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33 

at   every   gear   and   avoid   the   engine   runs   in   a   same   gear   ratio   for   a   long   time.   
(3)

 

Change   the   engine   oil,   clean   filter,   check   and   adjust   valve   clearance,   clutch   stroke   per   500   kilometers.   

   

6

 

Daily   maintenance

   

(1)

 

Change   the   engine   oil   per   2000   kilometers   after   the   running-­‐in   period.   You   can   also   replace   the   engine   oil   in   advance   if   it   

has   deteriorated   in   quality

   

(2)

 

Check   the   engine   oil   before   daily   running.   If   the   oil   is   below   the   lower   scale   of   oil   dipstick,   refill   the   oil   to   the   upper   scale.   

(3)

 

Open   water   tank   cover   to   check   if   the   cooling   fluid   is   enough   before   daily   running,   add   enough   cooling   fluid   if   it   is   not   lack.   

(4)

 

Normally,   the   valve   clearance   is   adjusted   to   standard   value.   It   can   adjust   the   valve   clearance   in   0.04mm   to   0.06mm   if   the   

cylinder   head   has   noise.       
(5)

 

Clean   carburetor   termly,        check   and   adjust   it   if   it   is   necessary.   

Air   cleaner   should   be   checked   and   cleaned   termly:   clean   the   filter   core   with   gasoline   and   dry   it   if   its   material   is   sponge,   then   
smear   a   little   oil   on   filter   core;   if   the   material   of   filter   core   is   paper,   it   only   needs   to   clean   with   gasoline   and   dry   it.   
(6)

 

Check   and   adjust   all   fasten   bolts   whether   is   loose   termly.   

7

 

Method   of   adding   Cooling   fluid:   open   water   tank   cover   first   adds   cooling   fluid   in   it   till   the   water   tank   is   full.   Then   start   

engine,   slowly   open   and   close   the   throttle   again   and   again   till   eliminate   out   the   air   in   water   pipe   and   water   jacket.   Continue   to   
add   cooling   fluid   to   full   and   cover   the   water   tank   cover.       

8

 

Method   of   change   cooling   fluid:   on   the   condition   of   stop   engine,    take   out   the   plug   which   in   the   bottom   of   water   tank,   and   

let   out   the   cooling   fluid   ;    disassemble   the   intake   pipe   od   water   pump,   and   let   out   the   cooling   fluid   in   water   pipe   and   water   
jacket;    Assembly   the   plug   and   intake   pipe,   and   add   cooling   fluid   according   to   step   8.       

9

 

Waster   tank   cover:   Don’t   open   the   water   tank   cover   or   repair   water   passages   after   the   engine   run   at   full   load   to   protect   

user   from   burning.   

10

 

Maintenance   note:   please   let   out   the   cooling   fluid   if   it   needs   to   loose   cylinder   nuts   in   maintenace   to   avoid   the   cooling   

fluid    flow    into    crankcas.    When    add    cooling    fluid    renewedly,    it    must    eliminate    air    from    cooling    fluid    at    idling    speed    to   

Summary of Contents for ZTR Series

Page 1: ......

Page 2: ...nce and troubleshooting of ATV It will help you familiarize yourself with all the necessary skills so that you will bring your vehicle into full best play with minimized trouble for a long service lif...

Page 3: ...Installation Guide The Standard distance between front frame and ground is 125mm...

Page 4: ...The height of chassis is adjustable Warning the screw of bearing joint must be tighten tighten the screws can t less than 15mm...

Page 5: ...Camber adjustment method Front wheel camber standards values is 1...

Page 6: ...Front toe adjustment method Front wheel toe Standard value is 4MM A 4MM B...

Page 7: ...Push the front frame to reach the lowest position adjust the limit screw beside right front shock absorption Make sure the minimum distance between tie rod of steering linkages and frame is 10mm...

Page 8: ...CH 8 REAR HYDRAULIC DISC BRAKE 21 FUEL AND FUEL TANK 9 CHECK OF BRAKE SYSTEM 22 LEFT HANDLEBAR CONTROLS 10 BRAKELIQUID 22 SAFETY SWITCH 10 EXHAUST MUFFLER 23 SPEED LIMITING DEVICE 11 BATTERY 24 ENGINE...

Page 9: ...erate this vehicle while under the influence of alcohol or drags That can impair judgment and result Keep a safe distance between your vehicle and other vehicle Do not allow your child to ride without...

Page 10: ...bey all national and local equipment regulations ACCESSORIES Genuine accessories by our Co have been specifically designed and tested on the atv Because our Company won t test accessories manufactured...

Page 11: ...l base 1670mm Idle speed 1600 100 r min Dry weight 245kg Start mode Electric Max speed 80km h Clutch Oil dipped in pieces Front brake type Disc brake Spark plug type D8TC Rear brake type Disc brake En...

Page 12: ...4 DESCRIPTION Speed meter Turning light Horn Fuel light Starter Choker rod Steering wheel Head light Flameout...

Page 13: ...5 shock absorber Safety belt Rearview mirror Headlight Turning light Front wheel Rear wheel...

Page 14: ...6 Rearview mirror Steering wheel Taillight Muffler...

Page 15: ...code of your ATV in blank below They will help order spare parts and find out the vehicle once stolen 1 VIN 2 ENGINE CODE VIN Engine code NOTES 1 The VIN is stamped on the rear fork 2 The engine code...

Page 16: ...8 IGNITION SWITCH The ignition switch is situated is situated on the front right of the vehicle body...

Page 17: ...mely flammable and is explosive under certain conditions Refuel in a well ventilated area with the engine stopped Do not smoke or sparks in the area where gasoline is stored or where the fuel tank is...

Page 18: ...10 STEERING WHEEL CONTROLS Emergency Switch The switch is set in middle position to stop the engine Starter button Press the button with the vehicle in braking to start up the engine...

Page 19: ...15W 40 SE class before being been delivered and the lubricant is only suitable at a temperature range from 40 C to 10 C If other motor oil is to be used instead the alternative must be technically eq...

Page 20: ...on See Yom dealer for change of damaged tires or punctured inner babes WARNING Do not attempt to patch a damaged tire or inner tire otherwise wheel balance and tire reliability may be impaired Imprope...

Page 21: ...t free play 4 Tires check condition and pressure 5 Throttle operation check for smooth opening and full closing in all steering positions check for throttle grip free play and throttle cable in lubric...

Page 22: ...efore riding the vehicle make sure that the engine is well warmed up CAUTION Opening or closing the throttle fully and rapidly may make the vehicles sudden moving forwards resulting in out of control...

Page 23: ...cle out of control 3 Open the throttle gradually so the vehicle moves forward 4 To speed down the vehicle reduce the throttle while carry out braking Coordinate the throttle with brakes for smooth dec...

Page 24: ...n the upper and lower level marks on the dipstick 1 Start the engine and let it idle for a few minutes 2 Stop the engine and put the vehicle on a level ground 3 After a few minutes remove the oil fill...

Page 25: ...ug cap from the spark plug 2 Clean any dirt from around the spark plug Remove the spark plug using the plug wrench containing in the tool kit 3 Inspect the electrodes and center porcelain for deposits...

Page 26: ...rwise a fire or explosion could result 4 Soak it in gasoline engine oil Class 15W 40QE until saturated and then squeeze out the excess oil 5 Clean the inside and outside of the air cleaner housing 6 I...

Page 27: ...hometer to the engine a remote con trolled one can be used Turn the throttle stop screw clockwise in the direction of the arrowhead A will increase idle speed while will decrease it running counterclo...

Page 28: ...s a precision apparatus don t disassemble it without the professional knowledge WARNING The balance pipe of carburetor should be often checked to make sure there is no dust or other impurity inside it...

Page 29: ...der disc brake The front and rear hydraulic disc brake are controlled by brake switch synchronously NOTES Make sure the curved slot in the adjusting nut is seated on the brake ann pin after making fin...

Page 30: ...d must not be beyond the limit specified in the manual If the hydraulic disc brake system needs to be maintained or repaired conduct the problem by your dealer only If you feel soft when operating the...

Page 31: ...tem is non petroleum brake oil No 4604 Never mix with other oil sue has silicon oil or serious damage to brake system may occur CAUTION It is forbidden to use the used liquid or the liquid placed in t...

Page 32: ...e UPPER level mark and the LOWER level mark If battery electrolyte level is below the LOWER level mark add distilled water to the UPPER level mark CAUTION Before handing the vehicle over for long term...

Page 33: ...ctive clothing and a face shield If electrolyte gets in your skin flush with water If electrolyte gets in your eyes flush with for at least 15 minutes and call a physician immediately Electrolyte is p...

Page 34: ...some trouble see your dealer for help CAUTION Do not dismantle or maintain the vehicle without the professional knowledge CLEANING Clean your vehicle regularly to protect the surface finish and inspec...

Page 35: ...ehicle is subjected to long term storage so as to reduce the bad influence on its performance Before the storage make necessary maintenance to ensure the vehicle high performance after storage STORAGE...

Page 36: ...e procedures are just opposite During the operations above the ignition switch must be turn off 6 Seal the muffler outlet with plastics cloth to protect the former from moisture 7 Cover the vehicle do...

Page 37: ...hicle in sound condition Riding under unusually dusty or wet conditions service of the vehicle should be made more often than the specified in the schedule Maintenance work should be performed by prop...

Page 38: ...parameters 1 Min steady rotary speed without load 1400 1 10 r min 2 Min fuel consumption 354 g Kw h 2 Main structure parameters 1 dia of cylinder bore 69 0 mm 2 stroke 65 0mm 3 displacement 243 1mL 4...

Page 39: ...cal starting 6 spark plug model D8TC 7 gear ratio the first gear ratio 2 909 the second gear ratio 1 867 the third gear ratio 1 389 the fourth gear ratio 1 000 traverse gear 2 652 8 Fuel and lubricati...

Page 40: ...ghten the idle adjusting blot first then return 1 8 5 circle 3 Adjust the throttle stop screw until the engine speed reach to the define rpm The engine is easy to fire out if the rpm is too low 4 Turn...

Page 41: ...ilter core if the material of filter core is paper it only needs to clean with gasoline and dry it 6 Check and adjust all fasten bolts whether is loose termly 7 Method of adding Cooling fluid open wat...

Page 42: ...pluged Dredge up the fuel pipes there is fuel in cylider release the fuel in cylinder air filter is pluged clean air cleaner No fuel mixture in cylinder intake system is leakage Tighten the bolts whic...

Page 43: ...lean the carbon fuel mixture is too thick or thin Adjust carburetor Others Incorrect fuel change fuel 2 Poor idle speed Problem Cause Correction No idle speed Improper adjustment of carburetor Readjus...

Page 44: ...k plug electrodes Clean the carbon depositing 4 The engine is overheating Problem Cause Correction Poor radiating condition Cooling system malfunction refer to chapter 5 Repair or change components Ru...

Page 45: ...ubricating oil 5 The engine stops automatically Problem Cause Correction Fuel system failure The fuel has run out of Refill fuel There is no output fuel Oil way plugged Carburetor plugged Electrics In...

Page 46: ...7 Gear shifting failure Problem Cause Correction No gear shifting Poking fork broken or distortion replace porking fork Poking fork pothook or gearshift shaft assembly broken or distorted Replace Gea...

Page 47: ...damaged 2 Radiator cover is damaged main valve or negative pressure valve is not sensitive 3 Radiator or radiating fin is pluged 4 The cooling fluid in radiator is not enough the installation position...

Page 48: ...he joints between water pump cover and water pump body 3 Water pipe is damaged 4 Cylinder head sealing gasket is damaged Open the water tank cover properly open throttle it shows cylinder head sealing...

Page 49: ...41 Circuit diagram...

Page 50: ...42...

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