check surface of cam lobes for weary surface break down, scuffing or cracking.
Check camshaft and bearing for loose fit or damage. If any excessive wear or damage is found, replace the camshaft.
Disassembly of camshaft seat and rocker arm assembly

Take out camshaft rocker arm bearing by using 5mm screw. Take off camshaft rocker arm.
CHAPTER 3B ENGINE
PAGE 3B - 9 -

Checking of rocker arm. camshaft bearing
Check if camshaft fixed seat and camshaft rocker arm and camshaft rocker arm bearing is worn or broken.
Measure outer diameter of camshaft rocker arm bearing and inner diameter of camshaft rocker arm. Inner diameter of camshaft rocker arm Used limit: 10.10mm, change if worn larger Outer diameter of camshaft rocker arm bearing Used limit: 9.91mm, change if worn larger The gap between camshaft rocker arm and camshaft rocker arm bearing. Used limit: 0.10mm ,change if worn larger
3.2.3 Disassembly of cylinder head Remove camshaft bearing. Remove carburetor. Remove exhaust pipe. Remove inlet manifold.
Remover fan cover. Remover bolt and screw of engine cover. Disassemble + remove engine cover.
CHAPTER 3B ENGINE
PAGE 3B - 10 -

Disassembly cylinder head
Take off location pin and cylinder head gasket. Take off camshaft chain guide bar.
Breaking down cylinder head Use valve spring compressor to take off lock clip supportervalve spring and valve. Place parts in a sequence after disassembling and assemble at a reverse process .
Clean carbon deposit from combustion chamber. Get rid of gasket material on cylinder head surface Dont damage cylinder head sealing surface. Checking Cylinder head Check spark plug hole for damage. Check valve spring seats for alignment. Used limit: 0.05mm above align

Measure length of inner and outer springs Used limit: Inner spring below 26.1mm change Outer spring below 30.5mm change
Valve and valve guide Check if valve is curved, burnt or broken. Check if valve and valve guide is blocked. Measure every valve stem outer diameter. Used limit: below 4.9mm change
Remove carbon deposit from valve guide using a reamer. Special tools Rotate reamer is proper direction and do not Stop rotation to push in or pull out.
Measure inner diameter of every valve guide. Used limit: IN: above 5.3mm change EX: above 5.3mm change
Valve guide replacement Operate cylinder at the temperature of about 100115 ( 212239). Heat cylinder head quickly and evenly to prevent warpage.

pry out valve guide pipe Be careful to not damage cylinder head Surface. Press in the new valve guide pipe. Spread engine oil on new O-ring and build up new valve guide pipe. Make sure cylinder head is still warm when pressing in new guides.
Size valve guide with reamer after installing. Use cutting oil on reamer. Rotate reamer in proper direction and do not stop rotation to push in or pull out. Clean cylinder head and get rid of cut bits of metal and dust. Special tools Valve guide pipe reamer
Valve seat checking and correcting Valve seat checking Get rid of carbon deposit from combustion chamber and valves. Spread emery on seat surface between valve and valve seat. Use polishing bar to wear-in valve. Take out valve and check valve seat surface. Change if valve surface is coarse or facial polished. Valve seat surface width checking. Used limit: above 1.8mm correct. Correct valve seat by chamfered tool if surface width is not even or too wide and too narrow. Valve seat chamfer cutting tools Refer to valve chamfered tool handbook for detailed. Press and rotate with 4-5 kg (10-12lb) force to polish and cut when correcting.
Use chamfered tool after spreading engine oil on it.


Valve seat cutting Do not polish or cut excessively.
Cut primary surface with 45cutting head. Chamfer inner edge with 32cutting head. Chamfer outer edge with 60cutting head. Correct inner surface by 60chamfered tool.
Trim valve seat to assigned width with 45chamfered cutting tool. Standard valve: 1.0mm
CHAPTER 3B ENGINE
PAGE 3B - 14 -

Check contact place of valve seat. Polish by 30chamfered cutting tool if the contact place is too low. Trim to assigned width by 45chamfered cutting tool. Polish valve contact surface with emery and polishing bar after correcting bar. Wash and clean cylinder and valve after polishing and grinding. Rotate and press softly, when polishing Dont put emery into valve and valve guide pipe when polishing Spread red inkpad on 45 seat surface and confirm if the centre of contact surface of valve is even after correcting.
Building-up of cylinder head Build up spring seat Use new oil seals when reassembling. Spread engine oil on valve stem and put into valve guide.
Build up inner and outer valve spring and put in valve collar using spring compressor. Use Valve spring compressor accessorily to make valve contact with valve collar.
Use plastic mallet to beat edge on ends of valve to seat collars two or three times softly. When using mallet be careful not to damage valves.
CHAPTER 3B ENGINE
PAGE 3B - 15 -

Installing Cylinder Head Install locating pin and gasket. Install cam chain adjuster plate. Slide cylinder head over studs and into place
3.2.4 Camshaft assembly Install camshaft fixed seat. Assemble rocker arm and rocker shaft. Make alignment between shaft end and hole of camshaft seat when valve rocker shaft is assemblied.
Assembling of camshaft fixed seat Rotate fly wheel and align T mark on fly wheel with crankcase mark.. Align camshaft chain gear round hole away from engine. Install camshaft on fixed seat and check alignment. Install camshaft chain on camshaft gear.
CHAPTER 3B ENGINE
PAGE 3B - 16 -

Assemble locating pin.
Assemble camshaft seat and nut into cylinder head. Lock cylinder head nuts securely. Torque value: Camshaft fixed nut: 20N.m 15 ft lbs
Camshaft chain regulator assembling Firstly build up camshaft chain regulator and spacer. Secondly lock two fixed bolts. Thirdly put spring into camshaft chain regulator Finally assemble O-ring and fixed bolt. Press down regulator master jaw and drive down driving bar when camshaft chain regulator is assemblied. Torsion value:8-12 N.m Regulate valve gap Change the ring of cylinder head cover and assemble cylinder head cover. Put O-ring into furrow. Lock fixed screws of cylinder head cover Torsion value:5-8N.m Spread glue on threading position of camshaft fixed seat screw. Lock two or three times at diagonal of camshaft fixed seat screws.

3.3 The cylinder and the piston
3.3.1 Important points The work on the cylinder and piston can be done on the engine without complete disassemble. After taking them apart, clean and dry the cylinder and piston with the compressed air before measuring and testing. Tech criterion Item ID(50cc) ID(80cc) Cylinder Distortion Cylindricity Out-of-roundness Piston ring Clearance between the ring and the ring groove end gap OD of piston(50cc) Piston OD of piston(80cc) Check point of OD Clearance between piston and cylinder the top ring the 2nd ring the top ring the 2nd ring the oil side ring Normal Size 39-39.01 47-47.01 ----------------0.015-0.055 0.015-0.055 0.08-0.20 0.05-0.20 0.20-0.70 38.942-38.982 46.963-46.993
10mm away from skirt
Max. Service Allowance 39.10 47.10 0.05 0.05 0.05 0.09 0.09 0.45 0.45 ----38.9 46.9 ----0.1
PAGE 3B - 18 -
0.010-0.040
CHAPTER 3B ENGINE

ID of piston pin hole OD of the piston pin Clearance between the piston pin and the hole ID of the small end of the connecting rod
13.002-13.008 13.992-13.000 0.002-0.014 13.016-13.027
13.04 12.96 0.02 13.06
Trouble shooting In case of difficult starting, unsteady low speed running, check if there is any problem. Low compression pressure The piston ring worn, burnt/broken The cylinder or the piston worn or damage. Too high compression press carbon deposit on the piston and the combustion chamber. White smoke out of the exhaust pipe The piston ring worn/damaged. The piston/cylinder worn or damaged. Knocking noise by the piston. The cylinder, the piston or the piston ring worn The piston pin and piston hole worn.
3.3.2 Removing the cylinder

Detach the cylinder head Remove the chain guide of the cam chain Remove the cylinder Remove the cylinder gasket and the locating pin from the the cylinder.
3.3.3 Removing the piston

Remove the piston pin circlip. Attention: Dont drop the circlip into the crankcase Take out the piston pin and then the piston Push the piston pin from the side opposite the removed snap ring Pay attention to avoid scratching the piston surfaces Checking the piston, the piston pin and the piston ring. Attention: Dont damage or break the rings. Clear off all the carbon deposit from the ring groove.
CHAPTER 3B ENGINE
PAGE 3B - 19 -
Install the ring and measure the clearance of the ring groove. Max. service allowance: The top ring: Replace when is goes beyond 0.09mm. The 2nd ring: Replace when it goes beyond 0.09mm Remove the piston rings. Install the piston into the bottom of the cylinder, Attention: Use the piston head to press the rings in place in the cylinder. Measure the piston ring end gap in bore Max service allowance: Replace when it goes beyond 0.45mm. Measure the ID of the piston pin hole. Max service allowance: Replace when it goes beyond 13.04mm.
Measure the OD of the piston pin. Max service allowance: Replace when it is below 12.96mm
Measure the OD of the piston Attention: Measure it in a position which is 90 from the center of the piston pin, and it is 10mm away from the skirt. Max. service allowance: Replace when it is below 38.9mm50cc Replace when it is below 46.9mm80cc Measure the clearance between the piston pin and the pin hole Max service allowance: Replace when it goes beyond 0.02mm

Checking the cylinder Check whether its scratched, worn or damaged in its inner surface. Measure its ID in three positions(upper, middle and lower) which is 90(x-y direction) from the piston pin hole. Replace if it goes beyond 39.1mm (50cc) Replace if it goes beyond 47.1mm (80cc) Between the piston and the cylinder. Max. service allowance: Repair or replace when it goes beyond 0.1mm The difference between X and Y directions is out-of-roundness The cylindricity is the ID difference (between X and Y directions), measuring at three positions (upper, middle and lower).The largest measured value will be considered the result. This indicate taper of the cylinder. Max. service allowance: Out-of-roundness: Repair or replace when it goes beyond 0.05mm. Cylindricity: Repair or replace when it goes beyond 0.05mm. Check the distortion of the cylinder Max service allowance: Repair or replace when it goes beyond 0.05mm
Measure the ID of the small end of the connecting rod Max service allowance: Replace when is goes beyond 13.06mm
CHAPTER 3B ENGINE
PAGE 3B - 21 -

Attention: Dont scratch the piston and break the piston ring. When replacing the ring, keep the surface with a mark facing upwards. After assembling make sure that the ring can be turned freely in the ring groove.
Lubricate the rings with engine oil before installing

them on piston. Make sure to offset ring end gaps at 120.
Lubricate the piston and rings liberally with engine oil
Install the chain guide lever of the cam
Attention: Make sure that the guide lever enters the notch of the cylinder.
3.3.4 Assembling the piston

Scrape away the gasket adhering on the surface of the crankcase Attention: Be sure not to let any matter drop into the crankcase. Assemble the piston, and piston pin Attention: When assembling, keep the mark in (on the top of piston) towards the inlet valve Be sure not to let the piston pin circlip fail into the crankcase. Use a cloth to keep debris out of the crankcase..

3.3.5 Assembling the cylinder
Install the locating pin and the gasket to the crankcase. Lubricate the inner surface of the cylinder, the piston and the piston ring with engine oil. When assembling the piston rings, they must be compressed into the cylinder. Attention: Dont damage or break the piston ring. Be sure not to make the position of the ring end gaps point to the inlet and outlet valves and parallel with the piston pin.
CHAPTER 3B ENGINE
PAGE 3B - 23 -

3.4 Driving belt device the starting lever
3.4.1 Important points This chapter is about the driving unit, the clutch / driven unit and the starting lever. The assembly and disassembly of the driving unit can be done without dismounting the engine. The surface of the driving belt and the drive units are not allowed any oil, if there is any, remove it to minimize the slip between the belt and the drive units. Tech Criterion Item ID of the driving pulley OD of the driving pulley sleeve Width of the driving belt Thickness of the clutch brake lining ID of the clutch housing Free length of the driven belt spring OD of the transmission pulley ID of the transmission pulley OD of the roller 106.9-107.1 92.5 33.955-33.98 33.995-34.03 15.9-16.1
CHAPTER 3B ENGINE
Unit. mm Normal Size 20.0-20.012 19.947-19.96 18 Max Service Allowance 20.062 19.9 17 2.0 107.5 87.2 33.93 34.06 15.4
PAGE 3B - 24 -
Torque The nut of the driving plate The nut of the clutch housing The locknut clutch assembly Tool(Common) Universal stand Driver rod A Driver(for housing)32X35mm Guide rod 20mm
45N.m 33ft lbs 40N.m 30ft lbs 55N.m 40ft lbs (special) compressing device for clutch spring Socket (39mm) for the fix nut Bearing driver Bearing driver
Trouble shooting The motorcycle doesnt run after the engine starting The driving belt worn The driving plate broken Power cant develop fully The brake lining worn or broken The driving belt worn The spring of the clutch assembly fractured Distortion of the driven belt spring The roller worn Sudden breakdown during running The driving plate surface dirty The spring of the brake lining fractured
3.4.2 The left crankcase cover detaching

Unlock the clip of the air tube form the left crankcase. Remove eight bolts and then take off the left crankcase cover and locating pins. Check whether the gasket is damaged or fractured.
Removing the starting pivot

Remove the starting lever from the pivot. Remove the circlip and the washer from the starting pivot.
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Turn the starting pivot gently, and remove the driving gear and the friction spring together.
Remove the starting pivot and the return spring. Detach the starting pivot sleeve.
Checking the starting pivot

Check if the pivot and the gear are worn. Check if there is any softness of the starting return spring. Check if there is any excessive worn on the pivot sleeve.
Check if the driven gear is worn / failed. Check if the friction spring is worn / fractured.
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Check if there is any excessive wear on the bearing part of the starting pivot and of the shaft of the driven gear. Replace any parts showing excessive or unusual wear.
3.4.3 Installing the starting assembly

Install the starting pivot sleeve and the return spring to the crankcase cover.
As shown in the picture on the right, assemble driven gear and the friction spring. Maintain the orientation as shown. Install the starter pivot.
Install the washer, then the circlip.
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Assembling the left crankcase cover First, install the locating pin. Then, the gasket. Assemble the left crankcase cover, then tighten the eight fix bolts diagonally. Install the air tube to the left crankcase, then install the clip.
3.4.4 The driving belt

Detach the left crankcase cover.
Checking
Check if the driving belt is cracked, frayed, or abnormal wear. Measure the width of the belt. Max service allowance:17mm
Replacing
Remove the eight fix bolts, then remove the crankcase cover. Remove driving pulley Use a retaining device to hold the driving pulley and screw out the 12mm bolt. Remove the driving pulley.
Remove the driving belt from the clutch driving pulley.
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Assembling the driving belt
Turn the driving pulley clockwise to keep the notches of the belt in expanded condition, then install the new driving belt.
Install the driving belt on the driving pulley. Install the driving pulley, the starting ratchet and 12mm washer. The install and tighten the nut. Torque45N.m 33ft lbs Attention: During assembly, be sure to align the splints of the driving unit, is correct ratchet with those on the crank shift.
3.4.5The driving pulley dismounting

Use a retaining device or spanner wrench to hold the driving pulley, screw out the 12mm nut, then remove the ratchet, the 12mm nut and the driving pulley.
Taking the driving pulley apart

Remove the driving pulley and the sleeve from the crankshaft.
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Remove the retainer
Remove the rollers Checking the driving pulley. Measure the ID of the driving pulley Max service allowance: Replace, when it is beyond 20.062mm. Check the wear of the rollers. Measure the OD of the roller. Max service allowance: Replace, when it is below 15.4mm. Check the wear of the driving pulley sleeve. Measure the OD of the driving pulley sleeve. Max service allowance: Replace, when it is below 19.9mm.
3.4.6 Assembling the driving pulley

Install driving pulley sleeve and the driving pulley on the crankshaft. Install driving belt on the crankshaft. Install the driving pulley and the washer. Tighten 12mm nut . Torque:45N.m 33ft lbs Attention: There mustnt be any grease on the surface of the driven belt and the driving pulley. The overrunning clutch (starter pinion) Removal Remove the left crankcase cover . Remove the driving pulley. Remove the seat of the overrunning clutch. Remove the overrunning clutch.
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Checking Check if the bearing part of the overrunning clutch shaft is worn. Check if the clutch runs smoothly. Check the wear of the gear and the bearing part of the shaft.
Assembling
Lubricate the bearing part of the clutch shaft with a bit of grease. Assemble it in the opposite sequence of removal.
3.4.7 The clutch/transmission pulley Removing the clutch/transmission pulley

Remove the driving pulley Then, use a spanner wrench to hold the clutch housing to screw out the 10mm nut. Remove the clutch housing.
Remove the clutch/transmission pulley. Remove the driving clutch/transmission pulley. belt from the
Disassembling pulley
the clutch/ transmission
Use a spring compressor for the clutch spring to press down the transmission pulley spring to remove the special nut (28mm). Remove the clutch spring.
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Remove the sealing cover of the shaft collar.
Remove the guide rolling pin from the transmission pulley assembly, then take out the o-ring and the oil seal.
Checking the clutch transmission pulley Check the wear of the clutch housing. Measure the ID of the clutch housing. Max service allowance: Replace, when it goes beyond 107.5mm.
Check the wear of the clutch lining Measure the thickness of the lining Max service allowance: Replace, when it is below 2.0mm.
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Measure the free length of the transmission pulley spring. Max service allowance: Replace, when it is below 87.2mm.
Check the wear of the transmission pulley Measure the OD of the pulley Max service allowance Replace, when it is below 33.93mm Check the wear of the transmission pulley. Measure the ID of the pulley Max service allowance: Replace, when it goes beyond 34.06mm Check if the guide rolling pin is excessively worn or unevenly worn. Replace as necessary.
Replacing the transmission pulley and the bearing. Check the needle bearing for wear or excessive free play, gritty feel or noise. Replace as necessary. Check the housing bearing for wear.
Remove the retainer and take out the housing bearing Driving in the new housing bearing, keeping the lid side facing upwards.
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Attention: Grease new bearings When installing Grease able to resist > 230.
Drive in the new needle bearing, keeping the mark side up.
The clutch / transmission Pulley assembly Assemble the transmission pulley guide pin and oil seal. Install the sealing cover of the collar.
Assemble the transmission pulley disk and the spring to the clutch assembly, pressing down with the spring compressor for the clutch spring.
Install the 28mm fix nut and tighten it. Torque:50~60kgm 35~40ft lbs
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Assembling the clutch/transmission pulley Put the driving belt onto the clutch/transmission pulley, then onto the driving shaft.
Assembly the clutch housing Use a spanner wrench to hold the housing, then install the 10mm nut and tighten it Torque:40Nm 30ft lbs Assemble the left crankcase cover
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3.5 The final transmission assembly
3.5.1 Instructions

Designated oil: SEA 15W/40SE Filling 0.12L Changing 0.1L Tool Special tool Bearing pulling set 12mm Bearing pulling set 15mm Sleeve shaft for assembling the crankshaft Sleeve lever for assembling the crankshaft Common tool Bearing outer race driver 3740mm Bearing outer race drive 3235mm Guide lever for the bearing driver 17mm Guide lever for the bearing driver 15mm Guide lever for the bearing driver 12mm Bearing driver Trouble shooting The scooter doesnt run after the engine starting The transmission gear failed The driving belt worn or broken The clutch failed Developing abnormal noise when it runs The gear worn or burnt, or damaged on teeth The bearing worn and getting loose Oil leakage Too much oil The oil seal broken 3.5.2 Dismantling assembly the final transmission
Remove the left crankcase cover Remove the driven pulley of the clutch Drain the oil out of the final transmission. Remove the bolts of the final transmission gearbox.
Remove the transmission gearbox cover. Remove the gasket and locating pin.
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3.5.3 Detach gearbox cover
the
final
transmission
Checking the final transmission assembly. Check if countershaft gear is worn or damaged. Check if the final transmission gear is burn or damaged.
Check if the bearing in the left crankcase and the oil seal are worn / damaged.
Check if the driving shaft (the main clutch shaft) and the gear are worn / damaged. Check if the oil seals are worn / failed.
Replacing bearing (on the transmission gearbox cover)
side
of
the

Remove the oil seal on the final transmission shaft. Heat the final transmission gearbox to 120 to remove the bearing. Drive in the new bearing to the final transmission cover.
Oil leakage
Too much oil The oil seal broken Replacing the bearing (on the side of the crankcase) Remove the driving shaft (the clutch main shaft). Then, remove the oil seal of the shaft. Heat the final transmission gearbox to 120 to remove the bearing Drive the new bearing into the final transmission gearbox. Install the new oil seal for the driving shaft.
3.5.4 Assembling the final gear set

First, install the driving shaft to final gearbox. Then install the final transmission gear shaft (output shaft) to the final gearbox.
Attach the countershaft to the final transmission gearbox. Install the resin washer to the countershaft, install the locating pin and the new gasket.
Put on the final gearbox cover.


Tighten the bolts of the final gearbox cover. Assemble the clutch/driving pulley disk.
After assembling, fill it with the gear oil. Designated gear oil: SEA 15W/40SE Volume of the gearbox: Filling: 0.12L Changing:0.10L Screw up the oil screw and tighten it Torque: 17-23Nm Check the oil level. Replenish it with the designated gear oil when the oil is not sufficient (through the oil checking hole) 12.5-17ft lbs Start the engine to check if there is oil leakage.
3.6 The crankcase the crankshaft
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3.6.1 Important points

The chapter gives instructions related to the crankshaft and dismantling the crankcase Before striking, its necessary to take the engine apart. Complete the following work before taking the crankcase apart. Remove the following. The cylinder head The cylinder & the piston The driving plate & the driven plate AC generator The carburetor & the air filter The starting motor The oil pump Tech Criteria Item The clearance of the both sides of the big end of the connecting rod Crankshaft The clearance of X Y Directions of the journal of the big end of the connecting rod Run out Torque:
Unit: mm Normal Size Max Service Allowance 0.55 0.05 0.10
0.100.35 00.008

Crankcase bolt Bolt for the chain adjusting guide lever the cam Trouble Shooting Abnormal noise from the engine The crankshaft bearing getting slack The crankshaft pin bearing getting loose 9 N.m 6.6ft.lbs 10N.m 7.4ft.lbs
3.6.2 Dismantling the crankcase

Detach the bolt of the chain adjusting guide lever of the cam and remove the lever.
Remove assembly Bolt of the crankcase. Dismantle the right and left crankcases. Attention: Dont damage the gasket surface When separating the crankcases, dont use screw driver to try them apart.
Remove the gasket and the locating pin.
Remove the crankshaft from the crankcase. Take out the cam chain.
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Scrape the gasket away from the joint surfaces. Attention: Be sure not to scratch the joint surfaces.
Remove the oil seal from the left crankcase.
Remove the oil seal from the right crankcase.
3.6.3 The crankshaft

Measure the left and right clearance between both sides of the big end of the connecting rod. Max. service allowance: Replace, when it goes beyond 0.55mm
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Check the clearance of the journal of the big end of the connecting rod in XY directions Max. service allowance: Replace, when it goes beyond 0.05mm
Measure the run out of the crankshaft Max service allowance: Replace, when it goes beyond 0.10mm
Check if there is any abnormal noise and looseness, when the crankshaft bearing revolves. Replace totally, if any abnormal noise/looseness is detected.
3.6.4 Assembling the crankcase

Use the following tools to install the oil seal of the crankcase. Bearing outer race driver Bearing outer race 32x35mm
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Install the cam chain into the left crankcase. Assemble the crankshaft into the left crankcase. Attention: Be sure not to let the chain damaged the oil seal.
Put the new locating pin and gasket onto the left crankcase. Attention: Keep the left crankcase downward to assemble with the right crankcase.
Tighten the bolts of the crankcase. Torque:9N.m 6.6ft.lbs
Install the cam chain adjusting lever. Install the O-ring onto the bolt of the chain adjusting lever. Coat the O-ring with oil, then lock it. Torque:10N.m 7.4 ftlbs
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Attention: Be sure to put the O-ring into the groove.
3.7 Lubricating system
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3.7.1 Over all engine requirements Special attention Use proper Motor oil SAE 15W/40SE Use only clean fresh oil. Do not rebuild oil pump. Replace with a new pump when needed. Check for leakage after replacing pump.
Basic material

item gap between inner rotator and external rotor Engine oil pump gap between external rotor and pump body gap between and surface of rotor and pump body Problem diagnosis Loss of engine oil engine oil natural consumption engine oil leakage piston ring wear bad assembly valve guide oil seal worn No oil pressure pump worn use of wrong oil oil level low -----
Standard value
Replace at 0.12mm 0.005in 0.12mm 0.005in 0.2mm 0.008in
0.05-0.10mm 0.001-0.004in
Engine burning excessive oil blocked oil passage use of wrong oil worn rings valves worn or damaged
3.7.2Engine oil / filter screen

Oil volume check oil with scooter parked on level ground on center stand. put motorcycle on the plain place when oil volume is checked. run engine for two or three minutes and stop. After 2-3 minutes check oil level. Check oil level when oil dipstick is screwed out. Add oil to upper limit on dipstick. Oil changed It is easier to drain oil when motor is warms. Remove drain bolt to drain oil completely. Disassemble oil filter screen cover and take off oil filter screen. Use high pressure air to clean filter screen, wash with solvent and dry before reinstalling. Check O-ring for damage. Replace if necessary. Assemble engine oil filter screen and filter screen cover. Torsion value:15N.m 10.8ft.lbs Add assigned oil to determined volume. Engine oil capacity:0.8L Check for oil leaks. Run engine for 1-2 minutes at idle speed. Turn engine off and check oil lever. Add if necessary.
3.7.3 Oil pump removal


Remove engine right outer cover fan magnetor. Remove alternator rotor. Remove stator pulse coil. Remove 8 bolts of right crankshaft case cover and take off crankshaft case cover.
Remove washer and fixed pin. Remove the fixed nut of gear in oil pump. Take off gear of oil pump.
Remove fixed bolts of oil pump. Take off oil pump.
Take off two O-rings. Check O-rings for damage. Replace if necessary.
Oil pump disassembly


Remove three fixed screws in oil pump body. Disassembly oil pump.
Checking Check the gap between oil pump body and external rotator. Used limited: 0.12mm(0.005inch)
Check the gap between inner rotator and external rotator. Used limited: 0.12mm(0.005inch)
Check the gap between surface of rotator and body. Used limited: 0.2mm(0.008inch)
Assembling Assemble inner and outer rotators and oil pump shaft. Be careful of alignment between pump bearing unfilled corner and inner rotator unfilled corner.
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Assemble pump cover and tighten screws.
Installation First put two O-rings at oil pump seat.
Put oil pump in crankshaft case. First add oil to pump and then assembly. Tighten three fixed screws.
Install gear of oil pump and then fixed nut. Torsion value: 5-8N.m(3.6-5.8ft.lbs)
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Assemble right crankshaft case cover, tighten 8 screws . Assemble pulse coil and stator and rotor. Install fan and cover.
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3.8 Carburetor
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3.8.1General Information:
WARNING! Work on the fuel system in a well-ventilated area free form sparks or open flames. Do not breath the vapors from the gasoline. Wear protective gloves to prevent skin irritation. Open the bowl drain and allow all gasoline in the carburetor to drain into an appropriate container prior to removing or servicing it. Remove control cables and wires carefully to prevent damage. Check all O rings for damage. Replace as necessary. Remove carburetor from the scooter before attempting to service the fuel bowl or vacuum diaphragm. When cleaning the carburetor, remove the vacuum diaphragm before using air or solvents for cleaning. This will prevent damage to the diaphragm. When storing the scooter for any period of time exceeding one month, use a quality fuel stabilizer to prevent deterioration of the fuel and damage to the carburetor. Repairing material Specification Carburetor Venturi Bore Fuel level Main Jet Idle Jet Idle Speed Throttle Free Play Mixture screw setting Special tools required- Float Gage Troubleshooting Hard Starting Engine No Spark Low Compression No fuel in carburetor -Blocked fuel line -Blocked fuel filter -Blocked vacuum line -Leaky vacuum line -Dirty float needle -Float set too high Too much fuel to engine -Blocked air filter -Manifold air leak -Bad auto choke -Blocked air passage in carburetor Air/Fuel mixture too rich or too lean Bad auto choke Plugged idle jet Float needle stuck or dirty
standard valve Constant velocity-CVK 18mm 20.5 mm #82 #35 1900190 RPM 2-6mm 2 turns1/4 turn
Poor Drivability Weak spark/Bad Ignition System Blocked fuel line Blocked fuel filter Bad fuel Water in fuel Air leak at carburetor or manifold Improper float level Bad auto chock Obstructed jet in carburetor Vacuum slide stuck Damaged vacuum diaphragm Dirt in carburetor

Blocked air passage in carburetor Dirty air filter Air leak at carburetor or manifold Backfire from exhaust at idle Air mixture screw set too lean Bad auto choke operation Misfire under acceleration Poor spark Air mixture screw too lean Bad accelerator pump
3.8.2 Disassembly of carburetor

Disconnect cable connector for auto chock.
Loosen carb drain screw and drain fuel from float bowl.
Loosen throttle cable and remove from support and throttle control plate. Remove fuel line from carburetor. Remove air inlet tube from carburetor and pull carburetor straight back out of intake manifold. Remove auto choke from carburetor.
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Checking auto choke Check resistance value. Standard value below 5 when cold. Connect auto choke to 12V battery. Plunger should extend 3/8 inch in 5 minutes. Disassembling Disassemble fixed plate screw and take off fixed plate. Take off enrichment equipment from carburetor.
Check pin and seat for wear. Replace if necessary. Place auto choke in mounting location and press down firmly. Put lock ring in position and fasten screw.
Air cut off valve Disassembling Disassemble two screws in fuel guide fixed plate and remove fixed plate. Disassemble two screws in air cut off valve. Take off spring and vacuum plate. Check for wear on plate, replace if necessary. Clean the passage way to remove dirt. Assembling Install plate to carburetor. Install spring and cover of air cut-off valve. Build up fuel guide line fixed plate and tight two screws.
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Be sure that furrow of vacuum plate is aligned with carburetor furrow. Make sure that cover tightens into place. Vacuum Chamber break-down Remove two screws and take off cover.
Remove spring, diaphragm piston. Remove needle and slide.
Take special care to not or damage diaphragm replace if damaged.
Checking Check pin for wear and replace if necessary.
Assembling Install piston or plate to body of carburetor. Push the bottom of the piston to vacuum chamber side and keep open completely. Install spring and cover. Install and tighten screw. Be sure to hold slide and piston in up position when installing cover and tighten screw.
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Float Bowl Disassembling Disassembling three screws and take off float bowl. Remove float pin spring.
Remove high speed jet, low speed jet and fuel volume control screw. careful not to break fuel jets and control screw. Be Count the turns when removing the fuel volume control screw. When reinstalling jets and screws do not over tighten.
Clean jets with solvent and compressed air. Clean body of carburetor by air blowing through all passages.
Checking Check float valve, and valve seat for damage. Check float valve and valve seat wear, pitting or build up of dirt.

Any leakage of the valve or a build up of dirt will affect the fuel level in the float bowl and cause drivability problems.
Assemble the low speed jet, fuel pin spray nozzle, fuel pin spray seat and main jet into the bottom of the carburetor housing. Set the fuel level in the bowl by adjusting the fuel regulation screw. The standard setting is 2 turns+ or -1/4 turn.
Assemble the float valve, float and float pin to the bottom of the carburetor using the retainer pin. Check the operation of the float and valve. All part should move freely.
After assembling the float, check for proper fuel level using a small ruler or a float gage. The proper fuel level is 20.5mm.
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Accelerator pump disassembling Remove two screws on pump and take off cover. Take off spring and acceleration pump plate.
Checking Check acceleration pump plate for cracks or hardening of the rubber. Replace if necessary.
Check for blocked fuel passages. Clean by high pressure air. Reverse steps to reassemble. Take special care with the accelerator pump plate to avoid damage.
3.8.3 Assembly of carburetor

Slide carburetor carefully into the manifold making sure to align the tab on the manifold with notch on the carburetor.

Securely tighten the clamp screw to fix the carburetor in place. Do not over tighten the screws as this can cause damage to the manifold. Attach the inlet pipe to the rear of the carburetor and tighten the clamp screw. Attach the throttle cable to the throttle on the throttle plage.
Use the adjusting nut and stop nut to set the cable tension, Correct adjustment should allow 1/4 inch of free play in the cable. Attach the fuel line from the tank to the inlet on the carburetor and clamp securely. Connect the wiring harness form the auto choke to the proper connection on the main wiring harness. After starting the engine, set the idle speed using the idle adjusting screw.
Carburetor Adjustment It is generally not necessary to adjust the mixture screw on the side of the carburetor. This screw is preset at the factory and will have little affect on the performance of the carburetor. If this screw has been removed for cleaning of the carburetor, it should be reset carefully. The standard setting is 2 turns out + -1/4 turn.
set this position, run the engine until warm and To allow it to idle. Turn the screw in or out a little at a time and measure the idle RPM. The correct setting is achieved when the idle speed is maximized. Adjust the idle speed of the engine once the engine had been warmed up. Set the warm idle speed to 1900RPM +or 190RPM.

Check for engine return to idle speed after running at part throttle. Make sure that the throttle cable allows the throttle control plate return to the stop screw. If needed, readjust the mixture screw to help stabilize idle performance.
3.9 Starter system

3.9.1Installation information Operation point The starter motor can be removed without disassembly of the engine. Installation reference standard item Starter motor brush length Fastener torque specification Starter motor clutch cover bolt Tool Special tools Hex key General tools Open end wrenches
Standard valve 8.5mm
Wear limit 5mm
12N.m
8-9ft.lbs

Troubleshooting Starter motor does not turn Fuse broken Battery discharged Faulty main switch Faulty starter clutch Faulty brake switch Faulty starter relay Poor or faulty cable connections Faulty starter motor 3.9.2 Starter motor removal Never work on starter motor until main switch is turned off, battery ground-wire disconnected to ensure that starter motor cannot turn.
Starter motor turns over slowly Battery discharged Poor or faulty cable connections Starter motor gear seized by a foreign object Starter motor turns- Engine does not rotate Faulty starter clutch Starter motor reversal Battery discharged
Remove the two bolts and remove the starter motor. Roll up the water-proof rubber cover to disconnect the starter motor.
Disassembly Remove the two blots and remove the motor housing and the other parts.
Inspection Other components inspection. Inspect them for wear, damage or discoloration. Replace them if necessary. Clean attached metal commutator surfaces. particles from the

Measure the resistance between each contact surface of the components. Make sure there is no conduction current between each commutator segment and the armature shaft.
Check starter motor housing conductivity. Be sure there is no conduction current between the cable terminal and starter motor housing.
Check conductivity between the lead terminal and brush. Replace them if necessary.
Measure brush length. Its service limit is 5mm. Replace it if necessary. Inspect brush holder for conduction current. Replace it if necessary.
Inspect bearing in front bracket for smooth rotation


and for looseness when installed. Replace it if necessary. Inspect dust cover for wear or damage. Apply grease to the dust cover. Install spring brush in its holder. Apply a light film of grease to both ends sliding surfaces of armature shaft. Install armature in front bracket. Make sure the surfaces between the brush and armature are not damaged. Be sure the dust cover lip is not damaged by the armature mount shaft. Install a new O-ring in front bracket. Engage motor housing with that of front bracket. Install two housing bolts. When engaging the housing with front bracket, install the armature first, hold the armature shaft and then install the housing in case the armature is drawn out by the magnet. Starter motor installation Apply grease to starter motor O-ring and install the starter motor. Install the two bolts. Connect the starter motor terminals to the harness.
3.9.3 Starter pinion removal

Remove the left crankcase cover. Remove the pinion. Make sure not to damage the drive belt during the removal.
INSPECTION Check if the starter pinion operates properly. Check the gears and bearing for wear or damage. Check for extensions of driver gear. Check for spring return of driver gear.

Clean assembly with solvent and lube with dry graphite or light grease. Do not use heavy grease. This will limit the fast movement of the starter pinion.
INSTALLATION Apply a light film of grease to the gears and install the starter pinion by reversing the removal procedure. Install the left crankcase cover.
3.10 Magneto 3.10.1 Dismantling:

Remove the four screws, and remove the fan cover.
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Remove the four bolts and remove the cooling fan.
Use a universal solid wrench to secure the flywheel. Detach the fix nuts of the flywheel.
Use a spanner wrench hold fly wheel while removing the retaining nut. Use a fly wheel puller to remover the flywheel. Remove and save the key.
Detach the stator of the magneto. Remove the bolts of the triggering coil. Remove the rubber sleeve of the magneto wire from the right crankcase.. Remove the triggering coil.
3.10.2 Assembling
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Attach the triggering coil to the right crankcase. Lock the fix bolts of the triggering coil. Torque: The triggering coil:5N.m the staror:9N.m 44in.lbs 6.6ft.lbs
Set up the rubber sleeve of the magneto wire.
Clean the cone part of the crankshaft and of the flywheel. Be sure to lay the locating key of the flywheel into the keyway on the crankshaft precisely. Point the groove of the flywheel to the locating key on the crankshaft and then assemble it.
Attention: Make sure that there is no bolt/nut inside the flywheel, then assemble it. Use a universal solid wrench to hold the flywheel, then lock the nut. Torque:55N.m
Universal tool

Universal solid wrench Set up the cooling fan Torque:9N.m
Install the fan cover and securely tighten fastness.
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3.11 IGNITION SYSTEM
3.11.1 INSTALLATION INFORMATION OPERATING POINTS
Check ignition system in accordance with the troubleshooting procedure in section 3.11.2 As the ignition system has an electric automatic spark control in CDI unit, there is no need for spark advance angle adjustment. Poor contact may be the cause of many ignition system faulty cases. Check all terminal connections to be sure they are clean and tight whenever troubleshooting an electrical problem. Make sure spark plug heat range is correct. Using incorrect spark plug will result in improper engine operation or spark plug damage. Peak voltage is used as reference point in tests. Record coil resistance tests. REFERENCE STANDARD item Specific spark plug spark plug gap spark plug angle Maximum advance in F position Primary coil Secondary Pickup coil resistance(20) Primary Ignition coil peak voltage Pickup coil peak voltage 3.11.2 TROUBLESHOOTING High Tension Voltage Too Low Crankshaft revolution too low or battery voltage too low Ignition system wiring loose Faulty Ignition coil Faulty CDI unit Faulty pickup coil High Tension Voltage Intermittent Faulty main switch Poor CDI terminal connection Poor CDI ground Faulty pickup coil Poor high tension lead terminal connection Faulty CDI unit High Tension Voltage Normal but No Spark Faulty spark plug Faulty spark plug cap No High Tension Voltage
Standard value (NGK)C7HSA (LD)A7TC 0.6-0.7mm 131(1500r/min) 0.1-1.0 With cap Without cap 7-9k 3-4k 80-160 Over 120V Over 2.1V
Ignition coil resistance(20)

Faulty main switch Faulty Ignition coil Faulty CDI unit No or Intermittent High Tension Voltage Faulty Ignition coil 3.11.3 CDI INSPECTION Remove the three screws from the battery case cover. Disconnect the CDI module from the wire harness Test resistance of the terminals with an multi-meter. Since there is semiconductor in return circuit, testing result may be significantly different if different multi-meter are used. If the pointer on the dial flickers and finally stops at in testing, it should be regarded as normal. Because the capacitor in the CDI module is charged while being tested and it cannot discharge at this time.
3.11.4 IGNITION COIL

Removal Steps Remove the middle box. Remove the spark plug cap. Disconnect the wires, remove ignition coil Jam nuts and remove the ignition coil.
Inspection Check the ignition coil circuit. The spark advance angle does not need to be adjusted. If spark advance is abnormal, check the CDI, pickup coil or magneto. Replace the ignition coil if necessary. Test the primary coil resistance, the standard value of which should be 0.1-1.0.
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Test the secondary coil resistance from spark plug cap negative terminals, the standard value of which should be 7-9k(with cap) and 3-4k(without cap). Coil test using after market spark tester.
Perform the following inspection in accordance with the operating instructions in the Manual. 1. Set the ignition coil tester switch in 12V and connect the tester to the ignition coil. 2. Turn the switch to the ON position to check spark frequency from the inspection door. In good condition: Sparking continuously In faulty condition: Sparking abnormally
3.11.5 MAGNETO
Pickup Coil Inspection This test is to be conducted with the stator mounted in the engine. Remove the cover. Disconnect the magneto. Test the pickup coil resistance between the blue/yellow and the green lead terminals, whose standard value is 80-160. Dismounting the magneto. Charging Coil Inspection Test the charging coil resistance between the black/red and the green lead terminals, whose standard value is 300-400. Spark Advance Angle Inspection Since CDI is used, there is no need to adjust the timing advance. If the spark advance is abnormal, inspect CDI, pickup coil or magneto. Replace if necessary. Remove timing lid. After the engine is warmed up, check the spark advance angle by the spark timing lamp. It is proper for F to

align within 2with the engine revolving at a speed of 1500rpm. The spark advance angle should be 13 1 (1500r/min)
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CHAPTER 3B ENGINE 50cc/80cc NOTES
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CHAPTER 3C ENGINE 100/125/150/200
SERVICE MANUAL09.0
CHAPTER 3C ENGINE
100cc/125cc Chain Drive WARNING
The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service.
150cc /200cc Shaft Drive
3.1 PREPARATION FOR REMOVAL PROCEDURES 3.2 REPLACEMENT PARTS

3.2.1 Gaskets, oil seals and o-rings 3.2.2 Bearings and oil seals
3.3 PERIODIC INSPECTION AND ADJUSTMENT

3.3.1 Air filter 3.3.2 Spark plug 3.3.3 Valve clearance adjustment 3.3.4 Carburetor idle adjustment 3.3.5 Transmission oil inspection (for MINI ATV100/150) 3.3.6 Transmission oil inspection (for B-type 150/200) 3.3.7 Crankcase oil inspection
3.4 ENGINE REMOVAL AND INSTALLATION

3.4.1 Cylinder head 3.4.2 Cylinder body, piston and piston ring 3.4.3 V-belt, AND CVT 3.4.4 Transmission (for MINI ATV100/150) 3.4.5 Transmission (for B-type 150/200) 3.4.6 Crankcase and crankshaft 3.4.7 Magneto 3.4.8 Electric starter 3.4.9 Oil pump
3.5 CARBURATION 3.6 TIGHTENING TORQUES OF ENGINE MAIN FASTENERS 3.7 IGNITION SYSTEM
3.7.1 INSTALLATION INFORMATION 3.7.2 TROUBLESHOOTING 3.7.3 CDI INSPECTION 3.7.4 IGNITION COIL 3.7.5 MAGNETO
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SERVICE MANUAL09.0
3.1 PREPARATION FOR REMOVAL PROCEDURES

1. Remove all dust and dirt before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. During machine disassembly, clean all parts and place them in the order of disassembly, which will speed up assembly and allow for the correct installation of all parts. 4. Keep all parts away from any source of fire.
3.2 REPLACEMENT PARTS

3.2.1 Gaskets, oil seals and o-rings 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned 2. Properly oil all mating parts and bearings during reassembly and apply grease to the oil seal lips.
3.2.2 Bearings and oil seals Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips and oil bearings liberally when installing.
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3.3 PERIODIC INSPECTION AND ADJUSTMENT

3.3.1 Air filter (for MINI ATV100/150)
1. Remove air filter case cover and fixing screws. 2. Remove filter element and wash in soapy water and dry it. 3. Install the air filter in the reverse order of removal.
Air filter (for B-type 150/200)

1. 2. 3. 4. Remove seat. Release clips and remove cover. Loosen screw and remove filter. Remove fabric type pre-filter from main filter. Wash pre-filter in soapy water and dry it. 5. Reinstall pre-filter over main filter. Replace main filter as required. 6. Reinstall filter into air box and tighten screw.
3.3.2 Spark plug

1. Remove spark plug. 2. Check for burnout, dirt or carbon deposit. Clean them away with a sparkplug cleaner or a cast-steel wire brush. 3. Spark plug gap specification: 0.6-0.7mm 4. Check for screw thread damage 5. Such spark plug as NGK (C7HSA, C6HSA) and CHAMPION Z9Y are recommended in replacement.
3.3.3 Valve clearance adjustment

1. Remove cylinder head cover. 2. Rotate cooling fan to set the mark on camshaft sprocket in Top Dead Center position, that is, to align the timing line on the rotor with the mark on the crankcase.
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NOTE:
Since the crankshaft is equipped with a decompression, the fan cannot be rotated counterclockwise, or it is impossible to adjust the valve. 3. Measure the valve clearance by using a feeler gauge. Valve clearance specification: Intake valve 0.040.06mm; Exhaust valve 0.040.06mm 4. To adjust valve clearance, loosen the locknut, turn the adjuster in or out with valve adjusting tool until specified clearance is obtained. Measure the valve clearance once more after the locknut is tightened.
3.3.4 Carburetor idle adjustment

1. Start the engine and let it warm up for several minutes. 2. Turn the idling adjusting screw in or out until specified idling speed is obtained. 3. Idling speed specification: 1700170rpm 4. If the idling speed is unstable or it is not smooth when accelerating the throttle slightly, adjust the fuel quantity adjusting screw, which is better to be done by professionals.
3.3.5 Transmission oil inspection (for MINI ATV100/150) 1. Stand the engine on a level surface. 2. Remove the oil filler cap after the engine stops. 3. Check if the oil level reaches the lower edge of the filing orifice. 4. Always use the same type of oil when refilling. The type used for this engine: SAE15W/40SG 5. Tighten the oil filler cap. 6. If the oil needs replacing, warm up the engine and then stop. Remove the drain bolt to drain the oil. And fill the case with new oil. 7. The oil capacity of a new engine: 110ml The top filling for replacement: 90ml
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3.3.6 Transmission oil inspection (for B-type 150/200)

1. Remove the oil level plug. 2. Wipe the oil on the plug and insert it into the filler hole without screwing. The oil level should reach the fourth mark. 3. When replacing the oil, remove transmission case drain plug located on the front cover and drain the oil.. 4. Check the O-ring for damage and replace it if necessary. 5. Install the drain plug. 6. Add SAE80W/90GL5 oil in the recommended amount. Install oil dipstick. 7. The oil capacity of a new engine: 500ml. The top filling for replacement: 450ml.
3.3.7 Crankcase oil inspection

8. Stand the engine on a level surface. 9. Have the engine run at idle speed for several minutes. Inspect the oil level after the engine is turned off 2-3 minutes. 10. Remove the oil level plug. 11. Wipe the oil on the plug and insert it into the filler hole without screwing. The oil level should reach the mark. 12. When replacing the oil, perform the first two steps and remove the oil strainer to drain the oil. 13. Check the O-ring for damage and replace it if necessary. 14. Add SAE15W/40SG oil in the recommended amount. 15. The oil capacity of a new engine: 900ml. The replacement volume: 750ml. 16. Install the oil strainer, spring and strainer lid. 17. After replacement, start the engine and keep it idling for 2-3 minutes and inspect the oil level according to the above instructions.
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3.4 ENGINE REMOVAL AND INSTALLATION

3.4.1 Cylinder head
A. Camshaft removal
1. Remove cylinder head cover
2.
Remove camshaft chain pensioner screw and then O-ring.
3.
Lock camshaft chain pensioner by turning it clockwise.
4.
Rotate fan to have the mark on the camshaft chain in an upward position, which is TDC of engine compression stroke.
5. Remove cylinder head bolts, fixing nuts and gasket of camshaft holder.
NOTE:
Tighten the nuts in a crisscross pattern, each 1/2 or 1/3 turn at a time.
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6.
Remove camshaft holder and pins
7.
Remove camshaft.
8.
Check for intake and exhaust cam damage. Replace when intake valve below 25.75mm exhaust valve below 25.41mm.
9.
Check camshaft bearing for looseness and wear and tear and sprocket for abnormal wear. If so, replace as a whole.
B. Camshaft holder installation
removal
and
1. Remove rocker arm shafts by using a bolt of 5mm. Remove one-way exhaust valve and rocker arm.
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2. Check camshaft holder, rocker arms and rocker arm shafts for abnormal wear and tear.
3. Measure the inside diameter of rocker arm shaft hole in camshaft holder. Limit: 10.10mm. 4. Measure the inside diameter of rocker arm hole. Limit: 10.10mm. 5 Measure the diameter of rocker arm shaft. Limit: 9.91mm.
C. Cylinder head removal

1. Remove the pipe composition of carburetor intake valve.
2. 3.
Remove fan cover composition. Remove upper and lower shrouds.
4.
Remove cylinder head.
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5. 6.
SERVICE MANUAL09.0
Remove dowel pin, cylinder head gasket and take out chain guide. Remove the gasket on cylinder surface.
NOTE:
Make sure the contact cylinder surfaces are not scratched. Make no other objects fall into the crankcase.
NOTE:
The cylinder head gasket must not be reused. 7. Take out valve seat, lock plate, spring, oil seal and valve by using a compressor. 8. Clean off carbon deposits in the combustion chamber. 9. Check spark plug, valve guide and their surrounding areas for cracks. 10. Check contact face evenness. Limit: 0.05mm. 11. Measure valve spring free length. Limit: inner spring 31.2mm outer spring 34.1mm.
12. Check valve stem bend and check for burnout. Clean carbon deposits off its surface. 13. Measure valve stem diameter. Limit: 4.9mm.
14. Clean off carbon deposits in valve guide.
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SERVICE MANUAL09.0
15. Eliminate carbon deposits from valve seat.
NOTE:
Be sure not to scratch the valve seat contact face.
16. Measure valve guide inside diameter. Limit: Intake 5.08mm exhaust 5.10mm Install cylinder head in the reverse order of removal.
3.4.2 ring
1.
Cylinder body, piston and piston

Remove cylinder body.
2.
Remove cylinder gasket dowel pin. Eliminate carbon deposits from gasket.
3.
Remove piston pin circlip, piston pin and piston.
NOTE:
Make sure the circlip does not fall into the crankcase.
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4.
Remove piston ring. Eliminate the carbon deposits from the piston ring grooves and rings.
NOTE:
Be sure to keep the piston ring undamaged.
5.
Position piston ring. Measure the gap between piston ring and ring groove.
Limit: first ring 0.09mm 2nd ring 0.09mm.
6.
Measure piston pin bore diameter, Limit: 15.04mm.
7.
Measure piston pin outside diameter Limit : 14.96mm.
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8. Measure piston outside diameter from an angle of 90 to piston pin bore, in a position some 9mm from piston bottom. piston diameter limit 46.9 mm (100cc) 52.3 mm (125cc) 56.9mm (150cc) 62.4mm (200cc)
9. Check cylinder inside surface for scratches and wear. Measure cylinder inside diameter from and angle of 90to piston pin and in upper, middle and lower three positions. cylinder diameter limit 47.1 mm (100cc) 52.5 mm (125cc) 57.1mm (150cc) 62.6mm (200cc) Check cylinder body evenness. limit 0.05mm. Install cylinder in the reverse order of removal.
NOTE:
Make sure to install the piston rings so that the slots are staggered by 120 and the sides with letters on are located upwards.
3.4.3 V-belt AND CVT

1. Remove left crankcase cover.
2.
Remove drive face.
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3.
SERVICE MANUAL09.0
Take out V-belt.
4. 5.
Check belt for cracks, wear, scaling or chipping. Measure V-belt width. limit 19.0mm,
6.
Remove sliding sheave.
7.
Remove movable cams.
8.
Remove clutch weights.
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9. Check weights wear. 10. Measure weight outside diameter. Limit 17.44mm
11.
Measure sliding sheave inside diameter Limit 24.06mm.
12. Check collar wear. Measure collar outside diameter. Limit 23.94mm, replace.
13. Remove clutch.
14. Check clutch disk wear. Limit 125.5mm
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15. Check spacer wear. Measure its thickness. Limit 1.5mm
16. Remove clutch assembly.
17. Remove clutch locknut.
18. Take out secondary fixed sheave and sliding sheave.
19. Measure compression spring free length. Limit: 163mm
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20. Check secondary sliding sheave wear. Measure its shaft inside diameter. Limit 34.06mm
21. Check secondary fixed sheave wear. Measure its shaft diameter. Limit 33.94mm Install them in the reverse order of removal.
NOTE:
Never smear grease to the V-belt, secondary sheave and clutch.
3.4.4Transmission (for MINI ATV100/150)

1. Remove drain cock to drain transmission oil. 2. Remove transmission case cover.
4. Remove gasket and dowel pins. 5. Remove middle gear set, secondary driven gear and secondary driven axle. Check each for wear.
6. Inspect axles for proper operation. Check if secondary driven axle oil seal is abnormal. If so, replace.
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7. Check oil seals and axles wear. 8. Take out primary gear axle and check its wear. Install it in the reverse order of removal. And add sufficient oil.
3.4.5 Transmission (for B-type 150/200)

3.4.5.1 Transmission Disassembly
1. Remove transmission case drain plug located on the front cover and drain the oil.
2. Remove transmission case fixing bolts.
3. Knock the input shaft carefully with a soft face hammer to separate the transmission case from the left crankcase.
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4. Remove input shaft, forward/reverse shaft, middle shaft and shift fork as an assembly.
5. Remove bearing and helical gear.
6. Remove pinion shaft retainer plate and pinion shaft.
7. Remove front cover transmission case.
bolts
from
the
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8. Remove output shaft. 9. Clean all components and inspect for wear. 10. Inspect engagement dogs of gears and replace if edges are rounded. 11. Inspect gear teeth for wear, cracks, chips or broken teeth. 12. Remove seals from transmission case.
IMPORTANT: New seals should be installed

after the transmission is completely assembled. 13. Inspect bearings for smooth operation. Check for excessive play between inner and outer race.
3.4.5.2 Transmission Assembly

1. Install output shaft. 2. Before installing the front cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply silicon glue to mating surfaces. 3. Reinstall cover and torque bolts in a cross pattern in 3 steps to 14.5 ft. lbs. (20 Nm). 4. Install new output shaft seal. 5. Install pinion shaft with bearing. 6. Install retainer plate with flat side toward bearing. 7. Apply Loctite 242(Blue) to screw threads and torque screws to 7.2 ft-lbs. (10N.m). 8. Assemble shafts and shift fork. 9. Carefully install forward/reverse shaft and middle shaft assembly and gear cluster as a unit into their respective bearing case areas. Tap with a soft face hammer to seat shaft assemblies.
TM
NOTE: NOTE:
Make sure shift fork pins is properly
positioned in the slot on selector arm. Be sure gear indicator switch are
removed from transmission case before installing shafts.
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SERVICE MANUAL09.0
10. Prior to reinstalling the transmission make sure the mating surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon glue to mating surfaces. 11. Reinstall left crankcase and torque bolts in a cross pattern in 3 step to 14.5 ft.lbs. (20Nm). 12. Install new input shaft seal. 13. Install drain plug with a new sealing washer. Torque drain plug to 14 ft.lbs. (19Nm). 14. Add SAE80W/90GL5 oil in the recommended amount. Install oil dipstick. 15. Install gear indicator switch. Apply Loctite 13-16 in. lbs. (1.5-1.9 Nm).
TM
242 (blue) to screw threads and torque screws to
3.4.5.3 TROUBLE SHOOTING CHECKLIST

Check the following items when shifting difficulty is encountered Idle speed adjustment Transmission oil type/quality Driven clutch (CVT) deflection Loose fasteners on rod ends Loose fasteners on gear shift box Worn rod ends, clevis pins, or pivot arm bushings Linkage positioning Shift selector rail travel *Worn, broken or damaged internal transmission components rod adjustment and rod end
*NOTE : To determine if shifting difficulty or

problem is caused by an internal transmission problem, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
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3.4.6 Crankcase and crankshaft

13. Remove chain guide fixing bolt to take out chain.
14. Remove driven gear from crankshaft and inspect gear for wear.
15. Remove crankcase fixing bolts and separate the left crankcase from the right one.
16. Remove gasket fitting pin.
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17. Take out crankshaft and timing chain.
18. Clean gasket on crankcase contact face .
NOTE:
Make sure the contact faces are not scratched to avoid oil leakage.
19. Remove oil seal from crankcase. Inspect oil seal for wear.
20. Measure connecting rod big end side clearance. Limit 0.55mm.
21. Measure big end crankpin diametral clearance. limit 0.55mm 22. Measure small end orifice inside diameter. limit 15.06mm
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23. Inspect crankshaft bearings for abnormal noise and looseness. If so, replace. Install them in the reverse order of removal.
NOTE:
Be sure to drain crankcase oil before crankcase removal.
3.4.7 Magneto
1. Remove magneto cover fixing bolts and screws to dismount magneto cover. Inspect cover for damage and cracks.
2. Remove 4 fixing bolts to take out fan. Inspect fan for blade aging and cracks. If so, replace.
3. Remove magneto flywheel locknut.
4. Take out magneto rotor using the flywheel puller. Inspect magneto flywheel tapered orifice and key way for wear, scratches and cracks. If so, replace.
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5.
SERVICE MANUAL09.0
Remove stator fixing screw to take out stator. Install it in the reverse order of removal.
NOTE:
As there is magnetism inside the magneto rotor, make sure no metal object is taken in and the inside of the rotor is cleaned out before installation.
3.4.8 Electric starter

1. Remove starter clutch. 2. Remove idler gear and idle gear shaft.
3. When turning the starter wheel gear counterclockwise, it should turn freely. When turning the starter wheel gear clockwise, it should be engaged.
4. Inspect clutch wheel gear for abnormal wear. If so, replace it with a new one. 5. Measure gear wheel orifice inside diameter. If it goes beyond the limit of 32.06mm, replace. 6. Inspect needle roller bearing for wear. Check if needle roller turns freely in its holder. If it works improperly, replace it with a new one.
7. Take spring, spring sleeve and roller out of clutch outer race. Inspect roller for wear, spring for distortion and out race for wear. If there appears anything abnormal, replace.
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8. Measure clutch disk hub outside diameter. Limit 27.94mm
9. Inspect idler gear and idle gear shaft for abnormal wear. If so, replace. 10. Measure idle gear shaft orifice inside diameter. Limit 10.05mm 11. Measure idle gear shaft outside diameter. Limit 9.94mm Install them in the reverse order of removal.
3.4.9 Oil pump

1. Remove bolts to dismount right crankcase cover.
2. Remove gasket and dowel pin. Remove clutch.
3. Remove oil pump cover. 4. Remove nut to take out oil pump sprocket and chain. Inspect them for abnormal wear. If so, replace
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5. Measure tip clearance between rotors and pump housing. Limit 0.2mm
6.
Inspect oil pump inner and outer rotors for abnormal wear. If so, replace the oil pump assembly.
7. Fasten oil pump assembling.
with
screws
after
Install oil pump in the reverse order of removal.
NOTE:
Be sure to point the arrow on the oil pump to the direction of crankshaft in installation and infuse some oil into the pump beforehand.
3.5 CARBURETION
1. Remove auto choke lead coupler.
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2. Remove fuel hose and air pressure tube.
3. Remove throttle cable locknut to take out throttle cable. Loosen inlet-valve seat screw and air filter fixing screw to remove carburetor.
NOTE:
Make sure the fuel in the fuel bowl is drained before the carburetor removal lest the cylinder head be sprinkled with the fuel, which is likely to bring about a fire.
4. Inspect auto choke unit. Connect yellow auto choke unit lead to the positive pole (+) of a battery and green lead to the negative pole (-). Some 5 minutes later, connect a pipe to idle port and blow it with the mouth. Being blocked up means a good condition of the unit. Disconnect the leads from the battery. Around 30 minutes later, blow the pipe with the mouth or a vacuum pump. If it is unblocked, the unit is in good condition. 5. Remove fixing screw to take out auto choke unit.
6. Inspect auto choke unit, piston and needle for abnormal wear. If so, replace as a set.
7. Fit auto choke unit on carburetor.
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8. Remove screw to take out air pressure diaphragm cover, spring and diaphragm. Inspect spring for distortion and diaphragm for damage. If that is the case, replace as a set. Install in the reverse order of removal.
NOTE:
Make sure the slot on the air pressure diaphragm is in alignment with the corresponding setting slot on the carburetor.
9.
Remove two screws to take out air pressure chamber cover.
10.
Remove spring, air pressure diaphragm and piston.
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11. Remove fixing device on top of needle by depressing the device and turning it left. Remove spring and needle.
12. Inspect needle for wear, air pressure piston for damage and diaphragm for cracks and aging. Replace as a set if necessary.
13. Remove fuel bowl, float and needle valve.
14. Inspect needle valve and valve seat for damage and blockage.
NOTE:
If the needle valve is damaged or blocked, the air-tightness between the valve and valve seat is not proper, which results in float height raise and then oil leakage. In such a case, the valve must be replaced with a new one. 15. Remove main jet, needle valve seat, idle metering jet and jet adjuster.
NOTE:
Make sure the jet, the nozzle seat and the adjuster are not damaged. Note down the turns given to the adjusting screw in removal.
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16. Wash jet and nozzle in clean gasoline and clear them of filth with compressed air. Blow each fuel passage of carburetor clean with compressed air. And install them in their original positions.
17. Measure fuel level by holding the gauge vertically to the float chamber and in alignment with the main jet. The standard fuel level is 18.5mm. After inspection, fit the lid on the float chamber and install the carburetor.
NOTE:
Generally, fuel level adjusting screw has already been adjusted before leaving factory. There is no need for adjusting. If need be, it should be done by a professional. Adjustment steps: Run the engine 3-5 minutes. Adjust the idle screw with a screw driver to keep the revolution within the range of 1700170rpm. The adjusting screw should usually be screwed in gently and screw out by 2 3/8-3 7/8 turns.
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3.6 TIGHTENING TORQUES OF ENGINE MAIN FASTENERS

Description Cylinder head bolt Oil filter screen cover bolt Exhaust pipe nut Camshaft seat nut Valve adjuster locknut Cam chain tensioner bolt Transmission case drain bolt Clutch drive plate nut Clutch driven disk nut Starter clutch nut Spark plug Driven clutch woodruff key nut Case (right & left) and case cover (right & left) Thread size M6 M30 M6 M8 M5 M6 M8 M12 M12 M12 M10 M22 M16 Tightening torque (Nm) 9 15 9 20 9 10 19 55 55 55 12 45 9
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CHAPTER 3C ENGINE 100/125/150/200 3.7 IGNITION SYSTEM

3.7.1 INSTALLATION INFORMATION OPERATING POINTS
SERVICE MANUAL09.0
Check ignition system in accordance with the troubleshooting procedure in section 3.11.2 As the ignition system has an electric automatic spark control in CDI unit, there is no need for spark advance angle adjustment. Poor contact may be the cause of many ignition system faulty cases. Check all terminal connections to be sure they are clean and tight whenever troubleshooting an electrical problem. Make sure spark plug heat range is correct. Using incorrect spark plug will result in improper engine operation or spark plug damage. Peak voltage is used as reference point in tests. Record coil resistance tests. REFERENCE STANDARD item Specific spark plug spark plug gap spark plug angle Ignition coil resistance(20) Maximum advance in F position Primary coil S e c o n d ar y Wit h ca p Wit ho ut ca p Standard value (NGK)C7HSA 0.6-0.7mm 131(1700r/min)
0.1-1.0 7-9k
3-4k
Pickup coil resistance(20) Primary Ignition coil peak voltage Pickup coil peak voltage 3.7.2 TROUBLESHOOTING High Tension Voltage Too Low Crankshaft revolution too low or battery voltage too low Ignition system wiring loose Faulty Ignition coil Faulty CDI unit Faulty pickup coil
80-160 Over 120V Over 2.1V
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High Tension Voltage Intermittent Faulty main switch Poor CDI terminal connection Poor CDI ground Faulty pickup coil Poor high tension lead terminal connection Faulty CDI unit High Tension Voltage Normal but No Spark Faulty spark plug Faulty spark plug cap No High Tension Voltage Faulty main switch Faulty Ignition coil Faulty CDI unit No or Intermittent High Tension Voltage Faulty Ignition coil 3.7.3 CDI INSPECTION Disconnect the CDI module from the wire harness Test resistance of the terminals with an multi-meter. Since there is semiconductor in return circuit, testing result may be significantly different if different multi-meter are used. If the pointer on the dial flickers and finally stops at in testing, it should be regarded as normal. Because the capacitor in the CDI module is charged while being tested and it cannot discharge at this time.
SERVICE MANUAL09.0
(CDI for MINI ATV100/150)
(CDI for B-type 150/200):
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CHAPTER 3C ENGINE 100/125/150/200 3.7.4 IGNITION COIL

Removal Steps Remove the middle box. Remove the spark plug cap. Disconnect the wires, remove ignition coil Jam nuts and remove the ignition coil.
SERVICE MANUAL09.0
Inspection Check the ignition coil circuit. The spark advance angle does not need to be adjusted. If spark advance is abnormal, check the CDI, pickup coil or magneto. Replace the ignition coil if necessary. Test the primary coil resistance, the standard value of which should be 0.1-1.0. Test the secondary coil resistance from spark plug cap negative terminals, the standard value of which should be 7-9k(with cap) and 3-4k(without cap). Coil test using after market spark tester.
Perform the following inspection in accordance with the operating instructions in the Manual. 1. Set the ignition coil tester switch in 12V and connect the tester to the ignition coil. 2. Turn the switch to the ON position to check spark frequency from the inspection door. In good condition: Sparking continuously In faulty condition: Sparking abnormally
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CHAPTER 3C ENGINE 100/125/150/200 3.7.5 MAGNETO

Pickup Coil Inspection This test is to be conducted with the stator mounted in the engine. Remove the cover. Disconnect the magneto. Test the pickup coil resistance between the blue/yellow and the green lead terminals, whose standard value is 80-160. Dismounting the magneto. Charging Coil Inspection(for MINI ATV100/150) Test the charging coil resistance between the black/red and the green lead terminals, whose standard value is 450-550. Spark Advance Angle Inspection Since CDI is used, there is no need to adjust the timing advance. If the spark advance is abnormal, inspect CDI, pickup coil or magneto. Replace if necessary. Remove timing lid. After the engine is warmed up, check the spark advance angle by the spark timing lamp. It is proper for F to align within 2with the engine revolving at a speed of 1700rpm. The spark advance 131(1700r/min) angle should be
SERVICE MANUAL09.0
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NOTES
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CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B
CHAPTER 4A CHASSIS
ATV 260 / 300 / 400 and B-Type ATV400-2 / ATV400-2B
4.1 A-RM REPLACEMENT 4.2 SWING ARM 4.3 FRONT STRUT REPLACEMENT 4.4 FRONT STRUT BALL JOINT REPLACEMENT 4.5 STEERING POST ASSEMBLY
CHAPTER 4 A
CHASSIS
PAGE. 4A-
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B 4.1 A-RM REPLACEMENT (MacPherson)
EARLY DESIGN ( Only ATV 260 EARLY MODEL)
1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup. 3. Using a soft face hammer, tap nut to loosen A- arm from bolt. Remove nut and A-arm from hub strut assembly. 4. Loosen two bolts on A-arm by alternating each about 1/3 of the way until A-arm can be removed.
5. Examine A-arm shaft. Replace if worn. Discard hardware. 6. Insert A-arm shaft into new A-arm. 7. Install new A-arm assembly onto vehicle frame. Apply Loctite 242 to screw threads and Install new bolts. Torque new bolts to 30 ft. lbs. (41.4 Nm ). WARNING DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation. 8. Attach A-arm to strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite directions around nut. 9. Locate grease fitting in center of A- arm and pump A- arm full of grease. WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
CHAPTER 4 A CHASSIS PAGE. 4A2

MANTENANCE-FREE PIVOT DESIGN
1. Elevate and safely support vehicle 2. Remove cotter pin from ball joint cup at wheel end of A- arm and loosen nut until it is flush with end of cup. 3. Using a soft face hammer, tap nut to loosen A- arm from bolt. Remove nut and A-arm from hub strut assembly. 4. Loosen and remove two bolts on A-arm, and remove A-arm. 5. Examine bushing. Replace if worn or tore. Discard hardware. 6. Install new A-arm assembly onto vehicle frame. Install new bolts and new nuts. NOTE. Tighten the nuts only finger-tighten at this time. They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground. WARNING DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation. 7. Attach A-arm to strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite directions around nut. 8. Install hubs, calipers and wheels, lower the vehicle to the ground. Apply Loctite 242 to screw threads of the A arm bolts and torque bolts to 37-44 ft. lbs. (50-60 Nm ). WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
CHAPTER 4 A
CHASSIS
PAGE. 4A-
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B 4.2 SWING ARMEXCEPT ATV400-2ATV400-2B
Swing Arm Assembly Installation 1, Screw swing arm pivots into frame on each side (about 3 turns). 2, Install swing arm assembly in frame with lubricated bearing taper roll, and install seal in each side of swing arm asm . 3, Apply Loctite 242 to R H swing arm pivot. 4, Tighten swing arm pivot until both are engaged in tapered roll. 5, Adjust right side swing arm pivot in ward until firmly seated against bearing, torque to 120 ft. lbs. (165Nm) and apply Loctite 271. 6, Torque left side swing arm pivot to 14 ft. lbs. (19 Nm ) and apply Loctite 271 . 7, Apply Loctite 242 (Blue) to exposed threads of swing arm pivot and threaded pivot. 8, Torque threaded pivot to 120 ft. lbs. (165 Nm) and apply Loctite 271.
CHAPTER 4 A
CHASSIS
PAGE. 4A-
4.3 FRONT STRUT REPLACEMENT ATV260/ 300 /400 /400-2 /400-2B

1. Hold strut rod with wrench and remove top nut 2. Compress spring. 3. Remove upper strut pivot assembly. 4. Remove coil spring and collapse strut body. 5. Remove two pinch bolts from strut body. 6. Remove strut body. 7. Install front shock cartridge until bottomed in strut casting. 8. Install pinch bolts with clamp(s). Torque pinch bolts to 15ft.lbs.(21Nm). 9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully. 10. Torque strut rod nut to specification. Do not over torque nut. Strut Rod Nut Torque 15 ft. lbs. (21 Nm)
CHAPTER 4 A
CHASSIS
PAGE. 4A-
4.4 FRONT STRUT BALL JOINT REPLACEMENT ATV260/300/400/400-2B

1. Loosen front wheel nuts. 2. Elevate and safely support ATV under footrest/frame area. . CAUTION: Serious injury may result if ATV tips or falls. Be sure ATV is secure before beginning this service procedure. 3. Remove wheel nuts and wheels. 4. Remove cotter pin from ball joint 5. Remove castle nut and separate Aarm from ball joint stud. 6. Remove screws and ball joint mounting bracket. 7. Using ball joint cup removal/installation toolkit, remove ball joint cup from strut housing. Refer to photos at right. Install puller guide (1) . Thread bolt (2) with nut (3) onto bal joint stud as shown . Hold bolt (2) and turn nut (3) clockwise until ball joint is removed from strut housing. 8. To install new ball joint cup. Insert new ball joint into driver (installation toolkit). Drive new bal joint cup into strut housing until fully seated. 9. Apply Loctite 242 (blue) to threads of mounting bracket new screws. Torque screw s to 8 ft.lbs. (11 Nm). 10. Install A- arm on bal joint cup and torque castle nut to 25 ft. lbs. (35 Nm ). 11. Reinstall cotter pin with open ends toward rear of machine.
CHAPTER 4 A
CHASSIS
PAGE. 4A-
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B 4.5 STEERING POST ASSEMBLY
Note: 1, Hand tighten the crown nut of the steering post. 2, Align cotter pin hole. 3, Install cotter pin. Bend both ends of cotter pin around nut in opposite directions. 4, Check steering, must move freely and easily from full left to full right without binding.
CHAPTER 4 A
CHASSIS
PAGE. 4A-
CHAPTER 4A CHASSIS ATV 260 / 300 /400 and B-Type/ATV400-2/400-2B NOTES
CHAPTER 4 A
CHASSIS
PAGE. 4A-
CHAPTER 4B CHASSIS
CHAPTER
4 B CHASSIS
Youth ATV for USA: 50 / 80 Mini ATV for Europe: 50 / 100 /125 / 150
4.1 FRONT WHEEL / HUB / DRUM BRAKE 4.2 A-RM REPLACEMENT 4.3 FINAL DRIVE 4.4 SWING ARM
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
4.1 FRONT WHEEL/ HUB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TIRE FRONT COTTER PIN BOLT M10X1.25X20 CASTLE NUT M12X1.25 WASHER VALVE WHEEL FRONT OIL SEAL SPACER 1 BEARING 6002Z SPACER 2 HUB ASSY BEARING 6003Z BRAKE CAM RETURN SPRING BRAKE SHOE SET BRAKE PANEL. LEFT/ RIGHT BRAKE ARM. LEFT/ RIGHT 19 22 SPRING. LEFT/ RIGHT RUBBER CAP
FRONT WHEEL REMOVAL 1. Place the vehicle on level ground with engine off and fuel off, set the parking brake, 2. Loosen the 4 bolts (3), but not removal. 3. Elevate front end and safely support machine under frame area, Removal the bolts. 4. Remove the front wheel. Inspect all wheels for runout and damage. FRONT HUB REMOVAL 1. Remove the wheel as described above. 2. Remove the RUBBER CAP (22), and cotter pin. 3. Loosen and remove the CASTLE NUT (4) and washer. 4. (Release the front parking brake) Removal the front hub. FRONT HUB/ DRUM/ BRAKE SHOE/ BRAKE PANEL/ BRAKE CAM and ARM INSPECTION Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. Inspect the whole hub for damage replace if necessary. Inspect the drum/ shoes and springs/ panel/ cam/ arm for any damage or fracture, replace if necessary. See the CHAPTER 2 MAINTENANCE for the service limit of the brake shoe and drum.
CHAPTER 4 CHASSIS PAGE. 4B2
CHAPTER 4B CHASSIS
NOTE: Replace the brake shoes as a set either is worn to the limit.
HUB BEARING REPLACEMENT 1. Remove the oil seals. 2. Remove the SPACER 1. 3. Remove the bearings. 1. Apply grease to the bearings. 2. Drive the bearing 6002Z in first, seal side facing out, 3. Put in the SPACER 2. 4. Drive the bearing 6003Z in, seal side out, 5. Install new seal into hub (with numbers facing out) until flush with end of seal bore. Do not damage the surface of the seal. Coat the lip with special grease. NOTE. Drive the bearing 6002Z in first. Reverse the wheel and hub removal procedure for installation.
DRUM BRAKE Disassembly NOTE: If the brake shoes are going to reinstalled, they must be installed in their original locations. Mark the brake shoes with R U, L U, L U, L L. R-right, L-left, U-upper, L-lower
Assembly 1. Install the BRAKE CAM, notch facing the center of the BRAKE PANEL.
2. Install the SHOE SET. 3. Install the BRAKE ARM. align the point mark to the notch.
NOTE: Always replace the shoes as a set. Replace the brake shoes as a set either is worn to the limit.
CHAPTER 4B CHASSIS
NOTE: If reinstalling old brake shoes, install them into their correct locations on the brake panel. Refer to the R U, L U, L U, L L *marks made in the Note of Disassembly. *R-right, L-left, U-upper, L-lower NOTE: If new linings are bring installed, file off the leading edge of each shoe a little so that the brake will not grab when applied.
4.2.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
A-RM REPLACEMENT
A-ARM PIVOT SHAFT RIGHT A-ARM PIVOT SHAFT SEALED RING BUSHING 1 GREASE FITTING GREASE FITTING CAP BUSHING 2 NUT M10X1.25 A-ARM PIVOT SHAFT CAP COTTER PIN2.5X20 A-ARM RITGHT BOLT M10X1.25X48 A-ARM RUBBER BUSHING CASTLE NUT M10X1.25 A-ARM PIVOT SHAFT LEFT A-ARM LEFT FRONT SHOCK ABSORBER BOLT M10X1.25X38 NUT M10X1.25
REMOVAL 1. Remove wheel/ hub as described above. 2. Remove CAP (8), COTTER PIN (9), CASTLE NUT (13), and removal the PIVOT SHAFT (14/ 1). 3. Remove BOLTS (17) and removal FRONT SHOCK ABSORBER. 4. Remove 4 bolts (11) and removal A-ARM. INSPECTION Clean and Inspect the bushing 1, bushing 2, A-ARM RUBBER BUSHING, FRONT SHOCK RUBBER BUSHING and the PIVOT SHAFT for nicks, scratches, or damage. Replace if necessary.
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
INSTALLATION NOTE: Always use new A-ARM PIVOT SHAFT SEALED RING for re-installation. Apply grease on A-ARM PIVOT SHAFT Reverse the hub removal procedure for installation.
4.3 FINAL DRIVE

REAR WHEEL Removal 1. Place the vehicle on level ground with engine off and fuel off, set the front parking brake, 2. Loosen the 4 bolts (3), but not removal. 3. Elevate rear end and safely support machine under frame area, Removal the bolts. 4. Removal the wheel. Inspection Inspect all wheels for runout and damage. Installation Reverse the wheel removal procedure for installation.
DRIVE CHAIN Chain Removal 1. Place the vehicle on level ground with engine off and fuel off, set the front parking brake, 2. Rotate rear wheel to place master link in accessible position between two sprockets. 3. Remove the rear wheels as described above. 4. Loosen, but not removal the four mounting bolts. Loosen the chain adjuster. 5. Slide the retaining clip of the master link and remove clip and side plate. 6. Slide master link out and remove the chain.
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
Chain Inspection, Installation and Adjustment 1. Clean and Inspect chain and chain sprocket for wear. NOTE: To clean the chain, remove the chain from the ATV, dip it in solvent, and clean out as much dirt as possible. Take the chain out of the solvent and dry it. Immediately lubricate the chain to prevent rust. 2. If sprockets are worn, replace sprockets and chain as a set. 3. Replace guards if damaged. 4. Slide the pin portion of the master link(3) in to each end of chain to be connected. 5. Slide the side plate(2) portion of the master link on to the pins. 6. Slide the retaining clip(1) on to the pins until clip snaps securely in to place. CAUTION: The master link should be installed with the open end of the retaining clip (1) facing away from direction of chain rotation (4).
7. Turn the chain adjuster to obtain 1/4 (6mm) to 3/8 (10mm) chain flex. To tighten the chain, turn the chain adjuster clockwise. To loosen the chain, turn the chain adjuster count clockwise and push the rear axle forward.
CHAPTER 4B CHASSIS
8. Securely tighten the mounting bolts. Torque Specifications: 41-44Ft.Lbs (55-60N.m)
9. Recheck the chain tension: At the center point between the two sprockets, push and pull the chain and note total flex. If flex is more than 1/2 (12mm), readjust chain. 10. Apply proper type spray-on chain lubricant thoroughly inside and outside plates and rollers of chain. Move ATV as needed to access entire chain. FINAL DRIVE Removal 1. Remove wheels, chain as described above. 2. Remove the 4 M12X1.25X28 mounting bolts. 3. Remove the final drive assembly from the swing arm, Installation Reverse the removal procedure for installation. Adjust chain tension as described above. Securely tighten the mounting bolts (1). Torque Specifications: 41-44Ft.Lbs (55-60N.m) Final Drive Disassembly
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TIRE REAR AT18X7-8FOR EUROPE 19 20 21 22 23 24 25 26 27 28 29 SPROCKET 2 CHAIN CHAIN COVER BOLT M6X75 (only for 50/ 80) BOLT M6X10 RUBBER STICK BRACKET RUBBER CAP RIM REAR PLUG BOLT M10X1.25X28 REAR AXLE COTTER PIN 50/ 80 CASTLE NUT 100/125/150 WASHER 1 REAR HUB SPROCKET HUB. SPROCKET BOLT M10X1.25X28 SPACER RIGHT BOLT M10X1.25X20 BRAKE DISC FLANGE NUT M10X1.25 SPECER LEFT AXLE TUBE SPACER BEARING OIL SEAL, REAR AXLE TIRE REAR AT19X7-8 M20X2 M16X1.5
1. 2. 3. 4. 5. 6.
Remove the RUBBER CAP (26) and cotter pin. Loosen and removal the CASTLE NUT (3) and washer. Remove the rear hub. Remove the SPACER RIGHT (9) and SPACER LEFT (13). Remove the BRAKE DISC with FLANGE and removal the sprocket. Remove the rear axle.
Final Drive Inspection Remove the oil seal from the AXLE TUBE. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident. Inspect the whole things for damage replace if necessary.
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
Final Drive Assembly 1. Drive in bearings to the AXLE TUBE. NOTE: Drive the bearing which near the brake disc first by press the bearing outer race, then put in the SPACER (15) and drive in another bearing by press the bearing both inner and outer race till it touch the SPACER (15). 2. Install new oil seals. 3. Install the rear axle from the brake disc side. 4. Reverse the rest procedure for installation till the hub. 5. Screw in the left side castle nut and align the hole to the notch of the nut. Install the right side castle nut and securely tighten the nut, install a new cotter pin. 6. Securely tighten the left nut and install a new cotter pin. Torque Specifications: 50/ 80 M 16 X 1.5 62Ft.Lbs ( 83N.m ) 100/ 125/ 150 M 20 X 2 81Ft.Lbs ( 110N.m ) 7. Install the rubber cap.
4.4 SWING ARM

1 2 3 4 5 6 7 8 9 10 11 12 SWINGARM ASSY SWING ARM PIVOT BUSHING SEAL SWING ARM PIVOT BUSHING 3 SWING ARM PIVOT NUT M14X1.25 DISK BRAKE MANTLE BOLT M8X12 CHAIN WHEEL MANTLE CHAIN ADJUSTER BOLT M10X1.25X28 NUT M6
CHAPTER 4
CHASSIS
PAGE. 4B-
CHAPTER 4B CHASSIS
Removal 1. Removal rear shock absorber. 2. Removal NUT (6), washer, and SWING ARM PIVOT (5).
Inspection Inspect the SWING ARM PIVOT BUSHINGs and the SWING ARM PIVOT shaft for nicks, scratches, or damage. Replace if necessary. Installation Reverse the removal procedure for installation. Note. Install new seal. Coat the lip, bush, and pivot with grease. Torque Specifications: NUT(6) M14X1.25: 40-44Ft.Lbs (55~60N.m ) Bolt for rear shock absorber: 21-24Ft.Lbs (28~32N.m)
CHAPTER 4
CHASSIS
PAGE. 4B-
10
CHAPTER 4B CHASSIS NOTES
CHAPTER 4
CHASSIS
PAGE. 4B-
11
CHAPTER 5 FINAL DRIVE

ATV 260/300/400-2 and B-Type/400-2B
(PLEASE SEE CHARPTER 4B IN THIS MANUAL FOR THE WHEEL, HUB, AND DRIVE C H A I N O F M I N E / Y O U T H AT V )
WHEEL, HUB, AND SPINDLE TORQUE TABLE FRONT HUB DISASSEMBLY/INSPECTION FRONT HUB ASSEMBLY FRONT HUB INSTALLATION (2WD) FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/ INSPECTION (4X4) 5.6 FRONT DRIVE AXLE INSTALLATION (4X4) 5.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION (4X4) 5.8 FRONT DRIVE AXLE ASSEMBLY (4X4) 5.9 REAR HUB INSPECTION 5.10 REAR AXLE REMOVAL 5.11 REAR AXLE INSTALLATION 5.12 REAR AXLE BEARING REMOVAL 5.13 REAR AXLE BEARING INSTALLATION 5.14 REAR GEARCASE DISASSEMBLY 5.15 REAR GEARCASE ASSEMBLY 5.16 FRONT GEARCASE SLIP LIMIT TORQUE TEST (4X4) 5.17 FRONT GEARCASE DISASSEMBLY/ INSPECTION (4X4) 5.18 FRONT GEARCASE ASSEMBLY (4X4) 5.19 FRONT DIFFRENTIAL DISASSEMBLY/ INSPECTION (4X4) 5.20 FRONT DIFFRENTIAL ASSEMBLY (4X4) NOTE. ELECTRIC 4WD SHIFT---See CHAPTER 8 ELECTRICAL 5.21 REAR, FRONT PROP SHAFT REMOVAL
5.1 5.2 5.3 5.4 5.5
CHAPTER 5
FINAL DRIVE. 5-
5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE

Item
Front Wheel Nuts
Specification ATV26./300/B Type20 Ft.Lbs ATV40048 Ft.Lbs 27 N.m 66 N.m 69 N.m 66 N.m
Rear Wheel Nuts
ATV26./300/B Type50 Ft.Lbs ATV40048 Ft.Lbs
Front Hub Nut on Spindle/ outer CV joint Rear Hub Retaining Nut
Refer to FRONT HUB INSTALLATION ATV26./300/B Type80 Ft.Lbs ATV400101Ft.Lbs 110.6 N.m 137N.m
CAUTION: Locking nuts, and bolts with pre-applied locking agent should be replaced if
removed. The self- locking properties of the nut or bolt are reduced or destroyed during removal.
5.2 FRONT HUB DISASSEMBLY/INSPECTION

1. Elevate front end and safely support machine under footrest/frame area.
CAUTION
Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. Check bearings for side play by grasping tire/wheel firmly and checking for movement. It should rotate smoothly without binding or rough spots. Remove wheel nuts and wheel. Remove brake caliper Remove hub cap, cotter pin, front spindle nut, and washer. Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or
CHAPTER 5 FINAL DRIVE. 52
2.
3. 4. 5.
6.

roughness is evident. 7. Place a shop towel on hub to protect surface. Carefully pry seal out of hub. Do not damage the surface of the seal. Clean the hub. 8. Drive bearing out through opposite side of hub and discard. 9. Drive other bearing out and discard. 10. Clean hub and spacer thoroughly.
5.2 FRONT HUB REMOVAL/INSPECTION 4x4(ATV400-2 / ATV400-2B)

1. Elevate front end and safely support machine Under footrest/frame area.
CAUTION:
Serious injury may result if machine tips or falls, Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. 2. Check bearings for side play by grasping the tire/Wheel firmly and checking for movement. Grasp The top and bottom of the tire. The tire should rotate smoothly without binding or rough spots. 3. Remove wheel nuts and wheel. 4. Remove the two brake caliper attaching bolts.
CAUTION:
Do not hang the caliper by the brake Line. Use wire to hang the caliper to prevent. Possible damage to the brake line. 5. Remove hub cap, cotter pin, front spindle nut, and Washer. 6. Rotate each bearing by hand and check for smooth rotation. Visually inspect

bearing for moisture, dirt, or corrosion, or roughness is evident.
5.3 a. FRONT HUB ASSEMBLY (ATV150/200/260/300)
1. Drive or press one new bearing in to hub using a bearing driver (2WD). 2. Drive or press the other bearing into hub until seated against the hub shoulder (2WD). 3. Coat the new bearing with grease (2WD). 4. Coat the spline with grease (4WD) 5. Install new seal into hub (with numbers facing out) until flush with end of seal bore. Do not damage the surface of the seal. Coat the lip with special grease.
CHAPTER 5
FINAL DRIVE. 5-
5.3 b. FRONT HUB INSTALLATION 4X4 (ATV400-2 / ATV400-2B)
1. Inspect the hub strut bearing surface for wear or damage. 2. Apply grease to drive axle spindle. 3. Install spindle through the backside of the hub strut. Install the hub onto the spindle. 4. Install spindle nut and tighten to specification. 5. Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 6. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of Spindle in different directions. 7. Install hub cap. 8. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 9. Install brake caliper using new bolts. Tighten bolts to specified torque.
CAUTION: New bolts have a pre-applied

locking. agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 10. Install wheel and wheel nuts and tighten evenly in a cross pattern to specified torque.
CHAPTER 5
FINAL DRIVE. 5-
CHAPTER 5 FINAL DRIVE 5.4 .a .FRONT HUB INSTALLATION (ATV150/200/260/300)
1. Inspect spindle seal on strut and bearing surface for wear or damage. 2. Apple grease to spindle and bearing. 3. Install spindle into strut.
4. Install bearing to spindle. 5. Install spacer on spindle (2WD).
6. Install bearing 30205 on spindle (2WD) . 7. Apply grease.

8. Install hub.
9. Install bearing 30205 on spindle.
10. Install washer and spindle nut. Torque spindle nut to 160-170 inch lbs (18-19N.m), while rotating hub continuously, back off nut 1/2 turn, and rotate the hub several turns. Re-torque spindle nut to 110-140 inch lbs

(12-16N.m). 11. Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
12. Rotate hub and check for smooth operation. Bend both ends of cotter pin around end 13. Lightly grease a new O- ring and install on hub cap. 14. Install hub cap. 15. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 16. Install brake caliper using new bolts (Apply Loctite 242 (blue) to threads). Tighten bolts to specified torque. CAUTION Always use new brake caliper mounting bolts upon assembly. 12. Install wheel and wheel nuts and tighten evenly in a cross pattern to specified.
5.4 b. FRONT HUB BEARING REPLACEMENT 4X4 (ATV400-2 / ATV400-2B)

1. Remove outer snap ring. 2. Form the back side, tap on the outer bearing race with a drift punch in the relief as shown. 3. Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed. 4. Inspect bearing.
CHAPTER 5
FINAL DRIVE. 5-
CHAPTER 5 FINAL DRIVE NOTE: Due to extremely close tolerances

and minimal wear, the bearings must be inspected visually, and by feel. inspect for rough spots, discoloration, The bearings should turn smoothly and quietly, no detectable up and down movement and minimal movement sideways between inner and outer race. 5. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged.
5.5 FRONT DRIVE AXLE (INNER AND OUTER CV JOINT) REMAVAL/ INSPECTION (4X4)
NOTE The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Drive axle/ outer CV joint assembly. 2. Boot band A. 3. Outer board boot. 4. Boot band B. 5. Stopper ring 6. Outer CV joint * 7. Circlip 8. Bearing * 9. stopper ring 10. Inboard boot. NOTE: Always order and replace 6 and 8 together.

REMOVAL 1. Place the vehicle on level ground and set the parking brake, Block the rear wheels so the vehicle will not roll in either direction. 2. Remove the front wheels, steering tie rods, disconnect the A arm on the ball joint end as described in this Chapter and Chapter 4.
CAUTION
To avoid damage to the front differential oil seal, hold the front drive shaft horizontal and straight out from the front differential during removal. 3. Hold the drive shaft straight out. 4. Place a tire lever between the inner CV joint and the differential housing, with a small piece of wood against the housing to help get "leverage" and protect the casting. "pop" the in inner CV joint out from the front differential. INSPECTION NOTE The boots are subjected to a lot of abuse if the vehicle is ridden in rough terrain. If the boots are damage and left un-repaired, the driveshaft joints will fair prematurely by allowing the joint to be exposed to dirt, mud and moisture. This also allow the loss of critical lubrication. 1. Check the rubber boots for wear, cuts or damage and replace if necessary as described under the Disassembly / Assembly procedure in this chapter. 2. Move each end of the drive shaft in a circular motion (and also a reciprocate for inner one) and check the drive shaft joints for excessive wear or play. 3. This inner CV joint (inboard pivot joint) can be serviced if there is wear or play. The outer CV joint (outboard pivot joint) cannot be serviced if worn or damage and if necessary, the drive shaft assembly must be replaced.
CHAPTER 5
FINAL DRIVE. 5-
10
CHAPTER 5 FINAL DRIVE 5.6 FRONT DRIVE AXLE INSTALLATION (4X4) CAUTION
To avoid damage to the front differential oil seal and the strut oil seal, hold the front drive shaft horizontal and straight into the strut during installation. Hold the drive shaft straight in from the front differential. Push the drive shaft straight into the front differential and push it in all the way until it bottoms out. If necessary, carefully tap on the outer end of the drive shaft with a rubber mallet or soft-faced mallet. After the drive shaft is installed, pull the inner CV joint a little to make sure the drive shaft stopper ring has locked into the front differential side gear groove. Carefully install the outer CV joint (spindle) into the strut install the front hub and wheel. Install the ball joint on the A arm, the steering tie rods, the hubs and the wheels as described in this Chapter and Chapter 4.
1. 2.
3.
4.
5.
5.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION (4X4)

INNER CV JOINT DISASSEMBLY NOTE The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Open the clamps on both boot bandA and B the inner CV joint, then remove on boot bandB.Discard the boot band, it cannot be reused. 2. Carefully slide the boot (A) onto the drive axle and off the inboard joint. 3. Wipe out all of the molybdenum disulfide grease within the inboard joint cavity. 4. Remove the stopper ring from the inboard joint.
Remove the stopper ring


5. Remove the inner CV joint. 6. Remove the circlip and slide off the bearing assembly. Be careful not to drop any of the steel balls from the bearing cage. 7. slide the inner CV off the drive axle and discard the boot bandA cannot be it reused. 8. If the outboard boot requires replacement, perform the following: a. Open the clamps on both boot bands AandB on the outer CV joint, then remove boot bandB.Discard the boot band, it cannot be reused. b. Slide the outboard boot off the drive axle and discard the boot bandA, it cannot be reused. 9. Inspect the drive axle as described in this chapter. INNER CV JOINT INSPECTION 1. Clean the bearing assembly in solvent and thoroughly dry. 2. Inspect the steel balls, bearing case and the bearing race for wear or damage. 3. Check for wear or damage to the inner splines of the bearing race. 4. If necessary, disassembly the bearing assembly for further inspection. Carefully remove the steel balls from the bearing cage then remove the bearing race from the bearing cage. 5. If any of the components of the bearing assembly are damaged, replace the entire assembly as no replacement parts are available. 6. Clean the inner CV joint in solvent and thoroughly dry. 7. Inspect the interior of the inboard joint where the steel balls ride. Check for wear or damage and replace the joint if necessary. 8. Inspect the snap ring groove on the inboard joint for wear or damage. 9. Inspect the splines on the inner CV joint
Inspect
groove
CHAPTER 5
FINAL DRIVE. 5-
12
for wear or damage. Check the movement of the joint 10. Check the stopper ring in the end of the inboard joint. Make sure it seats in the groove correctly, if damage the ring must be replaced. 11. Inspect the exterior of the inner CV joint for cracks or damage, replace if necessary. Check the movement of the joint for excessive play or noise by moving the drive axle in a circular and reciprocate direction. 12. Inspect the drive axle for bending, wear or damage. 13. Inspect the inner end splines, the outer end splines and the front hub cotter pin hole for wear or damage. If any of these areas are worn or damaged, replace the drive axle. NOTE. Inner CV joint must be replaced with the bearing as an assembly.
5.8 FRONT DRIVE AXLE ASSEMBLY (4X4)

1. The rubber boots are not identical and must be installed on the correct joint. The boots are marked as follows: a. Inner CV joint boot : inner, b. Outer CV joint boot: outer. 2. IF the outboard boot was removed, install a new boot onto the drive axle at this time.
NOTE
Position the new boot bands with their tabs facing toward the rear of the vehicle. 3. Install 2 new small boot bands onto the drive axle. 4. Install the inboard boot and move the small boot band onto the boot. Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer. Make sure they are locked in place. 5. If the bearing assembly was disassembled, assemble the bearing as follows:

a. Position the bearing race and install the race into the bearing case. Align the steel ball receptacles in both parts. b. Install the steel balls into their receptacles in the bearing case. c. Pack the bearing assembly with molybdenum disulfide grease. This will help hold the steel balls in place. 6. Position the bearing assembly with the small end of the bearing going on first and install the bearing onto the drive axle. 7. Push the bearing assembly on until it stops, then install the circlip, Make sure the circlip seats correctly in the drive axle groove. 8. Apply a liberal amount of molybdenum disulfide grease to the bearing assembly. Work the grease in between the balls, the race and the case. Make sure all voids are filled with grease. 9. Apply a liberal amount of molybdenum disulfide grease to the inner surfaces of the inboard joint. 10. Install the inboard joint over the bearing assembly and install the stopper ring. Make sure it is seated correctly in the inboard joint groove. 11. After the stopper ring is in place, fill the inboard joint cavity behind the bearing assembly with additional molybdenum disulfide grease. 12. Pack each boot with the following amounts of molybdenum disulfide grease: a. Inboard boot:35-55grams(1.2-1.9oz.). b. Outboard boot:30-50grams(1.1-1.8oz.). 13. Move the inboard boot onto the inner CV joint. 14. Move the inboard joint on the drive axle.
NOTE
Position the new boot bands with their tabs facing toward the rear of the

vehicle . 15. Move the small boot band onto the boot. Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer. Make sure they are locked in place. 16. Install the large boot bands onto each boot.
CAUTION
It is critical to avoid undue stress on the rubber boots after the drive axle is installed and the vehicle is run. Dont twist the boot, and always set the both ends in designed position. 17. Secure all large boot bands. Bend down the tab on the boot band and secure the tab with the locking clip and tap them with a plastic hammer. Make sure they are locked in place. 18. If removed, install the stopper ring and make sure it is seated correctly in the drive axle groove. 19. Apply molybdenum disulfide grease to the end splines.
5.9 REAR HUB INSPECTION

1. Support machine securely with rear wheels elevated. 2. Grasp wheel/hub and check for movement. 3. If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary.
5.10
REAR
AXLE
R E M O VA L ( E X C E P T AT V 4 0 0 - 2 / AT V 4 0 0 - 2 B )
1. Lock the parking brake. Remove rear axle cap.

2. Remove cotter pin. 3. Loosen- but do not remove- the hub retaining nut. 4. Loosen- but do not remove- the wheel nuts. 5. Safely support the rear of the ATV.
CAUTION
7. Serious injury could occur if machine tips or falls. 8. Remove wheels. 9. Remove hubs. 10. Remove brake hose clamp and brake shield(s). 11. Remove rear brake caliper(s) and support it from machine frame. 12. Remove rear brake disc(s). 13. Remove skid plate(s). 14. Remove left swing arm asm bolts. 15. Remove axle tube(s) bolts from rear gear case(and remove the right side tube). 16. Slide axle through rear gearcase to the right enough to allow the axle tube to slip off between axle and swing arm asm. 17. Remove ring retainer(the hog ring) and spacer(collar) from axle. 18. Slide axle through the gear case and remove from vehicle. 19. Remove o-ring seals from both sides of gear case and discard.
5.11 REAR AXLE INSTALLATION

1. Grease and install new o - rings on rear gearcase. 2. Slide axle through rear gearcase until ring retainer groove is accessible to the left of gearcase. 3. Install new hog ring and retainer. NOTE Retainer (Spacer) should enclose stopper ring (hog ring). 4. Slide axle tube assembly over axle shaft

until it engages the swing arm asm . 5. Install new axle tube bolts loosely. 6. Install left swing arm asm bolts and torque to 59-67 ft. lbs ( 80-90Nm). 7. Torque axle tube bolts in a cross pattern to 60 ft. lbs( 80 Nm). 8. Re- install skid plate and torque bolts to 25 ft.lbs (34Nm). Install new greased o - ring on axle and slide brake disc on splines of the axle. Install brake caliper on brake disc and torque bolts to 20 ft.lbs( 25 Nm) . Anchor the brake hoses to the swing arm asm using the hold down clamp. Install wheel hub, large flat washer. Install cone nuts with domed side facing outward. Torque axle nut and wheel nuts. Install a new cotter pin. Tighten nut slightly to align holes if required. Install hub cap. Rear Hub Nut Torque: 80 ft.lbs.(110.6Nm) Rear Wheel Nut Torque: 50 ft.lbs.(69Nm)
5.12 REAR AXLE BEARING REMOVAL

1. 2. 3. 4. Remove the axle tube from the machine. Remove outer axle seal and discard Remove outer bearing and spacer. Remove inner bearing retaining ring and inner bearing.
5.13 REAR AXLE BEARING INSTALLATION

1. Clean bearing surface on axle tube and

install new bearing (s), retaining ring and seals reversing steps of rear axle bearing removal.. 2. Torque brake caliper, rear hub nut, and rear wheel nuts to specifications.
5.14 REAR GEARCASE DISASSEMBLY

1. Drain and properly dispose of used oil. 2. Remove bolts and output shaft cover. 3. Remove ring gear assembly from the act put cover. 4. Remove ring gear bearing shim from the cover and retain for re-assembly. 5. Remove and discard the output cover seal and O- ring. 6. Remove input cover and O- ring. Remove pinion shaft assembly. Inspect pinion gear for chipped, broken or missing teeth .Replace assembly if necessary.
5.15 REAR GEARCASE ASSEMBLY

1. Replace all O-rings, seals, and worn
components. 2. Press pinion shaft seal into input cover until flush with sealing surface. 3. Inspect pinion shaft bushing. 4. Inspect bearings on rear axle and pinion shafts. To replace, press new bearing on to. NOTE Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for

rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side . 5. Clean pinion shaft and snap ring and apply Loctite 242 to threads. Tighten lock nut to specification. 6. Install pinion shaft and input cover plate with new o- ring and torque bolts to 14 ft. lbs. Cover Bolts Torque 14ft.lbs.(20 Nm) 7. Install ring gear assembly NOTE The same shim thickness placed behind ring gear bearing must also be put behind the cover button. 8. Install out put cover with new o- ring and torque bolts to 14 ft. lbs. Cover Bolts Torque 14ft.lbs.(20Nm) REAR GEARCASE EXPLODED VIEW
CHAPTER 5
FINAL DRIVE. 5-
19
5.16 FRONT GEARCASE SLIP LIMIT TORQUE TEST

CAUTION: Slip limit torque relate to the preload on the differential (see 5.20 FRONT DIFFRENTIAL ASSEMBLY), and affect the Steering Effort (heavy steering). Always field test the ATV carefully and thoroughly after front gearcase and differential service for vehicle maneuvers and operation. Mount the front gear case assembly to Torque Test Jig. The input shaft must be firmly held by the jig, and measure one side output shaft by turning with a torque gauge until another side start to spin counter wise. Slip torque: 35---45N.m for Europe 45---55N.m for USA Note: It is recommended to replace the FRONT DIFFRENTIAL as an assembly when out of specification.
CHAPTER 5
FINAL DRIVE. 5-
20
5.17 FRONT GEARCASE DISASSEMBLY/ INSPECTION

1. Drain and properly dispose of used oil. 2. Remove bolts and selector cover..
3. Remove screws and selector switch from the selector cover. 4. Remove bolt, washer, spring and detent ball from the selector cover.
5. Remove seal, washers, circlip and selector shaft assembly from the selector cover.
6. Remove bolts and diff case cover. 7. Remove pins, gear and selector rail.
CHAPTER 5
FINAL DRIVE. 5-
21
8. Remove selector fork, splined dog and input shaft.
9. Remove bearing and seal.
gear, screws, pinion shaft retainer plate and pinion shaft.
10. Remove
11.
Remove seal from the case.
CHAPTER 5
FINAL DRIVE. 5-
22

12. Remove bolts, left cover and differential.
Differential
13. Remove seal from left cover.
14. Clean all components and inspect for wear. Inspect gears for wear, cracks, chips or broken teeth. Inspect engagement dogs and detent ball housing, replace if edges are rounded. Inspect casting for crack. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. Inspect detent spring and finger spring for wear, cracks, relaxation. Replace part with any defects.
IMPORTANT: New seals should be installed after the transmission is completely assembled.
CHAPTER 5
FINAL DRIVE. 5-
23
CHAPTER 5 FINAL DRIVE 5.18 FRONT GEARCASE ASSEMBLY

1. Install pinion shaft with bearing. 2. Install retainer plate with flat side toward bearing and torque screws. Apply LoctiteTM 243(Blue) to screw threads and torque screws to 8ft.lbs. (12Nm) 3. Install gear.
4. Install oil seal.
IMPORTANT: New seals should be

installed after the transmission is completely assembled.
5. Install input shaft, splined dog, selector fork. 6. Install selector rail, gear and pins.
518 to mating surfaces, reinstall cover and torque bolts. 8ft.lbs. (12Nm)
7. Apply LocTite
TM
8. Install selector shaft assembly, washers, circlip, and new seal into the selector cover. 9. Install detent ball, spring, washer and bolt. 10. Install selector switch with new O-ring and screws. 11. Apply LocTiteTM 518 to mating surfaces, reinstall selector cover and torque bolts.

8ft.lbs. (12Nm)
12. Install differential into case.,
Apply LocTiteTM 518 to mating surfaces, reinstall left cover and torque bolts. 14ft.lbs. (20Nm) 13. Install new seals.
5.19 FRONT DIFFRENTIAL DISASSEMBLY/ INSPECTION

1. Remove bolts and bevel crownwheel.
2. 3.
Remove bolts and differential cap A. Remove spring seat, springs, outer single clutch plate, differential plat, outer double clutch plate, bevel gear and gear axle washer.
CHAPTER 5
FINAL DRIVE. 5-
25

4. Remove bolts and differential cap B.
5. Remove spring seat, springs, outer single clutch plate, differential plat, outer double clutch plate, bevel gear and gear axle washer.
CHAPTER 5
FINAL DRIVE. 5-
26

6. Remove roll pin from center pin. 7. Remove center pin, bevel pinion washers, bevel pinions and center spacer from differential housing.
8 Clean all components and inspect for wear. Inspect gears for wear, cracks, chips or broken teeth. Inspect inner and outer splines on the spider gears and friction plates, replace if edges are rounded. Inspect casting for crack. Inspect axletree for smooth operation, check for excessive play between inner and outer race. Inspect dish spring for wear, cracks, relaxation. Replace part with any defects.
5.20 FRONT DIFFRENTIAL ASSEMBLY

1. Install center pin, bevel pinion washers,
bevel pinions and differential housing.
center
spacer
into
CHAPTER 5
FINAL DRIVE. 5-
27

2. Install bevel gear, gear axle washer, outer
double clutch plate ,differential plate, outer single clutch plate, springs, spring seat.
3. Install differential cap A.
4. Check the preload clearance. Clearance: 1.21.5mm Out of specification change spring seat, spring, .replace clutch plate as necessary,
CHAPTER 5
FINAL DRIVE. 5-
28

5. Install bevel crownwheel, Apply LoctiteTM 271 red to screw threads and torque bolts to 24ft.lbs. (32Nm)
6. Install bevel gear, gear axle washer, outer double clutch plate, differential plate, outer single clutch plate, springs, spring seat.
7. Install differential cap B.
8. Check the preload clearance. Clearance: 1.21.5mm Out of specification change spring seat, spring, .replace clutch plate as necessary, 9. Apply LoctiteTM 271(red) to screw threads and torque bolts to 16ft.lbs. (22Nm) CAUTION: Slip limit torque relate to the preload clearance on the differential, and affect the Steering Effort (heavy steering). Always field test the ATV carefully and thoroughly after front gearcase and differential service for vehicle maneuvers and operation.

FRONT GEARCASE EXPLODED VIEW
TROUBLE SHOOTING Symptom: Gears wont stay in position when shift 2WD/ 4WD. Solution: Increase the preload to indent ball by turning the grub screw or change a new spring. Note: Make sure not to over press the spring by shifting 2WD/ 4WD. Remember to tighten the jam nut on the grub screw.
CHAPTER 5
FINAL DRIVE. 5-
30

DIFFERENTIAL CENTRE EXPLODED VIEW
5.21 REAR, FRONT PROP SHAFT REMOVAL

Using roll pin remover, remove the roll pin from prop shaft
Slide the prop shaft back and away from the gear case. (The swing arm must be disassembly from the frame before the rear prop shaft removal).
CHAPTER 5
FINAL DRIVE. 5-
31
CHAPTER 5 FINAL DRIVE NOTES
CHAPTER 5
FINAL DRIVE. 5-
32
CHAPTER 6 TRANSMISSION
ATV
SERVICE MANUAL 09.0
CHAPTER 6
TRANSMISSION
ATV 260/300/400-2 and B-Type 260/300/400-2B

( P L E A S E S E E C H A R P T E R 3 B I N T H I S M AN U A L F O R T H E T R A N S M I S S I O N O F Y O U T H / M I N I AT V 5 0 / 8 0 , C H A R P T E R 3 C F O R M I N I AT V 1 0 0 / 1 5 0 A N D B - T Y P E 1 5 0 / 2 0 0 . )
6.1 GEAR SHIFTER REMOVAL 6.2 GEAR SHIFTER DISASSEMBLY 6.3 GEAR SHIFTER ASSEM BLY 6.4 GEAR SHIFTER INSTALL ATION 6.5 SHIFT LINKAGE ADJUSTMENT 6.6 ENGINE ANDTRANSMISSION REMOVAL 6.7 ENGINE AND TRANSMSSION INSTALL ATION 6.8 TRANSMISSION DISASSEMBLY 6.9 TRANSMISSION ASSEMBLY 6.10 TROUBLE SHOOTING CHECKLIST
CHAPTER 6
TRANSMISSION
PAGE. 6-
CHAPTER 6 TRANSMISSION 6.1 SHIFTER REMOVAL

1. Remove parts that interfere with access to shift selector (seat, right side panel etc.). 2. Disconnect the two linkage rods from gear shift selector slides. 3. Remove five bolts attaching gear shift selector to the mounting bracket. 4. Lift gear selector out of mounting bracket and away from frame.
ATV
SERVICE MANUAL 09.0
6.2 SHIFTER DISASSEMBLY CAUTION

Wear eye protection during this procedure. Read each step completely before proceeding .Essential parts maybe lost or damaged if you do not heed this caution! 1. Clamp shifter housing lightly in a soft jawed vice. Using a cross pattern, loosen each of the four screw s holding the cover to the shifter housing. Loosen each screw only a few turns, then proceed to another screw.
NOTE: These parts are under pressure from

the internal springs. 2. Carefully pull the cover and shift lever from the shifter housing. 3. Set the shift cover lever assembly aside. 4. Remove the three springs from shifter housing.
NOTE: Do not tip shifter housing upside

down or detent bullets and stop pin may fall out. Check for signs of moisture in the shifter housing. Inspect shift boot closely if moisture is present in selector box. 6. Tap shifter housing, top down, against a hard, smooth, flat surface to jar the dowel pin and two detent bullets loose. Pulte
CHAPTER 6 TRANSMISSION PAGE. 62
detent bullets and the dowel pin out of the shifter housing . 7. Remove the two slides, one at a time.
ATV
SERVICE MANUAL 09.0
NOTE: The LH (low ) slide has two short

notches and the R H (high/rev) slide has one short and one long notch. The slides must be replaced in the proper channels. 8. Inspect O-rings for damage. Replace if any damage is found. 9. Flush housing with parts washer fluid or penetrating oil to remove all moisture. 10. Dry all parts and remove any corrosion with a wire brush.
6.3 SHIFTER ASSEMBLY

1. Grease and insert slides into shifter housing, taking care not to cut or tear O-ring in the process.
NOTE: The LH slide has two short notches

and the R H side has one short and one long notch. The slides must be replaced in the proper channels for the shifter to function properly. 2. Replace detent bullets, dowel pin, and springs by reversing steps 5-7 of shift rod Disassembly. 3. Clamp shifter housing lightly in a soft jawed vise. 4. Apply grease to notches and the slides. 5. Carefully reattach shift cover lever assembly to shifter housing. Make sure slides are in neutral, or parts may be damaged. 6. Torque cover screws to 12 ft. lbs. (16Nm). 7If re-install the knob, apply LoctiteTM 406 and screw the knob in the lever firmly, install the gear shifter on the ATV. Put a new sticker on the knob in correct direction.
NOTE: If moisture or corrosion is found in the

shift rod the boot should be replaced.
ATV
SERVICE MANUAL 09.0
6.4 SHIFTER INSTALL ATION
1.
Place shift rod back into the mounting bracket and replace five bolts. 2. Reconnect linkage rods to shift rod slides. Adjust as required. See linkage adjustment procedures. 3. Replace remaining parts.
6.5 SHIFT LINKAGE ADJUSTMENT

Linkage rod adjustment is necessary when symptoms include: Noise on deceleration Inability to engage a gear Excessive gear clash(noise) Shift selectors moving out of desired range
NOTE: When adjusting linkage, always

adjust both linkage rods. The adjustment of one rod can prevent proper adjustment of the other rod. Remove necessary components to gain access to shift linkage rod ends. 1. Inspect shift linkage tie rod ends, and pivot bushings and replace if worn or damaged. Lubricate the tie rod ends with a light aerosol lubricant or grease. 2. Loosen all rod end adjuster jam nuts. 3. Note orientation of tie rod end studs with stud up or down. Remove both rod end studs from transmission bell cranks. 4. Be sure idle speed is adjusted properly.
NOTE: It is important to disconnect both rod

ends from the transmission bell cranks. If one linkage rod is incorrectly adjusted, it can affect the adjustment of the other rod. 5. Place gear selector in neutral. Make sure the transmission bell cranks are engaged in the neutral position detents. 6. Be sure the shift linkage rod ends are firmly
attached to the gear selector slides. Adjust the low range (inside) rod so the rod end is centered on the transmission bell crank. Mark for counter Install the lock nut to the rod end and torque to 35 in.lbs ( 4 Nm). 7. Rotate the linkage rod clockwise unit resistance is felt. Mark the rod so revolutions can be easily counter. 8. Rotate the linkage rod counterclockwise unit the same resistance is felt, counting the revolutions as the rod is turned. 9. Turn the rod clockwise again one half of the revolutions counted in Step 8. 10. Tighten the rod end jam nuts securely while holding the rod end. The jam nuts must be tightened with both front and rear rod ends parallel to each other. If jam nuts are properly tightened, the rod should rotate freely 1/4 turn without binding. 11. Repeat steps 7-10 for the High/Reverse rod.
ATV
SERVICE MANUAL 09.0
6.6 ENGINE AND TRANSMISSION REMOVAL
1. Switch fuel valve to "OFF". 2. Remove seat, rack(s ), plastic body work, air box and exhaust system . 3. Remove CTV outer cover, drive and driven clutches, feed and return hoses ( refer to Engine chapters). 4. Remove shift rods. 5. Remove throttle cable wire connected to carburetor. 6. Disconnect engine from wiring harness completely. 7. Disconnect gear position indicator switches. 8. Remove fuel line connected to carburetor and drain line.
9. Loose all bolts on the brackets which

connect the engine/ transmission between 2 brackets the frame, except the 2 brackets between transmission the engine and transmission and left them on the transmission. See picture.
ATV
SERVICE MANUAL 09.0
between
the
engine
and
10. Remove right and left side engine mount bolts, and remove engine from engine stay.
11. Remove front drive shaft (4WD, see chapter 5). 12. Remove lower left bracket, rear bracket and right mount bolts .(M 10x1.25x70 ) 13. Remove transmission from frame and remove drive shaft.
6.7 ENGINE AND TRANSMSSION INSTALL

Transmission 1. Position transmission in frame, Align rear drive shaft and slide shaft into the yoke. 2. Install all brackets, loosely install new fasteners. 3. Tighten fasteners in right -left rear order. NOTE: While tightening, it is important to turn the rear drive shaft by hand to check the position of transmission. If the rear drive axle can not turn freely, it is necessary to loose (but not remove) the fasteners to re-position the transmission by tightening the fasteners in
different order. Transmission Mounting Bolts Torque: 25 ft. lbs. (35 Nm ). 4. Drive in a new roll pin. Engine 5. Position Engine in frame, Install all brackets, loosely install new fasteners, but not tighten fasteners. 6. Make sure those spacers are in correct position. 7. Install rear inside cover components on transmission (in new model there is no removable rear inside cover). 8. Link engine and transmission together with engine mount jig, (center distance of engine shaft and transmission main shaft is 252 mm and distance of side surface and shaft shoulder 62 .5 mm)
ATV
SERVICE MANUAL 09.0
9. Tighten engine mounting fasteners in top-to bottom order. 10. Remove jig. 14. Install both drive and driven clutches and outer CVT cover. Engine Mounting Bolts Torque: 25 ft. lbs. (35 N.m).
CHAPTER 6
TRANSMISSION
PAGE. 6-
CHAPTER 6 TRANSMISSION 6.8 TRANSMISSION DISASSEMBLY

1. Place gears in neutral.
ATV
SERVICE MANUAL 09.0
2. Remove gear position indicator switches.
IMPORTANT: The gear position indicator

switches must be removed prior to disassembly. 3. Remove the transmission cover bolts. 4. Carefully remove the cover with a soft face hammer tap on the cover bosses. 5. Remove bearing and helical gear.
6. Remove input shaft, reverse shaft, and both shift fork shafts as an assembly.
7. Remove pinion shaft retainer plate and pinion shaft.
CHAPTER 6
TRANSMISSION
PAGE. 6-
ATV
SERVICE MANUAL 09.0
8. Remove front drive output housing cover screws. Carefully remove the cover with a soft face hammer tap on the cover bosses.
9. Note position of shim washers and thrust button. 10. Remove shafts as an assembly. 11. Clean all components and inspect for wear. 12. Inspect engagement dogs of gears and replace if edges are rounded. 13. Inspect gear teeth for wear, cracks, chips or broken teeth. 14 . Remove seals from transmission case.
IMPORTANT: New seals should be installed

after the transmission is completely assembled. 15. Inspect bearings for smooth operation. Check for excessive play between inner and outer race.
CHAPTER 6
TRANSMISSION
PAGE. 6-
CHAPTER 6 TRANSMISSION 6.9 TRANSMISSION ASSEMBLY

1. Install sprocket on front output shaft with sprocket step side inward as shown (only for 4X4).
ATV
SERVICE MANUAL 09.0
2. Assemble front ( only for 4X4).and rear output shafts
3. a. (4X4) Install front and rear output shafts with chain as an assembly. 3b. (2X4) Install rear output shaft.
4. Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply silicon glue to mating surfaces. 5. Reinstall cover and torque bolts in a crisscross pattern in 3 steps to 14 ft. lbs. (20 Nm).
6. Install new front ( only for 4X4) and rear output shaft seals.
ATV
SERVICE MANUAL 09.0
7. Install pinion shaft with bearing .
8. Install retainer plate with flat side toward bearing. 9. Apply LoctiteTM 242(Blue) to screw threads and torque screws to 8 ft-lb. (12Nm).
10. Assemble shafts with chain and shift forks.
11. Carefully install high/reverse shaft assembly and gear cluster as a unit into their respective bearing case areas. Tap with a soft face hammer to seat shaft assemblies.
NOTE: Make sure shift shaft pins are

properly positioned in the slot on selector arms.
NOTE: Be sure gear indicator switch(es)

are removed from transmission case before installing shafts. 12. Install output shaft and gear assembly
along with sprocket and chain. 13.Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon to mating surfaces. 14. Reinstall main cover and torque bolts in a cross pattern in 3 step to 14 ft.lbs. (20Nm). 15. Install new input shaft seal. 16. Install drain plug with a new sealing washer. Torque drain plug to 14 ft.lb. (19Nm). 17. Install transmission and add 80W/90 oil in the recommended amount. Refer to Maintenance Chapter. 18. Install gear indicator switches. Apply LoctiteTM 242 (blue) to threads of switch screws and torque to 13-16 in. lbs. (1.5-1.9 Nm).
ATV
SERVICE MANUAL 09.0
6.10 TROUBLE SHOOTING CHECKLIST

Check the following items when shifting difficulty is encountered Idle speed adjustment Transmission oil type/quality Driven clutch (CVT) deflection Loose fasteners on rod ends Loose fasteners on gear shift box Worn rod ends, clevis pins, or pivot arm bushings Linkage rod adjustment and rod end positioning Shift selector rail travel *Worn, broken or damaged internal transmission components Check the following items when transmission locked Gear shifter malfunction (Selector lever end come out from slides notches), engage the Hi and Lo Gear at the same time. *NOTE : To determine if shifting difficulty or problem is caused by an internal transmission problem , isolate the transmission by disconnecting linkage rods from transmission bell cranks . Manually select each gear range at the transmission bell crank, and test ride vehicle. If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
2X4 TRANSMISSION EXPLODED VIEW
ATV
SERVICE MANUAL 09.0
CHAPTER 6
TRANSMISSION
PAGE. 6-
13
4X4 TRANSMISSION EXPLODED VIEW
ATV
SERVICE MANUAL 09.0
CHAPTER 6
TRANSMISSION
PAGE. 6-
14
CHAPTER 6 TRANSMISSION NOTES
ATV
SERVICE MANUAL 09.0
CHAPTER 6
TRANSMISSION
PAGE. 6-
15
CHAPTER 7 BRAKES
CHAPTER 7 BRAKES
NOTE Also See Chapter 2 for Maintenance Information. See Chapter 4B for Assembling information about Drum Brake of Youth/ Mini.ATV. 7.1 SPECIFICATIONS 7.2 TORQUE 7.3 BRAKE SYSTEM SERVICE NOTES 7.4 BURNISHING PROCEDURE 7.5 FLUID REPLACEMENT/BLEEDING PROCEDURE 7.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION 7.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION 7.8 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT 7.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION 7.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION 7.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION 7.12 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT
CHAPTER 7
BRAKES
PAGE. 7-
CHAPTER 7 BRAKES 7.1 SPECIFICATIONS

Item Brake Pad Friction material Thickness B rake Disc Thickness Brake Disc Thickness Variance Between Measurements Brake Disc Runout Item hydraulic Brake Pad Friction Hydraulic with material mechanics park Thickness mechanics park Brake Disc Thickness Brake Disc Thickness Variance Between Measurements Brake Disc Run out Front Brake Caliper Standard 0.157"/ 4mm 0.150- 0.164"/3.810- 4.166m m Rear Brake Caliper Standard 0.157"/ 4mm 0.236"/ 6mm 0.197"/ 5mm 0.177-0.187"/4.496-4.750m m -
Service Limit 0.04"/ 1mm 0.140"/3 .556m m 0.002 "/ .051m m 0.005 "/ .12 7m m Service Limit 0.04"/ 1mm 0.167"/4.242mm 0.002 "/ 0.051m m 0.005 "/ 0.12 7m m
7.2 TORQUE
Item Front Caliper Mounting Bolts Rear Caliper Mounting Bolts Master Cylinder Mounting Bolts Master Cylinder Reservoir Cover Bolts Hand Brake Hose Banjo Bolt Front Brake Disc Front Wheel Mounting Nuts Torque (ft. lbs. except where noted*) 18.0 18 .0 *55 in. lbs *5 in. lbs 15 .0 18 .0 20 .0 Torque (Nm ) 25 25 6.0 .6 21 25 27
7.3 BRAKE SYSTEM SERVICE NOTES

It is strongly recommended always change the caliper and (or) the master cylinder as an assembly. The parts inside maybe not interchangeable due to different brake manufactures and (or) different brake type. Do not over fill the master cylinder fluid reservoir. Make sure the brake lever and pedal returns freely and completely.
CHAPTER 7 BRAKES PAGE. 72
CHAPTER 7 BRAKES
Check and adjust master cylinder reservoir fluid level after pad service. Make sure atmospheric vent on reservoir is unobstructed. Adjust foot brake after pad service. Test for brake drag after any brake system service and investigate cause if brake drag is evident. Make sure caliper moves freely on guide pins (where applicable) . Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. Perform a brake burnishing procedure after install new pads to maximize service life.
7.4 BURNISHING PROCEDURE

Brake pads (both hydraulic and mechanical) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. 1. Choose an area large enough to safely accelerate the ATV to 50 km/h (30 mph ) and to brake to a stop. 2. Using hi gear, accelerate to 50 km/h (30 mph); then compress brake lever (pedal) to decelerate to 0-8km/h (5 mph). 3. Repeat procedure on each brake system 20 times until brake pads are burnished. (4. Adjust the mechanical parking brake (if necessary).) 5. Verify that the brake light illuminates when the hand lever is compressed or the brake pedal is depressed. WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury.
7.5 FLUID REPLACEMENT/BLEEDING PROCEDURE

NOTE : When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. CAUTION Always wear safety glasses. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV.
BRAKE BLEEDING-FLUID CHANGE

This procedure should be used to change fluid or bleed brakes during regular maintenance.
CHAPTER 7 BRAKES
1. Clean reservoir cover thoroughly. 2. Remove screws, cover and diaphragm from reservoir. 3. Inspect vent slots in cover and remove any debris or blockage. 4. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. NOTE: Do not remove brake lever when reservoir fluid level is low. 5. Add brake fluid up to the indicated MAX level on the reservoir. 6. Begin bleeding procedure with the caliper that is farthest from the m aster cylinder. Install a box end wrench on the caliper bleeder screw. Attach a clean, clear hose to the fitting and place the other end in a clean container. Be sure the hose fits tightly on the fitting. NOTE: Fluid may be forced from supply port when brake lever is pumped. Place diaphragm in reservoir to prevent spills. Do not install cover. DOT 3 Brake Fluid Reservoir Cover Torque 5 in. lbs. (.6 Nm ) 7. Slowly pump brake lever (D) until pressure builds and holds. 8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. NOTE: Do not release lever before bleeder screw is tight or air m ay be draw n into caliper. NOTE: In some versions of brake, there are 2 hydraulic circulates in one caliper for foot brake and hand brake. Make sure you bleed the right circulate. 9. Repeat procedure until clean fluid appears in bleeder hose and al air has been purged. Add fluid as necessary to maintain level in reservoir. CAUTION:
CHAPTER 7
BRAKES
PAGE. 7-
CHAPTER 7 BRAKES
Maintain at least 1/2 " (13mm of brake fluid in the reservoir to prevent air from entering the master cylinder. 10. Tighten bleeder screw securely and remove bleeder hose. 11. Repeat procedure steps 5- 9 for the remaining caliper (s). 12. Add brake fluid to MAX level on reservoir. Master Cylinder Fluid Level: MAX level or Sight glass must look dark, if sight glass is clear, fluid level is too low. 13. Install diaphragm, cover and screws. Tighten screws to specification. 14. Field test machine at low speed before putting into service. Check for proper braking action and lever reserve. With lever firmly applied, lever reserve should be no less than 1/2 " (13mm ) from handlebar. 15. Check brake system for fluid leaks and inspect al hoses and lines for wear or abrasion. Replace hose if w ear or abrasion is found.
7.6 HAND BRAKE MASTER CYLINDER REMOVAL/ INSPECTION /INSTALLATION

CAUTION: The master cylinder is a non-serviceable Component; it must be replaced as an assembly.
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BRAKES
PAGE. 7-
CHAPTER 7 BRAKES
NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction. REMOVAL 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Place a shop towel under brake hose connection at m aster cylinder. Loosen bolt, remove bolt and sealing washers. CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 3. Remove master cylinder from handlebars. INSPECTION Inspect parking brake for wear. If teeth or locking cam are worn, replace lever and test the parking performance, if any locking problem exists, Replace the master cylinder as an assembly. NOTE: Mechanics parking brake is equipped for new Europe model. INSTALLATION 1. Install master cylinder on handlebars. Torque mounting bolts to 55 in. lbs. (6 N m). NOTE: To speed up the brake bleeding procedure the m aster cylinder can be purged of air before brake hose is attached. Fill with DOT3 brake fluid and pump lever slowly two to three times with finger over the outlet end to purge master cylinder of air. 2. Place new sealing washers on each side of hand brake hose and torque bolt to specification. Master Cylinder Mounting Bolt Torque 55 in. lbs . (6 N m) Brake Line Banjo Bolt Torque 15 ft. lbs. (21 Nm ) 3. Fill reservoir with DOT 3 fluid. 4. Follow bleeding procedure, Check all connections for leaks and repair if necessary.
CHAPTER 7 BRAKES
7.7 FRONT PAD REMOVAL / INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support front of ATV safely. CAUT ION: Use care w hen supporting vehicle so that it does not tip or fall. Severe injury m ay occur if machine tips or falls. 2. Remove the front wheel. 3. Remove caliper from mounting bracket. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 6. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. INSPECTION Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Service Limit 0.3/64"(1 mm)
INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease. Front Caliper Mounting Bolts Torque 18 ft. lbs. (25 Nm ) 3. Install caliper on hub strut, and torque mounting bolts. 4. Slowly pump the brake lever until pressure
CHAPTER 7 BRAKES
has been built up. Maintain at least 1/2 ". (13 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counter clockwise). 6. Install reservoir cap. Hand and (or) Foot Brake Master Cylinder(s) Fluid Level: Between MIN and MAX lines 7. Install wheels and torque wheel nuts, test and burnish. See BURNISHING PROCEDURE
7.8 FRONT DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New0.150-0.164"(3.810-4.166mm) Service Lim it 0.140"/3 .556 mm Brake Disc Thickness Variance Service Limit 0.002 " (0.051mm) difference between measurements Brake Disc Runout Service Limit 0.005" (0.127 mm) REMOVAL/ REPLACEMENT 1. Removal caliper and hub. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent. 2. Remove bolts and disc. 3. Clean mating surface of disc and hub. 4. Install new disc on hub. 5. and tighten to specified. CAUTION: Always use new brake disc mounting bolts. Front Brake Disc Mounting Bolt Torque : 18 ft. lbs. (25 Nm )
CHAPTER 7 BRAKES
7.9 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION

CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction. REMOVAL 1. Remove wheel, remove caliper from the strut. 2. Loosen and remove brake hose(s) to caliper. Place a container under caliper to catch fluid draining. INSPECTION Inspect caliper body for nicks, scratches or worn. Replace caliper as an assembly if any problem exists. INSTALLATION 1. Install caliper on hub strut, Apply Loctite 242 to screw threads and Install new bolts. Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm ) 2. Install brake hose and tighten securely. NOTE: In some versions of brake, there are 2 hydraulic circulates (for foot brake and hand brake) in one caliper. Make sure you install the right hose. 3. Bleeding and Install wheels, If new brake pads are installed, burnishing procedure should be performed. See BURNISHING PROCEDURE, And field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation.
CHAPTER 7
BRAKES
PAGE. 7-
CHAPTER 7 BRAKES
7.10 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION

NOTE: The brake pads should be replaced as a set. REMOVAL and INSPECTION 1. Remove caliper mounting bolts and lift caliper off of disc. NOTE. When removing caliper, be careful not to damage brake hose . Support caliper so as not to kink or bend brake hose. 2. Push caliper pistons into caliper bore slowly with pads installed. NOTE: Brake fluid will be forced through compensating port into m aster cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 3. Remove brake pad retaining pin, and pad spacer. NOTE: Do not over spread this spring pin apart farther than necessary to remove it. 4. Clean. 5. Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Rear Brake Pad Service Limit 0.3/64"(1 mm) INSTALLATION 1. Install new pads in caliper body. Be sure to put spacer between pads. 2. Install caliper and torque mounting bolts. Brake Caliper Torque: 18 ft. lbs. (25 Nm ) 3. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2 " (13 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder. Hand and (or) Foot Brake Master Cylinder(s) Fluid Level: Between MIN and MAX lines 4. Install wheels, burnishing procedure should be performed. See BURNISHING PROCEDURE, And field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make
CHAPTER 7 BRAKES
sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation.
7.11 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION

CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the ATV manufacture via the agent for the parts and special instruction. 1Clean caliper area. 2Using a flare nut wrench, remove hose(s). Place a container to catch brake fluid draining from brake hose. 3. Remove caliper. 4. Remove brake pad as described above. 5. Inspect surface of caliper for nicks, scratches or damage and replace if necessary. 6. Install brake pads in caliper body with friction material facing each other, with the spacer between the pads. Install retaining pin through outer pad, pad spacer and inner pad. 7. Install caliper and torque mounting bolts. Caliper Mounting Bolt/ Caliper body Bolt Torque: 18 ft. lbs. (25 Nm) 8. Install brake hose and tighten to specified torque. Banjo Bolt Torque: 15 ft. lbs. (21 Nm) NOTE: In some versions of brake, there are 2 hydraulic circulates (for foot brake and hand brake) in one caliper. Make sure you install the right hose. 9. Bleed. 10. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when lever is released. If the brake drags, recheck assembly and installation.
CHAPTER 7
BRAKES
PAGE. 7-
11
CHAPTER 7 BRAKES
7.12 REAR BRAKE DISC INSPECTION / REMOVAL / REPLACEMENT

INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New0.177-0.187"(4.496-4.750mm) Service Lim it 0.167"(4.242 mm) Brake Disc Thickness Variance Service Limit 0.002 " (0.051mm) difference between measurements Brake Disc Runout Service Lim it 0.005" (0.127 mm) REMOVAL/ REPLACEMENT 1. Removal wheel/ hub and caliper. 2. Remove bolts and disc from the flange. 3. Clean mating surface of disc and hub. 4. Install new disc on flange. 5. Tighten to specified. CAUTION: Always use new brake disc mounting bolts. Rear Brake Disc Mounting Bolt Torque : 18 ft. lbs. (25 Nm )
7.13 FOOT BRAKE PEDAL FOR B-TYPE

ADJUSTING If the push rod joint is reinstalled, adjust the push rod length so that the distance between the centers of the master cylinder lower mounting bolt hole and joint pin hole is 831mm.After adjustment, tighten the joint nut.
CHAPTER 7
BRAKES
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12
CHAPTER 7 BRAKES NOTES
CHAPTER 7
BRAKES
PAGE. 7-
13
CHAPTER 8 ELECTRICAL
CHAPTER
8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14
ELECTRICAL
PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM COOLING SYSTEM LIGHTING SYSTEM REVERSE LIMIT SYSTEM GEAR POSITION INDICATOR SWITCH TEST SPEEDOMETER SYSTEM MAIN SWITCH AND HANDLE SWITCH FUEL GAUGE/ FUEL LEVEL SENSOR THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT WIRING DIAGRAM
CHAPTER 8 ELECTRICAL PAGE.8-
CHAPTER 8 ELECTRICAL 8.1 PARTS INSPECTION AND SERVICE
HEADLIGHT LAMP REPLACEMENT A. O5 model 1. Remove the cover 1 from the ATV. 2. Remove the bulb socket with the wire harness from the backside of the lens unit by turn the socket CCW. 3. Remove the bulb from the bulb socket carefully. 4. Replace the bulb with a new one (12V 35W/35W), Align the tab with the groove, locating it properly and securely. 5. Reinstall the bulb socket, Align the tab with the groove, locating it properly and securely. 6. Reinstall the cover. 7. Adjust the aim. B. Headlight on handlebar 1. Remove the front cover of the handlebar from the ATV. 2. Remove the bulb socket with the wire harness from the backside of the lens unit by turn the socket CCW. 3. Remove the bulb from the bulb socket carefully. 4. Replace the bulb with a new one (12V 35W/35W), Align the tab with the groove, locating it properly and securely. 5. Reinstall the bulb socket, Align the tab with the groove, locating it properly and securely. 6. Reinstall the cover. 7. Adjust the aim.
C. 04 and early model 1. Remove lens unit from the headlight. 2. Remove the bulb socket with the wire harness from the backside of the lens unit by turn the socket CCW. 3. Remove the bulb from the bulb socket carefully. 4. Replace the bulb with a new one (12V 35W/35W), Align the tab with the groove, locating it properly and securely. 5. Reinstall the bulb socket, Align the tab with the groove, locating it properly and securely. 6. Reinstall the cover. 7. Adjust the aim.
D. Special Edition Anniversary and B-Type /400ATV-2 1. Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip before dismounting the bulb. 3. Fit a new bulb into the socket, sitting properly in the three slots, install the clip as shown in the fig. and connect the cable plug to the conducting strip. 4. Change the bulb. E. ATV400-2B
1. Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip before dismounting the bulb. 3. Fit a new bulb into the socket, sitting properly in the three slots, install the clip as shown in the fig. and connect the cable plug to the conducting strip. 4. Change the bulb.
HEADLIGHT ADJUSTMENT 1. The headlight beam can be adjusted vertically (all models) and horizontally (except the light on handlebar). 2. Place the vehicle on a level surface with the headlight approximately 25(7.6m) from a wall. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 4. Start the engine and turn the headlight switch to high beam. 5. Observe headlight aim. The most intense part of the headlight beam should be aimed 2 (51mm) below the mark placed on the wall in step 2. NOTE : Riding weight must be included on the seat. 6. Loosen but not remove pivot bolt/ screw and adjust beam to desired position. 7. Tighten nut and bolt / screw.
Special Edition Anniversary and B-Type and 400ATV-2
To turn the two adjusting screws clockwise is to lower the beam. To turn the two adjusting screws counterclockwise is to heighten the beam.
TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recommended lamp. 3. Reinstall the lens cover removed in step 1. 4. Test the taillight / brake light.
INDICATOR LAMP REPLACEMENT 1. Disconnect light from harness, depress locking tabs and remove from pod. 2. Install new light and reassemble pod
8.2 BATTERY
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEER OUT OF REACH OF CHILDREN WARNING: The gases given off by a battery are explosive. Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. If battery acid gets on anyone, wash the affected area with large quantities of cool water and seek immediate medical attention. To ensure maximum service life and performance from a new battery, perform the following steps. NOTE: Do not service the battery unless it will be put into regular service within 30 days. After initial service, add only distilled water to the battery. Never add electrolyte after a battery has been in service. NOTE: New Battery must be fully charged before use. 1. Remove vent plug from vent fitting. 2. Fill battery with electrolyte to upper level marks on case. 3. Set battery aside and allow it to cool and stabilize for 30 minutes. 4. Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water. 5. Charge battery at 1 /10 of its amp /hour rating. Examples: 1 /10 of 14 amp battery = 1.4 amp; 1/10 of 7 amp battery = 0.7 amp (recommended charging rates). 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher.
CHAPTER 8 ELECTRICAL PAGE.85
BATTERY INSPECTION / REMOVAL The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid nears the lower level, the battery should be removed and distilled water should be added to the upper level line. To remove the battery: 1. Disconnect holder strap and remove cover. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. CAUTION Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstall the negative cable last! 3. Disconnect the vent hose. 4. Remove the battery. 5. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. To refill use only distilled water. Tap water contains minerals which are harmful to a battery. Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery. 5. Reinstall the battery caps. BATTERY INSTALLATION 1. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one cup water and one tablespoon baking soda. Rinse with clean water and dry thoroughly. 2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (- ) (black) cable. 3. Install clear battery vent tube from vehicle to battery vent. WARNING:Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. Vent should be routed away from frame and body to prevent contact with electrolyte. Avoid frame, corrosion will occur. 4. Route cables so they are tucked away in front and behind battery. 5. Reinstall battery cover and holder strap. Do not start the engine with the battery disconnected. Vehicle lamps will burn out if battery is disconnected during vehicle operation. Also, the reverse speed limiter can be damaged. BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first. Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test. MF (Maintenance Free) battery does not require the Specific Gravity Test and Refill Open Circuit Voltage Test Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require further battery testing and charging. NOTE: Lead acid batteries should be kept at or near a full charge as possible.
Load test CAUTION: Remove spark plug high tension leads and connect securely to engine ground before proceeding. NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly. A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage capacity necessary to properly function in the electrical system. For this reason, a battery capacity or load test should be conducted whenever poor battery performance is encountered. To perform this test, hook a multitester to the battery in the same manner as was done in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and view the registered battery voltage while cranking the engine. Continue the test for 15 seconds. During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery.
8.3 IGNITION SYSTEM

IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark Spark plug gap incorrect Fouled spark plug Faulty spark plug cap or poor connection to high tension lead Related wiring loose, disconnected, shorted, or corroded Engine stop switch or ignition switch faulty Terminal board or connections wet, corroded Poor ignition coil ground (e.g. coil mount loose or corroded) Faulty stator (measure resistance of all ignition related windings) Incorrect wiring (inspect color coding in connectors etc. ) Faulty ignition coil winding (measure resistance of primary and secondary) Worn magneto (RH) end crankshaft bearings Sheared flywheel key Flywheel loose or damaged Trigger coil air gap too wide (where applicable) should be 0.030-0 .050" (0. 75-1.25 mm) Excessive crankshaft run out on magneto (RH) end should not exceed 0.005" (0.13mm) Faulty CDI module
CIRCUIT DIAGRAM
IF THE IGNITION SYSTEM FAILS TO OPERATE
Procedure Check: 1. Fuse (Main) 2. Battery 3. Spark plug 4. lgnition spark gap 5. Spark plug cap resistance 6. Ignition coil
7.Pickup coil resistance 8.Main switch 9.Engine stop switch 10.Wiring connection (entire ignition system)
1.Fuse Check switches CONTINUITY 2. Battery Check the battery condition. Refer to INSPECTION" "BATTERY CORRECT 3.Spark plug Check the spark plug condition. Check the spark plug type. Check the spark plug gap.
NO CONTINUITY Replace the fuse.
INCORRECT Clean battery terminals. Recharge or replace the battery. Standard spark plug: DR8EA / NGK OUT OF SPECIFICATION Repair or replace the spark plug
Spark plug gap: 0.6 0.7mm *
* 4.lgnition spark gap Disconnect the spark plug cap from the spark plug Connect the ignition tester 1 as shown. 2 Spark plug Turn the main switch to "ON". Check the ignition spark gap . Check the spark by pushing the starter switch, and increase the spark gap until a misfire occurs.
MEETS SPECIFICATION The ignition system is not faulty.
Minimum spark gap: 6mm (0.24 in) OUT OF SPECIFICATION OR NO SPARK 5.Spark plug cap resistance Remover the spark plug cap. Connect the pocket tester (X1 k) to the spark plug cap. NOTE: When removing the spark plug cap. do not pull the spark plug cap from high tension cord. RemoveTurning counterclockwise ConnectTurning clockwise. Check the high tension cord when connecting the spark plug cap. When connecting the spark plug cap, cut the high tension cord about 5mm. Spark plug cap resistance: 5K(20 ) CORRECT *
Tester (+) lead Spark plug side Tester () lead High tension cord side
OUT OF SPECIFICATION Replace the spark plug cap
10
* 6. Ignition coil resistance Disconnect the ignition coil connector from the wire harness. Connect the pocket tester (1) to the ignition coil. Check if the primary coil has the specified resistance.
Tester (+) lead Pink Terminal Tester ( ) lead B/Y Terminal
Primary coil resistance: 3.6-4.8(20 ) Tester (+) lead Spark plug lead Tester ( ) lead Pink Terminal
Connect the pocket tester (1k ) to the ignition coil. Check the secondary has the specified resistance Secondary coil resistance: 10.7-14.5 K (20) BOTH MEET SPECIFICATION * Replace the ignition coil. OUT OF SPECIFICATION
11
* 7. Pickup coil resistance Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester ( 100) to the pickup coil coupler.
Tester (+) lead BI/Y Terminal Tester (- ) lead B/R Terminal Check the pickup coil has the specified resistance. Replace the pickup coil. Primary coil resistance: 168 -252 (20) MEETS SPECIFICATION 8.Main switch CHECK SWITCHES CONTINIUTY 9.Engine stop switch ( for USA model) CONTINIUTY 10.Wiring connection Check the connection of the entire ignition system Refer to CIRCUIT DIAGRAM. CORRECT Replace the igniter unit. POOR CONNECTIONS Correct NO CONTINUITY NO CONTINUITY Replace the main switch OUT OF SPECIFICATION
Replace the handlebar switch.
12
8.4 CHARGING SYSTEM

CHARGING SYSTEM CIRCUIT DIAGRAM
CURRENT DRAW
KEY OFF
CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off, if the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw. Current draw key off: Maximum of 0.01DCA(10mA)
CHAPTER 8 ELECTRICAL CTRICAL PAGE 8-
13
CHARGING SYSTEM Procedure Check: 1. Fuse (Main) 2. Battery 3.Charging voltage 1. fuse
4.Stator coil resistance 5.Wiring system (entire charging system)
NO CONTINUITY
Replace the fuse 2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" INCORRECT
Clean battery terminals Recharge or replace the battery 3.Charging voltage Connect the engine tachometer to the spark plug lead. Connect the pocket tester (DC20V) to the battery Test (+) lead Battery (+) terminal Tester (-) lead Battery (-) terminal Measure the battery terminal voltage. start the engine and accelerate to about 5,000rpm check the terminal voltage Measured voltage-terminal Voltage: 0.2-2.5V up NOTE: Use a fully changed battery.
MEETS SPECITICATION
The charging circuit is not faulty Replace the battery
OUT OF SPECICATION
14
4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (X1) to the stator coil Tester (+) lead yellow terminal Tester (-) lead yellow terminal Measure the stator coil resistance Stator coil resistance 0.5-0.820
OUT OF SPECITICATION
Replace the stator coil MEETS SPECIFICATION
5.Wiring connection check the entire charging system for connections Refer to CIRCUIT DIAGRAM
POOR CONNECTION
correct CORRECT
Replace the rectifier/regulator
15
CHAPTER 8 ELECTRICAL 8.5 ELECTRICS STARTING SYSTEM

DIAGRAM
16
TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 2. Battery 3. starter motor 4. starter relay 5. starting circuit cut-off relay 6. main switch 1. fuse refer to CHECKING section
7. Engine stop switch 8. front/rear brake switch 9. starter switch 10. wiring connection (entire starting system)
SWITCHES
NO CONTINUITY
Replace the fuse
2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" section in CHAPTER 3
INCORRECT
Clean battery terminals Recharge or replace the battery
3. Starter motor Connect the battery positive terminal and starter motor cable using a jumper lead. Check the starter motor operation
DOES NOT MOVE
Repair or replace the starter motor
17
4.Starter relay Disconnect the relay unit coupler from the wire harness. Connect the pocket tester (x1) and battery (12V) to the relay unit coupler terminals. Battery (+) lead Green/Yellow terminal Battery (-) lead Yellow/Red terminal Check the starter relay for continuity. Test (+) lead terminal Test (-) lead terminal
WARNING A wire used as a jumper lead must have the equivalent capacity as that of the battery lead or more, otherwise it may burn. This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity
CONTINUITY Replace the starter replay 5. .Starting circuit cut-off relay Disconnect the starting circuit cut-off relay coupler from the wireharness. Connect the pocket tester (x1) and battery (12V) to the starting circuit cut-off relay coupler terminals. Battery (+) lead terminal Battery (-) lead terminal Check the starting circuit cut-off relay for continuity. Test (+) lead terminal Test (-) lead terminal
Replace the cut-off relay
starting
circuit
18
6. Main switch CHECK SWITCHES
NO CONTINUITY
Replace the main switch 7. Engine stop switch NO CONTINUITY
Replace the handlebar switch
8 Front /rear brake switch CHECKING SWITCHES NO CONTINUITY
Replace the brake switch 9. Starter switch CHECKING SWITCHES NO CONTINUITY
Replace the handlebar switch 10. Wiring connection Check the connections of the entire starting system. Refer to CIRCUIT DIAGRAM Correct POOR CONNECTION
19
CHAPTER 8 ELECTRICAL 8.6 COOLING SYSTEM
IF THE FAN MOTOR FAILS TO TURN Procedure Check: 1. Fuse (Main, Fan) 2. Battery 3. Main switch
4. Fan motor (inspection) 5. Thermo switch 6. Wiring connection (entire cooling system)
20
1. fuse CHECK SWITCHES
NO CONTINUITY
Replace the fuse 2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" section INCORRECT
Clean battery terminals Recharge or replace the battery 3 Main switch CHECK SWITCHES NO CONTINUITY
Replace the main switch
4. Fan motor(inspection 1) Connect the battery to the fan motor. Battery (+) leadGreen/Blue terminal Battery (-) leadGreen ground Check the fan motor operation
DOES NOT MOVE
Replace fan motor 5. Fan motor (inspection 2) Turn the main switch to off. Remove the thermo switch lead from thermo switch. Connect jumper lead to thermo switch leads. Turn the main switch to on
DOES NOT MOVE
The wiring circuit from battery to fan motor is faulty. Repair
21
6. Thermo switch Remove the thermo switch from the radiator. Connect the pocket tester (X1) to the thermo switch . Immerse the thermo switch in the water Check the thermo switch for continuity. NOTE: Measure temperatures while heating the coolant with the temperature gauge
WARNING Handle the thermo switch with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. Do not touch the thermo switch to the bottom of the heated vessel. 883Thermo switch ON 80 Thermo switch OFF OUT OF SPECIFICATION
Replace the thermo switch
Wring connection Check the connection of the entire cooling system. Refer to CIRCUIT DIAGRAM
UPPER CONNECTION
Correct
22
IF THE HEAT ALARM UNIT WORKING When the main switch is turned on, the temperature of the engine begins to go up. As it comes to 883 the thermostat is connected and the fan starts to work, cooling the coolant, if the thermostat or the fan, fails to work; the coolant temperature will keep rising. The heat alarm unit operates the moment the temperature reaches 1155 with the buzzer sounding and the signal flashing. Stop the engine now to have the circuit fixed. Procedure Check: 1 .Fuse(Main, Fan) 4. Thermo unit 2. Battery 5. Voltage 3.Main switch 6. Wiring connection (entire cooling system) 1. fuse CHECKING SWITCHES NO CONTINUITY
Replace the fuse 2. Battery Check the battery condition. Refer to "BATTERY INSPECTION" INCORRECT
Clean battery terminals Recharge or replace the battery
3.Main switch CHECKING SWITCHES
NO CONTINUITY
Replace the main switch
23
4.Thermo unit Drain the coolant and remove the thermo unit from the cylinder head. Immerse the thermo unit in the coolant . Thermometer.
Handle the thermo unit with special care. Never subject it to strong shocks or allow it to be dropped. Should it be dropped, it must be replaced. Do not touch the thermo unit to the bottom of the heated vessel.
Coolant temperature 80 100
Resistance 47.5~56.8 26.2~29.3
OUT OF SPECIFICATION
Replace the thermo unit MEETS SPECIFICATION
Voltage Connect the pocket tester (DC20V) to the Temperature gauge couple. Tester (+) leadGreen/Blue terminal Tester (-) leadGreen ground Turn the main switch to on. Check for voltage (12V) on the temperature gauge lead.
8.
The wiring circuit from main switch to temperature gauge is faulty. Repair.
8.
Wiring connection check the connections of the entire cooling system. Refer to CIRCUIT DIAGRAM
POOR CONNECTION
CORRECT Replace the temperature gauge
24
CHAPTER 8 ELECTRICAL 8.7 LIGHTING SYSTEM
FOR USA MODEL
25
FOR EUROPE MODEL
26
TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 2. Battery 3. Main switch 1.fuse refer to section CHECKING SWITCHES
4.Lights switch 5.Dimmer switch 6. Wiring connection (entire lighting system) NO CONTINUITY
Replace the fuse 2. Battery Check the battery condition. Refer to BATTERY INSPECTION section in CHAPTER 3 INCORRECT
Clean battery terminals Recharge or replace the battery 3. Main switch NO CONTINUITY CHECK SWITCHES
Replace the main switch 4. Light switch CHECK SWITCHES NO CONTINUITY
Replace the right handlebar switch 5. Dimmer sw CHECK SWITCHES NO CONTINUITY
Replace switch
the
left
handlebar
27
6. Wiring connection Check the connection of the entire lighting system correct
POOR CONNECTIONS
7. check the condition of each of the lighting systems circuits Refer to LIGHTING SYSTEM CHECK LIGHT SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on NO CONTINUITY 1.Blub and bulb socket CHECK SWITCHES Replace the bulb and/ or bulb socket 2. Voltage Connect the pocket tester (DC20V) to the headlight and high beam indicator light couplers. A When the dimmer switch is on low beam. B When dimmer switch is on high beam Headlight:: Tester (+) lead White or Blue lead Tester negative (-) lead Green lead
Turn the main switch to on. Turn the light switch to on position. Turn the dimmer switch to low beam or high beam. Check for voltage (12V) on the lead at bulb socket connectors
This circuit is not faulty
The wiring circuit from the main switch to bulb socket connector is faulty. Repair
28
2. the taillight fails to come on 1. Bulb and bulb socket CHECK SWITCHES
NO CONTINUITY
Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the bulb socket connector. Tester (+) lead Black terminal Tester (-) lead Green terminal Turn the main switch to on. Turn the lights switch to on pilot position. Check the voltage (12V) on the bulb socket connector
The wiring circuit from main switch to bulb connector of faulty. Repair This circuit is not faulty
29
CHAPTER 8 ELECTRICAL 8.8 REVERSE LIMIT SYSTEM
The limit set for the speed limiter by the manufacturer is 13~15 km/h, which can be reset in accordance with the users practice. Turning the adjusting bolt clockwise is to increase the speed, while counterclockwise decrease it.
NOTE. This limit can be released by the override switch.
30
CHAPTER 8 ELECTRICAL 8.9 GEAR POSITION INDICATOR SWITCH TEST Switch table
31
CHAPTER 8 ELECTRICAL Switch schematic
32
CHAPTER 8 ELECTRICAL 8.10 SPEEDMETER SYSTEM
OPERATION OF SPPED SENSOR Speed Sensor is on the rear axle Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor A. B. Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack. Main Technical Parameter for sensor Item Code Vol value Unit Operating voltage Vcc 5-20 V Operating current Icc 15 mA Low voltage output Vol 0.4 V Hight voltage output Voh (Vcc-1) V Operating distance D 1mm D 2.5mm mm The following is the graphic illustration for sensor installation, Wire 1 (red) is positive and wire 2 (black) negative, Wire 3 (yellow) works as the one to output signals.
C.
Note: Always screw in the sensor by hand when installation or adjustment. 1, Align one tooth of the splines to the centre of the hole of the sensor by turning the rear axle. 2. Screw the senor in (CW) by hand slightly until resistance is felt. 3. Turn the sensor CCW by 1 to 2 turn(s). 4. Tighten the jam nut.
33
Speed Sensor on the Transmission Out Put Shaft. Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter Item Code Vol value Operating voltage Vcc 5-20 Operating current Icc 15 Operating distance D 1mmD8mm The following is the graphic illustration for sensor installation
Unit V mA mm
1. OIL SEAL 2. DOWEL PIN 3. MAGNET
4. THE COVER 5. THE HALL SENSOR
METER Dial Meter Item Operating voltage Operating current Operating Environmental temperature Battery warning voltage Vol value 10V~18V 500mA -10~65 11.5V Unit V A V
34
LCD Meter
1. Neutral indicator light 2. High beam indicator light 3. Turn indicator light 4. Reverse indicator light 5. Speedometer 6. Coolant temperature meter*
7. Engine rpm meter 89. The odometer 10.Engine working hour counter 11. 2WD/4WD indicator* A: km/ mile selector B: hour / distance selector 12. Fuel gauge Indicator
8.11 MAIN SWITCH AND HANDLE SWITCH
35
HANDLE SWITCH SCHEMATIC FOR USA MODEL 2004 model
2005 model
HANDLE
SWITCH
SCHEMATIC
FOR
EUROPE
MODEL
36
400ATV-2 / 400ATV-2B HANDLE SWITCH SCHEMATIC FOR USA
MODEL
400ATV-2 / 400ATV-2B
HANDLE SWITCH
SCHEMATIC
FOR
EUROPE
MODEL
37
CHAPTER 8 ELECTRICAL 8.12 FUEL GAUGE/ FUEL LEVEL SENSOR

Removal Turn the ignition switch toOFF. Remove the fuel tank cover. Remove the three bolts, retaining plate and fuel level sensor from the fuel tank.
Installation Install a new seal rubber onto the fuel level sensor. Install the retainer plate onto the sensor by aligning the tab with the grove.
Install the sensor into the fuel tank while aligning the grove in the plate with the boss on the fuel tank. Install and tighten the bolts securely. Install the removed parts in the reverse order of removal.
Fuel Gauge / Fuel level Sensor Inspection Move the float to the bottom (RESERVE) position, turn the ignition switch toONand check the fuel gauge.
38
SegmentRESshould blink.
With the fuel level sensor float at the top (FULL) position, turn the ignition switch to ON and check the fuel gauge. All segments up to segment Fshould come on.
If the fuel gauge does not function properly, check the fuel level sensor If the fuel level sensor is OK, replace the LCD Meter. RESISTANCE(20/ 68) 4-10 100-110
Fuel level Sensor Inspection Disconnect the fuel level sensor 2p Green connector and connect the ohmmeter to the sensor side connector terminals. Measure the fuel level sensor resistance with the float at the top (FULL) And bottom (RESERVE) positions.
FLOAT POSITION TOP(FULL) BOTTOM(RESERVE)
39
8.13 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT
(Fig 1) 1, The rider shifts 2WD to 4WD by the Switch on handlebar. 2. The Switch gives signal to Controller. 3, The controller gives power to the Shift Motor. 4, If the Splined Dog (Fig 2) is in right position, 4WD will engage immediately. This information will be given to the Sensor by the Magneto on the Selector Plate, and then to the Controller. Controller lights the 4WD indicator. 5. If the Splined Dog is not in right position, 4WD wont engage, this information will be given to the Sensor by the Magneto on the Selector Plate, and then to the Controller. The controller will try to drive the Shift Motor several times in 1 min. During this time, the 4WD indicator is not on, this requires the rider to back or move (ride) the ATV a little to allow the Dog change position for engagement. ( See owners manual or decal). If the rider doesnt do as the owners manual, after 1 min, the buzzer comes on and 4WD indicator blinks, remind the rider to re-shift. Shift from 4WD to 2WD is same as above.
40
(Fig 2)
Fig 3Page from owners manual
41
Fig 4
42
CHAPTER 8 ELECTRICAL 8.14 WIRING DIAGR
43
44
45
46
47
48
49
50
51
52
53
54
ATV SERVICE MANUAL EUROPE 09.0 PN. F010102A01

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What are the main components covered in the manual?

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How does the electric 4WD system work?

2009 ATV

SERVICE MANUAL EUROPE 09.0

Model 2004 2005 Special Edition - Anniversary 2x4 4x4

Engine Management System Service

Information Maintenance Engine Chassis Final Drive Transmission Brakes Electrical

ATV SERVICE MANUAL 09.0

CHAPTER 1 GENERAL INFORMATION

ATV SERVICE MANUAL 09.0

1.1 IMPORTANT INFORMATION

CIRCLIPS 1. Check all circlips carefully before reassembly.

ATV SERVICE MANUAL 09.0

ATV SERVICE MANUAL 09.0

CHAPTER 1 GENERALINFORMATION 1.2 V.I.N AND ENGINE SERIAL NUMBER

ATV SERVICE MANUAL 09.0

CHAPTER 1 GENERALINFORMATION 1.3 VEHICLE DIMENSIONS

ATV SERVICE MANUAL 09.0

Special Edition - Anniversary

ATV SERVICE MANUAL 09.0

05 Model ATV 260 / 300

ATV SERVICE MANUAL 09.0

ATV SERVICE MANUAL 09.0

B-Type 260/ 300

ATV SERVICE MANUAL 09.0

ATV SERVICE MANUAL 09.0

ATV SERVICE MANUAL 09.0

CHAPTER 1 GENERALINFORMATION NOTES

ATV SERVICE MANUAL 09.0

ATV SERVICE MANUA 09.0

2.7 TIRE PRESSURE

ATV SERVICE MANUA 09.0

LT* Only ATV 260 early model LT*

21-25 21 25 16 16 27 Refer to FRONT HUB INSTALLATION 25 30-35 110.6 137 25 80 80-90

CHAPTER 3A ENGINE 260/ 300 / 400 cc

ATV SERVICE MANUAL09.0

260cc / 300 cc /400 cc

CHAPTER 3A ENGINE 260/ 300 / 400 cc 3.1 MAINTENANCE SPECIFICATIONS

ATV SERVICE MANUAL09.0

260:70.000- 70.014 mm 300:72.500- 72.514 mm 400: 80.000- 80.014 mm

260:70.025 mm 300;72.525 mm 400:80.025mm

36 .545- 36 .645 mm 30.021-30.121 mm 6.524 mm 36 .547- 36 .647 mm 30 .067- 30.167 mm 6.48 mm ..

36 .45 mm 29.92 mm 36 .45 mm 29 .97 mm 0.03m m

CHAPTER 3A ENGINE 260/ 300 / 400 cc

ATV SERVICE MANUAL09.0

5.94 mm 5.92 mm 6.05 mm 6.05 mm

Item Stem-to-guide clearance Stem runout limit

CHAPTER 3A ENGINE 260/ 300 / 400 cc

ATV SERVICE MANUAL09.0

0 .45 mm 0 .12 mm 0.7 mm 0.12 mm

0.5 mm 0.1 mm 0.73 mm 0.1 mm

59.95-60.00 mm 0.03 mm 0.35- 0.85 mm

CHAPTER 3A ENGINE 260/ 300 / 400 cc

ATV SERVICE MANUAL09.0

CHAPTER 3A ENGINE 260/ 300 / 400 cc

ATV SERVICE MANUAL09.0

CHAPTER 3A ENGINE 260/ 300 / 400 cc