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KEEWAY 500ATV Service Manual - Foreword

Summary of 500ATV

  • Page 1

    Service manual 500atv/500atv-2 4×4.

  • Page 2: Foreword

    Foreword this service m anual is designed prim arily for use by certified keeway service center. Technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicl e are from the operator's perspective when seated in a norm al ridi...

  • Page 3

    1. Service information 1-1 a few words about safety ……………1-1 tightening torque………………………1-9 vin number engine number…………1-3 lubricating oil, and brake liquid ……1-12 main data table………………………1-4 cables pipes, cable routing ……………1-13 overhaul datasheet……………………1-5 a few words about safety service informa...

  • Page 4

    1. Service information 1-2 ● protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protection. ● use other protective...

  • Page 5

    1. Service information 1-3 identification number records record the vehicle identification number and engine number in the spaces provided for assistance when ordering spare parts from your dealer or for reference in case the vehicle is stolen. Vehicle identification number(500atv): lcxgsts1~ vehicl...

  • Page 6: Main Data Table

    1. Service information 1-4 main data table item parameter model 500atv /500atv-2 length 2085 mm/ 2285 mm width 1180 mm height 1175 mm/ 1270 mm wheel base 1300 mm/1500mm engine type xy192 displacement 498.3 ml fuel type unleaded gasoline 93octane or above mass of whole equipments (not include driver)...

  • Page 7

    1. Service information 1-5 item parameter fuel type higher class than rq-93 transmission v-belt with teeth on, auto stepless gear change, plus gear change cam with change gear transmission gear change type gear lever with hand clutch type wet, hoof centrifugal type primary speed change ratio (steple...

  • Page 8

    1. Service information 1-6 item parameter gearing gearbox gear ratio total low gear: 4.39, high gear: 2.57, reverse gear: 3.21 right 40° steering device steering angle left 40° front hydraulic disc brake type rear hydraulic disc bumper device suspension swing arm frame type welded steel tube and pla...

  • Page 9

    1. Service information 1-7 fuel device item parameter fuel tank capacity full capacity 22l type keihin aw6a main jet 99101-939-1380(#140 idle jet n424-25b35(#40) carburetor idle speed 1400±100r/min cooling device item standard full capacity 1000ml reservoir tank capacity 300 ml coolant capacity stan...

  • Page 10

    1. Service information 1-8 brake system item standard service limit brake lever play 0mm -- brake disc thickness 4mm 3mm brake pedal play 0mm front brake brake disc thickness 4mm 3mm battery、charging system item standard model permanent magnet ac type output 3- phase ac ac magneto motor charging coi...

  • Page 11

    1. Service information 1-9 screwing moment of important bolts engine： sequence number item thread diameter mm torque （ n·m） remark 1 crankcase m8×88 25 2 spark plug m14×1.25 20 3 shift cam/ secondary shaft/secondary shaft m8×32 30 4 rear cover,bearing m8×28 25 5 oil pump installing bolts m6×50/m6×45...

  • Page 12

    1. Service information 1-10 32 crankcase m6×85 10 33 crankcase m6×92 10 34 thermostat/ temperature switch m14×12 30 35 cvt cover,left(lower) m6×12 10 36 cover,shift shaft m6×139 10 37 cover,shift shaft m6×28 10 38 flange,output m16 300 m5 4.5—6 m6 8—12 39 other bolts m8 18--25.

  • Page 13

    1. Service information 1-11 front, rear suspension： s.Q. Item qty. Thread diameter mm torque （ n·m） remark 1 nut, stabilizer 2 m10 45～50n.M 2 bolt, stabilizer holder 4 m8×16 20～25n.M 3 nut, front/ rear axle 4 m10 45-50n.M 4 bolt, front/ rear axle support 8 m8×16 23-25n.M 5 bolt, steering shaft 2 m8×...

  • Page 14

    1. Service information 1-12 specification tightening moment m6 8~12n·m m8 18~25n·m m10 40~50n·m other screws（8.8 grade） m12 50~60n·m specification and usage quantity for fuel lubricating oil and brake liquid category specification capacity remark fuel rq-93or upper grade lead-free gasoline 22l conte...

  • Page 15

    1. Service information 1-13 cables, pipes, cable routing 1. Light switch 2. Warning indicator light switch 3. Low beams/high beams turning switch 4. Turning light switch 5. Horn switch 6. Start switch 7. Engine stop switch 8. Starter (choke) 9. Drive select lever 10. Winch switch 11. 4wd/4wd-lock 12...

  • Page 16

    1. Service information 1-14.

  • Page 17

    1. Service information 1-15 1.

  • Page 18

    1. Service information 1-16.

  • Page 19

    2. Vehicle body，muffler 2-1 overhaul info……………………………2-1 l eft footrest board …………………………2-5 troubleshooting…………………………2-1 right footrest board ………………………2-6 front rack………………………………2-2 rear cover assembly ... ... ... ... .. ... ... ... ...2-7 front bumper……………………………2-2 store box cover…………............ ......

  • Page 20

    2. Vehicle body，muffler 2-2 front rack remove remove two bolts 1 remove two bolts 2 remove two bolts 3 remove front rack installation reverse the removal procedure for installation front bumper remove remove four bolts 4 remove bumper. Installation reverse the removal procedure for installation seat...

  • Page 21

    2. Vehicle body，muffler 2-3 rear rack remove remove seat( →2-2 ) remove two bolts 1 remove two bolts 2 remove two bolts 3 remove rear rack installation reverse the removal procedure for installation rear bumper remove remove two bolts 4 remove rear bumper. Installation reverse the removal procedure ...

  • Page 22

    2. Vehicle body，muffler 2-4 left side panel remove remove seat (→2-2) remove bolt 1 for left side panel and store box cover. Remove bolt 2 for left side panel and front cover(l). Remove bolt 3 for left side panel and footrest board (l). Installation reverse the removal procedure of installation.

  • Page 23

    2. Vehicle body，muffler 2-5 right side panel remove remove seat (→2-2) remove bolt 1 for right side panel and store box cover. Remove bolt 2 for left side panel and footrest board (r). . Installation reverse the removal procedure of installation left footrest board remove: remove left side panel (→2...

  • Page 24

    2. Vehicle body，muffler 2-6 remove bolt 5 remove left footrest board installation reverse the removal procedure of installation right footrest board remove: remove right side panel (→2-5) remove bolt 1 & nuts for front cover(r) remove bolt 2 & nuts for rear cover remove bolt 3 remove right footrest ...

  • Page 25

    2. Vehicle body，muffler 2-7 rear cover assembly remove: remove seat (→2-2) remove bolt 1 remove fuel tank cap remove connector of taillight remove rear cover install fuel tank cap for fuel tank installation reverse the removal procedure of installation. Rear cover assembly disassembly/installation 1...

  • Page 26

    2. Vehicle body，muffler 2-8 store box cover remove: remove globe joint of gearshift remove bolt 2 remove meter cover remove bolt 3 remove bolt 4 remove connector of ignition switch remove connector of power output remove store box cover installation reverse the removal procedure of installation. Fro...

  • Page 27

    2. Vehicle body，muffler 2-9 remove connector of meter remove connector of headlight remove front cover assembly. Installation reverse the removal procedure of installation. Front cover assembly disassembly /installation 1. Meter assembly 2. Washer( φ 5) 3. Nut, flange（m5） 4. Cover, water tank 5. Scr...

  • Page 28

    2. Vehicle body，muffler 2-10 muffler: caution: perform disassembly only after the muffler is cooled down. Remove: remove seat (2-2) remove left footrest board（→2-5） nut1, nut 2 for exhaust pipe elbow. Remove nut1, nut 2. Remove: remove bolt 1 remove bolt 2 remove muffler remove exhaust pipe installa...

  • Page 29

    2. Vehicle body，muffler 2-11 rear left & right wheel assembly remove: remove cap of wheel center(rubber) remove nut 1 remove rear left & right wheel assembly installation reverse the removal procedure of installation fuel tank warning: gasoline is highly flammable, therefore smoke and fire are stric...

  • Page 30

    2. Vehicle body，muffler 2-12 remove bolt 1 remove bolt 2 remove fuel tank installation reverse the removal procedure of installation fuel tank assembly disassembly /installation 1. Fuel tank 2. Pipe fuel 3. Fuel sensor 4. Fuel filter 5. Fuel pump 6. Cap, fuel tank 7. Cushion rubber(φ25) 8. Cushion r...

  • Page 31

    2. Vehicle body，muffler 2-13 guard plate (plastic) disassembly /installation note: guardplate, middle, guard plate, rear and guard plate, tail are located at the bottom of vehicle. The maintenance person should have to work under the vehicle bottom when disassembling the above parts. For safety purp...

  • Page 32: Visible Parts

    2. Vehicle body，muffler 2-14 visible parts.

  • Page 33

    3. Checks & adjustment 3-1 overhaul info………………………3-1 suspension system……………………3-10 maintenance table…………………3-2 gear shifting, fuel device……………3-11 inspection & maintenance…………3-3 throttle lever check…………………3-12 steering stem………………………3-6 cooling system………………………3-13 wheels………………………………3-8 overhaul info...

  • Page 34

    3. Checks & adjustment 3-2 regular maintenance table the table below lists the recommended intervals for all the required periodic maintenance work necessary to keep the vehicle at its best performance and economy. Maintenance intervals are expressed in terms of kilometer, miles and hours, whichever...

  • Page 35

    3. Checks & adjustment 3-3 inspection & maintenance ○ ： interval check item interval part item daily 1/2 year annual standard handlebar operation agility ○ damage ○ installation condition of steering system ○ steering system steering system sway of ball stud○ free play ○ ○ ○ front: lever end 0mm fro...

  • Page 36

    3. Checks & adjustment 3-4 check item intervals part item daily 1/2 year annual standard looseness of joint parts ○ ○ ○ drive trainfinal shaft (drive shaft) sway of spline ○ spark plug ○ ○ ignition device ignition timing ○ ○ battery terminal joint ○ electrical system wiring looseness and damage of j...

  • Page 37

    3. Checks & adjustment 3-5 check item intervals part item daily 1/2 year annual standard lighting device and turning indicators function ○ ○ ○ alarm and lock device function ○ instruments function ○ looseness or damage caused by improper installation ○ exhaust pipe and muffler function of muffler ○ ...

  • Page 38

    3. Checks & adjustment 3-6 steering stem park the vehicle on level place, hold steering handlebar, and shake in the direction as illustrated on the right and see if there is any sway. In case of any sway, check if it is the problem of the steering stem or other parts and then do the maintenance acco...

  • Page 39

    3. Checks & adjustment 3-7 master cylinder fluid level check the brake fluid level when the brake fluid level is near to the lower limit line, check master cylinder, brake hoses and joints for leakage. Remove the two mounting screws on fluid reservoir cap . Add dot3 or dot4 brake liquid till the upp...

  • Page 40

    3. Checks & adjustment 3-8 wheels lift front wheel on level place, and make sure there is no loading on the wheels. Shake the front wheel left and right to check whether the joint of front wheel is tightened and check whether it sways. Not tighten enough: → tighten it sway: → replace the rocker arm ...

  • Page 41

    3. Checks & adjustment 3-9 tire pressure check the pressure of the tires with a pressure gauge. Note check the tire pressure after tires are cooled. Driving under improper tire pressure will reduce the comfort of operation and riding, and may cause deflected wear of the tires. Specified pressure /ti...

  • Page 42

    3. Checks & adjustment 3-10 wheel nut and wheel axle check front and rear wheel axle nuts for looseness loosened axle nuts tighten tightening torque: front wheel axle nut: 180-200n.M (18.3kgf.M-20.3kgf.M) rear wheel axle nut: 180-200n.M (18.3kgf.M-20.3kgf.M) sway of wheel bearing lift the front whee...

  • Page 43

    3. Checks & adjustment 3-11 adjusting the absorber use special tools to adjust the length of absorber according to loading requirement turn clockwise to adjust from high to low. 1. To increase the spring preload, turn the adjusting ring in direction ○ a . 2. To decrease the spring preload, turn the ...

  • Page 44

    3. Checks & adjustment 3-12 throttle lever check check the free play of throttle lever free play: 3-5mm out of range: →adjust loosen locknut of throttle cable turn the regulator and adjust free play of throttle lever after adjusting, tighten locknuts and install throttle cable sleeve replace with a ...

  • Page 45

    3. Checks & adjustment 3-13 cooling system note ● check coolant level from reservoir tank. Do not check from radiator. If the radiator cap is opened while the engine is hot (over 100 ℃ ), the pressure of the cooling system will drop down and the coolant will get boiled rapidly. Do not open the radia...

  • Page 46

    3. Checks & adjustment 3-14 when the coolant level is below the lower limit, remove reservoir tank cap and add coolant till upper limit. (add coolant or diluted original liquid). Recommended coolant: xypower coolant standard density: 50% ( freezing temperature of coolant varies according to the diff...

  • Page 47: ●

    4. Cooling system 4-1 overhauling info…………………………4-1 adding coolant………………………4-6 trouble shooting…………………………4-2 cooling system chart…………………4-7 check and maintenance…………………4-3 cooling system assembly disassembly reservoir tank……………………. ……4-5 /installation……………………………4-8 overhaul information note ● if the...

  • Page 48: ●

    4. Cooling system 4-2 trouble shooting sharp rise of water temperature ● faulty radiator cap ● air in cooling system ● faulty water pump ● faulty thermostat (thermostat is not open) ● clogged radiator pipe or cooling pipes ● damage or clogged radiator fin ● coolant is not enough ● faulty or malfunct...

  • Page 49

    4. Cooling system 4-3 check and maintenance checking coolant density note: open the radiator cap after coolant is fully cooled. Remove: remove bolt 1 and battery panel remove radiator cap (counter clockwise). Check with a densimeter if the coolant density adapts to the local temperature. Check coola...

  • Page 50

    4. Cooling system 4-4 pressure testing of cooling system install the radiator cap tester to the radiator cap; apply the specified pressure (radiator cap opening pressure) for 6 seconds and make sure that there is drop in pressure. Note do not apply pressure over the specified pressure [108~137kpa(1....

  • Page 51

    4. Cooling system 4-5 remove drain bolt remove drain bolt, seal gasket from water pump, and drain coolant. After drainage, assemble with a new seal gasket, drain bolt and tighten. Reservoir tank remove: remove seat (→2-2) remove front cover assembly (→2-8) remove 2 mounting bolts remove water hose o...

  • Page 52

    4. Cooling system 4-6 adding coolant add coolant through filling port. Start the engine and discharge air from cooling system check from filling port that air is fully discharged from cooling system and install the radiator cap remove reservoir tank cap and add coolant till the upper limit. Note: ch...

  • Page 53

    4. Cooling system 4-7 cooling system chart 4.

  • Page 54

    4. Cooling system 4-8 cooling system assembly disassembly/installation code part code description（en） q'ty remarks 1 17901-5010 radiator 1 2 17902-5010 reservoir tank 1 3 9852-223205 clamp（22-32） 4 4 17812-5010 water hose(φ20×φ28×500) 1 5 17813-5010 water hose(φ20×φ28×760) 1 6 9852-080003 clamp（φ8） ...

  • Page 55

    5. Removal of engine, transmission system and gearshift 5-1 inspection information……………5-1 removal and installation of front and rear engine removal and installation…5-2 axle……………………………………5-5 removal and installation of gearshift…5-7 inspection information note: ● when removal engine, please use jac...

  • Page 56

    5. Removal of engine, transmission system and gearshift 5-2 disassembly engine remove front and rear rack.(→chapter 2). Remove front and rear bumper.(→chapter 2) remove plastic parts.(→chapter 2) remove air filter. Remove exhaust pipe and muffler（→chapter 2） remove hoop . Remove water inlet hose of ...

  • Page 57

    5. Removal of engine, transmission system and gearshift 5-3 remove spark plug separate jacket of starter relay, remove nut, remove anode cable of starter relay. Remove clamp of air inlet duct for cvt remove carburetor remove air filter 5.

  • Page 58

    5. Removal of engine, transmission system and gearshift 5-4 remove clamp of air outlet duct for cvt remove muffler（→2-10） remove gearshift（→5-7） remove fixing bolt of engine.

  • Page 59

    5. Removal of engine, transmission system and gearshift 5-5 installation of engine put engine onto the frame, install the two lower bolts and nuts. Then install the rear upper engine bracket. Tightening torque: rear upper bracket of engine:23～25n·m(m8)/ 45～50n·m(m12) engine lower bolt: 23～25n·m(m8)/...

  • Page 60

    5. Removal of engine, transmission system and gearshift 5-6 remove bolt and nut fixed in the frame of front axle. Remove bolt and nut fixed in the frame of rear axle.

  • Page 61

    5. Removal of engine, transmission system and gearshift 5-7 remove joint bolt in drive shaft, front and rear axle. Remove front and rear axle, drive shaft and rear brake disc installation installation as contradictorily process of remove bolt torque of front axle(m8)：23-25n·m bolt torque of front ax...

  • Page 62

    5. Removal of engine, transmission system and gearshift 5-8 gearshift system assembly disassembly/installation please reference to 500atv parts catalog..

  • Page 63: Wu Yang 500 Cc Engine

    6. Engine removal;inspection & installation 6-1 wu yang 500 cc engine maintenance manual 6.

  • Page 64: Warning

    6. Engine removal;inspection & installation 6-2 warning maintenance engine is a dangerous job. If there is no acceptance and maintenance related training, injury, damage to property, and can't normal maintenance of risk will increase. The maintenance manual recommendations of engine maintenance prog...

  • Page 65: Preface

    6. Engine removal;inspection & installation 6-3 engine maintenance manual preface the operating manual for the above the engine, explains the it down, and the inspection, repair, and reassemble program. In order to be able to secure, fast and accurate operation of these steps, you must first learn t...

  • Page 66: Essential Information

    6. Engine removal;inspection & installation 6-4 essential information 00 z summary…………………………………………………………00 00―00 summary how to use the manual ………………………………………………………………… 6-4 engine fuel, lubricating oil and cooling fluid …………………………………………6-5 basic rules ………………………………………………………………………………6-6 electrical sys...

  • Page 67

    6. Engine removal;inspection & installation 6-5 engine fuel, lubricating oil and cooling fluid. Fuel use unleaded gasoline with octane number over 90. Lubricating oil since antifreeze also has corrosion and rust-inhibiting properties, always use coolant containing antifreeze, even if the atmospheric...

  • Page 68

    6. Engine removal;inspection & installation 6-6 use vaseline suitable vaseline replacement parts type o sealing ring, washer and so on use sst or equivalent tools the right tools information of tips z in this manual, you will find a few given disciplinary warning, warning, attention, specifications ...

  • Page 69

    6. Engine removal;inspection & installation 6-7 special maintenance tools z if have related requirements, should use the special maintenance tools or equivalent tools. Disassemble z if remove the process is more complex, there are many zero department a need to remove, should be in all parts do not ...

  • Page 70

    6. Engine removal;inspection & installation 6-8 parts clean z all need to use again parts should seriously with proper thoroughly clean way. Warning use of compressed air may lead to dust and other particles will spatter damage to the eyes. Use of compressed air should wear protective gear eyes . Re...

  • Page 73

    6. Engine removal;inspection & installation 6-11 engine information 6.

  • Page 74: Engine

    6. Engine removal;inspection & installation 6-12 engine 01 mechanical... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 00 01―00 machine engine overhaul warnings.... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ......

  • Page 75

    6. Engine removal;inspection & installation 6-13 good-ventilated place. (indoor when you start the engine, ensure exhaust forced to use dangerous or outdoor. If (when two or more people who work together, to be on the safe side, keep remind each other. Caution replace the removed washer, o-rings, se...

  • Page 76

    6. Engine removal;inspection & installation 6-14 1.1 as shown in figure remove left upper lid hex flange bolts 1.2 as shown in figure remove cvt active wheel and driven wheels on the flange bolts 1.3 remove the cvt active wheel as shown in figure: 1.3.1 with specialized tools twist intothe cvt activ...

  • Page 77

    6. Engine removal;inspection & installation 6-15 1.4 no pneumatic board in the hand with dedicated tools will be active wheel fixed remove. 1.5 as shown in figure cvt active wheel dial the come out, even with driven pulley and belt off together. 1.6 as shown in figure remove three m6 * 18 hex flange...

  • Page 78

    6. Engine removal;inspection & installation 6-16 standard width：29.4-31 mm minimum width：28.2 mm 1.7.3. Cvt belt length inspection ； standard width：1016.5-1025.7 mm maximal length：1050mm 1.8 active round of inspection ： 1.8. 1. Drive wheel back spring length standard length：65 1.8.2. Drive wheel bac...

  • Page 79

    6. Engine removal;inspection & installation 6-17 1.8.3. Sliding mat wear degrees 1.8.4. Roller wear degree 1.8.5. Centrifugal piece of wear degrees 1.8.6 bush of wear degree 1.9.Cvt driven pulley examination 1.9.1．driven pulley damping twist spring length and vertical degree 1.9.2. Buffer piece of w...

  • Page 80

    6. Engine removal;inspection & installation 6-18 2． right cover remove check according to the list of instructions on the order 1 hexagon flange bolts m6*30 18 change shaft cover 2 right box 19 shift shaft cover gasket 3 right cover gasket 20 dowel pin Φ8*10 4 locating pinΦ6*12 21 shift shaft assemb...

  • Page 81

    6. Engine removal;inspection & installation 6-19 2.1. As shown in figure remove the right cover hex flange bolts 2.2 . As shown in figure remove the right cover hex flange bolts 2.3 turn the handwheel chronological, make the flywheel scribed line and coil fixed a carved on the line alignment. 6.

  • Page 82

    6. Engine removal;inspection & installation 6-20 2.4 as shown in figure remove the flywheel m16 nuts. 2.5 as shown in figure loaded on the flywheel dial is taken 2.6 have the remove the flywheel 2.6.1．with specialized tools into the flywheel remove screw of screw hole, and by pneumatic wrench tighte...

  • Page 83

    6. Engine removal;inspection & installation 6-21 2.6.3. In no pneumatic wrench to work with only when a fixed flywheel to will pull out of the flywheel. 2.7 as shown in figure remove magneto five hexagonal bolt 2.8 as shown in figure with a screwdriver pry out the crankshaft on flat to key. 6.

  • Page 84

    6. Engine removal;inspection & installation 6-22 2.9 as shown in figure with both hands captures magneto will coil fixed a dial out. 2.10 as shown in figure remove shift shaft hex bolt on the cover..

  • Page 85

    6. Engine removal;inspection & installation 6-23 2.11 shift shaft cover bolts removed, with glue like light striking the shift shaft cover to that of the case apart. 2.12 as shown in figure remove hexagonal bolt, remove the shift shaft and change shift gears clicked 2.13 as shown in figure remove th...

  • Page 86

    6. Engine removal;inspection & installation 6-24 2.14.As shown in figure remove water pump on the cover hexagonal bolt, the pump cover taken down. 2.15. As shown in figure remove cover type shape nuts. 2.16 as shown in figure remove water pump impeller.

  • Page 87

    6. Engine removal;inspection & installation 6-25 2.17 magneto that fold points 1 hexagon flange boltsm6*30 5 o-ringΦ2*Φ24.8 2 hexagon flange boltsm5*12 6 o-ringΦ2*Φ129.5 3 coil assembly 7 oil seal Φ 25 * Φ 38 * 7 (see z-03 oil split explain) 4 the supplied pan-head screwsm5*8 8 coil fixed a 2.18 mag...

  • Page 88

    6. Engine removal;inspection & installation 6-26 3．tubing remove check according to the list of instructions on the order 1 hexagon flange boltsm6*28 6 tubing boltm12*30 2 tubing boltm12*43 7 oil inlet 3 tubing boltm10*28 8 copper washerΦ10*Φ18*1.5 4 the tubing a 9 copper washerΦ12*18*1.5 5 the tubi...

  • Page 89

    6. Engine removal;inspection & installation 6-27 4. Cylinder head cover and cylinder head remove check according to the list of instructions on the order 1 hexagon flange boltsm6*28 10 hexagon flange boltsm6*22 2 clinder head cove 11 spring washer 3 cylinder head gasket 12 timing driven sprocket 4 h...

  • Page 90

    6. Engine removal;inspection & installation 6-28 4.1 as shown in figure remove the intake pipe piece the supplied pan-head screws, take down the carburetor. 4.2 as shown in figure cylinder head cover remove the hexagonal bolt, take down cylinder head cove. 4.3 as shown in figure remove hex bolt on t...

  • Page 91

    6. Engine removal;inspection & installation 6-29 4.4 as shown in figure remove tensioning device on the bolts of tensioning device take spring. 4.5 as shown in figure remove tensioning device two 4.6 hexagonal bolt tensioning device take ontology. 4.7 as shown in figure remove the sprocket driven th...

  • Page 92

    6. Engine removal;inspection & installation 6-30 4.8 as shown in figure disassembly of cylinder head four hexagonal bolt. 4.8 as shown in figure with glue knock like the cylinder head side parts of cylinder head off..

  • Page 93

    6. Engine removal;inspection & installation 6-31 4.9 the cylinder head combination that resolution according to the list of instructions on the order 1 take tooth hexagonal flange sur nutm6 12 o-ringΦ2*Φ43 2 the cone set screw tightlym6*17 13 camshaft 3 rockshaft 14 lock clamp 4 inlet rocker assembl...

  • Page 94

    6. Engine removal;inspection & installation 6-32 4.9.1. Remove the clip that gas door lock as shown in figure with a special tool to overcome valve spring tension, making the lock clip from bearing the position of the valve plate with magnets will lock clip suck out. 4.9.2. Rocker check 4.2.1 rocker...

  • Page 95

    6. Engine removal;inspection & installation 6-33 4.9.4. Valve spring check valve spring length standards：41.5 mm ● if the test result its less than standard ● requirements, the replacement valve spring. 4.9.5. The valve, the vertical degree 1. The valve spring rotating week, at the location of the m...

  • Page 96

    6. Engine removal;inspection & installation 6-34 2. Check valve diameter measurement. 4.10 lock shaft check lock shaft diameter standards：21.73-21.84 mm ● if the test result is less than standard requirements, the replacement lock shaft. 4.11. Camshaft check ●check the camshaft inlet cam and cam fac...

  • Page 97

    6. Engine removal;inspection & installation 6-35 2．exhaust cam standard height： 32.763 mm min-height： 32.643 mm ● if less than rating, please replace the camshaft. 3 cam shaft axis shaft neck inspection shaft neck standard outside diameter： 37.946-37.960 mm such as measuring results less than rating...

  • Page 98

    6. Engine removal;inspection & installation 6-36 5. Cylinder and the piston remove check. According to the list of instructions on the order. 1 chain guide a 7 wrist pin 2 hexagon flange boltsm10*78 8 piston assembly 3 hexagon flange boltsm6*28 9 locating pinΦ15*12 4 cylinder combination 10 tension ...

  • Page 99

    6. Engine removal;inspection & installation 6-37 5.2 as shown in figure with glue like tapping cylinder side parts took down the cylinder. 5.3 as shown in figure card ring plier take down the piston pin cards ring and then taking off the piston pin and the piston. 5.4inspection of the cylinder in th...

  • Page 100

    6. Engine removal;inspection & installation 6-38 5.4.1 piston check 1.The 90 ° in the piston pin, piston 12 mm diameter of piston position measurement 2.The diameter of piston standard 91.96-91.98 mm 3. Measuring the clearance between the piston and cylinder ●if it is not within the scope of specifi...

  • Page 101

    6. Engine removal;inspection & installation 6-39 5.6 the piston pin examination 1 as shown in the piston pin and the piston and connecting rod joints three parts along the x and y directions measuring the outer diameter of piston pin. ● if more than specification limits, please the piston, piston, p...

  • Page 102

    6. Engine removal;inspection & installation 6-40 6. The removal decomposition around check according to the list of instructions on the order. 1 hexagon flange bolts m6*85 5 hexagon flange bolts m8*90 2 hexagon flange bolts m6*95 6 right case components 3 hexagon flange bolts m6*105 7 left the compo...

  • Page 103

    6. Engine removal;inspection & installation 6-41 6.2 as shown in figure on the left with copper rod knock output flanges and axial shaft out, or so the decomposition. 6.3 as shown in figure or so the decomposition. 7. The removal decomposition right check according to the list of instructions on the...

  • Page 104

    6. Engine removal;inspection & installation 6-42 1 hexagon flange bolts 14*26 7 hexagon flange bolts m8*32 2 shift positioning spring 8 driven shaft 3 shift positioning steel balls 9 countershaft 4 o-ringΦ2*Φ10 10 shift drum assembly (see z-05 explain) 5 drive shaft 11 water seal 6 reverse gear shaf...

  • Page 105

    6. Engine removal;inspection & installation 6-43 7.4 the right of the bearing inspection 1. Use hand turn sluggish, bearing whether card bearing radial clearance is too large, if have, replace bearing. 2. 6001 bearing radial clearance standards 0.011-0.025 mm 3. 6304 bearing radial clearance standar...

  • Page 106

    6. Engine removal;inspection & installation 6-44 3. The depth standard：64.40-64.45 mm 8. Driven shaft block decomposition remove check according to the list of instructions on the order 1 with the lock flange surface nut m16 6 driven shaft block 2 washerΦ16*Φ32*2 7 c form block circle 3 axle drive b...

  • Page 107

    6. Engine removal;inspection & installation 6-45 8.1 as shown in figure will be driven shaft block in special the combination fixed, use the tool to loosen the m16 nut. 8.2 active bevel gear check ● check the cone tooth gear tooth surface crack, point or corrosion, so the defects, such as a crack, p...

  • Page 108

    6. Engine removal;inspection & installation 6-46 9. Vice shaft combination decomposition remove check according to the list of instructions on the order 1 into reverse components 6 bridge active tooth 2 sliding set of 2 7 washerΦ26*Φ35*1.5 3 washerΦ23.5*Φ33*1 8 low block gear components 4 sliding se...

  • Page 109

    6. Engine removal;inspection & installation 6-47 10. Left the combination decomposition remove check. According to the list of instructions on the order 1 hexagon flange boltsm6*20 16 o-ringΦ2.5*Φ27 2 spring ring6mm 17 the output axis flange constructed put shaft flange constructed that split) 3 was...

  • Page 110

    6. Engine removal;inspection & installation 6-48 10.1 as shown in figure decomposition in the left 10.2 as shown in figure left cabinet remove, with rubber hammer pump driven gear tapping oil, the oil pump driven gear pump shaft from removed. 10.3 turn will the crankshaft and balance axis, make the ...

  • Page 111

    6. Engine removal;inspection & installation 6-49 10.5 the output axis of the flange constructed remove 10.6 the left of the bearing inspection 10.7 the diameter standard of the left crankshaft hole: ∮ 80.000～∮80.025 6.

  • Page 112

    6. Engine removal;inspection & installation 6-50 10.8 the depth standard of the left crankshaft hole: 77.40～77.45mm the max depth:77.65 10.9 check the oil pump oil pump ontology rotor aperture standards ∮ 40.68～40.72 10.10 the oil pump rotor diameter standards ∮ 40.45～40.49 10.11 the oil pump rotor ...

  • Page 113

    6. Engine removal;inspection & installation 6-51 10.12 the depth standard of the oil pump rotor hole: 9.030～9.045 10.13 the gap between the outer rotor and the inner rotor: 10.14 the gap between the connect rod and the crankshaft 0.25～0.45 10.15 the diameter of the connect rod small side ∮ 23.010～∮2...

  • Page 114

    6. Engine removal;inspection & installation 6-52 11. The left of the assembly. 1. According to the list, as shown in the assembly sequence 1 left the components 22 o-ringΦ2.5*Φ27 2 oil sealΦ35*Φ48*8 23 o-ringΦ3*Φ16 3 check valve components 24 taper washer 4 check valve spring 25 with the lock flange...

  • Page 115

    6. Engine removal;inspection & installation 6-53 14 oil sealΦ25*Φ40*7 35 spring ring 6mm 15 o-ringΦ2.5*Φ47 36 hexagon flange bolts m6*20 torsion 10n.M 16 hexagon flange bolts m6*22 torsion 10n.M 37 crankshaft assembly 17 rear bearing cover 38 copper packingΦ20*Φ28*0.5 18 oil sealΦ40*Φ62*8 39 balance...

  • Page 116

    6. Engine removal;inspection & installation 6-54 11.4 as shown in figure balance shaft markers and crankshaft marker on is balanced shaft after striking tongbang end, main shaft put in place 11.5 as shown in figure crankshaft balance of shaft active teeth and balance on the driven shaft tooth marks ...

  • Page 117

    6. Engine removal;inspection & installation 6-55 12. The left of the assembly. According to the list, as shown in the assembly sequence 12.1 the driven shaft assembly instructions according to the list, as shown in the assembly sequence 1 washer Φ15*Φ36*2 6 reverse gear shaft (see the reverse shaft ...

  • Page 118

    6. Engine removal;inspection & installation 6-56 12.2the figure shows flange surface nut torque to300.N.M 1 driven shaft block 6 c form block circle 2 bearing plate 7 axle drive bevel pinion 3 hexagon flange boltsm6*22 torsion10n.M 8 washerΦ16*Φ32*2 4 driven shaft 9 flange facingnutm16 torsion300n.M...

  • Page 119

    6. Engine removal;inspection & installation 6-57 12.3 deputy shaft assembly instructions according to the list, as shown in the assembly sequence 1 countershaft 6 c form block circle 2 washerΦ26*Φ35*1 7 sliding set of 1 3 low block gear components 8 washerΦ23.5*Φ33*1 4 washerΦ26*Φ35*1.5 9 into rever...

  • Page 120

    6. Engine removal;inspection & installation 6-58 as shown in figure reverse gear shaft assembly, reverse gear shaft to vice axis tilt to success in the right. 13. Box assembly 1．according to the list, as shown in the assembly sequence 1 hexagon flange boltsm8*90 torsion25n 6 shift positioning spring...

  • Page 121

    6. Engine removal;inspection & installation 6-59 2. Seal to divide evenly all coated in the right box processing surface（at about 0.3 mm thickness）. 3.All of the flange bolts lock first diagonal tighten, which in turn lock. 4. Close box lock bolts crankshaft, examined the output shaft, and shift dru...

  • Page 122

    6. Engine removal;inspection & installation 6-60 bolts on the diagonal lock, points secondary tighten oil pump oil seal type with specialized tools the water seal type with specialized tools.

  • Page 123

    6. Engine removal;inspection & installation 6-61 14. Cylinder piston and flywheel assembly .1according to the list, as shown in the assembly sequence 1 timing chain 13 hexagon flange boltsm8*25 torsion75n.M 2 tension rod bolt torsion10n.M 14 beyond the clutch assembly 3 chain tension rod 15 piston a...

  • Page 124

    6. Engine removal;inspection & installation 6-62 fixed a coil assembly instructions 1. According to the list, as shown in the assembly sequence 1 coil fixed seat 5 o-ringΦ2*Φ24.8 2 o-ringΦ2*Φ129.5 6 hexagon flange boltsm6*30 torsion10n.M 3 oil sealΦ25*Φ38*7 7 hexagon flange boltsm5*12 torsion6n.M 4 ...

  • Page 125

    6. Engine removal;inspection & installation 6-63 the piston assembly instructions cylinder assembly instructions cylinder bolt assembly instructions 6.

  • Page 126

    6. Engine removal;inspection & installation 6-64 the cylinder head assembly instructions timing chain assembly instructions.

  • Page 127

    6. Engine removal;inspection & installation 6-65 1 locating pinΦ15*20 10 the cylinder head side cover gasket 2 cylinder head of cushion 11 cylinder head side cover 3 the cylinder head combination (see cylinder head with the department that) 12 hexagon flange boltsm6*20 torsion 10n.M 4 hexagon flange...

  • Page 128

    6. Engine removal;inspection & installation 6-66 1 cylinder head components 12 rockshaft 2 valve oil seal (valve seal assembly instructions) 13 the cone set screw tightly m6*17 3 exhaust valve 14 take tooth hexagonal flange surface nut m6 torsion 10n.M 4 intake valve 15 o-ringΦ2*Φ43 5 valve springΦ3...

  • Page 129

    6. Engine removal;inspection & installation 6-67 1 pump impeller components 12 hexagon flange boltsm6*20 torsion10n.M 2 copper packingΦ7*Φ12*2 13 shift shaft assembly 3 flange surface nut covered formm7 torsion10n.M 14 locating pinΦ8*10 4 water pump cover gasket 15 shift shaft cover gasket 5 water p...

  • Page 130

    6. Engine removal;inspection & installation 6-68 1 oil inlet 6 the tubing a 2 tubing bolt m12*30 torsion 35n.M 7 tubing bolt m10*28 torsion 35n.M 3 copper packingΦ12*18*1.5 8 tubing bolt m12*43 torsion 35n.M 4 copper packingΦ10*Φ18*1.5 9 hexagon flange bolts m6*28 torsion 10n.M 5 the tubing b 10 oil...

  • Page 131

    6. Engine removal;inspection & installation 6-69 1 starting motor 11 cvt driven wheel 2 hexagon flange bolts m6*32 torsion 10n.M 12 cvt leather belt 3 archives show is 13 cvt driving wheel 4 hexagon flange bolts m6*16 torsion 10n.M 14 steps mat 5 drive shaft clapboard down 15 hexagon flange bolts m1...

  • Page 132: Technical Parameters：

    6. Engine removal;inspection & installation 6-70 technical parameters： item engine cylinder head the cylinder head gasket contact deformation （ mm {in}） maximum 0.10 maximum 0.15 each surface deformation （mm {in}） maximum amount grind 0.20 in 0.08 valve clearance [engine low temperature] （mm {in}） e...

  • Page 133

    6. Engine removal;inspection & installation 6-71 13 kgf(36mm) pressing forc （ n{kgf,1bf})[mm {in}] standard heighth 40 kgf(28mm) camshaft camshaft wear （mm {in}） maximum 0.15 in 32.769 standard ex 32.763 in 32.764 cam peach height （mm {in}） minimum ex 32.758 standard ∮37.90 the cam shaft neck（mm {in...

  • Page 134

    6. Engine removal;inspection & installation 6-72 oilring 0.20～0.70 compression ring on 0.60 compression ring in 0.55 maximum oilring 0.90 connecting rod and the bearing standard 0.25～0.45 connecting rod axial clearance （mm {in}） maximum 0.65 link rod bearing size（mm {in}） standard 34*43*21.8 standar...

  • Page 135

    7. Carburetor 7-1 carburetor removal…………………………………………………………7-2 inspection………………………………………………………………………7-3 . Measurement and adjustment………………………………………………7-4 carburetor assembly………………………………………………………7-5 carburetor installation………………………………………………………7-6 carburetor parameters……………………………………………………7-6 7.

  • Page 136

    7. Carburetor 7-2 1. Carburetor removal disassemble the carburetor in the following serial number: serial no description serial no description 1 carb assy 10hc-a73e-0000 13 main jet (mj) 99101-939-1380(#140) 2 top comp 1030-906-2100 15 star jet 99101-939-0600 4 spg 1290-880-2000 17 fv comp 16155-zg8...

  • Page 137

    7. Carburetor 7-3 2. Inspection ● check carburetor body for cracks or damage. Cracks or damage:→ replace ● check carburetor float chamber, fuel passage for dirt or clog. Clean these parts. ● check float①, float tang ② for damage. Damage: → replace ● check valve seat①, needle valve②, o-ring③ for dama...

  • Page 138

    7. Carburetor 7-4 ● check the jet needle ①, main jet ②, needle jet③, idel speed adjust bolt ④, pilot jet⑤, starter jet⑥ and starter plunger ⑦ for wear and bends; wear or bends: → replace ● check above jets for clog. Blow out the jets with compressed air. ● insert piston valve into carburetor body an...

  • Page 139

    7. Carburetor 7-5 ● if float height is not within the specification, check the valve seat and needle valve; ● if either of valve seat or needle valve is worn, replace both; ● if both are fine, adjust float height by bending the float tang ①on the float; ● measure float height again till it’s within ...

  • Page 140

    7. Carburetor 7-6 carburetor installation ① -vacuum breather hose ②-starter cable ③-carburetor joint (engine intake manifold) ④ -throttle valve cover ⑤-throttle cable ⑥-carburetor joint (air filter) ⑦ -carburetor ⑧-drain hose ⑨-fuel inlet hose 6. Carburetor parameters type keihin aw6a aperture no. 0...

  • Page 141

    8. Front wheel, front brake，suspension，steering 8-1 overhaul info……………………..…8-1 brake system…………………………8-4 troubleshooting………………….…8-2 suspension……………………………8-7 front wheel………………………...8-3 steering………………………………8-12 overhaul information operating cautions notes ● securely support the vehicle when overhau...

  • Page 142

    8. Front wheel, front brake，suspension，steering 8-2 troubleshooting heavy heavy steering ● steering bearing is damaged or worn ● inner & outer bearing races are damaged, worn or stepped ● steering stem is distored ● tire pressure is too low ● worn tire shaking handlebar ● steering bearing is damaged...

  • Page 143

    8. Front wheel, front brake，suspension，steering 8-3 front wheel removal securely support the front wheels remove: cap of wheel center 4 nuts 1 from wheel hub front wheel inspection rim damage, warpage or serious scrapes: →replace replace with a new one, if any. Slowly turn the wheel, measure the rim...

  • Page 144

    8. Front wheel, front brake，suspension，steering 8-4 brake system front brake caliper removal remove: --front wheel（→8-3） --2 bolts from front knuckle --front brake caliper inspection check brake caliper for cracks and tightening parts for oil leakage. Replace if any. Installation reverse the removal...

  • Page 145

    8. Front wheel, front brake，suspension，steering 8-5 brake disc removal remove: --front wheel（→8-3） --brake caliper（→8-4） --front brake disc and wheel hub --4 bolts from brake disc --brake disc inspection： brake disc thickness: installation install brake disc tightening torque fixing bolt, brake disc...

  • Page 146

    8. Front wheel, front brake，suspension，steering 8-6 disassembly remove: --footrest board(→2-6) --nut 1, bolt 1 --guard of master cylinder remove: --bolt 2 foot brake master cylinder. Separate foot brake master cylinder from vehicle assembly reverse the removal procedure for installation. Note do not...

  • Page 147

    8. Front wheel, front brake，suspension，steering 8-7 front left suspension note: do not remove both left and right suspension at the same time to avoid fall down of the vehicle. Park the vehicle on a level ground and securely support front part of the vehicle. Removal: remove: --front wheel(→8-3) --f...

  • Page 148

    8. Front wheel, front brake，suspension，steering 8-8 front suspension system disassembly /installation 1. Front left guard 2. Front right guard 3. Front right arm (lower) 4. Front right arm (lower) 5. Screw(m6×20） 6. Bolt,flange（m10×1.25×70） 7. Dust cap 8. Bush (φ10.5×φ16×48.5) 9. Bush(φ16×φ21×20) 10...

  • Page 149

    8. Front wheel, front brake，suspension，steering 8-9 front wheel assy disassembly /installation 1.Cap , wheel center 2. Pin , split（3×35） 3. Screw cap，drive axletree(m20×1.5) 4. Nut , wheel(m10×1.25) 5. Valve , rim 6. Rim , fr. Wheel(12×6) 7. Front tire（25×8-12） 8. Hub, fr. Wheel 9. Bolt, wheel（m10×3...

  • Page 150

    8. Front wheel, front brake，suspension，steering 8-10 disassembly: note: replacing the front shock absorber does not require removal of other parts. Remove bolt (24) and nut (10) remove front right shock absorber. Inspection: oil leakage, aged oil seal, damage→ replace installation: reverse the remov...

  • Page 151

    8. Front wheel, front brake，suspension，steering 8-11 constant velocity drive shafts note: the disassembly, inspection and installation of left and right constant velocity drive shafts of front rear axles are the same. The following will give instruction only on the disassembly, inspection, installat...

  • Page 152

    8. Front wheel, front brake，suspension，steering 8-12 steering system handlebar handlebar cover remove handlebar cover (→ 2-3) remove store box cover (→ 2-8) installation: reverse the removal procedure for installation right handlebar switch remove: --front cover assembly (→2-8) --right handlebar swi...

  • Page 153

    8. Front wheel, front brake，suspension，steering 8-13 left handlebar switch disassembly remove --2 screws --left handlebar switch connector --left handlebar switch installation install left handlebar switch (→8-15) rear view mirror disassembly turn counter clockwise and loosen nut, remove left rear v...

  • Page 154

    8. Front wheel, front brake，suspension，steering 8-14 separate left & right master cylinders from handlebar remove: -- handlebar cover (→ 2-3) --4 fixing bolts --handlebar installation reverse the removal procedure for installation tightening torque: 20-30n.M (2.0-3.0kgf.M) note main cable, throttle ...

  • Page 155

    8. Front wheel, front brake，suspension，steering 8-15 installation of left handlebar switch match the limit pin of left handlebar switch with positioning hole on handlebar. Tighten with screw 1 and 2 from under insert connector of left handlebar switch into socket of main cable installation of right ...

  • Page 156

    8. Front wheel, front brake，suspension，steering 8-16 installation of left and right grip install: clean off stains and grease from handlebar and inner left and right grips. Install left and right grips install guard of handle grip. Tighten the bolt. Note: before applying adhesive, wipe off grease or...

  • Page 157

    8. Front wheel, front brake，suspension，steering 8-17 steering system 1. Bolt, flange（m8×55） 2. Holder,steering stem 3. Bush,steering 4. Shaft,steering 5. Nut（m10×1.25l） 6. Joint,tie-rod（l） 7. Pin，cotter（3×35) 8. Arm,steering 9. Washer（φ14×φ28×2） 10. Nut,castle（m14×1.5） 11. Pin，cotter（2.5×25) 12. Tie...

  • Page 158

    8. Front wheel, front brake，suspension，steering 8-18 steering stem remove: -- remove handlebar cover (→ 2-3) -- remove store box cover (→ 2-8) -- remove front cover assembly (→ 2-8) --front wheel (→8-2) disconnect handlebar switch connector hammer the holder of steering stem flat with a flat screwdr...

  • Page 159

    8. Front wheel, front brake，suspension，steering 8-19 steering bearing, oil seal remove: --front wheel (→8-3) --steering stem (→8-18) remove front left & right arms(upper & lower)( →8-8) remove steering bearing and oil seal from frame with special tool special tools: bearing removal tool set rotor pu...

  • Page 160

    9–1 9. Rear wheel、rear brake、suspension overhaul info………………………………9-1 rear brake………………………………9-4 troubleshooting……………………………9-2 rear suspension…………………………9-5 rear wheel…………………………………9-3 overhaul info: note: ● securely support the vehicle when overhauling the rim and suspension system. ● use genuine parts...

  • Page 161

    9–2 9. Rear wheel、rear brake、suspension troubleshooting rear wheel wobbles ● rim warpage ● faulty tire. ● tire pressure too low ● improper wheel balance ● improper tightening of wheel axle nut ● loosened wheel nut rear shock absorber is too soft ● weak spring. ● oil leakage from rear shock absorber ...

  • Page 162

    9–3 9. Rear wheel、rear brake、suspension rear wheel removal: refer to front wheel remove.（→8-3） inspection rim: damage, warpage, serious scrapes, etc. Replace if necessary. Slowly turn the wheel, measure the rim vibration with a dial gauge. Service limit：axial: 2.0mm radial: 2.0mm installation: refer...

  • Page 163

    9–4 9. Rear wheel、rear brake、suspension rear brake(parking brake) rear brake caliper ● remove: ● rear right wheel（→9-3） ● 2 bolts from arm ● brake caliper inspection: brake caliper: cracks, oil leakage: → replace installation reverse the removal procedure for installation. Note： refer to chapter 1 f...

  • Page 164

    9–5 9. Rear wheel、rear brake、suspension rear suspension system rear right suspension note do not remove both left and right suspension at the same time to avoid fall down of the vehicle. Rear suspension system disassembly /installation 1.Rear left guard 2.Rear right guard 3. Screw（m6×16） 4. Bolt,fla...

  • Page 165

    9–6 9. Rear wheel、rear brake、suspension rear knuckle disassembly /installation 1. Shaft set, l.Rear 2. Shaft set, r.Rear 3. Bearing（k35×62×40） 4. Circlip（φ62×2） 5. Cap,pivot 6. Bush ,rr knuckle 7. Collar ,rr knuckle 8. Knuckle set,l.Rr. 9. Knuckle set,r.Rr. 10. Knuckle set,l.Rr. 11. Knuckle set,r.Rr...

  • Page 166

    9–7 9. Rear wheel、rear brake、suspension disassembly stabilizer bar remove: bolt (6), holder, stabilizer (5), pin, split(8), nut (9) remove stabilizer bar . Installation: reverse the removal procedure for installation right rear absorber removal: note: securely support the vehicle when removing rear ...

  • Page 167

    10. Front/rear axle 10–1 front/rear axle overhaul information z standard lubricating period replaced item capacity initially afterwards front axle i:0.28l/r: 0.25l rear axle sae15w/40 sf or sae85w/90 gl-5 i:0.28l/r:0.25l 350km 5000km i= initial, r=replaced tightening torque table item qty type torqu...

  • Page 168

    10. Front/rear axle 10–2 inspection & overhaul inspection and overhaul if any of problems below happens to front and rear axle. Descriptions causes 1. Unstable moving during accelerating, decelerating or constant speed. 2. Abnormal sound in front rear axle; 3. Engine power transmission failure to fr...

  • Page 169

    10. Front/rear axle 10–3 disassembly of front axle 1. Front axle housing group ref.N o description qty ref.No description qty 1 front axle left case 1 11 oil seal (45×68×8) 1 2 oil seal (25×40×7) 1 12 front axle right case 1 3 o-ring (ф16.5×ф2.5) 1 13 bearing (16007) 1 4 bolt(m18×1.5×10) 1 14 circli...

  • Page 170

    10. Front/rear axle 10–4 2. Rear axle housing group ref.No description qty ref.No description qty 1 rear axle case 1 13 hex screw (m8×45) 1 2 needle bearing cage(55×68×20) 1 14 aluninum pad(ф16×ф8×2) 1 3 joint, breather pipe(ф5×20) 1 15 nut (m8) 1 4 o-ring (ф16.5×ф2.5) 1 16 bolt,flange(m10×1.25×25) ...

  • Page 171

    10. Front/rear axle 10–5 3. Rear axle housing group ref.No description qty ref.No description qty 1 adjust washer c(ф56×ф38.5×0.2) 1 13 bearing (61913) 1 2 friction pad(ф57×ф39.5×1.25) 1 14 adjust washer a( ф 78×ф88×0.2) 1 3 washer(ф53×ф39.5×1) 1 15 drive clutch 1 4 left half axle gear(z=16) 1 16 dr...

  • Page 172

    10. Front/rear axle 10–6 4. Gearshift group (front axle) ref.No description qty ref.No description qty 1 driven bevel gear front asle（levorotary/z=33） 1 6 bearing retainer（m65×2.0hl） 1 2 bearing（6008/p6） 1 7 coupler（14t） 1 3 adjust washer b （ φ 54× ф 66×0.2） 1 8 washer（φ12×ф30×4） 1 4 drive pinion ge...

  • Page 173

    10. Front/rear axle 10–7 5. Gearshift group (rear axle) ref.No description qty ref.No description qty 1 driven bevel gear rear asle （ dextral / z=33） 1 6 bearing retainer(m65×2.0hl) 1 2 adjust washer e（φ67×ф55×0.8） 1 7 bearing(tm6305) 1 3 needle bearing（k556120） 1 8 coupler, rear axle 1 4 adjust was...

  • Page 174

    10. Front/rear axle 10–8 6. Two-four-drive conversion mechanism for group ref.No description qty ref.No description qty 1 gear motor 1 9 washer(φ8×ф4×1) 3 2 ring 1 10 spring pad 4 3 3 dowel pin(φ8×10) 2 11 hex nut 3 4 bolt,flange(m6×25) 3 12 contact cover 1 5 conntact components 1 13 washer(φ8×ф4×1)...

  • Page 175

    10. Front/rear axle 10–9 inspection after front axle disassembly z check if there is damage or crack on the front differential gear case cover and bearing assembling hole is ok. Replace case cover if necessary; z check if front axle bearing clearance ok or turning stable, and roll way, steel ball, n...

  • Page 176

    10. Front/rear axle 10–10 front axle assembly and adjustment z front axle case cover assembly item“31”tightening torque60nm item“24”tightening torque70nm note：use engine oil for oil seal, bearing and drive clutch assembly; “ 24” use screw thread fastening glue; z front differential gear case cover a...

  • Page 177

    10. Front/rear axle 10–11 z front axle assembly and adjustment illustration： tightening torque item“ 1” 25nm item“25” 10nm item“30” 13nm use fastening glue for item“30” assembly. A. Use proper washer 8 and 10 thick ness to adjust gear side clearance between drive pinion gear and differential gear. D...

  • Page 178

    10. Front/rear axle 10–12 c. Use special equipment or vehicle control circuit into two stroke position(m6×25) before gear motor assembly; d. Make sure b and c is assembled using illustrated positioning bolt before gear motor and front axle..

  • Page 179

    10. Front/rear axle 10–13 needle bearing removal a. Disassemble needle bearing 55btm6820 as illustration if necessary. B. Disassemble needle bearing na5903 as illustration after heating upto 150 . ℃ rear axle inspection after disassembly z check if there is crack or damage in rear gear case, see mou...

  • Page 180

    10. Front/rear axle 10–14 rear axle assembly and adjustment z illustration tightening torque item“ 1” 35nm item“ 2” 25nm item“ 12” 70nm item“ 15” 25nm item“ 20” 60nm item“ 31” 16nm use glue for item“29”assembly z assembly clearance and adjustment of drive bevel gear assembly rear axle. A. Adjust ins...

  • Page 181

    10. Front/rear axle 10–15 f. Adjust item 29 as illustrated, and make sure its end and back clearance of drive gear is 0.3～0.6. Tighten item 31. 10

  • Page 182

    11. Battery，charging system 11-1 charging system layout…………11-1 inspection of charging system……11-5 overhaul info……………………11-2 rectifier/regulator…………………11-6 troubleshooting …………………11-3 inspection of ac magneto………………11-8 battery……………………………11-4 layout for electricity equipment in vehicle…………11-9 charg...

  • Page 183

    11. Battery，charging system 11-2 overhaul information note ● usually no hydrogen will be generated during charging except when over charged. Keep away from fires when charging. ● electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight. Wash with plenty of wa...

  • Page 184

    11. Battery，charging system 11-3 overhaul standard item standard model permanent magnet alternator output 3-phase ac ac magneto resistance of charging coil (20℃) 0.2-0.3Ω rectifier type 3-phase loop rectification, controllable parallel connection, regulated voltage battery 12v18ah current leakage le...

  • Page 185

    11. Battery，charging system 11-4 battery remove note: keep the ignition switch at off before operation. Remove: remove the two screws and the battery cover. Remove the holder band of battery. Loosen negative pole screw and disconnect. Negative lead. Remove positive pole cap and screw. Disconnect pos...

  • Page 186

    11. Battery，charging system 11-5 remove battery from vehicle. (refer to above content) connect charger’s positive wire to battery’s positive pole. Connect charger’s negative wire to battery’s negative pole. Charging current/time: standard:0.9a/5~10hours fast charge:4.0a/60mins note: keep the electro...

  • Page 187

    11. Battery，charging system 11-6 remove negative wire from battery remove fuse box from inside of battery panel. Connect amperemeter between battery negative pole and negative lead measure current leakage with ignition switch at the “off” position. Note: if the measured current is higher than the ma...

  • Page 188

    11. Battery，charging system 11-7 check the connector terminals for loosening, bending, rust or come-off. Check the following items of the main cable terminals of the two rectifier connectors: installation: reverse the removal procedure for installation. Note: wires, hoses and cables should be routed...

  • Page 189

    11. Battery，charging system 11-8 ac magneto inspection remove engine cover（→2-3） remove ac magneto (yellow, yellow, yellow), pickup coil (black/white, green) connecter. Resistance of generator coil ● measure resistance between the three lead wires; ● replace a new stator coil if resistance not withi...

  • Page 190

    11. Battery，charging system 11-9 layout for all electricity equipment in vehicle.

  • Page 191

    12. Ignition system 12-1 overhaul information ………………12-1 pickup coil……………………………12-7 ignition system diagram……………12-2 ignition coil……………………………12-7 troubleshooting………………………12-3 layout for ignition system equipment in vehicle inspection of ignition system………12-4 ……………………………………………12-10 overhaul informat...

  • Page 192

    12. Ignition system 12-2 ignition system diagram.

  • Page 193

    12. Ignition system 12-3 troubleshooting ◆ engine cannot be started. ◆ check fuel and air channels for any faults; if the fuel and air channels are normal, check the ignition system. ◆ inspect ignition system for the following items: 1. Spark inspection: check in the following steps: remove spark pl...

  • Page 194

    12. Ignition system 12-4 inspection of ignition system note: ● if there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. ● use the recommended digital multimeter or a commercially available digital multimeter with an impedance of 10mΩ/dcv mi...

  • Page 195

    12. Ignition system 12-5 main and ignition fuses ● check the main and ignition fuses for continuity. ● refer to “checking the fuses” in chapter 11. ● if the main and ignition fuses is bad. →replace the fuse(s). ① fan fuse: 15a ② power output fuse: 10a ③ main switch fuse: 10a ④ light fuse: 20a ⑤ rese...

  • Page 196

    12. Ignition system 12-6 main switch ● check the main switch for continuity. Refer to “checking the switches”. ● if the main switch is bad. →replace the main switch. Engine stop button ● check the engine stop button for continuity. Refer to “checking the switches”. ● if the engine stop button is bad...

  • Page 197

    12. Ignition system 12-7 pickup coil remove: — ac magneto connector —water pump inlet hose and outlet hose, and drain coolant. (chapter 4) —right side panel (→2-5) —right footrest board (→2-6) —engine decorate cover —magneto cover note: stator is installed on the right crankcase and is attached by t...

  • Page 198

    12. Ignition system 12-8 starting group 1. Starting motor,assy 2. Bolt,flange 3. Clutch,starter,assy 4. Limit bush,handle 5. Handle assy 6. Cover,handle 7. Spring,coil 8. Sheave drum assy 9. Rope 10. Pawl 11. Pawl spring 12. Spring 13. Friction plate 14. Spring washer 15. Bolt,flange 16. Starter pul...

  • Page 199

    12. Ignition system 12-9 brushes ● check brushes for abnormal wear, cracks or moothness in the brush holder. Wear, cracks or non-smoothness: →replace commutator ● check commutator for discoloration, abnormal wear or undercut. Abnormal wear or damage: →replace ● if the commutator is discolored, polis...

  • Page 200

    12. Ignition system 12-10 layout for ignition system equipment in vehicle.

  • Page 201

    13. Lighting, instruments, switches 13-1 overhaul info……………………..13-1 fuel sensor ………..……………13-9 troubleshooting ………………….13-2 water temperature transducer.....13-11 replacing bulbs.. …………………13-3 circuit diagram…………………13-12 head light ……….……………….13-5 ignition switch………….…………13-6 handlebar switch ……………...

  • Page 202

    13. Lighting, instruments, switches 13-2 troubleshooting head light cannot turn on ▲broken fuse ▲ open circuit with main cable ▲ burnt bulb ▲ faulty switch.

  • Page 203

    13. Lighting, instruments, switches 13-3 replacing bulb headlight bulb warning headlight bulb will be very hot when it is turned on. Do not touch it after it is just turned off. Operation should be done when the bulb is cooled down. Remove headlight. (→10-5) disconnect headlight remove dust-proof ca...

  • Page 204

    13. Lighting, instruments, switches 13-4 brake light/tail light bulb turn socket counter clockwise and remove the socket from the tail light cover. Turn brake light/tail light bulb counter clockwise and. Remove it. Replace brake light/tail light bulb bulb specification: 12v-21/5w reverse the removal...

  • Page 205

    13. Lighting, instruments, switches 13-5 headlight remove: --front cover (→2-8) --4 fixing bolts of headlight. -- headlight fender. --fixing bolt of headlight, headlight connector --headlight. Disconnect headlight connector. Reverse the removal procedure for installation. Note: be careful not to dam...

  • Page 206

    13. Lighting, instruments, switches 13-6 start switch inspection remove store box cover (→2-8) disconnect connector of ignition switch check according to the following table if the connector terminals are in continuity. ●----● means proper continuity. Remove: remove store box cover (→2-8) disconnect...

  • Page 207

    13. Lighting, instruments, switches 13-7 turning light switch and warning indicator light switch horn switch 2 wd、4 wd、4wd diff-lock switch faulty handlebar switch: → replace (→8-12 or 8-13). Brake light switch disconnect brake light switch connector and check terminators for continuity hold the bra...

  • Page 208

    13. Lighting, instruments, switches 13-8 removal and installation remove connector of horn. Remove fixing bolt and horn. Reverse the removal procedure for installation. Meter run the vehicle at low speed and check if the speed indicator moves. Faulty speedometer: →replace removal and installation re...

  • Page 209

    13. Lighting, instruments, switches 13-9 fuel sensor remove: --fuel tank (→2-11) --5 fixing bolts --fuel sensor disconnect connector inspection remove fuel sensor (refer to above steps) connect connector turn ignition switch to on shake fuel sensor float with hand, locate the float position and chec...

  • Page 210

    13. Lighting, instruments, switches 13-10 installation put fuel sensor into installation hole of fuel tank. Fuel sensor should be fitted properly. No fuel leakage is allowed. Connect connector of horn. Inspection of fuel gauge switch on power supply and check if fuel level gauge functions normally. ...

  • Page 211

    13. Lighting, instruments, switches 13-11 water temperature transducer warning: be careful not to get scalded and do not place flammables nearby. Warning ▲ coolant must reach the switch thread, and the depth from vessel bottom to sensor top should be over 40mm. ▲ keep liquid temperature for three mi...

  • Page 212

    13. Lighting, instruments, switches 13-12 500atv circuit diagram..

  • Page 213

    14. Troubleshooting 14-1 1. Engine common failure diagnosis…………………………………14-2 2. Carburetor……………………………………………………………14-5 3. Cooling system/radiator………………………………………………14-6 4. Ignition system…………………………………………………………14-6 14.

  • Page 214

    14. Troubleshooting 14-2 1. Engine common failure diagnosis complaint symptom and possible causes remedy engine will not start of is hard to start compression is too low 1. Worn cylinder 2. Worn piston ring 3. Leakage with cylinder gasket wear valve guide or improper valve seating 4. Loose spark plu...

  • Page 215

    14. Troubleshooting 14-3 complaint symptom and possible causes remedy poor engine running in high-speed range. 1. Week valve spring 2. Worn camshaft 3. Fouled spark plug 4. Insufficient spark plug gap 5. Improper valve timing 6. Faulty ignition coil 7. Low fuel level in float chamber 8. Dirty air fi...

  • Page 216

    14. Troubleshooting 14-4 complaint symptom and possible causes remedy valve chatter 1. Excessive valve clearance 2. Worn or broken valve spring 3. Worn rocker arm or camshaft replace replace replace noise from piston 1. Worn piston 2. Worn cylinder 3. Carbon deposit in combustion chamber 4. Worn pis...

  • Page 217

    14. Troubleshooting 14-5 complaint symptom and possible causes remedy difficulty or locked gearshift 1. Broken drive or driven bevel gear teeth 2. Distorted shift fork 3. Worn shift cam 4. Improper gearshift rod replace replace replace adjust 2. Carburetor complaint symptom and possible causes remed...

  • Page 218

    14. Troubleshooting 14-6 3. Cooling system/radiator complaint symptom and possible causes remedy engine overheats 1. Clogged water passage or radiator 2. Air in the cooling system; insufficient coolant 3. Faulty water pump 4. Incorrect coolant 5. Faulty thermostat 6. Faulty fan motor or thermoswitch...