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DAELIM ET-250 Service Manual
Summary of ET-250
Page 1
1 et-250
Page 2
2 contents 1. Information..........................................................................................................................................5 1.1 safety ...............................................................................................................................
Page 3
3 6-3 troubleshooting...............................................................................................................................37 6-4 cylinder head removal ..................................................................................................................38 6-5 cy...
Page 4
4 11-5 crankshaft inspection..................................................................................................................102 11-6 assembly of crankcase ................................................................................................................103 12. Cooling...
Page 5: 1. Information
5 1. Information 1.1 safty 1.2 notes 1.3 specification 1.4 serial number 1.5 torque value 1.6 special tools 1.1 safety gasoline gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. ● carbon monoxide never run the engine i...
Page 6: 1.3 Specification Engine
6 1.3 specification engine type 4 stroke，single cylinder, water cooled displacement 249c.C. Bore and stroke 71 mm x 63 mm compression 10.6:1 maximum hp 19ps / 5600 maximum torque (nm/rpm) 22.3 nm / 5500 carburetor ignition dc-cdi starting electric lubrication auto oil injection transmission automati...
Page 7: 1.4 Serial Number
7 1.4 serial number the frame serial number is stamped on the front of the frame. The engine serial numbe r is stamped on the left side of the crankcase. Frame serial number.
Page 8: 1.5 Torque Values
8 1.5 torque values standard ● 5 mm bolt and nut 5 n.M (3.5 lbf.Ft) ● 6 mm bolt and nut 10 n.M (7.2 lbf.Ft) ● 8 mm bolt and nut 22 n.M (16 lbf.Ft) ●10 mm bolt and nut 35 n.M (25 lbf.Ft) ●12 mm bolt and nut 55 n.M (40 lbf.Ft) engine ● cylinder head nut 28 n.M (20.7 lbf.Ft) ● spark plug 12 n.M (8.9 lb...
Page 9: 1.6 Special Tools
9 1.6 special tools 1. Adjustable hook spencer (e1105-lra0-ft1) purpose: adjusting of suspension 2. Ball joint puller(e0205-lra0-ft1) purpose: taking out the ball joint from front knuckle as repairing..
Page 10: 2.1 Maintenance Data
10 2.Maintenance 2.1 maintenance data 2.8 idle speed 2.2 maintenance schedule 2.9 drive chain 2.3 fuel tuble 2.10 brake system 2.4 throttle operation 2.11 wheels and tires 2.5 throttle cable ajustment 2.12 steering system 2.6 air cleaner 2.13 toe-in 2.7 spark plug 2.1 maintenance data specification ...
Page 11: 2.2 Maintenance Schedule
11 2.2 maintenance schedule the internal maintenance in the following table is based on average riding, normal conditions. Riding in unusually dusty areas, require more frequent servicing. 300km every every every every notes 1 month 3 months 6 months 1 year 2 years fuel lines i i r throttle operatio...
Page 12: 2.4 Throttle Operation
12 2.4 throttle operation inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttl...
Page 13: 2.8 Idle Speed
13 change a new spark plug if the ele ctrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.6-0.7mm with the sealing washer attached, thread the spark plug in by hand...
Page 14: 2.10 Brake System
14 2.10 brake system inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the brake lever free play at the end of the brake lever trip. Front brake lever free play is 15-25 mm. Turn the parking brake to the left side is “parking off”, wh...
Page 15
15 note: Ÿ the second method to adjust brake level is under the driver seat and rear brake component. Ÿ in order to avoid a pre-load occurred between brake disk and lining. After all adjusting of brake system are completed, please check the small clearance between brake disk and lining. Adjustable n...
Page 16: 2.11 Wheels and Tires
16 2.11 wheels and tires inspect the tire surfaces for cuts, nails or other sharp objects. Check the each tire surface at cold tire condition. *the standard of tire pressure is 12(0.8) psi ( kgf/cm2) steering shaft holder bushing remove the front fender first. Remove the steering shaft holder and ch...
Page 17
17 if the toe- in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 n.M lock nuts.
Page 18: 3.1 General Information
18 3. Engine remove and installation 3.1 repair condition 3.3 engine installation 3.2 engine removal 3.1 general information engine shall be removed in the conditions of necessary repairment or adjustment to the transmission and combustion system only 3.2 engine removal before removing engine, you n...
Page 19: 3.3 Engine Installation
19 3.3 engine installation the engine installation is essentially in the reverse order of removal. The torque of engine hanger bolt is 30 n.M route the wires and cable in reverse order properly..
Page 20: 4. Lubrication System
20 4. Lubrication system 4-1 mechanism diagram 4-2 precautions in operation 4-3 troubleshooting 4-4 engine oil 4-5 engine oil strainer clean 4-6 oil pump.
Page 21: 4-1 Mechanism Diagram
21 4-1 mechanism diagram valve rocker arm cam shaft spray lubrication spray lubrication press-in lubrication press-in lubrication oil route con-rod oil route oil pump rotate direction oil strainer.
Page 22: 4-3 Troubleshooting
22 4-2 precautions in operation general information: l this chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications engine oil quantity disassembly: 1400 c.C. Change: 1200c.C. Oil viscosity sae 10w-30 (recommended king serial oils) gear oil disassembly...
Page 23: 4-4 Engine Oil
23 4-4 engine oil turn off engine, and park the atv in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. Oil change caution drain oil as engine warmed up so th...
Page 24: 4-6 Oil Pump
24 4-6 oil pump oil pump removal remove generator and starting gear. (refer to chapter 10) ? Remove cir clip and take out oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump. Oil pump disassembly remove the s...
Page 25
25 oil pump inspection check the clearance between oil pump body and outer rotor. Limit: 0.25 mm check clearance between inner and outer rotors. Limit: 0.20 mm check clearance between rotor side face and pump body limit: 0.12 mm oil pump re-assembly install inner and outer rotors into the pump body....
Page 26
26 tighten the oil pump screw. Oil pump installation install the oil pump, and then tighten screws. Torque value ? 0.8~1.2kgf-m make sure that oil pump shaft can be rotated freely. Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft. Install starting gear and gen...
Page 27: 4-7 Gear Oil
4-7 gear oil gear oil change remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value : 1.0~1.5kgf-m make sure that the drain bolt washer can be re-used. Add oil to specified quantity from the join hole. Gear oil quantity: 650c.C. When replac...
Page 28: 5. Fuel System
5. Fuel system 5-1 mechanism diagram 5-2 precautions in operation 5-3 trouble diagnosis 5-4 carburetor remove / install 5-5 air cut-off valve 5-6 throttle valve 5-7 float chamber 5-8 adjustment of idle speed 5-9 fuel tank 5-10 air cleaner 5-1 mechanism diagram carburetor fuel unit inlet pipe auto fu...
Page 29
5-2 precautions in operation general information warning gasoline is a low ignition point and explosive materials, so always work in a well- ventilated place and strictly prohibit flame when working with gasoline. Cautions Ÿ do not bend off throttle cable. Damaged throttle cable will make unstable d...
Page 30: 5-3 Trouble Diagnosis
5-3 trouble diagnosis poor engine start Ÿ no fuel in fuel tank Ÿ clogged fuel tube Ÿ too much fuel in cylinder Ÿ no spark from spark plug(malfunction of ignition system ) Ÿ clogged air cleaner Ÿ malfunction of carburetor chock Ÿ malfunction of throttle operation stall after started Ÿ malfunction of ...
Page 31
5-4 carburetor remove / install removal drain out fuel in the float chamber. Loosen the choke cable fixed iron sheet screw from plate. Remove the choke cable. Disconnect the fuel hose. Release the clamp strip of air cleaner. Remove the carburetor upper parts from the carburetor. Release the 2 nuts o...
Page 32: 5-5 Air Cut-Off Valve
5-5 air cut-off valve disassembly remove 2 screws. Remove air cut-off valve cover, spring and valve. Inspection check the valve is in normal. If the valve is in normal, it will restrict air- flow. If air- flow is no restricting, replace carburetor assembly. Check the vacuum pipe o-ring is in normal....
Page 33: 5-6 Throttle Valve
5-6 throttle valve disassembly remove carburetor upper parts, and then remove throttle valve and throttle cable. Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Assembly place the fuel needle onto the throttle valve and...
Page 34: 5-7 Float Chamber
5-7 float chamber disassembly remove 3 mounting screws and remove float chamber cover. Remove the fuel level plate, float pin, float and float valve. Inspection check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt. Caution in ...
Page 35
Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Caution take care not to damage jets and adjust screw. Ÿ before removing adjustment screw, turn it all the way down and note the number of turns. Ÿ does not turn adjust screw forcefully to avoid damaging valve seat fa...
Page 36
5-8 adjustment of idle speed caution Ÿ air screw was set at factory, so no adjustment is needed. Note the number of turns it takes to screw it all the way in for ease of installation. Ÿ the parking brake must be used to stop the atv to perform the adjustments. Use a tachometer when adjusting engine ...
Page 37: 5-9 Fuel Tank
5-9 fuel tank fuel unit removal open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (covers remove please refer chapter 13) disconnect fuel unit coupler. Remove fuel unit (4 bolts). Caution ˙do not bend the float arm of fuel uni...
Page 38: 5-10 Air Cleaner
5-10 air cleaner removal loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts). Installation install the tank in the reverse order of removal. Cleaning ...
Page 39: 6-1 Mechanism Diagram
6. Cylinder head/valve 6-1 mechanism diagram 6-2 precautions in operation 6-3 troubleshooting 6-4 cylinder head removal 6-6 valve stem replacement 6-7 valve seat inspection and service 6-8 cylinder head reassembly 6-9 cylinder head installation 6-10 valve clearance adjustment 6-1 mechanism diagram.
Page 40
6-2 precautions in operation general information Ÿ this chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Ÿ cylinder head service can be carried out when engine is in frame. Specification of cylinder head item standard limit compression pressu...
Page 41
Exhaust 5.70 5.65 id of valve rocker arm 11.982~12.000 12.080 rocker arm od of valve rocker arm shaft 11.966~11.984 11.936 intake 4.975~4.990 4.900 od of valve stem exhaust 4.950~4.975 4.900 id of valve guide 5.000~5.012 5.030 intake 0.010~0.037 0.080 clearance between valve stem and guide exhaust 0...
Page 42: 6-3 Troubleshooting
6-3 troubleshooting engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Ÿ improper valve adjustment Ÿ burnt or bent valve Ÿ im...
Page 43: 6-4 Cylinder Head Removal
6-4 cylinder head removal remove engine. (refer to chapter 5) remove the inlet pipe (2 nuts). Remove 1 bolt of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts). Remove air inject...
Page 44
Remove left crankcase cover, and turn the turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at tdc position. Remove cam sprocket bolts and then remove the sprocket by prying chain out. Remove cam shaft setting plate (1 bolt). Remove rocker arm shaft...
Page 45
Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder...
Page 46
Remove valve stem seals. Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution do not damage the matching surface of cylinder head. 6-5 cylinder head inspection check if spark plug and valve holes are cracked. Measure cylinder he...
Page 47
Rocker arm measure the cam rocker arm i.D., and wear or damage, oil hole clogged? Service limit: replace when it is less than 12.10 mm. Rocker arm shaft measure the active o.D. Of the cam rocker arm shaft and cam rocker arm. Service limit: replace when it is less than 11.91 mm. Calculate the clearan...
Page 48
Valve guide caution before measuring the valve guide, clean carbon deposits with reamer. Tool: 5.0 mm valve guide reamer measure and record each valve guide inner diameters. Service limit: 5.03 mm the difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the c...
Page 49: 6-6 Valve Stem Replacement
6-6 valve stem replacement heat up cylinder head to 100~150 ℃ with heated plate or toaster. Caution Ÿ do not let torch heat cylinder head directly. Otherwise, the cylinder head may be deformed as heating it. Ÿ wear on a pair of glove to protect your hands when operating. Hold the cylinder head, and ...
Page 50
6-7 valve seat inspection and service clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Ÿ do not let emery enter into between valve stem and valve guide. Ÿ clean u...
Page 51
Use 32° cutter to cut a quarter upper parts out..
Page 52
Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat. Use 45° cutter to grind the valve seat to specified width. Caution make sure that all roughness and uneven faces had been ground. Grind valve seat again if necessary. Coat the valve seat surface with red pai...
Page 53
After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground. 6-8 cylinder head reassembly lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve...
Page 55
6-9 cylinder head installation clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution do not damage the matching surfaces of cylinder and cylinder head. Avoid...
Page 56
Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts. Caution make sure timing marks are matched. Install cylinder head side cover (3 bolts). Install thermostat (2 ...
Page 57
Install air injection system (ai) pipe. (4 bolts) install inlet pipe onto cylinder install and tighten spark plug torque value: 1.0~2.0kgf-m caution this model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinde...
Page 58
Stop the engine after confirmed, and then install the cylinder head cover and ai pipe. Caution Ÿ if lubricant does not flow to cylinder head, engine components will be worn out seriously. Thus, it must be confirmed. Ÿ when checking lubricant flowing condition, run the engine in idle speed. Do not ac...
Page 59: 7. Cylinder/piston
7. Cylinder/piston 7-1 mechanism diagram 7-2 precautions in operation 7-3 trouble diagnosis 7-5 piston ring installation 7-6 piston installation 7-7 cylinder installation.
Page 60: 7-1 Mechanism Diagram
7-1 mechanism diagram 0.8~1.2kgf-m 1.0~1.4kgf-m.
Page 61: 7-3 Trouble Diagnosis
7-2 precautions in operation general information Ÿ both cylinder and piston service cannot be carried out when engine mounted on frame. Specification of cylinder item standard limit id 70.995~71.015 71.100 cylinder bend - 0.050 top ring 0.015~0.050 0.090 clearance between piston rings 2 nd ring 0.01...
Page 62
7-4 cylinder and piston removal remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston. Remove cylinder gasket and dowel pin. Clean ...
Page 63
Check cylinder if warp. Service limit: 0.05 mm measure clearance between piston rings and grooves. Service limit: top ring: 0.09 mm 2 nd ring: 0.09 mm remove piston rings check if the piston rings are damaged or its grooves are worn. Caution pay attention to remove piston rings because they are frag...
Page 64
Measure the outer diameter of piston pin. Service limit: 17.00 mm measure the inner diameter of connecting rod small end. Service limit: 17.02 mm measure the inner diameter of piston pin hole. Service limit: 17.02 mm calculate clearance between piston pin and its hole. Service limit: 0.02 mm measure...
Page 65
7-5 piston ring installation clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Ÿ do not damage piston and piston rings as installation. Ÿ all marks on the piston rings must be forwarded to ...
Page 66: 7-6 Piston Installation
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase. Caution soap the residues into solvent so that the residues can be removed more easily. 7-6 piston installation install piston and pist...
Page 67: 7-7 Cylinder Installation
7-7 cylinder installation install dowel pins and new gasket. Dowel pins.
Page 68
Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution do not push piston into cylinder forcefully because piston and piston rings will be damaged.。 install coolant hose ont...
Page 69: 8. V-Belt Driving System
8. V-belt driving system 8-1 mechanism diagram 8-2 maintenance description 8-3 trouble diagnosis 8-4 left crankcase cover 8-5 drive belt 8-6 drive face 8-7 clutch outer/driven pulley 8-1 mechanism diagram 5.0~6.0kgf-m 5.0~6.0kgf-m 8.5~10.5kgf-m.
Page 70: 8-2 Maintenance Description
8-2 maintenance description precautions in operation general information Ÿ drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Ÿ drive belt and drive pulley must be free of grease. Specification of v-belt system item standard value (mm) limit (mm) driving belt width 24.000...
Page 71: 8-4 Left Crankcase Cover
8-4 left crankcase cover left crankcase cover removal release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) remove 2 dowel pin and gasket. Left crankcase cover install install left crankcase cover in the reverse procedures of remo...
Page 72
Left crankcase cover inspection release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) remove 2 dowel pin and gasket. Clamp strips 9 bolts.
Page 73: 8-5 Drive Belt
8-5 drive belt removal remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special tool：universal holder hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer. Caution Ÿ using special service tools for tightening ...
Page 74
Installation caution l pull out driven face to avoid it closing. L cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end t...
Page 75: 8-6 Drive Face
8-6 drive face removal remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Remove movable drive face comp and drive face boss from crankshaft. Remove ramp plate. Remove weight rollers from movable drive face. Crankshaf...
Page 76
Inspection the weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter. Replace it if excee...
Page 77
With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution the movable drive face surface has to be free of grease. Clean it with cleaning solvent. Install movable drive face comp. Onto crankshaft. Driven pulley installation press drive belt into pull...
Page 78
8-7 clutch outer/driven pulley disassembly remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily. Caution do not press the compressor too much. Hold the clutch spring compres...
Page 79
Clutch lining measure each clutch weight thickness. Replace it if exceeds service limit. Service limit: 2.0 mm driven pulley spring measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 83.2 mm driven pulley check following items: Ÿ if both surfaces are dama...
Page 80
Clutch weight replacement remove snap ring and washer, and the n remove clutch weight and spring from driving plate. Caution some of models are equipped with one mounting plate instead of 3 snap rings. Check if spring is damage or insufficient elasticity. Check if shock absorption rubber is damage o...
Page 81
Install snap ring and mounting plate onto setting pin. Replacement of driven pulley bearing remove inner bearing. Caution Ÿ if the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. Ÿ if the pulley equipped with ball bearing, it has to remove snap ri...
Page 82
Installation of clutch outer/driven pulley assembly install new oil seal and o-ring onto mo vable driven face. Apply with specified grease to lubricate the inside of movable driven face. Install the movable driven face onto driven face. Install the guide pin and guide pin roller. Install the collar....
Page 83: 9. Final Driving Mechanism
9. Final driving mechanism 9-1 mechanism diagram - transmission cover 9-2 precautions in operation 9-3 trouble diagnosis 9-4 disassembly of transmission 9-5 inspection of mission mechanism 9-6 bearing replacement 9-7 re-assembly of final driving mechanism 9-1 mechanism diagram - transmission cover f...
Page 84: 9-3 Trouble Diagnosis
9-2 precautions in operation specification application oil: scooter gear oil recommended oil: king mate serial gear oils oil quantity: 750c.C. (650c.C. When replacing) torque value gear box cover 2.6~3.0kgf-m gear oil drain bolt 0.8~1.2kgf- m gear oil fill bolt 3.5~4.5kgf- m tools special tools bear...
Page 85
9-4 disassembly of transmission remove gear change lever (1 bolt). Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box. Caution the socket bolt is provided with left tu...
Page 86
Remove gear box cover bolts (9 bolts) and then remove the cover. Remove shift drum catch ball, spring and bolt. Remove shift spind le, shift fork shaft, shift fork and shift drum. Remove final shaft, counter shaft and reverse shaft. 9 bolts shift drum fixed catch bolt shift drum shift spindle shift ...
Page 87
Remove drive shaft bearing setting plate (1 bolt). Remove the drive shaft. Special tool: shaft protector remove gasket and dowel pin. Caution Ÿ if non- essential do not remove the drive shaft from the case upper side. Ÿ if remove the drive shaft from the gear box, then its bearing and oil seal has t...
Page 88
9-5 inspection of mission mechanism check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Check if the counter shaft is wear or damage..
Page 89
Check if the reverse shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounte...
Page 90: 9-6 Bearing Replacement
9-6 bearing replacement caution Ÿ never install used bearings. Once bearing removed, it has to be replaced with new one. Crankcase side remove drive shaft bearing setting plate, and then remove drive shaft bearing from left crankcase using following tools. Remove reverse shaft bearing and counter sh...
Page 91
Install drive shaft. Special tool: drive shaft puller drive shaft and oil seal install bush clutch nut wrench apply with grease onto new drive shaft oil seal lip, and then install the oil seal. Special tool: drive shaft and oil seal install bush install drive shaft bearing setting plate (1 bolt). Ge...
Page 92
Special tool: inner bearing puller remove oil seal from gear box cover and discard the seal install new bearing and bearing driver into gear box cover outer side. Install the universal bearing puller and bearing driver. Turn the universal bearing puller to install drive shaft bearing. Special tool: ...
Page 93: Mechanism
9-7 re-assembly of final driving mechanism apply with grease onto the oil seal lip of final driving shaft. Install counter shaft, reverse shaft and final shaft onto gear box. Install shift drum, shift fork and fork shaft onto gear box. Install shift drum fixed catch ball, spring and bolt onto gear b...
Page 94
Align the position mark on the shift spindle sprocket with that of shift drum, and then install shift spindle. Install dowel pins and new gasket. Install gear box cover and bolts, and tighten. Torque value: 1.0~1.4kgf-m install the shift spindle bracket, drive chain protector, speedometer gear box a...
Page 95: 10-4 A.C.G. Set Removal
10. Alternator/starting clutch 錯誤! 書籤的自我參照不正確。 錯誤! 表格製作不正確。 錯誤! 表格製作不正確。 10-4 a.C.G. Set removal 10-5 right cover bearing 10-6 flywheel removal 10-7 starting clutch 10-8 flywheel installation 10-9 a.C.G. Set installation.
Page 96: 10-1 Mechanism Diagram
10-1 mechanism diagram 5.0~6.0kgf-m 1.0~1.4kgf-m 0.8~1.2kgf-m.
Page 97
10-2 precautions in operation general information Ÿ refer to chapter 17: the troubleshooting and inspection of alternator Ÿ refer to chapter 17: the service procedures and precaution items of starter motor specification item standard value (mm) limit (mm) id of starting clutch gear 25.026~25.045 25....
Page 98: 10-4 A.C.G. Set Removal
10-3 right crankcase cover removal remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. 10-4 a.C.G. Set removal remo...
Page 99: 10-6 Flywheel Removal
Check the oil seal for wear or damage. Replace it if necessary. Install a new one bearing (6201lu) by bearing driver. Special tool: bearing driver 10-6 flywheel removal remove right crankcase cover. Remove left crankcase cover. Hold the flywheel by drive face with universal holder. Remove flywheel n...
Page 100: 10-7 Starting Clutch
Remove starter reduction gear and shaft. Pull out flywheel with a.C.G. Flywheel puller. Special tool: a.C.G. Flywheel puller remove flywheel and starting driven gear. 10-7 starting clutch starting clutch inspection remove starting clutch driven gear. Check the gear for wear or damage. Measure the id...
Page 101
Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in c.C.W direction freely, but not c.W direction. (view as shown in this figure.) one way clutch removal remove starting driven gear. Remove 3 socket bol...
Page 102: 10-8 Flywheel Installation
One way clutch installation install the components in the reverse procedures of removal. Caution tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m install starting driven gear. 10-8 flywheel installation align the key on crankshaft with the flywheel groove, and then ...
Page 103: 10-10 Right Crankcase Cover
Install reduction gear shaft and reduction gear. 10-9 a.C.G. Set installation install the a.C.G. Coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution make sure that the wire harness is placed under pul...
Page 104
Install right crankcase cover (11 screws). Install the dowel pin, new gasket and water pump cover onto crankcase cover. Connect water hoses to the right crankcase cover and water pump cover. 11 bolts water pump cover bolts.
Page 105: 11. Crankcase / Crank
11. Crankcase / crank 11-1 mechanism diagram 11-2 general information 11-3 trouble diagnosis 11-4 disassembly of crankcase 11-5 crankshaft inspection 11-6 assembly of crankcase 11-1 mechanism diagram eng. Oil drain bolt 3.5~4.5kgf-m 0.8~1.2kgf-m 1.0~1.4kgf-m 0.8~1.2kgf-m.
Page 106: 11-2 General Information
11-2 general information operational precautions Ÿ this section concerns disassembly of the crankcase for repair purpose. Ÿ remove following components before disassembling crankcase. －engine remove section 5 －cylinder head section 6 －cylinder and piston section 7 －drive face and driven pulley secti...
Page 107
11-4 disassembly of crankcase remove the cam chain setting plate, and then remove cam chain. Loosen the pivot bolt and remove the tensioner. Loosen 2 bolts on the right crankcase. Loosen 11 bolts on the left crankcase. Place right crankcase downward and left crankcase up. Tap the left crankcase with...
Page 108
Remove balance shaft from right crankcase. Remove crankshaft from right crankcase. Remove gasket and dowel pins. Scrape gasket residues off the crankcase contact surface. Caution do not damage contact surface of the gasket. It is better to moisten the gasket residue for easy scrapping. Drive out lef...
Page 109: 11-5 Crankshaft Inspection
11-5 crankshaft inspection use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm place the crankshaft on a v-block, measure run-out of the crankshaft. Service ...
Page 110: 11-6 Assembly of Crankcase
Check bearings on right and left crankcase. Rotate each bearings inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Special ...
Page 111
Install 2 dowel pins and new gasket. Install the left crankcase onto the right crankcase. Tighten 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m tighten 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m dowel pins 11 bolts 2 bolts.
Page 112
Clean the crankshaft. Apply a layer of grease on the lip of oil seal, puts on the left crank shaft. Install the oil seal in the left crankcase with care not to damage the lip of the oil seal. By oil seal driver (27×42×7), oil seal will knock into located. Special tool: oil seal driver (27×42×7) inst...
Page 113: 12. Cooling System
12. Cooling system 12-1 mechanism diagram 12-2 general information 12-3 trouble diagnosis 12-4 trouble diagnosis for cooling system 12-5 system test 12-6 radiator 12-7 water pump 12-8 thermostat 12-1 mechanism diagram radiator filler cap.
Page 114
Radiator reserve tank thermo switch (fan) coolant inlet pipe coolant outlet pipe by-pass pipe water pump thermostat cooling fan to cylinder head.
Page 115: 12-2 General Information
12-2 general information general warning: while the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. Ÿ refill the radia...
Page 116
12-4 trouble diagnosis for cooling system the temperature indicated is too high y y y water hose clogged y b-2. Inspect the circuits of water temperature have short or earth? Short or earth handle y y b. Turn on main switch and check the water temperature indicator back to zero? B-1. Measure thermo ...
Page 117
E-4. Remove thermostat from holder then heats it by water directly to check its operation? F. Confirm the cooling fan was convulsion? E-3. Keep eng. 3000~4000 rpm and inspect coolant flow into reserve tank after the temperature gauge over 3 checks? For bleed the air bubbles completely, open radiator...
Page 118: 12-5 System Test
12-5 system test test on the filler cap hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low. The specified pressure shall be...
Page 119: 12-6 Radiator
Check reserve tank Ÿ remove the front center cover, and then remove reserve tank filler cap. Ÿ check the liquid level in the front fender right side. Add coolant to proper level if too low. Ÿ reinstall the reserve tank filler cap. Caution the reserve tank liquid level coca too is not high, after avo...
Page 120
Loosen the radiator 4 bolts. Remove coolant upper side pipes. Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. Disassembly loosen the 3 bolts from the fan duct, and then remove the fan duct. Loosen 3 screws from the fa...
Page 121: 12-7 Water Pump
12-7 water pump check water pump seal / cooling system divulges inspection Ÿ disassembles the refrigerant drain bolt, overflows little buckles the n actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. Ÿ turns on lathe the engine oil gauge rule, the inspection engine oil ...
Page 122
Check any wear and damage of the mechanical seal and inside seal. Caution the mechanical seal and inside seal must be replaced as a unit. Replacement of mechanical seal remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase. Special too...
Page 123
Install the new inner seal onto the right crankcase. Special tools: water pump oil seal driver (inner) install a new outside bearing to the right crankcase cover. Special tools: water pump bearing driver (6901) caution do not reuse old bearing. It must be replaced with a new one once it has been rem...
Page 124
Install the seal washer into the rotor. Caution washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and tighten. Torque value: 1.0~1.4kgf-m caution the rotor is left thread. Install the dowel pin and right cover gasket. The rotation water pump rotor...
Page 125: 12-8 Thermostat
12-8 thermostat please refer to chapter 17 for inspection of temperature sensor. Removal drain out the coolant. Remove the thermostat set. (2 bolts) inspection visually inspect thermostat for any damage. Place the thermostat into heated water to check its operation. Caution whenever the thermostat a...
Page 126: 13.1 Parts Drawing
13. Steering and suspension 13.1 parts drawing 13.2 troubleshooting 13.3 handlenar 13.4 throttle housing 13.5 steering system 13.1 parts drawing steering handle bar.
Page 127: 13.2 Troubleshooting
13.2 troubleshooting hard steering front wheel wobbling steers to one side front suspension noise hard suspension soft suspension ★ faulty tire ★ steering shaft holder too tight ★ insufficient tire pressure ★ faulty steering shaft bushing ★ damaged steering shaft bushing ★ faulty tire ★ worn front b...
Page 128
Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Remove the handle cover and instrument panel by four screws at right and left side as shown in picture. Remove the bolts attaching the handlebar upper holder. Remove the handlebar. Bolts screws screws.
Page 129: Installation
Installation put the handlebar on the lower holders. Make sure the handlebar punch marks match with the top end of the handlebar of lower holders. Install the handlebar upper holders with the l or r marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts. Install the h...
Page 130: 13.4 Throttle Housing
13.4 throttle housing disassembly loosen the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. Note: assembly is in the reverse order of disassembly. 13.5 steering system when the stee...
Page 131: Step 1
Step 1 tie-rod inspection ü inspecting the tie-rod for damage or bending. ü inspecting the ball joint rubbers for damage, wearing or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. Steering shaft removal remove the handle bar cover and handle bar. ...
Page 132
Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50 n.M (37 lbf.Ft).
Page 133: 14.1 Parts Drawing
14. Front wheel and brake system 14.1 parts drawing 14.2 troubleshooting 14.3 front wheel 14.4 hydraulic brake 14.5 suspension system 14.1 parts drawing front wheel front beake.
Page 134: 14.2 Troubleshooting
14.2 troubleshooting hard steering front wheel wobbling brake drag steers to one side poor brake performance ★ faulty tire ★ insufficient tire pressure ★ faulty tire ★ worn front brake drum bearing ★ bent rim ★ axle nut not tightened properly ★ incorrect brake adjustment ★ sticking brake cable ★ ben...
Page 135: 14.4 Hydraulic Brake
14.4 hydraulic brake this type of brakes are applying in front of two wheels of ra1 removal raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures. Loosen fours nut...
Page 136
Before loosening castle nut, you have to remove cotter pin then using the power tools to take the screw out from brake stopping plate. You can take the brake disc off. When change brake shoe wear, you must push the master piston to rearward. After removal the front brake assembly, you must fabricate...
Page 137
Add brake oil the brake oil tank is under the driver seat at right hand side. Please check the brake oil level position at outside of tank. To open the cap of brake oil tank, please turn “ccw” direction. Brake oil tank.
Page 138
14 .5 suspension adjustment suspension system in this type of avt can be adjustable its hardness and softness (fig 1). 1. You can raise the all atv body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner, e1105- lra0-ft1 ) to ad...
Page 139: 15.1 Parts Drawing
15. Rear wheel and brake system 15.1 parts drawing 15.2 troubleshooting 15.3 remove rear wheel and rear brake 15.4 swingarm & rear axle holder 15.5 suspension adjustment 15.1 parts drawing rear wheel rear wheel axel.
Page 140
Rear brake.
Page 141: 15.2 Troubleshooting
15.2 troubleshooting bad brake performance ★ brake shoes are worn ★ bad brake adjustment ★ brake linings are oily, greasy or dirty ★ brake drums are worn ★ brake arm setting is improperly engage vibration or wobble ★ axle is not tightened well ★ bent rim ★ axle bearings are wo rn ★ faulty tires ★ re...
Page 142
Loosen two bolts to take out rear brake disk as shown in picture. Loosen bolts and remove the brake disc check the thickness of disc and replace a new one if the thickness less than 3mm to replace the brake shoe to replace the brake shoe, please loosen this bolt as shown in picture. Please push the ...
Page 143
Eventually, you can take all brake shoe out the hub. There are two kind of brake linings as shown in picture to replace the brake hydraulic oil loosen the bolts and open the cover loosen the bolt and drain the used oil out. Tighten the bolt after the used oil being drained out completely add the bra...
Page 144
15.4 swingarm & rear axle holder this section is to introduce how to repair the swing-arm, the following pictures are going to teach you how to install the swing-arm. 1. Put the swingarm at proper position as shown in picture. Two hanger bolts will be used to hold the swing-arm at right and left sid...
Page 145
3. Screw another hanger bolt on the left side as shown in picture. But do not tighten it. Let the cross-section of bolt and cross-section of hole in the same plane. 4. Tighten the nut hanger bolt.
Page 146: 15.5 Suspension Adjustment
15.5 suspension adjustment suspension system in this type of avt can be adjustable its hardness and softness (fig 1). 1. You can raise the all atv body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner) to adjust the suspension...
Page 147: 16.1 Fenders Drawing
16. Fenders and exhaust pipe 16.1 fendres drawing 16.3 front fender removal 16.2 rear fenders removal 16.4 exhaust pipe removal 16.1 fenders drawing exhaust pipe (for all serials).
Page 148: 16.2 Rear Fenders Removal
16.2 rear fenders removal there are two seat release bars located at the right and left hand side of the seat. Please remove the seat first. Procedures of remove the rear fender: remove the rear rack. 1. Open the seat. 2. Loosen four bolts which connect the front fender and rear fender. 3. Loosen th...
Page 149
Pull the seat handle up first. There are two screws on the top of seat compartment. Please remove them. Finally, you must remove the bolts on the footrest. Bolts.
Page 150: 16.3 Front Fender Removal
16.3 front fender removal to remove the front fender, there are sever trips to indicate users how to remove it. 1. First picture shows there are two screw, loosen it. Remove the mounting bolts from the front fender. Please remove the two screws on the top of the headlight. Then you can see there is ...
Page 151: 16.4Exhaust Pipe Removal
16.4exhaust pipe removal you must wait at least 15 minutes after stopping the engine. You need to remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Loosen the two exhaust pipe bolts that fixed on the engine. Warning：do not service the exhaust pipe while they are ...
Page 152: 17. Electrical System
17. Electrical system 17.1 troubleshooting 17.2 ignition coil 17.3 ignition timing 17.4 battery information 17.5 electric starter 17.6 light bulbs replacement 17.7 instrument panel 17.8 wiring diagram 17.1 troubleshooting engine starts but stops ★ improper ignition timing ★ faulty spark plug no spar...
Page 153: 17.2 Ignition Coil
17.2 ignition coil remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. Standard: 0.1 - 0.3Ω(20℃) measure the secondary coil resistance with the spark plug cap in place. Standard : 7.4 – 12 kΩ(20℃) 17.3 ignition timing the ign...
Page 154: 17.5 Electric Starter
Charging firstly, connect the charged positive cable to the battery positive terminal. Secondly, connect the charged negative cable to the battery negative terminal. Using 0.9a-charging current about 11 hours. (normal charging) or using 4a-charging current about 3 hour. (quick charging) keep flames ...
Page 155
To replace the direction lights must loosen the screws as shown in picture. Front position light removes there are two screws inside the cap. Please disassemble first then push the cap upward. You could replace the electrical bulb. Turn around the cap, you could see the connector. Turn the seat to r...
Page 156
Rear brake lights remove on the back of the brake light, you could see the cap. There are two screws to fix this cap, loosen them can open the cap. Please rotate the electrical bulb, and then it could be removed. Rear direction lights remove the same disassembling procedure like front direction ligh...
Page 157: 17.7 Instrument Panel
17.7 instrument panel the instrument panel includes fuel gauge, speed meter, water temperature gauge, right and left turn signal, trip do-meter, and indicator camp. A lcd is used on atv8e’s instrument panel to display all driving information for users. Therefore, this is an all-in-one instrument pan...
Page 159: 17.8 Wiring Diagram
17.8 wiring diagram.
Page 160: 18.1 Engine Can Not Work
18.Troubleshooting 18.1 engine can not work 18.2 poor performance at low and idle speeds 18.3 poor performance at high speed 18.4 loss power 18.5 poor handling 18.1 engine can not work possibility ★ no fuel in fuel tank ★ clogged float valve ★ clogged fuel tank cap breather hole ★ clogged at fuel tu...
Page 161
18.2 poor performance at low and idle speeds n.G. O.K. Check carburetor n.G. Air screw adjustment o.K check for leaking n.G intake pipe o.K. Perform spark test week or intermittent spark possibility ★ faulty cdi unit or pulse generator ★ improperly adjusted air screw ★ deteriorated insulator o-ring ...
Page 162: 18.4 Loss Power
18.4 loss power raise wheels off ground does not spin freely and spin by hand spin freely pessure low check tire possibility ★ brake dragging ★ drive chain too tight ★ damaged wheel bearing ★ wheel bearing needs lubrication ★ punctured tire ★ faulty tire valve ★ fuel / air mixture ratio too rich or ...
Page 163: 18.5 Poor Handling
18.5 poor handling possibility ★ damaged steering bearing ★ damaged steering shaft bushing ★ bent rim ★ improperly installed wheel hub ★ excessive wheel bearing play ★ bent swingarm ★ bent frame ★ swing arm pivot bushing excessively ★ worn ★ bent tie-rod ★ incorrect tie-rod adjustment ★ rear tie air...