TGB Blade 250 Service Manual - [PDF Document] (2023)

250 points

Service manual

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This maintenance manual contains the technical maintenance data for each part of the BLADE 250 ATV, with photos and text, focusing on "maintenance procedures", "operation points" and "inspection and adjustment", providing service instructions for technicians.

If the style and construction of the ATV BLADE 250 differs from the photographs, images shown in this brochure, the actual vehicle will prevail. Specifications are subject to change without notice.

service department

Taiwan Golden Bee Co., Ltd.

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HOW TO USE THIS MANUAL This service manual describes the various system components of your BLADE 250 ATV and basic system inspection and service information. In addition, when checking and adjusting, check the manual content of the model you are repairing in detail.

Chapter 1 provides general information and troubleshooting. Chapter 2 includes service maintenance information and special tool manuals. Chapters 3 through 11 describe the engine and drivetrain. Chapter 12 refers to the cooling system. Chapters 13 through 16 cover the assembly of the support frame body components. Chapter 17 deals with electrical equipment. Chapter 18 is the wiring diagram. See the catalog for quick access to specific components and system information.

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Page content index

1-1 ~ 1-18 General Information 1

2-1 ~ 2-14 Service and maintenance information 2

3-1 ~ 3-8 Lubrication system 3

4-1 ~ 4-12 Fuel system 4

5-1 ~ 5-6 Engine removal 5

6-1 ~ 6-16 Cylinder head/valve 6

7-1 ~ 7-8 Cylinder/piston 7

8-1 ~ 8-14 "V" belt drive system / starting 8

9-1 ~ 9-12 Final Drive 9 10-1 ~ 10-10 Generator 10

11-1 ~ 11-8 Crankshaft/Crankcase 11

13-1 ~ 13-9 Body Cover 13

14-1 ~ 14-14 Front brake and front wheel 14

15-1 ~ 15-10 Steering/Front Suspension 15

16-1 ~ 16-18 Rear brake/rear wheel/rear buffer 16

17-1 ~ 17-22 Electrical Equipment 17

18-1 ~ 18-2 Wiring Diagram 18

serial number

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number of frames

machine number

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1. General information

Symbols and Markings................................... 1-1

General Security ................................................ ..... ...... 1-2

Maintenance Precautions................................... 1-3

Determination................................................. .. 1-9 Symbols and signs

Standards................................................. 1-10 1

Torque Values................................... 1-11 Troubleshooting... .. .. ... ............................................. 1- 13 Lubrication points ................................................ ........................................ 1-18

The symbols and signs used in this manual indicate the contents and locations that require special services, and if additional information about these symbols and signs is required, explanations will be added to the text instead of using these symbols or signs.

warn

This means that serious injury or even death can result if procedures are not followed.

CAUTION indicates that equipment damage may occur if procedures are not followed.

lubricant

Restrictions on the use of SAE 10W-30 API Grade SG oil. The warranty does not cover damage caused by failure to use restricted oil.

(Recommended engine oil: KING MATE G-3 engine oil)

King Mate G-3 grease is recommended.

Lubricant

Sealer

Recommended range of King Mate gear oils. (Bramax oil for subspecialty gears

#140) Apply sealant, unless otherwise specified medium strength sealant should be used.

Oil Sealing Apply lubricant.

Update Replace with new parts before installation.

Brake fluid Use DOT3 recommended brake fluid or WELLRUN brake fluid.

special tools special tools

Correct Meaning It has been installed correctly.

Wrong concept Wrong installation.

Instructions for accessories.

Directions indicate location and direction of operation

The components are assembled together.

Indicates the direction of bolt installation, --- indicates that the bolt passes through the component (not visible)

1-1

in this chapter

1. General Information General Safety

Carbon Monoxide If you must run the engine, make sure the area is well ventilated. Never run the engine in an enclosed space. Run the engine in an open area, and if you must run the engine indoors, be sure to use an exhaust fan.

warn

Exhaust gases contain toxic gases that can cause unconsciousness or even death.

Gasoline Gasoline is an explosive substance with a low flash point. Work in a well-ventilated area without flames and sparks in the workplace or where gasoline is stored.

warn

Gasoline is highly flammable and can explode under certain conditions, keep out of reach of children.

used oil

warn

Prolonged exposure to used engine oil (or transmission fluid) may cause skin cancer, although this may not be proven. We recommend that you wash your hands with soap and water immediately after contact. Keep used oil out of the reach of children.

heating element

warn

With the engine running, engine and exhaust system components can become very hot. Even after stopping the engine for a while, they are still hot. Wear insulated gloves and wait for them to cool while performing repair work on these parts.

Battery

CAUTION • Batteries emit explosive gases, flames are strictly prohibited

forbid. Keep the battery well ventilated when charging the battery.

• Batteries contain sulfuric acid (electrolyte) which can cause severe burns, so be careful not to spray it in your eyes or skin. If battery acid gets on your skin, wash it off immediately with water. If battery acid gets into your eyes, flush them immediately with water and go to the hospital to see an ophthalmologist.

• If swallowed, drink plenty of water or milk, take laxatives such as castor oil or vegetable oil and seek medical help.

• Keep the electrolyte solution out of the reach of children. Brake shoes Do not use an air hose or a dry brush to clean the brake system components, use a vacuum cleaner or similar device to keep the dust from flying.

warn

Breathing in brake pad or shoe dust can cause respiratory disease and cancer. brake fluid.

CAUTION Brake fluid splashed on painted, plastic or rubber parts can damage components. When servicing the brake system, place a clean towel over the above mentioned parts to protect them. Keep brake fluid out of the reach of children.

1-2

in this chapter

1. GENERAL INFORMATION SERVICE PRECAUTIONS Always use genuine SANYANG spare parts and

recommended oil. USING PARTS NOT DESIGNED FOR SANYANG ATVS MAY DAMAGE THE ATV.

Special tools are designed to remove and

Install parts without damaging the part you are working on. Using the wrong tools can damage components.

Use only metric tools when servicing this ATV. Metric bolts, nuts and screws are not interchangeable with the imperial system and using the wrong tools and fasteners can damage this vehicle.

Clean the outside of any parts or covers before removing them from the ATV. Otherwise, dirt and deposits accumulated on the surface of the components can fall into the engine, chassis or brake system and cause damage.

Wash and clean parts with high flash point solvent and dry with compressed air. Pay particular attention to O-rings or oil seals as most cleaners will affect them adversely.

Never bend or kink the control cables to avoid them

Irregular control and premature wear.

Rubber parts wear out over time,

And it is easily destroyed by solvents and oils. Check these parts before installation to make sure they are in good condition and replace them if necessary.

When loosening components with different sized fasteners, work diagonally from the inside out. Loosen the small fasteners first. If the larger fastener loosens first, the smaller fastener may be overstressed.

Store complex assemblies, such as powertrain components, in the correct assembly order and connect them for future installation.

Mark important reassembly locations

Check components before disassembly to ensure they will be reassembled with the correct dimensions (depth, distance or position).

Non-reusable parts must be replaced when disassembled, including gaskets, metal sealing rings, O-rings, oil seals, circlips and pins.

1-3

in this chapter

1. General information Bolt and screw lengths for assembly,

Covers or boxes vary, make sure they fit correctly. In case of confusion, insert the bolt into the hole, compare its length with the other bolts, if it comes out of the hole the same length as the other bolts, it is the correct bolt. Bolts of the same part must be the same length.

Narrow sleeves of different sizes

The fasteners are as follows: Tighten all the fasteners with your fingers, then use a special tool to first tighten the large fasteners diagonally from the inside to the outside, and the important parts should be tightened 2-3 times and increase appropriately to avoid distortion unless otherwise specified. Screws and fasteners must be kept clean and dry. Do not oil the threads.

When installing the oil seal, fill the groove with grease, put the oil seal manufacturer's name on the outside, and check that the shaft on which the oil seal is installed is smooth and free of burrs that may damage the oil seal.

Remove any old gaskets or sealant residue.

Before reinstallation, if the contact surface is damaged, it should be polished with a stone.

The end of the rubber hose (for fuel, vacuum or

coolant) should be pushed into the connection as far as possible so that there is enough space under the enlarged end for the clamp to tighten.

Groove clamp plug

Rubber and plastic boots must be correct

Place back in the original correct position as designed.

The launcher must be pressed on both (inside)

and outer) grooves when removing bearings. Damage may occur if the tool presses only one race (inside or outside). In this case, the bearing must be replaced. To avoid damaging the bearings, use equal force on both races.

manufacturer name

1-4

Both of these examples can lead to bearing damage.

in this chapter

1. General information Lubricate the rotating surfaces with lubricant

Lubricate lubrication points before assembly.

Check that the installation location and operation are correct

The parts are correct and correct.

When you make sure the services are safe from each other

Driving two people.

Just make sure the pieces don't fall.

After completing the service, make sure that everything

The connection point is secure. The positive (+) battery cable must be connected first.

The two battery posts should be greased after connecting the cables.

Make sure the battery terminal cover

Correct placement after battery terminal repair.

If a fuse blows, you need to find out why and

solve. Then replace the fuse with the specified capacity.

Before removing the battery, you must

First remove the negative (-) battery cable. Other tools, such as open-end wrenches, etc., should not come into contact with the body, so as not to cause short circuits and sparks.

capacity control

1-5

in this chapter

1. General information When separating a plug, its box must be

Unlock first. Then perform service operations.

Do not pull on the cable as you would remove the connector.

or cables. Hold the connector body.

Make sure the connecting pins are bent,

tighten or loosen

Insert the plug fully.

If there are two cabinets on either side of the plug, make sure the cabinets are closed. Check for loose wires.

Check if the link is covered by the twin.

The connector guides are fully and correctly seated.

Before connecting the terminal, check whether the boot is normal

Cracks or loose terminals.

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Enter the terminal fully.

Check that the terminal is not covered by the trunk. Do not leave the trunk open.

Attach the wires and harness to the frame

Use the corresponding tape in the specified position. Pull the strap taut so that only the insulating surface is in contact with the wire or braid.

Cable ties and cable straps must

properly fastened.

Do not squeeze the wires between the solder or

clamp.

in this chapter

1. General information Keep the wiring harness away from

Moving or vibrating components such as harness routing.

Keep wiring away from heat sources

part.

never touch

Route the wiring harness to avoid sharp edges or

At the corners, also avoid protruding ends of bolts and screws.

Guide the belts so they are not pulled too tight

Not too loose.

Wire or cable protection

Use tape or tubing if they come into contact with sharp edges or corners. Thoroughly clean the surface to which the tape will be applied.

Attach the rubber boots to

wiring

Do not use insulated cables or straps

Lost. Wrap electrical tape around damaged parts or replace them.

Never hold or squeeze the wiring

Install other components.

Never hold or squeeze the wiring

never too tight

1-7

in this chapter

1. General information Do not twist the wiring

Setting up.

Wiring routed along handlebar

In all steering positions, it should not be excessively tightened or loosened, rub or interfere with adjacent or surrounding parts.

Before operating the test equipment, the operator

You should read the instrument's operating manual. Then follow the instructions to try it out.

Clean the oxide layer of the connector with sandpaper

Pin/Terminal (if found). Do the login later.

pure rust

Do you know how to set up the instrument in your measuring position and where your two probes are inserted?

1-8

in this chapter

1. General Information Specifications

Manufacturer TGB Model UA25A

Front arms total length 2160 mm

Total anchor 1160 mm

pause

Rear drive system shock absorber

Overall height 1175 mm front AT22x7-10 (on the highway)

Wheelbase 1300mm

AT22x10-10 rear tire specifications (road use)

Aluminum front wheels with 940 mm rims

Front and rear discs 890 mm (Ø 180 mm)

Front brake system 137 kg

Trasero disc (Ø 220 mm)

Rear maximum 118 kg. Speed over 86 km/h curb weight

Total weight 255 kg

Scalability less than 25?

Passengers/weight 2 people/150 kg

179 kg before

main reset zone

Back 244 kg

Wei

fight

darkness

exists

gross weight

Total weight 423 kg

Secondary reducer/gear

Type 4-stroke engine clutch Centrifugal, dry Positioning and arrangement

vertical, below center, oblique

restrict

Gearbox C.V.T., automatic gear change

Fuel used for unleaded speedometer above 92 0 ~ 300 km/h

Cycle/four-stroke cooling/water-cooled horn 93~112dB/A

Diameter Ø71 mm muffler extension and pulse type

63 mm travel Exhaust pipe position and orientation

left upside down C

more than

Quantity/Layout Single Cylinder Lubrication System

Force loop and splash

Displacement 249.4 cc solids

Compression ratio 10.5 : 1 CO less than 7.0 g/km

Max HP 14.7 kw / 6500 rpm HC less than 1.5 g/km

upper limit. Torque 23.5 Nm / 5500 rpm

August

scam

cent

relationship

North

NOx below 0.4 g/km

Encendido C.D.I Central and Eastern Europe.

Starting system Electric starter P.C.V.

ING

internal line

Catalytic reaction control system with air filter sponge

1-9

in this chapter

1. General Information Specifications

Manufacturer TGB Model UA25C

Front arms total length 2160 mm

Total anchor 1160 mm

pause

Rear drive system shock absorber

Overall height 1205 mm front AT25x8-12 (on the highway)

Wheelbase 1300mm

Rear Tire Specifications AT25x10-12 (Road)

Aluminum front wheels with 940 mm rims

Front and rear discs 890 mm (Ø 180 mm)

145 kg front brake system

Trasero disc (Ø 220 mm)

Rear maximum 129 kg. Speed over 86 km/h curb weight

Total weight 274 kg

Scalability less than 25?

Passengers/weight 2 people/150 kg

186 kg before

main reset zone

Back 256 kg

Wei

fight

darkness

exists

gross weight

Total weight 442 kg

Secondary reducer/gear

Type 4-stroke engine clutch Centrifugal, dry Positioning and arrangement

vertical, below center, oblique

restrict

Gearbox C.V.T., automatic gear change

Fuel used for unleaded speedometer above 92 0 ~ 300 km/h

Cycle/four-stroke cooling/water-cooled horn 93~112dB/A

Diameter Ø71 mm muffler extension and pulse type

63 mm travel Exhaust pipe position and orientation

left upside down C

more than

Quantity/Layout Single Cylinder Lubrication System

Force loop and splash

Displacement 249.4 cc solids

Compression ratio 10.5 : 1 CO less than 7.0 g/km

Max HP 14.7 kw / 6500 rpm HC less than 1.5 g/km

upper limit. Torque 23.5 Nm / 5500 rpm

August

scam

cent

relationship

North

NOx below 0.4 g/km

Encendido C.D.I Central and Eastern Europe.

Starting system Electric starter P.C.V.

ING

internal line

Catalytic reaction control system with air filter sponge

1-10

in this chapter

1. General information Torque values

The torque values listed in the table above refer to the most important tightening torque values. For those not listed in the table, please refer to the standard price.

Typical torque value for reference

Type Tightening torque Type Tightening torque

5 mm bolt, nut 0.45~0.6 kgf-m 5 mm bolt, 0.35~0.5 kgf-m 6 mm bolt, nut 0.8~1.2 kgf-m 6 mm bolt, SH nut 0.7~1.1 kgf-m 8 mm bolt, 1.8~ 2.5 kgf-m 6 mm bolt, nut 1.0 ~ 1.4 kgf-m 10 mm, nut 3.0 ~ 4.0 kgf-m 8 mm, nut 2.4 ~ 3.0 kgf-m 12 mm bolt, nut 5.0 ~ 6.0 kgf-m1 mm Bolts and nuts 3.5~ 4.5kgf-m

Motor torque value

Item Quantity Thread Diameter (mm) Torque Value (kgf-m) Remarks

Cylindrical nail 4 10 1.0~1.4

Cylinder head nut 4 8 3.6~4.0

Right cylinder head bolt 2 8 2.0~2.4

Cylinder head side cover bolts 2 6 1.0~1.4

Cylinder head cover bolts 4 6 1.0~1.4

Cylinder head spark plug (intake pipe) 2 6 1.0~1.4

Cylinder head bracket (explosion tube) 2 8 2.4~3.0

Gas injection pipe bolt 4 6 1.0~1.4

Reed jet valve bolt 2 3 0.07~0.09

Faucet adjusting nut 4 5 0.7~1.1 Threaded lubrication

Spark plug 1 10 1.0~1.2

Tensioner lift bolt 2 6 1.0~1.4

Carburetor insulation bolt 2 6 0.7~1.1

Oil pump bolt 2 3 0.1~0.3

Water pump impeller 1 7 1.0~1.4

Left cover bolt 9 6 1.1~1.5

Engine oil drain bolt 1 12 3.5~4.5

Oil filter plug 1 30 1.3~1.7

Send 1 drain bolt 8 1.1~1.5

Work filler bolt 1 12 3.5~4.5

Shift drum fixing bolt 1 14 3.5~4.5

Clutch drive plate nut 1 28 5.0~6.0

Clutch outer nut 1 14 5.0~6.0

Drive face nut 1 14 8.5~10.5

two dimensional. Flywheel nut 1 14 5.0~6.0

Crankcase Bolts 7 6 0.8~1.2

Lab bolt 7 8 2.6~3.0

1-11

in this chapter

1. General information Frame torque values

Item Quantity Thread Diameter (mm) Torque Value (kgf-m) Remarks

Steering wheel mounting screw 4 6 2.40

Steering axle nut 1 10 5.00

Rod Nut 4 10 5.00

Hinge nut 2 10 5.00

Steering shaft support bolt 2 8 3.40

Rod Lock Nut 4 10 3.60

Handlebar under mounting nut 2 8 4.00

Front wheel nut 8 10 2.40

Channel nut, front axle 2 14 5.00

Rear axle channel nut 2 14 5.00

Rear wheel nut 8 10 2.40

Engine mount nut 4 12 8.50

Rear axle support bolt 4 12 9.20

Drive screw 2 10 4.6

Drive nut 4 10 4.6

Scissor rotation screw 1 14 9.20

Front Suspension Arm Nut 4 10 5.00

Front and rear shock absorber mounting bolts 6 10 4.60

Brake Lever Nut 2 6 1.00

Brake oil pipe screw 13 10 3.50

Brake caliper bolt 6 6 3.25

Brake disc fixing bolts 11 8 4.25

Exhaust valve 3 5 0.50

Muffler mounting bolts 2 8 3.00

Muffler connection nut 2 7 1.20 1-12

in this chapter

1. General information Troubleshooting

A. Engine difficulty or failure to start

Check and set error status Possible cause

Loosen the carburetor oil drain bolt and check for gasoline in the carburetor.

Sufficient fuel supply to carburetor

Remove the spark plug, place it in the spark plug cap, and test the effect of the spark on the engine ground.

No fuel is supplied to the carburetor

No fuel in tank Check line from tank to carburetor

and the intake gap is blocked. Clogged float valve oil tank exhaust pipe

Blocked system Defective fuel pump Loose or damaged fuel pump

Suction hose Clogged fuel filter Faulty spark plug Faulty spark plug

Check spark Weak spark, no spark

Perform a cylinder compression pressure test.

Defective CDI assembly Defective alternator Open or shorted ignition coil Open or shorted ignition coil wire Defective main switch

Normal cylinder compression pressure

Follow the boot process to reboot

low or no compression pressure

Worn piston rings Faulty cylinder valves Worn cylinder and piston rings Leaking cylinder gaskets Sand holes in compression fittings

Failure Some signs of ignition, engine not starting

Throttle valve failure Air drawn into intake manifold Improper ignition timing

Remove the spark plug again and check.

Dry plug Wet plug

Carburetor oil level too high Throttle valve failure Throttle valve opening too wide

After 30 minutes remove the carburetor and connect the hose to the rich oil circuit. Then blow the hose with air

normal hit blocked hit

autostart failure

1-13

in this chapter

1. General information

B. Engine runs slowly (speed does not increase and power is insufficient)

Check and set error status Possible cause

Try the gradual acceleration and check the engine speed

Engine speed can be increased.

Check ignition timing (use ignition light)

The engine speed cannot be increased.

Air filter is clogged, oil supply is not smooth, fuel tank line is vaporized

Clogged system Clogged exhaust pipe Clogged fuel nozzle in carburettor. The fuel nozzle in the carburetor is blocked.

Correct ignition timing Incorrect ignition timing

CDI Faulty Alternator Faulty

Check cylinder compression pressure (use a compression gauge)

correct compression pressure

Check for clogged carb jets

without compression pressure

Worn cylinder and piston rings Leaking cylinder gaskets Sand holes in compression fittings Worn valves Frozen piston rings

Unblocked Blocked

remove the aliens

Remove the spark plug

No dirt or discoloration Dirt and discoloration

Check if the engine is overheating

normal engine overheating

Continuous acceleration or high speed driving

i don't touch

Debris cleaning Incorrect spark plug heat range Worn piston and cylinder Lean mixture Poor fuel quality Excessive carbon deposits

In combustion chamber Ignition timing too early Bad cooling system circuits Excessive carbon build-up

In the combustion chamber Lean mixture Poor quality fuel Ignition timing is too slow

1-14

in this chapter

1. General information

C. Engine runs slowly (especially when idling at low speed)

Check and set error status Possible cause

Check ignition timing (use power light)

normal abnormal

Incorrect ignition timing (malfunction

CDI or alternator)

Adjust the carburetor air screw.

Good or bad

Air is drawn in through the carburetor flange

No recruitment recruitment

Remove the spark plugs, install the spark plugs in the spark plug caps and check the engine ground for sparks.

Good Spark Bad D. Engine Runs Slow (High RPM)

Rich mixture (loosen screw) Lean mixture (tighten screw)

Bad Insulating Gasket Loose Carburetor Lock Bad Intake Gasket Bad Carburetor O Ring Cracked Vacuum Tube

Faulty CDI spark plug Faulty alternator Faulty ignition coil Open or short in spark plug wire Faulty main switch

Check and set error status Possible cause

check the ignition timing

normal abnormal

CDI Faulty Alternator Faulty

Check the oil supply system in the car oil pan

so perverted

Insufficient fuel in fuel tank Clogged fuel filter Blocked fuel tank vent

Check if the carburetor is clogged

Unclogged Clocked Clean

1-15

in this chapter

1. General information

E. Clutch, drive pulley and drive

Malfunction Possible cause

The engine can start, but the motorcycle cannot move.

Worn or warped drive belt Damaged drive face ramps Damaged drive pulley springs Damaged clutch weights Damaged drive shaft slip gear grooves Damaged drive gears

Engine runs and shuts off when motorcycle starts to move forward or jumps suddenly (rear wheels spin while engine is running)

Broken clutch weight spring Clutch weight stuck out of clutch Worn or burnt joint on clutch and shaft

Poor initial movement (poor scoring ability)

Worn or warped drive belt Worn counterweight roller Worn drive face drive shaft Warped drive pulley spring Worn drive pulley shaft Lubricate drive belt and drive face.

F. Mishandling

Malfunction Possible cause

heavy steering wheel

Steering bearing damage Steering shaft bushing damage

a wheel oscillates

Bent rim Improperly fitted hub Excessive wheel bearing clearance Bent arm bent frame Excessive wear on pivot arm pivot ring

the vehicle pulls to the side

Bent bars Incorrect tire bar adjustment Incorrect rear bar air pressure Incorrect wheel alignment Bent frame

1-16

in this chapter

1. General information

G. Turn off

Check and set error status Possible cause

Lift the wheel off the ground and turn it by hand

free spins anomaly

check the tire pressure

Brakes drag drive chain too tight Worn wheel bearings Wheel bearings need lubrication

normal abnormal

Accelerate slightly, the engine speed may increase

normal abnormal

check the ignition timing

normal abnormal

Flat tire Defective tire valve Air/fuel ratio too rich or too lean Restricted air filter Restricted muffler Restricted fuel flow Restricted fuel cap vent Defective pulse generator Defective CDI unit

Cylinder compression test

normal abnormal

Cylinder head gasket leaks Worn cylinder and piston rings

check the carburetor

normal blocked

clean

check the spark plugs

Normal soiled or discolored

Check if the engine is overheating

normal overheating

accelerate or run at high speed

normal hit

Clean spark plug Incorrect spark plug calorific value range Excessive carbon deposits

In combustion chamber Incorrect fuel type Lean air/fuel ratio Inferior fuel used Worn pistons and cylinders Lean air/fuel ratio Incorrect fuel type Too early ignition timing Excessive carbon deposits

in the combustion chamber

1-17

About this Chapter 1. General Information

lubrication point

Drive chain flywheel / Front and rear brake lever pivots

Speedometer Gear Bearing 1-18

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2. Maintenance information

Precautions during operation

Routine Maintenance Schedule... 2-2

Fuel Line·····························································| ····························································· ············; 2-3

Throttle Mode··························· ··|

Air filter 2-3

Spark plug················································ · ··············································································; ····························································· ············; ············ 2-3

Valve clearance

Carburetor Idle Adjustment 2-5

Ignition system

Cylinder compression pressure 2-6

Conveyor Belt ·························· ··············; ····························································· ············; ·········································· 7

Drive chain ··············; ········································ 2- 8

2 Brake Light Switch/Ignition Stop Switch····························· ·······| ········. ····························································· ············; · ········································································· ······················; ·······························································; ····························································· ············; ····························································· ············; 2-11 Tighten the nuts and bolts. ····························································· ············; ························2-12

Notes to the Code of Ethics

Fuel tank capacity 12000 c.c.

Capacity 1400 c.c oil

gearbox oil

Refrigerant capacity

change 1200 k.e.

Capacity 750 c.c.

gearbox 650 c.c

Engine + Fridge 850 c.c Upper storage 420 c.c.

Throttle valve clearance 1~3mm

Type NGK CR8E

spark plug

Gap 0.8mm

Mark "F" at idle BTDC 10º / 1700 rpm

Advanced complete timing BTDC 27º / 4000 rpm

Idle speed 1700±100 rpm

Cylinder compression pressure 12.0 ±2 kgf/cm²

Valve clearance IN: 0.10 ± 0.02 mm EX: 0.15 ± 0.02 mm

Frontline AT22x7-10 / AT25x8-12

tire size

Rear AT22x10-10 / AT25x10-12

Tire pressure (cold) 3 ±1 psi / 5 ±1 psi

12V12Ah battery type (MF battery):

2-1

Go to the contents of this chapter 2. Maintenance information

routine maintenance program

maintenance code each

300 kilometers

every 1 month

1,000 km

every 3 months

3,000 km

every 6 months

6,000 km

every 1 year

12,000 km

every 15 months

14,500KM 1 Air filter I C R 2 Fuel filter I I R 3 Oil filter C C 4 Oil change R Every 1000 km 5 Tire pressure I I 6 Battery check I 7 Brake and paint check I 8 Steering handle check I I 9 Shock absorber function check Check each screw I1 tightness I I 11 Gearbox oil leakage check I I 12 Spark plug check or replacement I I R 13 Gearbox oil change R every 5000 km 14 Frame lubrication L 15 Exhaust pipe I I 16 Ignition timing I I 17 Idle emissions check A I 18 Throttle I9 Engine operation I0 CVT drive (Belt) I 21 CVT (Roller) Drive) C R 22 Chain Drive I / L I / L C

23 Lights/Electrical Equipment/Polymeter I I

24 Fuel lines I I 25 Timing chain I I 26 Valve clearances I A 27 Cooling lines and connections I I 28 Coolant tank I I 29 Coolant I I R

Code: I ~ Inspection, Cleaning and Adjustment R ~ Replacement

C ~ Clean (replace if necessary) L ~ Lubricate Regularly let the authorized TGB dealer check, adjust and record the maintenance data of the ATV to keep the ATV in the best condition The above maintenance schedule is based on 1000 kilometers per month as reference Whichever comes first. Remarks: 1. ATVs driving on dusty roads or

highly polluted environment. 2. If the ATV is often driven at high speed, it should be maintained more often

After you accumulate more miles on the ATV. 3. Preventive maintenance

reach. Ignition System: Perform maintenance and inspection when continuous misfires, misfires, afterburning, or overheating occur.

b. Remove carbon deposits: Remove carbon deposits on the cylinder head, piston head and exhaust system when power is noticeably low. no way

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in this chapter

2. Maintenance Information Fuel Lines Remove the seat. Loosen 2 screws and 2 bolts Remove tank cover Check all lines and replace if worn, damaged or leaking

WARNING Gasoline is a highly flammable substance and therefore no open flame of any kind is strictly prohibited when handling.

Throttle Operation Hold the wide-open throttle valve as a handle in any position, then release it to the original (fully closed) position. Check that the handle works smoothly. Check the throttle cable and replace it if it is frayed, twisted or damaged. If it does not run smoothly, lubricate the cable. Measure the free play in the flange portion of the throttle lever. Remove the rubber sleeve, loosen the fixing nut and turn the adjustment screw to adjust. Tighten the retaining nut and check the operation of the throttle valve. Free play: 1~3mm. Air filter Remove the valve seat. Release the 4 hooks on the air filter cover and remove the cover. Loosen the fixing strap and 1 screw on the air filter element, then remove the air filter element. Clean the filter element with a non-flammable or high flash point solvent and wring it out.

CAUTION Never use gasoline or acidic organic solvents to clean the parts. Wipe the parts with clean oil and wring them out. Place the element on the element base, then install the air cleaner cover.

Spark Plug Recommended Spark Plugs: CR8E Remove the spark plug cap. Clean the debris around the spark plug hole. Remove the spark plug. Measure the spark plug gap. Spark plug gap: 0.8mm Carefully bend the spark plug ground electrode to adjust the gap if necessary. Hold the spark plug washer and screw it in to install the spark plug. Once installed, turn the socket an additional 1/2 turn to tighten the socket. Tightening torque: 1.0~1.2kgf-m

Tank

vacuum tube

throttle adjustment screw

Earth electrode clamp

central electrode

0.8~0.9mm

fuel filter fuel pipe

fasten the screw nut

element

2-3

Go to the contents of this chapter 2. Maintenance information

valve group

warn

Check and adjust when engine temperature is below 35°C.

Remove the front fender, filler cap and fuel tank. Remove the cylinder head cover. Remove the cylinder head side cover. Turn the camshaft bolt clockwise to align the "T" mark on the camshaft sprocket with the mark on the cylinder head and move the piston to the TDC position on the compression stroke.

CAUTION Do not turn the bolt counterclockwise. Direction to prevent loosening of camshaft bolts.

2 bolts

time stamp

Check and adjust valve clearance. Check and adjust the valve clearance with a feeler gauge. Standard value: IN 0.10±0.02mm

EX 0.15 ± 0.02 mm Loosen the clamping nut and turn the adjusting nut to adjust.

NOTICE Recheck the valve clearance after tightening the lock nut.

2-4

in this chapter

2. Maintenance Information Carburetor Idle Speed Adjustment

warn

The idle inspection and adjustment should be performed after all engine parts that need to be adjusted have been adjusted.

Checking and adjusting the idle speed should be done after the engine has warmed up. (10 minutes of engine running from standstill is enough.)

Park the ATV on the main stand and warm up the engine. Connect the tachometer (tachometer cable clamp to the high voltage cable). Turn the throttle stop screw to the specified idle speed. Specified idle speed: 1700 ± 100 rpm

Idle Emissions Adjustment Allow the engine to warm up for approximately 10 minutes before making this adjustment. 1. Connect the tachometer to the engine. 2. Adjust the throttle valve stop screw so that

The motor runs at a speed of 1600±100 rpm. 3. Insert the exhaust gas sampling tube

Analyzer in the front part of the exhaust pipe. Adjust the air adjustment screw to make the idle emission value within the standard range.

4. Lightly press the accelerator and release immediately. Repeat this action 2 to 3 times.

5. Read the engine speed and values on the exhaust gas analyzer. Repeat the procedure from step 2 to step 4 until the measured value is within the standard range.

Emission standard CO: below 2.5~3.5% HC: below 2000ppm

Power Cord

Stop screw Air adjustment screw

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in this chapter

2. Maintenance information Ignition system

warn

The C.D.I ignition system is set by the manufacturer and therefore cannot be adjusted.

The ignition timing inspection procedure is to check if the CDI operation is normal.

Connect the tachometer and power light. Start the engine. As engine idle: 1600 rpm, align the "F" mark with the power light. This means the ignition timing is correct. Increase engine speed to 6000 rpm to check ignition progress. If the indentation is within the ignition advance angle, it means that the ignition advance angle is normal. If the ignition timing is incorrect, check the CDI assembly, pulse runner and pulse generator. If any of these components are found to be defective, replace them.

Cylinder compression pressure Warm up the engine. Turn off the engine. Remove the trunk. Remove the center cover. Remove the spark plug cap and spark plug. Install the manometer. Open the throttle fully and use the starter to start the engine.

Carefully crank the engine until the gauge stops increasing. Usually the highest pressure reading is reached within 4 to 7 seconds.

Compression pressure: 12 ± 2 Kg/cm² If the pressure is too low, check the following items: Incorrect valve clearance. Valve leaks. Cylinder head, piston, piston rings and

Worn rollers. If the pressure is too high, it means there is carbon deposit in the combustion chamber or on the piston head.

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2. Drive belt maintenance information Unscrew the 2 clips on the left crankcase cover and remove the steam hose from the left crankcase cover. Remove 9 bolts from the left engine cover and cover.

paper clip

9 bolts

Check for broken or worn belts. Replace belts as necessary or according to a regular maintenance schedule. Width limit: 22.5 mm or higher

Drive Chain Check the Drive Chain Park the ATV on level ground and shift the transmission to neutral. Measure the drive chain slack in the middle of the sprocket.

Loose chain: 15~25 mm (5/8~1 inch)

Adjust the chain tension. Loosen the axle support nuts and bolts. Insert the pin (∮6) as far as possible, turning the wheel clockwise to tighten it.

Torque: 3.25 kgf-m

teeth

Ancho

2-7

Go to the contents of this chapter 2. Maintenance information

Brake System (Disc Brakes) Brake System Hoses Check that the brake hoses are not corroded or leaking.

Brake fluid Check the brake fluid level in the brake fluid reservoir. If the fluid level is below the lower limit, add brake fluid to the upper limit. If the brake fluid level is found to be low, also check the brake system for leaks

NOTICE Keep brake fluid in the reservoir

In the horizontal position, do not remove the cover until the handle stops.

Do not operate the brake lever with the cover removed. Otherwise, the brake fluid will overflow if you operate the lever.

Do not mix incompatible brake fluids. Filling brake fluid Tighten the drain valve and add brake fluid. Operate the brake lever to allow brake fluid to enter the brake system hoses.

master cylinder head bolts

Bleed mode Connect the clean hose to the bleed valve. Hold the brake lever and open the bleed valve. Perform this alternate operation until there is no air in the brake system hose.

CAUTION Do not release the brake lever until the bleed valve closes.

Diaphragm

diaphragm

Bubble relief valve

Predominant

Brake fluid added Add brake fluid to upper limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.

CAUTION Never mix or use impure brake fluid as this may damage the brake system or reduce brake performance.

transparent tube

2-8

in this chapter

2. Maintenance information Brake pad wear The markings on the brake pads are the wear limit. If the wear limit mark is near the edge of the brake disc, replace the brake lining.

NOTE To check the front brake pads must be removed

Front wheel first. No need to remove the brake hose

Replace the brake pads.

Front Brake Brake Liner Wear Limiting Groove

cover

disc brake

Replace the brake pads (see Chapter 14) Check the condition of the brake pads. If the brake lining wears the stop groove near the disc, replace the lining.

Never use the brake lever after the trimmer is finished

Remove to avoid cutting the brake pads. To maintain the brake force balance,

Brake pads must be replaced as a set.

Rear brake Brake pad wear reduction groove

Brake Light Switch/Ignition Inhibitor Switch The brake light switch must turn on the brake lights when the brakes are applied. Make sure the electric starter only works when you brake.

brake switch

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Go to the contents of this chapter 2. Maintenance information

Headlight beam distance Turn on the main headlight beam adjustment switch. Turn the headlight adjustment screw to adjust the headlight beam.

NOTE To adjust the headlight beam, follow the instructions

Regulations Improper adjustment of the headlight beam can lead to

In cases where the driver is dazzled or the lighting is insufficient.

Worn clutch plates Operate the ATV and gradually increase throttle opening to check clutch operation. If the ATV moves forward and shakes, check the condition of the clutch plates. replace it

adjustment screw

clutch weight

driving license

Wallpaper

warn

Do not ride an ATV with poor suspension. Loose, worn or damaged cushions will

Poor stability and drivability. Front pad Press the front pad several times to check its operation. Check for damage. If damage is found, replace the corresponding part. Tighten all nuts and bolts.

Back pad Press the back pad several times to check its operation. Check for damage. If damage is found, replace the corresponding part.

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in this chapter

2. Maintenance information Steering handle

warn

Check all wires and cables for interference with steering handle rotation.

Lift the front wheels off the ground. Turn the handle alternately from right to left to check for smooth rotation. If the handle does not swing flat, is bent, or if the handle runs vertically, check the bearings in the handle.

wheel tire

warn

Tire pressure must be checked with the engine cold.

Check the surface of the tire for signs of nails, stones or other material. Specified tire pressure

Tire size Front tire Rear tire

Tire pressure cold 5±1 psi Check if the front and rear tire pressures are normal. Measure the depth of the tire threads from the center surface of the tire. Replace the tire if the tread does not meet the following specifications:

Front tire: 1.5 mm Rear tire: 2.0 mm

nuts, bolts

Carry out regular maintenance according to regulations

Routine maintenance schedule Check that all frame bolts and nuts are tight. Check the security of all retaining pins, circlips, hose clamps and cable supports.

2-11

2. Maintenance information

List of special tools

Part Number: 440626 Part Name: ACG Flywheel Puller

Part Number: 440629 Part Name: Drive Shaft and Oil

seal installer

Part Number: 440627 Part Name: HMA COUNTER-SHIFT

Needle discs

Part Number: 440630 Part Name: L. Crankshaft and Oil

seal installer

Part Number: 440628 Part Name: Fitter Clearance

Regulator

Part Number: 440631 Part Name: 6205 Bearing

instigator

Part Number: 440632 Part Name: 6205 Bearing Driver

Part Number: 440635 Part Name: BRG. instigator

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2. Maintenance information

Part Number: 440633 Part Name: Left Crankcase Cover

6006 Bearing Installer

Part Number: 440636 Part Name: 6205 Bearing Puller (Air Wrench)

Part Number: 440634 Part Name: Right Crankcase Cover 6201 Bearing Driver

Part Number: 440637 Part Name: Pin Remover

Part Number: 440638 Part Name: Drive Shaft Puller

Part Number: 440641 Part Name: Water Pump Oil

Seal Installer (Internal)

Part Number: 440639 Part Name: Drive Shaft Bearing

instigator

Part Number: 440642 Part Name: Water Pump Oil

Stamping Machine (Iron)

2-13

2. Maintenance information

Part Number: 440640 Part Name: Water Pump 6901

bearing adapter

Part Number: 440643 Part Name: Clutch Lock Nut

Animation 46”

Part Number: 440644 Part Name: Engine Valve Puller

Part Number: 440647 Part Name: 6204 Bearing

installer

Part Number: 440645 Part Name: F02 Bearing Puller

Part Number: 440646 Part Name: Universal Wrench

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3. Lubrication system

Mechanism Diagram 3-1

Precautions during operation ····················· is 3-2 3-2

Troubleshooting················································ · ········································································· ·······; ,

Lubricant················································ ····································; ···· ········································ 3 -3

Oil filter cleaning···································· ··| 3-4 Gear Oil ·············· ··································· ···············; 3-7

3 schematic diagrams of mechanisms

valve rocker arm

pressure lubrication

oil circuit

Spray camshaft lubrication

White

oil circuit

spray lubrication

pressure lubrication

come back

oil pump

oil filter

3-1

3. Matters that need attention in the operation of the lubrication system

General information: z This chapter contains maintenance work

To change oil pump and gearbox oil.

Specifications Oil volume disassembled: 1400 c.c.

Variant: 1200c.c. oil viscosity SAE 10W-30 (recommended

King series oil) transmission oil disassembly: 750c.c.

Variant: 650c.c. Gear oil viscosity SAE 140 (TGB hypoid gear oil recommended)

Unit: mm

Standard Item Limit (mm) (mm)

oil pump

Inner rotor clearance 0.15 0.20 Outer rotor and body clearance 0.15~0.20 0.25

Clearance between rotor side and machine body 0.04~0.09 0.12

Torque value Torque value Oil filter screw 1.3~1.7 kgf-m Oil drain bolt 3.5~4.5 kgf-m Drive oil drain bolt 1.1~1.5 kgf-m Drive oil connection bolt 3.5~4.5 kgf-m Oil pump connecting bolt 0.1~0.3 kg force meter

Troubleshooting Low Engine Oil Oil Leaks Worn Valve Guides or Worn Piston Seat Rings

Low oil pressure Low oil level Clogged oil filter, circuit or line Damaged oil pump

Dirty oil No regular oil changes Damaged cylinder head gasket Worn piston rings

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in this chapter

3. Lubrication System Engine Oil Stop the engine and park the ATV on a level surface and check the oil level with a dipstick. So don't screw the dipstick into the engine to check it. If the oil level drops, top up to the recommended level.

oil change

warn

Drain the oil while the engine is warming up to ensure a smooth and complete drain.

Place an oil pan under the ATV and remove the oil drain plug. After draining, make sure the washer can be reused. Install the oil drain plug. Torque value: 3.5~4.5kgf-m

clean oil filter

Drain the oil. Remove the oil filter and spring. Clean the grease filter. Check that the O-rings are reusable. Install the oil filter and spring. Install the oil filter cap.

Torque value: 1.3~1.7 kgf-m Add engine oil to the crankcase (oil viscosity SAE 10W-30) It is recommended to use King series engine oil. Engine oil capacity: 1200 c.c When changing, insert the dipstick, start the engine and run it for a few minutes. Turn off the engine and check the oil level again. Check for oil leaks.

Oil filter cover

O-ring

oil filter

3-3

drain bolt

in this chapter

3. Lubrication system oil pump

Oil Pump Removal Remove the alternator and starter gear. (See Chapter 10).

Remove the connector and remove the drive chain and oil pump gear.

Make sure the pump shaft can rotate freely. Remove the 2 oil pump bolts, then remove the oil pump.

shorten

2 Screws Oil pump removal Remove the oil pump cover screws and remove the cover. Remove the shaft and rollers from the oil pump shaft.

1 screw

Volume 3-4

Contents of this chapter

3. Lubrication system Oil pump inspection Check the clearance between the oil pump body and the outer rotor. Limit: 0.25mm

Check the clearance between the inner and outer rotors. Limit: 0.20mm

Check the clearance limit between the rotor side and the pump body: 0.12mm

Oil Pump Assembly Install the inner and outer rotors into the pump body. Align the notch in the drive shaft with the notch in the inner rotor. Install the oil pump shaft and cylinder. Install the oil pump cover and retaining pin correctly.

animal foot

3-5

in this chapter

3. Lubrication system Tighten the oil pump screw.

1 screw

Drum Oil Pump Installation Install the oil pump and tighten the bolts. Torque value: 0.1~0.3 kgf-m to ensure that the oil pump shaft can rotate freely.

2 bolts Install the transmission chain and oil pump sprocket, then install the connector on the oil pump shaft.

Install starter gear and alternator. (See Chapter 10)

3-6

shorten

in this chapter

3. Lubrication system gearbox oil

Changing the gearbox oil Remove the oil connector screw. Remove the drain bolt and drain the transmission oil. Install the drain bolt after draining. Torque value: 1.1~1.5 kgf-m Make sure the drain bolt washer can be reused. Add the specified amount of oil from the manifold hole. Gearbox oil volume: 650 c.c When replacing, make sure that the union bolt washer can be reused and install the screw. Torque value: 3.5~4.5 kgf-m Start the engine and let it run for 2-3 minutes. Shut off the engine and make sure the oil level is at the correct level. Make sure there are no oil leaks.

Gearbox oil union bolt

transmission oil drain bolt

3-7

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3. Lubrication System Precautions:

3-8

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4. Fuel system

Organization chart................................................ . ..... 4-1

Handling Precautions................... 4-2

troubleshooting................................................ ...... .. 4-3

Carburetor Removal/Installation...................................4-4

Air Shutoff Valve ................................ 4-5

Throttle valve................................... 4-6 Float chamber.... ... . ............................................... ... .................. .4-7 Idle Speed Adjustment ..................... .... ............................ .................4- 9 Fuel tank ................................ .. .. ........ ..4-10

air filter ................................................ ...... ........4-11 4 Mechanism diagram

Fuel tank cap

Fuel unit

Tank

car nozzle

carburettor

Fuel filter

Intake pipe

4-1

4. Fuel system

in this chapter

Operating precautions

General information

warn

Gasoline is a low flash point and explosive substance, so when using gasoline, you must work in a well-ventilated area and open flames are strictly prohibited.

Precautions

Do not bend the throttle cable. A damaged throttle cable can make drivability erratic. When disassembling fuel system components, note the position of the O-ring and replace it with a new one if necessary.

Reassembly There is an oil drain screw in the float chamber to drain residual gasoline. Do not disassemble the air shut-off valve at will.

Determination

Module UA25A

Carburetor diameter Ø22mm

ID CARD. PTG number 050

Flammable 14.8mm

Main Injector #110

Idle injector #35

Idle speed 1700 ± 100 rpm

Throttle grip clearance 1~3mm

Lead screw 2 turns

tool

SPECIAL SERVICE TOOLS AIR/VACUUM PUMP OIL GAUGE

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in this chapter

4. Fuel system

troubleshooting

Poor engine start No fuel tank Oil pipe clogged Too much fuel in cylinder No spark in spark plug (misfire

) Air filter blockage Carburetor housing bearing failure Throttle valve failure

Flame after starting Defective carburetor bearing housing Incorrect ignition timing Defective carburetor Dirty engine oil Air in intake system Incorrect idle speed

Erratic idle speed Ignition system error Incorrect idle speed Carburetor error Dirty fuel

Intermittent misfire when accelerating Ignition system failure

Ignition timing delay Ignition system failure Carburetor failure

Insufficient power and fuel consumption Blocked fuel system Faulty ignition system

Mixture too lean Clogged injector Vacuum piston stuck Defective float valve Fuel level in float chamber too low

Mixture too rich Air injector clogged float valve Defective float chamber fuel level too high Defective carburetor plug Dirty air filter

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4. Fuel system

in this chapter

Carburetor removal/installation

Disassembly Drain the fuel into the float chamber.

Drain Bolts Loosen the choke plate cable mounting plate screws. Remove the choke cable.

1 screw

Choke cable Disconnect the fuel hose. Loosen the air filter retaining strap.

vacuum tube

fuel pipe

Clip Remove the carburetor top from the carburetor. Loosen the 2 carburetor isolation nuts, then remove the carburetor.

Installation Install in the reverse order of removal.

2 walnuts 4-4

in this chapter

4. Fuel system

Air Shutoff Valve Removal Remove 2 screws.

Remove the air shutoff valve cap, spring, and valve.

2 screw sealing springs

Inspection of air shut-off hood Check that the valve is in proper condition. If the valve is in its normal position, it will restrict the air flow. If airflow is not restricted, replace carburetor assembly. Check if the vacuum tube O-ring is normal.

Assembly Install in reverse order of disassembly.

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4. Fuel system

in this chapter

regulating valve

REMOVAL Remove the carburetor top, then remove the throttle valve and throttle cable.

throttle Disconnect the throttle cable from the throttle and remove the valve spring. Remove the fuel needle clip and fuel needle.

spring and summer

Assembly Place the fuel needle on the throttle valve and secure it with a needle clip. Install the stuffing box, carburetor top, and throttle spring. Connect the throttle cable to the throttle. Install the throttle valve to the carburetor body.

warn

Align the groove in the throttle valve with the throttle stop screw in the carburetor body.

Throttle cable

needle clip fuel needle clip fuel needle

Screw on the top of the carburetor. Adjust the throttle cable so that it moves freely.

4-6

in this chapter

4. Fuel system

floating chamber

Disassembly Remove the 3 set screws and remove the float chamber cover.

3 screws Remove the oil level plate, float pin, float and float valve.

float

Float valve

Oil level plate

brooch

Inspection Check float valve and seat for damage or obstruction. Check the float valve for wear and if the seating surfaces are worn or dirty.

brooch

warn

If wear or dirt occurs, the float valve and seat will not close tightly, causing the fuel level to rise, causing fuel flooding. Worn or dirty float valves must be replaced with new ones.

float

Float valve

Check for wear or damage.

4-7

4. Fuel system

in this chapter

Remove the main nozzle, needle nozzle base, needle nozzle, slow nozzle and air adjustment screw.

warn

Be careful not to damage the nozzle and adjustment screw. y Before removing the adjustment screw, turn it completely

Go down and mark the laps. Do not turn the adjustment screw too hard to avoid it

Damage to the seat surface.

The needle jet supports the main jet

Clean the nozzles with cleaning fluid. Then blow away the dirt with compressed air. Use compressed air to blow the passage into the oil cleaner body.

Assembly Install the main nozzle, needle nozzle base, needle nozzle, slow nozzle and air adjustment screw.

warn

Adjust the air adjustment screw to the number of turns noted before removal.

Install the float valve, float and float pin.

needle shot

slow flow

Air adjustment screw fuel level check

warn

Double-check to make sure the float valve and float are properly seated.

To ensure correct readings, position the float gauge so that the surface of the float chamber is perpendicular to the main jet.

Flammable: 14.8mm

Carburetor Installation with Float Indicator Install the carburetor in the reverse order of removal. The following settings must be made after installation. ˙Adjust the throttle cable. ˙Idle setting

fasten the screw nut

4-8 Throttle Adjustment Screw

in this chapter

4. Fuel system

idle adjustment

warn

The air screw is installed at the factory, so no adjustment is required. Note the number of turns it takes to screw it all the way in for easier installation.

The ATV must be stopped using the parking brake to make adjustments.

handbrake

Use the tachometer when revving the engine. Tighten the air adjustment screw slightly and return to standard RPM. Standard rpm: 2 turns to warm up the engine, set the throttle stop screw on the throttle valve to the standard rpm. S.a.l. at idle: 1700 ± 100 rpm Connect the exhaust gas analyzer hose to the front end of the exhaust. Press the test button on the analyzer. Adjust the lead screw and read the CO reading on the analyzer Typical CO value: 1.0~1.5% increases gradually, after the engine runs steadily, make sure the rpm and carbon monoxide value are in the standard value. If the rpm values and CO fluctuate, repeat the above steps to adjust the standard values.

air adjustment screw

Throttle stop screw

4-9

4. Fuel system

in this chapter

Tank

Removing the fuel module Open the seat. Remove the front cover and fuel tank. Remove the side cover and lower side cover. Remove the front fender. (Remove cap, see Chapter 13) Disconnect fuel cell coupler. Remove the fuel module (4 bolts).

warn

˙Do not bend the fuel unit float. ˙Do not fill the fuel tank with too much fuel.

Inspection of fuel facilities (See Chapter 17 for electrical equipment.)

Fuel Module Installation Install the pressure gauge in the reverse order of removal.

warn

Do not forget to install the fuel unit gasket or you will damage it.

Removing the fuel tank Open the seat. Remove the front cover and fuel tank. Remove the side cover and lower side cover. Remove the front fender. (Remove cap, see Chapter 13) Disconnect fuel cell coupler. Remove the fuel module (4 bolts). Remove the fuel pipe. Remove the vacuum tube.

4 bolts

Remove the 4 bolts from the front and rear of the fuel tank, then remove the fuel tank.

Installation Install the water tank in the reverse order of removal.

forehead

rear

4 bolts

4-10

air traffic control

fuel pipe

in this chapter

4. Fuel system

air filter

Removal Loosen the mounting straps on the air cleaner and carburetor, then remove the steam hose.

Loosen the clips on the air cleaner and remove the steam hose from the air cleaner. Remove the air filter (2 bolts).

Installation Install the water tank in the reverse order of removal.

clamp

Cleaning the air filter element Remove the air filter cover (4 hooks).

4 hooks

Remove the accessory mounting screws. Loosen the air filter element retaining strap, then remove the air filter element. Clean the filter element with a non-flammable or high flash point solvent and wring it out.

clamp

1 screw

warn

Never use gasoline or acidic organic solvents to clean components. Wipe the parts with clean oil and wring them out. Place the element on the element base, then install the air cleaner cover.

4-11

4. Fuel system

in this chapter

Degree:

4-12

home page content

5. Engine removal

Handling Precautions................................... 5-1

Removing the engine................................................... ...... 5-2

Engine Installation................................................... ................ ...... 5-6

Operating precautions

General Information The engine must be supported by a special service tool that can be lifted or adjusted. Engines will be retired for the sole purpose of repair or adjustment. 5 The following components can be serviced with the engine mounted on the frame:

carburettor. Assembly of drive pulleys, drive belts, clutches and moving drive surfaces. start the engine. A/C alternator, oil pump and one-way starter clutch. spreading.

Determination

Project potential

oil capacity

Spare 1200 c.c Disassembled 1400 c.c.

Gearbox oil capacity

Spare 650 c.c. Dismantling 750 c.c.

Engine and Fridge 780 c.c.

Refrigerant capacity

Deposit 420 c.c show AS indicators

Total 1200 k.e.

Torque value Engine mounting bolts 7.5~9.5 kgf-m Muffler mounting bolts 2.8~3.2 kgf-m Muffler connection nuts 1.0~1.4 kgf-m

5-1

5. Engine removal

in this chapter

engine disassembly

Remove the seat. Remove the negative (-) terminal of the battery. Remove the positive (+) terminal of the battery.

Remove the front wings and legs (see Chapter 13).

negative

The starter motor cable is removed.

Remove the spark plug cap.

Disconnect the line coupler from the alternator.

Starter cables Spark plug cap A.C.G.

5-2

in this chapter

5. Engine removal

Remove the muffler guard (2 bolts).

2 bolts

Loosen the bolts on the front side of the muffler.

2 bolts

Remove 2 bolts and then remove the muffler.

2 bolts and 2 nuts, then remove the exhaust pipe.

2 walnuts

5-3

5. Engine removal

in this chapter

Loosen 1 screw and disconnect the choke cable.

1 screw

Choke Cable Remove fuel and vacuum lines.

Release the clamp strips from the air filter tube.

vacuum tube

fuel pipe

clamp

Disconnect the carburetor top and cable. Loosen the 2 carburetor isolation nuts, then remove the carburetor.

2 nuts Release the pipe clamps from the left crankcase cover and remove the pipe.

integral component

5-4

in this chapter

5. Engine removal

Remove the coolant drain plug and drain the coolant. Remove the coolant inlet hose from the water pump.

Hose clamp for watering

drain bolt

Remove the thermal sensor wires, bypass tube and coolant outlet hose.

branch pipe

outlet pipe

Shift lever (1 screw) remove the thermal sensor cable.

1 bolt Remove the shifter link.

Replace the clutch switch

5-5

5. Engine removal

Loosen the speedometer cable mounting nut and remove the cable. Remove 3 bolts and remove drive chain guard. Turn the Allen bolt clockwise and remove the speedometer gear.

warn

The hex socket bolts turn counterclockwise.

Hilo.

Speedometer Cable Socket Head Cap Hex Screw

3 bolts

Remove 2 bolts, then remove the drive sprocket retaining plate, drive chain and drive sprocket.

2 bolts Remove the rear engine mount mounting bolts and nuts.

Remove the front engine mount mounting bolts and nuts. Remove the left engine mount, then remove the left engine.

Engine Mounting Inspect the engine mount bushing for damage. Install the motor in the reverse order of removal.

warn

Pay attention to hand and foot safety as a motorized vehicle

Avoid damage during installation. Do not bend or twist cables. The cable must comply with

normal design. Engine mount bolts: Torque value: 7.5~9.5kgf-m

2 walnuts 1 walnut

5-6

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6. Cylinder head/valve

Mechanism diagram...

Precautions during operation····················6-2

Troubleshooting 6-3

Remove the cylinder head······························6-4

Cylinder Head Inspection·················6-7

Valve Stem Replacement 6-10 Valve Seat Inspection and Service 6-13 Cylinder Head Installation 6-10 Valve Seat Inspection and Service 6-13 Cylinder Head Installation ····················· ····························································· ························································································· · ·······························································; ·········· 6 -16

Mechanism diagram

1,0~1,4kgf-m

3.6~4.0 kgf-meter

2,4~3,0 kgf-m

1,0~1,4kgf-m

1.0~1.4 kgfm 1.0~1.2 kgfm

0.7~1.1 kgfm

1,0~1,4kgf-m

1.0~1.2kgf-rice

6-1

in this chapter

6. Cylinder Head/Valve Operation Precautions General Information This chapter contains maintenance and servicing of the cylinder head, valves and

rocking chair. Cylinder head repairs can be done while the engine is on the chassis.

Determination

Standard project limit

Compression pressure 12±2 kg/cm2 ---

Registrations 34,880 34,860

Camshaft lobe height

escape 34,740 34,725

controller

Valve arm arm inner diameter 11.982~12.000 12.080 valve arm arm shaft outer diameter 11.966~11.984 11.936

Air Inlet 4.975~4.990 4.900 Stem Outer Diameter

Escape 4.950~4.975 4.900

Valve guide inner diameter 5.000~5.012 5.030

free space between

Input 0.010~0.037 0.080

valve

Valve stem and guide Exhaust 0.025~0.062 0.100 Length without valve Inner 38,700 35,200 Outer spring 40,400 36,900

Seat width 1,600 ---

Access 0.10±0.02mm ---

valve group

escapement 0.15±0.02mm ---

Stock tilt angle --- 0.050

Torque value Cylinder head bolts 1.0~1.4 kgf-m Exhaust pipe stud bolts 2.4~3.0 kgf-m Cylinder head bolts 1.0~1.4 kgf-m Cylinder head nuts 3.6~4.0 kgf-m Automatic chain tensioner sealing bolts 8-10 kgf. m automatic timing chain tensioner bolts 1.2~1.6 kgf-m cylinder side cover bolts 1.0~1.4 kgf-m cam sprocket bolts 1.0~1.4 kgf-m pusher adjusting nuts 0.7 ~1. 1 kgf-m spark plug 1 kgf-m

Tools Special Service Tools Valve Fitting: 5.0mm Valve Guide Screwdriver: 5.0mm Valve Spring Compressor

6-2

in this chapter

6. HEAD/VALVE TROUBLESHOOTING Engine performance can be affected by problems at the top of the engine. Typically, the problem can be identified by performing a compression test on the cylinder and evaluating the resulting rattle.

Low compression pressure 1. Valve

Incorrect valve adjustment Burnt or bent valves Incorrect valve timing Damaged valve springs Carbon deposits on valves.

2. Cylinder head Cylinder head gasket is leaking or damaged Cylinder is bent or cracked

3. Piston

Worn piston rings. High compression pressure Excessive carbon deposits in the combustion chamber or on top of the piston

Noise Improper valve lash adjustment Burnt valves or damaged valve springs Worn or damaged camshafts Worn or loose chains Worn or damaged automatic tensioners Camshaft gears Worn rocker arms or rocker arms

6-3

in this chapter

6. Cylinder Head/Valves Remove the cylinder head Remove the engine. (see Chapter 5) Remove the intake pipe (2 nuts).

Remove 1 bolt from the thermostat and remove the thermostat. Remove the bolt hole and spring from the timing chain tensioner. Loosen 2 bolts and remove tensioner. Remove the thermostat (2 bolts).

2 walnuts

thermostat bolt

Tensioner bolts Remove the AI pipe mounting bolts. Remove the spark plug.

Remove the fixing points on the side cover of the cylinder head and remove the side cover.

4 bolts 3 bolts

spark plug

6-4

in this chapter

6. Cylinder Head/Valves Remove the left crankcase cover and rotate the drive face to align the timing marks on the gear with the timing marks on the cylinder head with the piston at top dead center. Remove the camshaft sprocket bolts and unscrew the chain from the sprockets.

Remove the camshaft adjustment plate (1 bolt).

Remove the rocker shaft and rocker arm. Special Service Tools: Arm and camshaft pullers

2 bolts

Timing marks Camshaft setting plate

rotator

Rocker shaft and camshaft puller

Remove the camshaft. Special Service Tools: Arm and camshaft pullers

camshaft

Rocker shaft and camshaft puller

6-5

in this chapter

6. Cylinder Head/Valve Remove 2 cylinder head mounting bolts from the right side of the cylinder head, then remove 4 nuts and washers from the upper side of the cylinder head. Delete inventory.

4 walnuts

2 bolts Remove head gasket and 2 guide pins. Remove the chain guide. Clean debris from the mating surfaces of the cylinder and cylinder head.

Be careful not to damage the mating surface

cylinder and head. Avoid gasket residue or foreign objects.

Pour into sump for cleaning.

Packet

chain guide

brooch

Use the valve pin removal and installation tool to compress the valve spring, then remove the valve.

CAUTION To avoid loss of spring tension, do not

Putting too much pressure on the spring. Therefore, the length of the press depends on the removable valve.

SPECIAL SERVICE TOOLS: VALVE PIN REMOVAL AND INSTALLATION TOOLS

valve key

Disassembly tool

Intake valve

internal spring

spring retainer

petal

outer jetty

key

6-6

in this chapter

6. HEAD/VALVE Remove the stem seal.

Valve Stem Seal Cleans carbon deposits in the combustion chamber. Remove debris and foreign bodies from the mating surfaces of the cylinder head.

CAUTION Do not damage the contact surface of the cylinder head.

Cylinder Head Inspection Check the spark plugs and valve holes for cracks. Measure the cylinder head deflection with a ruler and feeler gauge. Service limit: 0.05 mm

Camshaft Check the height of the camshaft lobes for damage. Service Limits:

IN: Replace when less than 34,860 mm EX: Replace when less than 34,725 mm Check camshaft bearings for looseness or wear. If damaged, replace the entire camshaft and bearing kit.

6-7

in this chapter

6. Camshaft Bore/Cylinder Head Rocker Arm, Worn or Damaged, Clogged Oil Hole? Service Limit: Replace when less than 12,080 mm.

The regression axis measures the outer diameter of the element. Camshaft Rotor and Camshaft Arm. Service Limit: Replace when less than 11,936 mm.

Calculate the clearance between the rocker shaft and the rocker arm. Limit of use: replace when less than 0.10mm.

Valve spring free length measures the free length of the intake and exhaust valve springs. Usage restrictions: Inner spring 35.20mm Outer spring 36.90mm

Stem Check for bent, cracked or burnt valve stem. Check the condition of the valve stem on the valve guide, measure and record the outside diameter of the valve stem. Service Limit: IN: 4.90mm

Example: 4.90 mm 6-8

in this chapter

6. Cylinder head/valve guide

CAUTION Remove any carbon deposits with a mass before measuring the valve guides.

Tool: 5.0mm Valve Guide Reamer Measure and record the inside diameter of each valve guide. Usage Limit: 5.03mm The difference between the inner diameter of the valve guide and the outer diameter of the valve stem is the gap between the valve stem and the valve guide. Service limit: IN→0.08mm

EX→0.10mm

5.0mm valve guide clearance

warn

If the gap between the valve stem and the valve guide exceeds the service limit, check that the new gap replacing only the new valve guide is within the service limit. If so, replace the valve guide.

Correct with a sponge after replacement. If the gap still exceeds the service limit after replacing the valve guide, replace the valve stem at the same time.

CAUTION The valve seat must be corrected when replacing the valve guide.

6-9

in this chapter

6. Cylinder Head/Valve Stem Replacement Heat the cylinder head to 100~150 with a stove or toaster.

CAUTION Do not allow the torch to directly heat the cylinder head.

Otherwise, the cylinder head may be deformed due to heat.

Wear gloves to protect hands when handling.

5.0mm valve guide guide

Hold the cylinder head and press out the old valve guide from the combustion chamber side. Tool: Valve guide Screwdriver: 5.0mm

NOTICE Check the new valve guide for distortion

type. Pressing the new valve guide, cylinder

The head should still be kept at 100~150. Adjust the valve guide lifter so that the valve guide height is 13mm. Press in a new valve guide from the rocker arm side. Tools: Valve Guide Guide: 5.0mm Wait for the cylinder head to cool to room temperature, then align the new valve guides with a sponge.

Precautions for using cutting oil when correcting valve guides

Use a sponge. Rotate the cutting device in the same direction while

Enter or rotate. Align the valve seats and remove any metal debris from the cylinder head. Tool: Valve guide breather: 5.0mm

5.0mm valve guide clearance

Impeller valve guide 5.0mm

6-10

in this chapter

6. Cylinder Head/Valve Seat Inspection and Repair Remove any carbon deposits from the intake and exhaust valves. Lightly apply emery to the contact surface of the valve. Abrade the valve seats with a rubber hose or other hand sanding tool.

Be careful not to get emery into the valve stem

and valve guides. Clean emery after correction and apply

Apply engine oil to the valve and valve seat mating surfaces.

Remove the valve and inspect its contact surfaces.

NOTICE If the valve seal is rough, worn, or not touching the seat, replace it with a new valve.

Valve Seat Inspection Correct if the valve seat is too wide, too narrow, or too rough.

Seat width Service limit: 1.6 mm Check seat contact.

Grinding Seats Worn seats should be ground with a seat bevel knife. See Valve Seat Bevel Knife Operator's Manual. Use a 45° valve seat chamfer to remove any rough or uneven surfaces on the valve seat.

Note After replacing the valve guide, it must be ground with a 45° valve seal chamfer knife to correct the seating surface.

Seat width

roughness

45°

Cut the top quarter using the 32° cutter.

Old Seat Width

32°

6-11

in this chapter

6. HEAD/VALVE Cut the lower quarter using a 60° cutter. Remove the cutter and inspect the new valve seat.

Old Seat Width

60°

Grind the valve seat to the specified width with a 45° cutter.

NOTE Make sure all rough edges and irregularities are sanded away.

1.0 mm

Repair the seat if necessary.

45° Apply red paint to the seat surface. Insert the valve through the valve guide until the valve contacts the seat, pressing the valve down slightly but without rotating it, so that a sealed path is formed on the contact surface.

Note The contact surface between the valve and the valve seat is very important to the sealing performance of the valve.

If the contact surface is too high, wrap the seat with a 32° cutter. Then grind the seat to the specified width.

If the contact area is too low, wrap the seat with a 60° cutter. Then grind the seat to the specified width.

Contact surface too high Contact surface too low

Old Seat Width

32° old seat width

60° 6-12

in this chapter

6. CYLINDER HEAD/VALVE After the valve seat has been polished, apply a coat of sandpaper to the surface of the valve seat with sandpaper, then lightly press the polished surface. After sharpening, clean all diamond coatings from cylinders and valves.

Cylinder Head Assembly Lubricate the valve stem with engine oil, then insert the valve into the valve guide. Install a new valve stem oil seal. Install the valve springs and retainers.

NOTICE The valve spring closed ring must face the combustion chamber.

valve spring seat

Valve key Valve spring

Stem stamp

Intake valve

Use the valve pin removal and installation tool to compress the valve spring, then remove the valve.

petal

NOTICE To avoid damage to the valve stem and cylinder head, place a cloth between the valve spring remover/installer in the combustion chamber and compress the valve springs directly.

SPECIAL SERVICE TOOLS: VALVE PIN REMOVAL AND INSTALLATION TOOLS

Tap the valve stem gently with a plastic mallet to make sure the retainer and valve pin are in place.

CAUTION Place and support the cylinder head on a workbench to avoid damage to the valves.

valve key

Disassembly tool

6-13

in this chapter

6. Cylinder Head/Valve Head Installation Remove all debris and foreign matter from the cylinder head and cylinder head mating surfaces. Install the chain guide, guide pin and new head gasket onto the cylinder.

CAUTION Do not damage the mating surfaces of the cylinder and cylinder head. Prevent gasket residue or foreign matter from falling into the crankcase during cleaning.

chain guide

brooch

Packet

Install 4 washers and tighten 4 nuts on the upper side of the cylinder head, then tighten the 2 cylinder head mounting bolts on the right side of the cylinder head. Torque value: nut 3.6~4.0kgf-m bolt 1.0~1.4kgf-m

4 walnuts

2 bolts secure the camshaft to the cylinder head, install the rocker arm, rocker shaft.

Install the pin mounting plate.

Camshaft Mounting Plate 6-14

in this chapter

6. Cylinder Head/Valves Install the timing chain on the sprocket and align the timing mark on the sprocket with the timing mark on the cylinder head. Align the sprocket bolt holes with the camshaft bolt holes. Tighten the sprocket mounting bolts.

warn

Make sure the timestamps match.

2 bolts

time stamp

Install the cylinder head side cover (3 bolts). Install thermostat (2 bolts).

3 bolts

Thermostat bolt Loosen the auto tensioner set screw and remove the bolt and spring. Install the tensioner and install the spring and adjusting bolt.

Tensioner adjustment bolt Install the cylinder head (4 bolts).

4 bolts

6-15

Go to this chapter 6. Cylinder head/valve

Install the air injection (AI) system piping. (4 bolts) Install the intake pipe to the cylinder Install and tighten the spark plug Torque value: 1.0~2.0 kgf-m

warn

This model is equipped with a higher precision four-valve mechanism, so its tightening torque cannot exceed the standard value, so that cylinder head deformation, engine noise and leakage will not affect the performance of the motorcycle. Place the engine in the frame (see Chapter 5).

Valve lash adjustment Loosen the air injection (AI) pipe upper side bolts (2 bolts). Remove the cylinder head cover.

Remove the cylinder head side cover. Remove the left crankcase cover and turn the face of the unit so that the timing marks on the cam gear line up with the timing marks on the cylinder head with the piston at top dead center. Loosen the valve lash adjustment screw and nut located on the valve rocker arm. Measure and adjust the valve clearance with a feeler gauge. After the valve clearance is adjusted to the standard value, hold the adjusting bolt and tighten the adjusting nut. Standard value: IN 0.10±0.02mm

EX 0.15 ± 0.02 mm Install the cylinder head side cover. Start the engine and make sure oil is flowing into the cylinder head. Stop the engine after confirmation, then install the cylinder head cover and AI pipe.

CAUTION If the oil does not flow to the cylinder head,

Engine components are subject to severe wear. So it needs to be confirmed.

Allow the engine to idle while checking the oil flow. Do not rev the engine.

6-16

Spark plug with 4 bolts

time stamp

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7. Cylinder/piston

Mechanism Diagram 7-1

Precautions during operation 7-2

Troubleshooting················································ |

Remove the cylinder and piston... 7-3

Piston Spring Installation 7 -7 Installation Cylinder 7-7

Mechanism diagram

1,0~1,4kgf-m

0,8~1,2kgf-

subway

7-1

7. Cylinder/piston

Tuna fish

Operating precautions

General information and repairs to cylinders and pistons cannot be carried out when the engine is mounted on the chassis.

UA25A specification unit: mm

Standard project limit

Days 70,995~71,015 71,100

Cylinder

Curve - 0.050

Piston Top Ring Clearance 0.015~0.050 0.090

rings Second ring 0.015~0.050 0.090

Top Ring 0.150~0.300 0.500 Piston/Piston Ring

space at the end of the loop

Second ring 0.300~0.450 0.650

Oil Ring Side Rail 0.200~0.700 - Piston Outer Diameter (2nd) 70.430~70.480 70.380

Clearance between piston and cylinder 0.010~0.040 0.100

Piston Pin Inner Diameter 17.002~17.008 17.020

Piston pin outer diameter 16.994~17.000 16.960

Clearance between piston and piston pin 0.002~0.014 0.020

Big endian ID 17016~17034 17064 Error diagnosis

Low or unstable compression pressure Worn cylinder or piston rings

Knocking or noise Worn cylinder or piston rings Carbon deposits on top of cylinder head Worn piston pin holes and piston pins

Smoke from exhaust pipe Worn piston or piston ring Improper piston ring fit Damaged cylinder or piston Engine overheating Carbon buildup above cylinder head Clogged cooling pipe or insufficient coolant

Procedure 7-2

Go to this chapter 7. Cylinder/piston

Cylinder and Piston Removal Remove the cylinder head (see Chapter 6). Remove the coolant hose from the cylinder. Remove the cylinder.

Cover the holes in the crankcase and timing chain with cloth for the coolant pipes. Remove the clip from the piston pin, then remove the piston pin and piston.

Remove the cylinder head gasket and guide pin. Remove any debris or foreign matter from the two mating surfaces of the cylinder and crankcase.

warn

The soap residue is left in the solvent so that the residue is easier to remove.

brooch

Inspection Check the cylinder bore for wear or damage. At the top, middle, and bottom of the cylinder, measure the corresponding X and Y values on the cylinder.

Service limit: 71,100 mm

above the waist and below

7-3

7. Cylinder/piston

in this chapter

Check the cylinder for distortion.

Service limit: 0.05 mm

Measure the clearance between the piston ring and the notch.

Service Limit: Top Bushing: 0.09mm Second Bushing: 0.09mm

Remove piston rings Inspect piston rings for damage or worn ring grooves.

warn

Be careful when removing the piston rings as they are fragile.

Place the matching piston ring in the cylinder less than 20mm from the top of the cylinder. To keep the piston ring in the horizontal position of the cylinder, press the piston ring with the piston.

Service limit: Top ring: 0.50 mm

The second ring: 0.65mm

7-4

in this chapter

7. Cylinder/piston Measure the outside diameter of the piston pin.

Service limit: 16.96 mm

Measure the inside diameter of the connecting rod leg.

Service limit: 17.064 mm

Measure the inside diameter of the piston pin bore. Limit of use: 17.02 mm Calculate the clearance between the piston pin and its bore.

Service limit: 0.02 mm

Measure the outer diameter of the piston.

warn

The measuring position is 10 mm from the bottom of the piston, at 90° to the piston pin.

Operating Limit: 70.380 mm Compare the measured value with the operating limit to calculate the piston-to-cylinder clearance.

7-5

7. Cylinder/piston

in this chapter

Piston Ring Installation Clean the piston crown, ring grooves and piston surfaces. Carefully place the piston rings onto the piston.

Install the piston ring opening as shown.

warn

Do not damage the piston and piston rings during installation. All marks on the piston rings must face up. Make sure all piston rings can rotate freely after installation.

top ring

second ring

oil ring

top reception

second reception

Oil tank 7-6

in this chapter

7. Cylinder/piston

Remove all debris and foreign matter from the relevant crankcase surfaces. Be careful not to let these debris and foreign objects fall into the crankcase.

warn

The soap residue is left in the solvent so that the residue is easier to remove.

Piston Installation Install the piston and piston pin with the IN mark on the top side of the piston facing the intake valve.

Install a new piston pin clip.

warn

Do not align the piston pin clip opening with the piston notch.

Put a cloth between the piston and the crankcase to prevent the snap ring from falling into the crankcase while it is running.

IN signal Clamp end clearance

Cutting roller installation

Install dowel pins and new washers.

brooch

7-7

7. Cylinder/piston

in this chapter

Apply some oil to the inside of the cylinder, piston and piston rings. Care must be taken when installing the piston into the cylinder. Press the piston rings one by one during installation.

warn

Do not push the piston too hard into the cylinder as this will damage the piston and piston rings.

Install the coolant hose to the cylinder. Install the stock (see Chapter 6).

Coolant hose 7-8

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8. V-belt drive system

Mechanism Diagram 8-1

Maintenance Description...8-2

Troubleshooting 8-2

left crankcase cover ···········| ································· 8-3

Transmission belt …………………………………… ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・................................................................................................................................................................................................................... ……………………………………………………………….・・· · · · · · · · · · · 8-10

Mechanism diagram

8,5~10,5kgf-m

5.0~6.0 kgf-meter

8-1

Go to this chapter 8. V-belt drive system

Maintenance Instructions Handling Precautions General Information The running surfaces, clutch outer and driven pulley are all serviceable on the motorcycle. Drive belts and drive pulleys must be free of grease.

Determination

Standard project price limit

Belt width 24,000 mm 22,500 mm

The convex outer diameter of the movable driving surface 29.946~29.980mm 29.926mm

Movable driving surface ID 30,000~30,040mm 30,060mm

Counterweight cylinder outer diameter 19,500~20,000 mm 19,000 mm

ID del exterior del embrague 144.850~145.150 mm 145.450 mm

Weight Clutch Thickness 6,000 mm 3,000 mm

Pulley drive spring length without spring 102,400 mm 97,400 mm

Drive wheel hub outer diameter 40.950~40.990mm 40.930mm

Conductive surface ID 41,000~41,050 mm 41,070 mm

Weight Cylinder weight 17,700~18,300g 17,200g Torque value Drive face nut: 8.5~10.5 kgf-m Clutch outer nut: 5.0~6.0 kgf-m Disc drive nut: 5.0~6. 0kgf-m

Special Service Tools Clutch Spring Compressor: Puller Inner Bearing: TGB-440645

Clutch nut wrench 39 x 41 mm: TGB-440629

Universal Bracket: TGB-440646 Bearing Driver: TGB-440640

Troubleshooting Engine can start but motorcycle cannot move 1. Worn drive belt

2. Wear of the driving surface

3. Worn or damaged clutch weights 4. Damaged drive pulley

Shaking or not driving 1. Damaged clutch weight

2. Worn clutch weight

Insufficient horsepower or poor high speed performance 1. Drive belt is worn

2. Insufficient elasticity of the driven pulley

3. The roller is worn 4. The drive wheel does not work normally

8-2

in this chapter

8. left V-belt drive crankcase cover

Left crankcase cover removal Loosen the 2 hose clamps on the left crankcase cover and remove the hoses. Remove the left crankcase cover. (9 bolts) Remove 2 pins and washers.

Installing the Left Crankcase Cover Install the left crankcase cover in the reverse order of the removal steps.

Belt clip 9 screws

brooch

Left cap

Bearing adjustment plate

Drive shaft support bearing

Left Cover Gasket

8-3

Go to this chapter 8. V-belt drive system

Left Crankcase Inspection Remove 2 bolts and remove the left crankcase mounting plate.

2 bolts

9 bolts

Check the bearings in the left crankcase cover. Turn the inner race of the bearing with your fingers. Make sure the bearings rotate smoothly and quietly and that the outer raceways of the bearings are securely attached to the end shields. If the bearing turns unevenly, makes noise or is loose, replace it.

8-4

in this chapter

8. V-belt drive system drive belt

eliminate

Remove the left crankcase cover. With the drive face supported by the universal bracket, remove the nut and drive face.

Special tool: Universal clip

general support

Support the clutch outer ring with the universal support, remove the nut, bearing arm bushing and clutch outer ring.

warn

Tighten or loosen nuts with special service tools.

Immobilizing the rear wheel or rear brake will damage the reduction gear system.

general support

Bearing support ring

Push the drive belt into the belt groove as shown to loosen the belt, then remove the drive pulley. Remove the drive pulley. Do not remove the drive belt. Remove the drive belt from the drive pulley groove.

Inspection Check the drive belt for cracks or wear. Replace it if necessary.

Measure the width of the drive belt as shown.

Use limit: 22.5 mm If it exceeds the use limit, replace the belt.

warn

Use original parts for replacement. The surface of the drive belt or pulley must

No fat.

Remove any grease or dirt before installation.

toothed

Ancho

8-5

in this chapter

8. V-belt drive system

Setting up

warn

Pull out the trailing face so it doesn't close. Failure to compress friction plate assemblies in sequence

Avoid twisting or wear. Install the drive belt on the drive pulley.

Install the drive pulley with the belt installed on the drive shaft. On the drive belt, move the other end of the drive face.

Install the clutch outer ring and bearing support ring. Support the outside of the clutch with a general support and tighten the nuts to the specified torque value. Torque value: 5.0~6.0kgf-m

Install the drive bezel, drive bezel washer and nut. Support the face of the drive with a universal support, then tighten the nuts to the specified torque value. Torque value: 8.5~10.5kgf-m

driving surface

Universal support Bearing support

general support

8-6

in this chapter

8. V-belt drive system running surface

REMOVAL Remove the left crankcase cover. Support the front of the unit with the universal brackets, then remove the nuts of the front of the unit.

Remove the drive surface and drive belt. Remove the moving parts on the crankshaft drive surface and the projections on the drive surface.

Universal support for mobile transport planes

Crankshaft drive face boss Remove the swash plate.

Remove the counterweight rollers from the undercarriage.

Inclined plate moving surface

Counterweight roll

8-7

Go to this chapter 8. V-belt drive system

Check that the weight cylinder must be pressed against the drive surface by centrifugal force. Therefore, if the counterweight rollers are worn or damaged, the centrifugal force will be affected. Check the rollers for wear or damage. Replace it if necessary. Measure the outside diameter of each cylinder. If it exceeds the service limit, replace it.

Serving edge: 19.0mm Weight: 17.2g

Inspect the drive face heads for wear or damage, replace if necessary.

Measure the outer diameter of the active drive faceplate and replace if exceeded. Service limit: 29,962 mm

Measure the inside diameter of the drive face and replace it if it exceeds the service limits. Service limit: 30.060 mm INSTALLATION / INSTALLATION Install the counterweight rollers.

warn

The two ends of the counterweight cylinder must be different. To extend the life of the roller and avoid abnormal wear, assemble the end surface of the sealing surface counterclockwise to the movable guide surface.

Counterweight roll

moving surface

Protruding counterweight rollers from the running surface

Sealing surface

Place the ramp.

inclined board

Guide Ring 8-8

in this chapter

8. V-belt transmission system Use 4~5g of lubricating grease to spread and clean the transmission device in the shaft hole of the transmission moving surface.

Install the module faceplate boss.

warn

There should be no grease on the surface of the gearbox moving surface. Clean it with cleaning solvent.

The running surface protrudes from the mounting assembly. mobile transmission surface. on the crankshaft.

moving surface

driving boss person

Crankshaft Pulley Installation Press the drive belt into the pulley groove and pull the belt toward the drive shaft.

tightening

Drive Belt Install the faceplate, washer and drive nut.

warn

Make sure there is no grease on both sides of the pulley surface. Clean it with cleaning solvent. It supports all inclusive units that are generally embraced. Tighten the nuts to the specified torque. Torque value: 8.5~10.5 kgf-m Install the left crankcase cover.

8-9

Go to this chapter 8. V-belt drive system

External clutch/drive pulley

REMOVAL Remove the drive belt, outer clutch pulley and driven pulley. Install the clutch spring tensioner on the pulley assembly and operate the tensioner for easier installation of the key.

warn

Do not put too much pressure on the compressor. Clamp the clutch spring compressor in a vise and remove the retaining nut with a special service tool. Loosen the clutch spring compressor and remove the friction plate, clutch weight and spring from the driven pulley.

Remove the seal from the drive pulley.

clutch nut wrench

clutch spring compressor

Collar Remove the guide pin, guide pin cylinder and movable follower, then remove the O-ring and oil seal seat from the movable follower.

mobile powered person

stamp

pin guide

O-ring

pin guide

Roller guides

Clutch Outer Inspection Measure the inner diameter of the outer clutch. If the service limit is exceeded, replace the clutch outer ring. Service limit: 145,450 mm

internal diameter

external clutch

8-10

in this chapter

8. V-belt drive system clutch linings measure the thickness of each clutch weight. If it exceeds the service limit, replace it.

Service limit: 3.0 mm

clutch lining

Clutch Weight Drive Pulley Spring Measure the drive pulley spring length. If it exceeds the service limit, replace it.

Service limit: 97.4 mm

Free pulley with drive

Check the following items: y Both surfaces for damage or wear. y If the guide pin groove is damaged or worn. Replace damaged or worn parts. Measure the outer diameter of the driving surface and the inner diameter of the movable driving surface. If it exceeds the service limit, replace it.

Usage restrictions: 40.93mm outer diameter

Pulley Bearing Inspection 41.07mm ID Inspect the inner bearing oil seal for damage. Replace it if necessary. Check the needle roller bearings for damage or excessive clearance. Replace it if necessary. Use your fingers to turn the inside of the inner bearing to check that the bearing rotates smoothly and quietly. Check if the outer part of the bearing is closed and fixed. Replace it if necessary.

driving surface

mobile powered person

guide pin socket

Needle bearings

Outer bearing

8-11

Go to this chapter 8. V-belt drive system

Clutch Weight Replacement Remove the snap ring and washer, then remove the clutch weight and spring from the drive plate.

warn

drive spring

Some models have a mounting plate instead of 3 locking rings.

Check the spring for damage or insufficient spring force.

Check the shock absorber for damage or deformation. Replace it if necessary.

Apply grease to the adjusting pin.

Place the new clutch weight on the adjusting pin and push it into place.

Apply grease to the adjusting pin. However, clutch blocks should not be lubricated. If so, replace it.

warn

Grease or lubricants can damage the clutch weights and affect block engagement.

Clutch Weight Shock Absorber Rubber

Shock absorbing rubber clutch weight

Snap ring adjusting pin

Use pliers to install the spring into the groove.

spring and summer

8-12

in this chapter

8. V-belt drive Install the snap ring and retaining plate on the pin.

Pulley bearing snap ring replacement

Remove the inner bearing.

warn

If the bearing is fitted with an oil seal

The driven side of the pulley, then remove the oil seal first.

If the pulley has a bearing, you will need to remove the snap ring before removing the bearing.

Outer bearing

Clipper Needle Roller Inner Bearing

Buckle

Remove the snap ring and push the bearing to the other side of the inner bearing. Place the new bearing in the correct position with the sealing end facing out. Coat with the specified oil.

Buckle

Outer bearing

Install new inner bearings.

warn

Its sealed end should be sent abroad.

Placement as a bearing. Install the needle bearings with a hydraulic press.

Install the bearings with a hydraulic press.

Place the retaining ring in the groove on the face of the unit. Align the lip of the oil seal with the bearing and install a new oil seal (if necessary).

internal bearing

End bearing

8-13

Go to this chapter 8. V-belt drive system

Clutch Outer/Drive Pulley Assembly Installation Install a new oil seal and O-ring on the idler drive surface. Lubricate the inside of the moving surface with the specified grease.

oil seal

The bushing The specified grease Place the movable moving surface on the moving surface. Install the guide pin and guide pin rollers.

mobile powered person

oil seal

pin guide

O-ring guide pin cylinder guide pin

Install the collar.

Collars Place the clutch plates, spring and weights on the clutch spring compressor, then turn the handle to press down on the assembly until the retaining nuts can be installed. Clamp the compressor in a vise and tighten the mounting nuts to the specified torque with a clutch nut wrench.

Remove the clutch spring compressor.

Torque value: 5.0~6.0 kgf-m Install the clutch outer/drive pulley and drive belt on the drive shaft.

clutch nut wrench

8-14 Clutch Spring Compressor

home page content

9. Final drive mechanism

Mechanism Diagram-Transmission Cover ······································· 9-1

Precautions during operation ···················· is 9-2 9-2

troubleshooting················································ ·················································· 9 -2

Transmission Removal... 9-3

Work Tool Inspection 9-6 Bearing Replacement 9-8 Final Drive Reassembly · ······························ ················ 9-11

Mechanism diagram - gearbox cover

Gear oil filler bolt 3.5~4.5kgf-m

Reverse axis

Bearing (6205LLU)

mechanism

Bearing Drive Shaft (6304).

Bearings (6204)

Oil seal (30x46x7)

last axis

Gear oil drain bolt 0.8~1.2kgf-m

Anchor bolts 2.6~3.0kgf-m

Bearings (6204)

Oil seal (14x26x6)

shift fork

shift shaft shift drum

Bearings (6305)

Oil seal (25x40x7)

hairpin

Needle bearing (K25x29x10)

Drive shaft bearing adjustment plate

secondary axis

Needle roller bearings (HK2016)

Packet

Toggle Switches

Fixed gear shift drum pin 2.6~3.0kgf-m

9-1

9. Transmission

in this chapter

Operating Precautions Specifications Applicable Oil: Recommended Scooter Gear Oil: KING MATE Series Oil Oil Quantity: 750 c.c. (650 c.c. when replaced)

Standard project price limit (mm)

Fork Shaft Outer Diameter 11,982~12,000mm 11,970mm

Stroke inner diameter 12.016~12.043mm 12.010mm

Fork Claw Thickness 5,930~6,000mm 5,730mm Torque Value Gearbox Cover 2.6~3.0kgf-m Drive Oil Drain Bolt 1.1~1.5 kgf-m Drive Oil Filler Screw 3.5~4.5 kgf-m

Tool Special Tool Bearing Driver (6204): TGB-440647 Bearing Driver (6205LLU): TGB-440631 Bearing Driver (6305): TGB-440639 Needle Roller Bearing Driver (HK2016): TGB-440627 Driver Seil 440629 Drive Shaft Puller: TGB -440638 Inner bearing puller: TGB-440645

Troubleshooting The engine can start, but the motorcycle will not move. Damaged drive gear Burnt drive gear Damaged drivetrain

noise worn or burnt gears worn gears

Transmission oil leak Too much transmission oil. Worn or damaged oil seal

9-2

in this chapter

9. Final drive removal shift lever (1 bolt).

1 Bolt Loosen the speedometer cable support nut and remove the cable. Remove 3 bolts and remove drive chain guard. Turn the Allen bolt clockwise and remove the speedometer gear.

warn

Hex socket head screws have a left-hand thread.

speedometer cable

3 bolts

Allen bolts Remove 2 bolts, then remove the drive sprocket retaining plate, drive chain and drive sprocket.

2 bolts Remove the gear seal bolts. Place an oil pan under the ATV and remove the transmission oil drain bolt. After draining, make sure the washer can be reused. Install the oil drain plug. Torque value: Transmission oil filler bolt 3.5~4.5 kgf-m Transmission oil drain bolt 1.1~1.5 kgf-m

packing bolt

drain bolt

9-3

9. Transmission

in this chapter

Remove the transmission cover bolts (9 bolts), then remove the cover.

Remove the ball, spring and bolt from the shift drum block.

9 bolts

Shift Drum Mounting Bolts Remove the shift shaft, shift fork shaft, shift fork and shift drum.

drum change

Fork axle and fork

Replace the axle

Remove the final stage shaft, reverse shaft and reverse shaft.

Reverse axis

transmission shaft

last axis

secondary axis

9-4

in this chapter

9. Final drive Remove the propeller shaft bearing adjustment plate (1 bolt).

Bearing adjustment plate Remove the propeller shaft. Special tool: Shaft guard Remove the seal and guide pin.

warn

Do not remove the drive shaft from the top of the frame unless necessary.

If the drive shaft is removed from the gearbox, the bearings and oil seal must be replaced.

oil seal

ball bearing

9-5

9. Transmission

in this chapter

Transmission Gear Inspection Check the shift shaft for wear or damage.

Check the shift drum for wear or damage.

Check the fork and axle for wear or damage. Measure the outside diameter of the shift fork shaft and replace if it exceeds the service limit. Service limit: 11,970 mm Measure the inside diameter of the fork and replace if it exceeds the service limit. Use limit: 12.010mm Measure the thickness of the fork claw, if it exceeds the use limit, replace it. Service limit: 5,730 mm

Check the reverse shaft for wear or damage.

9-6

in this chapter

9. Final Drive Check the reverse shaft for wear or damage.

Check the final stage shaft and gear for burnt, worn or damaged.

Check the gearbox bearings and gearbox cover. Use your fingers to turn the inner race of each bearing. Make sure the bearings rotate smoothly and quietly and that the outer rings of the bearings are securely attached to the gears. If the bearing turns unevenly, makes noise or is loose, replace it. Check the oil seal for wear or damage and replace if necessary.

warn

If the drive shaft is removed from the upper side of the crankcase, its bearings must be replaced.

gearbox

reverse shaft bearing

Final shaft bearing gearbox cover

Drive shaft bearing

Secondary shaft needle bearing

shaft end bearing

reverse shaft bearing

9-7

9. Transmission

in this chapter

bearing replacement

warn

Never install used bearings. After the bearing is removed, it must be replaced with a new one.

Crankcase Side Remove the propeller shaft bearing retainer plate, then use the following tools to remove the propeller shaft bearing from the left crankcase. Use the following tools to remove the reverse axle bearing and reverse axle bearing from the left crankcase. Remove the drive shaft oil seal. Special tool: Internal bearing puller

Install new end shaft, idler shaft and reverse shaft bearings in the left crankcase. Special tools: Bearing Driver (6204) Needle Bearing Driver (HK2016)

Install new drive shaft bearings and bare drive in left crankcase.

Inner bearing puller Clutch nut

Bearing movement

Drive shaft and seal packing

Drive Shaft Pullers Install universal bearing pullers and bearing drives. Rotate the universal bearing puller to install the driveshaft bearing. Special Tool: Bearing Driver (6305) Universal Bearing Puller

Drive shaft and seal packing

9-8

in this chapter

9. Final drive Install the propeller shaft. Special Tools: Drive Shaft Puller Drive Shaft and Seal Ring Seal Wrench Clutch Nut

clutch nut wrench

Drive shaft and seal packing

Drive Shaft Puller Lubricate the new drive shaft oil seal lip and install the oil seal. Special tool: Drive shaft and oil seal mounting container Install the drive shaft bearing adjustment plate (1 bolt).

Gear Case Side Remove the end shaft needle bearing, derailleur shaft bearing and reverse shaft bearing from inside the cover using an internal bearing puller. Special tool: Internal bearing puller

Drive shaft and seal packing

The inner bearing puller removes the last disassembled side ring bearing. .

clip circle

9-9

9. Transmission

in this chapter

Remove the last side bearing. Special Tool: Inner Bearing Puller Remove the oil seal from the transmission cover and discard the oil seal

Install new bearings and bearing guides on the outside of the transmission cover. Install the universal bearing puller and bearing guide.

Universal internal bearing puller

Bearing puller

Bearing Guide Rotate the universal bearing puller to install the shaft bearings. Special tool: Bearing Driver (6205) Universal Bearing Puller

common

Bearing puller

Bearing Guide Install a new oil seal and bearing guide inside the transmission cover. Install the universal bearing puller and bearing guide. Rotate the general purpose bearing puller and install the drive shaft oil seal. Special tool: Bearing Driver (6205) Universal Bearing Puller

common

Bearing puller

9-10

in this chapter

9. Final drive Final drive assembly Apply grease to the oil seal lip of the final drive shaft.

oil seal

Install the intermediate shaft, reverse shaft, and end shafts into the transmission.

Reverse axis

transmission shaft

last axis

secondary axis

Install the shift drum, fork and fork shaft into the transmission.

drum change

Fork axle and fork

Replace the axle

Install the shift drum retaining ball, spring and bolt into the transmission.

Shift drum mounting bolt

9-11

9. Transmission

in this chapter

Align the alignment mark on the shift shaft gear with the alignment mark on the shift lever drum, then install the shift shaft.

Install dowel pins and new washers.

Install the gearbox cover and screws and tighten. Torque value: 1.0~1.4kgf-m

Install the shift shaft bracket, drive chain guard, transmission and shifter. Add gear oil. Gearbox oil volume: 750c.c.

9-12

position indicator

brooch

9 bolts

home page content

10. Alternator/starter clutch

Mechanism Diagram····················································· 10-1

Precautions during operation ····················· is 10-2

Right Crankcase Cover Removal... 10-3

Alternating Current Clear Set······································· ···········································································| ·

Right Cover Bearing····················································· 10-··············································· 3

Flywheel Removal … ·················································· ; ······································· 10-8 Install the right crankcase cover 10-8

Mechanism diagram

0,8~1,2 kgf-m

1,0~1,4kgf-m

5.0~6.0 kgf-meter

10-1

in this chapter

10. Alternator/Start Clutch Operating Precautions General Information See Chapter 17: Generator Inspection and Troubleshooting See Chapter 17: Starter Motor Service Procedures and Precautions

Determination

Item Standard value (mm) Limit value (mm)

Starter Clutch Gear ID 25.026~25.045 25.050

Starter Clutch Gear Outer Diameter 42.192~42.208 42.100

nominal value

Flywheel nut 5.0~6.0kgf-m

Starter Clutch Hex Bolt 1.0~1.4kgf-m With Glue

8mm bolt 0.8~1.2 kgf-m

12mm bolt 1.0~1.4 kgf-m

Special tool tool

AC flywheel puller: TGB-440626

Universal bracket: TGB-440646

10-2

in this chapter

10. Alternator/Starter Clutch Right Crankcase Cover Removal Remove the left foot. Drain the engine oil and coolant, then remove the coolant hose. Remove the water pump cover (4 bolts). Remove 11 bolts from right crankcase cover. Remove the right crankcase cover. Remove the pin and washer.

11 bolts

WATER PUMP COVER SCREW REMOVAL KIT A.C.G. Remove the 2 screws securing the pulse generator and remove the pulse generator. Remove the 3 bolts on the right crankcase cover, then remove the alternator coil assembly.

2 screws

3 Screw Right Cover Bearing Inspection Turn the bearing with your fingers to check that it rotates smoothly and quietly. Check if the outer part of the bearing is closed and fixed. Replace it if necessary.

Remove the bushing and then the bearing. Special tool: Internal bearing puller

clip circle

10-3

in this chapter

10. Alternator/Starter Clutch Check oil seal for wear or damage. Replace it if necessary.

Install new bearings (6201LU) using a bearing driver. Special tool: Bearing guide

oil seal

Bearing Drive Flywheel Removal Remove the right crankcase cover.

Remove the left crankcase cover. Use the gimbal to support the flywheel through the running surface. Remove the flywheel nut. Special tool: Universal clip

reducer

flywheel nut

10-4

in this chapter

10. Alternator/Starter Clutch Remove the shaft and gear from the starter motor. Use A.C.G. to remove the flywheel puller. Special Tool: A.C.G Flywheel Removal Remove flywheel and starter gear.

Starter Clutch Starter Clutch Inspection Remove the starter clutch gear. Check the gears for wear or damage. Measure the inside and outside diameter of the gear driven by the starter clutch. Service limits: Inner diameter: 25,050 mm

Depth: 42,100 mm

Flywheel Puller ID

Check the starter reduction gear and shaft for wear or damage.

Check each cylinder for wear or damage.

10-5

in this chapter

10. Alternator/Starter Clutch Install the starter clutch gear to the one-way clutch. Hold the flywheel and turn the starter clutch gear. The launch clutch mechanism should turn freely in the CCW direction, but not in the C.W. direction. (See how it looks in this picture).

One-Way Clutch Removal Remove the starter gear.

Remove the 3 hex socket head cap bolts, then remove the one-way clutch.

starter gear

3 hex socket head screws

one-way clutch

10-6 starter gears

in this chapter

10. ALTERNATOR/STARTER CLUTCH One-Way Clutch Installation Install the components in the reverse order of removal.

warn

Apply mounting tape to the threads of the hex bolt.

Torque value: 1.0~1.4kgf-m Install the starter gear.

Installing the flywheel Align the key on the crankshaft with the notch in the flywheel and install the flywheel.

Fit the flywheel with the gimbal through the running surface and tighten the flywheel nut. Torque value: 5.0~6.0 kgf-m Special tool: universal clamp

3 hex socket head screws

starter gear

coin slot

10-7

in this chapter

10. Alternator/Starter Clutch Install the reducer shaft and reducer.

reducer

AC ADJUSTMENT INSTALLATION Install the A.C.G coil set. (3 screws) on the right crankcase cover. Install the pulse generator (2 screws). Fasten the belt securely in the crankcase notch.

warn

Make sure the wiring is under the pulse generator.

cable

2 bolts

3 screws Install right crankcase cover Retaining pin and new gasket.

Remove the water pump cover. Install the right crankcase cover into the crankcase. NOTE: Align the notch in the water pump shaft with the oil pump shaft.

10-8

in this chapter

10. Alternator/Starter Clutch Install the right crankcase cover (11 bolts). Install dowel pins, new gasket and water pump cover to crankcase cover.

11 bolts

Water Pump Cover Bolts Connect the water pipes to the right crankcase cover and the water pump cover.

10-9

Go to Chapter 10. Alternator/Starter Clutch

use:

10-10

home page content

11. Crankcase/Crank

General information················································ ····························································· ···············································································; ····························································· ···········; ····························································· ············; ············· 11-2

troubleshooting················································ ··? ····························································· ············; ····································· 11-2

disassemble the crankcase ·················· is a crankshaft box complex 11-5 ...

Mechanism diagram

1,0~1,4kgf-m

0,8~1,2 kgf-m

Eng Oil Drain Bolt 3.5~4.5kgf-m

11-1

in this chapter

11. CRANKSHAFT / CRANKSHAFT GENERAL INFORMATION OPERATING PRECAUTIONS This section refers to the disassembly of the crankcase for service. Remove the following components before disassembling the crankcase. - Engine Removal, Section 5 - Cylinder Head, Section 6 - Cylinder and Piston, Section 7 - Drive Face and Drive Pulley, Section 8 - Alternator/Starter Freewheel, Section 10

If the crankshaft bearings, oil pump drive chain or timing belt need to be replaced

chain, and it is better to replace the crankshaft as a whole. Specification unit: mm

Standard project limit

Big End Reverse Connecting Rod 0.100~0.400 0.600 Crankshaft

Vertical clearance at big end of connecting rod 0~0.008 0.050 Warpage - 0.100

Torque Value Crankcase Bolts 0.8~1.2 kgf-m Engine Oil Drain Bolts 3.5~4.5 kgf-m Cylinder Bolts 1.0~1.4 kgf-m

Crankshaft oil screwdriver special tool L.(27*42*7): TGB-440630

Troubleshooting Engine noise Loose crankshaft bearings Loose crankshaft bearings Worn piston pins and pin holes

11-2

in this chapter

11. CRANKCASE / CRANKSHAFT REMOVAL Remove the timing chain adjuster plate and then the timing chain. Loosen the pivot bolt and remove the tensioner.

extensor muscle

Timing chain adjuster plate Loosen the 2 bolts on the right crankcase.

2 bolts Loosen 11 bolts on the left crankcase.

Place the right oil pan down and the left oil pan up. Tap the left crankcase with a plastic hammer to remove it.

warn

Care must be taken not to damage the contact surfaces.

11 bolts

11-3

in this chapter

11. Crankcase/Crankshaft Remove the balance shaft from the right crankcase.

Remove the crankshaft from the right crankcase.

Remove the washer and pin. Scrape the gasket residue from the mating surfaces of the crankcase.

warn

Do not damage the contact surface of the flange. Gasket scraps are best liquid for easier disposal.

Remove the left crankcase oil seal.

11-4

balance axis

in this chapter

11. Crankshaft / Crankshaft Inspection Measure the left and right big end clearance with a feeler gauge. Service limit: 0.6 mm

Measure the point on the big end of the connecting rod crankshaft.

Measure the large end gap in the vertical direction. Service limit: 0.05 mm

Place the crankshaft in the V-block and measure the crankshaft runout. Service limit: 0.10 mm

90 mm

60 mm

Check the crankshaft bearings Turn the bearings by hand to see if they rotate freely, smoothly and without noise. Check that the inner ring is firmly seated in the bearing. If roughness, noise and loose joints are found, replace them with new bearings.

warn

Bearings must be replaced in pairs.

Special tool: External bearing puller

crankshaft bearing

11-5

in this chapter

11. Crankshaft/Crankshaft Balance Check Shaft Bearings Check the bearings in the left and right crankcases. Use your fingers to turn the inner race of each bearing. Make sure the bearings rotate smoothly and quietly and that the outer rings of the bearings are securely attached to the gears. If the bearing turns unevenly, makes noise or is loose, replace it. Special tool: Internal bearing puller

The bearing drive crankcase is mounted in the right crankshaft bearing housing with a wave washer installed.

Balance shaft bearing

Wave washer Install the crankshaft in the right crankcase.

Align the balance shaft drive alignment mark with the balance shaft drive alignment mark, then install the balance shaft into the right crankcase.

position indicator

11-6

in this chapter

11. Crankcase/Crankshaft Install 2 dowels and a new washer.

Guide pin Install the left crankcase into the right crankcase.

Tighten the 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m

Tighten the 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m

11 bolts

2 bolts

11-7

in this chapter

11. Crankshaft / Crankshaft Clean the crankshaft. Apply a layer of grease to the lip of the oil pan and install the left crankshaft. Install the oil seal in the left crankcase, being careful not to damage the lip of the oil seal.

Using the oil seal driver (27×42×7), the oil seal will be installed. Special tool: oil screwdriver (27×42×7)

Install the tensioner and tighten the pivot bolt. Torque value: 0.8 ~ 1.2 kgf-m Install the timing chain. Install the timing chain adjuster plate.

Oil Seal Driver

extensor muscle

11-8 Timing Chain Adjuster Plate

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12. Cooling system

Mechanism Diagram ····························································· ·········|

General Information 12-2

Diagnosing Cooling System Problems 12-3

System Test ····? ····························································· ····················································; ····························································· ············; ············································· 12-12

Mechanism diagram

radiator filler cap

storage tank

branch pipe

in the ass

coolant outlet pipe

cooler

fan

coolant inlet pipe

Thermal switch (fan)

thermostat

water pump

12-1

12. Cooling system

in this chapter

General information

General

warn:

Never attempt to open the radiator filler cap while the engine is running, hot pressurized coolant will spray out and cause serious burns. No maintenance work is permitted unless the engine is completely cold.

Refill the cooler with distilled water or specific additives. Add coolant to the tank reservoir. The cooling system can be serviced on the ATV. Never pour coolant on painted surfaces. Check the cooling system for leaks after service. Refer to Section 17 to check the fan motor temperature sensor switch and

Specifications for water thermometers

item specification

Filling plug opening pressure 0.9±0.15 kgf/cm2

Coolant Capacity: Engine + Radiator Tank

850cc 420cc

82~95 thermostat start trip: 0.05~3m

The temperature switch (fan) starts to activate at 98±3

Boiling point No pressure: 107.7 Pressurized: 125.6

Water pump impeller torque value 1.0~1.4kgf-m

Tool Requirements Special Tools Water Pump Bearing Screwdriver (6901): TGB-440640 Water Pump Oil Seal Screwdriver (Inner): TGB-440641 Water Pump Mechanical Seal Screwdriver: TGB-440642 Puller Bearing Inner: TGB-440645

troubleshooting

Very high engine temperature Water temperature gauge and temp

The sensor is not working properly. Thermostat stuck closed. Insufficient coolant. The tube and jacket are clogged. Defective fan motor. The radiator filler cap is faulty.

Engine temperature too low Temperature and water temperature gauge

Sensor failure. Thermostat stuck open. There is a coolant leak and the mechanical seal of the water pump is not working

He worked hard. The O-ring is damaged. Water pipes are broken or old.

12-2

in this chapter

12. Cooling system

Cooling system troubleshooting

Indicates that the temperature is too high

Yes

A. Stop and wait for the engine to cool completely N. Open the cover to check the coolant capacity in the radiator.

Yes

A1. Fill the radiator with coolant and check for leaks.

North

Yes

Leakage problem

B. Turn on the main switch and check if the water temperature gauge returns to zero?

Yes

B-1. Measure the thermal module confirmation voltage 6V↑ ?

And B-2. check the circuit

Is there a short or ground in the water temperature?

North

Replacing thermal units and shorted or grounded handles

Nm problem

C. Open the radiator cap, accelerate N smoothly and check if the coolant is circulating.

Yes

C-1. eng stop and delete

Water pump cover, engine start and water pump rotation check? North

Yes

water pump repair

D. Cover the radiator cap, measure the thermal unit at N and confirm that the pressure drop corresponds to the temperature increase.

Replace the thermal unit

Yes

12-3

12. Cooling system

in this chapter

E. Maintenance. 3000~4000rpm, after checking the temperature gauge for more than 3 times, check if the cooling fan N is working.

E-1. Measure the thermal switch at

Confirm voltage change (12→0V);

Yes

Replace the thermal switch

Yes

F. Are you sure the cooling fan is stuck?

Yes

unusual gauge

E-2. Connecting the cooling fan

Check its operation directly with the battery terminals (12V)?

Yes

North

Replace the cooling fan

If the circuit wiring is reversed, the cooling fan will be forwarded, corrected and retested.

E-3. Mantener ing. 3000~4000

Check the coolant flow in the tank after checking the thermometer more than 3 times?

Yes

E-4. Remove the thermostat from the bracket and heat directly with water to test its operation?

North

replace the thermostat

Y Refill coolant and check again

To completely discharge the air bubbles, open the radiator cap and start the engine when the engine is cold, then press the water hose lightly with your hands to exhaust it. Rotate the throttle repeatedly until the coolant surface stabilizes.

Please note that the water pipe cannot be bent or twisted properly and remove air bubbles well.

12-4

in this chapter

12. Cooling system

System test

Filler Plug Test To seal the fill plug, add water and pressure to the fill plug. If the specified pressure cannot be maintained within a certain period of time or the crack pressure is too high or too low, replace it with a new one. The specified pressure must be maintained for at least 6 seconds during the test Filling plug relief pressure: 0.9-0.15 kgf/cm2

Apply pressure to the radiator, engine and water lines and check for leaks.

warn

Excessive pressure can damage the radiator. Never use a pressure greater than 1.05 kg/cm2.

If the system does not maintain the specified pressure for at least 6 seconds, repair or replace the part. coolant replacement

warn

Never attempt to service the cooling system unless the engine is completely cold, or you could burn yourself.

Remove the front center cap, then remove the fuel filler cap. Place a container of water under the water pump, loosen the drain bolt to drain the coolant. Reinstall the drain bolt.

Fill the system with coolant and expel any air bubbles. Start the engine and remove the bypass pipe. Check the bypass holes for air bubbles

broadcast. If you shoot without a bubble, you only have one

The coolant came out, the return line fitting caught fire and the engine stalled.

Remove the filler cap from the cooler. Start the engine and check for air

There are air bubbles in the radiator coolant and the coolant level is also stable.

Stop the engine. Add coolant to the correct level if necessary.

Screw and tighten the radiator filler cap.

CAUTION To avoid oxidation of the water tank, do not use an unknown brand of coolant. Recommended Coolant: TGB Bramax Radiator Fluid. Concentration: 50%

pressure meter

Bypass drain bolt

cap

12-5

12. Cooling system

in this chapter

Checking the water tank Remove the front center cover and then

Remove the filler cap from the oil pan. Check the fluid level in the right front fender

side. If the coolant is too low, add coolant to the correct level. Replace the reserve fuel tank filler cap.

warn

The liquid level of the water storage tank is also not high, to prevent the cooling system from overflowing and the coolant returning after the water temperature rises.

Superior and subordinate

cooler

INSPECTION Remove the front center cover, side covers and front fenders. (see Chapter 13), check for leaks at the welds. Clean the radiator with compressed air. If the radiator is clogged with dirt, it can be cleaned with a low-pressure water gun. Be careful when straightening your sink fan.

Disassembly Place a container of water under the water pump, loosen the drain bolt to drain the coolant.

Drain bolt Remove the coolant filler pipe.

Fuel hose clamp

12-6

in this chapter

12. Cooling system

Loosen the 4 radiator bolts. Remove the upper coolant pipe.

coolant inlet pipe

Remove the 4 bolts to remove the coolant outlet pipe. Disconnect the thermal switch and connector from the fan motor, then remove the heat sink and cooling fan.

r Removal Loosen the 3 bolts of the air duct, then remove the air duct. Loosen the 3 screws on the fan motor and remove the fan motor. Remove the nuts to remove the fan from the fan motor.

Installation Place the fan motor in the air duct and install the fan on the motor shaft. Apply a coat of glue to the threads of the motor shaft, then install the washer and lock nut. Fasten the fan duct to the radiator with 3 bolts. Refer to Chapter 17 for thermal switch inspection.

warn

A wet seal must be placed on the thermal switch before installation to prevent damage to the cooler.

Installation Install the removed parts in the reverse order of removal. Install the radiator in the reverse order of removal. When finished, check for leaks.

12-7

thermal switch

coolant outlet pipe

12. Cooling system

in this chapter

water pump

Check water pump seals/Cooling system leak check Remove coolant drain plug, overflow

Slightly double the N real fluid, be sure if it is oily it will overflow the coolant.

Turn on the oil gauge lathe and check if the oil has emulsified and turned white.

If you have the above two internal leaks, the two inner water pump seals, the engine cooling system, or the cylinder head gasket may be damaged. confirm the replacement of the water pump sealing ring, if not If there is a problem, disassemble the cylinder head and cylinder block to maintain the system cooling system.

Remove the water pump Loosen the drain screw to drain the coolant. Remove the water pipe. Loosen 4 bolts and remove the pump cover. Loosen 9 bolts and remove the right cover. Remove the washer and pin.

Turn the pump impeller clockwise and remove it.

warn

The impeller has a left hand thread. Remove the safety clip from the right crankcase cover. Remove the water pump shaft and inner bearing. Remove the outer bearing with an inner bearing puller. By rotating the inner ring of the bearing, the bearing moves smoothly and quietly. If the bearing does not rotate smoothly or makes noise, replace it with a new one. Special tool: Internal bearing puller

drain bolt

12-8

in this chapter

12. Cooling system

Check the mechanical seal and the inner seal for wear and damage.

warn

The mechanical seal and inner seal must be replaced as a unit.

Machinery stamp

Replacing the mechanical seal Remove the inner bearing with an inner bearing puller. Remove the mechanical seal and inner seal from the right crankcase. Special Tools: Inner Bearing Puller Water Pump Bearing Guide

warn

Replace with a new mechanical seal after disassembly.

Water pump impeller bearing

Before installing the new mechanical seal, apply a coat of sealant to the mating surface of the right crankcase.

Install the mechanical seal in the right crankcase. Special tool: mechanical water pump impeller

Mechanical seal mechanical impeller water pump

12-9

12. Cooling system

in this chapter

Install a new inner seal in the right crankcase. Special tool: water pump oil seal screwdriver (inside)

Install a new outer bearing in the right crankcase cover. Special Tool: Water Pump Bearing Driver (6901)

warn

Do not reuse old bearings. It must be replaced with a new one after removal.

Water Pump Oil Seal Driver (Inner)

Water Pump Impeller Bearing (6901)

Install the water pump shaft and inner bearing into the right crankcase cover.

internal bearing

Water pump shaft Install the snap ring to secure the inner bearing.

12-10

in this chapter

12. Cooling system

Install the sealing gasket on the impeller.

warn

The gaskets must be replaced along with the mechanical seal.

Install the impeller onto the water pump shaft and tighten. Torque value: 1.0~1.4kgf-m

warn

The impeller is left-hand threaded.

water pump rotor

Install the right cover pin and washer. Rotate the water pump impeller so that the water pump drive shaft bucket groove lines up with the oil pump drive shaft flange and install the right crankcase. (9 bolts)

Install cotter pins and new washers. Install the water pump cover with 4 bolts.

12-11

12. Cooling system

in this chapter

Thermostat See Section 17 Checking the temperature sensor.

Disassembly Drain the coolant. Remove the thermostat assembly. (2 bolts)

temperature sensor tube

2 Bolt Inspection Visually inspect the thermostat for damage.

Place the thermostat in hot water to test its operation.

warn

As long as the thermostat and thermometer are in contact with the wall of the hot water tank, the reading displayed will not be correct. If the thermostat valve remains open at room temperature or if the valve operation does not match the temperature change, it must be replaced.

Technical parameters Valve start to open 82~95 Valve travel 0.05~3mm

Installation Install the thermostat. Install the thermostat cover. (2 bolts) Refill coolant and expel air bubbles, page 12-5.

12-12

13. Body cover

Mechanism diagram

13-1

13. Body cover

Maintenance body cover removal sequence

l Be careful not to damage multiple covers when assembling or disassembling. l Do not damage the hooks molded into the body cover. l Align the tabs on the guard with the slots on the cover. l Make sure each hook is correctly positioned during assembly. l Do not forcefully compress or hammer the panels and covers during assembly.

13-2

Fuel tank cap

left and right footrest

Left and right front inner fenders

Left and right front shock mount, front bumper

front air intake panel

Left and right headlight brackets, body cover

rear body cover

front guard

back protector

upper arm assembly

13. Body cover

Remove the seat Remove the 2 bolts holding the battery

Remove the cables and the battery base

Remove 1 screw and remove the shift lever Remove the fuel tank cap

Remove 4 bolts and then remove the tank cap. Installation Install in the reverse order of removal.

13-3

13. Body cover

Remove the left or right leg bolts (4 bolts per side)

Remove the left or right leg screws (8 screws each side) Remove the left or right leg M6 bolts Remove the left or right leg (3 bolts each side)

Remove the left or right front inner fender bolts (5 bolts per side), then remove the left or right front inner fender

Remove 4 bolts from the front bumper. Remove the 2 front bumper bolts. Installation Install in the reverse order of removal.

13-4

13. Body cover

Remove the front bumper bolts (3 bolts each side)

Remove the headlight connector and then the front bumper.

Remove the left and right headlight arm bolts (2 bolts on each side)

Remove the front air intake plate bolts (2 bolts on each side), then remove the front air intake plate bolts (1 bolt on each side) INSTALLATION Install in the reverse order of removal.

13-5

13. Body cover

remove the locking cap

Remove the power supply, and then remove the front body cover.

Remove the bolts (1 bolt per side)

Removing the 2 links Installation Install in reverse order of removal.

13-6

13. Body cover

Remove 1 coupler and 1 nut from the starter relay, then remove the starter relay.

Remove 1 bolt from the rear body cover.

Remove 1 nut (1 bolt on each side) from the bear reflector assembly

Remove license plate lamp coupler, tail lamp assembly coupler (L/R) and turn signal coupler (L/R) INSTALLATION Install in reverse order of removal.

13-7

13. Body cover

Remove the back cover screws (2 screws on each side), then remove the back cover.

Remove the 2 front protective bolts.

Remove the 2 front bumper bolts, then remove the front bumper.

Remove the cover bolts (1 bolt per side) INSTALLATION Install in the reverse order of removal.

13-8

13. Body cover

Remove the cover bolts (1 bolt per side), then remove the cover.

Remove the upper arm assembly bolts (2 bolts on each side)

Remove the coupler from the speedometer assembly, then remove the upper arm assembly. Installation Install in the reverse order of removal.

13-9

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14. Front brake and front wheel

Mechanism Diagram························

Care Instructions ···································.

Front wheel ·································· ················; ····························································· ··············; ····························································· ·············; ····························································· ············; · · ·············· 14-4

Front Hub ······································· ········; ·······························································; ····························································· ···············································································; ····························································· ··············; ····························································· ·············; ····························································· 14-4

Disc Brake System Inspection... 14-7

Adding Brake Fluid 14-8 Replacing Brake Fluid/Bleed Air 14-9 Front Brake Calipers ·········| ····························································· · 14- 11 Front brake cylinder 14-11

Mechanism diagram

front master cylinder

forward pressure control valve

Brake hose bolt (3.5 kgf-m)

Bleed valve (0.5 kgf-m)

On back pressure control valve 14

Caliper Bolts (3.25 kgf-m)

Brake disc bolts (4.25 kgf-m)

Bearing (6203LU)

Front wheel nut (2.4kgf-m)

Front axle channel nut (5.0 kgf-m)

14-1

in this chapter

14. Front Brake and Front Wheel Maintenance Instructions Operating Precautions

warn

Inhaling asbestos can cause respiratory disease or cancer, so never use an air hose or dry brush to clean brake parts. Use a vacuum cleaner or other authorized tool.

The brake calipers can be removed without disassembling the hydraulic system. After removing the hydraulic system or if the brake system is too soft, bleed the hydraulic system.

System. When topping up the brake fluid, care must be taken to prevent foreign bodies from entering the brakes.

System. Do not spill brake fluid on painted surfaces, plastic or rubber parts as this may cause damage. Check the operation of the braking system before driving. Refer to the Tubeless Tire Maintenance Manual for instructions on removal, repair and

Tire installation. Determination

Standard (mm) Limit (mm)

Front and rear brake disc thickness 3.500 2.000

Disc eccentricity front and rear < 0.100 0.300

Master cylinder bore 14.000~14.043 14.055

Master Cylinder Piston Outer Diameter 13.957~13.984 13.945

Front Disc Diameter 175,000 -

Front brake pad thickness 5,500 2,000

Cold tire pressure: 0.8 kg/cm² (12 psi)

Torque value Brake hose bolt 3.50 kgf-m Brake caliper bolt 3.25 kgf-m Disc brake bolt 4.25 kgf-m Brake lever nut 1.00 kgf-m Bleed valve 0.50 kgf-m Front wheel nut 2 ,40 kgf-m Front axle 5. -M

14-2

in this chapter

14. Front Brake and Front Wheel Troubleshooting Soft brake lever

1. Air in hydraulic system 2. Leaking hydraulic system 3. Worn master piston 4. Worn brake pads 5. Bad brake calipers 6. Worn brake linings/discs 7. Insufficient brake fluid 8. Soft brakes Hose is clogged. /bent brake disc

10. Brake lever bent The brake lever is difficult to operate

1. Blocked brake system 2. Bad caliper 3. Blocked brake line 4. Blocked/Worn master cylinder piston 5. Brake flex lever

abnormal braking

1. Dirty brake pads/disc 2. Bad wheel alignment 3. Blocked brake hose 4. Bent or twisted brake disc 5. Blocked brake hose and fittings

tight brake

1. Dirty rotors/pads 2. Poor wheel alignment 3. Warped or warped rotors

brake noise

1. Dirty lining 2. Warped disc 3. Badly fitted brake caliper 4. Disc or wheel imbalance

hard steering wheel

1. Defective tire 2. Insufficient tire pressure

front wheel sway

1. Defective tire 2. Worn front brake drum bearings 3. Bent rim 4. Axle nuts not properly tightened

turn aside

1. Bent bar 2. Incorrect wheel placement 3. Uneven tire pressure 4. Incorrect wheel alignment

14-3

in this chapter

14. Front brake and front wheel Removing the front wheel Lift the front wheel off the ground by placing a jack or other support under the frame.

4 bolts Remove the front wheel nuts and remove the front wheel.

INSTALLATION Install the front wheel and tighten the nuts. Torque: 5.0 kgf-m

4 Nuts Front Hub Removal Remove the front brake caliper (2 bolts).

2 bolts Remove the fork, hub nuts and washers. Remove the brake hub and disc.

hub nut

Pins 14-4

in this chapter

14. Front brake and front wheel Remove 4 hex socket head cap bolts, then remove the brake rotor from the hub.

INSTALLATION Place the front brake disc on the hub. Install the brake hub and disc onto the joint. Install the hub washers and tighten the hub nuts. .Torque: 9.0kgf-m Install the key

4 bolt hub nuts

cotter pin

Install the front brake caliper.

Torque: 3.5kgf-m

2 bolts

14-5

in this chapter

14. FRONT BRAKE AND FRONT WHEEL Check the disc brake system Visually check for air leaks or damage, check the brake pipe joints with a wrench, if loose, turn the control lever right or left or press the Pad, either other than pipeline protection department, if there is interference, contact other parties.

Check the brakes behind the caliper. When the wear limit of the brake pads is reached on the brake disc, new brake pads must be replaced.

warn

Check that the front brake pads must be removed from the front wheels first.

Park the ATV on level ground and check that the fluid level is below the "LOW" mark. Recommended brake fluid: WELL RUN Brake Fluid (DOT 4).

warn

The vehicle is tilted or just stopped and the oil level is not checked accurately, it should be stable for 3-5 minutes.

To avoid chemical changes, do not use counterfeit or other unknown brands of brake fluid.

Of course, it must be used with brand brake fluid to ensure the performance of the ghost car.

14-6

on the capital stage

14. Front brakes and front wheels Adding brake fluid Before removing the brake fluid reservoir, turn the handle to level the brake fluid reservoir, then remove the brake fluid reservoir. When servicing the brake system, the surface must be painted or the rubber parts will be caught with rags.

warn

Provide brake fluid, do not exceed the upper limit, splashing brake fluid on painted surfaces, plastic or rubber parts can cause damage.

Remove the master cylinder head and diaphragm. To improve brake fluid quality, be sure to use a branded brake fluid joint in the master cylinder. Clean dirty brake discs.

warn

Dirty brake discs or linings reduce braking performance.

Mixing incompatible brake fluids will reduce braking performance.

Foreign objects can block the system, resulting in reduced or lost braking performance.

higher level

Bolt master cylinder Cylinder head Diaphragm

14-7

or the contents of this chapter

14. Front Brake and Front Wheel Fluid Change/Bleed Connect the drain hose to the bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is completely drained. Close the oil drain valve and add the specified brake fluid to the master cylinder. Recommended brake fluid: WELLRUN DOT 4 brake fluid

You need to bleed air from the pressure control valve cuff. Connect one end of the clear tube to the deflation valve and place the other end into the container.

Open the drain valve about 1/4 of a turn while holding the brake lever until there are no air bubbles in the drain hose and you feel resistance from the brake lever.

After the brake system filling process is completed, close the oil drain valve and operate the brake lever to check for air bubbles in the brake system.

If the brakes are still soft, follow these steps to bleed the system: 1. Firmly hold the brake lever and open the drain.

Valve about 1/4 of a turn, then close the valve.

warn

Do not release the brake lever until the drain valve closes.

Always check the brake fluid level when performing the bleeding procedure to prevent air from entering the system.

2. Slowly release the brake lever and wait a few seconds until it reaches the up position.

3. Repeat steps 1 and 2 until there are no air bubbles at the end of the hose.

4. Close the drain valve tightly. 5. Make sure the brake fluid is at the TOP level

master cylinder and refill with fluid if necessary.

6. Close the lid.

bubble

Release valve

transparent tube

14-8

in this chapter

14. Front Brake and Front Wheel Front Brake Caliper Removal Place a container under the brake caliper, loosen the brake hose bolt, and finally remove the brake hose.

warn

Do not spill brake fluid on painted surfaces.

Remove the two bolts and the caliper.

Check to make sure the brake pads are in good condition. If the brake lining wears the stop groove near the disc, replace the lining.

Replacing the brake pads Remove the two guide pins. Compress the caliper support plate and remove the brake pads. Install new bushing and tighten guide pin.

Installation Install the brake caliper and tighten the mounting bolts.

Torque: 3.25 kgf-m

warn

Use only M8 x 18 mm flange bolts. Long bolts can affect brake operation.

disc. Use two washers and hose bolts to secure the hose and caliper in place. Torque: 3.5 kgf-m Refill the brake fluid reservoir and bleed as necessary.

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in this chapter

14. FRONT BRAKE DISC AND FRONT WHEEL INSPECTION Visually inspect the brake disc for wear or cracks. Measure the thickness of the disc in several places. If the service limit is exceeded, replace the disk. Allowable limit: 2.5 mm

disc brake

Micrometer Remove the brake disc from the hub. Check the disc for warping and distortion. Allowable limit: 0.30 mm

warn

Dirty brake discs or linings reduce braking performance.

Brake pads contain asbestos and cannot be cleaned with an air gun. Operators must wear nozzles and gloves and vacuum them.

Removing the front brake master cylinder

warn

Do not allow foreign bodies to enter the cylinder.

warn

The complete master cylinder, piston, spring, diaphragm and circuit assembly must be replaced as a unit.

Push the brake light switch wire, then remove the brake light switch. Drain the brake fluid. Remove the brake lever from the master cylinder. Remove the brake hose. Remove the master cylinder head cover bolts and the master cylinder.

14-10

in this chapter

14. Front brake and front wheel Remove the rubber boot. Remove the round clip. Remove the piston and spring. Clean the master cylinder with the recommended brake fluid.

rubber boots

plunger

clip circle

piston cup

spring and summer

Master Cylinder Inspection Check the master cylinder for damage or scratches. Replace it if necessary. Measure the cylinder bore at several points along the X and Y directions and replace the cylinder if the measured value exceeds the allowable range. Permissible limit: 14,055 mm

Measure the outer diameter of the piston. If the measured value exceeds the permissible limit, replace the piston. Permissible limit: 13.945 mm

master cylinder assembly

warn

It is necessary to replace the entire assembly.

It consists of piston, spring, piston cup and clamp ring.

Make sure all parts are free of dust before assembly.

Apply clean brake fluid to the piston cup and place the cup on the piston. Place the longer end of the spring into the master cylinder. When installing the master cup, the hole in the master cup must face the master cylinder. Install the round clip.

warn

Never place the rim of the mug in the opposite direction. Make sure the round clip is securely attached to the

coin slot.

Place the rubber boot correctly in the groove.

rubber boots

plunger

piston cup

Cir clip Muelle

main tank

14-11

in this chapter

14. Front brake and front wheel installation master cylinder Install the rubber pads correctly in the grooves. Place the master cylinder on the steering wheel and install the bolts.

Install the brake lever and connect the wires to the brake light switch.

Connect the brake hose with 2 new washers. Tighten the brake hose bolts to the specified torque value. Torque: 3.2 kgf-m Make sure the hose is installed correctly. Place all cables, hoses and fittings carefully to avoid kinking.

warn

Improper routing can damage cables, hoses or pipes.

brake light switch lever bolt

warn

Bends in brake cables, hoses or pipes can reduce braking performance.

Add the specified brake fluid and bleed the system.

14-12

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14. Front brake and front wheel precautions:

14-13

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15. Steering/Front suspension

Mechanism Diagram ·······················, ··························· ················; ····························································· ···································································································; ····························································· ···································································································; ····························································· ·············; ····························································· ···············································································; ····························································· ···············; ····························································· ············; ··········· 15-1

Precautions during operation···································· ·······································································.

troubleshooting················································ ··? ····························································· ············; 15-2

Handling Handles·····································

Axis Direction ············; ····························································· ············; ········ 15-5

BAR Tie ································· ··············; ····························································· ···········; ····························································· ·····; ····························································· ············; ····························································· ···········; ····························································· ············; ····························································· ··············; ····························································· ············; ··· 15-10

Mechanism diagram

300~350 kgfcm

250~350 kgf-cm 700~900 kgf-cm

15 450~550 kgf cm

250~350 kgfcm

400~430 kgf-cm 400~430 kgf-cm 450~550 kgf-cm 450~550 kgf-cm

450~550 kgf-cm 600 kgf-cm 450~550 kgf-cm

15-1

in this chapter

15. STEERING / FRONT SUSPENSION Operating precautions Torque value Steering Upper arm bolt 300~350 kgf-cm Steering stem base bolt 300~350 kgf-cm Steering stem nut 250~350 kgf-cm Steering nut 300~350 kgf-cm Joint nut 6 00 kgf-cm Rod lock nut 450~550 kgf-cm Suspension arm nut 450~550 kgf-cm Front shock absorber mounting nut 450~550 kgf-cm cm

Troubleshooting Difficulty turning Defective tire. The steering shaft is mounted too tightly. Insufficient tire pressure. The steering shaft bushing is defective. The steering shaft bushing is damaged.

Front wheel wobbles Defective tire. Worn front brake drum bearings. The flange shaft nut is not tightened.

The direction in which the side straps bend. The wheels are not fitted correctly. Uneven tire pressure. Curved frame. Worn rocker pivot ring. Wheel alignment is not correct.

Front Suspension Noise Loose front suspension links. Connecting floating links. Stiff suspension Defective front bushings. Incorrect placement of front fork. Curved front shock absorber pivot rod. Soft suspension Weak front shock springs. Worn or damaged front wheel bushings.

15-2

in this chapter

15. Steering Handlebar/Front Suspension Removal Remove the handle cover, instrument panel, handle guard and front fender. (See Chapter 13)

Loosen the front brake master cylinder hex socket head screws and remove the front brake master cylinder.

warn

Do not allow foreign bodies to enter the cylinder.

Grip guard bolt

master cylinder bolt

Remove 2 bolts, then remove throttle tube bracket and throttle hose.

2 Screws Loosen the hex bolts of the front brake master cylinder and remove the front brake master cylinder.

warn

Do not allow foreign bodies to enter the cylinder.

master cylinder bolt

Grip guard bolt

15-3

in this chapter

15. Handlebar/front suspension Loosen 2 bolts, then remove the left handle switch and choke hose.

2 screws Remove the belt from the switch. Remove the handle mounting bolts, then remove the handle upper arm and handle.

Remove 2 nuts to remove the bracket and hold it under the gauge arm.

4 hex socket head screws

2 Installing nuts Install in the reverse order of removal.

Torque values: Lower steering arm nut 4.0 kgf-m Upper steering arm bolt 2.4 kgf-m

15-4

in this chapter

15. Steering Shaft/Front Suspension Removal Remove the tie rod pin and loosen the left and right tie rod nuts. Remove the straps.

Remove the pin under the steering shaft and remove the nut and washer from the steering shaft.

steering shaft nut

Cotter pin Bend the steering axle arm nut mounting plate. Loosen the 2 bolts and remove the steering shaft bracket, nut retaining plate, pressure plate and steering shaft.

Inspection Inspect the oil rings for wear or damage and replace if necessary. Measure the inner diameter of the stent. Maximum Limit: Ø39.5 mm

fixed plate

oil ring

Installation Install in the reverse order of removal. Grease the baking sheet and base.

Torque values: Axle base bolts 3.4 kgf-m Axle nuts 5.0 kgf-m Mounting nuts 5.0 kgf-m

oil ring

oil lining

15-5

in this chapter

15. Steering Rod/Front Suspension Removal Remove the pin and nut from the tie rod on the steering shaft side.

Remove the bolts and nuts from the side tie rods of the wheel.

Inspection Check the tie rods for damage or bending. Check the ball joint rubber for damage, wear or wear. Use your fingers to turn the ball joint. The ball joint must rotate smoothly and quietly.

Ball Joint Installation Place the ball joint into the "adjustment groove" on the side of the wheel. Install the rod nuts and tighten the nuts. Torque value: 5.0 kgf-m

After tightening the tie rod nuts, install the pins.

Adapter socket 15-6

in this chapter

15. Steering/Front Suspension Removal Remove the front wheels, front brake calipers, front calipers and brake rotors.

Remove the rod pin and nut and remove the rod.

Tight

Nut

cotter pin

Remove the pin and nut from the ball joint. Use a mallet to remove the top and bottom ball heads. Remove the joint.

Special tool: ball guide

general support

Ball Joint Inspection Inspect the upper and lower ball joints and stems for damage or cracks.

Installation Install in the reverse order of removal. Torque value: Rod nut 5.0 kgf-m Ball nut 5.0 kgf-m After tightening the nut, install the rod pin.

Finger joint

ball joint

15-7

in this chapter

15. Steering/Front Suspension Removal Front shock Remove the front shock under the bolt nut and remove the bolt.

Remove the nuts from the bolts on the front shock, then remove the bolts and shock.

Installation Install in the reverse order of removal. Torque value - Front shock nut 4.6 kgf-m

Nut

15-8

in this chapter

15. Steering/Front Suspension Suspension Arm Removal Remove the front wheels, hubs and calipers, brake discs, rods, joints and front shock absorbers.

Loosen the upper headlight nut and remove the rocker arm bolt. Remove the upper control arm.

Loosen the nuts under the suspension arms and remove the swing arm bolts. Remove the suspension bracket.

Inspection Check the control arms, ball joints and bushings for damage or bending.

Cantilever bolts and nuts

Installation Install in the reverse order of removal. Torque value: Suspension arm nut 5.0 kgf-m

Lubricate the suspension arm with grease.

dense

15-9

in this chapter

15. Steering/Front Suspension Toe In When repairing or removing steering components, the toe in must be adjusted. Keep the vehicle on level ground with the front wheels facing forward. Mark the center of the tire to indicate the height of the center of the axle. Measure the distance between the markers.

To move the vehicle backwards, carefully turn the wheels 180 degrees so that the markings on the tires line up with the height of the center of the axle. Measure the distance between the markers. Calculate the difference between the before and after measurements.

Front beam: 10±3 mm

If the toe-in is not standard, it can be adjusted by rotating the tie rod while holding the ball joint to hang the length of the tie rod evenly. Loosen the two lock nuts on the side straps, turn the lever to the inward adjustment position. Tighten the lock nut. Torque value: 3.6 kgf-m

fasten the screw nut

15-10 adapter socket

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16. Rear brake and rear wheel and rear pad

Mechanism Diagram························

Care instructions······························ 16-2

troubleshooting················································ ··? ····························································· ············; ·. ·. ····························································· ···? ····························································· ············; ······································ 16-3

Rear wheel ···································· 16-4

Rear wheel axle joint

Rear axle... ····························································· ············; ····························································· ·; ········································ 16-5

Disc brake system check·································· ··································································.

DISC BRAKE SYSTEM INSPECTION ····································· ················································································; ····························································· ··············; ····························································· ·······································································; ····························································· ············; ····························································· ············; ····························································· ···································································································; ····························································· ············; ····························································· ············; ··. ········································· 16-18

Mechanism diagram

Rear brake master cylinder A

Brake hose bolt (3.5 kgf-m)

Back pressure control valve

Bleed valve (0.5 kgf-m)

On the positive pressure control valve

Brake disc bolts (4.25 kgf-m)

Caliper Bolts (3.25 kgf-m)

Rear Axle Support Bolts (9.2 kgf-m)

Rear axle nut (9.2 kgf-m)

Rear brake master cylinder B

Drive nut 16 (4.6 kgf-m)

Rear wheel nut (2.4kgf-m)

Rear axle channel nut (5.0 kgf-m)

16-1

in this chapter

16. Rear brake, rear wheel and rear pad maintenance instructions Operating precautions

warn

Inhaling asbestos can cause respiratory disease or cancer, so never use an air hose or dry brush to clean brake parts. Use a vacuum cleaner or other authorized tool.

The brake calipers can be removed without disassembling the hydraulic system. After removing the hydraulic system or if the brake system is too soft, bleed the hydraulic system.

System. When topping up the brake fluid, care must be taken to prevent foreign bodies from entering the brakes.

Tire installation. Determination

Standard (mm) Limit (mm)

Front and rear brake disc thickness 4,000 2,500

Disc eccentricity front and rear < 0.100 0.300

Master cylinder bore (parking brake) 14,000 ~ 14,043 14,055

Master Cylinder Piston Outer Diameter (Parking Brake) 13.957 ~ 13.984 13.945

Master cylinder bore (foot brake) 15,900 ~ 15,943 15,955

Master Cylinder Piston Outer Diameter (Foot Brake) 15.857 ~ 15.884 15.845

Rear Disc Diameter 220,000 -

Rear brake pad thickness 7,000 2,000

Cold tire pressure: 0.8 kg/cm² (12 psi)

Torque value Brake pipe bolt 3.50 kgf-m Brake caliper bolt 3.25 kgf-m Brake disc bolt 4.25 kgf-m Brake lever nut 1.00 kgf-m Bleed valve 0.50 kgf-m Rear wheel nut 2 .40 kgf-m

Rear Axle Channel Nut 5.00 kgf-m Rear Axle Support Bolt 9.20 kgf-m Rear Axle Nut 9.20 kgf-m Rear Shock Mount Bolt 4.6 kgf-m Rocker Pivot Suspension Bolt 9.2 kgf-m

special tools

Inner Bearing Puller: SYM-6204022 Rear Axle Bearing Guide (6007LLU): SYM-9100100 RA1 A3017

16-2

in this chapter

16. Soft Brake Lever Rear Brake and Rear Wheel and Pad Troubleshooting

10. Brake lever bent The brake lever is difficult to operate

1. Blocked brake system 2. Bad caliper 3. Blocked brake line 4. Blocked/Worn master cylinder piston 5. Brake flex lever

abnormal braking

1. Dirty brake pads/disc 2. Bad wheel alignment 3. Blocked brake hose 4. Bent or twisted brake disc 5. Blocked brake hose and fittings

tight brake

1. Dirty rotors/pads 2. Poor wheel alignment 3. Warped or warped rotors

brake noise

1. Dirty lining 2. Warped disc 3. Badly fitted brake caliper 4. Disc or wheel imbalance

vibration or vibration

1. The axle is not tight 2. The rim is bent 3. The axle bearing is worn 4. The tire is defective 5. The rear axle bearing support is defective

hard suspension

1. Bent shock rod 2. Defective scissor pivot ring

soft suspension

1. Weak shock absorber 2. Weak shock absorber spring

16-3

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16. Rear brake, rear wheel and rear pads Removing the rear wheel Place a jack or other support under the frame to lift the rear wheel off the ground. Remove the rear axle cover (4 bolts).

4 bolts Remove the rear wheel nuts and remove the rear wheel.

INSTALLATION Install the rear wheel and tighten the nuts. Torque: 2.4 kgf-m

4 Nut Rear axle connector removal Remove the fork, rear axle connector nut and washer.

hub nut

Cotter pins to remove left and right rear wheel axle plugs.

INSTALLATION Install the rear axle connector. Install the axle connector washers and tighten the axle connector nuts. Torque: 2.4 kgf-m Installation key.

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in this chapter

16. Rear brake, rear wheel and rear shock absorber Rear axle Remove the rear left and right wheels and wheel connectors. Remove 2 bolts and then remove the rear brake caliper.

Remove 2 bolts and 1 nut, then remove the drive chain cover.

2 bolts

1 nut Remove 4 bolts to remove the rear skid plate.

2 screws on the front

Rear 2 bolts Remove the drive chain retaining clip, the main link and then the drive chain.

main link

lock clip

16-5

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16. Rear brake and rear wheel and rear shock absorber Remove 4 nuts and remove the drive sprocket. Bend the rear axle nut retaining plate.

Bend the mounting plate for the rear axle mounting nut.

Mounting plate Remove the rear axle nuts. Special Tool: Rear Axle Nut Wrench (55mm)

Remove the rear brake disc bracket and brake disc.

brake disc support

16-6

in this chapter

16. Rear brake, rear wheel and rear pad Remove the rear axle and drive sprocket support.

Sprocket Bracket Inspection Check the bearings in the rear wheel half shaft bearing housings. Use your fingers to turn the inner race of each bearing. Check that the bearing rotates smoothly and quietly and also check that the outer race of the bearing is seated in the housing. If the bearing turns unevenly, makes noise or is loose, replace it. Check the oil seal for wear or damage and replace if necessary.

to be disassembled

warn

Never install used bearings. After the bearing is removed, it must be replaced with a new one.

Use the following tools to remove the bearings and housing seals from the rear axle. Special Tool: Inner Bearing Puller (SYM-6204022) Remove the bearing components.

Assembly Fit new left side bearing and seal to rear axle bearing housing. Install the rear wheel bearing half shaft inner spacer. Install a new right outboard bearing and seal on the front hub. Apply grease to the oil seal lip of the rear axle. Special tool: bearing guide (6007LLU) oil seal guide (48×62×7) oil seal guide (43×62×12)

Puller inner bearing

16-7

in this chapter

16. Installing the rear brake, rear wheel and rear pad Install the rear axle and drive sprocket support.

Gear support

Install the rear brake disc bracket and brake disc.

Install the rear axle nuts, rear axle nut mounting plate and tighten the nuts. Torque: 9.2 kgf-m Special tool: Rear axle nut wrench (55 mm) Rear axle nut torque wrench Torque wrench

After tightening the axle nuts, bend the rear axle nut mounting plate.

brake disc support

fixed plate

16-8

in this chapter

16. Rear brake and rear wheel and rear shock Install the drive gear, drive chain, drive chain cover and brake caliper.

warn

Note the orientation of the chain lock clips.

Direction of movement

main link

Install the rear axle connector, rear wheel.

Pinion Inspection with Locking Clip Check the condition of the driven gear teeth.

If worn, replace the gear. or X note

Also check the drive chain, drive sprocket and drive sprocket for wear.

Rear Swingarm Removal Remove the rear skid plate, drive chain, drive sprocket, rear brake caliper, brake rotor and rear axle. Remove 2 nuts and bolts, then remove the rear axle support.

Remove the lock nut from the rear scissor. Remove the rear swing arm bolts, then remove the rear swing arm.

fasten the screw nut

16-9

in this chapter

16. REAR BRAKE, REAR WHEEL AND REAR CUSHION Check the disc brake system Check the visual inspection, if there is air leakage or damage, check with an inspection key, the joint of the brake pipe is loose, the inspection area of the steering wheel is turned to the right or left, or Tap on the mat. , if there is interference other than the conductor protection section, contact other parties.

Check the brakes behind the caliper. When the wear limit of the brake pads is reached on the brake disc, new brake pads must be replaced.

warn

Check that the rear brake pads must be removed from the rear wheel first.

Brake pad wear limit groove

disc brake

Park the ATV on level ground and check that the fluid level is below the "LOW" mark. Recommended brake fluid: WELL RUN Brake Fluid (DOT 3).

warn

The vehicle is tilted or just stopped and the oil level is not checked accurately, it should be stable for 3-5 minutes.

To avoid chemical changes, do not use counterfeit or other unknown brands of brake fluid.

Of course, it must be used with brand brake fluid to ensure the performance of the ghost car.

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16. Rear Brakes and Rear Wheels and Rear Shock Add Brake Fluid Before removing the brake fluid reservoir, turn the handle to level the brake fluid reservoir, then remove the brake fluid reservoir. When servicing the brake system, the surface must be painted or the rubber parts will be caught with rags.

warn

Provide brake fluid, do not exceed the upper limit, splashing brake fluid on painted surfaces, plastic or rubber parts can cause damage.

liquid cup

Remove the brake fluid cap and diaphragm. To improve brake fluid quality, be sure to use a branded brake fluid joint in the master cylinder. Clean dirty brake discs.

warn

Dirty brake discs or linings reduce braking performance.

Mixing incompatible brake fluids will reduce braking performance.

Foreign objects can block the system, resulting in reduced or lost braking performance.

main tank

higher level

threaded brake fluid cap

diaphragm

16-11

in this chapter

16. Change/Bleed Rear Brake Fluid, Rear Wheel and Rear Pad Connect the drain hose to the bleed valve. Open the drain valve on the caliper and operate the brake lever until the old brake fluid is completely drained. Close the oil drain valve and add the specified brake fluid to the master cylinder. Recommended brake fluid: WELLRUN DOT 3 brake fluid

Release valve

Connect one end of the clear tube to the drain valve and place the other end in the container. Open the drain valve about 1/4 of a turn while holding the brake lever until there are no air bubbles in the drain hose and you feel resistance from the brake lever. After the brake system filling process is completed, close the oil drain valve and operate the brake lever to check for air bubbles in the brake system.

If the brakes are still soft, follow these steps to bleed the system: 1. Firmly hold the brake lever and open the drain.

Valve about 1/4 of a turn, then close the valve.

warn

Do not release the brake lever until the drain valve closes.

Always check the brake fluid level when performing the bleeding procedure to prevent air from entering the system.

2. Slowly release the brake lever and wait a few seconds until it reaches the up position.

3. Repeat steps 1 and 2 until there are no air bubbles at the end of the hose.

4. Close the drain valve tightly. 5. Make sure the brake fluid is at the TOP level

master cylinder and refill with fluid if necessary.

6. Close the lid.

bubble

Release valve

transparent tube

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16. Rear brake, rear wheel and rear pad removal Rear brake caliper Place a container under the brake caliper, loosen the brake oil pipe screw, and finally remove the brake oil pipe.

warn

Do not spill brake fluid on painted surfaces.

brake hose bolt

Remove the two bolts and the caliper. Check to make sure the brake pads are in good condition. If the brake lining wears the stop groove near the disc, replace the lining. Installation Install the brake caliper and tighten the mounting bolts.

Torque: 3.25 kgf-m

warn

Use only M8 x 20mm flange bolts. Long bolts can affect brake operation.

disc. Use two washers and hose bolts to secure the hose and caliper in place. Torque: 3.5 kgf-m Refill the brake fluid reservoir and bleed as necessary.

Replacing the brake pads Remove the two guide pins.

Remove the cylinder from the caliper, then remove the brake pads. Install new caliper liners and cylinders. Tighten the guide pins.

Torque: 1.8 kgf-m

2 bolts

pin guide

16-13

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16. Brake Disc Inspection Rear Brakes, Rear Wheels and Rear Shocks Visually inspect the brake discs for wear or cracks. Measure the thickness of the disc in several places. If the service limit is exceeded, replace the disk. Allowable limit: 2.5 mm

disc brake

Micrometer Remove the brake disc from the rear axle. Check the disc for warping and distortion. Allowable limit: 0.30 mm

warn

Dirty brake discs or linings reduce braking performance.

Brake pads contain asbestos and cannot be cleaned with an air gun. Operators must wear nozzles and gloves and vacuum them.

Rear brake master cylinder removal

warn

Do not allow foreign bodies to enter the cylinder.

warn

The complete master cylinder, piston, spring, diaphragm and circuit assembly must be replaced as a unit.

brake lever bolt

brake light switch coupler

brake lever nut

Left Handle: Rear Master Cylinder A Remove the brake light switch connector. Drain the brake fluid. Remove the brake hose. Remove the brake lever from the master cylinder. Remove the master cylinder head cover bolts and the master cylinder.

2 socket cover screws 16-14

in this chapter

16. Rear Brakes and Rear Wheels and Rear Pads Right Footrest Side - Rear Brake Master Cylinder B Place a container under the brake master cylinder, remove the fluid hose clamps and drain the brake fluid. Loosen the brake hose bolts and finally remove the brake hose.

Remove the clip and remove the pin from the brake pusher. Remove the master cylinder head cover bolts and the master cylinder.

Removal Remove the rubber boot. Remove the round clip. Remove the piston and spring. Clean the master cylinder with the recommended brake fluid.

rubber boots

plunger

piston cup

clip circle

spring and summer

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in this chapter

16. Rear brake and rear wheel and rear shock absorber Measure the outside diameter of the piston. If the measured value exceeds the permissible limit, replace the piston. Permissible limit: handbrake 13,954 mm. footbrake 15,850 mm.

master cylinder assembly

warn

It is necessary to replace the entire assembly.

It consists of piston, spring, piston cup and clamp ring.

Make sure all parts are free of dust before assembly.

warn

Never place the rim of the mug in the opposite direction. Make sure the round clip is securely attached to the

coin slot.

Place the rubber boot correctly in the groove.

rubber boots

plunger

piston cup

Cir clip Muelle

main tank

master cylinder installation

warn

Improper routing can damage cables, hoses or pipes.

warn

Bends in brake cables, hoses or pipes can reduce braking performance.

Left Handle: Rear Master Cylinder A Position the rubber pad correctly in the groove. Place the master cylinder on the steering wheel and install the bolts. Install the brake lever and connect the coupler to the brake light switch. Connect the brake hose with 2 new washers. Tighten the brake hose bolts to the specified torque value. Torque: 3.5 kgf-m Make sure the hose is installed correctly. Place all cables, hoses and fittings carefully to avoid kinking. Add the specified brake fluid and bleed the system.

brake light switch coupler

2 hex socket head bolts

Brake Lever Bolt Brake Lever Nut

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16. Rear brake, rear wheel and rear leg RIGHT: Rear brake master cylinder B Install the master cylinder and master cylinder bolts.

Place the brake pusher on the brake pedal and install the pin and clip.

warn

The steering push rod pin must be removed when adjusting the brake pedal. Loosen the lock nut, turn the adjusting nut and the push rod bracket to adjust the brake clearance.

Install the fluid hose and clamps. Connect the brake hose with 2 new washers. Tighten the brake hose bolts to the specified torque value. Torque: 3.5 kgf-m Make sure the hose is installed correctly. Place all cables, hoses and fittings carefully to avoid kinking. Add the specified brake fluid and bleed the system.

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16. Rear Brake, Rear Wheel and Rear Pads Remove the rear pads to support the frame. Loosen the rear shock under the bolt nut and remove the rear shock under the bolt.

Nut

screw on the rear shock absorber

Remove the rear seat cushion upper bolts, then remove the rear seat cushion.

INSTALLATION Install the rear seat cushion and install the rear seat cushion bolts. Place the rear shock under the bolt and install the nut. Tighten the upper bolt and lower nut of the rear shock absorber to the specified torque value. Torque: 4.6 kgf-m

rear shock absorber bolt

16-18

home page content

17. Electrical system

Mechanism Diagram························

Maintenance Data···························· ··········································································| ············· 17-2

Technical specifications················································ ········|

Battery················································· 17-4

Billing System ·············-

Ignition system·················································|

Booting the system ···············; ········································· 17-10

Meter 17 -12 Light / Lamp ·································································· ····························································· ············; ····································; ····························································· ··.

Mechanism diagram

starter relay

Fuse box

front brake switch

Battery

CDI unit x

Related blink risk control unit

central transmission control unit

rear brake switch

air conditioner generator

heat unit

direct current. plug

Starter, lights, indicators, horn and brake switches

headlight relay

trumpet

Rectifier spark plug ignition coil change switch

17-1

in this chapter

17. Electrical Installation Maintenance Data Handling Precautions When removing the battery, the order in which the cable terminals are disconnected must be strictly observed.

(Disconnect the negative cable terminal first, then the positive cable terminal.) Spark plug size and torque. ignition time. Headlight adjustment. Alternator Disassembly. Maintenance-free batteries do not require checking electrolyte levels or filling with distilled water. To charge the battery, remove it from the chassis without removing the vent cover. Never fast charge the battery except in an emergency. The voltage should be checked with a voltmeter while charging the battery. No ignition timing check required due to C.D.I installation. If the ignition timing is incorrect, check it

C.D.I and alternator. If necessary, check with the ignition timing light after replacement. Technical Specifications Charging System

Description Specifications

Battery

Capacity 12V12Ah Charging rate 1.4A / 5~10 hours (standard)

14A/0.5 hours (quick charge)

Leakage current < 1mA

Charging current 1.2 A / 1500 rpm

Load control voltage 14.5 + 0.5 V / 1500 rpm ignition system

Description Specifications

spark plug

ignition coil and

Model NGK CR8E (recommended) Separate primary winding 0.8 mm 0.17 ± 10% Ω

Without cap: Secondary winding resistance 3.1±10KΩ

"F" marking for ignition timing

Con tapa: 8,1 ± 10KΩ 10° TDC / 1700rpm 27°TDC / 4000rpm

17-2

in this chapter

17. Electrical System Troubleshooting No Voltage Low Battery Voltage Wire Fuse Disconnected Fuse Blown The Main Switch

Low voltage Battery not fully charged Bad contact Bad charging system Bad voltage regulator

Spark plug does not light Spark plug does not work Poor wire connection, open circuit or

Short circuit - between AC.G. and C.D.I.

Poor connection between C.D.I. and ignition coil

- Bad connection between C.D.I and main switch

Bad main switch C.D.I. Bad A.G. Not working

Starter not working Fuse blown Battery not fully charged Faulty main switch Faulty starter switch Front and rear brake switches not working

Normal operation Starter relay does not operate Poor ignition coil contact, open circuit or

Short circuit The starter motor does not work

Intermittent power supply Variable charging system socket

Loose battery cable connection Bad connection or short circuit

Evacuation system Poor contact or short circuit of supply

manufacturing system

Charging system not working properly Blown fuse Bad contact, open circuit or short circuit Bad voltage regulator ACG motor not turning smoothly Main winding circuit

- Bad ignition coil - Bad cable connections and plugs - Bad main switch

Secondary winding circuit - Bad ignition coil - Bad spark plug - Bad ignition coil wire - Spark plug leak

Incorrect ignition timing - bad AC.G. - Pulse sensor not installed correctly - C.D.I error.

Weak starter motor Bad charging system Battery not fully charged Bad winding connections Motor gears caught by foreign object Starter motor runs but engine won't start Bad starter gear Reverse starter Low battery

17-3

in this chapter

17. Electrical System Battery Removal Remove the seat and you can access the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clip and then remove the battery...

Check Clamp Voltage Check battery voltage with a digital voltmeter. Voltage: Fully Charged: 13.0~13.2V at 20 Insufficient Charge: Below 12.3V at 20

Charging Connect the positive (+) terminal of the charger to the positive (+) terminal of the battery. Connect the negative (-) terminal of the charger to the negative (-) terminal of the battery.

typical max

Charging current 1.4A 14.0A

Charging time 5H 0.5H

warn

Keep it away from fire sources when charging. Charging is fully controlled by

Turn on/off the charger, not the battery cable.

CAUTION Do not fast charge the battery unless you

Emergency situations. Check if the battery is charged with current.

and the period specified above. High current and fast charging time

battery damage. When installing the battery, cover the cable terminals with grease.

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in this chapter

17. Electrical system Charging system Charging circuit

Main switch

green red

Refractory 20A

Black man

yellow

Battery

rectifier regulator

A/C Alternator Leakage Current Check Turn the main switch to the OFF position and remove the negative (-) terminal of the battery cable. Connect an ammeter between the negative terminal of the cable and the negative terminal of the battery.

Notes In the leakage current test, adjust the current

on maximum scale, then gradually decrease to minimum scale as the test progresses to avoid possible damage to the ammeter and fuses.

Do not turn the main switch to the ON position during the test.

If the leakage current exceeds the specified value, it may indicate a short circuit. Allowable leakage current: less than 1mA Remove each wire one by one, measure the current of each wire and find out the short circuit.

negative battery terminal

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17. Check the charging voltage of the electrical system

Voltmeter

electric meter

Connect the tachometer. Turn on the high beam headlights and start the engine. Accelerate the motor to the specified rpm and measure the charging voltage. Rated charging current:

1.2 A / 6000 rpm Controlled charging voltage:

14.5 + 0.5 V / 2000 rpm

safety plug

NOTE To replace an old battery, use a new battery with the same current and voltage.

CAUTION Before proceeding with the inspection, make sure

The battery is fully charged. If your power runs out, the current can change dramatically.

Use a fully charged battery with a voltage greater than 13.0V

When starting the engine, the starter draws a lot of current from the battery.

After the engine warms up, replace the original battery with a fully charged one. Connect a digital voltmeter to the battery terminals. Connect an ammeter across the main fuse.

warn

When the probe is reversed, use a voltmeter to indicate that current is flowing in the positive or negative direction and the reading should be zero and the ammeter only uses one direction.

Note Do not use short cables. The current can be measured by

Connect an ammeter between the positive battery terminal and the cable position terminal; however, the ammeter will be damaged by the excessive current the engine draws from the battery when the starter is engaged. Start the engine using the starter.

During the inspection, the main switch will be in the OFF position. Never handle the ammeter and cables while current is flowing. You may damage the ammeter.

The following issues are related to the charging system. If they appear, follow the instructions provided in the checklist to correct them. (1) The charging voltage cannot exceed

The charging voltage and current between the two terminals of the battery is in the discharging direction.

(2) The charging voltage and current are much higher than the standard value.

The following issues are not related to the charging system. If they are related, follow the steps indicated in the checklist to fix them. (1) Typical charging voltage and current

It can only be achieved when the engine speed exceeds the specified speed. - used lamps have exceeded their capacity and

Excessive energy consumption. - The replacement battery is old and

There is not enough capacity. (2) The charging voltage is normal, but

Currently not. - The replacement battery is old and

There is not enough capacity. - The used battery is low

current or overload. - Ammeter fuse blown. - Bad ammeter connection.

(3) The charging current is normal, but the voltage is abnormal. - Blown voltmeter fuse.

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17. ELECTRICAL INSTALLATION Check rudder rectifier Remove the seat, rear luggage rack and rear fender. Disconnect the two 3-pin connectors from the regulator rectifier. Check the compliance of the rectifier coupler in the harness.

Element Checkpoint Standard value

Main switch connection battery R – B

battery voltage

(exists)

Connect the R – G battery voltage

Load coil Y – Y 0.17 ~ 0.8 Ω If the measurement reading is abnormal, check the circuit component. If the component is OK, the problem is with the wiring. If the components and wiring are OK, replace the regulator rectifier.

17-7

in this chapter

17. Ignition System Ignition Circuit Diagram ELECTRICAL SYSTEM

transmission control unit

gram

early late

data center. unit

Gross weight/weight

pass through

B Black R Red G Green W White Y Yellow L Blue

gram

A/B

Fusible 15A

B fusible master

30A

left right

spark plug

transition to

Spiral

Battery

Main switch

gram

Pulse generator C.D.I unit Disconnect the C.D.I unit connector. Check the following connectors shown on the wiring side panel.

item point of the control result

Main switch turned to "ON" position Black/White ~ Green Battery voltage

Pulse Generator Green/White ~ Blue/Yellow 50~170Ω

Primary circuit Black/Marillo ~ Green 0.17±10%Ω

Ignition coils

secondary circuit

Black/Yellow ~ No cap 3.6±10%Ω

Black/yellow~cap 7.3~11KΩ 17-8

in this chapter

17. ELECTRICAL SYSTEM Ignition Coil INSPECTION Disconnect the multiplier connector and the spark plug cap. Measure the resistance between the terminals of the primary winding. Typical resistance: 0.17 Ω ± 10% Remove the spark plug cap and measure the resistance between the spark plug and the primary winding. Typical resistance:

Without cover: 3.6Ω ± 10% With cover: 7.3~11 KΩ

Replacing the ignition coil Loosen the locking bolts and replace the ignition coil if necessary.

Pulse Check Disconnect the pulse coupler and measure the resistance between the green/white and blue/yellow terminals. Typical resistance: 50~170Ω

ignition coil spark plug

17-9

in this chapter

17. Electrical system Starting system Starting circuit diagram

transmission control unit

bra

Gross weight/weight

GG/R

Fused 15A W/B B

Main switch

Fusible Principal 30A

front

red yellow

brake switch

Battery

Toggle Switches

B Black R Red G Green W White Y Yellow

coffee

Electricity/Electricity

start switch

Yes Yes

starter relay

start the engine

gram

hair / hair

Brake lights Check the starter relay Turn on the main switch. Brakes. Press the start switch. If you hear "Looh Looh", the relay is working properly.

Remove the seat. Disconnect the negative terminal of the battery cable. Disconnect the positive terminal of the relay cable. Disconnect the positive wire from the starter. Disconnect the relay coupler. Connect an ohmmeter to the end of the large lead. Connect the yellow/red wire to the battery positive and the yellow/black wire to the battery negative. Check the continuity of the large terminal. If none, replace the relay.

17-10

starter relay

in this chapter

17. Removal of electrical system Engine starter Remove the seat. Disconnect the negative (-) cable terminal and then the positive (+) cable terminal.

Remove the starter motor cable. Loosen the locking bolt and remove the starter.

Boot Installation Follow the reverse order of removal to install.

negative

2 bolts

starter motor cable

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in this chapter

17. Electrical System Meter Disassembly Loosen the 4 screws on the meter bracket.

2 bolts on each side Remove the front center cover, then remove the gauge coupler and main switch connector. Remove the speedometer cable.

main switch coupler

Remove the speedometer cable, then remove the gauge kit, main switch and handle cover

speedometer cable

Remove 4 nuts and gauge cable, then remove speedometer and fuel gauge.

4 walnuts

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in this chapter

17. LIGHT/LAMP ELECTRICAL SYSTEM Headlight bulb replacement Remove the headlight waterproof cover.

Remove the bulb trim clip.

Disconnect the bulb plug and the bulb. Replace the lamp with a new one if necessary. (High Beam H3 12V 55W)

(Submersible 12V 55W)

CAUTION Never touch the lamp with your fingers as it is

Create a hotspot. Clean fingerprints left on the lamp

Alcohol. Install the headlight bulbs in the reverse order of removal. After the replacement is complete, turn on the main switch to make sure the headlights work normally. Adjust the beam and distance of the headlights if necessary.

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17. ELECTRICAL SYSTEM HEADLIGHT BULB REPLACEMENT Remove the front light housing.

Replace with new front turn signal bulbs. (12V 21W)

Position lamp replacement Remove the position lamp housing.

Replace with new parking lamps. (12V 5W)

17-14

front flash bulb

lamp position

in this chapter

17. Electrical System Tail Lamp Replacement Turn the tail light and tail light connectors counterclockwise.

Replace with new tail lamps. (12V 5W/21W)

The taillights were replaced with new taillight bulbs. (12V 21W)

Replacing the license plate lamp Turn the license plate lamp connector counterclockwise. Replace with new license plate bulb.

rear flash rear flash

License plate light

17-15

in this chapter

17. Electrical system main switch/horn switch inspection Remove the front center cover. Disconnect the main switch connector. Check continuity between two points as follows:

BAT1 BAT2 pin location

permission

exists

main switch coupler

Wire color red black

Replace the main switch Disconnect the main switch coupler. Pull out the main switch. Align the master switch cap with the notch in the meter cover and install the master switch. Install the main switch coupler.

The handle switch disconnects the handle coupler on the left side of the front fender. Check the continuity between the two points as shown in the table below.

headlight switch coupler

start switch

brooch

start switch

Location ST SG

Free

Wire color Yellow/Red

yellow/black

17-16

in this chapter

17. Electrical system headlight switch

Pin location BAT3 LO HI PL

headlight switch

Wire Color White/Black White Blue Brown Flasher

L WR R pin location

don't push

Wire Color Pink Black Brown/White

Flasher

horn switch

brooch

BAT3 HO position

Free

Wire Color White/Black Light Green

Hazard switch Horn Hazard switch

brooch

HD E bit

hazard switch

Wire Color Green/Red Green

17-17

in this chapter

17. Electric System Front Brake Switch Hold the brake lever firmly, the brown/blue and green/yellow brake terminals should be conductive. If damaged, replace the switch.

Rear Brake Switch Hold the brake lever firmly, the white/black and green/yellow brake terminals should be conductive. If damaged, replace the switch.

Horn Remove the horn from the front fender.

brake light switch brake light switch

Pin 1 Apply 12V power to the two speaker pins and the speaker should sound. Replace the horn if necessary.

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17. Remove the seat from the electrical system fuel assembly. Remove the fuel tank cap. Remove the fuel filler cap and front fender (see Chapter 13). Disconnect the fuel cell coupler. Remove the fuel module (4 bolts).

CAUTION Great care must be taken to avoid damage or

Bend the pointer floating arm.

4 bolts

fuel module coupler

When the floating arm is set to position F or E, the measured resistance value is as follows:

Position resistance

full

E (vacuum) 97.5~107.5Ω

F (full) 4~10Ω

Connect the wires to the fuel cell and ohmmeter as shown.

Connect the fuel cell connector to the wiring harness. Turn on the main switch. Move the float arm to make sure the fuel gauge needle is in the correct position.

Arm position bar graph

Peak (Complete) 7 Bargrahpic (Complete)

down (empty) E (empty)

empty

warn

To test, turn on the flash and make sure the battery is in good condition.

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17. Electrical system cooling fan thermal switch The thermal switch installed on the radiator controls the operation of the cooling fan motor. If the fan motor does not work, disconnect the green and black/blue wires and connect the jumpers to the terminals, then turn on the main switch and the fan motor should work. If the blower motor still does not run, measure the battery voltage between the green and black/blue wires. If no voltage, check for blown fuse, loose connection or short circuit. If the fan motor is running, check the thermal switch as follows: hang the thermal switch in a container of coolant, check the opening and closing temperature of the switch, make sure the switch is open at room temperature, and gradually increase the temperature of the coolant. The switch should have 98±3 continuity.

NOTE Keep the coolant at a constant temperature

At least three minutes. Sudden increases in coolant temperature can cause thermometers and gauges to misread.

Never let the thermometer and thermal switch touch the wall of the container, this can cause incorrect readings.

The thermal switch must be placed in the coolant until the teeth are fully immersed.

thermometer

thermal switch

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in this chapter

17. Electrical system Thermal unit Remove the thermal unit. Connect the thermal unit to the oil heater, heat the oil and measure the resistance at each temperature.

Temperature 50°C 80°C 100°C 120°C

heat unit

Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2

Note Wear gloves and goggles when performing

this test.

CAUTION Engine oil must be used as fuel

The medium used as the test temperature must be above 100°C.

Incorrect readings may be obtained if the thermometer and thermal unit touch the wall of the vessel.

heat unit

Water Temperature Light Disconnect the water temperature gauge and connect it to engine ground. Turn on the main switch. The fuel gauge light should come on.

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in this chapter

17. Precautions for the electrical system:

17-22

home page content

18. Electrical diagram

18-1

home page content

18. Notes on electrical diagrams:

18-2

TGB Blade 250 Service Manual - [PDF Document] (2023)

References