WD400U Service Manual

For any questions please contact Baja Motorsports at 888-863-2252

 Content

Content..................................................................................................................................................2
Chapter I General description...............................................................................................................5
Section 1 Special tools, instruments & meters.................................................................................... 6
(I) Special tools.........................................................................................................................7
Section 2 Identification code, label of model and engine No...............................................................8
Section 3 Points for attention in maintenance......................................................................................8
Section 4 Specification...................................................................................................................... 12
I. How to use conversion table of unit................................................................................... 12
(1) How to use conversion table............................................................................................ 12
(2) Definition of unit...............................................................................................................12
II. Basic specification.............................................................................................................13
III. ATV body......................................................................................................................... 15
IV. Electric system................................................................................................................. 16
V. Maintenance specification of engine................................................................................. 17
Section 5 Requirements for torque of fastener................................................................................... 20
(3) General torque specification............................................................................................ 22
Section 6 Lubrication point and type of lubricants............................................................................ 23
(I) ATV body......................................................................................................................... 23
(II) Engine............................................................................................................................. 24
Chapter II Maintenance and adjustment of vehicle............................................................................ 25
Section 1 Periodic maintenance/lubrication...................................................................................... 25
Section 2 Disassembly and assembly of cushion, fender and fuel tank............................................. 26
(I) Cushion...............................................................................................................................26
(II) Rear fender...................................................................................................................... 26
(III) Fuel tank.......................................................................................................................... 29
(IV) Front fender..................................................................................................................... 30
Section 3 Maintenance and adjustment of vehicle body.................................................................... 32
(I) Wear inspection of front and rear brake............................................................................ 32
(II) Adjustment of front brake..................................................................................................32
(III) Adjustment of free clearance of left lever and rear brake pedal.......................................33
(IV) Position adjustment of steering lever............................................................................. 35
(V) Lubricating oil level inspection of rear driving gearcase................................................. 35
(VI) Replacement of engine oil of rear driving gearcase....................................................... 36
(VII) Rubber sleeve inspection of rear wheel fork................................................................. 37
(VIII) Inspection of steering system....................................................................................... 37
(IX) Adjustment of toe-in of front wheel............................................................................... 38
(X) Inspection of front/rear shock absorber........................................................................... 39
(XI) Adjustment of rear shock absorber............................................................................... 39
(XII) Inspection of tire.......................................................................................................... 40
(XIII) Inspection of rim........................................................................................................ 41
Section 4 Maintenance and adjustment of electrical appliance......................................................... 42
(I) Inspection of battery......................................................................................................... 42
(II) Inspection of fuse............................................................................................................ 43
(III) Replacement of headlight lamp.......................................................................................44


Section 5 Maintenance and adjustment of engine.............................................................................. 46
(I) Cleaning of air filter...........................................................................................................46
(II) Inspection of spark plug.................................................................................................. 47
(III) Adjustment of idle speed............................................................................................... 48
(IV) Adjustment of free clearance of throttle grip................................................................ 48
(V) Adjustment of speed limiter............................................................................................ 49
(VI) Adjustment of valve clearance..................................................................................... 50
(VII) Adjustment of timing chain tension..............................................................................52
(VIII) Measuring of compressive force................................................................................. 53
(IX) Inspection oil quantity of engine................................................................................... 54
(X) Replacement of engine oil and inspection of oil flow..................................................... 55
Chapter III Repair and maintenance of vehicle body.........................................................................57
Section 1 Rear driving gearcase and driving shaft.............................................................................57
(I) Troubleshooting.................................................................................................................58
(II) Inspection.........................................................................................................................58
(III) Troubleshooting table.....................................................................................................59
(IV) Disassembly.................................................................................................................. 60
(V) Inspection.........................................................................................................................63
Section 2 Rear wheel/Rear brake/Rear wheel axle............................................................................ 64
(I) Removal steps................................................................................................................... 66
(II) Inspection stepes............................................................................................................ .68
(III) Installation steps............................................................................................................. 70
Section 3 Rear shock absorber and rear wheel fork.......................................................................... 74
(I) Disassembling steps......................................................................................................... 75
(II) Checking steps................................................................................................................ 77
(III) Mounting steps.............................................................................................................. 79
Section 4 Steering operation system................................................................................................. 82
(I) Removal steps of steering bar........................................................................................... 83
(II) Removal steps of steering vertical column welding....................................................... 84
(III) Inspection content......................................................................................................... 85
(IV) Installation steps........................................................................................................... 86
(V) Installation steps of steering bar.................................................................................... 89
Section 5 Front Wheel and Front brake.............................................................................................90
(I) Disassembly......................................................................................................................92
(II) Installation.......................................................................................................................93
Section 6 Front shock absorber and front wheel fork and Front differential.................................. 95
(I) Disassembly.................................................................................................................... 97
(II) Installment steps.......................................................................................................... 100
Chapter IV Electric appliance........................................................................................................ 102
Section 1 Electric assembly............................................................................................................ 102
Section 2 Inspect switch................................................................................................................. 104
Section 3 Check headlight lamp..................................................................................................... 105
Section 4 Troubleshooting the ignition system failure................................................................... 106
Section 5 Running starting circuit.................................................................................................. 108


Section 6 Troubleshooting electric starting system......................................................................... 109
Section 7 Battery will not hold charge............................................................................................. 112
Section 8 Troubleshooting................................................................................................................ 114
Section 9 Inspection of lighting system........................................................................................... 116
(I) Headlight not working..................................................................................................... 116
(II) Taillight not working...................................................................................................... 117
Section 10 Troubleshooting.............................................................................................................. 118
(I) If indicated lamp is out of work....................................................................................... 118
Section 11 Inspection of signal system........................................................................................... 120
(I) If the neutral indicated lamp is out work......................................................................... 120
(II) If the reverse indicated lamp is out work........................................................................ 121
(III) If the HB indicated lamp is out work............................................................................ 122
Chapter V Engine.............................................................................................................................. 123
Section 1 Disassembly of Engine...................................................................................................... 123
(I) Remove the engine from finished ATV.............................................................................. 123
(II) Disassembly of engine..................................................................................................... 145
Section 2 Inspection and maintanence of engine............................................................................... 135
Section 3 Assembly and adjustment of engine................................................................................... 154
(I) Installation......................................................................................................................... 183
Chapter VI Vehicle Troubleshooting.................................................................................................. 180
(I) Starting trouble/difficulty................................................................................................... 180


 Chapter I General Description
Section 1 Description

2 5 6 7 8
1

1. Front wheel
2. Headlight
3. Forward/Reverse lever
4. Shift pedal
5. Fuel valve
6. Hand-operated lever 3 4
7. Air choke
8. Taillight
9. Rear wheel 10 11 12 13 14 15
10. Rear luggage carrier
11. Exhaust silencer
12. Cushion
13. Fuel tank cover
14. Rear brake pedal
15. Front luggage carrier
16. Left rear brake lever
17. Hand-operated parking brake
18. Main switch lock
19. Throttle grip 16 17 18 19
20. Right front brake lever
21. Left switch unit
22. Left and right mirror (not 20
shown)

21

CAUTION:
The ATV you purchased may be slightly different from the pictures in the
manual due to improvements.


 Section 1 Special tools, instruments and meters

(I) Special tools

There are special tools needed to properly adjust and assemble this unit. These tools are
intended to prevent maintenance defects and damage.
1. Wrench for valve adjustment, mainly used to adjusting the valve clearance. Specification:
3mm, 90890-01311
2. Puller for piston pin, used for removing piston pin.
3. Remover for rotator, mainly for pulling the magneto rotator from crank.
4. Clamp for rotator, for clamping magneto rotator when removing it to prevent it’s rotation due
to torque force.
5. Stop rotating meter for rotator, used for removing and assembling rotator of kick starter.
6. Puller for crank, for disassembling crank from crankcase.
7. Puller for rocker shaft, used for the removing rocker shaft.
8. Compressing tools for spring of valve, for fixing and compressing spring when assembling
valve lock clamp.
9. Assembling and disassembling tools for valve guide.
10. Assembling buffer, used for assembling crank and balancing gear.
11. Hollow sleeve, for assembling crank and balancing gear.
12. Assembling tool for crank, used for assembling crank and balancing gear.
13. Assembling and disassembling joint for universal coupling.
14. Assembling and disassembling disc, used for assembling and disassembling reverse gear.
15. Fixed puller for gear.


(II) Instruments and meters
The following instruments and meters can be selected with
reference to the same type of vehicle.


Section 2 Identification code, label
of model and engine No.

Identification code
Engraved in the left or right side of the front
supporting main tube of engine of frame

Engine No.
This is engraved on the top middle part of the
right crankcase of engine.

Section 3 Points for attention in maintenance

1. Preparation when disassembling
• Clean and dirt or mud from vehicle.
• Be sure to use proper tools when disassembling
• Keep all the components away from fire. Pay attention to hot surfaces such as the engine,
exhaust etc.
• When disassembling the ATV, keep alike parts such as gear pairs, cylinder, piston, etc.
together. When assembling or replacing these components they should be kept in pairs.
• When disassembling the engine, clean all components and place in a tray in the order of
disassembly, not only increasing the assembling speed, but also ensuring the correct assembly.
2. Replace the components
When replacing components use only the products, lubricants and grease recommended by
manufacturer.
3. Oil seal, shim, O-ring, clip, split pin, elastic washer
• When disassembling to maintain the engine, to ensure that the reassembled engine has good
sealing and connected parts are fixed and reliable, the oil seal, shim, o-ring, clip, split pin and
elastic washer should be replaced, be sure to keep lip of oil seal, surface of shim and o-ring in a
clean condition.
• When reassembling, apply lubricant to all the alike components and bearings,
apply grease for oil seal.


4. Clip
Before assembling, check all the clips carefully.
Replace with a new one after removing from piston
pin. When mounting clip ring (1), make the sharp
end face (2) on the opposite position of
impacted face (3) of clip. (see figure at left)

5. Locking washer/shim and location pin

When reassembling, replace all locking washer/shim
and location pin (a) . After bolt or nut is in the lock
position, bend and fix both ends of locking shim
along head of bolt or direction of nut.

6. Bearing and oil seal

When assembling bearing and oil seal, put the mark
(specification of manufacturer) outside. When as-
sembling oil seal, apply a thin layer of lithium-based
grease on the lip of oil seal.

CAUTION:
Do not dry inside of bearing by blowing out with
compressed air, this will cause damage to the surface
of the bearing.


7. Check of electric parts
Make sure there is no rust, dirt or moisture at the
connection, if there is blow it dry or clean.

The electrolyte inside the battery is corrosive, take

extra precautions as to not get this on your body.

When repairing wires on electrical parts, remove

the wire on the terminal of negative pole of battery
(see figure 7.1). When tightening or loosening bolt
on terminal of battery, do not let the wrench contact
the engine or other metal parts of the vehicle body to
avoid electric shock.

When connecting the wire to battery, first connect

the positive pole then connect the negative pole.
After wires are connected, apply clean grease on the
terminal to increase resistance of rust.

Check the terminal of connector

A. Grip the two terminals of connector together,
check with the multimeter (see figures 7.3 and 7.4)


B. If there is slack in the joint, bend the plug pin
upward, then connect with connector plug (see figure
7.5)

Before mounting the new fuse, check if the load of

fuse on the components are correct, especially the
portion being broken regularly, then mount the fuse
having proper current value.

There are two kinds of wire connectors, a single-

head connector, another a multi-head connector.
Before connecting single-head connector, make sure
there are no defects on the housing of the joints.
When inserting the joint, after defects are fixed, put
plastic coating on.
In general, multi-head connectors are plastic and
designed to lock. When disassembling the connector,
first open lock; when connecting again make sure the
joints are in good condition and there are no bends
or twists. After connecting, align the lock device and
lock.

8. Use torque spanner to tighten screw and nut, and

as per specified torque. It should be tightened in
steps from big to small, from inside to outside and
along the direction of a diagonal line that intersects
(see figure 8.1).

10
 Section 4 Specification

I. How to use conversion table of unit

(1) How to use a conversion table
All the specified documents in this manual are taken SI and Metric as unit. With the following
conversion table, metric unit could ne conversed into imperial unit.

Metric Multiply Imperial

mm 0.03937 in
2mm x 0.03937 = 0.08in

Conversion Table
Known Unit Multiply Product
Torque m•kg 7.233 ft.lb
m•kg 86.794 in•lb
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb
Weight kg 2.205 lb
g 0.03527 oz
Length km/hr 06.214 mph
km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
Volume/capacity cc(cm³) 0.03527 oz(IMP lig.)
cc(cm²) 0.06102 cu•in
lit(liter) 0.8799 qt(IMP lig.)
lit(liter) 0.2199 gal(IMP liq.)
Others kg/mm 55.997 lb/in
kg/cm² 14.2234 psi(lb/in2)
Centrigrade 9/5(˚C)+32 Fahrenheit(˚F)
(2) Definition of unit
Unit Read Definition Measurement
mm Millimeter 10ֿ³Meter Length
cm Centimeter 10ֿ²Meter Length
kg kilogram 10³Gram Weight
N Newton 1 lilo x meter/second Force
Nm Newton meter Newton x meter Torque
m•kg Meter kilogram Meter x kilo Torque
Pa Pascal Newton x meter² Pressure
N/mm Newton per millimeter Newton/centimeter Rigid of spring
L Liter
cm³ Cubic centimeter ¯ ¯
r/min Revolutions per minute − Rotational speed

11
II. Basic specification
Dimensions: Shaft drive
Overall length 75.5in
Overall width 41in
Overall height 44in
Seat height 35.25in
Wheel base 49in
Ground clearance 7.75in
Minimum turning radius 118.1in
Weight with oil and fuel 573lbs.
Engine:
Type Oil cooled 4-stroke
Cylinder arrangement Forward-inclined single cylinder
Displacement 387cc
Bore and stroke 83*71.6mm
Compression ratio 9.50:1
Starting system Electronic ignition with recoil
Lubrication system Wet sump
Final gear case oil:
Type SAE80 API GL-4 Hypoid gear oil
Quantity 0.23L (0.24 US qt.)
Differential gear case oil:
Type SAE80 API GL-4 Hypoid gear oil
Quantity 0.35L (0.37 US qt.)
Air filter Wet element
Fuel:
Type UNLEADED GASOLINE ONLY
Fuel tank capacity 13.5L (3.57 US gal)
Fuel reserve amount 3.3L (0.87 US gal)
Carburetor:
Type PD33G
Spark plug:
Type DR8EA/NGK
Gap 0.6-0.7mm (0.02-0.03in)
Clutch type Dry centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Shaft drive
Secondary reduction ratio 41/21 24/1 33/9 (9.545)
Transmission type V-belt automatic
Operation Left hand operation
Forward gear 35/20 (1.750)
Reverse gear 26/15 (1.733)

12
Chassis:
Frame type Steel tube frame
Caster angle 4
Trail 21mm (0.83in.)
Tire: Tubeless
Type AT25 8-12
Size AT25 10-2
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand and right foot operation
Suspension:
Front Double wishbone
Rear Swing arm (mono cross)
Shock absorber:
Front Coil spring/oil damper
Rear Coil spring/oil damper
Wheel travel:
Front 160mm (6.30in)
Rear 180mm (7.09in)
Electrical:
Ignition system DC-C.D.I.
Generator A.C. magneto
Battery type YTX14AH
Battery capacity 12V, 12Ah
Headlight type: Krypton bulb
Bulb voltage, wattage capacity:
Headlight 12V, 30/30W2
Tail/brake light 12V, 5/21W1
Neutral light indicator 12V, 1.7W1
Reverse indicator light 12V, 1.7W1
Oil temperature warning light 12V, 1.7W1
Four-wheel drive indicator light 12V, 1.7W1
Fuses:
Main fuse 30A
Headlight fuse 15A
Ignition fuse 15A
Four-wheel drive fuse 3A
Signaling system fuse 10A

13
III. ATV body

Item Standard Limit

Steering system Powder metallurgy sliding
Type of steering bearing bearing
Type Rim, tubeless tire
Front Material of rim Steel plate
Wheel Size of tire AT25x8-12
Size of rim AT 12x8
Front Brake Type Hydraulic disc
Type Spoke rim, tubeless tire
Rear Material of rim Steel plate
Wheel Sixe of tire AT22x10-10
Size of rim AT 10x8.0
Type Drum type
Rear Thickness of friction piece 4.0mm (0.16in) 2.0mm
Brake Free length of back spring of brake 71.0mm (2.77in)
shoe
Free play of brake lever (left) 5-7mm (0.195-0.273in)
Brake lever
Free play of brake lever (right) 5-7mm (0.195-0.273in)
and brake
Free play of rear brake pedal 20-30mm (.78-1.17in)
pedal
Free play of throttle grip 3-5mm (0.117-0.273in)

14
IV. Electric system
Item Standard
Voltage of electric system 12V
Spark plug Type DR8EA/NGK
Resistence 10Ω
Clearance of spark plug 0.6-0.7mm (0.023-0.027in)
Resistence of primary coil At 20°C(68˚F), 0.5-1.5Ω
Ignition coil
Resistence of secondary coil At 20°C(68°F), 10.3-12.2Ω
Clearance of min. spark 6mm(0.24in)

Item Standard
Resistence of induction coil/color At 20˚C (68˚F), 189-231Ω Blue-black
Magneto Resistence of source coil/color At 20˚C (68˚F), 470-530Ω yellow/green-red
Type of C.D.I. Electric capacity contactless type
Rectifier No-loading adjusting voltage 14.1-14.9V
Voltage-resisting value 200V
Type A·C magneto
Charging Rated output voltage At 2000r/min 14-15V
system
Coil resistence/color At 20˚C (68˚F) 0.7-1.8 white-white
Battery Specific gravity 1.28
Type/capacity 12N14-BS/12V, 14Ah
Broken Type Fuse
circuit of Main fuse 30A
system
Ignition fuse 15A
Relay of cut- Coil resistence At 20˚C (68˚F), 72-88Ω
off current Diode Yes
Electric start- Type Constant mesh type
ing motor Output power 0.35KW
system Resistence of armature coils At 20˚C (68˚F), 0.003-0.0048Ω
Electric Ampere 100A
starting relay
system
coils resistence At 20˚C (68˚F), 4.8-5.3Ω

15
 V. Maintenance Specification of Engine
Item Standard Limit
Axle Drive
Meshing clearance of last end gear 0.1-0.2mm (0.004-0.008in)
Meshing clearance of middle gear (forward) 0.1-0.2mm (0.004-0.008in)
Meshing clearance of middle gear (backward) 0.1-0.25mm (0.004-0.01in)
Lubrication system:
Type of oil filter Wire filter net
Type of oil pump Rotor type, pressure splash type lubrication
Clearance of side 0.04-0.09mm (0.0015-0.0351in)
Endface clearance “A” or “B” 0.15mm (0.006in) 0.09mm
Releasing pressure of safety valve 80-120Kpa 0.20mm
Cylinder 70.97-71.02mm (2.768-2.77in)
(Distance between measuring point and
Bore size upper endface of cylinder is 40mm) 80.50mm
Cylinder head Measure the surface warp of every portion 0.10mm
Flatness of lower endface on the lower endface of cylinder head with
ruler.
Timing chain
Type of timing chain Roller chain
Tension type of timing chain Free adjustment
Pneumatic camshaft:
Driving method Chain driven
Roundness tolerance of camshaft 0.03mm
Outside diameter of camshaft 24.96-24.98mm
Cam size
Exhaust: A 40.38mm (1.574in)
B 32.18mm (1.255in)

Intake: A 32.18mm (1.255in)

B 40.55mm (1.581in)

Rocker arm/ Rocker arm shaft

Outside diameter of shaft 11.981-11.991
Inside diameter of rocker arm 12.000-12.018
Clearance between arm and shaft 0.009-0.037

16
V. Maintenance Specification of Engine
Item Standard Limit
Valve spring:
Outside spring:
Free length: intake/exhaust 37.2mm (1.45in)
Setting length when valve is closed: 32.0mm (1.25in)
Compressing pressure when assembling:intake/exhaust 162.8-200.1N
Limit value of sqaureness:intake/exhaust 2.5˚/1.6mm
Twisting direction of spring (top view):intake/exhaust clockwise
Valve, valve seal, valve guide
Valve clearance (it’s cold): intake 0.02-0.03mm(0.00078-.00117in)
exhaust 0.03-0.05mm(0.00117-0.00195in)
Size of valve

A-diameter of valve head exhaust 33.93mm(1.32in)

intake 40mm(1.56in)
B-width of valve face intake/exhaust 3.19mm/3.45mm(0.124-0.135in)
C-width of valve set intake/exhaust 0.6mm/1.03mm(0.023-0.040in) 1.6mm
D-limit thickness intake/exhaust 1.18mm/0.98mm(0.046-0.038in)
Outside diameters of valve stem exhaust 6.94-6.91mm(0.271-0.269in)
intake 6.93-6.89mm0.270-0.269in)
Inside diameter of valve guide: intake/exhaust 6.000-6.012mm(0.234in) 0.10mm
Clearance between valve stem and guide:
exhaust 0.025-0.052mm(.001-.002in) 0.08mm
intake 0.10-0.037mm(0.0039-0.0014in)
Roundness of valve seem 0.03mm
Piston ring:
First ring

Type Bucket-shaped back round

Size (BxT) 1.11x3.33mm(0.043-0.13in)
0.4mm
0.12mm

Type
Size (BxT) Flat type
1.45x3.33mm(0.057-0.130in)

Size (BxT)
0.4mm
0.12mm
2.74x2.48mm(0.107-0.097in)

17
V. Maintenance Specification of Engine
Item Standard Limit
Piston

Piston size “D” 70.92-70.97mm(2.77in)

Measuring point “H” (from bottom line of piston lower portion) 4.0mm(0.156in)
Piston offset 0.5mm(0.0195in)
Direction of piston offset Inward
Clearance between piston and cylinder 0.04-0.006 0.15mm
Outside diameter of piston pin 15.991-16mm(0.624-0.624in)
Inside diameter of pin hole 16.002-16.013mm(0.624-0.625in)
Driving method of balancing block gear driving
Connecting rod of crank

Limit value of runout: C1 0.03mm

C2 0.06mm
Width of crank “A” 55.95-56.00mm(2.18in)
Small end free play of connecting rod “F” 0.8-1.0mm(0.031-.039in) 2.0mm
Big end free play of connecting rod “D” 0.35-0.65mm(0.014-0.025in)
Big end radial clearance of connecting rod “E” 0.01-0.025mm(0.0004-0.001in)
Automatic centrifugal clutch
Clutch shoe: quantity 3 pieces
thickness 2.0mm(0.078in) 1.5mm
Clutch meshing revolution 1800-2100r/min
Clutch stalled revolution 3200-3600r/min
Free length of back spring of brake shoe 32.47mm(1.27in)
Clutch:
Action method of clutch Outside pushing type
Clutch piece: quantity 4 pieces
thickness 1.45-1.75mm(0.057-0.068)
Friction piece: quantity 5 pieces
thickness 2.94-3.06mm(0.115-0.119in) 2.8mm
Spring of clutch: quantity 4
free length 35.1mm(1.37in) 32.9mm
Shifting mechanism
shifting method shift gear cam drunk and fork
beading limit of fork guide 0.8mm
Transmission device
offset limit of spindle 0.08mm
offset limit of transmission output shaft 0.08mm

18
Section 5 Requirements for torque fastening

Torque value of fasteners

Locking component and location on ATV Hard- Size of Qty Nm ft·lb
ware thread
Cylinder head Bolt M10x238 2 45 33
Cylinder head Bolt M10x216 2 45 33
Front and rear valve cover Bolt M6x20 5 10 7
Cam timing gear cover Bolt M6x25 2 10 7
Oil shield plate comp Bolt M6x12 2 10 7
Cylinder head hexangle Bolt M8x50 2 23 17
Cam stop plate Bolt M6x12 2 10 7
Exhaust stud Bolt M8x45 2 23 17
Intake manifold Bolt M8x25 2 23 17
Timing gear Bolt M10x25 1 45 33
Tensioner plate bolt Bolt M6x16 2 10 7
Tensioner Bolt M6x25 2 10 7
Tensioner plug Bolt M10x12 1 45 33
Cylinder bolt Bolt M6x30 1 10 7
Balanced initiative gear Bolt M10x40 1 45 33
Balanced shaft gear Nut M16 1 197 146
Clutch protection cover bracket Bolt M6x30 4 10 7
Protection cover inner bearing Bolt M6x12 1 10 7
Drain plug Bolt M12x40 1 80 59
Crankcase Bolt M6x50 12 10 7
Crankcase Bolt M8x45 3 23 17
Crankcase Bolt M6x70 3 10 7
Bearing press plate Bolt M6x12 2 10 7
Forward and reverse gear switch Nut M10 2 45 33
Press plate sank Screw M6x16 1 10 7
Rotate speed transducer Bolt M6x12 2 10 7

19
Torque value of fasteners
Locking component and location on ATV Hard- Size of thread Qty Nm ft·lb
ware
Clutch cover Bolt M6x20 2 10 7
Inner left cramlcase cover Bolt M6x50 8 10 7
Outside left crankcase cover Bolt M6x30 4 10 7
Pullstarter ratchet Bolt M14x21 1 136 101
Internal lockup clutch net Nut M22 1 588 435
Bearing seat/outer cover Bolt M6x30 8 10 7
Drive pulley Nut M16 1 197 146
Driven pulley Nut M16 1 197 146
Bearing seat output shaft Screw M8x24 4 23 17
Inner drive gear Nut M23 1 479 355
Output shaft turning yoke Nut M14 1 136 101
Output shaft bearing seat Bolt M8x30 4 23 17
Pull starter Bolt M6x14 4 10 7
Oneway drive Bolt M8x16 6 23 17
Oil pump cover Bolt M6x12 3 10 7
Starter motor Bolt M6x20 2 10 7
Stator Bolt M6x30 3 10 7
Oil pump Bolt M6x25 3 10 7
Internel oil net Bolt M6x14 2 10 7
Oil cooler Bolt M6x20 4 10 7
Oil cooler fan Bolt M6x20 3 10 7
Pickup coil Screw M5x12 2 6 4.5
Steering shaft coller Nut M8x60 2 23 17
Steering shaft control arm Nut M14 1 136 101
Handle clamp Bolt M8x35 4 23 17
Front shock Bolt M10x50 4 45 33
Upper/lower A-Arm Bolt M10x1.25x70 8 45 33
Protection cover lower A-Arm Bolt M6x12 2 10 7
Rear shock Bolt M12x80 2 80 59
Rear swing arm Bolt M12x80 2 80 59

20
 Torque value of fasteners
Locking component and location on engine Hardware Size of thread Qty Nm ft·lb

Rear axel tubing Bolt M10x20 7 45 33

Rear protection plate Bolt M8x12 2 23 17
Rear axel Nut M16 2 197 146
Gearshifter Bolt M8x20 3 23 17
Drum brake back plate Bolt M8x40 4 23 17
Rear drive case Bolt M10x25 4 45 33
Gear shift arm Bolt M6x35 1 10 7
Front caliper Bolt M8x14 2 23 17
Front brake disc Bolt M8x20 4 23 17
Foot pedal Bolt M6x35 12 10 7
Foot pedal Screw M6x12 12 10 7
Rear brake pedal protection plate Bolt M6x12 1 10 7
Meter bracket Bolt M6x12 2 10 7
Meter Screw M3.2x30 2 3 2
Meter comp Screw M3.2x30 4 3 2
Fuel tank cover Screw M6x12 2 10 7
Front and rear rack Bolt M8x12 8 23 17
Front bumper Bolt M8x12 23 17
Front bumper Screw M6x30 2 10 7
Front protection cover Bolt M8x16 4 23 17
Fuel tank Bolt M6x25 4 10 7
Tail light Nut M6 2 10 7
(III) General torque specification A (Nut) B (Screw) m·kg
General torque specification (standard screw)
10mm 6mm 0.6
This figure is a screw locking specification
drawn by International Standard Association. 12mm 8mm 1.5
In order to avoid twisting or unbalancing when
locking screw, cross lock as stated below. 14mm 10mm 3.0
17mm 12mm 5.5
* When measuring torque force, standard torque
force testing spanner must be used. 19mm 14mm 8.5
22mm 16mm 13.0

21
Section 6 Lubrication point and type of lubricants
(I) Lubrication point and type of lubricants (ATV body)
Lubricant point
Lip of oil seal (full)
O-ring (full)
Steering shaft (upper end, lower end)
Ball connection of steering pushing rod
Front wheel fork (ball-shaped joint)
Front wheel bearing
Front & rear brake: Braking camshaft,
Rotating pin seat, Lip of oil seal
Dust-proof ring of brake
Joint of front brake cable
Front brake lever axle & rear brake lever axle
Adjusting nut & pin of front brake cable
Adjusting nut & pin of rear brake cable
Rear brake pedal pivot & brake pedal axle hole Light lithium-base grease
Throttle rotating frame shaft & end section of
throttle cable
Reverse gear lever pivot
Connection bolt of rear wheel fork & frame,
rear wheel fork bearing
Rubber sleeve & rear wheel fork
Rear shock absorber bushing
22
Type of lubricants
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Grease used for bearing
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Seal gum
Light lithium-base grease
(II) Lubrication point and type of lubricants (Engine)

Lubricant point (name of component) Type of Lubricant

Lip of oil seal (Crank,shift,gearshaft,spindle,shiftgear operation shaft) Light lithium-base grease

All bearing (Crank,spindle,driving shaft,output shaft,balancing Lubricating oil

shaft,shift gear camshaft,pneumatic camshaft)
O-ring (Contact position of o-ring) Light lithium-base grease
Stem end of intake & exhaust valve (Intake & exhaust valve, valve adjusting screw) Lubricating oil
Fastener of cylinder head (Bolt flange face, thread portion, washer endface) Lubricating oil
Outside surface of piston pin (Piston, piston pin, small end of connecting rod) Lubricating oil
Oustide surface of piston, piston ring (Cylinder block, piston, piston ring) Lubricating oil
Inner hole of main driving gear (Crank, main driving gear) Lubricating oil
of main clutch
Inner hole of assistant clutch gear (Assistant clutch gear unit,spindle) Lubricating oil
Assistant clutch releasing (Operation rocker & it’s contact portion) Lubricating oil
operation rocker unit
Upper cam plate guide rod (Upper cam plate unit, guide rod) Lubricating oil
Inner hole of upper cam plate unit (Shift gear shaft, upper cam plate unit) Lubricating oil
Steel ball bracket unit (Steel ball bracket unit, upper & lower cam plate) Lubricating oil
Surpassing clutch (Surpassing clutch, main clutch cover, inner spline sleeve) Lubricating oil
Outside surface of reverse gear (Reverse gear controlling rod, rear transmission) Lubricating oil
controlling rod
Outside surface of reverse gear (Reverse gear fork shaft, reverse gear fork, steel ball) Lubricating oil
fork shaft
Spindle & inside hole jointing (Spindle, right crankcase) Lubricating oil
face of right crankcase
Outside surface of reverse gear (Reverse gear controlling rod, crankcase) Lubricating oil
controlling rod
Contractor of reverse gear switch (Reverse gear switch, reverse gear fork) Lubricating oil
(Fork shaft, fork, crankcase)
Outside surface of short fork shaft Lubricating oil
Outside surface of long fork shaft (Fork shaft, fork, crankcase) Lubricating oil
Shift gear camshaft portion, slot (Fork, shift gear cam, crankcase) Lubricating oil
portion, contator
Outside surface of shift gear shaft (Shift gear shaft & it’s contacting portion) Lubricating oil
Outside surface of over-wheel shaft (Over-wheel shaft, crankcase) Lubricating oil
Bushing inner hole of big gear of (Bushing, left crankcase) Lubricating oil
electric starter
Electric starting clutch (Rolling post & the contacting portion) Lubricating oil

23
 Chapter II Maintenance
adjustment of vehicle
NOTE:
The correct maintenance and adjustments are necessary to ensure the vechicle’s in normal driving
condition. The repair personnel should be familiar with the contents of this article.

Section 1 Periodic Maintenance/Lubrication

Everytime Every
Item Requirement 1MO 3MO 6MO 6MO 1YR
Valve Check the valve clearance. Adjust if necessary. ○ ○ ○
Spark plug Check the clearance & clean. Replace if necessary. ○ ○ ○ ○
Air filter Clean. Replace is necessary. Maintain every 20-40 hr’s of use
Carburetor Check the idle/starting state. Adjust if necessary. ○ ○ ○
Cylinder head Check for cracks/damage in gas tube. ○ ○
Replace if necessary
Exhaust system Check for leakage. Tighten if necessary. ○ ○
Replace gasket if necessary
Spark surpressor Clean ○ ○
Oil circuit Check for cracks/damage in oil tube. ○ ○
Replace gasket if necessary
Engine oil Replace (preheat engine before draining oil). ○ ○ ○
Oil filter Clean ○ ○ ○
Oil filter screen Clean ○ ○ ○
Gear case oil Check oil level and leakage. Replace ○ ○
Brake Check the operation. Adjust if necessary. ○ ○ ○ ○
Clutch Check the operation. Adjust if necessary. ○ ○ ○
Wheel Check the balance,damage,run-out etc. ○ ○ ○
Replace if necessary
Wheel bearing Check for looseness/damage. Replace if necessary. ○ ○ ○
Front & rear Check the operation & correct if necessary ○ ○
suspension system
Steering system Check the operation/correct if necessary, ○ ○ ○ ○
Check toe-in & adjust if necessary
Bearing of steering Lubricate every 6 MO (lithium soap grease). ○ ○
column
Connecting piece Check all connecting pieces & fasteners of ○ ○ ○ ○
& fastener chassis. Correct them if necessary.

24
Section 2 Disassembly and assembly of Cushion,
Fender and Fuel tank

1Cushion:
Disassembly
1- Place the vehicle on level ground.
2- Disassemble the cushion (1) : Pull the
cushion lock lever (2) up, then raise the
rear of cushion.

(II) Rear fender:

Disassembly
1
1- Place vehicle on level ground.

2- Disassemble the rear luggage carrier (1)

3- Be sure the seat cushion is disassembled

(see cushion disassembly in this section).

25
5
3

Battery Removal
4 CAUTION:
Disconnect negative wire first.
4- Disconnect the negative wire (2) and
positive wire (3) of battery.

2 5- Remove battery clamp bracket (4)

6- Remove battery (5)

7- Remove protective bracket (6) disconnect

6 all wires from main wire harness (7) and
electrical parts from switch box (8)

9- Remove the rear fender (8)

26
 2. Installation
Reverse procedure for “Disassembly”.
Pay attention to the following points:
1- Install:
• Rear fender (1) torque bolts to 7N.m (5ft.lbs)

3. Attach wire harness (1) and electrical parts

2 connecting to switch box (2).

4. Install Protective bracket (3).

5. Connect battery (4)

A.Connect the positive wire (5) to battery
3
B.Connect the negative wire (6) to battery
Install battery bracket (7)

4 5

6
7

4. Install the cushion (1)

1 CAUTION:
Insert the support lug of cushion into the plug
seat on the frame, then press down on the seat.

27
1 5. Install rear luggage carrier (1)
Torque requirement for fasteners:
Bolt (2) fastening torque: 3N·m (2ft.lbs)
Bolt (3) fastening torque: 9N·m (7ft.lbs)
CAUTION:
Remember to install the bushing on the con-
necting point of luggage carrier and frame.

Fuel tank disassembly

CAUTION:
Seat, rear fender and rear luggage carrier will
need to be removed before fuel tank disas-
sembly is started
1. Remove fuel tank cover

1. Turn fuel valve to OFF. Disconnect fuel

hose (1)
2. Remove fuel valve (2)

3. Remove fuel tank (3) (4 bolts total)

28
 1
Front fender disassembly
1. Place the vehicle on level ground.
2. Disassemble the front luggage carrier (1)

3. Disassemble the front plastic bumper (2)

2

4. Remove front metal bumper (3)

5. Remove front fender

Fuel tank Installation

Reverse Disassembly procedure

29
 1 2. Installation
Reverse procedure for “Disassembly”.

1. Install:
Front fender
Front metal bumper (1)

2
2- Install front plastic bumper (2) .
The fastening torque of bolt (bumper and
frame) is 16N·m (12ft.lbs).

3
4- Install the front luggage carrier (3) .
Bolt (2) (front luggage carrier and frame). The
fastening torque is 34N·m (25ft.lbs).
Bolt (3) (front luggage carrier and bumper).
The fastening torque is 11N·m (8ft.lbs).

5. Install seat cushion (1)

See Disassembly and installation of seat.
1

30
Section 3 Maintenance and Adjustment of
vehicle body
(I) Wear inspection of front and rear brake
1.Check the front brake
1- Stop the vehicle using the front brake
2- Check:
2 • Brake pad between caliper (2) and disc.
• If pads are worn, replace.
Refer to “Front wheel and front brake” sec-
tion in Chapter VII.

2.Check the rear brake

1- Tread down the rear brake pedal to rake
the vehicle.
2- Check
• Wear indication (1)
• If the wear reaches the limit mark (2)
replace the brake shoe assy.
Refer to “Rear wheel and rear brake” section
in Chapter VII.
(II) Adjustment of front brake
2 CAUTION:
Before adjusting, check the degree of wear
on the front brake according to the above
1 procedures.
CAUTION:
In order to avoid too large or too small brake
force when braking, make sure there is prop-
a er free clearance of left/right brake lever and
rear brake pedal:
1. Check
If the free clearance of right lever does not
conform to (a) specification as shown in
firgure, adjust it according to following stan-
dard.
Standard free clearance (a) of right lever:
5-7mm (0.195-0.273in)
Calculate from the fulcrum ( (a) in figure).

31
 2. Adjustment
2 1
Adjusting procedure of the free clearance of
right lever:
• Loosen the lock nut (1) , rotate the cable
adjusting screw (2) clockwise to reduce the
tension of front brake cable.
• Lift the front end from the ground, rotate the
two front wheels. Apply brake to verify it is
adjusted correctly.
• Rotate the adjusting screw (2) clockwise
or counterclocksiwe to gain proper free clear-
ance.
Clockwise: wear free clearance
Counterclockwise: decrease free
clearance
• Tighten the lock nut

(III) Adjustment of free clearance of left lever

and rear brake pedal.
CAUTION:
Before adjusting, check the wear condition of
rear brake.
CAUTION:
In order to avoid too large or too small brake
force of rear brake.

WARNING:
When braking after adjusting, must adjust the
left lever and rear brake pedal simultaneously.

32
 2. Adjust
• Free play of left lever.
1
2
• Free play of rear brake pedal.
Adjusting procedure:
CAUTION:
Before adjusting, depress the rear brake pedal
2-3 times.
• Loosen the locking nut (1) completely, and
screw in the cable adjusting screw (2)
completely.

• Loosen adjusting nut (3) of the rear brake

cable and adjusting nut (4) of rear brake.
3 • Tighten the adjusting nut (4) of rear brake
6
pedal until correct clearance is met: Free
4 5 clearance (rear brake pedal):20-30mm (0.78-
1.17in).

• Rotate adjusting nut (3) of rear brake cable

until correct clearance is met :
0-1mm
(5) Rear brake arm assy.
(6) Pin

b 1 2 • Screw out the adjusting screw (2) of rear

brake cable untl gaining correct free clearance
(b) :Free clearance (b) (left lever):5-7mm
(0.195-0.27in).

• Tighten the locking nut (1)

• Check the free play of left lever and rear
brake pedal.
If correct adjust is not met, repeat above
procedures to adjust.
WARNING:
After adjusting, raise the rear wheels from the
ground and rotate them to confirm no brake
force to block the rotation.
Otherwise repeat above adjustment.

33
 CAUTION:
After adjusting the steering lever, ensure the reverse
gear indicator lights up when the steering lever is in
the reverse position.

(V) Lubricating oil level inspection of rear driving

gear case.
Check the lubricating oil level of the gear case.
CAUTION:
The engine must be in a cold state
Checking procedure:
• Place the vehicle on level ground.
• Placce oil catcher under the gear case.
• Remove the oil filling screw plug (1) and sealing
washer.
• Observe the oil level: the correct amount should be
on the bottom of oil filling hole.
• If the oil level is too low, refill the recommened
engine oil to specified oil level.
Refer to the section “replacement of engine oil of
rear driving gear case”.
1 • Check for any damages to the sealing washer, if
damaged replace it.
• Install the sealing washer and oil fill screw plug
(1).
CAUTION:
• Install the sealing washer before installing the oil
filling screw plug.
• After installing the oil fill screw plug, check for
leaks.
Torsion of oil fill screw plug: 23N·m (17ft.lbs)

34
 (VI) Replacing engine oil of rear driving gear case.
1. Place the vehicle on level ground.
2. Place an oil catcher under the rear driving gear
case.
3. Remove:
• Lower cover of gear case
• Oil fillin screw plug
• Oil drain screw plug (1)
Drain the engine oil of the rear driving gear case.
4. Check:
• Sealing washer (oil fill screw plug position)
• Sealing washer (oil drain screw plug position)
If damaged, replace it.
1
5. Install:
Oil drain screw plug (rear driving gear case)
Torsion of oil drain screw plug: 23N·m (17ft.lbs)

6. Oil fill screw plug

CAUTION:
Avoid any forgein matter from entering the driving
gear case.

Recommended oil:
SAE80API “GL-4” engine oil of hypoid gear
If needed, you may use SAE80W90 engine oil of
hypoid gear

Total capacity:
0.35L

7. Install:
• Oil fill srew plug (rear drain gear case)
CAUTION:
After refilling, check for leaks.
Torque oil fill screw plug to: 23N·m (17ft.lbs)

35
 (VII) Rubber sleeve inspection of rear wheel fork
check
• Rubber sleeve (1)
If damaged or worn, replace it.
Refer to chapter 3 section 6 “rear shock absorber
and rear wheel fork”.

1 (VIII) Inspection of steering system

1. Place the vehicle on level ground
2. Check:
• Steering clamp seat of column and
bearing on the lower end of the steering column,
upper & lower and front & rear moving section
steering bar.
If the clearance is too large, replace the bearing.
Refer to Chapter 3 section 4 ”Steering system”.

3. Check:
• Ball joint unit of steering tension rod.
Rotate the steering bar leftward and/or rightward,
then rotate from left to right. If the ball pin unit (1)
of steering tension rod has too much
vertical clearance, replace it.
1 Refer to Chapter 3 section 4 “Steering system”.

4. Lift the front end of vehicle to make the front

wheel not bear any load.

5. Check:
• Left/right front seat assy on front brake position,
and/or bearing 6005-2Z/bearing 6203. When
moving the wheel back and forth horizontally, if
the clearance is too large, replace the following
components:
1) Bearing 6005-2Z/bearing 6203
2) Left/right front seat assy
3) Split pin
4) Front fork ball connection
5) Bushing assy
Refer to Chapter 3 section 4 “Steering system.

36
 (IX) Adjustment of toe-in on front wheels.
1. Rest the vehicle on level ground.
2. Measurement:
• Toe-in, adjust if not in specification.
Adjustment steps for toe-in
• Mark the center of tire thread on both front
wheels
• Lift the front end to keep force off wheels
• Point tires forward, measure the width between
the marks made on tire (A) .
• Rotate the front tires 180˚ in reverse.
• Measure the width B between two marks.
• Calculate the toe-in with the following formula
Toe-in= (B) - (A)

Standard value of toe-in:0.5mm (.012in)

• If the toe-in is not correct, adjust

3. Adjustment
Adjustment steps of toe-in:
• Mark determination marks at the end of the left/
right tension rod (1)
• Loosen the locking nuts at the end of left/right tie
rod (2)
• Left/right tie rods (3) should turn the same
amount turns left or right to obtain the specified
toe-in and make the left/right tension rods the same
in strength.
Tighten up the locking nuts (2) at the end of the
left/right tie rod.
Torque of locking nut: 30N·m (22 ft.lbs)

CAUTION:
• Make sure that the left/right tie rods have been
adjusted the same. Otherwise the vehicle will still
have toe in.
3 2
• After adjusting the toe-in correctly drive the
1
vehicle to test the toe-in adjustment. If the steering
is not normal as specified, adjust again.

37
 (X) Inspection of front/rear shock absorbers
1. Rest the vehicle on level ground
1 2. Inspection:
• (1) Upper part of front shock
absorber.
If broken or damaged, replace the front shock
3 absorber.
• Rear shock rod (rear shock absorber)
If broken or damaged, replace
• Oil leakage (3)
If there is a heavy leak from the front/rear shock
absorber repalce it.
Refer to Chapter 3 section 5 and 6 “Front shock
absorber and front wheel fork” and “Rear shock
absorber and rear wheel fork”.

3. Inspection
• Operation:
• Move the front/rear shock absorbers up and
down.
If it is not operating correctly replacce the compo-
nent.
Refer to Chapter 3 section 5 and 6 “Front shock
absorber and front wheel fork” and “Rear shock
absorber and rear wheel fork”.

(XI) Adjustment of front/rear shock absorber

Adjustment of spring preload:
Turn the adjuster (1) to increase or decrease the
spring upload.
A B C D E CAUTION:
The spring preload of rear shock absorber can be
adjusted to your needs, weight of the operator and
driving condition.
Standard Position: (B)
A-softest
E-hardest

38
(XII) Inspection of tire
WARNING:
This vehicle is equipped with low pressure tires, so correct filling pressure and keeping the
proper pressure is very important.

• Tire characteristics
1) Quality charicteristics of tire will affect the driving reliability of ATV. The following types of
tires are approved by the manufacturer and can be used safely. The use of any other tires is NOT
recommended.
Manufacturer Dimension
Front Wan Da AT25x8-12
Rear Wan Da AT25x10-12

• Tire pressure
1) Recommended tire pressure.
Front 34.5Kpa (5Psi)
Rear 34.5 Kpa (5Psi)
2) Low tire pressure will cause the tire to dislodge from the rim in bad driving condition.
The Minimum tire pressure
Front 34.5Kpa (5Psi)
Rear 34.5Kpa (5Psi)

3) When installing the tire to the rim, the tire pressure should be no more than:
Front 103.5Kpa (15Psi)
Rear 103.5Kpa (15Psi)

After installing the tire to the rim, fast pressure will cause an explosion. Filling pressure should
be conducted slowly and carefully.

CAUTION:
The max load of the ATV is 165kg (including driver)

39
1. Measurement
• Tire pressure (normal atmospheric temperature):
If out of specification, adjust.
CAUTION:
• The tire pressure gauge (1) is included with the
tool kit (Never use high pressure).
• If there is any dust or debris in the tire
pressure gauge you will not receive an accurate
reading. Always take two measurements and the
second should be the one used.
WARNING:
• Uneven and improper tire pressure is not safe and
may cause the loss of control.
• Keep the proper tire pressure

Normal
Temp. Front Rear
Tire Pressure
Standard 34.5Kpa(5Psi) 34.5Kpa(5Psi)
Min 34.5Kpa(5Psi) 34.5Kpa(5Psi)
Max 103.5Kpa(15Psi) 103.5Kpa(15Psi)

2. Inspection
• If wear or damage is found on the surface of the
tire, replace.
WARNING:
Using worn tires is extremely dangerous.
If the tire is worn to the specified postion replace
immediately.
Wear Limit of tire:
Front and rear tires: 2.0mm (.078in) (a)

(XIII) Inspection of rim

Inspection of rim (1) :
CAUTION:
Keep the rim in balance when replacing the rim or
tire.
WARNING:
Never attempt to repair the rim.

40
Section 4 Maintenanace and Adjustment of
Electrical Appliance
(I) Inspection of battery
WARNING:
The electrolyte is dangerous and includes sulfuric acid, so
it is poisonous and corrosive.
• Please operate by the following steps:
a. Avoid touching any part of your body with the
electrolyte especially your eyes.
1 b.Wear protective glasses when operating near battery.
• Emergency measures (external):
a. Wash the skin with water.
b. Wash eyes for 15 minutes with water, then conducte
treatment at hospital.
• Emergency measures (internal):
3 Drink plenty of water or milk, magnesia oxide, egg or
rapeseed oil and seek treament as soon as possible.
• The battery can produce explosive gas, so follow the
protection measures below:
a. When changing the battery be in a well
4 ventilated area.
b. Keep away from flame or spark such as welding
equipment, burning cigarettes, etc.
c. Smoking is strictly prohibited when charging or
operating the battery.
d. Keep away from children
1. Removal (refer to Section 2 of this chapter)
• Cut off (refer to “Removal of cushion” of this chapter.
• Battery electrode (negative electrode (1) , positive
2
electrode (2)).
WARNING:
First remove the negative electrode (1)
3. Removal:
a. Battery clamp plate (4)
b. Battery (3)
CAUTION:
Before using a new battery, be sure to charge to ensure
optimum condition of vehicle.
4. Inspection of battery electrode
If dirt or dust is found clean with a brush, check
connections.
CAUTION:
After cleaning the elctrode apply a film of lubrication

41
 1
5. Inspection of battery
If damaged, replace it

6. Installment of battery (3)

7. Connect
3 • Battery electrode (positive electrode (1) negative
electrode (2) )

First connect the positive electrode (1)

4
8. Installment:
a. Battery clamp plate (4)
b. Cushion

(II) Inspection of fuse

CAUTION:
Close the main switch when checking or replacing
2
the fuse, otherwise, it will cause a short circuit.

1. Inspection steps
• Remove the fuse (1)
• Connect the small size test instrument to measure
if the fuse is connected well.

1 CAUTION:
Set the test instrument at the position of “52x1”

Small sixe test instrument:

9/N·YU-.3112
90890-03112

• If the indicating needle points toward ∞, the fuse

is broken and needs to be replaced.

42
1 2. Replacement of bad/old fuse
Replacement steps:
• Cut off engine and circuit
• Install the new fuse.
• Start the power for electrical appliance inspection.
• If the fuse is not responding check the system
again (Refer to “Electrical Appliance” of chapter 4)

3. Installment of fuse cover

(III) Replacement of headlight bulb

1. Cut off engine
• Connecting wire terminal of headlight (1)
2. Removal
• Headlight unit (2)

3. Remove lens (1)

4. Remove the lens seat (2)
2
Rotate countereclockwise when taking out the lens
(1) .
CAUTION:
When removing the headlight hold the front side of
it with hand.

5. Removal:
• Bulb (1)

WARNING:
The bulb is very hot never touch before cooling.

43
6. Installment
• Bulb (1)
CAUTION:
Be sure that the projective part of the bulb (2) is
engaged with the convex groove (3) on the light
seat.
CAUTION:
Never touch the glass part otherwise the bulb will
loose illuminating value. If there are some oils on it
clean off with cloth mixed with alcohol.

7. Connect
• Light seat (1)
CAUTION:
Be sure that the projective part of the bulb is
engaged with the convex groove on the light seat.

8. Install the lens to the light seat.

9. Installment
• Headlight
CAUTION:
Install the rubber guard ring of the headlight con-
necting wire to the headlight.

10. Connect
• Connecting wire terminal of headlight.

44
Section 5 Maintenance and Adjustment of
Engine
(I) Clean the air filter
1. Remove the cushion (Refer to “Cushion Remov-
al” of this chapter).
2. Remove the air filter box cover (1) and air filter
components.

3. Removal
a. Air filter (1)
b. Foam supporting cylinder (2)
CAUTION:
1 Never start the engine without filter, otherwise the
piston and cylinder will be overworn.
4. Inspection
a. Air filter (1)
b. Foam cylinder (2)
If damaged replace it.
5. Clean the foam cylinder. Clean off the dust on
the inner surface with compressed air.
6. Clean the foam filter
a. Clean with water completely.
b. Squeeze the excess water of the foam and let dry.
NOTE:
When squeezing the water from the foam filter, do
not twist.

7. Installament
a. Install the foam filter core to the foam supporting
cylinder to combine an air filter assy.
b. Install the air filter assy.
c. Install the air filter cover.
CAUTION:
Make sure that the close fit surface of air filter is
engaged with the close fit surface of air filter box,
and there is no air leakage.

9. Installment of cushion (Refer to section 2

“Cushion Installment” of this chapter.
45
1

(II) Inspection of spark plug

1. Rest the vehicle on level ground and clean the
spark plug with compressed air to avoid dust from
entering the engine.
2. Remove the spark plug (1)
The standard spark plug: DR8EA, if not correct,
replace it.

3. Inspection of spark plug

a. Electrode (1)
Worn or damaged, replace it
b. Insulator (2) color
Brown or light brown is normal condition
If the color is clearly different, check the engine.

4. Clean the spark plug

Clean the spark plug with spark plug cleaner.

5. Measure the spark plug clearance (1) .

Measure with feeler gauge. If out of specification,
adjust.
Spark plug standard clearance: 0.6-0.7mm (.023in-
.027in)

6. Installment of spark plug

a. Clean the washer surface and spark plug surface
before installing the spark plug.
b. Tighten up the spark plug with hand before in-
stalling it according to specification.
Torque of Spark plug: 17.5N ·m (13ft.lbs)

60 46
 (II) Adjustment of idle speed
1. Rest the vehicle on level ground
2. Start the engine and warm it at idle speed of
1000-2000r/min, after several minutes, increase the
engine speed to 4000-5000r/min.
3. Set the specified idle speed through adjusting the
throttle adjusting screw (1) . Tighten to increase
the engine speed and loosen to decrease the speed.
Specified idle speed: 1450-1550r/min
4. Measure the engine speed with measuring meter.

5. Make sure that the free play of the throttle grip is

within 3-5mm, otherwise readjust the idle speed.

(IV) Adjustment of free play of throttle grip

CAUTION:
First adjust the engine idle speed when adjusting
throttle grip.
1. Rest the vehicle on level ground.
2. Inspection
• Freeplay of throttle grip (a) . If out of speci-
fications adjust free play of throttle grip: 3-5mm
2 (.117in-.195in)
1
3. Adjustment
Adjustment steps of free play of throttle grip.
a. Loosen the locking nut (2) .
b. Turn the adjusting bolt (1) up to the free clear-
3-5mm ance of throttle grip (a) is 3-5mm(.117in-.195in).
c. Tighten up the locking nut (2) .

a CAUTION:
After adjusting the free play, move the lever for-
ward and backward to make sure that the engine
will not lift.

47
 (V) Adjustment of speed limiter:
The speed limiter can limit the throttle in full open-
ing condition when the throttle grip is pulled to
the max position, screwing the adjuster inward can
stop increasing the speed.
1. Adjust speed limiting length (a)

Adjustment steps:
a. Loosen the locking nut (1)
b. Adjust the adjusting screw (2) clockwise or
2 1
counter-clockwise to make (a) obtain the speci-
fied length of 12mm (.47in).
c. Lock the locking nut (1)

WARNING:
a. For the beginner driver, pay extra attention to
screw the limiter inward and screw out with im-
provement of driving skills. Never remove the
adjusting screw of speed limitor.
b. For the correct throttle grip operation, never
screw out the adjuster to exceed 12mm (0.47in),
and adjust the free clearance of throttle grip to 3-
5mm (0.12in-.0195in).

48
1
(VI) Adjustment of valve clearance
CAUTION:
The valve clearance should be adjusted only after
the engine is cold, the valve clearance should be
adjusted when the piston is at the end point posi-
tion of compress stroke.

1. Removal:
1) Rest the vehicle on level ground

3) Remove:
a. Manual operation start mechanism (1)
b. Timing observation hole scsrew (2)

2 1 4) Remove:
a. Valve cap (1) (the side of exhaust valve)
b. Valve cap (2) (the side of intake valve)

2. Adjustment
1) Measure the valve clearance
a. Turn the crankshaft counterclockwise with
wrench.

49
1
b. Make the mark “T” on the rotor align with the
mark on the crankcase. When aligned the piston
ties in Top Dead Center (TDC)
c. Inspection of top dead center in pressure stroke:
(i) When the mark (1) on the rotor is align with
mark (2) on the crankcase, the two arms must be
clear.
(ii) If there is no clearance, turn the crankcase
counterclockwise to meet the above requirement.
2
d. Measure the valve clearance (3) with a plug
gauge. Adjust the clearance if it is out of specifica-
tion.
Intake valve clearance: 0.02-0.03 (0.00078-
0.00117in) (normal temp.)
Exhaust valve clearancee: 0.03-0.05mm
(0.001170.00195in) (normal temp.)

(2) Adjustment of valve clearance:

a. Loosen lock nut (1)
b. Insert the plug gauge spanner (2) between
adjusting screw (3) and valve stem.
c. Turn the adjusting screw (3) clockwise with
valve adjusting spanner until the right clearance
has been met.
Size of valve adjusting spanner: 3mm (0.117in)
Code: 90890-01311
d. Fix the adjusting screw (3) to avoid turning,
and fasten the lock nut (1) .
Torque of lock nut: 14N ·m (10.36ft.lbs)

3. Adjust the valve clearance again: If the clearance

is not correct adjust it again by using the above
procedures.

50
2 1
3. Installation:
Follow the opposite steps of “Removal”.
(1) Mount:
a. Valve cap (1) (side of outlet door)
b. Valve cap (2) ( side of inlet door)

CAUTION:
(i) Valve cap (1) (2) should be placed in the
upright position (3)
(ii) Check if the o-ring (4) is damaged, if so re-
place immediately.
Torque of valve cap: 10N·m (7.4ft.lbs)

(VII) Adjustment of timing chain tension

The engine has an automatic adjusting tensioner on
the chain, so manual adjustment is not neccessary.

51
(VIII) Measurement of compressionforce
CAUTION:
Inadequate compression force will reduce the en-
gine performance.
Before measuring the compression force, the valve
clearance should be adjusted (refer to “Adjustment
of valve clearance” section).
1. Put vehicle on level ground
2. Take the spark plug off
3. The following are steps for measuring compres-
sion force:

a. Install compression gauge (1) with proper

adjuster.
b. Open throttle lever completely.
Start engine (battery has been charged fully) until
there is no increase on the pressure gauge.

WARNING:
When starting the engine, the spark plug must be
connected to ground to avoid sparks.
c. Reading the pressure gauge
Compressive foce on sea level:
Standard value: 900Kpa (9.0kg/cm²)
Min. value: 800Kpa (8.0kg/cm²)
Max value: 1000Kpa (10.0kg/cm²)

52
d. If pressure drops below min. value:
(i) Drop some oil to active cylinder.
(ii) Measure the pressure again

Compression read Reason

Read is higher than filling
before
Read is equal when no oil
added
Read is over max value
Piston or rings are worn or
damaged.
Piston ring, cylinder head
or gasket may be dam-
aged.
Valve chamber and top
of piston is covered with
carbon deposits.

4. Remove pressure gauge

5. Mount spark plug, torque of mount equals

17.5N∙m

(IX) Inspection of engine oil level.

1. Place vehicle on flat ground

2. Check engine oil level and fill if necessary.
Inspection steps:
a. Warm up engine after several minutes. Let engine
cool for 10 minutes allowing oil to settle in engine.

53
 Chapter III Repair and Maintenance of Vehicle Body
Section 1 Rear Differential

1. Rear transmission case 9. Coller 17. Oil seal 25. Thrust washer
2. Left case 10. Bearing retainer 18. Bearing 26. Ring gear shim
3. Stud bolts M10x25 11. O-ring 19. O-ring 27. Washer
4. Needle bearing 12. Oil seal 20. Bolt M8x15
5. Oil seal 13. Drain plug 21. Bolt M10x25
6. Needle bearing 14. Gasket 22. Bolt M8x15
7. Ring gear set 15. Breather 23. Fill plug
8. Bearing 16. Bearing housing 24. Thrust shim

54
(I) Trouble
• Trouble judging guidance
Problem Reason
1. The vehicle appears to stop or there is A. Damaged bearing
irregular axial run-out with an abnormal B. Improper clearance (free play)
noise while the vehicle accelerates, C. Damaged gear
decelerates or is in idle state. (Do not D. Driving shaft breaks
confuse with engine trouble) E. Gear teeth break
2. The vehicle makes an irregular noise at F. Jam caused by shortage of lubricating oil
low speed and when decelerating or G. The gear is jammed by foreign matter
accelerating.
3. The rear wheel can not rotate and the
transmission shaft jams

CAUTION:
“A”, “B”, and “C” are difficult to judge because the performance is very subtle and it’s difficult
to distinguish them from normal operating noise. Remove these parts for special inspection if
you think they may have been damaged.
(II) Inspection
1. Check abnormal noise:
Noises during these actions may indicate mechanical malfunction
a. When vehicle is accelerating, or decelerating and the noise is not in direct ratio with higher
engine and transmission case speed, but is in direct ratio with rear wheel speed.
CAUTION:
Noise must differentiate from normal operating noise of vehicle.
Judgment: Teeth of gear cracked

WARNING:
You should stop driving immediately if there is any indication that the gear teeth are cracked.
This could mean that the transmitting components are jammed by gear fragments and it is pos-
sible to lose control of the vehicle, possibly injuring the driver.

2. Check the following :

a. Drain the lubricating oil

55
It is necessary to check for bearing damage, and if there is a great deal of metal or metal
fragments on the oil draining screw plug.
CAUTION:
It is normal for some metal fragments to be in the oil.
3. Check oil leakage
Check according to following procedures.
a. Completely clean, wipe, and dry the entire vehicle.
b. Check for any gear oil leaks.
If leaking, check component
If damaged, replace component
CAUTION:
1. Improper installation or damage of oil seal causes oil leakage in new vehicles.
2. To avoid unnecessary disassembly, check and confirm the oil leakage carefully.

(III) Trouble-shooting table

Check following points if there is basic trouble condition.

To check if the wheel bear-

YES Refer to “Front wheel and front
ings are damaged, lift the brake” of this chapter to replace the
front end of vehicle and front wheel bearings
rotate the front wheels.

NO

Recheck or remove single com-

Check the rear wheel shaft NO ponent. May not be damage to the
to see if the bearings are rear wheel bearing or driving shaft
damaged. bearing.
YES

To check if the bearing is Refer to “Rear wheel and rear

YES
damaged, remove the rear wheel shaft” of this chapter to re-
wheel shaft place the rear wheel shaft bearing.

NO

Remove the transmission

shaft components

56
 (IV) Disassembly
WARNING:
Ensure that the vehicle does not turn over by
firmly supporting it.

1. Drain the rear differential case oil (1)

Refer to section 3, chapter 2, “Replacement of
1
engine oil of rear driving gear case”
2. Disassemble
1) Cushion
2) Rear luggage carrier
3) Rear fender
Refer to “rear fender”

3. Disassemble
1) Rear wheel (left)
2) Connecting plate of rear wheel
1 3) Rear wheel (right)
4) Rear brake and rear brake hub
5) Rear axle shaft
Refer to “Rear wheel/rear brake/rear wheel
shaft”
2

4. Disconnect:
Breather tube (1) (rear driving gear case)
5. Disassemble
Rear differential case body (2)

CAUTION:
1) The transmission shaft (3) could possibly
drop out while rear differential case is re-
moved from the rear wheel axle.
2) Do not lose these components.

57
 1. Disassembly
a. Remove: bolt (1) M6
bolt (2) M8

CAUTION:
2 Loosen each bolt by ¼ circle and remove bolts
alternately.

b. Disassemble:
1
1) Rear driving gear case body (1)
2) Annular gear pad
3) Shift gear
4) Thrust plain pad

c. Disassemble:
Bearing gasket (transmission shaft-last grade)
CAUTION:
On the bearing there is left-handed thread.
The bearing gasket may be loosened if rotated
clockwise.

CAUTION:
Use special wrench when reinstalling the bear-
ing gasket.

58
 d. Disassemble
With a soft hammer lightly tap the main driv-
ing gear (1) and remove (with thrust pad (2)
and bearing (3))
CAUTION:
Remove the main driving gear first if it is nec-
essary to replace the gear. Replace the original
bearing thrust pad, do not reuse.

e. Disassemble:
1) Oil seal (1)
2) Bearing (2)
Properly support rear differential case and use
proper pressure assemble tool (3)

f. Disassemble:
Bearing (1) (main driving gear)
Procedures for disassembly:
1) With a proper punching pin (2) , remove
the outer circle of bearing.
2) On the main driving gear remove the inner
circle of bearing.
CAUTION:
Removing the inner circle of the main driving
gear bearing is difficult and generally unneces-
sary.

59
(V) Inspection
1. Replace the main driving gear and shift gear
if there are any scratches or wearing on the gear
teeth of bevel gear pair (1)
2. Check oil seal (2)
3. Check the O-ring (3)
Replace if damaged
4. Check the bearing (4)
Replace if damaged

CAUTION:
Be sure to adjust the main driving gear and/or
shift gear when replacing them. Turn to “Choice
of Main Driving and Shift Gear Pad”

5. If the transmission shaft (5) (spline) has any

wear or damage, replace it.

6. If there are any cracks or damage on the driv-

ing gear case body (6) and cover (7) replace
them.

CAUTION:
Be sure to adjust the pad of main driving and
shift gear while replacing the driving gear case
body and cover. Turn to “Choice of Main Driv-
ing and Shift Gear Pad”

60
Section 2 Rear wheel, rear brake, rear wheel axle
No. Item Parameter

1 Tire specification AT25x10-12

2 Rim Dimension 12x10
3 Tire air pressure
(Normal Temperature) Standard value
Min. value
Max. value
4 Runout
Radial runout 2mm
End face runout 2mm
5 Wear limit of tire 2mm
6 Wear limit of friction disk 2mm
7 Rear brake hub wear limit 161mm

1. Rear wheel rim 24. Washer 47. Wheel cap

2. Rear wheel tire 25. Bolt M6x12 48. Bolt M10x25
3. Valve core 26. Dust seal 49. Plate washer
4. Rear wheel rim 27. Plate 50. Tube
5. Rear wheel tire 28. Cotter pin 3x20 51. Clip spring
6. Valve core 29. Brake spring 52. Rear bridge assembly
7. Hub 30. Plate cover
8. Bolt 31. Dust seal
9. Nut M10, tire 32. Bolt M6x12
10. Bearing 33. O-ring
11. Dust cover 34. Retainer
12. Oil seal 35. Bolt M8x40
13. Bearing 36. Rear axel
14. Oil seal 37. Collar
15. Nut M10, tire 38. Seal o-ring
16. Brake plate 39. Brake drum
17. Brake camshaft 40. Drum assy. w/ring
18. Brake shoe 41. Left connecting plate
19. Return spring 42. Bolt
20. Indicator plate 43. Wheel washer
21. Bolt M6x30 44. Plate washer
22. Self lock nut M6 45. Castle nut M16
23. Camshaft lever 46. Cotter pin 3x20

61
62
 (I) Removal steps
1. Keep front wheel from moving then put a
1
proper stand under the frame so as to lift the
rear wheels.

WARNING:
2
In order to avoid the parts falling, (which will
cause danger), during the removal process, rest
the vehicle firmly.
2. Removal of left wheel
(1) Nut of rear wheel
4 (2) Left rear wheel
(3) Cotter pin
6
(4) Axle nut
CAUTION:
3 Remove rear wheel axle nut from rear wheel
5
axle housing soft hammer.
(5) Washer
(6) Spindle

(7)
(8)
(9)

3. Removal of right wheel

• Nut of rear wheel
• Right rear wheel
• Cotter pin
• Axle nut
• Washer
• Spindle

63
 3
1 8. Removal:
2 (1) Adjusting nut, pin and spring of rear
brake arm and rear brake tension rod assy.
9. Removal:
(2) Rear brake cable
(3) Rear brake tension rod assy

10. Brake shoe removal:

(1) Cotter pins
3 (2) Plate
1
(3) Brake shoes (including springs)

2
10. Removal:
(1) Bearing retainer
(2) Rear brake hub

11. Removal
• Tension spring
1 • Rear brake arm
• Brake indicating plate
• Rear brake shoe cam
2
12. Removal:
(1) Sealed bearing

13. Removal:
1 (2) Rear wheel axle: Push the left side of the
rear wheel axle, slightly pull the rear wheel
axle from right end.

2 WARNING:
While taking out the rear wheel axle, in order
to protect the thread
and gear groove from damage, do not hit the
rear wheel axle directly with hammer.

64
8. Inspection
(1) Inner surface of rear brake hub
If there is some engine oil or scrapes, remove it
and treat it. The method of treatment is as fol-
lows:
Removal of engine oil: Clean with cloth dipped
in volatile dilute or volatile solvent.
Removal of scrapes: Wipe scrapes slightly and
with even force to remove them.
(2) Gear groove of rear brake hub
If worn or damaged, replace it.

9. Inspection
(1) If there are any cracks, bends, or damage
on the brake cover, replace it.
(2) If the dust-proof seal is worn or damaged,
replace it.

10. Inspection
(1) If cam shaft of rear brake is worn, scraped,
or damaged, replace it.
(2) If the air pipe of rear brake is clogged,
remove this pipe and clean out the dirt, if dam-
aged, replace it.
11. Clean the air hole on the rear brake cover
with compressed air.

12. Inspection of rear wheel axle (1)

a: If the rear wheel axle is heavily scraped or
broken, replace it.
b: If the thread or gear groove on the rear wheel
axle is worn or damaged, replace it.

65
13. Measurement
The radial run-out of the piston (a) on the rear
wheel axle, if out of specification, replace it.

WARNING:
If the axle is bent, do not straighten it force-
fully.
14. Inspection:
(1) Bearing on the rear wheel axle
Rotate the rear wheel axle, if the axle shakes
left and right in the bearing or run-out it indi-
cates that the bearing is heavily worn and needs
to be replaced.
(2) If the oil seal is worn or damaged, replace
it.
Replacement steps of bearing and oil seal:
a: Clean around the bearing of gear case end.
b: Remove the oil seal (1) with plain screw-
driver.

CAUTION:
In order to protect the oil seal out edge from
damage during the removal process, place a
wood block (2) under the screwdriver.
Remove the bearing (3) with corresponding
tool.
The installment of new bearing and oil seal is in
reverse.
Caution
During the installment, the pressing tool of
bearing (4) should be matched with the outer
diameter of bearing outer race (7) and that of
oil seal.

WARNING:
Never beat the inner race (5) and bearing ball
(6) , the pressing tool needs to touch the bearing
outer race (7) .

66
 (III) Installment steps:
The reversal steps of “removal steps” are in-
stallment steps. Pay attention to the following
points when installing:
1. Lubrication part
(1) Oil seal lip of rear wheel axle.
(2) Bearing of rear wheel axle.
The corresponding splint tooth of rear wheel
axle.
The lubrication oil is lithium base grease.

2. Installment
Installment of rear wheel axle (1)

CAUTION:
Before installing the rear wheel axle, loosen
all bolts on the rear differential (2) ; hold the
rear wheel axle with hand to help guide the
gear groove of gear case, apply on the left end
of the axle slightly with soft hummer.

WARNING:
In order to protect the axle thread and splint
tooth of axle, never beat the end face of axle
directly with hummer.

3. Installment
Plain pad of rear brake cover
O-ring

4. Lubrication of rear brake cam shaft.

The lubrication oil is lithium base grease.

67
 5. Installment
Cam shaft of rear brake (1)
Indicating plate of brake (2)
Rear brake arm assy (3)

CAUTION:
When installing the brake indicating plate (2)
to rear brake cam shaft (1) , be sure to align
the projective part (a) of brake indicating
plate (2) with the concave part (b) of rear
brake cam shaft (1) .

At the same time, align the punch mark (c)

on the rear brake cam shaft with that (d) of
the rear brake arm assy (3) .
The torque of rear arm assy; 9Nm

6. Application
Sealing agent: Be suitable for the rear brake
cover assy and rear wheel axle bushing sur-
face.
Attached: Sealing agent: P/N: ACC-QUICK-
GS-KT

7. Installment
Rear brake cover assy (1)
Bearing block of rear brake (2)
CAUTION:
Install the rear brake cover with bolt (3) , the
torque of bolt installment is: 28N∙m۪ (21ft.lbs)

68
 8. Installment
(1) Brake shoe assy
9. Lubrication
• Dust-proof seal
Lubrication oil for dust-proof seal: lithium
base grease.
Warning
The lubrication oil is not allowed to be used
for brake shoe assy, the lithium base grease is
used for rear brake hub splint groove.

WARNING:
The lubrication oil is not allowed to be used
for splint on the right end of rear wheel axle,
other wise, during the work, the surplus lubri-
cation oil will leave on the brake shoe, affect-
ing the brake performance.

10. Installment:
Rear brake hub
11. Installment
(2) Rear brake tension rod assy
(3) Rear brake cable
12. Installment
• Spring
• Pin
Adjusting nuts (4) of rear brake tension rod
assy and rear brake cable.

13. Installment
(1) Washer 16
(2) Nut M16
14. Tighten up nut M16

Attached: (2) Torque of nut M16: 150Nm

69
15. Installment
• Cotter pin (1)
CAUTION:
After fastening the torque, the nut on the rear
axle is not allowed to be loose. If the nut con-
cave groove is not aligned with the splint hole
on the screw rod, align it by tightening up the
nut.
WARNING:
Always use the new cotter pin
16. Installment
Right rear wheel (1)
Lock nut of rear wheels (2)
Attached: The torque of the lug nut of rear
wheels is 55Nm.

WARNING:
When installing the core nut to the rear wheel,
be sure to face its core edge to the wheel.

18. Installment
• Connecting plate of rear wheel (1)
• Washer 16 (2)
• Rear wheel axle nut M16 (3)
• Cotter pin (4)
• Left rear wheel (5)
Connecting nut of front and rear wheels (6)
Refer to “Rear wheel” section of this chapter.

19. Adjustment

• Rear brake cable clearance

Refer to “Adjustment of left Lever and Rear
Brake Pedal Free Clearance” Section of chap-
ter 2.

• Clearance of left lever center: 5.0-8.0mm

(0.2-0.3in)

70
Section 3 Rear shock absorber and Rear swing arm
1. Rear shock absorber assembly
2. Bolt M12x1.25x70
3. Lock nut M12x1.25
4. Clevis pin
5. Cover
6. Washer
7. Cotter pin
8. Rear swing arm
9. Rear axle housing
10. Bolt M10x20
11. Lock nut M10
12. Bushing
13. Bolt M12x1.25x80
14. Lock nut M12x1.25
15. Rubber boot
16. Tension spring
17. Hose clamp
18. Protective plate cover
19. Stopper cushion
20. Bolt M8x12
21. Warning label
22. Trailer hitch ball mount
23. Bolt M10x20

71
 (I) Disassembling steps
1. Take off left rear wheel, rear wheel joint
plate, right rear wheel, rear brake hub, rear
brake, and rear axle.
1
Refer to “Disassembly of rear wheel/rear
brake and rear wheel axle” section in this
chapter.

2. Take off lower cap of gear case.

3. Take off the rear driving gear case

sub-assembly (1)
Refer to “Dischargment of rear driving gear
case sub-assembly and driving shaft” section
of this chapter.

4. Take off cotter pin (1) , washer (2) and rear

shock absorber pin shaft (3) .

CAUTION:
When taking off rear shock absorber pin shaft
(3) , hold rear wheel fork so that rear wheel
fork does not drop.

72
5. Remove nut (1) on the rear shock absorber,
bolt (2), rear shock absorber (3) .

6. Remove rear brake tension spring (1) .

7. Remove dust cap on rear arm axle.

8. Check the free play of rear wheel fork

checking steps.
a: Check the torque value of rear arm joint bolt
and the torque value of rear arm bolt, and nut
of rear wheel fork right side.

Attached: Torque of rear arm joint bolt and nut

is 130N ∙ m
Torque of rear arm joint nut is 6N ∙ m (4ft.lbs)

b: Move the rear wheel fork across to check

the side clearance [A]. If the clearance is big,
check the relevant parts of bush bearing and
frame.
Attached: Free clearance value is less than
1.00mm
c: Move the rear wheel fork up and down to
check the vertical clearance. If the clearance is
too tight, limited, or uneven, check the relevant
parts of bush bearing and frame.

73
 9. Remove axle housing (1)

10. Remove driving axle hose clamp assy

1
(front) (1), rear arm nut (right side) and rear
arm joint bolt.

11. Remove rear swing arm (1) .

1 (II) Checking steps

1. Check
a: If rear shock absorber is leakage, if any,
replace it.
b: If rear shock absorber is bent or damaged, if
any, replace it.
c: Pull the spring up and down to check if
spring is fatigued or damaged, if it is, replace
rear shock absorber.

74
 2. Check if the rear wheel fork assy is cracked,
bent, and damaged. If any, replace it.
Check if the rear wheel bush is cracked, bent,
and damaged. If there is one of these problems,
replace it.

3. Check the gear case lower cap. If there are

any cracks, bends, or damage, replace this part.

4. Check the rear arm joint bolt (1) , rear arm

joint bolt (2) , and bush (3) . If one of these
parts are worn or damaged, replace it.

5. Check the bearing of rear wheel fork assy, if

there is free play during the bearing match with
the rear wheel fork, or uneven swirl, replace
the bearing. Check the oil seal. If it is worn or
damaged, replace it.

Replacing steps of bearing and oil seal.

a. Clean the bearing round
b. Take off the oil seal (1) with flat screw-
driver.
CAUTION:
Put a wooden block (2) at the outer side in
order to protect the outer side.

75
 Remove bearing (3).
The reverse step of “bearing and oil sealing
replacing step” is the mounting step of new
bearing and new oil sealing.

CAUTION:
Tool (4) which is matched with outer diam-
eter of bearing race (7) and oil sealing.

WARNING:
Don’t strike the bearing inner race (5) and
roller.

(III) Mounting steps:

The reverse step of “disassembly” is the
mounting step, but the following points must
be paid attention to during the installation:
1. Lubricate the bearing (10, oil sealing (2)),
bush (3) , and rear arm joint bolt (4) .
Lubrication oil is Lithium base grease.

2. Mount the real wheel fork assy, rear wheel

fork bushing and rear arm joint bolt.

76
3. Fix the rear arm bushing (1) (left), rear arm
bushing (2) (right) and bushing (3) .

Fixing steps:
a: Fix the left rear arm bushing (1) by standard
torque.
Attached: Bolt torque value: 130Nm (96 ft.lbs)
b: Fix the right rear arm bushing (2) until it
makes contact with the bushing (3) .
Attached: Bolt torque value: 6Nm (4ft.lbs)
c: Fix right rear arm nut (4) by standard torque.
Attached: Rear arm nut torque: 130Nm (96ft.
lbs)

4. Check rear wheel fork free play.

Refer to step 8 in “disassembly”

5. Lubricate the upper and lower end surface of

rear shock absorber (see figure)
Use Lithium base grease as lubrication oil

6. Mount rear shock absorber

Upper nut torque of rear shock absorber: 50Nm
(37 ft.lbs)

7. Mount slip pin

77
 8. Mount the rear differential case
sub-assembly (1)
Refer to “Installation of rear driving gear case
sub-assembly and driving shaft” section of this
chapter.

1 9. Mount the rear wheel axle, rear brake hub,

right rear wheel, rear wheel joint plate and left
rear wheel.
Refer to “Installation of rear wheel/rear brake/
rear wheel axle” section of this chapter.

78
Section 4 Steering Operation system

1. Steering column 8. Bracket 15. Tie rod assy.

2. Pitman arm 9. Bolt M8x60 16. Nut M12
3. Upper handle holder 10. Lock washer
4. Bolt M8x35 11. Collar
5. Cotter pin 12. Washer
6. Steering bearing 13. Nut M14
7. Oil seal 14. Cotter pin

79
 (I) Removal steps of steering column
1. Removal
• Front luggage carrier
• Bumper
• Front fender
Refer to chapter 2, section 2

2. Removal
• Ignition switch
• “Neutral” indicating light wire
• “Reverse” indicating light wire
• “High beam” indicating light wire
1
• Clutch switch wire
3. Removal
(1) Brake cable from rear brake drum
4. Removal
(2) Throttle grip assy

5. Removal
Rear brake cable (1) from left handlebar

2 6. Removal
(1) Handlebar
(2) Handlebar clamps

80
 (II) Removal steps of steering vertical column
welding
1. Lock pad
(1) Unlock locking tab on lock pad
2. Removal
(2) Bolt M8x60
(3) Locking washer
(4) Clip assy

3. Removal
• Cotter pin
• Nut M10
• Washer 10

4. Removal
Split pin 3.2x24
Nut M12x1.25
Tie rod (1)
1 CAUTION:
When removing the tie rod end and steering ball
pin from the steering vertical column welding
assy and front seat assy of front brake with com-
mon bearing tension tool and other tools, pay
attention not to damage the relevant parts.

5. Removal
Remove the steering vertical column weld-
ing assy together with steering vertical column
holder.

6. Removal
(1) Steering vertical column holder
(2) Bushing
(3) Oil seal

81
(III) Inspection content
1. Check the handlebar for any damage. If it is,
replace it.

2. Inspect the steering vertical column welding

assy for any bends or damage. If there is, re-
place it.
WARNING:
In order to avoid decreasing the performance of
the steering vertical column, do not straighten it
forcefully if it is bent.

3. Inspection
Check the steering vertical column holder (1)
and seal ring (2) . If they are worn or damaged
replace them.

4. Inspection:
If the tie rod (1) is bent or damaged replace
them.

5. Correcting:
If the free clearance is found on the ball pin
head, replace the ball pin. If the part around the
ball pin head is uneven, replace the ball pin.
If there is convex point, wear, or damage on the
core surface of ball pin end head, replace it.

82
6. Adjustment
Assembly length of tie rod
Adjustment steps of tie rod assembly length
1- Loosen the connecting nut [A] [B]
2- Adjusting the assembly length of tension rod
by rotating the tie rod.
Attached: Tie rod assembly length @: 297mm
(11.58in)
[A] Right-handed thread
[B] Left-handed thread
Connect [C] position to the steering vertical col-
umn welding assy.
Connect [D] position to the front seat assy, the
front brake.

CAUTION:
The connection nut [A] [B] can be tightened up
only when the revealed thread length (b) of two
ends of tension rod are the same.
Attached: Lock nut torque of tie rod: 30Nm
(22ft.lbs)
7. Inspection
If the bearing (1) and O-seal (2) under the
steering vertical welding are worn or damaged,
replace them.

(IV) Installment steps

The reversal steps of “Removal” steps are the
“Installment” steps. Pay attention to the follow-
ing points during installment.
1. When installing steering vertical column
welding, lubricate the bearing (1) and seal ring
2 under the steering vertical column welding.

83
 2. Lubricate the steering vertical column hold-
er (1) and seal ring (2) during installation
of the steering vertical column welding.

3. Installment
Install the seal ring (1) to the steering verti-
cal column welding, then install bushing (2).
Finally, install the steering vertical column
holder (3).
CAUTION:
Never damage the seal ring when installing.

4. Installment
When installing the steering vertical column
holder and steering vertical column welding
take them as a unit.

WARNING:
In order to ensure that the correct circuit of
brake cable and wire, never damage or wind
the cables and wires.

5. Installment of left and right tie rod (2)

CAUTION:
Make sure that the ball pin (1) at the side of
scraped marking connects with the front seat
assy of front brake.

1
6. Tighten up the nut (1) of ball

84
7. Mounting cotter pin (1)
CAUTION:
Don’t loosen the nut after the torque is fixed.
If the nut recess does not correspond with split
pin hole on the double-screw bolt, tighten the
nut to align them.
WARNING:
Always use new cotter pin

8. Tightening
Mount the washer and nut on steering vertical
column.
Nut torque: 30Nm
After you torque the nut use the cotter pin.

9. Install
Clip (1) , locking washer (2) , bolt (3)
Attached: bolt torque: 23Nm (17ft.lbs)

WARNING:
Always use new locking washer.

10. Bent showing supporting lug of locking

washer to lock lightly the bolt.

11. Fill the lubrication oil at the oil cup to

lubricate the bearing under the steering vertical
column. Lubrication oil is Lithium base grease.

85
(V) Installation steps of handlebar
1. Install the lower holding seat (1) , steering
tube (2) and upper holding seat (3) .
WARNING:
When tightening the bolt of holding seat, make
sure clearance (b) is clear.
Attached: bolt torque: 20Nm

2. Install the thumb throttle grip assembly

CAUTION:
The projection (1) of thumb throttle grip as-
sembly must correspond with the sunken part
(2) on the right lever seat when installed.

WARNING:
Correct installation of cable and wire is very
important to ensure the safe operation of ve-
hicle.
Refer to chapter 1 “Wiring diagram of vehicle”

3. Adjusting the free play of brake cable

Refer to “Adjustment of Rear Brake” and “Ad-
justment of free clearance about right handle
lever and rear brake pedal” in chapter 2.

4. Adjusting the toe-in of front wheel

Refer to “Adjustment of front wheel Toe-in” in
chapter 2.

86
Section 5 Front Wheel and Front brake

87
1. Front wheel rim 12x6 26. Front wheel seal
2. Front wheel tire 25x8-12 27. Washer
3. Valve core 28. Castle nut M16
4. Lug nut 29. Cotter pin
5. Dust proof axle nut cover 30. Front brake plate protection cover
6. Uniform velocity turning assembly 31. Bolt M6x12
7. Out sphere cage 32. Hydraulic hose
8. Clip clamp 33. Bolt M6x35
9. Dust cover 34. Bolt M6x12
10. Clip clamp 35. Hydraulic hose bracket
11. Element rod 36. Bolt M6x12
12. Clip clamp 37. Hydraulic hose bracket
13. Clip spring 38. Hydraulic hose seat
14. Inner sphere cage 39. Bolts and washers
15. Clip clamp 40. Right brake caliper
16. Clip block 41. Bolt M8x20
17. Left knuckle assembly 42. Brake disc
Right knuckle assembly 43. Bolt M8x14
18. Bearing 44. Left brake caliper
19. Outer seal 45. Brake pads
20. Inner seal
21. Sleeve
22. Ball joint
23. Axle spring circlip
24. Front wheel hub
25. Front wheel shaft setting bolt

88
 Item Parameter
Tire specification 25x8-12
Rim dimension 12x8
Tire air pressure
(normal temperature) Standard 5
Bead seat 15
Runout
Radial
End face
Wear limit of tire 2mm

Disassembly
1. Place vehicle on level ground.
2. Remove lug nuts (1) and dust proof cover
(2) of front wheel.
3. Place a stand under the frame to support the
1
vehicle.

4. Remove:
4 • Cotter pin (1)
• Castle nut (2)
3 • Washer (3)
• Hub and rotor (4)
2

89
 5. Remove:
1 Brake caliper (1)
Brake rotor
CAUTION:
• Check the brake rotor for any damage and
replace if necessary.
• Check brake caliper for any leaks.
• Check the brake pads for wear or damage
and replace if necessary.

6. Remove:
Brake protective plate (1)

Installation:
1. Attach Brake protective plate (1) to steering
1
knuckle

90
 1 2. Attach brake caliper (1).

3. Attach:
• Hub and rotor (4)
• Washer (3)
• Castle nut (2)
4
• Cotter pin (1)
3

1 4. Attach:
• Front wheel (1) secure with lug nuts (2)
• Dust proof cover (3)

91
Section 6 Front shock absorber and
Front wheel fork and Front Differential

1. Left upper A-arm

2. Ball joint
8. Cotter pin 14. Front shock
3. Spring circlip
9. Left lower A-arm 15. Lock nut M10x1.25
4. Right upper A-arm
10. Right lower A-arm 16. Bolt M10x50
5. Ball joint
11. A-arm bushing 17. A-arm protective cover
6. Spring circlip 7.
12. Bolt M10x1.25x70 18. Tap nut clip M6
Castle nut
13. Lock nut M10x1.25 19. Bolt M6x12
92
Section 6 Front shock absorber and
Front wheel fork and Front
Differential

1. Front differential assembly

2. Right case
3. Left case
4. Clutch toper gear wheel
5. Seal
6. Differential speed outer
7. Bolt M10x18
8. Bolt M8x20
9. Bolt M8x25
10. Clip spring
11. Cylinder pin 21. Spout 31. Bolt M14x15
12. Divided move assembly 22. Seal o-ring 32. Washer
13. Fork 23. Seal 33. Tube
14. Clutch gear gasket 24. Bolt M10x16 34. Tube clip clamp
15. Rank 25. Washer 35. Long connecting end
16. Bearing 26. Clip spring 36. Short connecting end
17. Rolled needle bearing 27. Clutch gear wheel 37. Spring
18. Transducer 28. Clip spring 38. Dust cover A
19. Washer 29. Seal 39. Dust cover B
20. Seal o-ring 30. Bearing
93
 (I) Disassembly of front shock absorber
and front wheel fork: These instructions
are for one side of the unit only.
1 CAUTION:
Before starting disassembly make sure you
have completely drain the oil from the front
differential.
1. Place container under drain bolt (1) and let
drain completely.
2. Remove front luggage rack, bumper, and
front fender.
3 Refer to the second section of chapter 2
Disassemble the front wheel front brake hub,
brake shoe unit, and front brake cap unit.
2
3. Remove Steering knuckle (1)
• Tie rod castle nut (2)
1 • Upper A-arm castle nut(3)

• Lower A-arm castle nut (4)

• Front differential axle (5) (output shaft)

4. Remove
• Front shock absorber (1)
1

94
 1

5. Remove
• Upper A-arm (1) from frame

• Lower A-arm (2) from frame.

6. Remove
• Front differential case (1)

95
 Remove M6 bolts (2) and electric motor
comp.(1)

2 1

Use force on the end bearing to dislodge the

drive assembly (3).

96
 One side only
Upper A-arm

Front differential axle

Protective plate
Washer

Castle nut
Hub and rotor
Knuckle

Lower A-arm
Front differential
(II) Installation of front shock absorber and
front wheel fork- These directions are as-
sembly for one side on the unit only.
1. Reverse “Disassembly steps”.

2. Install the front differential driving case (1)

to the frame.

3. Attach the lower A-arm (1) to the frame.

97
 1

4. Attach the upper A-arm (1) to the frame.

5. Install the front shock absorber (1) to the

frame (2) and the top of the upper A-arm (3).
1

6. Attach the front differential axle to the front

differential.

7. Attach the steering knuckle (1) to the lower

(2) and upper (3) A-arms, secure with castle
nut and cotter pin (a)
a 2

3
4
8. Attach the steering tie rod (4) the steering
knuckle (1), secure with castle nut and cotter
pin
9. Attach front wheel assembly (refer to “Front
wheel and front brake section”)
1
CAUTION: Add correct amount gear oil as
specified to front differential.
98
 Chapter IV Electric Appliance
Section 1 Electric Assembly

1. CDI ignition unit

2. Starting motor relay
3. 30A fuse
4. Nut M6
5. Zip tie
6. Zip tie
7. Ignition coil
8. Bolt M6x20
9. Stop lamp switch assembly
10. Battery
11. Rectifier
12. Bolt M6x25
13. Negative cable
14. Battery press plate stand
15. Rubber washer
16. Main cable protection plate
17. Bolt M6x20
18. Tapping screw
19. Positive cable
20. Clamper
21. Fuse box
22. 25A fuse
23. 20A fuse
24. 10A fuse
25. Ignition switch
26. Wiring harness
27. Cable
28. Cable

99
 G/W
Right switch assembly
B Bl Y1 R R DG Bl Y1
B R B W
High&Low
W/R R2 Y/W W/G W/R beam light
W/Bl R2 Reverse switch OFF Ngear
G/W W/G Flameout Lb G/W Outer
G/Bl B/W Indicator indicator
switch Fgear
Magneto light light
Electrical
starting switch
Ngear
CDI Comp. Y/W Rgear
R/W Lb
Lb R/B DG W WW
B
O Y/B Bl/W Rectifier
R/W
B R Front Rear
brake brake
switch switch
R/B

Oil Temp. Bl
Bl/W R/W indicator light
Starting Fan
Relay motor
M Y1 DG Y1 Y1 DG Y1 Y2
M
P

15A
Oil cooling

100
M
switch
B Y/B R/Br
Y2
Parking
R switch
Bl/B 4wd shift motor
M
Ignition Coil Battery
R Lb Bl/B B Headlight 1 Headlight 2 Tail/brake light
12V 12Ah Br R Br BrBl R/W Y/R Br Br/W 12V 18W/18W 12V 5W/21W
Br B 12V 18W/18W
2wd W1 Front side light 1 Front side light 2
5A 25A
R Br/Bl (2wd 4wd) (ignition) 4wd 12V 15W 12V 15W
Spark plug B/W
B 10A(signal 25A (headlight)
4wd shift switch B B
Power lock indicator) B B
B
Master fuse box

B - black DG - deep green

W - white G - green
Bl - blue O - orange
Br - brown Lb - light blue
P - pink Y - yellow
R - red
Section 2 Inspect switch

(I) Inspect kill switch

Make certain the wire end is on the pocket mul-
timeter. If there are any problems replace the
switch

Pocket multimeter

• Turn the multimeter to “O”

• Turn the multimeter to “Ωx1” when inspecting
the circuit
• Turn the switch on and off many times while
inspecting

The left figure indicates the wire position of

switch. The vertical line indicates switch posi-
R/B R/W tion. The first row indicates color of wire. “O-O”
OFF indicates the circuit between the wire ends.
ON 1 When the switch is turned to “OFF” the red/
black wire and the red/white wire are not
connected.
2 When the switch is turned to “ON” the red/
black and red/white wire are connected.

101
Section 3 Check Lamp (headlight)
Check the headlight condition
1. Remove the headlight bulb
CAUTION:
Pay attention to support the lamp. Do not pull the lead wire, otherwise it will brake.
WARNING:
When the headlight illuminates, remove your hand from the lamp, it will be very hot. Do not
touch until it has cooled down.

2. Check if the circuit of lamp terminal in on

• Adjust the choice knob of the pocket multime-
ter to “Ωx1”
• Connect the multimeter pen to correspond-
ing lamp wire end, First connect the multimeter
pen (+) to wire end (1) and pen (-) to wire end
(2) to check the circuit between (1) and (2) .
Then connect the multimeter pen (+) to wire end
1 pen (-) to wire end 3 to check the circuit be-
tween (1) and (3). If it displays “∞” one time,
replace the lamp.
3. Mount a checked lamp to check the lamp
seat. The same as checking the lamp, connect
the multimeter pen to related lamp seat wire and
check the circuit by the same method as above.

102
Section 4 Troubleshooting
Ignition System failure
If the ignition system does not work (No spark)
Check:
1. Spark plug 5. Main switch
2. Spark plug gap
3. Resistance of ignition coil and wire
4. Engine stop switch

Power spark tester:

Ignition tester:
Pocket multimeter:

• Check and repair

1. Spark plug
• Check the spark plug condition
• Check the spark plug type Standard spark plug
• Check the spark plug gap DR8EA
Refer to chapter 3 “Check the spark plug”

Spark plug gap

0.6~0.7mm (0.024~0.028in)

103
2. Ignition spark clearance
• Remove the spark plug
• Connect as shown in figure
(1) Spark testing instrument
(2) Spark plug cap
(3) Spark plug
• Turn the main switch to the “ON” position
• Check the ignition spark clearance
• Press the starting switch to start the engine.
Increase the spark clearance until the engine
can not be started.

Min spark clearance

6.0mm (0.24in)

No spark Ignition system has no problem

3. Resistance of spark plug cap

• Remove the spark cap
• Connect the pocket multitester to spark plug
cap

4. Resistance of ignition coil

• Remove the ignition coil connector from
cable
• Connect the pocket multimeter (Ωx1) to igni-
tion coil.

104
Section 5 Running of Starting circuit
The starting circuit of this vehicle including
starting motor, cut-off relay, rear brake switch
and neutral switch. If the main switch is in
position, the starting motor could be operated
only at the following conditions:

• Driving device is in the neutral position

(neutral switch is closed)
OR
• Rear brake switch (rear switch is closed)

When the vehicle is in drive or reverse, and

the rear brake is in idle, then the cut-off relay
will prevent starting device from running. In
this state the cut-off relay is closed.

When drive device is in neutral

When rear brake is tensioned

(1) Battery
(2) Start motor
(3) Start relay
(4) Cut-off relay
(5) Start switch
(6) Rear brake switch
(7) Neutral switch
[A] C.D.I.
[B] From main switch

105
Section 6 Troubleshooting electric starting system
If starting motor does not work
• Check
1. Fuse 6. Main switch
2. Battery 7. Neutral switch
3. Starting motor 8. Rear brake switch
4. Cut-off relay 9. Starting switch
5. Starting relay 10. Circuit connection
(entire starting system)

• Remove the following parts before trouble-

shooting Pocket multimeter
1) Cushion
2) Front frame
3) Front fender

No electricity
1. Safety
Refer to “Check of switch”
Replace the safety
PASS

2. Battery
• Check the condition of the battery FAIL
Refer to “Check battery” chapter 3
Voltage of open circuit •Clean the battery terminal
At 20˚C (68˚F), 12.8V or much more • Recharge or replace the battery

PASS

3. Starting motor
• Connect the positive terminal (1) of the
battery to cable (2) of starting motor by
wire (3)
• Inspect the running condition of starting
motor

106
 No rotation

Repair or replace starting motor

Operation

4. Power off relay

• Remove relay from cable
• Connect portable multitester (Ωx1) and bat-
tery (12V) to end of wire on relay
Battery end (-) - yellow/white wire end (1)
Battery end (-) - red/white wire end (2)
Battery end (-) - red/black wire end (3)
• Inspect if the power off relay is on The circuit is NOT on

The circuit is on Replace power off relay

5. Starting relay
• Remove the connector of the starting relay
from cable.
• Connect the multimeter (Ωx1) and battery
(12V) to end of wire on relay.
Battery end (+) - blue/white wire end (1)
Battery end (-) - red rectifier wire (2)
Mutlitester pen (+) - red wire batter wire (3)
Inspect if the starting relay is on
The circuit is NOT on
The circuit is on
Replace the starting off relay

107
6. Main switch FAIL
Refer to “Check system”
Replace main switch
PASS

7. Neutral switch FAIL

Refer to “Check system”
Replace neutral switch
PASS

8. Rear brake switch FAIL

Refer to “Check system”
Replace rear brake switch
PASS

9. Starting switch FAIL

Refer to “Check system”
Replace left handlebar switch
PASS

10. Circuit connection FAIL

• Check the circuit connection of entire start-
ing system Connect entire starting system correctly
Refer to “Electric diagram”

108
Section 7 Battery will not hold charge
Check:
1. Safety 4. Stator coil
2. Battery 5. Coupling of circuit
3. Charging voltage (entire charging system)

• Remove parts before maintenance

1) Cushion Coil techometer
• Repair with special tools Engine tachometer

Pocket multimeter
1. Safety
Refer to “Inspection of switch”
No electricity
PASS

2. Battery Replace the safety

• Check the condition of battery
Refer to “Inspection of battery” in chapter 3
Voltage:
12.8V or more under load FAIL

PASS

3. Charging voltage • Clean the battery terminal

• Connect engine tachometer to the wire to • Recharge or replace battery
spark plug
• Connect pocket tester (DC 20V) to the battery
Pocket multimeter (+) - white terminal
Pocket multimeter (-) - white terminal

109
• Start engine and accelerate to 2000r/m
Charging Voltage: 14-15V at 2000r/m
Use fully charged battery Specification met

Out of specification

4. Resistance value for stator coil

• Remove the lighting coil of AC magneto
• Connect pocket multimeter to stator coil
(Ωx1)
Pocket multimeter (+) - white terminal 1
Pocket multimeter (-) - white terminal 2
Pocket multimeter (+) - white terminal 3
Measure the resistance value of stator coil
Out of specification

At 20˚C (68˚F), 0.7-1.80Ω

Replace parts of stator coil

Specification met

5. Coupling of circuit Poor connection

• Circuit the whole coupling of charging wire.
Refer to “Electric diagram”
Connect the charging system correctly

Correct

110
Section 8 Troubleshooting
If the headlight or taillight is out
Check:
1. Safety 4. Lamp switch
2. Battery 5. Coupling of wires
3. Main switch (entire lighting sys-
tem)
Pocket multimeter: P/N
• Remove the following parts before starting YU-03112 90890-03112
troubleshooting maintenance
1) Cushion
2) Front luggage carrier
3) Front covering parts
•Use special tools for troubleshooting

1. Safety No electricity
Refer to “Inspection of switch”

PASS Replace fuse

2. Battery
• Check the condition of battery FAIL
Refer to “Inspection of battery” in chapter 3
Voltage of open circuit
12.8V or more at 20˚C (68˚F) • Clean terminal of battery
• Recharge or replace the battery
PASS

FAIL
3. Main switch
Refer to “Inspection of switch”
Replace main switch
PASS

111
4. Change lamps FAIL
Refer to “Inspection of switch”

PASS If the lamp switch fails, replace the switch on

left handle

5. Coupling of wires
• Check the wire coupling for entire lighting
system
Refer to “Diagram” Poor coupling

PASS
Connect whole lighting system correctly

Check the returning condition of each lighting

system.
Refer to “Inspection of lighting system”.

112
Section 9 Inspection of Lighting System
(II) If headlight is out
No electricity
1. Bulb and socket
• Check if the bulb and socket are correct
Replace bulb and socket
PASS

2. Voltage
• Connect the pocket tester (DC 20V) to the
headlight
A B

DB DB
DB DB

Multimeter (+) - green terminal (1) or yel-

low terminal (2)
Multimeter (-) - black terminal (3)
[A] When switch is in “LOW” position
[B] When switch is in “HI” position

• Turn main switch to “ON” position

•Turn lamp switch to “LOW” or “HI” position
• Check the voltage of green and yellow wires
in coupler of bulb socket
PASS
Out of specification
If there is failure on the circuit from main
switch to bulb socket coupler, repair it

No failure on this circuit

113
(II) If taillight is out
No electricity
1. Bulb and socket
• Check if the bulb and socket are correct
Replace bulb and socket
PASS

2. Voltage
• Connect the pocket tester (DC 20V) to the
taillight terminal
Multimeter (+) - blue terminal (1)
Multimeter (-) - black terminal (2)

• Turn main switch to “ON” position

•Turn lamp switch to “LOW” or “HI” position
• Check the voltage of blue wire in coupler of
bulb socket (12V)
PASS
Out of specification
If there is failure on the circuit from main
switch to bulb socket coupler, repair it

No failure on this circuit

114
Section 10 Troubleshooting

(I) If indicator lamp is out

Check:
1. Safety 4. Coupling of wires
2. Battery (whole signal system)
3. Front switch

• Remove the following parts before trouble-

shooting Picket multimeter
1) Seat
2) Front frame
3) Front pedal
• Use specific tools for troubleshooting

1. Safety No electricity
Refer to “Inspection of switch”

PASS Replace fuse

2. Battery FAIL
• Check the condition of the battery
Refer to “Inspection of battery” in chapter 3.
Voltage of open circuit • Clean battery terminal
12.8V or more under load • Recharge or replace the battery

PASS

115
3. Main switch FAIL
Refer to “Inspection of switch”

PASS Replace main switch

4. Coupling of wires
• Check the coupling of whole signal system Poor connection
wires
Refer to “Diagram of wires”
Connect it correctly
PASS

Check the condition of each signal system

Refer to “Inspection of signal system”

116
Section 11 Inspection of Signal System

(I) If the neutral indicator lamp is out No electricity

1. Bulb and socket

•Check if the bulb and socket circuit B are Replace bulb and socket
correct.
PASS
No electricity

2. Neutral switch
• Refer to “Inspection of switch” Replace neutral switch

PASS

B B
3. Voltage B B
• Connect pocket tester (DC 20V) to the tail Bl Bl
lamp terminal Bl Bl
Pocket tester (+) - blue terminal (2)
Pocket tester (-) - black terminal (1)


• Adjust main switch to “ON” position Out of specification
• Check voltage (12V)

Meet specification If there is failure on the circuit from the main
switch to the bulb socket, repair it.

No failure on this circuit

117
(II) If the reverse indicator lamp is out No electricity

1. Bulb and socket

• Check if the bulb and socket are in good Replace bulb and socket
condition.

PASS No electricity

2. Reverse switch Replace reverse switch

• Refer to “Inspection of switch”

PASS

3. Voltage B B

• Connect pocket multimeter (DC 20V) to the B B

Bl Bl
taillight terminal
Bl Bl
Multimeter (+) - blue terminal (2)
Multimeter (-) - black/blue terminal (1)


Out of specification
• Adjust main switch “ON” position
• Check the volts (12V)

Meet specification If there is failure on the circuit from the main
switch to the bulb socket, repair it.

No failure on this circuit

118
(III) If the HB indicator light is out No electricity

1. Bulb and socket

•Check if the bulb and socket circuit B are Replace bulb and socket
correct.
PASS
No electricity

2. High or low beam switch

• Refer to “Inspection of switch” Replace handlerbar switch (left)

PASS

3. Voltage B B

• Connect pocket tester (DC 20V) to the tail B B

Bl Bl
lamp terminal
Pocket tester (+) - blue terminal (1) Bl Bl

Pocket tester (-) - black terminal (2)

• Adjust main switch to “ON” position Out of specification
• Check voltage (12V)

Meet specification If there is failure on the circuit from the main
switch to the bulb socket, repair it.

No failure on this circuit

119
 Chapter V Engine
Section I Disassembly of Engine
(I) Remove the engine from ATV
1. Remove
• Cushion
• Front luggage carrier
• Front bumper
• Front fender
• Rear luggage carrier
• Rear fender
The disassembling method refers to “Fender,
fuel tank disassembly” of chapter II.
2. Oil draining
1 Screw out oil draining screw plug. Drain
the lubricating oil of the engine from the oil
draining hole.
3. Exhaust pipe and silencer
1) Remove
• Exhaust pipe (1)
2) Remove
• Silencer (2)
2
4. Carburetor and air intake pipe
2
Place the throttle cock grip on “OFF”
position, and remove:
1 • Throttle cable (1)
• Fuel line (2)
• Clip (3)
3
4 • Carburetor, carburetor seat and hook hitch
assy (4)
CAUTION:
Before disassembling, drain off the gasoline
of the carburetor float cabinet firstly. Wrap
the overflow pipe with cloth to absorb the
splashed gasoline. The gasoline is
inflammable. Pay attention not to splash
gasoline on a hot engine.
5. Starting motor
1) Remove
• Starting motor line (1)

120
 5. Disconnect gearshift linkage from engine.

6. Wire and hose

1) Remove
• Spark plug cap
• CDI magneto wire (1)
• Reverse switch wire (2)
• Neutral switch wire (3)
• Air pipe (4)

7. Disassembly of engine
1) Remove
• Bolt (1) (top supporting of engine)
3 • Bolt (2) (bottom supporting of engine)
• Bolt (3) (rear upper supporting of engine)
• Bolt (4) (rear lower supporting of engine)
2) Remove the engine unit from right side
2 4

121
 (II) Disassembly of engine
1. Remove
• Hand starting unit (1)

45. Remove
• Starting lever cap (1)
2
• Starting lever (2)
CAUTION:
• Before untying the knot (3) , pull out the
rope long enough to tie a knot to avoid to be
pulled into the cap
1 3 46. Remove
• Screw pin (1)
• Guide plate (1)
3 • Compressing spring (3)
6 • Circlip (4)
• Driving jaw (5)
• Torsion spring (6)
5
2

4
1

4 47. Remove
3 • Coiling spring (1)
•Coiling spring backboard (2)
• Driving plate assy (3)
• Left side cover assy (4)
1

122
 2. Remove
• Shifter linkage rod (1)
1 Pay attention not to lose washer

3. Remove
• Cam sprocket cover (1)

2
3
4. Remove
• Spark plug (1)
• Upper valve cap (intake) (2)
• Lower valve cap (exhaust) (3)

123
 2
1 5. Remove
• Chain tensioner (2)

CAUTION:
Before removing the chain tensioner, loosen the
screw (1) first.

6. Remove
• Bolt (1)
• Timing sprocket (2)
CAUTION:
1
• When loosening the bolt, it is needed to fix the
2 hand starting ratchet (4)
• Use a wire to hold chain so the timing chain
does not drop into crankcase.

7. Remove
• All the bolts and nut on the cylinder cover.
CAUTION:
Loosen every bolt and nut by ¼ circle, then disas-
4 semble
• Loosen them from big to small according to the
numbers marked on the cylinder cover.

8. Remove
• Cylinder cover unit (1)
• Cylinder cover pad (2)
• Location pin (3)
• Oil seal (4)
• Lower guide plate (exhaust side)

124
5 9. Remove
• Cylinder body assembly (2)
• Cylinder gasket (3)
2 • Dowel pin (4)
• O-ring (5)

10. Remove
• Circlip (1)
• Piston pin (2)
2 3
• Piston unit (3)
CAUTION:
• Before disassembling the piston pin circlip,
cover the crankcase with a clean cloth to avoid
the circlip suddenly dropping into the case.
• Before disassembling the piston pin,
remove the burr of circlip groove and piston pin.
1 If it is still difficult to remove the piston pin,
remove it with drawing aid.

11. Remove
• Snap ring (1)
• Yoke (2)
• U joint caps (3), lightly press out
3 1

125
 5 • Nut (4) securing Primary yoke (5)

12. Remove
• Primary output shaft (1)

• Shims (2)
1 4 • Internal yoke for tension spring (3)
• Tension spring (4)

13. Remove
2
• Starting ratchet (1)
CAUTION:
1
Fix the starting ratchet with special tool, and
loosen the bolt on the starting ratchet.

14. Remove
• Left crankcase cover (2)

1
15. Remove
• Stator (1) from inside crankcase cover.

126
 16. Remove
• Flywheel; (1)
CAUTION:
1 Disassemble the flywheel with a puller.

5
17. Remove
7 • Gasket of left crankcase cover (1)
• Dowel pin
1 • Intermediate gear shaft (3) key way
• Washer
3 6 • Duplex intermediate gear (5)
• Oil pump protective plate (6)
• Counter balance gear (7)

18. Remove
• Oil pump

19. Remove
• Upper timing chain guide (1)
1 • Timing chain (2)

20. Remove
• Main drive output shaft cover (1)
2 • Left crankcase cover assembly (2)

127
 2 3
4 21. Remove
1 • Forward/Reverse shifter linkage (1)
5 • Seal (2)
• Snap ring (3)
• Washer (4)
7 6 • Shifter (5)
• Shifter guide (6)
•Shifter fork (7)
1
22. Remove
• Washer
• Forward/Reverse output shaft (1)
4
• Drive chain (2)
• Washer
5 • Input shaft drive (3)
6
• Slider (4)
• Forward gear (5)
2
• Needle bearing (6)
3
• Washer

3 23. Remove
4 • Main drive gear (1)
• Bearing retainer (2)
1
• Bearing (3)
2 • Bearing housing (4) snap ring
• Output drive gear (5) snap ring
• Main output drive shaft (6)

2
3
24. Remove
• Internal oil screen (1)
• Counter balance (2)
1
• Crankshaft (3)
128
 25. Remove
1 • CVT cover (1)

2
• Clutch support bracket (2)
• Secondary clutch (3)
• Primary clutch (4)
• Primary clutch sleeve (5)
• V-belt (6)

3 4

3 6

• CVT rear cover (7)

129
 26. Remove
• Clutch cover (1)

1
• gasket (2)

27. Remove
3 • Seal (1)
• Snap ring (2)
2 • Output Shaft (3)

1
28. Remove
• Lock nut (1)
• One way clutch bearing (2)
• Clutch (3)

2 40. Remove
• Stop plate (2)
1 • Pressing plate (3)
CAUTION:
Knock the locking part (1) of stop plate flat (1)
2 before removing the stop plate.
3
1

130
 2
42. Remove
• Rocker shaft (1)
3 • Air intake and exhaust rocker (2)
CAUTION:
1 • Screw the slip hammer assy into rocker shaft,
then pull out the rocker.

43. Remove
• Valve lock clip (1)
CAUTION:
• Disassemble the valve lock clip with valve
spring compressing device.
1 2

44. Remove
• Valve outer spring (1)
• Valve inner spring (2)
• Valve (3)
1 • Valve locking clips (4)
CAUTION:
• Pay attention to position of each component
for installation to original position.

131
Section 2 Inspection and Maintenance of Engine
1. Cylinder cover
1) Clean
• Carbon deposit
Use circular scraper (1)
CAUTION:
Please do not use sharp tool to avoid scraping
• Nut of spark plug
• Valve seat ring
• Bottom face of cylinder
2) Measure
• Flatness of cylinder cover bottom face
Correct the bottom face or replace if
unqualified

2. Intake and exhaust valve

1) Check
• Valve surface
• Valve rod end
Replace it if it is worn, exfoliation corroded or
unqualified

2) Check
• Valve rod end (1)
Replace the valve, valve guide pipe and valve
rod oil seal if it is mushroom-shaped or its
diameter is bigger than other rod diameter.
CAUTION:
Remove the deformation of valve rod end (1)
by polishing the valve end with oilstone.

132
 3) Measure
• Rod part run-out of valve rod
Replace it if unqualified

4) Measure
• Clearance between valve rod and valve guide
pipe
Clearance=[A]-[B]
Inner diameter of valve guide pipe [A]
Valve rod diameter [B]
Replace the valve or valve guide pipe if
unqualified.
Measure with micrometer and inner diameter
gauge (1)

CAUTION:
• When replacing the valve, replace the valve
guide pipe and valve rod oil seal
together.

3. Valve guide pipe

1) Check
• Valve guide pipe
Replace it if it is worn or the oil leaks into the
cylinder
2) Disassemble
• Valve guide pipe
Use valve guide pipe disassembling device (1)

CAUTION:
Place the cylinder cover in the furnace to heat
to 100°C (212F) for the convenience of
disassembly and installation of valve guide
pipe. And it can ensure correct installing
clearance.

133
3) Install
• Circlip (1)
• Valve guide pipe (2)
Use the installing and disassembling device of
valve guide pipe

4) Ream the inner diameter of valve guide pipe

to get proper valve rod clearance.

CAUTION:
Regrind the valve race after installing valve
guide pipe

4. Valve race
1) Clean
• Carbon deposit (valve race and valve face)
2) Check
• Valve seat ring
Regrind the valve race if it is exfoliation
corroded.

3) Measure
• Contacting width of valve and valve race.
Regrind the valve race if unqualified
• Paint red lead powder on the valve fit
pyramidal force of valve race
• Place the valve into the cylinder cove

134
 • Press the valve on the valve race through
valve guide pipe to leave clear trace on the
valve.
• Remove the valve from cylinder cover
• When the valve contacts with valve race,
the reddle is marked on the valve from valve
race. Then can measure the contacting width of
valve and valve race.

• If the contacting width is too wide, too

narrow or not in the middle, it is necessary to
correct valve race.

4) Correct
• Valve race
Use reamers of 30°, 45°, and 60°
CAUTION:
Rotate the reamer with even force to avoid
cutting mark. And remove surplus part to get
ideal valve race.

Reamer used on each part

Part Reamer
A 30°
B 45°
C 60°
Valve race correcting procedure
The contacting part [A] is in the middle
of valve face. But the contacting width is too
wide.
Reamer assy of valve race Reamer
Operate Reamer 30° Reduce the
lightly Reamer 60° contacting width to 1.0mm
(0.04in)

135
The contacting part [B] is in the middle of valve
face. But the width is too narrow
Reamer assy of valve rale Result
USE Reamer 45˚ Get unified contacting width
1.0mm (0.04in)
The contacting part [C] is too narrow, and on
the upper edge of valve face
Reamer assy of valve rale Result
Reamer 35˚ Make the contacting part in
USE middle and get the
Reamer 45˚ contacting width 1.0mm
(0.04in)
[D] The contacting part is too narrow and on
bottom of valve.
Reamer assy of valve rale Result
USE Use reamer of 60˚ first Make the contracting part in
Reamer of 45˚ the middle and increase the
width
5) Grind
• Valve face
• Valve race
CAUTION:
Should grind the valve face and valve race after
correcting the valve race or replacing valve and
valve guide pipe.

Grinding procedure of valve face

• Paint a layer of grinding powder (1)
CAUTION:
Ensure no grinding powder enters the clearance
between the valve and valve gauge.

136
 • Paint molybdenum disulfide oil on the valve
rod part.
• Place the valve in to the cylinder cover
• Rotate the valve to grind in with seat fully on
the valve face, then clean the dirt
• Repeat procedure until the contacting width
of valve face and valve seat

CAUTION:
In order to get the best grinding quality, you
may slap the valve lightly when rotating the
valve forward and backward. Be sure to clean
all the dirt on the valve face and valve race
after every grinding.
6) Measure the contacting width again after
correcting and grinding
• Measure the contacting width and
position of valve and valve race again
according to method explained in 3)
• If the contacting width and position do not
conform to specification yet, correct and grind
the valve race

5. Valve spring
1) Measure
• If the free length (a) (inner and outer spring)
of valve spring is unqualified, replace it.

137
2) Measure
• Installing pressure of valve spring
If unqualified, replace the inner and outer
spring totally.

6. Seal check of valve

1) Installation of valve
Lubricate
• Valve rod part (1)
• Valve rod oil seal (2)

Install
• Valve spring seat (1) (lower part)
• Oil seal of valve rod (2)
• Valve (3)
• Inner spring (4) of valve
• Outer spring (5) of valve
• Spring cover (6) of valve
• Locking clip (7) of valve

138
CAUTION:
Must install the long pitch end of all valve
spring upward

2) Check the valve seal

If there is leakage on the valve face, repair
again and regrind or replace the valve and
regrind.
Inspecting procedure of valve seal
• Inject the clean solvent (1) into intake way
and exhaust way respectively.
• Check the valve seal. There should be no
leakage on valve race (2)

3) Regrinding procedure
• Remove components of the cylinder cover
again
• Grind repeatedly with fine grinding
powder
• Clean totally
• Reassemble and check the leakage with
solvent
• Repeat above procedures until getting ideal
seal

7. Distribution cam
1) Check
• Distribution cam
Replace if there is cave, scratch, or
discoloration

2) Measure
• Distribution cam (use micrometer)
Unqualified→ Replace

139


8. Valve rocker and rocker shaft

1) Check
• Rocker hole
• Contacting surface with distribution cam
If ever worn, replace it

2) Check
• Rocker shaft surface
Replace or check lubrication if there are dents,
scratches, or discoloration

3) Measure
• Measure inner diameter of valve rocker hole
Replace it if unqualified

• Measure the outer diameter (b) of rocker

shaft
Replace it if unqualified

140
 • Subtract the outer diameter of rocker shaft
from inner diameter of valve rocker hole to
calculate clearance.

Clearance between rocker hole and shaft= (a) - (b)

Inner diameter of valve rocker hole (a)
Outer diameter of rocker shaft (b)

Replace a set if unqualified

9. Timing chain
Check
• Timing chain
Replace it if the chain is stretched, or not
flexible or broken.

10. Timing sprocket and crankshaft sprocket

Check
• Timing chain
• Crankshaft sprocket (on crankshaft)
If there is wear and damage, replace the
sprocket and chain totally

11. Guide plate

1) Check
• Lower guide plate (1) (exhaust side)
• Upper guide plate (2) (intake side)
Replace it if it is worn or damaged

12. Chain tensioner

1) Check
• Pushing rod of chain tensioner (1)
• Washer (2)
Replace it if it is worn or damaged

141
2) Check
Flexibility of chain tensioner
Checking procedure
• Press the tensioner pushing rod lightly with
finger, and rotate it clockwise with thin
screwdriver to screw it in.
• Press the pushing rod lightly with finger and
remove screwdriver, then the pushing rod screws
out stably
• If the operation is inflexible, replace chain
tensioner.

13. Valve cover and sprocket cabinet cover

1) Check
• Valve cover (upper valve cover (1) and lower
valve cover (2))
• Sprocket cabinet cover (3)
• O-ring (4)
Replace it if there is cracks and damage
14. Cylinder and piston
1) Check
• Carbon deposit (from piston top to ring slot)
2) Check
• Surface of cylinder and piston
Re bore cylinder or replace cylinder and piston if
there is vertical scratch, hone the cylinder bore un-
less the scratch is too deep.

142
If out of specification, hone or replace the
cylinder and piston (replace in a set)

If out of specification, replace the piston and

piston ring as a set at the same time.

•Calculate the mating cylinder clearance with

the following formulas
Mating cylinder clearance=“C”-“P”
Inner diameter of cylinder “C”
Piston lower part diameter “P”

•If out of specification, hone or replace the cyl-

inder, and replace the piston and piston ring as a
set at the same time.

15. Piston ring and piston pin

Piston ring
1) Measure
• Clearance between piston ring and ring groove
• Use feeler gauge (1)
If out of specification, replace piston and a set
of rings
CAUTION:
First clean the carbon deposits inside the piston
ring and ring groove, followed by measuring the
clearance between piston ring and ring groove.

143
 Clearance between piston ring and ring groove
Standard Limit
First 0.03~0.07mm 0.12mm
Ring (0.001~0.003 in) (0.005in)

Second 0.02~0.06mm 0.12mm

Ring (0.008~0.024in) (0.005in)

2) Measurement:
• Closed clearance of piston ring
• Install the piston ring to the cylinder, pull
forward about 20mm (0.8in), then pull the pis-
ton ring with piston top to make it vertical with
cylinder wall.
• Use feeler gauge (1)
If out of specification replace a set of ring

Closed clearance
Standard Limit
Piston 0.15~0.30mm 0.4mm
ring 1 (0.006~0.012in) (0.016in)
Piston 0.15~0.30mm 0.4mm
ring 2 (0.006~0.012in) (0.016in)
Oil ring 0.2~0.7mm
(0.008~0.028in)

CAUTION:
You cannot measure the closed clearance of
scraping plate of oil ring assy, if the clearance
of scraping plate is bigger, replace a set of oil
ring

144
Main points of reassembly of crankshaft:
The oil traces on crankshaft (1) and crank pin
(2) should be connected correctly, the position of
two oil traces should be within 1mm (0.04 in)
17. Driving gear of balance shaft and gear of
balance shaft
Inspection:
• Driving gear of balance shaft (1)
• Gear of balance shaft (2)
If worn or damaged, replace two gears at the
same time.

18. Primary gear and electric starting gear

1) Inspection
• Duplex Intermediate gear (1)
• Intermediate gear axle (2)
If scraped, worn, or damaged, replace it.
• Electric starting gear assy (3)
• Contact surface of overrunning clutch (4)
• Bimetallic bushing (5)
If scraped, worn, or damaged, replace duplex
intermediate gear, intermediate gear axle, electric
starting gear assy as a set.
2) Inspection of overrunning:
• Install the electric starting big gear to the run-
ning clutch and fasten the running clutch
• Turn the starting big gear counterclockwise in
direction A as shown on the drawing, the
starting big gear will drive the overrunning
clutch, if out, it indicates the running clutch is out
of operation, replace it.
• Turn the electric starting big gear clockwise in
direction B as shown or the drawing, the starting
big gear will run in idle speed if not, it indicates
that the overrunning clutch is out of operation,
replace it.

145
 • Inspection
• Bolt (1) (overrunning clutch)
• Loosen then replace with new one and
apply fastening agent
CAUTION:
Fastening torgue of bolt (overrunning clutch) is
30Nm(3.0m·kg22yd·pound)
Apply the fastening agent on the bolt

19. Main clutch

Clutch case
1) Inspection:
• Clutch case assy (1) (inner surface)
Abrasion, wear, or damaged, replace it
• Single direction (2) (inside the clutch case
assy)
If scraped, worn, or damaged, replace it
2) Inspection the operation of single direction
clutch
Make sure that the inner spline cover (1) can
only rotate clockwise in direction A, if the in-
ner spline cover functions unsoundly or rotates.
Counterclockwise, replace the inner spline
cover (1) and main clutch case assy (2) at
the same time.

146
 22. Shift fork and fork shaft
1) Inspection:
• Fork
Connecting surface to gear and shift cam
If worn, scraped, bent, or damaged, replace it.

2) Inspection
• Fork shaft
(Roll the fork shaft on a plane)
If bent replace it.
WARNING:
Never attempt to straighten a bent fork shaft

3) Inspection
• Movement of fork on the fork shaft (1)
If not smooth in operation, replace fork or fork
shaft

24. Main/vice shaft and gear

1) Measurement
• Runout of shaft (1) (Main/vice shaft)
Measure with bracket and runout meter
If out of specification, replace it.

147
 27. Bearing and oil seal
1) Inspection
• Bearing
If jammed in operation or there are pits and
damage, replace it.
2) Inspection
• Oil seal
If damaged or worn replace it.

28. Circlip and washer

Inspection:
• Circlip
• Washer
If damaged, loose, or bent, replace it.

29. Crankcase
1) Clean crankcase with soft agent completely
2) Clean all sealing surfaces and closing
surfaces completely

3) Inspection:
• Crankcase
Cracks/damage, replace it.
• Oil trace
If jammed, blow with compressed air.
CAUTION:
When replacing the crankcase be sure to
readjust the output gear washer.

148
 30. Hand operated mechanism
1) Inspection
• Inspection (1)
If cracked, bent, or damaged, replace it.
• Driving jaw (2)
• Compressing Spring (3)
• Torsion spring (4) (Driving jaw position)
Wear/cracks/damage, replace it.

2) Inspection:
• Rolling spring (1) (Starting)
Wear/cracks/damage, replace it.
• Tension wire (2)
Wear/cracks/damage, replace it.
• Driving plate assy (3)
Cracks/damage, replace it.

31. Output Mechanism

1) Inspection
• All gears (1)
If pressing mark/abrasion/wear is found,
replace it.
• Connecting jaw (2)
If pressing mark/abrasion/wear is found,
replace it
• Driving shaft (3)
• Output shaft (4)
If damaged or bent, replace it.
CAUTION:
When replacing any gear or output shaft be
sure to readjust core gear washer, refer to
“Selection of adjusting washer” section.

2) Inspection
• Bearing (5)
If pressing mark or abrasion is found, replace
it.

3) Inspection
• Front joint and rear joint (1)
• Driving for (2)
• Needle bearing (3)

149
 4) Inspection
• Reverse fork (1)
If wear/abrasion/bend/damage is found on the
surface connecting with connecting jaw and
reverse operating shaft, replace it.
• Compressing spring (2)
If the elasticity is lost, or worn, replace it
• Steel ball (3)
If wear, damage, or scratch marks are found,
replace it.
5) Inspection:
• Reverse fork shaft
Roll the reverse fork shaft on the flat surface, if
bent, replace it.
CAUTION:
Never straighten a bent shaft and reuse it

6) Inspection
• Flexibility of fork movement
Install the reverse fork 1 to fork shaft, if not
active or smooth in operation, replace fork and
fork shaft.

7) Inspection
• Reverse control lever (1)
• Operating plate (2)
• Reverse operating shaft (3)
If bends, cracks, or damage is found, replace it.
8) Inspection
• Rear cover (1)
If cracks or damage on the position connecting
with left crankcase, rear driving cover is found,
replace the rear cover.
• O-ring (2)
If damaged or deformed, replace it
CAUTION:
When replacing the rear cover, be sure to read-
just the gear core washer, refer to “Selection of
adjusting washer” section.

150
 Section 3 Assembly and Adjustment of Engine
1. Crank connecting rod
2. Balanced initiative gear 11. Seal ring sheath
3. Buffer spring 12. Seal ring
4. Pin 13. Nut M16
5. Initiative gear clamp plate 14. Balanced shaft
6. Circlip 15. Bearing
7. Woodruff key 16. Bearing
8. Washer 17. Balanced driven gear
9. Bolt M10x40 18. Key
10. Bearing 19. Stop reverse washer

151
Shift gear mechanism
14. Driven gear
1. Main shaft 15. Pin
2. Seal o-ring 16. Cirlcip
3. Bearing 17. Rolled needle bearing
4. Bearing 18. Gearshift arm comp
5. Collar sheath 19. Fuel seal
6. Oil seal 20. Washer
7. Seal o-ring 21. Circlip
8. Middle shaft 22. Fork
9. Bearing 23. Fork shaft
10. Bearing 24. Steel ball
11. Chain with gear type 25. Spring
12. Output shaft 26. Washer
13. Circlip 27. Bolt M14x21

152
Clutch

1. Outer cover
2. Cintrifugal clutch
3. Bearing seat outer cover
4. Bearing 16010
5. Fuel seal SD32x66x8
6. Circlip 75.5
7. Circlip 49
8. Bearing seat seal cushion
9. Flange bolt mx
10. One way machine
11. Nut M22
12. Sliding sheath
13. Trigonometry belt
14. Drive plate
15. CVT first clutch comp
16. Washer M19.2x35x3.2
17. Nut M16
18. CVT second clutch

153
(III) Assembly of left crankcase

Output mechanism 10. Screw bushing 18. Nut

1. Output gear 11. Irregular left hand nut 19. Rear cover
2. Forward gear assy 12. Output shaft 20. O-ring
3. Reverse gear 13. Washer 21. Bolt M8x15
4. Nut 14. Bearing 22. Reverse fork
5. Bearing 15. Inner hexagonal screw 23. Compressing spring
6. Washer bushing 24. Steel ball 6.35G100b
7. Connecting jaw 16. Front connecting fork 25. Reverse fork shaft
8. Washer 17. Washer 26. Reverse control lever assy
9. Bearing 27. Reverse operating shaft
28. Circlip 14

154
Electric starting system

1. Circlip 12 10. Spring cover

2. Washer 11. Spring
3. Wheel axle 12. Timing chain
4. Double wheel 13. Up guide plate assembly
5. Woodruff key 14. Magneto rotor
6. Washer 15. Magneto stator
7. Electric starting gear assy 16. Left crankcase cover
8. Electric starting clutch 17. Starting ratchet assy
9. Roller

155
(V) Assembly of cylinder head
Cylinder cover assembly
1. Locking nut
2. Adjusting screw
3. Throttle arm
4. Arm axle 1
5. Valve locking
6. Valve spring cover
7. Valve recoil sealing
8. Valve spring
9. Valve outer spring
10. Valve spring seal
11. Inlet valve
12. Bolt M6x12
13. Locking plate
14. Clamp plate
15. Rolling bearing 6005-RS/C3
16. Driving pin
17. Valve cam shaft
18. Rolling bearing 6202-Z
19. Rocker axle 2
20. O-ring
21. Exhaust valve
156
Cylinder head 1

1. Cylinder head cover assem- 13. Screw M8x45-10.9 25. O-ring

bly 14. Washer 8 26. Screw M6x18-06025
2. Steel wire circlip 15. Sprocket wheel cover assy 29. Chain tensioner
3. Valve guide tube 16. Oil shield assembly 30. Tensioner washer
4. Bolt 95026-06010 17. Breather tube 31. Upper guide plate assembly
5. Washer 18. Hose clip 32. Bolt 95026-06014
6. Shock absorbing block 19. O-ring 33. Bolt M10V1.25x25
7. Cylinder cover washer as- 20. Screw 98512-06012 34. Washer
sembly 21. O-ring 35. Timing sprocket wheel
8. Locating pin 99510-14016 22. Screw 98512-06012 36. Lower guide plate
9. Locating pin 23. Upper valve cover 37. Timing chain
10. Oil sealing 24. Lower valve cover
11. Canopy nut
12. Washer

157
Cylinder head 2

1. Cylinder body assembly 7. Piston ring 2

2. Screw M6 x 25-10.9 8. Oil ring subassembly
3. Cylinder body gasket 9. Circlip
4. Locating pin 99530-14016 10. Piston
5. O-ring 11. Piston Pin
6. Piston ring 1 12. Double end bolt

158
 Installation

1 2

• Attach gear and shaft to bracket using circlip.

159
1 • Mount bracket (4) to crankcase (5) using M8
bolts (3). Torque of bolt: 23Nm (17ft.lbs)

• Install internal drive gear (1).

2

5
4

7
8

• Install reverse shaft (9) using circlip (6), seal

(5), and washer (4).

160
1 2

• Install oil screen (1) using M6 bolts(2).

Torque of bolts: 10Nm (7ft.lbs)

• Mount balanced shaft (3)

1 2

161
 1

• Attach shifting fork (1) to gear.

2 1 • Install crank chain (2).

• Install crankshaft (1).

4 5
• Attach right crankcase (5) to left crankcase
(4)using silicon as sealent.

162
 • Outside of right crankcase

2 2

• Attach clutch plates to right crankcase using one-

way bearing.

163
 •Use gasket (1) when installing cover (2).

1
2

•Use circlip (4) to hold in bearing.

5
4

2 3

• Mount cover (2) using M8 bolts(3).

Torque of bolts: 23Nm (17ft.lbs)

164
 •Make sure pieces are used in this order.

1
2

• Mount rear cover (1) using M10 bolts

Torque of bolts 45Nm (33ft.lbs).

• Make sure to use all shims (2), four on each

side.

• Mount u-joint using M12 nut.

Torque of nut: 80Nm (59ft.lbs)

165
 • Install universal joint (1) using circlips
2 1 (2).

• Mount oil pump gear (3) using M6 bolts (4)

Torque of bolts: 10Nm(7ft.lbs)

4
5

• Install timing chain guard (5).

6
• Install timing chain (6), make sure to feed
chain (6) onto sprocket (7).

166
 1

2 3

• Mount gear (3) in crankcase.

• Install pin (2) and spring (1) in gear (3).

4 5 6 7

• Install piston (6) using piston pin (5) and

clips (7).

• Install piston rings (4) on piston (6).

167
 • Install gearshift connector (1) assembly to
crankcase.

• Mount starter motor (2) using M8 bolts (3).

5
• Mount cylinder (5)using base gasket (4).
4

168
 • Valve, inner spring, outer spring, valve
locking clips

1 2

• Install camshaft (1) using bracket (3) and

M6 bolts (2).
Torque of bolts: 10Nm (7ft.lbs)

169
1

• Install rocker arms (1) in cylinder head (2).

2

2 • Install cylinder head (2) using M10 bolts (3).

Torque ob bolts: 45Nm (33ft.lbs)

• Attach valve covers (5) using M6 bolts (4).

5 Torque of bolts: 10Nm (7ft.lbs)

170
 • Mount intake manifold (1) using M6 bolts(2).
1
Torque of bolts: 10Nm (7ft.lbs)

• Mount timing sprocket (3) using bracket and

M8 bolts (4). Torque of bolts: 23Nm (17ft.lbs)
4

6
5
• Attach timing chain cover using M8 bolts.
Torque of bolts: 23Nm (17ft.lbs)

171
 • Mount chain tensioner (4) using M6 bolts (3).
1 Torqure of bolts: 10Nm (7ft.lbs)
2
• Install spring (2) using M10 bolt (1).
3 Torque of bolts: 45Nm (33ft.lbs)

• Install flywheel gear (5) on crankshaft.

• Make sure to use a gasket (6) when installing

left crankcas cover.

• Attach flywheel (7) using M12 nut.

Torque of bolts: 80Nm (59ft.lbs)

172
1

• Mount left crankcase cover (1) using M10

bolts (2).
Torque bolts:45Nm (33ft.lbs)

• Mount recoil ratchet (3) to crankcase cover

(2).

• Attach pull starter (5) using M8 bolts (4).

Torque of bolts: 23Nm (17ft.lbs)

173
 • Install oil filter (1) below pullstarter.

• Install inside right crankcase cover (2).

174
 • Install drive (2) and driven pulleys (1).

1 2

• Install holding plate (4) using M8 bolts (3).

• Install right crankcase cover (5) using M8

bolts (6).
Torque of bolts: 10Nm (7ft.lbs)

175
 Chapter VI Vehicle Ordinary
Trouble and it’s judgement
Trouble • Wrong spark plug heat value
CAUTION: • Inefficient spark plug cap
Please refer to relevant contents for the in-
spection, adjustment and replacement of (2) Ignition coil
parts. • Coil is damaged
(I) Starting trouble/difficulty • Inefficient high voltage wire
1. Fuel system
(1) Fuel tank (3) CDI magneto system
• No fuel • CDI failure
• Fuel filter is clogged • Coil failure
• Breather tube is clogged • Charging coil failure
• Fuel is polluted • Woodruff key is damaged

(2) Fuel valve (4) Switches and wires

• Fuel line is clogged • Main switch is bad
• Fuel valve is not opened • The engine is off and switch is
inefficient
(3) Carburetor • Wires are damaged
• Fuel is polluted • Neutral switch is bad
• Main jet is clogged • Starting switch is bad
• Air tube is clogged • Rear brake switch is bad
• Float is damaged
• Improper valve sealing (5) Staring motor
• Improper installation of starting nozzle • Starting motor is bad
• Starting nozzle is clogged • Starting relay is bad
• Improper work of starting plug • Off power relay is bad
• One-way clutch is bad
(4) Air filter
• Core of air filter is clogged 3. Cylinder
(1) Cylinder body and cylinder head
2. Electric system • Spark plug is loose
(1) Spark plug • Cylinder head or cylinder body is loose
• Improper spark plug clearance • Cylinder head washer is damaged
(standard clearance is 0.6-0.7mm) • Cylinder body is worn or damaged
• Terminal is worn
• Spark plug is damaged

176
(2) Piston and piston ring
• Improper piston ring installation
• Piston rings are worn and out of elasticity
• Piston rings are damaged
• Piston is damaged or cracked
(3) Valve, camshaft and crank shaft
• Valve didn’t close entirely
• Improper match between valve and valve
seat
• Wrong port timing
• Valve spring is damaged
• Valve camshaft is damaged
• Crank shaft is damaged
(II) Poor idle speed performance
(1) Carburetor
• Starting plug is not closed entirely
• Idle jet is loose
• Idle air metering jet is clogged
• Improper idle adjustment
• Improper adjustment of throttle stroke
• Carburetor leak
(2) Electric system
• Spark plug is bad
• CDI is bad
• Coil is bad
• Charging coil is bad
• Ignition coil is bad
(3) Valve system
• Improper adjustment of valve clearance
•Core of air filter is clogged
(III) Poor middle and high speed
performance
Refer to “starting trouble/ deficiency” and
“poor idle speed performance” section in
this chapter.
177
(1) Carburetor
• Wrong needle valve position
• Main jet is clogged or loose
• Fuel is polluted
• Wrong float chamber fuel level
(2) Air filter
• Core of air filter is clogged
(IV) Shifting trouble
1. Shifting difficulty
Refer to “slipping of clutch” and “ablation of
clutch” in this chapter
2. Shifting peddle is clogged
(1) Shifting shaft groups
• Shifting shaft is bent
• Shifting lever group is damaged
(2) Shifting cam, shifting fork
• There is foreign matter in shifting camshaft
recess
• Shifting fork is clogged
• Shifting fork is bent
(3) Driving system
•Driving gear is damaged
• Foreign matter has clogged gears
• Incorrect driving system installation
3. Improper shifting
(1) Shifting shaft groups
• Improper adjustment of limited lever
position
• Limited lever can’t back
(2) Fork
•Fork is worn
(3) Shifting cam
• Recess of shifting cam is worn
(4) Driving system (2) Fuel System
• Claw of gear end is down • Main jet of carburetor is damaged
• Improper fuel level
(V) Clutch slips • Core of air filter is clogged
(1) Clutch
• Improper adjustment of clamp plate release (3) Cylinder system
rod clearance of clutch • Serious carbon disposition
• Clutch spring is loose (primary clutch and/
secondary clutch) (4) Engine oil
• Clutch spring is worn (primary clutch and/ • Improper oil level
secondary clutch) • Improper oil
• Friction disc is worn • Poor oil quality
• Clamp plate is worn or deformed
• Main clutch shoe lining is worn (5) Brake
• Brake is stagnant
(2) Engine oil
• Low oil level (VIII) Brake trouble
• Poor quality (viscosity is low) Troubles: Poor brake efficiency
• Polluted oil • Brake shoe lining is worn
• Serious wear of brake shoe
(VI) Clutch is locked • Improper adjustment of brake clearance
(1) Clutch • Improper brake arm position
•Clutch is out of alignment or the clearance • Returning spring is worn or damaged
is incorrect • Brake cable is damaged
• Improper match between release lever and
release rod (IX) Shock absorber failure/ improper
• Deformed clutch clamp plate operation
• Friction disc is deformed 1. Shock absorber failure:
• Clutch hub is broken • Damping rod is bent or damaged
• Bad oil sealing lip
(2) Engine oil • Spring of shock absorber is worn
• High oil level
• Poor oil quality (viscosity is high) 2. Improper operation
• Polluted oil (1) Handle bar
• Improper installation or handlebar is bent
(VII) Engine is overheated
(1) Ignition system (2) Steering system
• Improper spark plug clearance • Wrong toe-in
• Wrong spark plug heating value • Steering pillar is bent
• CDI failure

178
 • Improper installation of steering 2. Bulb is off
pillar bearings • Incorrect bulb
• Holding seat of steering pillar or • Battery failure
sealing ring is damaged • Rectifier failure
• Rod is bent • Improper connection of ground wire
• Spherical connection is bent • Main switch or lighting switch
failure
(3) Wheel tire • Bulb is bad
• Incorrect tire pressure
• Uneven tire wear

(4) Front/ Rear tire

• Deformed rim
• Front wheel axle bearing is bent or
loose
• Radial run out of front/rear wheel is
too big

(5) Frame
• Bent
• Damaged frame

(6) Rear wheel fork

• Bearing is damaged or worn
• Rear wheel fork is bent or damaged

(X) Lighting System

1. Headlight malfunction
• Bulb is damaged
• Weight capacity exceeded
• Charging difficulty (Lighting rectifier
failure)
• Incorrect wire connection
• Improper ground wire connection
• Poor main switch or light switch
connection
• Belt is too worn to use

230