DAELIM ET-250, Service Manual

Page 1: ...1 ET 250...

Page 2: ...NGINE REMOVE AND INSTALLATION 18 3 1 General Information 18 3 2 ENGINE REMOVAL 18 3 3 ENGINE INSTALLATION 19 4 1 Mechanism Diagram 20 4 2 Precautions in Operation 21 4 3 Troubleshooting 21 4 4 Engine...

Page 3: ...8 5 Drive Belt 67 8 6 Drive Face 69 8 7 Clutch Outer Driven Pulley 72 9 FINAL DRIVING MECHANISM 77 9 1 Mechanism Diagram transmission cover 77 9 2 Precautions in operation 78 9 3 Trouble Diagnosis 78...

Page 4: ...HYDRAULIC BRAKE 127 15 REAR WHEEL AND BRAKE SYSTEM 131 15 1 PARTS DRAWING 131 15 2 TROUBLESHOOTING 132 15 2 TROUBLESHOOTING 133 15 3 REMOVE REAR WHEEL AND REAR BRAKE 133 15 4 SWINGARM REAR AXLE HOLDE...

Page 5: ...d call a doctor if electrolyte gets in your eyes HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts...

Page 6: ...Transmission Automatic C V T V belt Reverse CHASSIS Overall Length 1815mm Overall Width 1062mm Overall Height 1130mm Wheel base 1193mm Ground Clearance 150mm Dry Weight 225Kg Fuel Tank Capacity 12L SU...

Page 7: ...7 1 4 SERIAL NUMBER The frame serial number is stamped on the front of the frame The engine serial numbe r is stamped on the left side of the crankcase Frame serial number...

Page 8: ...aft nut 50 N m 36 9 lbf ft Steering shaft holder bolt 33 N m 24 lbf ft Wheel rim bolt 18 N m 13 3 lbf ft Tie rod lock nut 35 N m 25 8 lbf ft King pin nut 40 N m 29 lbf ft Handlebar lower holder nut 40...

Page 9: ...9 1 6 Special Tools 1 Adjustable Hook Spencer E1105 LRA0 FT1 Purpose Adjusting of suspension 2 Ball Joint Puller E0205 LRA0 FT1 Purpose Taking out the ball joint from front knuckle as repairing...

Page 10: ...2 6 AIR CLEANER 2 13 TOE IN 2 7 SPARK PLUG 2 1 MAINTENANCE DATA SPECIFICATION SPARK PLUG SPARK PLUG GAP 0 8 mm RECOMMENDED SPARK PLUGS NGK CR8E THROTTLE LEVER FREE PLAY 5 10 mm IDLE SPEED 1700 100 rp...

Page 11: ...th Brake Shoes I Brake System I I Brake Fluid I R Nuts Bolts Fasteners I WHEEL TIRES I I Wheels I I Steering System I I Suspension System I I C V T Drive belt I R Transmission Oil R Replace for every...

Page 12: ...play of the throttle lever by turning the adjuster on the throttle housing Inspect the free play of the throttle lever 2 6 AIR CLEANER Please remove the four hooks and then disassemble two screws ins...

Page 13: ...se will get lower speed IDLE SPEED 1700 100 rpm 2 9 DRIVE CHAIN Stopping the ATV and shift the transmission into neutral N Measure the drive chain slack midway between the sprockets Chain slack 15 25m...

Page 14: ...free play is 15 25 mm Turn the parking brake to the left side is parking off while turn to right side is parking on Inspect the rear brake lever and cable for excessive play or other damage Replace or...

Page 15: ...and rear brake component In order to avoid a pre load occurred between brake disk and lining After all adjusting of brake system are completed please check the small clearance between brake disk and l...

Page 16: ...e a new one Grease the steering shaft bushing and install the parts in the reverse order of removal Torque steering shaft holder bolt 33 N m 24 lbf ft 2 13 TOE IN Keep the vehicle on level ground and...

Page 17: ...17 If the toe in is out of standard adjust it by changing the length of the tie rods equally by turning the tie rod while holding the ball joint Tighten the lock nuts Torque 35 43 N m Lock Nuts...

Page 18: ...seat front and back fender fuel tube exhaust pipe carburetor cable and drive chain etc You can then see three hanger bolts which have screwed on engine Loosen these three hanger bolts You have succee...

Page 19: ...19 3 3 ENGINE INSTALLATION The Engine installation is essentially in the reverse order of removal The torque of engine hanger bolt is 30 N m Route the wires and cable in reverse order properly...

Page 20: ...20 4 LUBRICATION SYSTEM 4 1 MechanismDiagram 4 2 Precautions in Operation 4 3 Troubleshooting 4 4 Engine Oil 4 5 Engine Oil StrainerClean 4 6 Oil Pump...

Page 21: ...21 4 1 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication Oil Route Con Rod Oil Route Oil Pump Rotate Direction Oil Strainer...

Page 22: ...clearance 0 15 0 20 Clearance between outer rotor and body 0 15 0 20 0 25 Oil pump Clearance between rotor side and body 0 04 0 09 0 12 Torque value Torque value oil strainer cap 1 5 3 0kgf m Engine o...

Page 23: ...fter drained make sure washer can be re used Install oil drain bolt Torque value 1 9 2 5kgf m 4 5 Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check...

Page 24: ...p and take out oil pump driving chain and sprocket Make sure that pump shaft can be rotated freely Remove 2 screws on the oil pump and then remove oil pump Oil Pump Disassembly Remove the screws on oi...

Page 25: ...and outer rotors Limit 0 20 mm Check clearance between rotor side face and pump body Limit 0 12 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving s...

Page 26: ...nd then tighten screws Torque value 0 8 1 2kgf m Make sure that oil pump shaft can be rotated freely Install oil pump drive chain and sprocket and then install cir clip onto oil pump shaft Install sta...

Page 27: ...drain bolt washer can be re used Add oil to specified quantity from the join hole Gear Oil Quantity 650c c when replacing Make sure that the join bolt washer can be re used and install the bolt Start...

Page 28: ...uble Diagnosis 5 4 Carburetor Remove Install 5 5 Air Cut Off Valve 5 6 Throttle Valve 5 7 Float Chamber 5 8 Adjustment of Idle Speed 5 9 Fuel Tank 5 10 Air Cleaner 5 1 Mechanism Diagram Carburetor Fue...

Page 29: ...y When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassembl...

Page 30: ...Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insuffic...

Page 31: ...e the choke cable Disconnect the fuel hose Release the clamp strip of air cleaner Remove the carburetor upper parts from the carburetor Release the 2 nuts of carburetor insulator and then remove the c...

Page 32: ...e Inspection Check the valve is in normal If the valve is in normal it will restrict air flow If air flow is no restricting replace carburetor assembly Check the vacuum pipe o ring is in normal Assemb...

Page 33: ...ttle valve and clip it with needle clamp Install the sealed cap carburetor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into t...

Page 34: ...ve seat for damage blocking Check float valve for wearing and check valve seat face for wear dirt Caution In case of worn out or dirt the float valve and valve seat will not tightly close causing fuel...

Page 35: ...air adjustment screw Caution Set the air adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking fuel level Caution Check aga...

Page 36: ...ns 1 1 2turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1700 100 rpm Connect the hose of exhaust analyzer to exhaust front end Press test key on...

Page 37: ...unit installation Install the gauge in the reverse order of removal Caution Do not forget to install the gasket of fuel unit or damage it Fuel tank removal Open the seat Remove the front cover and fue...

Page 38: ...emove the air cleaner cover 4 catch hooks Remove element mounting screw Loosen the clamp strip of air cleaner element and then remove the air cleaner element Clean the element with non flammable or hi...

Page 39: ...Precautions in Operation 6 3 Troubleshooting 6 4 CylinderHead Removal 6 6 Valve StemReplacement 6 7 Valve Seat Inspection and Service 6 8 CylinderHead Reassembly 6 9 CylinderHead Installation 6 10 Va...

Page 40: ...ll as rocker arm Cylinder head service can be carried out when engine is in frame Specification of CYLINDER HEAD Item Standard Limit Compression pressure 12 2 kg cm2 Camshaft Height of cam lobe Intake...

Page 41: ...at width 3 400 4 000 Intake 0 10 0 02mm Valve Valve clearance Exhaust 0 15 0 02mm Tilt angle of cylinder head 0 050 Torque Value Cylinder head cover bolt 1 0 1 4kgf m Exhaust pipe stud bolt 2 4 3 0kgf...

Page 42: ...ve Improper valve timing Valve spring damage Valve carbon deposit 2 Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3 Piston Piston ring worn out High compression pressure...

Page 43: ...t Remove hole bolt and spring for the cam chain tensioner Loosen2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injectionsystem AI pipe mounting bolts Remove spark plug Remove t...

Page 44: ...d then remove the sprocket by prying chain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Rocker arm and cam shaft puller Remove cam shafts Spe...

Page 45: ...and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly toolto press the valve spring and thenremove valves Caution In or...

Page 46: ...ead Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 5 mm Camshaft Inspect cam lobe height for damaged Serv...

Page 47: ...m Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm Valve spring free length Measure the free length of intake and exhaust valv...

Page 48: ...e between the valve stem and valve guide Service Limit IN 0 08 mm EX 0 10 mm Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only re...

Page 49: ...hen pressing in the new valve guide cylinder head still have to be kept in 100 150 Adjust the valve guide driver and let valve guide height is in 13 mm Press in new valve guide from rocker arm side To...

Page 50: ...with new one if valve seal is roughness wear out or incomplete contacted with valve seat Valve seat inspection If the valve seat is too width narrow or rough corrects it Valve seat width Service limi...

Page 51: ...Use 32 cutter to cut a quarter upper parts out...

Page 52: ...e seat slightly press down the valve but do not rotate it so that a seal track will be created on contact surface Caution The contact surfaces of valve and valve seat are very important to the valve s...

Page 53: ...emove assembly toolto press the valve spring and thenremove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve sprin...

Page 54: ......

Page 55: ...nd cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Install 4 washers and tighten 4 nuts on the cylinder head upper side and then tighten 2 cylinder head...

Page 56: ...rocket mounting bolts Caution Make sure timing marks are matched Install cylinder head side cover 3 bolts Install thermostat 2 bolts Loosen auto tensioner adjustment bolt and remove bolt and spring In...

Page 57: ...tem AI pipe upper side bolt 2 bolts Remove cylinder head cover Remove the cylinder head side cover Remove left crankcase cover and turn the drive face and align the timing mark on the cam sprocket wit...

Page 58: ...linder head cover and AI pipe Caution If lubricant does not flow to cylinder head engine components will be worn out seriously Thus it must be confirmed When checking lubricant flowing condition run t...

Page 59: ...7 CYLINDER PISTON 7 1 MechanismDiagram 7 2 Precautions in Operation 7 3 Trouble Diagnosis 7 5 Piston Ring Installation 7 6 Piston Installation 7 7 CylinderInstallation...

Page 60: ...7 1 Mechanism Diagram 0 8 1 2kgf m 1 0 1 4kgf m...

Page 61: ...er 0 010 0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 16 970 OD of piston pin 16 994 17 000 16 960 Clearance between piston and piston pin 0 002 0 014 0 020 ID of connecting rod...

Page 62: ...nder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution Soap the residues into solvent so that the residues can be removed...

Page 63: ...ton rings Check if the piston rings are damaged or its grooves are worn Caution Pay attention to remove piston rings because they are fragile Place piston rings respective into cylinder below 20 mm of...

Page 64: ...ter of piston pin hole Service Limit 17 02 mm Calculate clearance between piston pin and its hole Service Limit 0 02 mm Measure piston outer diameter Caution The measurement position is 10 mm distance...

Page 65: ...n carefully Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that a...

Page 66: ...esidues can be removed more easily 7 6 Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to inlet valve Install new piston pin clip Caution Do not...

Page 67: ...7 7 Cylinder Installation Install dowel pins and new gasket Dowel pins...

Page 68: ...ken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged Install co...

Page 69: ...M 8 1 Mechanism Diagram 8 2 Maintenance Description 8 3 Trouble Diagnosis 8 4 Left Crankcase Cover 8 5 Drive Belt 8 6 Drive Face 8 7 Clutch Outer Driven Pulley 8 1 Mechanism Diagram 5 0 6 0kgf m 5 0 6...

Page 70: ...990 40 930 ID of driven face 41 000 41 050 41 070 Weight of weight roller 17 700 18 300 g 17 200 g Torque value Drive face nut 8 5 10 5kgf m Clutch outer nut 5 0 6 0kgf m Drive plate nut 5 0 6 0kgf m...

Page 71: ...then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal Clamp strips 9 bo...

Page 72: ...eft crankcase cover inspection Release the 2 clamp strips of left crankcase cover ducts and then remove the ducts Remove left crankcase cover 9 bolts Remove 2 dowel pin and gasket Clamp strips 9 bolts...

Page 73: ...roove as diagram shown so that the belt can be loosened and then remove the driven pulley Remove driven pulley Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspectio...

Page 74: ...e shaft On the drive belt another end to the movable drive face Install the drive face washer and drive face nut Hold drive face with universal holder and then tighten nut to specified torque value To...

Page 75: ...en remove drive face nut Remove drive face and drive belt Remove movable drive face comp and drive face boss from crankshaft Remove ramp plate Remove weight rollers from movable drive face Crankshaft...

Page 76: ...e outer diameter of movable drive face boss and replace it if it exceed service limit Service limit mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Servic...

Page 77: ...ulley installation Press drive belt into pulley groove and then pull the belt onto drive shaft Install drive face washer and nut Caution Make sure that two sides of pulley surfaces have to be free of...

Page 78: ...service tool Release the clutch spring compressor and remove friction plate clutch weight and spring from driven pulley Remove seal collar from driven pulley Remove guide pin guide pin roller and mova...

Page 79: ...e inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing oi...

Page 80: ...Replace it if necessary Apply with grease onto setting pins Install new clutch weight onto setting pin and then push to the specified location Apply with grease onto setting pins But the clutch block...

Page 81: ...of inner bearing Place new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified oil Install new inner bearing Caution Its sealing end should be forward...

Page 82: ...clutch weight into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut...

Page 83: ...chanism Diagram transmission cover Final shaft Drive sprocket Reverse shaft Counter shaft Drive shaft Bearing 6304 Bearing 6205LLU Bearing 6204 Bearing 6305 Change switch Gasket Gear oil fill bolt Dri...

Page 84: ...g driver 6204 SYM 9110400 Bearing driver 6205LLU SYM 9100400 HMA Bearing driver 6305 SYM 9100400 RB1 Needle bearing driver HK2016 SYM 9100300 RB1 Drive shaft and oil seal driver SYM 9120200 HMA Drive...

Page 85: ...n The socket bolt is provided with left turn thread Remove 2 bolts and then remove the drive sprocket fixing plate drive chain and drive sprocket Remove gear fill bolt Place an oil pan under the ATV a...

Page 86: ...catch ball spring and bolt Remove shift spindle shift fork shaft shift fork and shift drum Remove final shaft counter shaft and reverse shaft 9 bolts Shift drum fixed catch bolt Shift drum Shift spind...

Page 87: ...Special tool Shaft protector Remove gasket and dowel pin Caution If non essential do not remove the drive shaft from the case upper side If remove the drive shaft from the gear box then its bearing a...

Page 88: ...tion of Mission Mechanism Check if the shift spindle is wear or damage Check if the shift drum is wear or damage Check if the shift fork and shaft is wear or damage Check if the counter shaft is wear...

Page 89: ...bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if necessary Caution If re...

Page 90: ...l Special tool Inner bearing puller Install new final shaft counter shaft and reverse shaft bearings into left crankcase Special tool Bearing driver 6204 Needle bearing driver HK2016 Install new drive...

Page 91: ...tall bush Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaft bearing and counter shaft bearing from the c...

Page 92: ...all drive shaft bearing Special tool Bearing driver 6205 Universal bearing puller Install new oil seal and bearing driver into gear box cover inner side Install the universalbearing puller and bearing...

Page 93: ...ter shaft reverse shaft and final shaft onto gear box Install shift drum shift fork and fork shaft onto gear box Install shift drum fixed catch ball spring and bolt onto gear box Oil seal Reverse shaf...

Page 94: ...ll shift spindle Install dowel pins and new gasket Install gear box cover and bolts and tighten Torque value 1 0 1 4kgf m Install the shift spindle bracket drive chain protector speedometer gear box a...

Page 95: ...10 ALTERNATOR STARTING CLUTCH 10 4 A C G Set Removal 10 5 Right Cover Bearing 10 6 Flywheel Removal 10 7 Starting Clutch 10 8 Flywheel Installation 10 9 A C G Set Installation...

Page 96: ...10 1 Mechanism Diagram 5 0 6 0kgf m 1 0 1 4kgf m 0 8 1 2kgf m...

Page 97: ...f starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 100 OD of starting clutch gear 42 175 42 200 42 100 Torque value Flywheel nut 5 0 6 0kgf m Sta...

Page 98: ...al Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set 10 5 Right Cover Bearing Inspection Rotate the bearing...

Page 99: ...6201LU by bearing driver Special tool Bearing driver 10 6 Flywheel Removal Remove right crankcase cover Remove left crankcase cover Hold the flywheel by drive face with universal holder Remove flywhee...

Page 100: ...g driven gear 10 7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear Check the gear for wear or damage Measure the ID and OD of the starting clutch driven gear Service Limi...

Page 101: ...ar The starting clutch gear should be rotated in C C W direction freely but not C W direction View as shown in this figure One way clutch removal Remove starting driven gear Remove 3 socket bolts and...

Page 102: ...olt Torque value 1 0 1 4kgf m Install starting driven gear 10 8 Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive face...

Page 103: ...wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator 10 10 Right Crankcase Cover Installation Install dowel pin and new gasket Rem...

Page 104: ...right crankcase cover 11 screws Install the dowel pin new gasket and water pump cover onto crankcase cover Connect water hoses to the right crankcase cover and water pump cover 11 bolts Water pump cov...

Page 105: ...Diagram 11 2 General information 11 3 Trouble diagnosis 11 4 Disassemblyof crankcase 11 5 Crankshaft Inspection 11 6 Assemblyof crankcase 11 1 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1...

Page 106: ...ain of engine oil pump or the timing chain it is preferably to replace crankshaft as a unit Specification Unit mm Item Standard Limit Connecting rod side clearance of the big end 0 100 0 400 0 600 Ver...

Page 107: ...ove the tensioner Loosen 2 bolts on the right crankcase Loosen 11 bolts on the left crankcase Place right crankcase downward and left crankcase up Tap the left crankcase with a plastic hammer to remov...

Page 108: ...right crankcase Remove gasket and dowel pins Scrape gasket residues off the crankcase contact surface Caution Do not damage contact surface of the gasket It is better to moisten the gasket residue fo...

Page 109: ...e crankshaft Service limit 0 10 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely smoothly and noiseless Check the inner ring to see it links firmly on the bearing If an...

Page 110: ...is uneven noising or loose bearing mounted then replace it Special tool Inner bearing puller Bearing driver 11 6 Assembly of crankcase Install wave washer into right crank bearing seat Install crank...

Page 111: ...d new gasket Install the left crankcase onto the right crankcase Tighten 11 bolts on the left crankcase Torque value 0 8 1 2kgf m Tighten 2 bolts on the right crankcase Torque value 0 8 1 2kgf m Dowel...

Page 112: ...kcase with care not to damage the lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Oil seal driver 27 42 7 Install the tensioner and tighten the pivot bolt...

Page 113: ...12 1 Mechanism Diagram 12 2 General Information 12 3 Trouble Diagnosis 12 4 Trouble Diagnosis for Cooling System 12 5 System Test 12 6 Radiator 12 7 Water Pump 12 8 Thermostat 12 1 Mechanism Diagram R...

Page 114: ...Radiator Reserve tank Thermo switch fan Coolant inletpipe Coolant outlet pipe By pass pipe Water pump Thermostat Cooling fan To cylinder head...

Page 115: ...pper 850c c 420c c Thermostat Begins to activate at 82 95 Stroke 0 05 3mm Thermos switch fan Begins to activate at 98 3 Boiling point Not pressure 107 7 Pressurized 125 6 Torque Value For water pump r...

Page 116: ...unit Meter problem N D Close radiator cap measure thermo unit to confirm voltage reduced comply with temperature rise Replace thermo unit N Y Y N C Open radiator cap and softly throttle inspect coola...

Page 117: ...until the coolant surface becomes stable Y E 2 Connect cooling fan terminals with battery 12V directly to inspect its operation N Replace cooling fan Meter unusual Y Y Y Y Refill with coolant then che...

Page 118: ...s completely cooled down otherwise you may get scalded Remove the front center cover and then remove filler cap Place a water pan under the water pump loosen the drain bolt to drain out the coolant Re...

Page 119: ...ing in the cooling system the refrigerant backflow floods 12 6 Radiator Check Remove the front center cover side covers and front fender refer chapter 13 check for any leakage from weld seam Blow radi...

Page 120: ...shaft Apply a coat of the adhesive to the shaft thread of the motor and then install the washer and the lock nut Tighten the fan duct onto the radiator with 3 bolts Please refer to chapter 17 for the...

Page 121: ...s the replacement water pump seal if does not have the question to take apart for overhaul cooling systemof system again the cylinder head the cylinder Removal of water pump Loosen the drain bolt to d...

Page 122: ...seal out of the right crankcase Special tools Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to the mating surfaces of...

Page 123: ...Special tools Water pump bearing driver 6901 Caution Do not reuse old bearing It must be replaced with a new one once it has been removed Mount the water pump shaft and the inner bearing to the right...

Page 124: ...ten Torque Value 1 0 1 4kgf m Caution The rotor is left thread Install the dowel pin and right cover gasket The rotation water pump rotor causes the water pump drive shaft scoop channel aligns the oil...

Page 125: ...he thermometer are in contact to the wall of heated water container the reading displayed is incorrect If the valve of the thermostat remains open at room temperature or the valve operation is not cor...

Page 126: ...13 STEERING AND SUSPENSION 13 1 PARTS DRAWING 13 2 TROUBLESHOOTING 13 3 HANDLENAR 13 4 THROTTLE HOUSING 13 5 STEERING SYSTEM 13 1 PARTS DRAWING Steering Handle bar...

Page 127: ...Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment Loose front suspension fasteners Binding suspension link Faulty front...

Page 128: ...le bar Remove rear brake lever bracket assembly Remove the handle cover and instrument panel by four screws at right and left side as shown in picture Remove the bolts attaching the handlebar upper ho...

Page 129: ...ith the L or R marks facing forward Tighten the forward bolts first and then tighten the rear bolts Install the handlebar upper holder s cover Install the switch housing aligning the small dot of the...

Page 130: ...rom the throttle arm and remove from the throttle housing NOTE Assembly is in the reverse order of disassembly 13 5 STEERING SYSTEM When the steering shaft needs to be repaired you need to remove thre...

Page 131: ...holder bolt and remove steering shaft holder Take off the cotter pin below steering shaft Loosen the steering shaft fixed out below shaft Pull steering shaft carefully Step 2 Steering Shaft Holder In...

Page 132: ...Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 N m 37 lbf ft...

Page 133: ...14 FRONT WHEEL AND BRAKE SYSTEM 14 1 PARTS DRAWING 14 2 TROUBLESHOOTING 14 3 FRONT WHEEL 14 4 HYDRAULIC BRAKE 14 5 SUSPENSION SYSTEM 14 1 PARTS DRAWING FRONT WHEEL FRONT BEAKE...

Page 134: ...orrectly Unequal tire pressure Incorrect wheel alignment Brake shoes worn Worn brake drum Brake linings oily greasy or dirty Improper brake adjustment 14 3 FRONT WHEELS REMOVAL The disassemble of fron...

Page 135: ...sher and wheels Please follow the next three steps of right pictures Loosen fours nuts as shown in picutre Then take the wheel out you can find two bolts fixed at front hydraulic disk component Loosen...

Page 136: ...the power tools to take the screw out from brake stopping plate You can take the brake disc off When change brake shoe wear you must push the master piston to rearward After removal the front brake a...

Page 137: ...AKE OIL The brake oil tank is under the driver seat at right hand side Please check the brake oil level position at outside of tank To open the cap of brake oil tank please turn CCW direction Brake oi...

Page 138: ...ATV body up by using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner E1105 LRA0 FT1 to adjust the suspension How to use the Adjustable Hook...

Page 139: ...R WHEEL AND BRAKE SYSTEM 15 1 PARTS DRAWING 15 2 TROUBLESHOOTING 15 3 REMOVE REAR WHEEL AND REAR BRAKE 15 4 SWINGARM REAR AXLE HOLDER 15 5 SUSPENSION ADJUSTMENT 15 1 PARTS DRAWING REAR WHEEL REAR Whee...

Page 140: ...REAR BRAKE...

Page 141: ...earings are worn Faulty tires Rear axle bearing holder is faulty Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing armpivot bus...

Page 142: ...ove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE To replace the brake shoe please loosen this bolt as shown in picture Plea...

Page 143: ...oil being drained out completely Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup in order to avoid air in the brake system Loosen the bolt to vent the air from brake system Ti...

Page 144: ...lowing pictures are going to teach you how to Install the swing arm 1 Put the swingarm at proper position as shown in picture Two hanger bolts will be used to hold the swing arm at right and left side...

Page 145: ...3 Screw another hanger bolt on the left side as shown in picture But do not tighten it Let the cross section of bolt and cross section of hole in the same plane 4 Tighten the nut Hanger bolt...

Page 146: ...using a repair platform The four wheels are in the free position you can use special tool adjustable hook spanner to adjust the suspension How to use the Adjustable Hook Spanner When you use the adjus...

Page 147: ...16 FENDERS AND EXHAUST PIPE 16 1 FENDRES DRAWING 16 3 FRONT FENDER REMOVAL 16 2 REAR FENDERS REMOVAL 16 4 EXHAUST PIPE REMOVAL 16 1 FENDERS DRAWING EXHAUST PIPE For all serials...

Page 148: ...move the rear fender Remove the rear rack 1 Open the seat 2 Loosen four bolts which connect the front fender and rear fender 3 Loosen three bolts which connect the rear tender and frame these two bolt...

Page 149: ...Pull the seat handle up first There are two screws on the top of seat compartment Please remove them Finally you must remove the bolts on the footrest Bolts...

Page 150: ...1 First picture shows there are two screw loosen it Remove the mounting bolts from the front fender Please remove the two screws on the top of the headlight Then you can see there is a screw on the ti...

Page 151: ...st pipe bolts that fixed on the engine Warning DO NOT service the exhaust pipe while they are hot Remove the exhaust pipe bolts mounting on the frame below the seat Remove the exhaust pipe carefully E...

Page 152: ...Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil I...

Page 153: ...in an open area The battery contains sulfuric acid Electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous If swallowed drink...

Page 154: ...tion but engine can not be start Please go back to service TROUBLESHOOTING Starter Motor Turns Slowly Weak battery Poorly connected starter motor cable Failed starter motor Poorly connected battery gr...

Page 155: ...ical bulb Turn around the cap you could see the connector Turn the seat to replace the electrical bulb TAILLIGHT The taillight combines a position and a rear brake light Normally when users switch the...

Page 156: ...fix this cap loosen them can open the cap Please rotate the electrical bulb and then it could be removed Rear Direction lights remove The same disassembling procedure like front direction light Please...

Page 157: ...users Therefore this is an all in one instrument panel Instrument Panel REMOVAL There is a cable and connector on the back of the instrument panel After removing instrument panel users can find out a...

Page 158: ......

Page 159: ...17 8 WIRING DIAGRAM...

Page 160: ...tion coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire di...

Page 161: ...ternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch 18 3 POOR PERFORMANCE AT HIGH SPEED N G CHECK IG...

Page 162: ...ings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn pist...

Page 163: ...roperly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Imp...