HER CHEE ATV-50R, ATV-100R ATV SERVICE MANUAL
Below you will find brief information for ATV ATV-50R, ATV ATV-100R. This manual describes different aspects of the ATV-50/100R, including its initial setup, lubrication system, fuel system, and various engine components, which are all part of its high-power engine. You can find information on how to properly set up the ATV-50/100R after purchase, how to adjust the engine oil and gas, and how to identify and fix potential issues.
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SERVICE MANUAL ATV-50/100 R MARCH , 2005 High Power Engine HER CHEE INDUSTRIAL CO., LTD. Foreword This service manual contains information on servicing ATV-50/100R. This manual is written for use as a guideline only. It is recommended that any mechanic, with or without sufficient experience, thoroughly read through the manual and only attempt to service those areas that are fully understood in accordance with the guidelines provided by this manual. For fully qualified mechanics, this manual supplies service data necessary for repairs and maintenance. It is highly recommended that a qualified mechanic, regardless of technical level, should study the service manual in full before attempting service on ATV-50/100R. All the data and diagrams provided in this service manual are valid at the time of publication. Information may be updated without notice due to improvements or upgrades. No quotation, reproduction, or reprint of the service manual, as a whole or in part, will be permitted without the express written consent from ADLY Motor sports. INDEX Initial Set-Up Information-------------------------------------------------1 Information for Preparation-----------------------------------------------2 Check and Adjust----------------------------------------------------------3 EngineLubrication System---------------------------------------------------------4 Fuel System-----------------------------------------------------------------5 Remove of Engine----------------------------------------------------------6 Cylinder Head / Cylinder / Piston----------------------------------------7 Starter / Driving Disc / Clutch / Transmission Disc--------------------8 Final Transmission Mechanism-------------------------------------------9 Crank case / Crank shaft--------------------------------------------------10 ChassisFront wheel, Brake, Suspension------------------------------------------11 Rear heel, Brake, Suspension --------------------------------------------12 Electrical devices-----------------------------------------------------------13 Wiring diagram-------------------------------------------------------------14 Initial Set-Up Information Injector Oil Use a good grade of oil that is specially formulated for two-stroke engines, synthetic type is recommended. HC recommends SAE 30. Transmission Gear Oil Use multi-grade motor oil of SAE 90 or 85W-140. Break-In Procedure To insure maximum durability and optimal performance and to avoid engine damage, please pre-mix the first four tanks of fuel with two-stroke engine oil at 30:1 ratio. Do not operate the ATV at more than half throttle for the first three hours. During the break-in period (the first four tanks of fuel), operate the vehicle at various RPM’s and do not operate the vehicle above half throttle for extended periods. Engine The ATV-50/100 have a two-stroke, reed induction, piston port motor. It must use two-cycle oil and should never be run without oil in the oil tank. Rebel the regulation will have extreme damage to the motor will result. Ignition System The ignition system installed on ATV-50/100R is the Computerize Digital Ignition (CDI) type. There is no maintenance required for this type of system. Chassis The chassis is constructed of mild steel tubing. oxyacetylene welding can be used. If any frame repairs are necessary, If wire feed or arc welding is used, use extreme care and disconnect the battery while welding. 1Ё 1 Set-Up Procedure The following instructions provided a general overview of the procedures needed to properly set-up and deliver the ATV-50/100R to the retail customer. 1. Take out the battery and fill with acid liquid. Pre-charging the battery will extend its life. The preparation and charge procedure is based on the battery’s instruction. 2. Install the rear wheels and parts in the following order: A. 14×40×4.5mm washer (big) B. 14mm hex-bolt (torque 450-550kg-cm, 44-54N-m) C. Cotter pin (open up the end after installed) D. Rubber cap 3. Install the front wheels and parts in the following order: A. 12×40×4.5mm washer (big) B. 12mm hex-bolt (torque 300-350kg-cm, 29.5-34N-m) C. Cotter pin (open up the end after installed) D. Rubber cap 4. Set the handle bar into the lock-pin of the steering base. Tie-up the 4 hex-socket bolts. Install the rear cover into handle bar and adjust the cables and wires properly. Install the front cover into the rear cover. 5. Pull the seat-lock cable and remove the seat. Install the battery with the red wire to positive (+) and the black wire to the negative (-). 6. Remove the oil tank cap and fill with 2 stroke oil (SAE 30)of a synthetic and low-smoke type, and enough unleaded gasoline to operate. Be sure the arrow mark on the fuel valve arm (petcock) is set into the correct position (on). 7. Install the Front Bumper. 8. Turn on the main switch and try to start up the engine. In order to use the electric starter, you need to check the following. A. Turn on the engine operation switch located on left handle bar B. Pull the rear-brake lever C. Push the electric starter bottom to left or right 9. If the vehicle is operating in a very dusty area, please add more oil on the air cleaner filter. 1Ё 2 PDI (PRE DELIVERY INSPECTION) (For ATV-50/90/100) ϭʳ 1. Record the frame and engine number into the owner’s manual. ϭʳ 2. Check that all tires have correct pressure specified on the tire or in the owner’s manual. ϭʳ 3. Engine lubrication oil (2 stroke, Grade SAE30) tank is filled. ϭʳ 4. Battery is installed properly. ϭʳ 5. All brake cables are adjusted properly. ϭʳ 6. Fuel tank has enough gasoline to operate. ϭ 7. Check the suspension and drive chain for proper setup. ϭʳ 8. Check that all electrical components and lights are working properly. ϭʳ 9. Make sure that the owner’s manual and tool bag are installed under the seat. If there are any other questions, please check the owner’s manual for details. CAUTION: Before install the front rim, beware the stopper ȩ of front brake plate assembly must fit into the front knuckle 7-mm plate Ȫ. 1Ё 3 INFORMATION FOR PREPARATION Attention on Operation z All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item when dismounted. z Locking of all screws, nuts, cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks. z All items must use original parts, pure oil and greases. z All service shall use special tools and general tools to repair. z All dismounted items requiring for checks shall be duly cleaned and for assembly, all items shall be duly lubricated. 2-1 INFORMATION FOR PREPARATION Attention on Operation z Certified lubricants in cans shall be used on all the elements to be lubricated. z After assembly, performance of all elements shall be duly checked and the locking shall be duly verified. z In case of an operation is performed by over 2 people, the assignment shall be conducted in coordination and safety shall be the first priority. z Definition of signs: The sign given in the Service Manual shall refer to the operation methods and observation. OIL: Lubrication by designated lubricant. GREASE: Lubrication by grease Special Tool: Parts on which special tools shall be used Tool: General tools shall be used New: Replace by new items after dismounting Attention Dangerous and important operations 2-2 INFORMATION FOR PREPARATION MODEL SPECIFICATION ATV-50R ATV-100R ENGINE 50 C.C. 100 C.C. TYPE AIR-COOLED, 2-STROKE SINGLE CYLINDER STARTING KICK & ELECTRIC LUBRICATION OIL PUMP SEPARATE SUPPLY TRANSMISSION AUTOMATIC (C.V.T. V-BELT) SPARK PLUG NGK BPR7HS BATTERY YTX4L-BS 12V (Maintenance-free) OIL CAPACITY 1.0 Liter FUEL TANK 5.0 Liter OVERALL LENGTH 1465mm 1525mm OVERALL WIDTH 875mm 890mm OVERALL HEIGHT 890mm 930mm SEAT HEIGHT 700mm 740mm WHEEL BASE 955mm CLAIMED DRY WEIGHT 103KG 108KG FRONT BRAKE DOUBLE DRUM REAR BRAKE DRUM FRONT SUSPENSION OIL DAMPED, INDEPENDENT, SINGLE A-ARM REAR SUSPENSION OIL DAMPED, SWING SINGLE SHOCK 19Ø7-8 FRONT TIRE 18Ø9.5-8 REAR TIRE ϩSPECIFICATIONS SUBJECT TO CHANGE WITHOUT ANY NOTICE.!ϩ 2-4 INFORMATION FOR PREPARATION LOCKING TORQUE Adopt the standard torque locking for the item unlisted. STANDARD TORQUEΚ Type 5 mm Screw 6 mm Screw 6 mm Hex Washer Face Bolt / Nut 8 mm Hex Washer Face Bolt / Nut 10 mm Hex Washer Face Bolt / Nut Locking Torque (kg-m) 0.4 1.0 1.2 2.7 4.0 CHASSISΚ Locking Place Front Wheel Axle Nut Rear Axle Nut Rear Brake Arm Screw Front Shock Absorber Rear Shock Absorber Engine Mounting Nut – Front Engine Mounting Nut – Rear Quantity Dia. (mm) Locking Torque (kg-m) 1 12 3.5 1 14 5.0 1 6 1.2 4 10 4.0 2 10 4.0 1 10 4.5 1 8 3.0 ENGINEΚ Locking Place Quantity Dia. (mm) Locking Torque (kg-m) Screw of Cylinder Cap 4 6 1.0 Flywheel Nut 1 10 3.8 Clutch Cover Nut 1 10 3.8 Clutch Carrier Nut 1 28 5.5 Nut of Primary Fix Sheave 1 10 3.8 Oil-check Screw 1 8 1.3 Joint Screw of Exhaust Muffler 2 6 1.2 Exhaust Pipe Support Screw of Muffler 1 8 3.0 Spark Plug 1 14 1.4 Bolt of Crank Shaft Case 6 6 1.0 2-5 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV-50/100R (҈). 2-6 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for ATV-50/100R (ҋ). 2-7 CHECK AND ADJUST Way of Check & Adjustment 1. Mark “Ϥ” is checking time. 2. Mark “ϩ” is the regular exchange of service items. This exchange time is just for general riding of the majority not for the special use , please arrange with this principle according to the difference of the riding condition. Service Time (month) Service Items Before riding 1st Judgement Standard Remarks Each each 12 6 Operating Device Handle- Play, loose/tight Operation Ϥ Ϥ Ϥ! Ϥ Ϥ Ϥ Ϥ Wheels- Right/left turn round angle Front and Rear Cushion – Damage Installation of Bolt Ϥ! Ϥ! Ϥ Ϥ Ϥ! ϩ! Play Brake Device Brake- Play Ϥ ! Test Ride Ϥ Adjust Ϥ Wires- Loose / tight and damage Ϥ! Ϥ Ϥ Ϥ Ϥ Ϥ! Handle , handle front Ϥ 10-20 mm Ϥ Wore of brake & operating parts Ϥ Brake Hub. ϩ (mm) Front Rear 85 130 85.5 130.7 Standard diameter Limitation ! Riding Device 20Ø7-8 19Ø7.5-8 19Ø7-8 16Ø8-7 Normal 8 psi 10 psi 2.2 psi 4.5 psi Max. 9 psi 11 psi 2.6 psi 5 psi Min. 7 psi 9 psi 1.8 psi 4 psi Tire Size Tires pressure Ϥ! Ϥ! Ϥ! 3-1 Service Time (month) Service Items Before riding 1st Judgement Standard Remarks Each each 12 6 Riding Device Tire Check & damage of tires Ϥ Ϥ ϩ Ditch--- front wheel till 3 mm Rear wheel till 3 mm Abnormal & ditch in tires Ϥ Bolt & nut of tires locking Ϥ Ϥ ! ! Ϥ Ϥ Blocking torque Front wheel – 3.0~3.5 kg-m Rear wheel – 4.5~5.5 kg-m Tightness of front bearing Ϥ Tightness of rear bearing Ϥ Buffer device Spring - damage Ϥ Ϥ Suspension arm – damage of joint gap Ϥ Ϥ Ϥ Ϥ Ϥ Ϥ Ϥ ϩ Ϥ Ϥ Ϥ Ϥ Spring of shock absorber. & arm - oil leakage or damage Tightness of installation Power transmission device Clutch - action Ϥ Gear Box SAE 90 or 80W-90 Electric device Ignition device - Spark plug Battery - connection of terminal ϩ Wiring of electrical appliance – damage Ϥ Gap of spark plug 0.6~0.7 mm or loose in connection place Engine Ϥ Ϥ Ϥ Ϥ Idle : 1800²100 rpm exhaust Ϥ Ϥ air filter Ϥ ϩ Body – starting & abnormal noise Low speed & accelerating Ϥ 3-2 Service Items Service Time (month) Before riding 1st Ϥ Ϥ Judgement Standard Remarks Each each 12 6 Lubrication device Oil and oil filter Oil leakage Ϥ ϩ Ϥ Ϥ Check the oil level Fuel installation ϩ Fuel filter is dirty / Clogged Ϥ Leakage of fuel Ϥ Throttle gate & choke Ϥ Alteration of tubes Ϥ Lights Ϥ Action On/off normal , dirty , damage Ϥ Ϥ Exhaust pipe & muffler Installation loosed or damage Ϥ Function of muffler Ϥ Frame & body –loose or damage Ϥ Cleaning combustion chamber , exhaust Each 2 years pipe , and carbon muck in muffler DRIVE CHAIN Check the tension of drive chain Others Ϥ Ϥ - greasing of each part Abnormal from previous day –confirm normal ϩ Ϥ Tolerance: 10~20mm Ϥ Ϥ 3-3 CHECK AND ADJUST Disassembly of External Parts ATV 50/90/100R(҈) z Remove the external parts for check and adjustment. Disassembly the Rear Cover: z Pull the Seat Releaser Unit and take off Seat Ass’y. z Remove 4 Pan Flat Head Phillips Bolt. z Remove 2 Ladder Bolt. z Remove 4 Nylon Nut, 2 Plain Washer and 2 Rubber Washer. Remove Floor Panel: z Remove 4 Pan Flat Head Phillips Bolt. Disassembly the Handle Bar: z Release brake throttle and cables z Remove 4 Hex Socket Bolt and take off the Handle Bar. z Release 1 Hex Socket Bolt and take off the R. Lever Ass’y. z Disconnect light indicatorΔposition light and speedometer. z Release 2 Pan Flat Head Phillips Bolt and take off the L. Handle Switch Ass’y.( Optional ) z Release 1 Hex Socket Bolt and take off the L. Lever Ass’y.( Optional ) Disassembly the Front Cover: z Disassembly the Handle Bar. z Remove the Fuel Tank Cap. z Pull the Seat Releaser Unit and take off Seat Ass’y. z Remove 2 Ladder Bolt. and 4 Pan Flat Head Phillips Bolt. WARNNING: z Remove 2 Hex Washer Face Bolt and ϠDo not damage & break the cover. 4 Plain Washer And 2 Hex Flange ϠBefore locking screws, please confirm Nut With Serration. the matching is correct of all parts. z Disconnect Main Switch Wire and head light wire. 3-4 CHECK AND ADJUST Disassembly of External Parts z Remove the external parts for check and adjustment. ATV 50/100R(ҋ) Disassembly the Rear Cover: z Pull the Seat Releaser Unit and take off Seat Ass’y. z Remove 4 Pan Flat Head Phillips Bolt. z Remove 2 Ladder Bolt. z Remove 4 Nylon Nut, 2 Plain Washer and 2 Rubber Washer. Remove Floor Panel: z Remove 4 Pan Flat Head Phillips Bolt. Disassembly the Handle Bar: z Release brake throttle and cables. z Remove 4 Hex Socket Bolt and take off the Handle Bar. z Disconnect light indicatorΔposition light and speedometer. z Release 1 Hex Socket Bolt and take off the R. Lever Ass’y. z Release 2 Pan Flat Head Phillips Bolt and take off the L. Handle Switch Ass’y. z Release 1 Hex Socket Bolt and take off the L. Lever Ass’y. Disassembly the Front Cover: z Disassembly the Handle Bar. z Remove the Fuel Tank Cap. z Pull the Seat Releaser Unit and take off Seat Ass’y. WARNNING: z Remove 2 Ladder Bolt. and 4 Pan ϠDo not damage & break the cover. Flat Head Phillips Bolt. ϠBefore locking screws, please confirm z Remove 2 Hex Washer Face Bolt and the matching is correct of all parts. 4 Plain Washer And 2 Hex Flange Nut With Serration. z Disconnect Main Switch Wire and head light wire. 3-5 z CHECK AND ADJUST Adjustment of Oil Pump ϠWARNNING: Going on this operation after adjusting and checking the guide wiring of throttle. x The free play within 1 mm of the oil pump control cable is good. Starting the engine, push slightly the throttle to feed oil. At same time of rising the engine rotation, confirm the function of control rod. Control rod oil pump adjust nut x The condition will be appeared with bad synchronizing as follows : Ϡ Starting difficult and having smoke when opening degree of oil pump’s control rod is too big. Ϡ Piston will be burnt when the opening degree of oil pump’s control rod is too small. Adjustment of Drive Chain z z z z Loose 4 Hex Bolts on Rear Brake Panel. Adjust the drive chain adjuster to proper chain tolerance 10 ~ 20 mm (unload). Tie up 4 Hex bolt on Rear Brake Panel. Lubricate the chain. CANTION: Beware the direction of chain fix clip if disassembly the chain. 3-6 LUBRICANT SYSTEM Attention of Operation z Pay attention to avoid dust enter to the interior of engine and oil tube when disassembly the oil pump. z z Never disassembly oil pump. Must draw out the air in the pump if there have air in the pump when z disassembly tube of carburetor. After disconnect the oil tube, must fulfill the oil in the connection tube before installation. Diagnosis of Troubles Too much smoke, means too much carbon muck piping up the spark plug. z Poor synchronizing adjust of oil pump (too much exhaust gas). z Bad quality of engine oil. Overheating z Poor synchronizing adjustment of oil pump (too exhaust gas). z Bad quality of engine oil. Piston burnt z Short of engine oil, or engine oil tube is clogged. z Poor adjustment of oil pump. z Air in tube system or in oil pump. z Bad oil pump. Clogging oil from oil tank z Vent of oil tank’s cap is blocked. z Oil Filter is clogged. Preparation standard z Use separating engine oil appointed (use for 2-stroke). z Oil tank capacity: 1.1 liter 4- 1 LUBRICANT SYSTEM Disassembly of Motor Oil Pump z z Remove Generator Cover. Remove A.C.G. fly wheel and fly wheel base. ϠWARNING: Operating after cleaning motor oil pump around and no entering to the crank shaft case. 4- 2 LUBRICANT SYSTEM Operation / Parts Name Disassembly 1 Fuel tube Q’ty Remarks 1 4WARNING: Clogging the tube to avoid fuel flow out. 2 Fuel connection tube 3 Pan phillips bolt 1 2 x Remove from both side of oil pump. 4 Control cable 1 x Remove from oil pump. 5 Oil pump Assembly 5o1 1 x Assembly with sequence in reverse of disassembly. ϠWARNING: Smear oil to new O ring ,before install the oil pump into crank case. The oil pump must correctly installed into crank case. 4WARNING: Don’t loosen adjusted screw on control cable. Adjust the cable if it’s loose. 4- 3 LUBRICANT SYSTEM Disassembly of Oil Tank Operation / Parts Name 1 2 3 4 Disassembly Hex Bolt Oil level gauge Joint of oil disassembly oil pipe Oil tank Assembly 4o1 Q’ty Remarks 2 ϠWARNING: 1 Fill motor oil with clean container. 1 1 x Operation with sequence in reverse of disassembly. ϠWARNING: Connect correct oil pipe after assembly , release the air in motor oil pump. 4- 4 FUEL SYSTEM Attention in Operation Pay attention to the parts which using gasoline. Tube & Cable must be in accordance with the correct location. Release air in oil pump when disconnect oil tube. Diagnosis of Trouble No starting No gasoline in tank The arrow mark of Fuel valve pointed at “OFF” position Gasoline blocked Too much fuel in cylinder Air filter is clogged Idle speed unstable , of carburetor rotation not smooth Poor idle speed adjustment of carburetor. Low compression pressure Poor ignition system Bad adjustment of air adjusting screw on carburetor Air filter is clogged Defect of auto side-plunger on carburetor Idle speed nozzle is clogged Mixed air too thin Nozzle of carburetor is clogged Gasoline filter is clogged Vent of gasoline tank is clogged Gasoline tube cranked, broke, clogged Poor action of float chamber valve. Gasoline level too low Air pipe is clogged Mixed air too rich Poor action of float chamber valve Gasoline level too high Air nozzle is clogged Auto side-plunger defect 5- 1 FUEL SYSTEM Disassembly / Assembly Valve Of Throttle Disassembly carburetor. Operation / Parts Name 1 2 3 4 5 6 7 8 9 10 11 Disassembly Pan phillips bolt Throttle valve Throttle cable Throttle valve spring Gasket Throttle cover Rubber Sealing Washer Needle nozzle Clamp Adjust nut Q’ty Remarks 2 1 1 1 1 ϠWARNING: 1 Remove from guide wire of throttle 1 valve. 1 1 1 1 5- 2 FUEL SYSTEM Operation / Parts Name 11 10 9 8 7 6 5 4 3 2 Assembly Adjusted nut Clamp Needle nozzle Washer Sealing set of guide wire Throttle cover Washer Throttle valve spring Throttle cable Throttle valve 1 Pan phillips bolt Q’ty 1 1 1 1 1 1 1 1 1 1 1 Remarks ϠWARNING: Assembly of needle nozzle. Assembly of throttle valve. Assembly of throttle cable. Aim the ditch of throttle valve to chamber, then install throttle valve into carburetor. Lock the throttle cover. 5- 3 FUEL SYSTEM Remove Carburetor z Turn the arrow of fuel valve pointed at “OFF”. Operation / Parts Name 1 2 3 4 5 6 7 8 Disassembly Throttle valve set Gasoline tube Engine oil tube Auto-side plunger wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp Carburetor Q’ty Remarks 1 1 1 1 1 1 1 1 Assembly 8o1 3 Motor oil joint ϠWARNING: Don’t let dust enter into carburetor. ϠWARNING: Release air. 5- 4 FUEL SYSTEM Disassembly / Assembly Carburetor Disassembling of carburetor. Adjust the idle speed. Adjust the air adjust screw. ϠWARNING: ʳ ԦNo fire. ʳ ԦBefore disassembling, loose fuel-draining screw, draining out the gasoline from carburetor. 5- 5 FUEL SYSTEM Operation / Parts Name Q’ty Remarks Disassembly Plunger starter 1 Pan phillips bolt 2 Auto-side plunger 3 Oil ring 2 1 1 Float Chamber 4 5 6 7 8 9 10 Pan phillips bolt Drain screw Over flow tube Pan phillips bolt Float pin Float Needle valve 4 1 1 1 1 1 1 Carburetor Ass’y 11 12 13 14 15 16 Throttle screw set Air adjust screw set Float chamber seal Pilot jet Main jet base Main jet Assembly 16o1 12 Air adjust screw set 1 1 ϠWARNING: Must confirm rotation before disassembling. Not locking too much, avoid to 1 hurt seat face. 1 1 ΘOperating with sequence in reverse of Disassembling. ϠWARNING: use high pressure air clean each way of carburetor. ϠWARNING: must adjust air screw when changing air screw and carburetor ass’y. 5- 6 FUEL SYSTEM Disassembly of Inlet Valve Disassembly of handle bar & front cover. Disassembly of fuel tank Disassembly of carburetor. Operation / Parts Name 1 2 3 4 5 Disassembly Intake manifold hose clamp Hex washer face bolt Intake manifold Reed valve ass’y Reed valve gasket Assembly 5o1 Q’ty Remarks 1 4 1 1 1 ΘAssembling with sequence in reverse of disassembly. ϠWARNING: Using new gasket , the 4 Reed valve ass’y 5 Reed valve gasket gasket must aim at hole of reed valve. ϠWARNING: confirm no leaking of the reed valve and manifold. 5- 7 FUEL SYSTEM Disassembly of Fuel Tank z Disassembly of handle bar and front cover. Ϡ WARNING: ʳ ԦNo fire. ԦShall be wiped off when fuel overflowed. Operation / Parts Name Disassembly 1 Hex bolt 2 Clip 3 Fuel Tube Assembly 3o1 Q’ty Remarks 2 2 2 z Operating with sequence in reverse of disassembly. 5- 8 FUEL SYSTEM Replace Air filter z Disassembly of oil tank. z z Remove 2 Hex Bolt and move to the rear of the Air Cleaner Ass’y. Remove 3 Tapping Screw Truss Head Phillips. z z Remove Air Cleaner case cap. Replace new Air filter. Disassembly of Air Cleaner Ass’y z Disassembly of handle bar and front cover. z Disassembly of oil tank. Operation / Parts Name 1 2 3 4 5 Disassembly Air cleaner cover Air cleaner element Cleaner filter net Air cleaner case cap Cleaner guide pipe Assembly 5o1 Q’ty Remarks 1 1 1 1 1 z Operating with sequence in reverse of disassembly. 5- 9 REMOVE OF ENGINE Attention of Operation ΘOperation after disassembling the engine. ΩCrank shaft case ΩCrank shaft ΩExchange bearing of final transmission mechanisms. Disassembly of Engine ΘDisassembly of external cover of body. ΘDisassembly of throttle valve and cable. 1 3 11 2 5 1 6Ё 1 REMOVE OF ENGINE Operation / Parts Name 1 2 3 4 5 6 7 8 9 10 11 12 Disassembly Oil Tank Air Cleaner Ass’y Tail of Muffler ACG wire /wire of start motor Starter wire of carburetor Vacuum pressure tube Cap of spark plug Oil pump control cable Throttle cable Drive Sprocket Ass’y Hex washer face bolt of engine Engine Assembly 12o1 Q’ty Remarks 1 4WARNING: 1 The oil over-flow when remove the oil tube , so use clip or plug stop the seal. 1 2 1 1 1 1 1 1 ϠWARNING: 4 z Actually for brace the frame, avoid body turn inside out. 1 ϠWARNING: Carry out following adjusting after installation. ΩCable of throttle valve ΩOil pump control cable ΩRear break cable 6Ё 2 REMOVE OF ENGINE Disassembly of Muffler 1 2 3 4 5 6 Operation / Parts name Disassembly Q’ty Cotter pin Hex flange nut with serration Hex washer face bolt Silencer muffler Hex head Phillips bolt Exhaust pipe (front) 1 2 2 1 2 1 Assembly 6Ш˄ʳ Remarks • 2ͪ25 • 6mm • 6ͪ25 • Assembling with sequence in reverse of disassembly. 6Ё 3 CYLINDER HEAD / CYLINDER / PISTON Attention of Operation z z Can be operated when engine installed on vehicle. Must cleaning before operating, avoiding dust enter the engine. z z Remove the gasket dust stay on joint face. Avoid to use screw driver harm the joint face when remove the cylinder & z z cylinder head. Avoid to harm the cylinder inner surface and piston face. Cleaning before check parts, and smear motor oil appointed in sliding face before installing. Diagnosis of Troubles Low compression pressure , poor start , idle speed not stable z Air leakage of cylinder head gasket. z z Wear & damage the piston ring. Wrong installation of spark plug z z Wear & damage the cylinder and piston. Reed valve defect. Compression pressure too high, overheating, locking z Piling up carbon of cylinder head or piston head. Piston Noise z Wear the cylinder and piston. z Wear the piston pin hole and piston pin. z Wear the needle bearing of crank connecting rod (small end) . Piston ring noise z Wear or damage the piston ring. z Wear or damage the cylinder. 7Ё 1 CYLINDER HEAD / CYLINDER / PISTON Disassembly of Cylinder Head / Cylinder / Piston x Disassembly of cover x Disassembly of generator cover x Disassembly of muffler x Disassembly of spark plug cap 7Ё 2 CYLINDER HEAD / CYLINDER / PISTON Operation / Parts Name Q’ty Remarks Disassembly Cylinder head 1 Nut of cylinder head 2 Cylinder head 3 Cylinder head gasket Cylinder 4 ϠWARNING: Loosing nut 2-3 times. 1 1 4 Cylinder 5 Cylinder gasket 1 ϠWARNING: Don’t knock cooling fin. 1 ϠWARNING: Clean and not damage cylinder gasket of crank shaft case. Piston 6 7 8 9 10 Piston ring clip Piston pin Piston Piston ring needle bearing Assembly 10o1 2 1 1 2 1 ΘOperation with sequence in reverse of disassembly. Installation of Piston Ring ΘInstall top-piston ring & 2nd piston ring on piston. ΘDo not scratch piston and do not bend piston rings. ΘRemove carbon muck inside ring ditch and piston ring when not installed. ΘBe sure the rings rotate freely after install into piston. ϠWARNING: Change whole set of piston ring with genuine parts. 7Ё 3 Starter / Driving Disc / Clutch / Transmission Disc Attention of Operation z Don’t make greases stick to surface of transmission belt or belt plate. Otherwise , the efficiency of power transmission will be lowered by skid. Diagnosis of Trouble Vehicle does not move after engine start up z Drive belt wear-out z z z Drive face comp. damage Clutch lining wear-out Driven Ass’y spring defect Power insufficient z z Drive belt wear-out Driven Ass’y spring defect z z Drive face dirty or oily Weight roller wear-out 8-1 Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Left Crank Case Cover Operation / Parts name Disassembly 1 2 3 4 5 6 Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket Dowel pin Grommet Assembly 6Ш˄ Q’ty Remark 12 1 1 1 2 1 ΘOperation with sequence in reverse of disassembly. 8-2 Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Kick Starter z 1 2 3 4 5 6 7 8 9 Disassembly of left crank case cover. Operation / Parts name Disassembly Kick pinion spring clip Kick pinion Hex washer face bolt Kick crank External ring clamp Plain washer Starting shaft ass’y Starting shaft reset spring Bushing Q’ty 1 1 1 1 1 1 1 1 1 Remark ϠWARNING: Rotating pedal kick to crank and remove the case cover assembly. 8-3 Starter / Driving Disc / Clutch / Transmission Disc 9 8 7 6 5 4 3 2 1 Operation / Parts name Assembly Washer Starting shaft reset spring Starting shaft ass’y Plain washer External ring clamp Kick crank Hex washer face bolt Kick pinion Kick pinion spring clip Q’ty 1 1 1 1 1 1 1 1 1 Remark 4WARNING: Unable to install main shaft fix position when inside and outside reset spring overlap. Use flat-driver screw start from inside then outside spring and press main shaft. Installation of Kick Pinion / Kick Pinion Spring Clip ΘSet kick starter shaft first. ΘTurning starter, hang kick pinion spring clip on crank shaft case convex and assembly of kick pinion to the location of removing. ΘTurning starter, let starting shaft and kick pinion conjoin. Check of Starter ΘCheck the wear & damage of starting shaft or gear. ΘCheck the tightness & damage of starting shaft reset spring. ΘCheck the wear & damage of bush. 8-4 - Starter / Driving Disc / Clutch / Transmission Disc ΘCheck the wear & damage of kick pinion. ΘCheck the wear & damage of kick pinion spring clip. 8-5 - Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Left Crank Case 1 2 3 4 5 6 7 8 9 10 11 12 Operation / Parts name Disassembly Hex washer face bolt Cone spring washer One-way clutch gear Clamp washer Primary fixed sheave Bushing V-Belt Primary sliding slot wheel Oil ring Hex nut Clutch cover Drive face ass’y Assembly 12Ш˄ Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 Remark Ϡ.WARNING: Don’t damage transmission belt. ΘOperation with sequence in reverse of disassembly. 8-6 - Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Sliding Driving Disc Operation / Parts name Disassembly 1 2 3 4 Cam plate Cam plate slider Weight roller Primary sliding slot wheel Assembly 4Ш˄ Q’ty Remark 1 3 6 1 ΘOperation with sequence in reverse of separating. 8-7 - Starter / Driving Disc / Clutch / Transmission Disc Disassembly of Clutch / Transmission Belt Disc Operation / Parts name Disassembly Clutch 1 Nut 2 Clutch Weight Set Drive face ass’y 3 Axle ring of spring 4 Compression spring 5 Secondary spring seat 6 Guide pin 7 Secondary sliding slot wheel 8 Oil ring 9 Oil seal 10 Needle bearing 11 Internal circle clip 12 Radial ball bearing 13 Secondary fix slot wheel Assembly 13Ш˄ʳ Q’ty Remark 1 1 1 1 1 2 1 2 2 1 1 1 1 ΘOperation with sequence in reverse of separating. 8-8 Final Transmission Mechanism Attention of Operation z This chapter explain that final reduction mechanism maintenance can be operated in the vehicle. z Use professional tool to change driving shaft. Replace Transmission Gear Oil z z Remove 4 Hex Washer Face Bolt fixed on Floor Panel. Move forward the Floor Panel. z Remove Hex Washer Face Bolt and Copper Plain Washer. z z z Leak out oil Transmission Gear Oil. Fix Hex Washer Face bolt and Copper Plain Washer. Remove Oil Plug and add 80C.C. new Transmission Gear Oil. z z Fix Oil Plug. Recommend use grade SAE 90 or 85W-140 Gear Oil. Diagnosis of Trouble Engine starts but vehicle does not move. z Transmission gears broken. z Transmission gears burns out. Operate of noise z AbrasionΕwore and teeth hurted of gear z Bearing wore and loosened. Gear oil leaking z z Too much gear oil filled. Oil seal wear-out or damage. Reverse z Loose or damaged of bolt. z z Bad adjustment or defected of the link Ass’y. Bad adjustment or defected of the knuckle. 9Ё 1 Final Transmission Mechanism Disassembly of primary drive gear / final reduction mechanism z z Disassembly of Drive Sprocket Ass’y (Remove 1 Nylon Nut and 1 Plain Washer). Disassembly of clutch / drive face. ϠWARNING: First drain the oil of transmission. 1 2 3 4 5 6 7 8 9 10 Operation / Parts name Disassembly Bolt Mission cover Gasket Dowel pin Drive axle Main axle comp. Middle axle Gear shift arm Gear shift fork guide shaft Gear shift fork Assembly 10Ш˄ Q’ty 7 1 1 2 1 1 1 1 Remark z Check the wear & damage of shaft and gear. z Operation with sequence reverse of disassembly. in 9Ё 2 Final Transmission Mechanism Change the Driving Shaft z Remove the driving shaft from mission cover. ϠWARNING: Don’t damage joint face of mission cover. z Remove the oil seal of primary drive gear. z Remove the bearing. z Install the new bearing in the mission cover. 9Ё 3 Final Transmission Mechanism Assembly/Disassembly of reverse ʳ Operation / Parts name Disassembly reverse 1 Shift rod 2 Knob 3 Hex washer face bolt 6*22 Assembly 3Ш1 Q’ty Remarks 1 1 1 • Assembly with sequence in reverse of disassembly. 9Ё 4 Crank Case / Crank Shaft Attention of Operation z This chapter explain the necessary procedure of disassembling crank case due to repair & maintain the crank shaft. z Before disassembling of crank case , must operation with sequence of each chapter to disassembly. ΩDisassembly of oil pump ΩDisassembly of carburetor ΩDisassembly of intake valve ΩDis-mounting of engine ΩDisassembly of cylinder head and cylinder ΩDisassembly of ACG ΩDisassembly drive face ass’y z Must disassembly of final reduction mechanism when change the left crank case. z Must use special tool into the inner ring of crank shaft bearing , and pull in crank shaft to assembly when assembly crank case & crank shaft , put new bearing into crank case, and put into new oil seal after assembling crank case. Diagnosis of Troubles Noise of Engine z Damage of crankshaft bearing. z Damage of needle bearing of crankshaft pin. 10- 1 Crank Case / Crank Shaft Assembly / Disassembly of Crank Case 1 2 3 4 5 6 7 8 9 10 11 12 13 Operation / Parts name Disassembly Hex socket bolt Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing (Right) Radial ball bearing (Left) Hex socket bolt Oil seal bracket Right oil seal Left oil seal Radial ball bearing Assembly 13Ш˄ Q’ty Remark 6 1 2 1 2 1 2 1 1 1 1 1 2 10- 2 Crank Case / Crank Shaft separate the crank case, and never use the Disassembly of Crank Case z old oil seal. Install the puller on right crank case, separate the R. crank case and L. crank case. : Crank case puller (TLJT-03) z Install the puller on left crank case, remove the crank shaft from the crank case. : Crank case puller (TLJT-03) ϠWARNING: Don’t knock the crank shaft when disassembling. z Use the bearing puller to remove the crankshaft bearing from crank shaft, then remove the R/L crank case. : Bearing puller ( TLJT-00) ϠWARNING: Must remove the oil seal when Assembly of Crank Case z Clean the crank case with gasoline, and check each part whether damaged or cracked. ϠWARNING: z z Smear of oil on sliding surface of each shaft in crank case after checking. Cleaning the washer dust of joint face, and amend the part damage with oil stone. 10- 3 Crank Case / Crank Shaft z z Put new crank shaft into right crankcase. Put crank shaft assembly into left crank case. ϠWARNING: z Smear the 2-stroke oil to main bearing and big end of connecting rod. z Note the position of connecting rod. z Put left oil seal into L. crank shaft case, surface depth under 1.0 mm. 10- 4 Crank Case / Crank Shaft Assembly of Crank Case z z Install the dowel pins in the joint face of left crank case. ΘInstall the right crank case. : Bearing puller (TLJT-00) z Install the new R. oil seal to crank case. : Bearing puller (TLJT-00) 10- 5 Front Wheel Attention of Operation ΘRemove the body cover and support the frame body bottom before remove the front wheel, don’t invert the front wheel when front wheel depart ground. Diagnosis of Trouble Steering handle not straight x Loose, not correct adjustment or damaged, right (or left) link Ass’y. x Steering shaft bended. x x Suspension arm, knuckle damaged. Rim damaged. Heavy steering movement x x Air pressure too low inside of front tire. Rim radial ball bearing broken. Brake efficiency abnormal Front wheel shaking or deviation x Brake lining wear-out. x Front rim defected. x Brake pads adjust not correct or wear out. x Loose or damaged of front rim bearings. x x Brake drum wear-out. Tire wear-out. x x Tire defect. Bad adjustment or defected of the right (or left) link Ass’y. x Bad adjustment or defected of the right (or left) knuckle. 11- 1 FRONT WHEEL/FRONT SUSPENSION/ FRONT BRAKE Disassembly of Front Wheels Operation / Parts name Disassembly front wheels (L/R) 1 2 3 4 Rubber cover Cotter pin Scotch nut Plain washer 12*40*4.5 Q’ty Remarks 2 2 2 2 Disassembly front brake drum 5 6 7 8 Hex washer face bolt Front coller Front brake drum Rim Assembly front brake drumʳ ˋШˈʳ Assembly wheels ˇШ˄ 8 2 2 2 y Assembling with sequence in reverse of disassembly. ϠWARNING: Change the R/L bearing set if necessary. 11- 2 FRONT WHEEL/FRONT SUSPENSION/ FRONT BRAKE Disassembly of Front Brake Operation / Parts name Disassembly brake plate 1 Handle bar 2 Release adjustment screws 3 Release front (left or right) wheel Ass’y 4 Strain spring 5 Front brake shoe Comp. 6 Release brake cables 7 Front brake panels Assembly 7Ш1ʳ Q’ty Remarks 1 2 2 2 2 2 2 y Assembling with sequence in reverse of disassembly. 11- 3 FRONT WHEEL/FRONT SUSPENSION/ FRONT BRAKE Disassembly of Suspension Arm Operation / Parts name Disassembly (L/R) 1 2 3 4 5 6 Hex bolt Hex flange nut with serration Release front cushions Hex flange nut with serration Hex washer face bolt Suspension arms Assembly 6Ш1 Q’ty Remarks 2 2 2 4 4 2 y Assembling with sequence in reverse of disassembly. 11- 4 FRONT WHEEL/FRONT SUSPENSION/ FRONT BRAKE Disassembly of Steering Shaft Ass’y 1 1 2 3 4 5 6 7 8 9 10 11 12 Operation / Parts name Q’ty Remarks Disassembly steering shaft Ass’y Handle bar A’ssy 1 Hex flange nut with serration 2 Steering shaft holder 2 Holder spacer coller 2 Hex flange nut with serration 2 Release Ball joint, left (right) thread 1 Steering shaft Ass’y 1 1 Disassembly knuckles Cotter pin 2 Hex flange nut with serration 2 Left & right link Ass’y 2 Scotch flange nut 2 Left & right knuckle 2 y Assembling with sequence in reverse of Assembly knuckles disassembly. 12Шˋʳ ϠWARNING: Adjusting gap of throttle. Aassembly steering shaft Ass’y 7Ш˄ 11- 5 11- 6 REAR WHEEL / SUSPENSION / BRAKE Diagnosis of Troubles Rear wheel shaking or deviation z The shape of rear rim damaged. z Rear wheel axle damaged. z z Swing arm sub Ass’y damaged Rear rim bearing defected. Rear suspension too soft z Spring too soft or adjust not correct. Brake efficiency abnormal z Brake lining wear-out. z Brake pads adjust not correct or wear out. z z Brake drum wear-out. Tire wear-out. 12- 1 REAR WHEEL / SUSPENSION / BRAKE Assembly/Disassembly Rear Wheel of Operation / Parts name Disassembly (L/R) 1 2 3 4 5 6 7 8 9 Rubber cover Cotter pin Scotch nut Plain washer 14*40*4.5 Take off the wheel Ass’y Hex washer face bolt Take off shaft connector Rim Tire Assembly 9Ш˄ Q’ty Remarks 2 2 2 2 2 8 2 2 2 z Assembling with sequence in reverse of disassembly. 12- 2 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of Rear Brake, Rear wheel axle and Brake panel 1 8 1 2 3 4 5 6 7 Operation / Parts name Disassembly Rear Brake Left rear wheel Ass’y Left spacer collar Hex washer face bolt Rear drum cover Rear drum cover gasket Rear drum Rear brake shoe Comp. 8 9 10 11 Disassembly Rear wheel axle Right rear wheel Ass’y Right spacer collar Rear sprocket Ass’y Take off rear wheel axle 1 1 1 1 12 13 14 15 16 17 Disassembly Rear Brake Panel Hex flange nut with serration Rear brake cable Hex washer face bolt 12*27 Plain washer Hex washer face bolt 12*22 Rear brake panel 2 1 2 1 2 1 Assembly Rear break 7Ш1 Rear wheel axle 11Шˋ Rear break panel 17Ш12 Q’ty Remarks 1 1 6 1 1 1 1 z Assembly with sequence in reverse of disassembly. 12- 3 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of Rear Brake, Rear wheel axle and Brake panel 1 2 3 4 5 6 7 Operation / Parts name Disassembly Rear Brake Left rear wheel Ass’y Left spacer collar Hex washer face bolt Rear drum cover Rear drum cover gasket Rear drum Rear brake shoe Comp. 8 9 10 11 Disassembly Rear wheel axle Right rear wheel Ass’y Right spacer collar Rear sprocket Ass’y Take off rear wheel axle 12 13 14 15 16 17 18 Disassembly Rear Brake Panel Hex flange nut with serration Rear brake cable Hex washer face bolt 12*27 Plain washer Hex washer face bolt 12*22 Plain washer Rear brake panel Assembly Rear break 7Ш1 Rear wheel axle 11Шˋ Rear break panel 18Ш12 Q’ty Remarks 1 1 6 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 y Assembly with sequence in reverse of disassembly. 12- 4 REAR WHEEL / SUSPENSION / BRAKE Disassembly / Assembly of Swing arm sub Ass’y 1 1 2 3 4 5 6 7 Operation / Parts name Disassembly Swing arm sub Ass’y Rear brake panel Ass’y Nut Bush Swing arm spacer Oil-ring Swing arm bolt Swing arm sub ass’y Assembly 7Ш1 Q’ty Remarks 1 2 4 2 4 2 1 z Assembly with sequence in reverse of disassembly. 12- 5 REAR WHEEL / SUSPENSION / BRAKE Assembly/Disassembly of Front & Rear Cushion ʳ 1 2 3 4 Operation / Parts name Disassembly Front Cushion Hex washer face bolt Hex flange nut with serration Hex bolt Front cushion Disassembly Rear cushion 5 Hex washer face bolt 6 Rear cushion Assembly Front cushion 4Ш1 Rear cushion 6Ш5 Q’ty Remarks 2 4 2 2 2 1 • Assembly with sequence in reverse of disassembly. 12- 6 ELECTRICAL DEVICE Attention of Operation ϠʳBattery electrolyte contains sulfuric acid, which can cause severe burns. Avoid contact of skin, eyes, or clothing ϠʳWhen sulfuric acid water spill into clothing will stick to skin. Take off the clothing and flush with water. z Battery can be charged and discharged. Without charging, the battery will have less lifetime. z If the battery have short circuit inside, both terminal will not have voltage existed. z Besides, the regulator rectifier lost the function and shorter lifetime. If the battery stay too long without use, it will lost power and have less capacity. The battery need to charge each 2~3 months. z After fill up the electrolyte, the new battery will generate voltage. It’s necessary to recharge if the voltage is low. It’s necessary to leave the battery for more than 20 minutes before sealing the cap. It will increase the lifetime of new battery if recharged before installed. z Do not unplug the electrical components from wire hardness when the current is working. This will cause too high of voltage and damage other compounds such as rectifier, light bulbs…etc. Turn off the main switch to OFF before the operation. z z z The Maintenance Free battery does not need to refill electrolyte or water. All charge system needs to be installed before check. Do not use quick charge unless it’s in urgent. z z The battery needs to be taking out from vehicle when doing charge work. When checking the voltage, must use the electrical meter. 13- 1 ELECTRICAL DEVICE Diagnosis of troubles No Electrical Power No Continues Current x Over discharged of the battery x x Wire hardness did not connected to the battery Bad contact of battery with main wire hardness x Bad connection of charge system x Bad contact of the lighting system cause short circuit x x Fuse broken Main switch defect Low Voltage Charge System no function x x Battery charges insufficient Bad connection x Bad connection of the wire hardness connectors x x Charge system defect Regulator rectifier defect x Main wire hardness broken or short-circuit x Regulator rectifier defect x x AC Generator defect Fuse broken 13- 2 ELECTRICAL DEVICE Wiring Diagram (҈ʼ 13- 3 ELECTRICAL DEVICE Wiring Diagram (ҋ) MAIN SWITCH ASS’Y HEAD LIGHT ASS’Y 13- 4 ELECTRICAL DEVICE Disassembly Of Battery Operation / Parts name Disassembly 1 2 3 4 5 Release seat Remove rubber cap Battery Фʳ end Battery end Battery Assembly 5Ш˄ʳ 2 Battery terminal Q’ty 1 2 1 1 1 Remarks *WARNING: Disassembly battery from Ф end to end. • Assembling with sequence in reverse of disassembly. *WARNING: Connect end first, next Ф end , both terminals with caps. 13- 5 ELECTRICAL DEVICE Check Voltage of Battery z Remove seat and battery cap , disassembly connection wires of battery , check voltage between battery terminals. Уterminal Charging sufficiently: over 12.8 V Charging insufficiently: 11.5-12.8V 4WARNING: Must check battery voltage with digital voltmeter. \terminal Check Charging System Power leakage test z Disassembly ground guide wire from battery after turning “OFF ” main switch, next connect voltmeter to the end between terminal (Ωʼ & ground z guide wires. Check voltage when main switch is “OFF ”. 4WARNING: z Check voltage according to sequence from big to small. z z Voltmeter’s fuse will be broke when check voltage over the limitation chose. Don’t turn “ON” main switch when check current. Current Leakage: over 1 mA 13- 6 ELECTRICAL DEVICE Check Charging Status 4WARNING: z ˖harging status will change voltage z hugely, check battery voltage after battery charged completely, over 12.8 V. ˦̇˴̅̇ʳ˸́˺˼́˸ʳ̊˼˿˿ʳconsume a lot power of battery. z Assembly voltmeter to terminal of main fuse, start engine, open light, rise running amount and check charging voltage & current. Charging current: 1̑2 Amp/5000rpm Voltage of charging control: 14~15V/5000rpm Check Voltage of Head Light 4WARNING: Check head light which wires connecting. z Start engine, turn “ON“ light switch, open high beam. z Check voltage between green (+) & black (-) guide wires. z Control Voltage: 11~14V.AC/5000rpm 13- 7 ELECTRICAL DEVICE Terminal of connector ϠWARNING: Check in range of AC. Check Regulator rectifier when voltage is not in the range controlling. Control voltage: 12~14V/5000rpm regulator Check the Rectifier ΘCheck the rectifier. ΘDisassembly connector of rectifier. ΘCheck the terminal of connector. Disassembly of ACG 13- 8 ELECTRICAL DEVICE Operation / Parts name Disassembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Hexagon socket bolt Plain washer Self-tapping screw Generator Cover Hexagon socket bolt Plain washer Fan Hexagon nut Spring washer Plain washer Fly wheel of generator Semi-cycle key A.C.G base Hex socket bolt Assembly 14Ш˄ʳ Q’ty 2 2 1 1 4 1 1 1 1 1 1 1 1 2 Remarks 4WARNING: Beware not to damage the coil. ΘAssembling with sequence in reverse of disassembly. ACG (Charging Coil) Check ϠWARNING: Checking in the engine connected With start motor. z Disassembly ACG connection. z Check resistance of charging wire z & lighting wire. Connect Black and Black/Red Wire z then check resistance. Standard Resistance: 470~670Ө 13- 9 ELECTRICAL DEVICE Ignition Coil Disassembly ΘDisassembly spark plug cap. ΘSeparating cable, disassembling bolt, and disassembly ignition coil. Assembly ΘAssembly with sequence in reverse of disassembly. Conduction Test ΘCheck first coil resistance of ignition terminal. Standard valve (20к): 0.3̑˃ˁˈӨʳ ʳ ϠWARNING: Check ignition status with performance tester due to this test has its own standard. ΘCheck second coil resistance between spark plug cap & (-) terminal. Standard valve : 9.5̑˄˄ʳ˾Өʳ ʳ ʳ ʻ̆̃˴̅˾ʳ̃˿̈˺ʳ˶˴̃ʳ˼́̆̇˴˿˿˸˷ʼʳ ΘRemove spark plug cap from high tension coil. ΘCheck second coil resistance between high voltage & (-) terminal. Standard valve : 5̑ˊʳ˾Өʳ (without spark plug cap) 13- 10 ELECTRICAL DEVICE Assembly / Separation of Starting Motor Θʳ Disassembly of starting motor. Operation / Parts name Separation 1 2 3 4 5 6 7 Bolt set Casing Armature rotor Carbon brash Oil ring Oil ring Front fixed seat Assembly 7Ш˄ Q’ty Remarks 2 1 1 2 1 1 1 ΘAssembling with sequence in reverse of disassembly. 13- 11 ELECTRICAL DEVICE Check Main Switch ΘRemove connector of main switch wire, check conductivity between each terminal. Color Bk/W Bk OFF Ϥ Ϥ BR R ON Ϥ Ϥ Light Ϥ Ϥ BL YL/R Ϥ Ϥ Remove main switch ΘDisconnect main switch wire. ΘPull the main switch Bracket inside front cover. ΘPush the stopper on main switch underneath front cover then push out the main switch. Check safety switch Remove the connector of safety switch, check conductivity between terminal. Bk/R Color Bk/R Cap On Ϥ Ϥ Cap Off 13- 12 ELECTRICAL DEVICE Switch of Lights Color Yellow/red Blue OFF ON Ϥ Ϥ Color blue/white Black Up Down Ϥ Ϥ Start Switch Exchange of Bulbs Head light bulb z Remove handle bar and front cover z Press down the bulb base and turn left to change head light bulb. 13- 13 ELECTRICAL DEVICE Rear light bulb / Brake light bulb / Rear direction light bulb ΘRemove 2 screws, pull out the light cover then change bulb. ΘRemove R/L screw on direction light Cover, pull out the cover then replace the bulb. 13- 14
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Key Features
- High power engine
- 2-stroke, single cylinder
- Automatic transmission (C.V.T. V-belt)
- Kick & electric start
- Front & rear disc brakes
- Oil-damped suspension
- Maintenance-free battery
Frequently Answers and Questions
What type of oil should I use for the ATV-50/100R engine?
Use a good grade of oil that is specially formulated for two-stroke engines, synthetic type is recommended. HC recommends SAE 30.
What kind of gear oil should I use for the ATV-50/100R transmission?
Use multi-grade motor oil of SAE 90 or 85W-140.
What is the break-in procedure for the ATV-50/100R?
Pre-mix the first four tanks of fuel with two-stroke engine oil at 30:1 ratio. Do not operate the ATV at more than half throttle for the first three hours. During the break-in period (the first four tanks of fuel), operate the vehicle at various RPM’s and do not operate the vehicle above half throttle for extended periods.
What should I do if the engine is overheating?
Poor synchronizing adjustment of oil pump (too much exhaust gas). Bad quality of engine oil.
What should I do if the ATV does not move after the engine starts?
Drive belt wear-out, Drive face comp. damage, Clutch lining wear-out, Driven Ass’y spring defect.