Sym Quad Lander 300, Service Manual

Page 1: ...FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Quad Lander 300 SERVICE MANUAL...

Page 2: ...s and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ATV Quad Lander 300 are diff...

Page 3: ...for quick having the special parts and system information There are 4 buttons Forward Contents How to use this manual and Mechanism Illustrations on the CD R version and can be access to these items b...

Page 4: ...1 7 8 CYLINDER PISTON 7 8 1 8 16 V TYPE BELT DRIVING SYSTEM KICK STARTER 8 9 1 9 19 FINAL DRIVING MECHANISM 9 10 1 10 10 ALTERNATOR 10 11 1 11 8 CRANKSHAFT CRANKCASE 11 12 1 12 12 COOLING SYSTEM 12 13...

Page 5: ...Home page Contents SERIAL NUMBER Frame number Engine number...

Page 6: ...ine oil Limits to use SAE 10W 30 API SG class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil Grease King Mate G 3 is reco...

Page 7: ...even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution Battery emits explosive gases flame i...

Page 8: ...il seals because most cleaning agents have an adverse effect on them y Never bend or twist a control cable to prevent unsmooth control and premature worn out y Rubber parts may become deteriorated whe...

Page 9: ...ill the groove with grease install the oil seal with the name of the manufacturer facing outside and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may dama...

Page 10: ...to remove the battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark y After service completed make sure all connectio...

Page 11: ...eck if any wire loose y Check if the connector is covered by the twin connector boot completely and secured properly y Before terminal connection check if the boot is crack or the terminal is loose y...

Page 12: ...they neither pull too tight nor have excessive slack y Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to...

Page 13: ...adjacent or surrounding parts in all steering positions y Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the i...

Page 14: ...g Secondary Reduction Gear Sprocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Used...

Page 15: ...kg Secondary Reduction Gear Sprocket Type 4 Stroke Engine Clutch Centrifugal dry type Installation and arrangement Vertical below center incline Reduction Transmission C V T auto speed change Fuel Us...

Page 16: ...er head right bolt 2 8 2 0 2 4 Cylinder head side cover bolt 2 6 1 0 1 4 Cylinder head cover bolt 4 6 1 0 1 4 Cylinder head stud bolt inlet pipe 2 6 1 0 1 4 Cylinder head stud bolt EX pipe 2 8 2 4 3 0...

Page 17: ...1 GENERAL INFORMATION 1 12...

Page 18: ...l nut 8 10 2 40 Front axle castle nut 2 14 5 00 Rear axle castle nut 2 14 5 00 Rear wheel nut 8 10 2 40 Engine hanger nut 4 12 8 50 Rear axle holder bolt 4 12 9 20 Drive gear bolt 2 10 4 6 Driven gear...

Page 19: ...l is in open or short circuit y Ignition coil leads open or short circuit y Malfunction of main switch Check if sparks Weak sparks no spark at all Perform cylinder compression pressure test Cylinder c...

Page 20: ...ction of CDI y Malfunction of AC alternator y Cylinder piston ring worn out y Cylinder gasket leaked y Sand hole in compression parts y Valve deterioration y Seized piston ring y Remove foreign y Remo...

Page 21: ...carburetor clogged y Poor heat insulation gasket y Carburetor lock loose y Poor intake gasket y Poor carburetor O ring y Vacuum hose crack y Spark plug fouled y Malfunction of CDI y Malfunction of AC...

Page 22: ...initial forward moving or jumping suddenly rear wheel rotating as engine in running Poor initial driving Poor climbing performance y Drive belt worn out or deformation y Weight roller worn out y Movab...

Page 23: ...fuel flow y Clogged fuel tank cap breather hole Normal Abnormal Test cylinder compression Normal Abnormal y Faulty pulse generator y Faulty CDI unit y Leaking head gasket y Worn cylinder and piston r...

Page 24: ...To this chapter contents 1 GENERAL INFORMATION Lubrication Points Drive chain Acceleration cable Front rear brake lever pivot 1 19 Speedometer gear Wheel bearing...

Page 25: ...re 2 13 Nuts Bolts Tightness 2 13 Special Tools List 2 14 2 Precautions in Operation Specification Fuel Tank Capacity 12000 c c Capacity 1400 c c Engine Oil Change 1200 c c Capacity 1300 c c Transmiss...

Page 26: ...ulti meters I I 23 24 Fuel lines I I 25 Cam chain I I 26 Valve clearance I A Lines connections in cooling t I I 27 28 Coolant reservoir I I 29 Coolant I I R Code I Inspection cleaning and adjustment R...

Page 27: ...ner Remove seat loosen 4 hooks from the air cleaner cover and then remove the cover Loosen the clamp strip and 1 screw of air cleaner element and then remove the air cleaner element Clean the element...

Page 28: ...let the T mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke Caution Do not turn the bolt in C C W direction to prevent from ca...

Page 29: ...cified idle speed 1700 100 rpm Emission adjustment in idle speed Warm up the engine for around 10 minutes and then conduct this adjustment 1 Connect the tachometer onto engine 2 Adjust the throttle va...

Page 30: ...gnition timing is incorrect check CDI set pulse rotor and pulse generator Replace it if malfunction of these parts is found Cylinder Compression Pressure Warm up engine Turn off the engine Remove the...

Page 31: ...periodical maintenance schedule to replace it Width limit 22 5 mm or above Shaft Propulsion System Check the drive shaft Park the ATV on a level ground and remove brake pedal and change rod gear shaft...

Page 32: ...rom the drive shaft side Loosen 4 bolts from rear gear box by inner left side of the bottom of vehicle Then remove the rear gear box Use your hand to rotate and check the Rear Gear Box for abnormal no...

Page 33: ...drive chain slack midway between the sprockets Chain slack 15 25mm 5 8 1 inch Adjust the chain slack Loosen the axle holder lock bolts and turn drive chain adjusting nuts until get the correct slack T...

Page 34: ...ver y Do not mix non compatible brake fluid together Filling Out Brake Fluid Tighten the drain valve and add brake fluid Operate the brake lever so that brake fluid contents inside the brake system ho...

Page 35: ...ning condition Replace the lining if the brake lining wear limitation groove close to the brake disc Caution y Do not operate the brake lever after the clipper removed to avoid clipping the brake lini...

Page 36: ...opening gradually to check clutch operation If the ATV is in forward moving and shaking check clutch disc condition Replace it Cushion Warning y Do not ride the ATV with poor cushion y Looseness wear...

Page 37: ...check should be done as cold engine Check if tire surface is ticked with nails stones or other materials Appointed tire pressure Tire size Front tire Rear tire Tire pressure as cold 3 8 2psi Check if...

Page 38: ...otter remove assembly tool NAME AC G Flywheel puller NO SYM 2301000 HMA NO SYM 1471110 20 NO SYM 3110000 HMA NAME Left crank seal driver NAME Drive shaft puller NAME Driver shaft install bush seal dri...

Page 39: ...NAME Bearing driver 6205 NAME Seal driver 14x28x7 14x26x6 NAME Seal driver 30x40x5 NO SYM 9615000 NO SYM 9120600 RB1 RA1 NO SYM 9120100 RA1 12 20 5 6901 NAME Water pump oil seal driver NAME Water pump...

Page 40: ...04022 NO SYM 6204001 NAME Universal holder NAME Clutch nut wrench NAME Swing arm bearing 6007 puller NO SYM 2210100 NO SYM 9020200 NO SYM 2310000 RB1 RFA A6007 55mm 55mm NAME Rear axle nut wrench NAME...

Page 41: ...2 MAINTENANCE INFORMATION 2 17...

Page 42: ...ng 3 2 Engine Oil 3 3 Engine Oil Strainer Clean 3 3 Oil Pump 3 4 Gear Oil 3 7 Mechanism Diagram Valve Rocker Arm Cam Shaft Spray Lubrication Spray Lubrication Press In Lubrication Press In Lubrication...

Page 43: ...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 3 1 7kgf m Engine oil drain bo...

Page 44: ...er drained make sure washer can be re used Install oil drain bolt Torque value 3 5 4 5kgf m Engine Oil Strainer Clean Drain engine oil out Remove oil strainer and spring Clean oil strainer Check if O...

Page 45: ...nd 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 oil p...

Page 46: ...nd 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 sha...

Page 47: ...d then tighten screws Torque value 0 1 0 3kgf 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 star...

Page 48: ...her 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 Torque value 3 5 4 5...

Page 49: ...3 LUBRICATION SYSTEM 3 8 Notes To this chapter contents...

Page 50: ...Valve 6 Vacuum Chamber 7 Float Chamber 8 Adjustment of Idle Speed 10 Carburetor Remove Install for UA30A A UA30A1 6 11 Air Cut Off Valve 12 Throttle Valve 13 Float Chamber 14 Adjustment of Idle Speed...

Page 51: ...4 FUEL SYSTEM 4 2 UA30A A UA30A1 6 Fuel tank cap Fuel tank Carburetor Fuel valve Fuel Strainer...

Page 52: ...tion to O ring position replace with new one as re assembly yThere is a drain screw in the float chamber for draining residual gasoline yDo not disassemble air cut valve arbitrarily Specification ITEM...

Page 53: ...ction of carburetor yDirty fuel Intermittently misfire as acceleration yMalfunction of ignition system Late ignition timing yMalfunction of ignition system yMalfunction of carburetor Power insufficien...

Page 54: ...rottle lever cap Loosen throttle cable adjustment nut and remove throttle cable Disconnect the fuel hose and by starter and drain tube Release 2 clamps strip of air cleaner and inner pipe Remove the c...

Page 55: ...ection 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 Assembly Ins...

Page 56: ...hamber cover and the cover Remove compress spring and vacuum piston Remove fuel needle seat spring and injector needle Check if the vacuum piston for wear out crack or other damage Check if the diaphr...

Page 57: ...ocking 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 level to increase an...

Page 58: ...r 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 yCheck again...

Page 59: ...2 turns 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 the a...

Page 60: ...t screw from plate Remove 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 insulat...

Page 61: ...nd valve 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...

Page 62: ...he throttle 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...

Page 63: ...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 level t...

Page 64: ...ow jet and 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...

Page 65: ...urns Standard turns 2 turns Warm up engine adjust the throttle stopper screw of throttle valve to standard RPM Idle speed rpm 1600 100 rpm Connect the hose of exhaust analyzer to exhaust front end Pre...

Page 66: ...e front fender Remove 2 bolts from tank cover BRKT Covers remove please refer chapter 13 Remove the tank cap rubber remove 2 fuel tubes from fuel valve Remove 4 bolts from tank rear side front side an...

Page 67: ...r pipe and Loosen the clamp strip of air cleaner and then remove the vapor hose Loosen the clamp strip of air cleaner and then remove the air cleaner vapor hose Remove the air cleaner 4 bolts Installa...

Page 68: ...ent Clean the element with non flammable or high flash point solvent and then squeeze it for dry Caution Never use gasoline or acid organized solvent to clean the element Soap the element into cleanin...

Page 69: ...4 FUEL SYSTEM 4 20 Notes To this chapter contents...

Page 70: ...nly y The following parts can be serviced as engine mounted on frame Carburetor Drive pulley drive belt clutch and movable drive face assembly Start motor AC Generator oil pump and start one way clutc...

Page 71: ...e post Remove battery positive post Remove front fender and the footrest refer chapter 13 Remove starter motor wire Remove the spark plug cap Disconnect A C Generator wire couplers Starter motor wire...

Page 72: ...L 5 3 Remove muffler protect 2 bolts Loosen muffler front side bolt Remove 2 bolts and then remove the exhaust muffler Remove 2 nuts and then remove exhaust pipe 2 bolts 2 bolts 2 nuts To this chapter...

Page 73: ...them remove the side cover Loosen throttle cable adjustment nut remove the throttle cable Release the clamp stripes and remove the carburetor Release the clamp strips of left crankcase cover ducts an...

Page 74: ...mp Remove the thermo sensor wire by pass pipe and coolant outlet hose remove brake pedal and change rod Remove 2 c clips from brake pedal Remove brake spring stop switch spring Remove brake penal 1 bo...

Page 75: ...e by left side Remove left side engine hanger and then remove engine by left side Engine Installation Check if the bush of engine hanger parts for damage Install engine in the reverse procedures of re...

Page 76: ...ection 6 7 Valve Stem Replacement 6 10 Valve Seat Inspection and Service 6 11 Cylinder Head Reassembly 6 13 Cylinder Head Installation 6 14 Valve Clearance Adjustment 6 16 Mechanism Diagram 6 0 7 1 1k...

Page 77: ...2 5 030 Intake 0 010 0 037 0 080 Clearance between valve stem and guide Exhaust 0 025 0 062 0 100 Inner 38 700 35 200 Free length of valve spring outer 40 400 36 900 Valve seat width 1 600 Intake 0 10...

Page 78: ...valve timing y Valve spring damage y Valve carbon deposit 2 Cylinder head y Cylinder head gasket leaking or damage y Tilt or crack cylinder 3 Piston y Piston ring worn out High compression pressure y...

Page 79: ...emove hole bolt and spring for the cam chain tensioner Loosen 2 bolts and then remove tensioner Remove thermostat 2 bolts Remove Air Injection system AI pipe mounting bolts Remove spark plug Remove th...

Page 80: ...ain out Remove cam shaft setting plate 1 bolt Remove rocker arm shafts and rocker arms Special Service Tool Tool no SYM 1445100 TOOL number rocker arm and cam shaft puller Remove cam shafts Special Se...

Page 81: ...Avoid residues of gasket or foreign materials falling into crankcase as cleaning Use a valve cotter remove assembly tool to press the valve spring and then remove valves Caution y In order to avoid l...

Page 82: ...Inspection Check if spark plug and valve holes are cracked Measure cylinder head warp with a straightedge and thickness gauge Service limit 0 05 mm Camshaft Inspect cam lobe height for damaged Servic...

Page 83: ...mm 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 va...

Page 84: ...ce 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 r...

Page 85: ...When 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 T...

Page 86: ...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 limit 1 6mm Check the cont...

Page 87: ...ve 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...

Page 88: ...move assembly tool to press the valve spring and then remove valves Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spri...

Page 89: ...d 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 m...

Page 90: ...procket 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 I...

Page 91: ...n the timing mark on the cam sprocket with that of cylinder head piston is at TDC position Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearan...

Page 92: ...gram 7 1 Precautions in Operation 7 2 Trouble Diagnosis 7 2 Cylinder and Piston Removal 7 3 Piston Ring Installation 7 6 Piston Installation 7 7 Cylinder Installation 7 7 Mechanism Diagram 7 Home page...

Page 93: ...0 040 0 100 Piston Piston ring ID of piston pin boss 17 002 17 008 17 020 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 small en...

Page 94: ...linder gasket and dowel pin Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution y Soap the residues into solvent so that the residues can be rem...

Page 95: ...n 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 c...

Page 96: ...r 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 f...

Page 97: ...ully Place the openings of piston ring as diagram shown Caution y Do not damage piston and piston rings as installation y All marks on the piston rings must be forwarded to up side y Make sure that al...

Page 98: ...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 y Do not let the opening of piston pin clip a...

Page 99: ...en 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 coo...

Page 100: ...nism Diagram 8 1 Maintenance Description 8 2 Trouble Diagnosis 8 2 Left Crankcase Cover 8 3 Drive Belt 8 7 Drive Face 8 9 Clutch Outer Driven Pulley 8 12 Mechanism Diagram 5 0 6 0kgf m Home page Conte...

Page 101: ...40 990 mm 40 930 mm ID of driven face 41 000 41 050 mm 41 070 mm Weight of weight roller 17 700 18 300 g 17 200 g Torque value y Drive face nut 8 5 10 5kgf m y Clutch outer nut 5 0 6 0kgf m y Drive p...

Page 102: ...r 10 bolts Remove 2 dowel pin and gasket Left crankcase cover install Install left crankcase cover in the reverse procedures of removal To this chapter contents Clamp strips 10 bolts Left cover plate...

Page 103: ...n smooth and silent and also check if bearing outer ring is mounted on cover tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Remove the bearing 6006 with inner b...

Page 104: ...8 V BELT DRIVING SYSTEM 8 5 Disassembly Remove 5 screws from l cover plate and remove l cover plate Remove 1 bolt from ratchet cover Remove 2 starter ratchets and 2 ratchet springs 5 screws 1 bolt...

Page 105: ...the volute spring from the l crank cover then its has to be replaced Loosen the starter rope from the starter grip Installation Install in reverse order of removal procedures Caution First before inst...

Page 106: ...belt into belt groove 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...

Page 107: ...ive shaft On the drive belt another end to the movable drive face Install the clutch outer and bearing stay collar Hold the clutch outer whit universal holder and then tighten nut to specified torque...

Page 108: ...n 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 D...

Page 109: ...uter diameter of movable drive face boss and replace it if it exceed service limit Service limit 29 962 mm Measure the inner diameter of movable drive face and replace it if it exceed service limit Se...

Page 110: ...pulley 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 o...

Page 111: ...ice 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 movable...

Page 112: ...d the inner diameter of movable driven face Replace it if exceeds service limit Service limit Outer diameter 40 93 mm Inner diameter 41 07 mm Driven Pulley Bearing Inspection Check if the inner bearin...

Page 113: ...n 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 bloc...

Page 114: ...de 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 y Its sealing end should be for...

Page 115: ...nd 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 n...

Page 116: ...erse shaft Counter shaft Drive shaft Bearing 6204 Home page Contents Gear oil fill bolt 3 5 4 5kgf m Shift fork Oil seal 25x40x7 Oil seal tc 25x40x9 Cover bolt 2 6 3 0kgf m Tappet Adj Hole Cap Assy Be...

Page 117: ...bolt 1 1 1 5kgf m Gear oil fill bolt 3 5 4 5kgf m Tools Special tools Bearing driver 6204 SYM 9110400 Bearing driver 6205LLU SYM 9100400 HMA Bearing driver 6305 SYM 9100400 RB1 Needle bearing driver...

Page 118: ...Remove brake spring stop switch spring Remove brake penal Remove tappet adj hole cap and oil drain bolt remove gear box oil fill bolt Make sure that no oil leaking Torque value Gear oil drain bolt 1 1...

Page 119: ...n box Disassembly of mission box Remove 4 bolts from mission box rear cover Remove mission box rear cover Remove 4 bolts from mission box front cover Remove the mission box rear cover and gasket To th...

Page 120: ...e out cir clip Put the pulling out device in the bearing 6009 special tools tools number SYM 6204025 45 tools name F07 INNER BEARING PULLER Load special tool onto the inner bearing puller tools number...

Page 121: ...mission case and the special tool Assembly Cross the special tool the bearing and put in the position assembling Load onto and orientate the device Into the urgent nut then turn the nut install the b...

Page 122: ...s tools number SYM 2345100 RFA tools name OUTPUT SHAFT WRENCH g Installation the mission box rear cover then Lock 4 bolts Installation the mission box rear cover oil seal TC 25 40 9 with special tool...

Page 123: ...9 TRANSMISSION 9 8 RR PROPELLER SHAFT RR SHAET UNIVERSAL JOINT REMOVE Remove the mission box take out the rear shaft universal joint take out the rear propeller shaft...

Page 124: ...IVING MECHANISM 9 9 MISSION SYSTEM Remove Take out c clip with outer c clip pliers Remove the SPIRAL BEVEL PINION and washer Loosen 9 bolt then remove the mission cover Tack out all parts from the mis...

Page 125: ...e shaft Special tool Shaft protector Remove gasket and dowel pin Caution y If non essential do not remove the drive shaft from the case upper side y If remove the drive shaft from the gear box then it...

Page 126: ...ge Measure the outer diameter of shift fork shaft and replace it if it exceed service limit Service limit 11 970 mm Measure the inner diameter of shift fork and replace it if it exceed service limit S...

Page 127: ...ring 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 y If rem...

Page 128: ...aft and reverse shaft bearings into left crankcase Special tool Tool number SYM 9110400 Tool name Bearing driver 6204 Tool number SYM 9100300 RB1 2016 Tool name Needle bearing driver HK2016 Install ne...

Page 129: ...Drive shaft and oil seal install bush Clutch nut wrench Install drive shaft bearing setting plate 1 bolt Gear box side Use inner bearing puller to remove the final shaft needle bearing gear shift shaf...

Page 130: ...ool Tool number SYM 9120200 RFA 6305 Tool name Universal bearing puller Install new final shaft bearings and baring driver into left crankcase with air tools Tool number SYM 9100420 RB1 RFA A6305 Tool...

Page 131: ...rease to hold the washer in the illustrated position This can prevent the washer from falling out when assembling the reverse shaft Install the counter shaft set Install shift drum shift fork and fork...

Page 132: ...of shift drum and then install shift spindle Install the final shaft and Install shift drum fixed catch ball spring and bolt onto gear box Install shift drum fixed catch ball spring and bolt onto gear...

Page 133: ...washer with out cir clip pliers Install the rear propeller shaft and rear shaft universal joint Install the mission box and bolts Torque value 2 6 3 0 kgf m To this chapter contents spiral bevel pini...

Page 134: ...9 FINAL DRIVING MECHANISM 9 19 Install shaft drum fixed catch ball spring and bolt onto gear box Add gear oil Final gear oil 1300c c Gear box oil 150 c c shaft drum fixed catch ball...

Page 135: ...Crankcase Cover Removal 10 3 A C G Set Removal 10 3 Right Cover Bearing 10 3 Flywheel Removal 10 4 Starting Clutch 10 5 Flywheel Installation 10 7 A C G Set Installation 10 8 Right Crankcase Cover Ins...

Page 136: ...of starter motor Specification Item Standard value mm Limit mm ID of starting clutch gear 25 026 25 045 25 050 OD of starting clutch gear 42 192 42 208 42 100 Torque value Flywheel nut 5 0 6 0kgf m S...

Page 137: ...oval Remove 2 mounted screws from pulse generator and then remove it Remove 3 screws from right crankcase cover and then remove generator coil set Right Cover Bearing Inspection Rotate the bearing wit...

Page 138: ...new one bearing 6201LU by bearing driver Special tool Tool number SYM 9614000 HMA 6201 Tool name right crank case bearing 6201 puller Flywheel Removal Remove right crankcase cover Lock enter the prot...

Page 139: ...move flywheel and starting driven gear 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 driv...

Page 140: ...ch gear 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...

Page 141: ...exagon bolt Torque value 1 0 1 4kgf m Install starting driven gear Flywheel Installation Align the key on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel by drive f...

Page 142: ...e the wire harness securely onto the indent of crankcase Caution Make sure that the wire harness is placed under pulse generator Right Crankcase Cover Installation Install dowel pin and new gasket Rem...

Page 143: ...tall 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 To this chapter co...

Page 144: ...10 ALTERNATOR STARTING CLUTCH 10 10 Note To this chapter contents...

Page 145: ...1 General information 11 2 Trouble diagnosis 11 2 Disassembly of crankcase 11 3 Crankshaft Inspection 11 5 Assembly of crankcase 11 6 Mechanism Diagram Eng Oil drain bolt 3 5 4 5kgf m 0 8 1 2kgf m 11...

Page 146: ...chain 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 V...

Page 147: ...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 remove i...

Page 148: ...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 for...

Page 149: ...n out of the 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 be...

Page 150: ...is uneven noising or loose bearing mounted then replace it Special tool Tool number SYM 6204024 Tool name Inner bearing puller bearing driver Assembly of crankcase Install wave washer into right crank...

Page 151: ...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 152: ...lip of the oil seal By oil seal driver 27 42 7 oil seal will knock into located Special tool Tool number SYM 11332100 HMA RB1 Tool name crank and oil seal installation Install the tensioner and tighte...

Page 153: ...Diagnosis for Cooling System 12 3 System Test 12 5 Radiator 12 6 Water Pump 12 8 Thermostat 12 12 Mechanism Diagram Radiator filler cap Radiator Reserve tank Thermo switch fan Coolant inlet pipe Cool...

Page 154: ...0c 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 impeller...

Page 155: ...it 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 coolant...

Page 156: ...ntil 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 chec...

Page 157: ...ly 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 Reinstall th...

Page 158: ...levating in the cooling system the refrigerant backflow floods 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 159: ...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 160: ...r pump seal if does not have the question to take apart for overhaul cooling system of system again the cylinder head the cylinder Removal of water pump Loosen the drain bolt to drain out the coolant...

Page 161: ...4024 Tool name Inner bearing puller Tool number SYM 9100100 Tool name Inner bearing puller Water pump bearing driver Caution Replace a new mechanical seal after removing it Apply a coat of sealant to...

Page 162: ...r Special tools Tool number SYM 9100100 Tool name 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...

Page 163: ...en Torque Value 1 0 1 4kgf m Caution The impeller is left thread Install the dowel pin and right cover gasket The rotation water pump impeller causes the water pump drive shaft scoop channel aligns th...

Page 164: ...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 corres...

Page 165: ...m Home page Contents Left handle protect cover Front fender Fuel tank cover Rear fender Left footrest Front center cover Right side cover Seat Handle cover Right footrest Left side grille Right handle...

Page 166: ...lot on the covers y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during assembly Tail cover Rear bumper Rear fender...

Page 167: ...and then remove front center cover Installation Install in reverse order of removal procedures Fuel tank cover Remove Remove front center cover Remove seat Remove fuel tank cap Remove 1 bolt and then...

Page 168: ...ve 1 screw and then remove fixed support catch Loosen the 6 screws which connect the front fender and side lower covers these 6 screws just be twin the front fender two side Remove right and left side...

Page 169: ...side covers Loosen the front fender two side bolts each side 1 bolt Remove headlight front winker light couplers Remove front fender under side bolts each side 1 bolt 2 Bolt To this chapter contents...

Page 170: ...olts 2 bolts Remove the left crankcase cover duct 1 bolt and remove it Remove front fender upper bolt and then remove power outlet couplers Disassembly Remove 3 screws to remove front emblem 2 Bolts T...

Page 171: ...headlights front side 4 screws and then remove headlights Remove winker lights 4 screws and then remove winker lights Remove 8 screws and then remove right and left grille Each side 2 screws To this...

Page 172: ...covers screws each side 4 screws and then remove side lower covers Installation Install in reverse order of removal procedures Footrest REMOVE Remove Remove right and left foot peg bolts each side 2...

Page 173: ...ide 5 bolts Remove couplers of meter and main switch couplers Remove 4 bolts from meter stay Remove 3 screws and speedometer lamps them disassemble steering cover and speedometer 5 bolts Speedometers...

Page 174: ...res Rear fender Remove rear carrier Pull the Seat Release Bar up in order to remove the seat This seat release bar is under the rear side of the rear fender Remove 4 screws from side cover and lower s...

Page 175: ...ront side 1 screws Remove 4 bolts from under side for rear fender Loosen 2 nuts from starter relay them remove starter relay Loosen 1screw and remove starter relay stay Loosen 5 bolts from rear fender...

Page 176: ...ight set Remove battery CDI unit and fuse box Remove 2 tail light wire bands and couplers Remove rear fender Installation Install in reverse order of removal procedures wire band C D I unit license pl...

Page 177: ...umper and taillights Remove tail cover and rear bumper 6 screws and then remove tail cover Remove license light 2 screws and then remove license light Loosen the 10 screws and then remove taillights e...

Page 178: ...13 BODY COVER 13 14...

Page 179: ...replacement Air bleed 14 9 Front Brake Caliper 14 10 Brake Disk 14 11 Front Brake Master Cylinder 14 11 Mechanism Diagram Brake disk bolts 4 25kgf m Air bleed valve 0 5kgf m Brake caliper bolts 3 25k...

Page 180: ...rubber parts to avoid damage y Check the operation of the brake system before riding y Please refer to the Maintenance Manual of tubeless tire in respect to the removal repair and installation of the...

Page 181: ...1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel alignment...

Page 182: ...el axle cover 4 screws Remove the front wheel nuts and then remove front wheels Installation Install the front wheel and tighten the nuts Torque 2 4kgf m Front Wheel Hub Removal Remove front brake cal...

Page 183: ...mage and replace it if necessary Disassembly Caution y Never install used bearings Once bearing removed it has to be replaced with new one Remove out side bearing and seal from wheel hub using followi...

Page 184: ...de bearing and seal into front wheel hub Special tool Tool number SYM 9620000 Tool name Bearing driver 6203 Oil seal drive 24 35 7 Installation Install the front brake disk to the wheel hub Install wh...

Page 185: ...hen the brake pad wear limit reaches the brake disk Caution y Check the front brake lining must be removed front wheel first Park the ATV on a level ground and check if fluid level is under the LOWER...

Page 186: ...d on painted surfaces plastic or rubber components may result in their damages Remove the master cylinder cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade...

Page 187: ...e system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold th...

Page 188: ...brake disk Brake lining replacement Remove two guide pins Compress caliper mounting plate and then remove brake linings Install new linings and tighten the guide pins Installation Install the brake ca...

Page 189: ...cannot use the air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Front Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign ma...

Page 190: ...5 mm Master Cylinder Assembly Caution y It is necessary to replace the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before assembling Apply...

Page 191: ...shers Tighten the brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them tog...

Page 192: ...14 FRONT BRAKE FRONT WHEEL 14 14 Notes To this chapter contents...

Page 193: ...2 Trouble Diagnosis 15 2 Steering Handle 15 3 Steering Shaft 15 5 Steering Tie Rod 15 6 Knuckle 15 7 Front Cushion 15 8 Suspension Arm 15 9 Toe In 15 10 Mechanism Diagram 4 6kgf m 2 4kgf m 5 0kgf m 3...

Page 194: ...lty steering shaft bushing y Damaged steering shaft bushing Front wheel wobbling y Faulty tire y Worn front brake drum bearing y Bent rim y Axle nut not tightened properly Steers to one side y Bent ti...

Page 195: ...er Caution Do not let foreign materials enter into the cylinder Remove 2 screws and then remove throttle hosing holder and throttle hosing Loosen the socket bolts for the front brake master cylinder a...

Page 196: ...handle mounting bolt and then remove the handle upper holder handle Remove 2 nuts to remove handle under holder and meter bracket Installation Install in reverse order of removal procedures Torque va...

Page 197: ...holder nut fixed plate pressed plate and steering shaft Inspection Check oil rings for wear or damage and replace it if necessary Measure the holder inner diameter Maximum limit 39 5 mm Installation I...

Page 198: ...ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Installation Install the ball joint with adjustment groove on the...

Page 199: ...by ball joint driver Remove the knuckle Special Tool ball joint driver Inspection Inspect the upper and under ball joints and knuckle for damaging or cracking Installation Install in reverse order of...

Page 200: ...emove front cushion under bolt nut and remove the bolt Remove front cushion upper bolt nut and remove the bolt and cushion Installation Install in reverse order of removal procedures Torque value Fron...

Page 201: ...nsion arm Loosen under suspension arm nuts remove swing arm bolts Remove under suspension arm Inspection Inspect the suspension arm ball joint and bush for damage or bending Installation Install in re...

Page 202: ...le back let the wheels turn 180 degree so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measureme...

Page 203: ...Rear Brake Caliper 16 14 Brake Disk 16 15 Rear Brake Master Cylinder 16 15 Rear Cushion 16 19 Mechanism Diagram Home page Contents 16 Rear pressure control valve To front pressure control valve Brake...

Page 204: ...d installation of the tire Specifications Item Standard mm Limit mm The thickness of front and rear brake disk 4 000 2 500 Front and rear brake disk eccentricity 0 100 0 300 Master cylinder inner diam...

Page 205: ...en brake 1 Dirty brake lining disk 2 Poor wheel alignment 3 Clogged brake hose 4 Deformed or warped brake disk 5 Restricted brake hose and fittings Tight brake 1 Dirty brake lining disk 2 Poor wheel a...

Page 206: ...allation Install the rear wheel and tighten the nuts Torque 2 4kgf m Rear Wheel Axle Connecter Removal Remove cotter pin rear wheel axle connecter nut and washer Remove right and left rear wheel axle...

Page 207: ...gear box Remove 2 bolts and then remove rear brake caliper Remove 2 bolts and 1 nut and remove drive chain cover Remove 4 bolts to remove rear under protect Remove drive chain lock clip master link an...

Page 208: ...e Bend out the rear wheel axle holder nut fixed plate Remove rear wheel axle nuts Special tool Tool number SYM HT06007 Tool name rear axle nut wrench 55mm Tool number SYM 4230200 RB1 RFA Tool name rea...

Page 209: ...ed with new one Remove bearing and seal from rear wheel axle bearing seat using following tools Special tool Tool number SYM 6204025 Tool name Inner bearing puller Remove bearing spacer Assembly Insta...

Page 210: ...r wheel axle nuts rear axle nut fixed plate and tighten the nuts Torque 9 2kgf m Special tool Tool number SYM HT06007 Tool name rear axle nut wrench 55mm Tool number SYM 4230200 RB1 RFA Tool name rear...

Page 211: ...iven sprocket must be also inspected for wear Rear swing arm Removal Remove rear under protect drive chain driven sprocket rear brake caliper brake disk and rear axle Remove 2 nuts and bolt and remove...

Page 212: ...brake from behind the brake caliper The brake pad must be replaced with new lining when the brake pad wear limit reaches the brake disk Caution y Check the rear brake lining must be removed rear whee...

Page 213: ...16 REAR BRAKE REAR WHEEL REAR CUSHION 16 11...

Page 214: ...d on painted surfaces plastic or rubber components may result in their damages Remove the brake fluid cap and diaphragm Increases the high quality brake fluid uses by all means must with the trade mar...

Page 215: ...system refilling fluid procedure and operate the brake lever to check whether air bubble is in brake system or not If brake is still soft please bleed the system as described below 1 Tightly hold the...

Page 216: ...tallation Install the brake caliper and tighten the attaching bolts securely Torque 3 25kgf m Caution y Use M8 x 20 mm flange bolt only y Long bolt will impair the operation of brake disk Use two seal...

Page 217: ...air gun to be clean the operator should dress the mouthpiece and the glove use vacuum cleaner clean it Rear Brake Master Cylinder Master Cylinder Removal Caution Do not let foreign materials enter int...

Page 218: ...er Disassembly Remove the rubber boot Remove the cir clip Remove the piston and the spring Clean the master cylinder with recommended brake fluid Master Cylinder Inspection Check the master cylinder f...

Page 219: ...ke sure the cir clip is seated securely in the groove Install the rubber boot into groove properly Master Cylinder Install Caution Improper routing may damage leads hoses or pipes Caution Kink of brak...

Page 220: ...n lock nut and turn adjustment nut and push rod bracket to adjustment brake free play Install fluid hose and clamp Connect brake hoses with 2 new washers Tighten the brake hose bolt to the specified t...

Page 221: ...Remove rear cushion upper bolt and then remove rear cushion Installation Install rear cushion and install rear cushion upper bolt Install rear cushion under bolt and install nut Tighten the rear cush...

Page 222: ...ermo Switch 17 19 Thermo unit 17 20 Water Temperature Indicator Light 17 200 Mechanism Diagram Starter relay Winker relay Spark plug AC Generator Fuse box Battery Ignition coil Main switch C D I Unit...

Page 223: ...apid charge the battery y The voltage must be checked with the voltmeter while charging the battery y As C D I assembly does not require an ignition timing check In case ignition timing is incorrect c...

Page 224: ...ter motor is out of work Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short circuit of the discharging sys...

Page 225: ...to the battery positive terminal Connect the negative terminal of the charger to the battery negative terminal Standard Maximum Charging current 1A 4 0A Charging time 5H 1H Warning y Keep flames away...

Page 226: ...radually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse y Do not turn the main switch to ON position during test If the leaked current exceed...

Page 227: ...t a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Current 1 2 A 60...

Page 228: ...es the condition Item Check Points Standard Value Main switch connection R B Battery voltage ON Battery connection R G Battery voltage Charging coil Y Y 0 17 0 8 If the readings measured are not norma...

Page 229: ...N position Black white green Battery voltage Pulse generator Green White Blue yellow 50 170 Primary circuit Black yellow green 0 17 10 Black yellow with no cap 3 6 10 Ignition coil Secondary circuit B...

Page 230: ...the resistance between the spark plug and the primary winding Standard resistance With no cap 3 6 10 With cap 7 3 11 K Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if n...

Page 231: ...he starter motor Disconnect the coupler of the relay Connect an ohmmeter to the large terminal end Connect the yellow red cable to the battery positive terminal and the yellow black cable to the batte...

Page 232: ...the cable negative terminal then the cable positive terminal Remove starter motor cable Loosen the lock bolts and remove the starter motor Installation of Starter motor Install in reverse order of re...

Page 233: ...ide 5 bolts Remove couplers of meter and main switch couplers Remove 4 bolts from meter stay Remove 3 screws and speedometer lamps them disassemble steering cover and speedometer To this chapter conte...

Page 234: ...th new bulb if necessary H7 12V 55W Caution y Never touch the bulb with finger which will create a heat point y Clean the fingerprint left on the bulb with alcohol Install the bulb of the headlight in...

Page 235: ...ll out the front winker light bulb seat Replace with new front winker light bulb 12V 21W Replacing Bulb of Position Light Pull out the position light bulb seat Replace with new position light bulb 12V...

Page 236: ...connectors by CCW Replace with new taillight bulb 12V 5W 21W Replace with new rear winker light bulb 12V 21W Replacing Bulb of License Light Turn the license light bulb connectors by CCW Replace with...

Page 237: ...the coupler of the main switch Push out the main switch Align the main switch stopper with the meter cover groove and install main switch Install the main switch coupler Handle switches Disconnect the...

Page 238: ...ue Brown Winker switch Pin Position L WR R N PUSH OFF Wire color Pink Black Brown White Horn switch Pin Position BAT3 HO FREE Wire Color White Black Light green Hazard switch Pin Position HD E Wire Co...

Page 239: ...d Rear Brake Switch While grasp the brake lever firmly the terminals of white black and green yellow of the brake should have continuity Replace the switch if damaged Horn Remove the horn from front f...

Page 240: ...switch in the manner as described below Hang the thermo switch on the bowl filled with coolant to check the switch s opening and closing temperatures confirm the switch is open circuited at room temp...

Page 241: ...es when performing this test Caution y Engine oil should be used as a heating medium as the test temperature must be higher than 100 y Contacting the container wall by the thermometer and the thermo u...

Page 242: ...17 ELECTRICAL SYSTEM 17 21 To this chapter contents...

Page 243: ...18 ELECTRICAL DIAGRAM 18 1 18 Home page Contents QUAD LANDER 300 ELECTRICAL DIAGRAM...

Page 244: ...18 ELECTRICAL DIAGRAM 18 2 Notes Home page Contents...