Motive Power | PGO | PGO All Terrain Vehicle Service Manual INDEX Chapter 1 Model

PGO All Terrain Vehicle Service Manual
INDEX
Chapter 1
Model introduction
Chapter 2
Operation indicator
Chapter 3
Important operating torque table
Chapter 4
Periodically maintenance
Chapter 5
Frame inspection & adjustment
Chapter 6
Engine dismantle
Chapter 7
Engine & electric element inspection
Manufactured by
Motive Power Industry Co., Ltd.
Chap 1 - 1
SPECIFICATIONS
Model
XR50
XR110
XR150
ENGINE
Displacement
Cooling
Type
Bore* Stroke
Lubrication
Engine oil
Fuel capacity
Transmission
Drive train
Gear shift
Starting
49 / 82 cc
Force air cooled
2 stroke horizontal
40 * 39.2 / 50 * 42
Separated lub
2 stroke oil
5.2 liter
CVT belt
Chain
NA
Electric / Kick
106.2 cc
Force air cooled
2 stroke horizontal
52.0 * 50.0
Separated lub
2 stroke oil
5.2 liter
CVT belt
Chain
Drive & reverse(Option)
Electric / Kick
150.1 CC
Force air cooled & oil cooled
4 stroke horizontal
57.5 * 57.8 mm
Auto-separated lub
15W40 / 900 cc total
5.2 liter
CVT belt
chain
Drive & reverse
Electric / Kick
SUSPENSION
Front
Rear
Travel
Rear brake
Front brake
Signal A arm
Swing arm
2.5 in / 6.3 cm
Hydraulic disc / Drum
Drum
Signal A arm
Swing arm
2.9 in / 17.3 cm
Hydraulic disc
Drum
Signal A arm
Swing arm
2.9 in / 17.3 cm
Hydraulic disc
Drum
Foot brake
NA
Right foot (Option)
Right foot
1000 mm
1470 * 890 * 990 mm
268 LBS/ 128kg
700 mm
19*7-8 / 18*9.5-8
12V-10W*4
12V-18W*1
12V-21/5W
1000 mm
1470 * 890 * 990 mm
284 LBS/ 129kg
700 mm
19*7-8 / 18*9.5-8
12V-10W*4
12V-18W*1
12V-21/5W
1150 mm
1640 * 1015 * 1005
361 LBS/ 164kg
700 mm
19*7-8 / 21*9-8
12V-10W*4
12V-18W*1
12V-21/5W
DIMENSION
Wheelbase
Overall dimension :L * W * H
Dry weight
Seat height
Frt /
rear
tire
Signal indicator
Head lamp
Rear lamp
Chap 1 - 2
mm
MODEL INTRODUCTION: PART 1
Fuel tank cap
REAR SHOCK
DRIVE CHAIN
SAFETY COVER
SHIELD
HANDLEBAR CLAMP
RESISTOR
REGULATOR
Chap 1 - 3
MODEL INTRODUCTION: PART 2
REAR BRAKE LEVER
NUT
REAR BRAKE CABLE
2
3
Chap 1 - 4
Body Cover
Explosive Parts:
Chap 1 - 5
01
02
03
04
05
06
07
08
09
10
11
12
FRONT FENDER
REAR FENDER
SEAT ASSEMBLY
FOOTBOARD (R)
FOOTBOARD (L)
WITH WASHER BOLT
TAPPING SCREW
PAN PHILLIPS BOLT
"DAMPER MAT , FOOTREST"
HEX BOLT
TAPPING SCREW
"COVER , HANDLE BAR"
13
14
15
16
17
18
19
20
21
22
23
24
25
HEAD LAMP COVER
RUBBER
HEAD LAMP COVER
CONNECTING WIRE
HEAD LAMP BULB
BULB
TAPPING SCREW
"ADJUSTING PLATE,
TAPPING SCREW
COMPRESSION SPRING
PLAIN WASHER
ROUND HEAD BOLT
HEAD LAMP ASSY.
Operating indicator
Chap 2 - 1
Speedometer Counter(Optional)
1. Names of the parts
1.
Speed display
2.
Function indication
3.
Mode button
4.
Start/stop button
5.
Unit of speed
6.
Battery cover
7.
Contact point
8.
Reset button
Function
Display
Trip distance
Daily trip distance
DST
DST
0.1 – 9999 km / mile
0 – 999.9 km / mile Switch by MODE
2. Wheel circumference input
Total distance
ODO
0 – 999.9 km / mile
Average speed
Time display
Maximum speed
Speed
Clock
AVS
TM
MAX
SPD
0 – 99 km / mile
00:00:00 – 11:59:59
0 – 99 km / mile
5 – 99 km / mile
00:00 – 23:59
SET/RESET →
MODE
126 – 229 cm
Hold SET/RESET
&
press MODE to
select
Km/h and mile/hr
When DST blinking Hold SET/RESET
&
press MODE to
select
When DST blinking
2 – 4 mm
Fixed in rear axle
3. This counter is powered by a 3.0 V Lithium battery. Whenever replace
a new battery, you have to reset the parameters again.
4. Display and operation
A. You have to input the wheel circumference(cm) for precious
measurement. This parameter show at the right corner (item 5), you
should press on the button SET/RESET until the corresponding
value appears.(from 126 to 229), press on the MODE button to
record it.
B. Recommended table
Rear tire (D)
Wheel
(Diameter * Width)
circumference(L-cm)
18 * 9
144
19 * 8
152
21 * 9
166
21 * 10
166
D(inch) * W(inch)
2.54 * 3.14 * D
Wheel
circumference
Unit of speed
Daily trip distance
Trip distance
Non-touching
Sensor distance
Chap 2 - 2
DST
DST
Specification
Operation
Reset by hold
SET/RESET &
Press MODE
(1) TORQUE VALUE
1. 2 stroke engine:
NO Locking location
Q’TY
Thread dia.
Locking torque (kg-m)
(mm)
7
1.0~1.4
1
Cylinder head
4
2
Flywheel nut
1
10
3.2~4.0
3
Rear brake lever
1
6
1.0~1.2
4
Driving pulley nut
1
10
3.2~4.0
5
Clutch outer nut
1
10
3.5~4.0
6
Right crankcase
1
6
1.0~1.2
7
Drive gear box cover
1
6
1.0~1.2
8
Left crankcase
1
6
1.0~1.2
9
Draining & filling bolt
1
8
1.8
10 Inlet pipe
1
6
1.0~1.2
11 Flywheel Magneto Stator
2
6
1.0~1.2
12 Cooling Fan
1
6
1.0~1.2
13 Muffler nut on cylinder head
2
6
1.0~1.2
14 Muffler bolts on chassis
2
8
2.0~3.0
15 Starting motor
2
6
1.0~1.4
16 Spark Plug
1
22
2.5~3.0
17 Fan cover
4
6
1.0~1.2
18 Fixed plate, motoring idle gear
2
6
1.0~1.4
19 Nut of rear wheel axle
1
14
8.0~10.0
20 Kick starter
1
6
1.0~1.2
Chap 3-- 1 -
Remark
2. 4 stroke Engine: (XR150)
2
Thread dia.
(mm)
6
Locking torque
(kg-m)
0.9~1.1
2 Cylinder head bolt B (Exhaust)
2
8
2.2
3 Cap, oil filter graze
1
30
1.5~2.0
4 Flange nut, cam shaft base
4
8
2.2
5 Fixing nut, air valve adjustment
2
5
0.7
6 Guiding pin bolt, inner chain
adjustment
7 Oil bolt
1
6
0.9~1.1
1
8
1.7~2.0
8 Fixing nut, clutch outer
1
12
5.0~6.0
9 Nut, driven plate
1
12
5.0~6.0
10 Nut, driving plate
1
12
5.0~6.0
11 Spark plug
1
10
1.2~1.3
12 Nut, drive clutch
1
22
9.0~10.0
13 Screw, inner chain adjuster
1
6
0.4~0.6
N
Locking location
O
1 Cylinder head bolt A (intake)
Chap 3-- 2 -
Q’TY
Remark
Greasing
thread
Left thread
on
3. Chassis:
NO
Locking location
Q’TY
Thread dia.
Locking torque (kg-m)
(mm)
1
Locking nut, steering stem
1
14
4.0 ~ 5.0
2
Handle bar with steering stem
2
10
4.5 ~ 5.0
3
Steering stem holder
2
8
2.0 ~ 3.0
4
Wheel with hub(FRT & RR)
16
10
4.0 ~ 5.0
5
Rear axle nut
2
27
9~ 10
6
Front shock absorber bolt
4
10
3.5 ~ 4.5
7
Rear shock absorber bolt
2
10
4.0 ~ 5.0
8
Braking disc bolts
3
10
4.0 ~ 5.0
9
Rear brake caliper bolt
2
8
1.5 ~ 2.5
10 Chassis & engine hanger bolt
2
10
3.5 ~ 4.5
11 Engine hanger bolt with engine
2
8
2.0 ~ 3.0
12 Brake hose bolt
2
10
3.0 ~ 3.5
13 Air release valve
1
6
0.6
14 Front drum brake arm bolt
1
6
1.0
15 Suspension arm bolt(RH & LH)
4
10
3.5 ~ 4.5
16 Knuckle (RH & LH)
6
10
3.0 ~ 4.0
17 Swing arm fixing bolt
4
12
5.0 ~ 6.0
1
14
8.0 ~ 9.0
18
Swing arm & rear axle assy with
chassis
Chap 3-- 3 -
Remark
Steering stem nut
Handle bar nut
Steering holder
Wheel hub
Rear axle nut & disc screw
Frt cushion
Rear absorber
Swinging arm bolt & nut
Caliper bolt
Suspension arm bolt
Steering shaft nut
Engine bracket
Chap 3-- 4 -
4.Other parts please refer the following table:
Standard torque values:
NO
1
2
3
4
5
6
7
8
9
10
11
Item
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
5mm screw
6mm screw
6mm flange bolt and screw
7mm flange bolt and screw
8mm flange bolt and screw
10mm flange bolt and screw
Chap 3-- 5 -
Torque (kgf-m)
0.45-0.6
0.8-1.2
1.8-2.5
3.4-4.0
5.0-6.0
0.35-0.5
0.7-1.1
1.0-1.4
1.0-1.4
2.0-3.0
3.0-4.0
(2)Lubrication instruction:
A. Engine
NO
Lubrication location
Oil type
Remarks
Oil type
Remarks
MODEL
2 STROKE ENGINE
1 crankcase:rotating part,
sliding part
2 cylinder:rotating part,
4 STROKE ENGINE
Auto-separated
premium 2 stroke Lubrication
Auto-separated
premium 4 stroke Lubrication
motorcycle oil
motorcycle oil
Total 900 c.c.
sliding part.
or SAE#30
or SAE15W40
Replacement 800c.c
3 drive gear box
SAE85-140
Total 110 c.c.
SAE85-SAE140
Replacement 90c.c
Total 110 c.c.
Replacement 90c.c
4 gasket of starter shaft
clean grease
(#3)
clean grease
(#3)
5 start idle gear sliding
clean grease
(#3)
clean grease
(#3)
parts
Chap 3-- 6 -
(1) Periodical checking table:
1.[○] mark indicates periodical checking
2.[*] indicates changing the parts
Check item
A Suspension Loose,swing
Steering
Handlebar performance
Suspension: turning angle
a.cracked
b.shaft fixed
Front fork
condition
c.shaft:loose
B: Brake
a.clearance
Brake lever b.movement
of
brake
General
checking
Brake cam
Checking period
Home
Office
Per 6
per12
Per1
per3
per12 Judgement
Remark
standard
Months months
Months months
months
Or
or
Or
or
or
5000km 1000km 1000km 2500km 10000km
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Brake drum
And brake
c.brake drum
shoe
worn and
damage
○
○
○
○
○
○
○
○
○
○
front axle:damage or cracked
rear axle:worn
or damage
wheel
Axle nut screw
Pin tightness
Wheel rim swiNgness and daMage condition
Check from
Steering
column
※per 2 years
a.clearance between
drum and plate
b.brake shoe and br
ake plate worn out
Wheel cracked
Or damage
Wheel gap and
worn
Wheel surface
Or other metals
○
Front:10-20mm
Rear :10-20mm
Brake cables
change
Worn out
Wheel pressure
From steering
column
Clearance:
Loose or damage
brake
First
Month
Or
Initial
500km
Standard dia:
Rear:85.0mm
Limit of use:
Rear:86.0mm
mark type
○
Check rear
Axle
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
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○
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○
○
○
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○
○
○
○
○
Chap 4 - 1
○
○
○
○
Unit:kg/cm*cm:
1 driver
0.28 -0.30
Gaplimit:front wheel:
0.8mm rear
wheel:0.8mm
○
Steering nut
torque
4.0-5.0kg-m
rear axle torque
9..0-10.0kg-m
○
Swingness of front
Rear wheel rim.
Vertical
swing:2mmbelow
Horizontal ;
2mm below
Nut
location
Check item
Wheel
Damper
General
checking
Front
Bearing of axle,
Looseness
Rear
Rear damper spring
cracked
ass’ part loose
or damage
Connecting part
Loose
Bracket loose or
Damage
SuspenConnecting
sion
Part loose
Oil leakage
Cracked
damper
assy's part,
Loose
Clutch and
Change
Speed
mechanism
Power
TransmiSsion Supply
grease
Electric
InstallIgnition
Ment
Start
mechanis
m
wiring
battery
wire
circuit
First
Month
Or
Initial
500km
○
Checking period
Home
Office
Per6
per12
Per1
per3
per12 Judgement
Remark
standard
Months months
Months months
months
Or
or
Or
or
or
5000km 1000km 1000km 2500km 10000km
○
Wire connecting
Loose or
cracked
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
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○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Starting
Motorpinion
Meshing
Recharge
Effect
ElectrolyTe quantit
ElectrolyTe s. gravity
○
○
○
○
○
○
○
○
※per 2 year
Clearance:
0.6~0.7mm
NGK:BP7HS
NGK:
CR7HSA
○
○
○
○
○
○
○
○
○
○
Level between
“UPPER” AND
“LOWER”
○
○
WHEN 20℃
SPECIFIC
GRAVITY:
1.270-1.290
○
○
○
○
Chap 4 - 2
○
○
2T
4T
Check item
General
checking
First
Month
Or
Initial
500km
Engine Engine Performance,
parts
noise
○
Low speed,
Acceleration
Exhaust
Checking period
Home
Office
Per6
per12
Per1
per3
per12 Judgement
Remark
standard
Months months
Months months
months
Or
or
Or
or
or
5000km 1000km 1000km 2500km 10000km
○
Air cleaner
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Cylinder, cylinder head inlet
Pipe, locking
Condition
○
Compression
pressure
○
Oil leakage
LubricatIon
System
fuel
system
○
○
Oil quantity,
Dirty
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Carburetor
Float height
○
○
○
○
○
Carburetor
Adjustment
○
○
○
○
○
Fuel leakage
Carburetor
Parts dirty
Carburetor throttle and choke
Performance
Check the clolr
Or exhausting
-air
Locking torque
Cylinder head:
(cold)
1.0-1.4kg/m
inlet pipe/cp;d)
1.0-1.2kg/m
Using starting
Motor.
6kg/c ㎡(600rpm)
7kg/c ㎡(500rpm)
11kg/c ㎡(700rpm)
50 CC
110 CC
150CC
Fill
when-ever
oil light is
on
○
Oil filter
Fuel quantity
2T
4T
○
○
○
○
○
○
Oil quantity,
○
○
Idling:
1900±100rpm
1700±100rpm
Change every
5000km
○
Fuel pipe
Changing
※per 4 years
Chap 4 - 3
Clean
the
cooler
General
checking
Check item
Lamp system
Performance
Dirty, cracked
Horn turn
Signal
Reflector
lock
Rear view
mirror
Performance
First
Month
Or
Initial
500km
Checking period
Home
Office
Per6
per12
Per1
per3
per12 Judgement
standard
Months months
Months months
months
Or
or
Or
or
or
5000km 1000km 1000km 2500km 10000km
○
○
○
○
○
○
○
○
○
○
○
○
○
Performance
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Check the
illumination
Blinker linc-
Dirty
Nese plate nu-
cracked
○
○
Mber&mark
Instrument
performance
○
board
Ass’y part
Muffler
silencer
chassis
Loose
cracked
performance
loose or
cracked
The earlier
Confirm it does
Abnormal
Not happen
condition
○
again
Chassis
○
○
○
Lubrication
others
Decoking mixer
,muffler,
○
silencer
Chap 4 - 4
○
Remark
Horn
Turn signal
FRONT BRAKE INSPECTION AND ADJUSTMENT
(2) Adjustment
Properly turn the adjusting nuts until the free play is
as specified.
Proper brake lever free play can avoid brake dragging.
1. Front brake inspection
Apply the front brake lever.
To adjust the front brake, adjust the left and right
wheels at the same time.
After adjusting, apply the front brake lever to check
the left and right wheels for braking simultaneously.
Otherwise adjust again.
Check
If the arrowhead on the front brake overlaps with the flange
on the brake hub cover, replace the front brake shoe.
To replace the brake shoe, replace the left and right brake
shoes at the same time.
2. Front brake adjustment
Before adjusting the front brake. Check the brake shoe first.
Check:
Front brake lever free play
Not as specified adjust
Front brake lever free only : 10~20mm.
REAR BRAKE INSPECTION AND ADJUSTMENT
1. Check
(1) Brake disc
Worn/damaged replace
Not as specified replace
Min. Thickness limit : 3.0mm
Chap 5 - 1
brake inspection:
Chap 5 - 2
FRONT WHEEL
EXPLOSIVE PARTS:
19
20
21
22
23
24
25
26
27
01
02
03
04
05
06
07
08
09
STRAIN SPRING
HEX FLANGE BOLT
FRONT BRAKE CAM SHAFT
FRONT RETURN SPRING
FRONT BRAKE ARM (L)
FRONT BRAKE ARM (R)
O RING
PLAIN WASHER
FRONT HUB ASSY.
Chap 5 - 3
FRT BRAKE CABLE COMP.
OUTER SPACER
PLAIN WASHER
HEX SLOTTED & CASTLE NUTS
COTTER PIN
RUBBER CAP
FRONT BRAKE DRUM
OIL SEAL
BEARING
10
11
12
13
14
15
16
17
18
INNER SPACER
BEARING
WHEEL RIM
TIRE
RIM VALVE
HEX FLANGE BOLT
FRONT BRAKE PLATE (L)
FRONT BRAKE PLATE (R)
FRONT BRAKE SHOE COMPLETE
Rear brake inspection:
1. Remove the rear brake system
Remove the left rear wheel
Remove the axle collar
Remove the rear brake caliper
Remove the brake disc
NOTE: KEEP THE BRAKE PADS AWAY FROM THE GREASE
2. Brake disc holder inspection
Remove the right rear wheel
Remove the nut of front driving sprocket.
Remove the disc holder
Chap 5 - 4
01
02
03
04
05
06
07
08
09
10
11
12
REAR WHEEL
EXPLOSIVE PARTS:
13
14
15
16
17
18
19
HEX BOLT
"BASE , BRAKE"
PROTECTIVE COVER
"HOLDER , PROTECTIVE OVER"
REAR AXLE FIX SEAT
SPACER TUBE
BEARING
20
21
22
23
24
25
OIL SEAL
FINAL DRIVE SPROCKET
SPROCKET HOLDER
HEX FLANGE BOLT
SPRING WASHER
HEX FLANGE BOLT
Chap 5 - 5
REAR AXLE
WHEEL RIM
TIRE
PLAIN WASHER
HEXAGON SLOTTED&CASTLE
COTTER PIN
RUBBER CAP
HEX WASHER FACE BOLT
RIM VALVE
SHAFT CONNECTER
HEXNUT
"DISCPLATE , BRAKE"
NUTS
Foot brake inspection: (Option)
Adjust the front & rear brake screws to make the foot brake
balance, avoiding brake unevenly.
Make sure there is enough brake fluid in the reserver.
1
2
3
RIGHT STEP FLOOR ASSY.
KICK BRAKE
"LEVER, REAR BRAKE
PUMP"
4
"LEVER, KICK BRAKE"
5
KICK BRAKE SPRING
6
KICK BRAKE BUSH
7
HEXAGON FLANGE BOLT
8
REAR BRAKE MASTER
CYLINDER
9
"LOCK PIN, BRAKE MASTER
CYL."
10 CABLE CONNECTING PLATE
11 "BUSH, REAR BRAKE PUMP
LEVER"
12 RD. HEAD MACHINE SCREW
13 SAFETY SWITCH
14 CABLE ADJUSTING BOLT
ASSY.
15 E TYPE CLIP
16 "BUSH, KICK BRAKE LEVER"
17 RD. HEAD MACHINE SCREW
18 LEFT STEP FLOOR ASSY.
19 FRT BRAKE CABLE BRACKET
20 "SLIDE, FRT BRAKE CABLE"
21 REAR BRAKE CABLE COMP.
22 FRT BRAKE CABLE COMP. 3
23 FRT BRAKE CABLE COMP. 1
24 FRT BRAKE CABLE COMP. 2
Chap 5 - 6
3. FRONT & REAR SHOCK ABSORBERS
INSPECTION AND ADJUSTMENT
3. Check for
(1) Slack
Hold the handlebar and front wheel with your both hands, and shake left
and right.
If slack, tighten the lock nuts of steering shaft, handlebar clamp, and ball
joint arm.
Torque:
Steering shaft lock nut: 4.0~5.0 kg m
Steering shaft holder lock nut: 2.0~3.0 kg m
Handlebar clamp lock nut: 0.8~1.0 kg m
Ball joint arm lock nut:3.0~4.0 kg M
1. Check the front shock absorbers
Movement
Raise and drop the handlebar up and down several times.
If the movement has trouble or leaks, check.
Refer to VEHICLE BODY.
2. Rear shock absorber inspection
Movement
Press the handlebar and seat, and shake up and down several times.
If the rear shock absorber has trouble or leaks, check.
Refer to VEHICLE BODY.
(2) Turn the handlebar left and right. If it is hard to move, remove the
steering shaft assembly. Check the sleeve and lubricate the joint parts of
steering mechanism.
STEERING MECHANISM INSPECTION AND ADJUSTMENT
1. Place the ATV on a level surface.
2. Support the vehicle body with a work stand to raise the front wheel
Off the ground.
Chap 5 - 7
Steering Tie inspection & adjustment
1.
2.
3.
4.
Keep the vehicle in flat surface, turn the front
Wheel to forward parallel.
Make sure length C equals D by eyes.
Otherwise adjust the steering tie,
Loosen nut #2 & #3.( #2 is left thread)
Turn #4 to adjust the LH & RH tie length.
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
Chap 5 - 8
STEERING SHAFT
STEERING SHAFT BRACKET
STEERING SHAFT BUSH SLEEVE
HEX WASHER FACE BOLT
STEERING TIE-ROD ASSEMBLY(R)
STEERING TIE-ROD ASSEMBLY(L)
KNUCKLE (R)
KNUCKLE (L)
INSERT LOCK NUT
HEX SLOTTED AND CASTLE NUTS
OIL SEAL
CIRCLIP
RADIAL BALL BEARING
OIL SEAL
INNER SPACER
PLAIN WASHER
INSERT LOCK NUT
COTTER PIN
PLAIN WASHER
COTTER PIN
1
2
3
RIGHT STEP FLOOR ASSY.
KICK BRAKE
"LEVER, REAR BRAKE
PUMP"
4
"LEVER, KICK BRAKE"
5
KICK BRAKE SPRING
6
KICK BRAKE BUSH
7
HEXAGON FLANGE BOLT
8
REAR BRAKE MASTER
CYLINDER
9
"LOCK PIN, BRAKE MASTER
CYL."
10 CABLE CONNECTING PLATE
11 "BUSH, REAR BRAKE PUMP
LEVER"
12 RD. HEAD MACHINE SCREW
13 SAFETY SWITCH
14 CABLE ADJUSTING BOLT
ASSY.
15 E TYPE CLIP
16 "BUSH, KICK BRAKE LEVER"
17 RD. HEAD MACHINE SCREW
18 LEFT STEP FLOOR ASSY.
19 FRT BRAKE CABLE BRACKET
20 "SLIDE, FRT BRAKE CABLE"
21 REAR BRAKE CABLE COMP.
22 FRT BRAKE CABLE COMP. 3
23 FRT BRAKE CABLE COMP. 1
24 FRT BRAKE CABLE COMP. 2
ENGINE DISASSEMBLY(1)
• Loosen engine from
• frame.
ENGINE DISASSEMBLY(2)
• Loosen nut
• Remove throttle
cable
TRANSMISSION DISASSEMBLY(1)
• Loosen 10 hexagon
flange screws
TRANSMISSION DISASSEMBLY(1)
• Dismantle engine
LH cover
• Loosen 2 nuts of
driving face &
clutch outer
TRANSMISSION DISASSEMBLY(3)
• Remove driving face,
driving pulley,
v-belt, clutch outer,
driven pulley
• Loosen 2 hexagon
screws of starting
idle gear fixing plate
MAGNETO DISASSEMBLY(1)
• Loosen 3 screws
• Remove cooling
fan cover
MAGNETO DISASSEMBLY(2)
• Loosen 4 hexagon
screws
• Remove cooling
fan
MAGNETO DISASSEMBLY(3)
• Loosen nut of
magneto
MAGNETO DISASSEMBLY(4)
• Pull out magneto
with tool
(no:S620270G014)
• ☆Tighten tool to
prevent magneto
thread worse
MAGNETO DISASSEMBLY(5)
• Loosen 4 hexagon
screws of stator
MAGNETO DISASSEMBLY(6)
• Loosen 1 wire
fixing plate screw
• Remove wire fixing
plate and stator
CYLINDER HEAD &
CYLINDER DISASSEMBLY(1)
• Loosen 2 hexagon
screws
• Remove cooling
cover
CYLINDER HEAD &
CYLINDER DISASSEMBLY(2)
• Loosen 4 nuts of
cylinder
• Remove cylinder
head
CYLINDER HEAD &
CYLINDER DISASSEMBLY(3)
• Remove cylinder
CYLINDER HEAD &
CYLINDER DISASSEMBLY(4)
• Remove piston pin
clip
• Remove piston
pin/piston/bearing
☆ The piston pin clip
shall not overlap
the opening with
piston
CYLINDER HEAD &
CYLINDER DISASSEMBLY(5)
• Assemble the
cylinder head &
cylinder from LH to
RH
☆ The opening end of
piston ring shall be
mounted to piston
stopper pin, and the
mark faces upside
LH
RH
CYLINDER HEAD &
CYLINDER DISASSEMBLY(6)
• The arrow mark
upon piston shall
face to exhaust port
CYLINDER HEAD &
CYLINDER DISASSEMBLY(7)
• The ”EX” mark
upon cylinder head
shall face to
exhaust (down)
☆ Tighten nuts
crossly and lock
torque:1.2kg-m
CRANKSHAFT DISASSEMBLY(1)
• Loosen 3 hexagon
of intake manifold
• Dismantle oil pipe
• Remove intake
manifold
CRANKSHAFT DISASSEMBLY(2)
• Remove reed
valve comp.
CRANKSHAFT DISASSEMBLY(3)
• Loosen the screw
of cable-fixing
plate, remove
fixing plate
• Loosen 2 C-R
recess pan hd.
screws
• Remove oil pump
CRANKSHAFT DISASSEMBLY(4)
☆Do not miss plain
washer when
installing oil pump
• The oil inlet &
outlet pipe shall be
full of oil
(no residual air)
Don’t missing
CRANKSHAFT DISASSEMBLY(5)
• Loosen 2 C-R
recess pan hd.
screws
• Remove starting
motor
CRANKSHAFT DISASSEMBLY(6)
• Pull out R-clip of
central stand axle
• Remove central
stand spring
• Remove central
stand axle
• Remove central
stand
CRANKSHAFT DISASSEMBLY(7)
• Loosen 7 hexagon
screws of RH
crankcase
CRANKSHAFT DISASSEMBLY(8)
• Pull out RH
crankcase from
crankshaft with tool
CRANKSHAFT DISASSEMBLY(9)
• Remove
crankshaft assy.
CRANKSHAFT INSTALLATION(1)
• Pull crankshaft into
LH crankcase with
tool
CRANKSHAFT INSTALLATION(2)
• Assemble engine
hanger axle & RH
crankcase
• Tighten hexagon
screws of RH
crankcase crossly
step by step
☆ Replace oil seal
and packing
GEAR BOX DISASSEMBLY(1)
• Loosen nut of rear
wheel
• Remove rear wheel
GEAR BOX DISASSEMBLY(2)
• Loosen 6 hexagon
screws
• Remove
transmission cover
GEAR BOX DISASSEMBLY(3)
• Remove idle gear
comp & final gear
GEAR BOX DISASSEMBLY(4)
• Mount the idle gear
comp. first, then the
final fear
• The cone washer is
inside, and plain
washer outside when
assembling idle gear
☆ Replace oil seal
and packing
ENGINE DISMANTLE
• Loosen screws of
engine hanger from
frame
TRANSMISSION DISASSEMBLY(1)
• Loosen 8 hexagon
flange screws of
LH cover
• Remove engine LH
cover
TRANSMISSION DISASSEMBLY(2)
• Loosen nuts of
driving pulley and
clutch outer
• When installing
nuts, tighten torque
is 5.5 kg-m
TRANSMISSION DISASSEMBLY(3)
• Remove drive face,
driving pulley assy.,
driven pulley assy.,
V-belt
MAGNETO DISASSEMBLY(1)
• Loosen 2 hexagon
screws and 2 C-R
recess pan hd.
tapping screws
• Remove fan cover
MAGNETO DISASSEMBLY(2)
• Loosen 4 hexagon
screws of cooling
fan
• Remove cooling
fan
MAGNETO DISASSEMBLY(3)
• Loosen nut of
magneto
• When installing,
tighten lock torque
is 5.5 kg-m
MAGNETO DISASSEMBLY(4)
• Pull out the
magneto with
special tool
• part no:
S620402G01A
☆tool should be
tighten lock
MAGNETO DISASSEMBLY(5)
• Loosen 4 hexagon
screws of stator
• Remove stator
CYLINDER AND HEAD
DISASSEMBLY(1)
• Loosen 1 hexagon
screw and 2 tapping
screws of cooling
cowl(2)
• Remove cooling
cowl(2)
CYLINDER AND HEAD
DISASSEMBLY(2)
• Loosen 1 hexagon
screw of cooling
cowl(1)
• Remove cooling
cowl(1)
CYLINDER AND HEAD
DISASSEMBLY(3)
• Loosen 4 hexagon
screws of cylinder
head cover
• Remove cylinder
head cover assy.
CYLINDER AND HEAD
DISASSEMBLY(4)
• Loosen 1 hexagon
screw of chain
adjuster
• Loosen 2 hexagon
screws fixed in
cylinder
• Remove chain
adjuster comp.
CYLINDER AND HEAD
DISASSEMBLY(5)
• Loosen 4 nuts of
camshaft holder
• Loosen 2 hexagon
screw of cylinder
head
• Remove camshaft
holder、camshaft
and cylinder head
CYLINDER AND HEAD
DISASSEMBLY(6)
• Remove cam chain
guide comp.
• Remove cylinder
and piston rings
ONE WAY CLUTCH
DISASSEMBLY(1)
• Loosen 8 hexagon
screws of RH
crankcase cover
• Remove RH
crankcase cover
CYLINDER AND HEAD
DISASSEMBLY(2)
• Loosen nut of one
way clutch with
special tool (part no:
S620401G015)
• Remove one way
clutch comp and
starting idle gear
• The nut is LH thread
OIL PUMP DISASSEMBLY(1)
• Loosen 2 C-R
recess screws of oil
separator
• Remove oil
separator
OIL PUMP DISASSEMBLY(2)
• Loosen nut of oil
pump driving gear
• Remove oil pump
driving gear and
chain
OIL PUMP DISASSEMBLY(3)
• Loosen 2 hexagon
screws of oil pump
• Remove oil pump
CRANKSHAFT DISASSEMBLY(1)
• Loosen 2 hexagon
screws of RH
crankcase
• Remove RH
crankcase with
plastic hammer
CRANKSHAFT DISASSEMBLY(2)
• Pull out crankshaft
from LH crankcase
• Remove camshaft
chain
CRANKSHAFT INSTALLATION(1)
• Put camshaft chain
in LH crankcase
CRANKSHAFT INSTALLATION(2)
• Assemble
crankshaft in LH
crankcase
CRANKSHAFT INSTALLATION(3)
• Assemble RH
crankcase into
crankshaft
• Tight 2 hexagon
screws
• (torque is1.0kg-m)
• Replace the oil seal
and packing.
CRANKSHAFT INSTALLATION(4)
• To avoid the oil
seal detected, shall
assemble the oil
seal after crankshaft
is fixed in
crankcase
CYLINDER & CYLINDER HEAD INSTALLATION
• Notice the marks
upon piston
• “IN” mark shall in
the intake direction ;
“EX” mark shall in
the exhaust direction
To intake
IN
To exhaust
EX
CYLINDER & CYLINDER HEAD INSTALLATION
• Piston rings shall
be installed
according to marks
• 1st ring is marked
“1R” ; 2nd ring is
marked “RN”
• The marks shall
face to piston head
1st ring “1R”
2nd ring “RN”
CYLINDER & CYLINDER HEAD INSTALLATION
• The opening end of
piston rings shall
face to intake valve
and allied to 120
degree
• And shall not allied
to the piston pin
Allied to 120°
CYLINDER & CYLINDER HEAD INSTALLATION
• Installing camshaft,
the valve timing
shall be adjusted
• Rotate the magneto
“T” make to RH
crankcase allied
position
MAGNETO “T”
RH crankcase mark
CYLINDER & CYLINDER HEAD INSTALLATION
• Ensure 2 line marks
of camshaft parallel
to cylinder head
(refer to photo)
• And the hole shall
be in the top
position
(refer to photo)
Hole in camshaft
Line marks in
camshaft
CYLINDER & CYLINDER HEAD INSTALLATION
• Installing camshaft
holder,“EX”
mark shall face to
exhaust valve
• Tighten 4 nuts
crossly, lock torque
is 2.0 kg-m
Carburetor dismantle & inspection:
2 stroke engine
carburetor
1. dismantle
Remove:-carburetor assembly, pipes, cables and wires
Remove:-high-tension wire
2. adjustment
there are two screws might be adjusted to tuning the engine intake
mixture.
4 stroke engine
carburetor
1st is the stop screw: to adjust the engine idle speed.
2nd is the air screw to adjust the air/fuel ratio.
3.Auto-bystart function check
the carburetor is equipped with auto-bystart to improve the engine cold
start, it shall be warm after the engine has been starting for 5 minutes.
4. Float chamber function check
fuel level is controlled by float assembly, and stopped by valve set.
Whenever there is any flooded fuel leaks, check if there is any dirty
element or valve set is worn out.
5. Whenever the carburetor is exploded, be careful to install all the parts
properly to the original sequence.
Chap 7.2 - 1
CARBURETOR
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
CARBURETOR ASSY.
TOP SET
SPG., COMP.
PLATE SET
TUBE SET
JET NEEDLE
THROTTLE VALVE
SCREW SET
SCREW SET(A.S)
O RING
NEEDLE JET
SLOW JET
HOLDER, NEEDLE JET
MAIN JET
FLOAT VALVE SET
PIN, ARM
FLOAT SET
FLOAT CHAMBER SET
19
20
21
22
23
24
TUBE SET
"SCREW, WASHER"
CAP HOLDER
AUTO BYSTARTER SET
SCREW, WASHER
PLATE SET
Chap 7.2 - 2
Wiring diagram
Chap 7.3 - 1
Electric elements in vehicle:
Main switch (off-on-light)
Battery & fuse
horn
Signal flasher relay
Starting relay
Regulator & CDI
Spark coil
Oil sensor
Safety switch
Chap 7.3 - 2
Starting relay inspection
1.System diagram
2.Check the resistance with pocket tester
Starting motor
relay
battery
1.Start button
2.Safety switch
3.Main switch
3.Check the voltage action function with
12V battery
Regulator inspection: measure the resistance according to the following
table.
Chap 7.3 - 3
OP of replacing Brake Lever for
ATV150
1.Dismantle the clip of park
stopper.
2.Loosen the bolt of brake
lever.
OP of replacing Brake Lever for
ATV150
3. Replace the brake lever
& park stopper.
4. Lock torque : 1.0 kg-m.
OP OF REPLACING INTAKE PIPE
FOR ATV50
1. Take off the cover
OP OF REPLACING INTAKE PIPE
FOR ATV50
2. Loosen the 2 screws
OP OF REPLACING INTAKE PIPE
FOR ATV50
3. Take off the intake pipe by a
thin tool.
OP OF REPLACING INTAKE PIPE
FOR ATV50
4.Replace the intake pipe
OP of Replacing the Reverse-Gearbox
• Step 1:
• Dismantle the chain
coupling set with pivor.
OP of Replacing the Reverse-Gearbox
• Step 2
• Dismantle the foot
protector
• Loosen bolt (M8) of
brake kick
OP of Replacing the Reverse-Gearbox
• Step 3 :
• Loosen 3 bolts (M10)
OP of Replacing the Reverse-Gearbox
• Step 4 :
• Dismantle cable of
reverse-gearbox
OP of Replacing the Reverse-Gearbox
• Step 5 :
• Remove rubber cap &
Loosen bolt (M10)
OP of Replacing the Reverse-Gearbox
• Step 6 :
• Replace the gearbox
set
OP of Replacing the Reverse-Gearbox
2
1
• Step 7 :
• Lock the reverse-gearbox
(M10)
• Lock torque: ① 4 kg-m
•
②8~9 kgm
OP of Replacing the Reverse-Gearbox
• Step 8 :
• Fix the cable
OP of Replacing the Reverse-Gearbox
• Step 9 :
• Lock the nut
OP of Replacing the Reverse-Gearbox
• 步驟十 :
• Lock the RH stepplate
(M10)
• Lock torque: 4.5~5 kg-m
OP of Replacing the Reverse-Gearbox
• Step 11 :
• Lock bolt of brake
kick(M8)
• Lock torque: 3 kg-m
OP of Replacing the Reverse-Gearbox
• Step 12 :
• Assemble the driving
chain
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