1. DL manuals
  2. Baja
  3. Offroad Vehicle
  4. WD400U
  5. Service Manual

Baja WD400U Service Manual

Summary of WD400U

  • Page 1

    Wd400u service manual for any questions please contact baja motorsports at 888-863-2252.

  • Page 2

    Content content..................................................................................................................................................2 chapter i general description...............................................................................................................

  • Page 3

    2 section 5 maintenance and adjustment of engine.............................................................................. 46 (i) cleaning of air filter...........................................................................................................46 (ii) inspection of spark plug........

  • Page 4

    3 section 6 troubleshooting electric starting system......................................................................... 109 section 7 battery will not hold charge............................................................................................. 112 section 8 troubleshooting............

  • Page 5: Section 1 Description

    4 chapter i general description section 1 description . Front wheel 2. Headlight 3. Forward/reverse lever 4. Shift pedal 5. Fuel valve 6. Hand-operated lever 7. Air choke 8. Taillight 9. Rear wheel 10. Rear luggage carrier 11. Exhaust silencer 2. Cushion 13. Fuel tank cover 14. Rear brake pedal 15. ...

  • Page 6: (I) Special Tools

    5 section 1 special tools, instruments and meters (i) special tools there are special tools needed to properly adjust and assemble this unit. These tools are intended to prevent maintenance defects and damage. 1. Wrench for valve adjustment, mainly used to adjusting the valve clearance. Specificatio...

  • Page 7

    6 (ii) instruments and meters the following instruments and meters can be selected with reference to the same type of vehicle..

  • Page 8

    7 section 2 identification code, label of model and engine no. Identification code engraved in the left or right side of the front supporting main tube of engine of frame engine no. This is engraved on the top middle part of the right crankcase of engine. Section 3 points for attention in maintenanc...

  • Page 9

    8 4. Clip before assembling, check all the clips carefully. Replace with a new one after removing from piston pin. When mounting clip ring (1), make the sharp end face (2) on the opposite position of impacted face (3) of clip. (see figure at left) 5. Locking washer/shim and location pin when reassem...

  • Page 10

    9 7. Check of electric parts make sure there is no rust, dirt or moisture at the connection, if there is blow it dry or clean. The electrolyte inside the battery is corrosive, take extra precautions as to not get this on your body. When repairing wires on electrical parts, remove the wire on the ter...

  • Page 11

    0 b. If there is slack in the joint, bend the plug pin upward, then connect with connector plug (see figure 7.5) before mounting the new fuse, check if the load of fuse on the components are correct, especially the portion being broken regularly, then mount the fuse having proper current value. Ther...

  • Page 12: Section 4 Specification

    Section 4 specification i. How to use conversion table of unit (1) how to use a conversion table all the specified documents in this manual are taken si and metric as unit. With the following conversion table, metric unit could ne conversed into imperial unit. Metric multiply imperial mm 0.03937 in ...

  • Page 13: II. Basic Specification

    2 ii. Basic specification dimensions: overall length overall width overall height seat height wheel base ground clearance minimum turning radius shaft drive 75.5in 4in 44in 35.25in 49in 7.75in 8.In weight with oil and fuel 573lbs. Engine: type cylinder arrangement displacement bore and stroke compre...

  • Page 14

    3 chassis: frame type caster angle trail steel tube frame 4 2mm (0.83in.) tire: type size tubeless at25 8-2 at25 0-2 brake: front brake type operation rear brake type operation dual disc brake right hand operation drum brake left hand and right foot operation suspension: front rear double wishbone s...

  • Page 15: III. Atv Body

    4 iii. Atv body item standard limit steering system type of steering bearing powder metallurgy sliding bearing type rim, tubeless tire material of rim steel plate size of tire at25x8-12 size of rim at 12x8 type hydraulic disc type spoke rim, tubeless tire material of rim steel plate sixe of tire at2...

  • Page 16: IV. Electric System

    5 item standard voltage of electric system 2v type dr8ea/ngk resistence 10Ω clearance of spark plug 0.6-0.7mm (0.023-0.027in) resistence of primary coil at 20°c(68˚f), 0.5-1.5Ω resistence of secondary coil at 20°c(68°f), 10.3-12.2Ω clearance of min. Spark 6mm(0.24in) spark plug ignition coil iv. Ele...

  • Page 17

    6 v. Maintenance specification of engine item standard limit axle drive meshing clearance of last end gear meshing clearance of middle gear (forward) meshing clearance of middle gear (backward) 0.-0.2mm (0.004-0.008in) 0.-0.2mm (0.004-0.008in) 0.-0.25mm (0.004-0.0in) lubrication system: type of oil ...

  • Page 18

    7 item standard limit valve spring: outside spring: free length: intake/exhaust setting length when valve is closed: compressing pressure when assembling:intake/exhaust limit value of sqaureness:intake/exhaust twisting direction of spring (top view):intake/exhaust 37.2mm (.45in) 32.0mm (.25in) 162.8...

  • Page 19

    8 v. Maintenance specification of engine item standard limit piston piston size “d” measuring point “h” (from bottom line of piston lower portion) piston offset direction of piston offset clearance between piston and cylinder outside diameter of piston pin inside diameter of pin hole 70.92-70.97mm(2...

  • Page 20

    19 section 5 requirements for torque fastening locking component and location on atv hard- ware size of thread qty nm ft·lb cylinder head bolt m10x238 2 45 33 cylinder head bolt m10x216 2 45 33 front and rear valve cover bolt m6x20 5 0 7 cam timing gear cover bolt m6x25 2 0 7 oil shield plate comp b...

  • Page 21

    20 torque value of fasteners locking component and location on atv hard- ware size of thread qty nm ft·lb clutch cover bolt m6x20 2 0 7 inner left cramlcase cover bolt m6x50 8 0 7 outside left crankcase cover bolt m6x30 4 0 7 pullstarter ratchet bolt m14x21 36 0 internal lockup clutch net nut m22 58...

  • Page 22

    2 torque value of fasteners locking component and location on engine hardware size of thread qty nm ft·lb rear axel tubing bolt m10x20 7 45 33 rear protection plate bolt m8x12 2 23 7 rear axel nut m6 2 197 46 gearshifter bolt m8x20 3 23 7 drum brake back plate bolt m8x40 4 23 7 rear drive case bolt ...

  • Page 23

    22 section 6 lubrication point and type of lubricants (i) lubrication point and type of lubricants (atv body) lubricant point type of lubricants lip of oil seal (full) light lithium-base grease o-ring (full) light lithium-base grease steering shaft (upper end, lower end) light lithium-base grease ba...

  • Page 24

    23 (ii) lubrication point and type of lubricants (engine) lubricant point (name of component) type of lubricant lip of oil seal (crank,shift,gearshaft,spindle,shiftgear operation shaft) light lithium-base grease all bearing (crank,spindle,driving shaft,output shaft,balancing shaft,shift gear camshaf...

  • Page 25: Chapter Ii Maintenance

    24 chapter ii maintenance adjustment of vehicle note: the correct maintenance and adjustments are necessary to ensure the vechicle’s in normal driving condition. The repair personnel should be familiar with the contents of this article. Section 1 periodic maintenance/lubrication item requirement 1mo...

  • Page 26: Fender And Fuel Tank

    25 section 2 disassembly and assembly of cushion, fender and fuel tank 1cushion: disassembly 1- place the vehicle on level ground. 2- disassemble the cushion (1) : pull the cushion lock lever (2) up, then raise the rear of cushion. 2 (ii) rear fender: disassembly 1- place vehicle on level ground. 2-...

  • Page 27

    26 battery removal caution: disconnect negative wire first. 4- disconnect the negative wire (2) and positive wire (3) of battery. 5- remove battery clamp bracket (4) 6- remove battery (5) 7- remove protective bracket (6) disconnect all wires from main wire harness (7) and electrical parts from switc...

  • Page 28

    27 2. Installation reverse procedure for “disassembly”. Pay attention to the following points: 1- install: • rear fender (1) torque bolts to 7n.M (5ft.Lbs) 3. Attach wire harness () and electrical parts connecting to switch box (2). 4. Install protective bracket (3). 5. Connect battery (4) a.Connect...

  • Page 29

    28 5. Install rear luggage carrier (1) torque requirement for fasteners: bolt (2) fastening torque: 3n·m (2ft.Lbs) bolt (3) fastening torque: 9n·m (7ft.Lbs) caution: remember to install the bushing on the con - necting point of luggage carrier and frame. Fuel tank disassembly caution: seat, rear fen...

  • Page 30

    29 front fender disassembly 1. Place the vehicle on level ground. 2. Disassemble the front luggage carrier (1) 3. Disassemble the front plastic bumper (2) 4. Remove front metal bumper (3) 5. Remove front fender fuel tank installation reverse disassembly procedure 2 3.

  • Page 31

    30 2. Installation reverse procedure for “disassembly”. 1. Install: front fender front metal bumper (1) 2- install front plastic bumper (2) . The fastening torque of bolt (bumper and frame) is 16n·m (12ft.Lbs). 4- install the front luggage carrier (3) . Bolt (2) (front luggage carrier and frame). Th...

  • Page 32: Vehicle Body

    3 section 3 maintenance and adjustment of vehicle body (i) wear inspection of front and rear brake 1.Check the front brake 1- stop the vehicle using the front brake 2- check: • brake pad between caliper (2) and disc. • if pads are worn, replace. Refer to “front wheel and front brake” sec - tion in c...

  • Page 33

    32 2. Adjustment adjusting procedure of the free clearance of right lever: • loosen the lock nut (1) , rotate the cable adjusting screw (2) clockwise to reduce the tension of front brake cable. • lift the front end from the ground, rotate the two front wheels. Apply brake to verify it is adjusted co...

  • Page 34

    33 2. Adjust • free play of left lever. • free play of rear brake pedal. Adjusting procedure: caution: before adjusting, depress the rear brake pedal 2-3 times. • loosen the locking nut (1) completely, and screw in the cable adjusting screw (2) completely. • loosen adjusting nut (3) of the rear brak...

  • Page 35

    34 caution: after adjusting the steering lever, ensure the reverse gear indicator lights up when the steering lever is in the reverse position. (v) lubricating oil level inspection of rear driving gear case. Check the lubricating oil level of the gear case. Caution: the engine must be in a cold stat...

  • Page 36

    35 (vi) replacing engine oil of rear driving gear case. 1. Place the vehicle on level ground. 2. Place an oil catcher under the rear driving gear case. 3. Remove: • lower cover of gear case • oil fillin screw plug • oil drain screw plug (1) drain the engine oil of the rear driving gear case. 4. Chec...

  • Page 37

    36 (vii) rubber sleeve inspection of rear wheel fork check • rubber sleeve (1) if damaged or worn, replace it. Refer to chapter 3 section 6 “rear shock absorber and rear wheel fork”. (viii) inspection of steering system 1. Place the vehicle on level ground 2. Check: • steering clamp seat of column a...

  • Page 38

    37 (ix) adjustment of toe-in on front wheels. 1. Rest the vehicle on level ground. 2. Measurement: • toe-in, adjust if not in specification. Adjustment steps for toe-in • mark the center of tire thread on both front wheels • lift the front end to keep force off wheels • point tires forward, measure ...

  • Page 39

    38 (x) inspection of front/rear shock absorbers 1. Rest the vehicle on level ground 2. Inspection: • (1) upper part of front shock absorber. If broken or damaged, replace the front shock absorber. • rear shock rod (rear shock absorber) if broken or damaged, replace • oil leakage (3) if there is a he...

  • Page 40

    39 (xii) inspection of tire warning: this vehicle is equipped with low pressure tires, so correct filling pressure and keeping the proper pressure is very important. • tire characteristics 1) quality charicteristics of tire will affect the driving reliability of atv. The following types of tires are...

  • Page 41

    40 . Measurement • tire pressure (normal atmospheric temperature): if out of specification, adjust. Caution: • the tire pressure gauge (1) is included with the tool kit (never use high pressure). • if there is any dust or debris in the tire pressure gauge you will not receive an accurate reading. Al...

  • Page 42: Electrical Appliance

    4 (i) inspection of battery warning: the electrolyte is dangerous and includes sulfuric acid, so it is poisonous and corrosive. • please operate by the following steps: a. Avoid touching any part of your body with the electrolyte especially your eyes. B.Wear protective glasses when operating near ba...

  • Page 43

    42 5. Inspection of battery if damaged, replace it 6. Installment of battery (3) 7. Connect • battery electrode (positive electrode (1) negative electrode (2) ) first connect the positive electrode () 8. Installment: a. Battery clamp plate (4) b. Cushion (ii) inspection of fuse caution: close the ma...

  • Page 44

    43 2. Replacement of bad/old fuse replacement steps: • cut off engine and circuit • install the new fuse. • start the power for electrical appliance inspection. • if the fuse is not responding check the system again (refer to “electrical appliance” of chapter 4) 3. Installment of fuse cover (iii) re...

  • Page 45

    44 6. Installment • bulb (1) caution: be sure that the projective part of the bulb (2) is engaged with the convex groove (3) on the light seat. Caution: never touch the glass part otherwise the bulb will loose illuminating value. If there are some oils on it clean off with cloth mixed with alcohol. ...

  • Page 46: Engine

    45 (i) clean the air filter 1. Remove the cushion (refer to “cushion remov - al” of this chapter). 2. Remove the air filter box cover (1) and air filter components. 3. Removal a. Air filter (1) b. Foam supporting cylinder (2) caution: never start the engine without filter, otherwise the piston and c...

  • Page 47

    46 (ii) inspection of spark plug 1. Rest the vehicle on level ground and clean the spark plug with compressed air to avoid dust from entering the engine. 2. Remove the spark plug (1) the standard spark plug: dr8ea, if not correct, replace it. 3. Inspection of spark plug a. Electrode () worn or damag...

  • Page 48

    47 (ii) adjustment of idle speed 1. Rest the vehicle on level ground 2. Start the engine and warm it at idle speed of 1000-2000r/min, after several minutes, increase the engine speed to 4000-5000r/min. 3. Set the specified idle speed through adjusting the throttle adjusting screw (1) . Tighten to in...

  • Page 49

    48 (v) adjustment of speed limiter: the speed limiter can limit the throttle in full open - ing condition when the throttle grip is pulled to the max position, screwing the adjuster inward can stop increasing the speed. 1. Adjust speed limiting length (a) adjustment steps: a. Loosen the locking nut ...

  • Page 50

    49 (vi) adjustment of valve clearance caution: the valve clearance should be adjusted only after the engine is cold, the valve clearance should be adjusted when the piston is at the end point posi- tion of compress stroke. 1. Removal: 1) rest the vehicle on level ground 3) remove: a. Manual operatio...

  • Page 51

    50 b. Make the mark “t” on the rotor align with the mark on the crankcase. When aligned the piston ties in top dead center (tdc) c. Inspection of top dead center in pressure stroke: (i) when the mark (1) on the rotor is align with mark (2) on the crankcase, the two arms must be clear. (ii) if there ...

  • Page 52

    5 3. Installation: follow the opposite steps of “removal”. (1) mount: a. Valve cap (1) (side of outlet door) b. Valve cap (2) ( side of inlet door) caution: (i) valve cap (1) (2) should be placed in the upright position (3) (ii) check if the o-ring (4) is damaged, if so re - place immediately. Torqu...

  • Page 53

    52 (viii) measurement of compressionforce caution: inadequate compression force will reduce the en - gine performance. Before measuring the compression force, the valve clearance should be adjusted (refer to “adjustment of valve clearance” section). 1. Put vehicle on level ground 2. Take the spark p...

  • Page 54

    53 d. If pressure drops below min. Value: (i) drop some oil to active cylinder. (ii) measure the pressure again 4. Remove pressure gauge 5. Mount spark plug, torque of mount equals 17.5n·m (ix) inspection of engine oil level. 1. Place vehicle on flat ground 2. Check engine oil level and fill if nece...

  • Page 55: Section 1 Rear Differential

    54 chapter iii repair and maintenance of vehicle body section 1 rear differential . Rear transmission case 2. Left case 3. Stud bolts m10x25 4. Needle bearing 5. Oil seal 6. Needle bearing 7. Ring gear set 8. Bearing 9. Coller 10. Bearing retainer 11. O-ring 2. Oil seal 13. Drain plug 14. Gasket 5. ...

  • Page 56

    55 (i) trouble • trouble judging guidance problem reason caution: “a”, “b”, and “c” are difficult to judge because the performance is very subtle and it’s difficult to distinguish them from normal operating noise. Remove these parts for special inspection if you think they may have been damaged. (ii...

  • Page 57

    56 it is necessary to check for bearing damage, and if there is a great deal of metal or metal fragments on the oil draining screw plug. Caution: it is normal for some metal fragments to be in the oil. 3. Check oil leakage check according to following procedures. A. Completely clean, wipe, and dry t...

  • Page 58

    57 (iv) disassembly warning: ensure that the vehicle does not turn over by firmly supporting it. 1. Drain the rear differential case oil (1) refer to section 3, chapter 2, “replacement of engine oil of rear driving gear case” 2. Disassemble ) cushion 2) rear luggage carrier 3) rear fender refer to “...

  • Page 59

    58 1. Disassembly a. Remove: bolt (1) m6 bolt (2) m8 caution: loosen each bolt by ¼ circle and remove bolts alternately. B. Disassemble: 1) rear driving gear case body (1) 2) annular gear pad 3) shift gear 4) thrust plain pad c. Disassemble: bearing gasket (transmission shaft-last grade) caution: on...

  • Page 60

    59 d. Disassemble with a soft hammer lightly tap the main driv - ing gear (1) and remove (with thrust pad (2) and bearing (3)) caution: remove the main driving gear first if it is nec - essary to replace the gear. Replace the original bearing thrust pad, do not reuse. E. Disassemble: ) oil seal () 2...

  • Page 61

    60 (v) inspection 1. Replace the main driving gear and shift gear if there are any scratches or wearing on the gear teeth of bevel gear pair (1) 2. Check oil seal (2) 3. Check the o-ring (3) replace if damaged 4. Check the bearing (4) replace if damaged caution: be sure to adjust the main driving ge...

  • Page 62

    6 section 2 rear wheel, rear brake, rear wheel axle no. Item parameter tire specification at25x10-12 2 rim dimension 12x10 3 tire air pressure (normal temperature) standard value min. Value max. Value 4 runout radial runout end face runout 2mm 2mm 5 wear limit of tire 2mm 6 wear limit of friction di...

  • Page 63

    62.

  • Page 64

    63 (i) removal steps 1. Keep front wheel from moving then put a proper stand under the frame so as to lift the rear wheels. Warning: in order to avoid the parts falling, (which will cause danger), during the removal process, rest the vehicle firmly. 2. Removal of left wheel (1) nut of rear wheel (2)...

  • Page 65

    64 8. Removal: (1) adjusting nut, pin and spring of rear brake arm and rear brake tension rod assy. 9. Removal: (2) rear brake cable (3) rear brake tension rod assy 10. Brake shoe removal: () cotter pins (2) plate (3) brake shoes (including springs) 10. Removal: (1) bearing retainer (2) rear brake h...

  • Page 66

    65 8. Inspection (1) inner surface of rear brake hub if there is some engine oil or scrapes, remove it and treat it. The method of treatment is as fol - lows: removal of engine oil: clean with cloth dipped in volatile dilute or volatile solvent. Removal of scrapes: wipe scrapes slightly and with eve...

  • Page 67

    66 3. Measurement the radial run-out of the piston (a) on the rear wheel axle, if out of specification, replace it. Warning: if the axle is bent, do not straighten it force - fully. 14. Inspection: (1) bearing on the rear wheel axle rotate the rear wheel axle, if the axle shakes left and right in th...

  • Page 68

    67 (iii) installment steps: the reversal steps of “removal steps” are in - stallment steps. Pay attention to the following points when installing: 1. Lubrication part (1) oil seal lip of rear wheel axle. (2) bearing of rear wheel axle. The corresponding splint tooth of rear wheel axle. The lubricati...

  • Page 69

    68 5. Installment cam shaft of rear brake (1) indicating plate of brake (2) rear brake arm assy (3) caution: when installing the brake indicating plate (2) to rear brake cam shaft (1) , be sure to align the projective part (a) of brake indicating plate (2) with the concave part (b) of rear brake cam...

  • Page 70

    69 8. Installment (1) brake shoe assy 9. Lubrication • dust-proof seal lubrication oil for dust-proof seal: lithium base grease. Warning the lubrication oil is not allowed to be used for brake shoe assy, the lithium base grease is used for rear brake hub splint groove. Warning: the lubrication oil i...

  • Page 71

    70 5. Installment • cotter pin () caution: after fastening the torque, the nut on the rear axle is not allowed to be loose. If the nut con - cave groove is not aligned with the splint hole on the screw rod, align it by tightening up the nut. Warning: always use the new cotter pin 6. Installment righ...

  • Page 72

    7 section 3 rear shock absorber and rear swing arm 1. Rear shock absorber assembly 2. Bolt m12x1.25x70 3. Lock nut m12x1.25 4. Clevis pin 5. Cover 6. Washer 7. Cotter pin 8. Rear swing arm 9. Rear axle housing 10. Bolt m10x20 11. Lock nut m10 12. Bushing 13. Bolt m12x1.25x80 14. Lock nut m12x1.25 15...

  • Page 73

    72 (i) disassembling steps 1. Take off left rear wheel, rear wheel joint plate, right rear wheel, rear brake hub, rear brake, and rear axle. Refer to “disassembly of rear wheel/rear brake and rear wheel axle” section in this chapter. 2. Take off lower cap of gear case. 3. Take off the rear driving g...

  • Page 74

    73 5. Remove nut (1) on the rear shock absorber, bolt (2), rear shock absorber (3) . 6. Remove rear brake tension spring (1) . 7. Remove dust cap on rear arm axle. 8. Check the free play of rear wheel fork checking steps. A: check the torque value of rear arm joint bolt and the torque value of rear ...

  • Page 75

    74 9. Remove axle housing (1) 10. Remove driving axle hose clamp assy (front) (1), rear arm nut (right side) and rear arm joint bolt. 11. Remove rear swing arm (1) . (ii) checking steps 1. Check a: if rear shock absorber is leakage, if any, replace it. B: if rear shock absorber is bent or damaged, i...

  • Page 76

    75 2. Check if the rear wheel fork assy is cracked, bent, and damaged. If any, replace it. Check if the rear wheel bush is cracked, bent, and damaged. If there is one of these problems, replace it. 3. Check the gear case lower cap. If there are any cracks, bends, or damage, replace this part. 4. Che...

  • Page 77

    76 remove bearing (3). The reverse step of “bearing and oil sealing replacing step” is the mounting step of new bearing and new oil sealing. Caution: tool (4) which is matched with outer diam- eter of bearing race (7) and oil sealing. Warning: don’t strike the bearing inner race (5) and roller. (iii...

  • Page 78

    77 3. Fix the rear arm bushing (1) (left), rear arm bushing (2) (right) and bushing (3) . Fixing steps: a: fix the left rear arm bushing (1) by standard torque. Attached: bolt torque value: 130nm (96 ft.Lbs) b: fix the right rear arm bushing (2) until it makes contact with the bushing (3) . Attached...

  • Page 79

    78 8. Mount the rear differential case sub-assembly (1) refer to “installation of rear driving gear case sub-assembly and driving shaft” section of this chapter. 9. Mount the rear wheel axle, rear brake hub, right rear wheel, rear wheel joint plate and left rear wheel. Refer to “installation of rear...

  • Page 80

    79 1. Steering column 2. Pitman arm 3. Upper handle holder 4. Bolt m8x35 5. Cotter pin 6. Steering bearing 7. Oil seal section 4 steering operation system 8. Bracket 9. Bolt m8x60 10. Lock washer . Collar 2. Washer 13. Nut m14 4. Cotter pin 5. Tie rod assy. 16. Nut m12.

  • Page 81

    80 (i) removal steps of steering column . Removal • front luggage carrier • bumper • front fender refer to chapter 2, section 2 2. Removal • ignition switch • “neutral” indicating light wire • “reverse” indicating light wire • “high beam” indicating light wire • clutch switch wire 3. Removal (1) bra...

  • Page 82

    8 (ii) removal steps of steering vertical column welding 1. Lock pad (1) unlock locking tab on lock pad 2. Removal (2) bolt m8x60 (3) locking washer (4) clip assy 3. Removal • cotter pin • nut m10 • washer 0 4. Removal split pin 3.2x24 nut m12x1.25 tie rod () caution: when removing the tie rod end a...

  • Page 83

    82 (iii) inspection content 1. Check the handlebar for any damage. If it is, replace it. 2. Inspect the steering vertical column welding assy for any bends or damage. If there is, re - place it. Warning: in order to avoid decreasing the performance of the steering vertical column, do not straighten ...

  • Page 84

    83 6. Adjustment assembly length of tie rod adjustment steps of tie rod assembly length 1- loosen the connecting nut [a] [b] 2- adjusting the assembly length of tension rod by rotating the tie rod. Attached: tie rod assembly length @: 297mm (.58in) [a] right-handed thread [b] left-handed thread conn...

  • Page 85

    84 2. Lubricate the steering vertical column hold - er (1) and seal ring (2) during installation of the steering vertical column welding. 3. Installment install the seal ring (1) to the steering verti - cal column welding, then install bushing (2). Finally, install the steering vertical column holde...

  • Page 86

    85 7. Mounting cotter pin (1) caution: don’t loosen the nut after the torque is fixed. If the nut recess does not correspond with split pin hole on the double-screw bolt, tighten the nut to align them. Warning: always use new cotter pin 8. Tightening mount the washer and nut on steering vertical col...

  • Page 87

    86 (v) installation steps of handlebar 1. Install the lower holding seat (1) , steering tube (2) and upper holding seat (3) . Warning: when tightening the bolt of holding seat, make sure clearance (b) is clear. Attached: bolt torque: 20nm 2. Install the thumb throttle grip assembly caution: the proj...

  • Page 88

    87 section 5 front wheel and front brake.

  • Page 89

    88 1. Front wheel rim 12x6 2. Front wheel tire 25x8-12 3. Valve core 4. Lug nut 5. Dust proof axle nut cover 6. Uniform velocity turning assembly 7. Out sphere cage 8. Clip clamp 9. Dust cover 0. Clip clamp . Element rod 2. Clip clamp 13. Clip spring 14. Inner sphere cage 5. Clip clamp 16. Clip bloc...

  • Page 90

    89 disassembly 1. Place vehicle on level ground. 2. Remove lug nuts (1) and dust proof cover (2) of front wheel. 3. Place a stand under the frame to support the vehicle. 4. Remove: • cotter pin () • castle nut (2) • washer (3) • hub and rotor (4) item parameter tire specification 25x8-12 rim dimensi...

  • Page 91

    90 5. Remove: brake caliper (1) brake rotor caution: • check the brake rotor for any damage and replace if necessary. • check brake caliper for any leaks. • check the brake pads for wear or damage and replace if necessary. 6. Remove: brake protective plate (1) installation: 1. Attach brake protectiv...

  • Page 92

    91 2. Attach brake caliper (1). 3. Attach: • hub and rotor (4) • washer (3) • castle nut (2) • cotter pin () 4. Attach: • front wheel (1) secure with lug nuts (2) • dust proof cover (3) 2 3 4 2 3.

  • Page 93

    92 1. Left upper a-arm 2. Ball joint 3. Spring circlip 4. Right upper a-arm 5. Ball joint 6. Spring circlip 7. Castle nut section 6 front shock absorber and front wheel fork and front differential 8. Cotter pin 9. Left lower a-arm 10. Right lower a-arm 11. A-arm bushing 12. Bolt m10x1.25x70 13. Lock...

  • Page 94: Front Wheel Fork and Front

    93 1. Front differential assembly 2. Right case 3. Left case 4. Clutch toper gear wheel 5. Seal 6. Differential speed outer 7. Bolt m10x18 8. Bolt m8x20 9. Bolt m8x25 10. Clip spring . Cylinder pin 12. Divided move assembly 13. Fork 14. Clutch gear gasket 15. Rank 16. Bearing 17. Rolled needle beari...

  • Page 95

    94 (i) disassembly of front shock absorber and front wheel fork: these instructions are for one side of the unit only. Caution: before starting disassembly make sure you have completely drain the oil from the front differential. 1. Place container under drain bolt (1) and let drain completely. 2. Re...

  • Page 96

    95 5. Remove • upper a-arm (1) from frame • lower a-arm (2) from frame. 6. Remove • front differential case (1) 2.

  • Page 97

    96 remove m6 bolts (2) and electric motor comp.() use force on the end bearing to dislodge the drive assembly (3). 2 3.

  • Page 98

    97 castle nut washer hub and rotor protective plate knuckle upper a-arm lower a-arm front differential axle front differential (ii) installation of front shock absorber and front wheel fork- these directions are as- sembly for one side on the unit only. 1. Reverse “disassembly steps”. 2. Install the...

  • Page 99

    98 4. Attach the upper a-arm (1) to the frame. 5. Install the front shock absorber (1) to the frame (2) and the top of the upper a-arm (3). 6. Attach the front differential axle to the front differential. 7. Attach the steering knuckle (1) to the lower (2) and upper (3) a-arms, secure with castle nu...

  • Page 100: Section 1 Electric Assembly

    99 chapter iv electric appliance section 1 electric assembly 1. Cdi ignition unit 2. Starting motor relay 3. 30a fuse 4. Nut m6 5. Zip tie 6. Zip tie 7. Ignition coil 8. Bolt m6x20 9. Stop lamp switch assembly 0. Battery 11. Rectifier 12. Bolt m6x25 13. Negative cable 4. Battery press plate stand 15...

  • Page 101

    00 ignition c oil spar k plug b att er y 12v 12a h po w er lo ck m ast er fuse b ox m m b 15a m agnet o cdi c omp . R ec tifier 4w d shif t swit ch 4w d shif t mot or m m oil c o oling swit ch fan mot or fr on t br ak e swit ch r ear br ak e swit ch fgear ngear rgear r igh t swit ch assembly high&l ...

  • Page 102: Section 2 Inspect Switch

    0 section 2 inspect switch (i) inspect kill switch make certain the wire end is on the pocket mul - timeter. If there are any problems replace the switch pocket multimeter • turn the multimeter to “o” • turn the multimeter to “Ωx1” when inspecting the circuit • turn the switch on and off many times ...

  • Page 103

    02 section 3 check lamp (headlight) check the headlight condition 1. Remove the headlight bulb caution: pay attention to support the lamp. Do not pull the lead wire, otherwise it will brake. Warning: when the headlight illuminates, remove your hand from the lamp, it will be very hot. Do not touch un...

  • Page 104: Section 4 Troubleshooting

    03 section 4 troubleshooting ignition system failure if the ignition system does not work (no spark) check: 1. Spark plug 2. Spark plug gap 3. Resistance of ignition coil and wire 4. Engine stop switch • check and repair 1. Spark plug • check the spark plug condition • check the spark plug type • ch...

  • Page 105

    04 2. Ignition spark clearance • remove the spark plug • connect as shown in figure (1) spark testing instrument (2) spark plug cap (3) spark plug • turn the main switch to the “on” position • check the ignition spark clearance • press the starting switch to start the engine. Increase the spark clea...

  • Page 106

    05 the starting circuit of this vehicle including starting motor, cut-off relay, rear brake switch and neutral switch. If the main switch is in position, the starting motor could be operated only at the following conditions: • driving device is in the neutral position (neutral switch is closed) or •...

  • Page 107

    06 section 6 troubleshooting electric starting system if starting motor does not work • check . Fuse 6. Main switch 2. Battery 7. Neutral switch 3. Starting motor 8. Rear brake switch 4. Cut-off relay 9. Starting switch 5. Starting relay 10. Circuit connection (entire starting system) • remove the f...

  • Page 108

    07 operation 4. Power off relay • remove relay from cable • connect portable multitester (Ωx1) and bat - tery (12v) to end of wire on relay battery end (-) - yellow/white wire end () battery end (-) - red/white wire end (2) battery end (-) - red/black wire end (3) • inspect if the power off relay is...

  • Page 109

    08 6. Main switch refer to “check system” pass 7. Neutral switch refer to “check system” pass 8. Rear brake switch refer to “check system” pass 9. Starting switch refer to “check system” pass 0. Circuit connection • check the circuit connection of entire start - ing system refer to “electric diagram...

  • Page 110

    109 check: 1. Safety 4. Stator coil 2. Battery 5. Coupling of circuit 3. Charging voltage (entire charging system) • remove parts before maintenance ) cushion • repair with special tools 1. Safety refer to “inspection of switch” pass 2. Battery • check the condition of battery refer to “inspection o...

  • Page 111

    0 • start engine and accelerate to 2000r/m charging voltage: 14-15v at 2000r/m use fully charged battery out of specification 4. Resistance value for stator coil • remove the lighting coil of ac magneto • connect pocket multimeter to stator coil (Ωx1) pocket multimeter (+) - white terminal 1 pocket ...

  • Page 112: Section 8 Troubleshooting

    Section 8 troubleshooting if the headlight or taillight is out check: 1. Safety 4. Lamp switch 2. Battery 5. Coupling of wires 3. Main switch (entire lighting sys - tem) • remove the following parts before starting troubleshooting maintenance ) cushion 2) front luggage carrier 3) front covering part...

  • Page 113

    2 4. Change lamps refer to “inspection of switch” pass 5. Coupling of wires • check the wire coupling for entire lighting system refer to “diagram” pass check the returning condition of each lighting system. Refer to “inspection of lighting system”. Fail if the lamp switch fails, replace the switch ...

  • Page 114

    3 db db db db section 9 inspection of lighting system (ii) if headlight is out 1. Bulb and socket • check if the bulb and socket are correct pass 2. Voltage • connect the pocket tester (dc 20v) to the headlight a b multimeter (+) - green terminal (1) or yel - low terminal (2) multimeter (-) - black ...

  • Page 115

    4 (ii) if taillight is out 1. Bulb and socket • check if the bulb and socket are correct pass 2. Voltage • connect the pocket tester (dc 20v) to the taillight terminal multimeter (+) - blue terminal (1) multimeter (-) - black terminal (2) • turn main switch to “on” position •turn lamp switch to “low...

  • Page 116: Section 10 Troubleshooting

    5 section 10 troubleshooting (i) if indicator lamp is out check: 1. Safety 4. Coupling of wires 2. Battery (whole signal system) 3. Front switch • remove the following parts before trouble - shooting ) seat 2) front frame 3) front pedal • use specific tools for troubleshooting 1. Safety refer to “in...

  • Page 117

    6 3. Main switch refer to “inspection of switch” pass 4. Coupling of wires • check the coupling of whole signal system wires refer to “diagram of wires” pass check the condition of each signal system refer to “inspection of signal system” fail replace main switch poor connection connect it correctly.

  • Page 118

    7 section 11 inspection of signal system (i) if the neutral indicator lamp is out 1. Bulb and socket •check if the bulb and socket circuit b are correct. Pass 2. Neutral switch • refer to “inspection of switch” pass 3. Voltage • connect pocket tester (dc 20v) to the tail lamp terminal pocket tester ...

  • Page 119

    8 (ii) if the reverse indicator lamp is out 1. Bulb and socket • check if the bulb and socket are in good condition. Pass 2. Reverse switch • refer to “inspection of switch” pass 3. Voltage • connect pocket multimeter (dc 20v) to the taillight terminal multimeter (+) - blue terminal (2) multimeter (...

  • Page 120

    119 (iii) if the hb indicator light is out 1. Bulb and socket •check if the bulb and socket circuit b are correct. Pass 2. High or low beam switch • refer to “inspection of switch” pass 3. Voltage • connect pocket tester (dc 20v) to the tail lamp terminal pocket tester (+) - blue terminal (1) pocket...

  • Page 121: Chapter V Engine

    20 (i) remove the engine from atv . Remove • cushion • front luggage carrier • front bumper • front fender • rear luggage carrier • rear fender the disassembling method refers to “fender, fuel tank disassembly” of chapter ii. 2. Oil draining screw out oil draining screw plug. Drain the lubricating o...

  • Page 122

    2 5. Disconnect gearshift linkage from engine. 6. Wire and hose ) remove • spark plug cap • cdi magneto wire (1) • reverse switch wire (2) • neutral switch wire (3) • air pipe (4) 7. Disassembly of engine ) remove • bolt (1) (top supporting of engine) • bolt (2) (bottom supporting of engine) • bolt ...

  • Page 123

    22 (ii) disassembly of engine . Remove • hand starting unit (1) 45. Remove • starting lever cap (1) • starting lever (2) caution: • before untying the knot (3) , pull out the rope long enough to tie a knot to avoid to be pulled into the cap 46. Remove • screw pin () • guide plate () • compressing sp...

  • Page 124

    23 2 3 2. Remove • shifter linkage rod (1) pay attention not to lose washer 3. Remove • cam sprocket cover (1) 4. Remove • spark plug (1) • upper valve cap (intake) (2) • lower valve cap (exhaust) (3).

  • Page 125

    24 5. Remove • chain tensioner (2) caution: before removing the chain tensioner, loosen the screw (1) first. 6. Remove • bolt () • timing sprocket (2) caution: • when loosening the bolt, it is needed to fix the hand starting ratchet (4) • use a wire to hold chain so the timing chain does not drop in...

  • Page 126

    25 2 3 2 3 5 4 9. Remove • cylinder body assembly (2) • cylinder gasket (3) • dowel pin (4) • o-ring (5) 0. Remove • circlip () • piston pin (2) • piston unit (3) caution: • before disassembling the piston pin circlip, cover the crankcase with a clean cloth to avoid the circlip suddenly dropping int...

  • Page 127

    26 • nut (4) securing primary yoke (5) 2. Remove • primary output shaft (1) • shims (2) • internal yoke for tension spring (3) • tension spring (4) 3. Remove • starting ratchet (1) caution: fix the starting ratchet with special tool, and loosen the bolt on the starting ratchet. 4. Remove • left cran...

  • Page 128

    27 6. Remove • flywheel; (1) caution: disassemble the flywheel with a puller. 7. Remove • gasket of left crankcase cover (1) • dowel pin • intermediate gear shaft (3) key way • washer • duplex intermediate gear (5) • oil pump protective plate (6) • counter balance gear (7) 8. Remove • oil pump 19. R...

  • Page 129

    28 2. Remove • forward/reverse shifter linkage (1) • seal (2) • snap ring (3) • washer (4) • shifter (5) • shifter guide (6) •shifter fork (7) 22. Remove • washer • forward/reverse output shaft (1) • drive chain (2) • washer • input shaft drive (3) • slider (4) • forward gear (5) • needle bearing (6...

  • Page 130

    129 25. Remove • cvt cover () • clutch support bracket (2) • secondary clutch (3) • primary clutch (4) • primary clutch sleeve (5) • v-belt (6) • cvt rear cover (7) 2 3 3 4 4 6 4 7.

  • Page 131

    30 26. Remove • clutch cover () • gasket (2) 27. Remove • seal () • snap ring (2) • output shaft (3) 28. Remove • lock nut (1) • one way clutch bearing (2) • clutch (3) 40. Remove • stop plate (2) • pressing plate (3) caution: knock the locking part (1) of stop plate flat (1) before removing the sto...

  • Page 132

    3 2 3 42. Remove • rocker shaft (1) • air intake and exhaust rocker (2) caution: • screw the slip hammer assy into rocker shaft, then pull out the rocker. 43. Remove • valve lock clip (1) caution: • disassemble the valve lock clip with valve spring compressing device. 44. Remove • valve outer spring...

  • Page 133

    32 . Cylinder cover ) clean • carbon deposit use circular scraper () caution: please do not use sharp tool to avoid scraping • nut of spark plug • valve seat ring • bottom face of cylinder 2) measure • flatness of cylinder cover bottom face correct the bottom face or replace if unqualified 2. Intake...

  • Page 134

    33 3) measure • rod part run-out of valve rod replace it if unqualified 4) measure • clearance between valve rod and valve guide pipe clearance=[a]-[b] inner diameter of valve guide pipe [a] valve rod diameter [b] replace the valve or valve guide pipe if unqualified. Measure with micrometer and inne...

  • Page 135

    34 3) install • circlip () • valve guide pipe (2) use the installing and disassembling device of valve guide pipe 4) ream the inner diameter of valve guide pipe to get proper valve rod clearance. Caution: regrind the valve race after installing valve guide pipe 4. Valve race ) clean • carbon deposit...

  • Page 136

    35 • press the valve on the valve race through valve guide pipe to leave clear trace on the valve. • remove the valve from cylinder cover • when the valve contacts with valve race, the reddle is marked on the valve from valve race. Then can measure the contacting width of valve and valve race. • if ...

  • Page 137

    36 the contacting part [b] is in the middle of valve face. But the width is too narrow reamer assy of valve rale result use reamer 45˚ get unified contacting width .0mm (0.04in) the contacting part [c] is too narrow, and on the upper edge of valve face reamer assy of valve rale result reamer 35˚ mak...

  • Page 138

    37 • paint molybdenum disulfide oil on the valve rod part. • place the valve in to the cylinder cover • rotate the valve to grind in with seat fully on the valve face, then clean the dirt • repeat procedure until the contacting width of valve face and valve seat caution: in order to get the best gri...

  • Page 139

    38 2) measure • installing pressure of valve spring if unqualified, replace the inner and outer spring totally. 6. Seal check of valve 1) installation of valve lubricate • valve rod part () • valve rod oil seal (2) install • valve spring seat (1) (lower part) • oil seal of valve rod (2) • valve (3) ...

  • Page 140

    139 caution: must install the long pitch end of all valve spring upward 2) check the valve seal if there is leakage on the valve face, repair again and regrind or replace the valve and regrind. Inspecting procedure of valve seal • inject the clean solvent (1) into intake way and exhaust way respecti...

  • Page 141

    40 8. Valve rocker and rocker shaft 1) check • rocker hole • contacting surface with distribution cam if ever worn, replace it 2) check • rocker shaft surface replace or check lubrication if there are dents, scratches, or discoloration 3) measure • measure inner diameter of valve rocker hole replace...

  • Page 142

    4 • subtract the outer diameter of rocker shaft from inner diameter of valve rocker hole to calculate clearance. Clearance between rocker hole and shaft= (a) - (b) inner diameter of valve rocker hole (a) outer diameter of rocker shaft (b) replace a set if unqualified 9. Timing chain check • timing c...

  • Page 143

    42 2) check flexibility of chain tensioner checking procedure • press the tensioner pushing rod lightly with finger, and rotate it clockwise with thin screwdriver to screw it in. • press the pushing rod lightly with finger and remove screwdriver, then the pushing rod screws out stably • if the opera...

  • Page 144

    43 if out of specification, hone or replace the cylinder and piston (replace in a set) if out of specification, replace the piston and piston ring as a set at the same time. •calculate the mating cylinder clearance with the following formulas mating cylinder clearance=“c”-“p” inner diameter of cylin...

  • Page 145

    44 clearance between piston ring and ring groove standard limit first 0.03~0.07mm 0.2mm ring (0.001~0.003 in) (0.005in) second 0.02~0.06mm 0.2mm ring (0.008~0.024in) (0.005in) 2) measurement: • closed clearance of piston ring • install the piston ring to the cylinder, pull forward about 20mm (0.8in)...

  • Page 146

    45 main points of reassembly of crankshaft: the oil traces on crankshaft (1) and crank pin (2) should be connected correctly, the position of two oil traces should be within 1mm (0.04 in) 17. Driving gear of balance shaft and gear of balance shaft inspection: • driving gear of balance shaft (1) • ge...

  • Page 147

    46 • inspection • bolt (1) (overrunning clutch) • loosen then replace with new one and apply fastening agent caution: fastening torgue of bolt (overrunning clutch) is 30nm(3.0m·kg22yd·pound) apply the fastening agent on the bolt 19. Main clutch clutch case 1) inspection: • clutch case assy (1) (inne...

  • Page 148

    47 22. Shift fork and fork shaft 1) inspection: • fork connecting surface to gear and shift cam if worn, scraped, bent, or damaged, replace it. 2) inspection • fork shaft (roll the fork shaft on a plane) if bent replace it. Warning: never attempt to straighten a bent fork shaft 3) inspection • movem...

  • Page 149

    48 27. Bearing and oil seal ) inspection • bearing if jammed in operation or there are pits and damage, replace it. 2) inspection • oil seal if damaged or worn replace it. 28. Circlip and washer inspection: • circlip • washer if damaged, loose, or bent, replace it. 29. Crankcase 1) clean crankcase w...

  • Page 150

    149 30. Hand operated mechanism ) inspection • inspection () if cracked, bent, or damaged, replace it. • driving jaw (2) • compressing spring (3) • torsion spring (4) (driving jaw position) wear/cracks/damage, replace it. 2) inspection: • rolling spring (1) (starting) wear/cracks/damage, replace it....

  • Page 151

    50 4) inspection • reverse fork (1) if wear/abrasion/bend/damage is found on the surface connecting with connecting jaw and reverse operating shaft, replace it. • compressing spring (2) if the elasticity is lost, or worn, replace it • steel ball (3) if wear, damage, or scratch marks are found, repla...

  • Page 152

    5 1. Crank connecting rod 2. Balanced initiative gear 3. Buffer spring 4. Pin 5. Initiative gear clamp plate 6. Circlip 7. Woodruff key 8. Washer 9. Bolt m10x40 10. Bearing section 3 assembly and adjustment of engine 11. Seal ring sheath 12. Seal ring 13. Nut m16 14. Balanced shaft 15. Bearing 16. B...

  • Page 153

    52 shift gear mechanism 1. Main shaft 2. Seal o-ring 3. Bearing 4. Bearing 5. Collar sheath 6. Oil seal 7. Seal o-ring 8. Middle shaft 9. Bearing 10. Bearing 11. Chain with gear type 12. Output shaft 3. Circlip 14. Driven gear 5. Pin 6. Cirlcip 17. Rolled needle bearing 18. Gearshift arm comp 19. Fu...

  • Page 154

    53 clutch . Outer cover 2. Cintrifugal clutch 3. Bearing seat outer cover 4. Bearing 16010 5. Fuel seal sd32x66x8 6. Circlip 75.5 7. Circlip 49 8. Bearing seat seal cushion 9. Flange bolt mx 0. One way machine 11. Nut m22 12. Sliding sheath 13. Trigonometry belt 4. Drive plate 15. Cvt first clutch c...

  • Page 155

    54 (iii) assembly of left crankcase output mechanism 1. Output gear 2. Forward gear assy 3. Reverse gear 4. Nut 5. Bearing 6. Washer 7. Connecting jaw 8. Washer 9. Bearing 18. Nut 19. Rear cover 20. O-ring 21. Bolt m8x15 22. Reverse fork 23. Compressing spring 24. Steel ball 6.35g100b 25. Reverse fo...

  • Page 156

    55 electric starting system . Circlip 2 2. Washer 3. Wheel axle 4. Double wheel 5. Woodruff key 6. Washer 7. Electric starting gear assy 8. Electric starting clutch 9. Roller 10. Spring cover 11. Spring 12. Timing chain 13. Up guide plate assembly 14. Magneto rotor 15. Magneto stator 16. Left crankc...

  • Page 157

    56 (v) assembly of cylinder head cylinder cover assembly 1. Locking nut 2. Adjusting screw 3. Throttle arm 4. Arm axle 1 5. Valve locking 6. Valve spring cover 7. Valve recoil sealing 8. Valve spring 9. Valve outer spring 10. Valve spring seal . Inlet valve 12. Bolt m6x12 13. Locking plate 4. Clamp ...

  • Page 158

    57 cylinder head . Cylinder head cover assem- bly 2. Steel wire circlip 3. Valve guide tube 4. Bolt 95026-06010 5. Washer 6. Shock absorbing block 7. Cylinder cover washer as- sembly 8. Locating pin 99510-14016 9. Locating pin 10. Oil sealing . Canopy nut 2. Washer 25. O-ring 26. Screw m6x18-06025 2...

  • Page 159

    58 cylinder head 2 1. Cylinder body assembly 2. Screw m6 x 25-10.9 3. Cylinder body gasket 4. Locating pin 99530-14016 5. O-ring 6. Piston ring 1 7. Piston ring 2 8. Oil ring subassembly 9. Circlip 0. Piston . Piston pin 12. Double end bolt.

  • Page 160: Installation

    159 installation • attach gear and shaft to bracket using circlip. 2 3.

  • Page 161

    60 • mount bracket (4) to crankcase (5) using m8 bolts (3). Torque of bolt: 23nm (17ft.Lbs) • install internal drive gear (1). • install reverse shaft (9) using circlip (6), seal (5), and washer (4). 6 8 9 7 2 5 4 3.

  • Page 162

    6 • install oil screen (1) using m6 bolts(2). Torque of bolts: 10nm (7ft.Lbs) • mount balanced shaft (3) 2 3 2.

  • Page 163

    62 • attach shifting fork (1) to gear. • install crank chain (2). • install crankshaft (1). • attach right crankcase (5) to left crankcase (4)using silicon as sealent. 5 4 2.

  • Page 164

    63 • outside of right crankcase • attach clutch plates to right crankcase using one- way bearing. 2 2.

  • Page 165

    64 •use gasket (1) when installing cover (2). •use circlip (4) to hold in bearing. • mount cover (2) using m8 bolts(3). Torque of bolts: 23nm (17ft.Lbs) 3 2 2 4 5.

  • Page 166

    65 •make sure pieces are used in this order. • mount rear cover (1) using m10 bolts torque of bolts 45nm (33ft.Lbs). • make sure to use all shims (2), four on each side. • mount u-joint using m12 nut. Torque of nut: 80nm (59ft.Lbs) 2.

  • Page 167

    66 • install universal joint (1) using circlips (2). • mount oil pump gear (3) using m6 bolts (4) torque of bolts: 10nm(7ft.Lbs) • install timing chain guard (5). • install timing chain (6), make sure to feed chain (6) onto sprocket (7). 2 3 4 5 6 7.

  • Page 168

    67 • mount gear (3) in crankcase. • install pin (2) and spring (1) in gear (3). • install piston (6) using piston pin (5) and clips (7). • install piston rings (4) on piston (6). 3 2 6 5 4 7.

  • Page 169

    68 • install gearshift connector (1) assembly to crankcase. • mount starter motor (2) using m8 bolts (3). • mount cylinder (5)using base gasket (4). 2 3 5 4.

  • Page 170

    169 • valve, inner spring, outer spring, valve locking clips • install camshaft (1) using bracket (3) and m6 bolts (2). Torque of bolts: 10nm (7ft.Lbs) 2 3.

  • Page 171

    70 • install rocker arms (1) in cylinder head (2). • install cylinder head (2) using m10 bolts (3). Torque ob bolts: 45nm (33ft.Lbs) • attach valve covers (5) using m6 bolts (4). Torque of bolts: 10nm (7ft.Lbs) 2 2 3 4 5.

  • Page 172

    7 • mount intake manifold (1) using m6 bolts(2). Torque of bolts: 10nm (7ft.Lbs) • mount timing sprocket (3) using bracket and m8 bolts (4). Torque of bolts: 23nm (17ft.Lbs) • attach timing chain cover using m8 bolts. Torque of bolts: 23nm (17ft.Lbs) 2 3 4 5 6.

  • Page 173

    72 • mount chain tensioner (4) using m6 bolts (3). Torqure of bolts: 10nm (7ft.Lbs) • install spring (2) using m10 bolt (1). Torque of bolts: 45nm (33ft.Lbs) • install flywheel gear (5) on crankshaft. • make sure to use a gasket (6) when installing left crankcas cover. • attach flywheel (7) using m1...

  • Page 174

    73 • mount left crankcase cover (1) using m10 bolts (2). Torque bolts:45nm (33ft.Lbs) • mount recoil ratchet (3) to crankcase cover (2). • attach pull starter (5) using m8 bolts (4). Torque of bolts: 23nm (17ft.Lbs) 2 3 5 4.

  • Page 175

    74 • install oil filter (1) below pullstarter. • install inside right crankcase cover (2). 2.

  • Page 176

    75 • install drive (2) and driven pulleys (). • install holding plate (4) using m8 bolts (3). • install right crankcase cover (5) using m8 bolts (6). Torque of bolts: 10nm (7ft.Lbs) 2 3 4 5 6.

  • Page 177: Trouble and It’S Judgement

    76 • wrong spark plug heat value • inefficient spark plug cap (2) ignition coil • coil is damaged • inefficient high voltage wire (3) cdi magneto system • cdi failure • coil failure • charging coil failure • woodruff key is damaged (4) switches and wires • main switch is bad • the engine is off and ...

  • Page 178

    77 (1) carburetor • wrong needle valve position • main jet is clogged or loose • fuel is polluted • wrong float chamber fuel level (2) air filter • core of air filter is clogged (iv) shifting trouble 1. Shifting difficulty refer to “slipping of clutch” and “ablation of clutch” in this chapter 2. Shi...

  • Page 179

    78 (2) fuel system • main jet of carburetor is damaged • improper fuel level • core of air filter is clogged (3) cylinder system • serious carbon disposition (4) engine oil • improper oil level • improper oil • poor oil quality (5) brake • brake is stagnant (viii) brake trouble troubles: poor brake ...

  • Page 180

    • improper installation of steering pillar bearings • holding seat of steering pillar or sealing ring is damaged • rod is bent • spherical connection is bent (3) wheel tire • incorrect tire pressure • uneven tire wear (4) front/ rear tire • deformed rim • front wheel axle bearing is bent or loose • ...