EGL LYDA203E-6, Owner'S Manual

Page 1: ...WARNING READ THIS MANUAL CAREFULLY EGL MOTOR OWNER S MANUAL LYDA203E 6 ...

Page 2: ...nding of the features and operation of this ATV This manual includes important safety information It provides information about special techniques and skills necessary to ride your ATV It also includes basic maintenance and inspection procedures Please be close reading this manual it will maximize the performance and lifetime of ATV ...

Page 3: ...ol means attention Failure to follow warning instructions could result in severe injury or death to the machine operator a bystander or others who inspection or repairing the machine CAUTION A caution shows special precautions that must be taken to avoid damage to the machine NOTE A note provides key information to make procedures easier or much clearer ...

Page 4: ...engine 25 To start out and accelerate 27 To decelerate 27 Engine break in 28 Periodic maintenance and adjustment 28 Air filter element cleaning 30 Carburetor adjustment 31 Main technical specifications of the engine 32 Operation and maintenance 32 Troubleshooting of the engine 33 Troubleshooting of cooling system 36 Electric fan wiring diagram 37 Inspection of brake system 37 Brake pads inspection...

Page 5: ...met and you should also wear the eye protection gloves boots protective clothing as well 6 Never consume alcohol or drugs before or during you operating this ATV 7 Never attempt wheelies jumps or other stunts 8 Never operate at excessive speed for your skills or the conditions always go at the speed which is proper for the terrain visibility operating conditions as your experience 9 Always inspect...

Page 6: ...manual dismount on the uphill side or to a side if straight uphill Turn on the ATV and remount 17 Always check the obstacles before operate in a new area never attempt to operate over large obstacles 18 Always be careful when skidding or sliding learn to safely control skidding or sliding by practicing at low speed an on level smooth terrain 19 Never modify the ATV though improper installation or ...

Page 7: ...s poisonous and can cause injuries HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of vapor or get some gasoline on your eyes see doctor immediately if gasoline spills on your skin wash with soap and water ...

Page 8: ... oil capacity 1 1L Ground clearance 160mm Fuel capacity 6 3L Minimum turning radius Spark plug type D8TC Net weight 195KG Lubrication Press splash Engine type 4 stroke single cylinder water cooled Front brake type disc Displacement 250cc Rear brake type disc Compression ratio 10 0 1 magneto Permanent magnetic Ignition type CDI Start system Electric DESCRIPTION NOTE The ATV you have purchased may s...

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Page 10: ...mbers information in below space will provide assistance when you order parts or for reference in case stolen Vehicle identification number Engine number Vehicle identification number is stamped on the frame Engine number is stamped on the bottom of engine left side ...

Page 11: ...zard that could result in severe injury or death Main switch Functions of the each switch positions are as below ON The engine can be started only at this position OFF All electric circuits are turned off the key can be removed in this position ...

Page 12: ...ing the engine the engine stop switch control the ignition and can be used to stop engine at all times especially in the emergency the engine will not start while this switch is on the OFF position Start switch The engine will be starting when this switch is pushed backward Turning light switch The left indicator will be working when push this switch to left side conversely right indicator working...

Page 13: ...ngine control the speed of engine machine by mutative the throttle position since the throttle is loaded with spring the machine speed will down and return to the idle if hand removed from throttle 1 Throttle Before starting the engine check the throttle to be sure it is work smoothly also make sure it can be back to the idle once the lever released POTENTIAL HAZARD Malfunction of throttle WHAT CA...

Page 14: ...the throttle from fully opening when the throttle lever pushed to maximum Turning the adjustable screw limits to adjust the engine power and increase or decrease the speed of ATV A distance of ajustable screw no more than 1 2cm Potential hazard Improper operate the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged improper operate throttle could result in lose control ...

Page 15: ...ver to handlebar to disengage the clutch and release the lever to engage the clutch The clutch lever should be pulled rapidly and released slowly for smooth clutch operation Brake lever The brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake ...

Page 16: ... apply the rear brake Parking brake lever Use the parking brake when you have to park your ATV especially on a slope 1 park brake locked position move the parking brake lever to a direction apply the parking brake 2 unlocked position move the parking lever to direction b to release the park brake ...

Page 17: ...g the parking brake it could loss of the brake performance and an accident might to happen and you will wear out the brake earlier HOW TO AVOID THE HAZARD Always check the parking brake before starting the engine Always make sure you have released the parking brake before you ride ATV Gear shift lever This machine is equipped with a 4 speed forward with reverse transmission The gear shift lever is...

Page 18: ...ons OFF fuel will not flow at this position always turn the fuel cock to this position when the engine is not running ON fuel can flows to the carburetor from tank provides the normal riding when the fuel cock in this position RES this shows reserve turn to this position if you run out of the fuel while riding Then fill the tank in the first possibility Return the fuel cock to ON position after yo...

Page 19: ...ar of seat and the rear fender pull the seat lock lever upward and pull up the seat at the rear To install the seat insert the protecting of front seat into front seat holder and push down the seat at reat 1 Protecting NOTE make sure the seat is securely fitted ...

Page 20: ...oolant if necessary chain Check chain slack and condition adjust if necessary throttle Check for proper throttle cable and free play Rims and tires Check pressure wear damage Fittings and fasteners Check all fittings and fasteners Lights and switches Check for proper operation Tire Check for the pressure and the wear condition Potential hazard Failure to inspect the ATV before operating Failure to...

Page 21: ...if any brake fluid is leaking out of the pipe joints or brake fluid reservoirs If there is any leakage consult with dealer to inspect the bake system Brake operation Test the brakes at slow speed after starting out to make sure working properly If the brakes don t provide braking performance inspect the condition of brake pads for wear POTENTIAL HAZARD Driving with improperly operating brakes WHAT...

Page 22: ...aust system POTENTIAL HAZARD Careless when refill fuel WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heat up if the fuel tank is overfilled fuel could spill out due to heat from engine or sun HOW TO AVOID THE HAZARD Don t overfill the fuel tank Take care not to spill out especially on the engine or exhaust pipe Wipe up any spilled fuel right now Make ...

Page 23: ...pstick then repull out to check the level of engine oil if keep on the specified position add if necessary Change the engine oil The engine oil quantity is the most important cause for the engine life Change the engine oil as specified maintenance schedule 1 Drain out the engine oil completely 2 Refill the specified classification engine oil to proper level CAUTION In order to prevent clutch slipp...

Page 24: ...ir capacity 1L NOTE The radiator fan operation is completely automatic It s switched on or off according to the coolant temperature of the radiator The switch will be on in 80 4 and will be off in 72 4 Chain Check the general condition of the chain and check the chain slack before every ride Lubricate and adjust the chain if necessary Throttle level Check to see that throttle level operates correc...

Page 25: ...per tire pressure may cause loss of control and lead to risk or accident HOW TO AVOID THE HAZARD 1 Always comply with below recommended tire type and pressure 2 Check and adjust the tire pressure when the tires was cold 3 Tire pressure must be equal on both sides 4 Higher pressure may cause the tire to burst Inflate the tire very slowly and carefully Fast inflate could cause the tires burst 5 Chec...

Page 26: ...re is a control or function you don t understand ask your dealer Starting a cold engine 1 Set the parking brake 2 Turn the fuel cock to ON 3 Turn the main switch to ON 4 Shift the transmission to neutral Note the engine can be started at the following conditions When the transmission is in neutral the neutral indicator should come on When the clutch is disengaged with the transmission in any posit...

Page 27: ...n t crank the engine more than 10 seconds on each attempt Starting a warm engine To start a warm engine refer to the description of starting a cold engine the choke should not be used the throttle should be worked somewhat Warming up To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine Caution Do not coast for long distance with the engi...

Page 28: ... and gradually release the clutch lever 8 Follow the same procedure when shift next higher gears POTENTIAL HAZARD Open the throttle abruptly or release the clutch lever too quickly WHAT CAN HAPPEN This would increase the chance of an accident including collision overturn HOW TO AVOID THE HAZARD Open the throttle gradually as well as release the clutch lever slowly To decelerate When you want to sl...

Page 29: ...rication will keep your machine in the safest and most efficient condition possible Safety is an obligation of the machine owner The most important points of machine inspection adjustment and lubrication are described on below pages INITIAL EVERY ITEM ROUTINE 320km 1200km 2400km 2400km 4800km valves Check valves Adjust it if necessary Cooling system Check for leakage Repair if necessary Replace co...

Page 30: ...p damage Replace if damaged Steering system Check operation Repair if damaged Check toe in adjust if necessary Front and rear suspension Check operation Adjust if necessary Upper and lower arm pivot Steering column Lubricate every 6 months Rear arm pivot Rear axle system Lubricate every 6 months Fittings and fasteners Check all fittings and fasteners Correct if necessary Some of above items requir...

Page 31: ...cleaned every 24 48hours more often if the ATV is operated in extremely dusty areas Each time air filter element maintenance has done check the air input to the air filter case for obstruction Tighten all fittings securely to avoid the possibility of unfiltered air entering the engine CAUTION Never operate the engine with the air filter element removed This will allowed the unfiltered air to enter...

Page 32: ...ndition of spark plug can indicate the condition of the engine The ideal color on the white insulator around the center electrode is a medium to light tan color for an ATV is being ridden normally Don t attempt to diagnose such problems yourself You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode ...

Page 33: ...led 4 Clutch type manual wet and multiple disc 5 Gearshift 5 speeds 6 Starting system electrical starting and kick starting 7 Spark plug type D8TC 8 Fuel oil a gasoline No RQ 90 GB T7930 1999 b lubricating oil SF15W 40 GB11121 1995 c lubrication oil capacity 1 1L 9 Dimension 358mm 355 mm 450mm 10 Net weight 34 kg 11 Coolant coolant with glycol and corrupt inhibitor the 4916 coolant produced by Cho...

Page 34: ...ance of a new engine This period is very important for new engine as poor grinding would increase the engine s failure a Do not overload the engine during the grinding period of 0 to 500 kilometers for a new motorcycle Never open the throttle completely nor use the same speed for a long time The speed can not exceed 50Km h b Do not overload the engine during the grinding period of 500 to 1000 kilo...

Page 35: ...oil or defective welding Replace or re welding Improper circuit connecting or open circuit Check and get through All joint face leaks Tighten all joint bolts Air cleaner plugged Clean Spark plug leaks Tighten the spark plug Cylinder gasket leaks Tighten the nut on cylinder cover Valve leaks Re grinding or replace Piston ring or cylinder body abraded Replace Cylinder compression pressure is low Car...

Page 36: ...etor Idle speed is unstable Spark plug gap is narrow Reset the spark plug gap 3 The engine works unstable Problem Cause Correction Fuel pipe Fuel pipe is semi open Dredge up the fuel pipe High voltage wire or ignition coil has leaks Replace Capacitor is turnoff or has leaks Replace Electrics Too much carbon deposit on spark plug electrodes Remove the carbon deposit ...

Page 37: ...hick or over thin Adjust the carburetor No enough lubricating oil Refill the lubricating oil Lubricating system Defective lubricating oil Replace the lubricating oil 5 The engine stops automatically Problem Cause Correction The fuel has run out of Refill fuel Oil way plugged Clean oil way Fuel system failure There is no output fuel Carburetor plugged Clean the carburetor Electrics Interruption of ...

Page 38: ...pe has gas resistance 9 Radiator small circulation pipe leaks 10 Radiator sub jug is not get through with the atmosphere The reason for water thermometer can not indicates the temperature changes or the indications is not precise 1 Defective water thermometer or heat sensor parts 2 Defective thermostat The reason for water leakage 1 Poor mechanical sealing 2 O ring aging and poor sealing which is ...

Page 39: ...lic disc brake together Inspection of brake system The brake system should be inspected every day before your ride ATV 1 Check the main cylinder for proper level 2 Check to see there is no leakage of the system 3 Check the brake hose and main cylinder for crack 4 Check the brake pads for wearing CAUTION The hydraulic disc brake is designed to operate under high pressure For the benefit of safety a...

Page 40: ...ully loosen the locknut and the adjusting bolt at the rear brake caliper 3 Turn the adjusting nuts on the brake cable till the cable length A on the 56mm 60mm 4 Tighten the locknut on the brake cable and adjusting bolt at the rear brake caliper POTENTIAL HAZARD Operating with improperly adjusted brakes WHAT CAN HAPPEN The brake could malfunction causing reduced braking performance This could incre...

Page 41: ...ck check NOTE Move the ATV back and forth to find the tightest position of the drive chain Check or adjust the chain slack while it is in the tightest position To check the drive chain slack all tires must be touching the ground and there should be no weight on it Drive chain slack adjustment 1 Loosen the locknut of 1 and 2 2 adjust the locknut of 3 and 4 both them frontward till chain at the prop...

Page 42: ...ly lubricate the drive chain CAUTION Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the chain Cable inspection and lubrication POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables also can become frayed Operation of controls could be limited w...

Page 43: ...43 46 Lubrication for A arm Lubricates the front upper and lower A arms pivots 1 upper arm grease nipple 2 lower arm grease nipple Rear arm pivot lubrication Lubricates the rear arm pivot ...

Page 44: ...e useful life of many components 1 Before cleaning the ATV 2 Block off the end of exhaust pipe to prevent water entry 3 Make sure the spark plug and all filler caps are properly installed 4 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to the chain sprockets or wheel axles 5 Rinse the dirt and degreaser off with a garden hose has enough pressure...

Page 45: ...45 46 NOTE Make the necessary repairs before storing the ATV Assembling figure for that was disassembled while packing ...

Page 46: ...46 46 Circuit diagram ...