ET-300 Service Manual 1 Contents 1. INFORMATION 1-1 Safety 1-2 Notes 1-3 Engine Specifications 1-4 Serial Number 1-5 Torque Values 1-6 Special Tools 2. MAINTENANCE 2-1 Maintenance Data 2-2 Maintenance Schedule 2-3 Fuel Tube 2-4 Throttle Operation 2-5 Throttle Cable Adjustment 2-6 Air Cleaner 2-7 Spark Plug 2-8 Idle Speed 2-9 Drive Chain 2-10 Brake System 2-11 Wheels And Tires 2-12 Steering Shaft Holder Bushing 2-13 Toe-In 3. ENGINE REMOVE AND INSTALLATION 3-1 General Information 3-2 Engine Removal 3-3 Engine Installation 4. LUBRICATION SYSTEM 4-1 Mechanism Diagram 4-2 Precautions In Operation 4-3 Troubleshooting 4-4 Engine Oil 4-5 Engine Oil Strainer Clean 4-6 Oil Pump 4-7 Gear Oil 5. FUEL SYSTEM 5-1 Mechanism Diagram 5-2 Precautions In Operation 5-3 Trouble 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 6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram 6-2 Precautions In Operation 6-3 Troubleshooting 6-4 Cylinder Head Removal 6-5 Cylinder Head Inspection 6-6 Valve Stem Replacement 6-7 Valve Seat Inspection And Service 6-8 Cylinder Head Reassembly 6-9 Cylinder Head Installation 6-10 Valve Clearance Adjustment 7. CYLINDER/PISTON 7-1 7-2 7-3 7-4 7-5 7-6 7-7 Mechanism Diagram Precautions In Operation Trouble Diagnosis Cylinder And Piston Removal Piston Ring Installation Piston Installation Cylinder Installation 8. V-BELT DRIVING SYSTEM 8-1 8-2 8-3 8-4 8-5 8-6 8-7 Mechanism Diagram Maintenance Description Trouble Diagnosis Left Crankcase Cover Drive Belt Drive Face Clutch Outer/Driven Pulley 9. FINAL DRIVING MECHANISM 9-1 9-2 9-3 9-4 9-5 9-6 9-7 Mechanism Diagram - Transmission Cover Precautions In Operation Trouble Diagnosis Disassembly Of Transmission Inspection Of Mission Mechanism Bearing Replacement Re-assembly Of Final Driving Mechanism 10. ALTERNATOR/STARTING CLUTCH 10-1 Mechanism Diagram 10-2 Precautions In Operation 10-3 Right Crankcase Cover Removal 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 10-10 Right Crankcase Cover Installation 11. CRANKCASE / CRANK 11-1 Mechanism Diagram 11-2 General Information 11-3 Trouble Diagnosis 11-4 Disassembly Of Crankcase 11-5 Crankshaft Inspection 11-6 Assembly Of Crankcase 12. COOLING SYSTEM 12-1 12-2 12-3 12-4 12-5 12-6 12-7 12-8 Mechanism Diagram General Information Trouble Diagnosis Trouble Diagnosis For Cooling System System Test Radiator Water Pump Thermostat 13. STEERING AND SUSPENSION 13-1 13-2 13-3 13-4 13-5 Parts Drawing Troubleshooting Handlebar Throttle Housing Steering System 14. FRONT WHEEL AND BRAKE SYSTEM 14-1 14-2 14-3 14-4 14-5 Parts Drawing Troubleshooting Front Wheels Hydraulic Brake Suspension Adjustment 15. REAR WHEEL AND BRAKE SYSTEM 15-1 15-2 15-3 15-4 15-5 Parts Drawing Troubleshooting Remove Rear Wheel And Rear Brake Swingarm & Rear Axle Holder Suspension Adjustment 16. FENDERS AND EXHAUST PIPE 16-1 16-2 16-3 16-4 Fenders Drawing Rear Fenders Removal Front Fender Removal Exhaust Pipe Removal 17. ELECTRICAL SYSTEM 17-1 Troubleshooting 17-2 Ignition Coil 17-3 Ignition Timing 17-4 Battery Information 17-5 Electric Starter 17-6 Light Bulbs Replacement 17-7 Instrument Pane 17-8 Wiring Diagram 18.TROUBLESHOOTING 18-1 Engine Can Not Work 18-2 Poor Performance At Low And Idle Speeds 18-3 Poor Performance At High Speed 18-4 Loss Power 18-5 Poor Handling 1. INFORMATION 1-1 1-2 1-3 Safety Notes Engine Specifications 1-4 1-5 1-6 Serial Number Torque Values Special Tools 1-1 Safety GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flush thoroughly with water and 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. USED ENGINE/GEAR OIL Used engine oil and gear oil may cause skin disease if repeatedly contact with the skin for long periods. Keep out of reach of children. 1-2 Notes All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission. 6 1-3 Engine Specifications Type Displacement Bore and Stroke Compression Maximum Hp Maximum Torque Carburetor Ignition Starting Lubrication Transmission 4 StrokeSingle Cylinder, Water cooled 287.2c.c 75 mm x 65 mm 10.0:1 20ps / 6500 (Nm/rpm) 24.6 Nm / 5000 DC-CDI Electric Auto oil injection Automatic (C.V.T. V-belt + Reverse) CHASSIS Overall Length Overall Width Overall Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity 1830mm 1040mm 1150mm 1190mm 150mm 225Kg 12L SUSPENSION Front Rear Double A-Arm & Adjustable Swing Arm & Adjustable Shock Front Hydraulic Disc*2 Rear Hydraulic Disc*1 21x7-10 22x10-10 12(0.8) 12(0.8) BRAKES Front Rear TIRES Front Rear PRESSURE psi ( kgf/cm2) Front Rear COLORING Specifications subject to change without notice. 7 1-4 Serial Number The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number 8 1-5 Torque Values STANDARD 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 N.m (3.5 lbf.ft) 10 N.m (7.2 lbf.ft) 22 N.m (16 lbf.ft) 35 N.m (25 lbf.ft) 55 N.m (40 lbf.ft) ENGINE Cylinder head nut Spark plug Cylinder head bolt Alternator bolt 38 N.m (27.4 lbf.ft) 12 N.m (8.9 lbf.ft) 15 N.m (10.1 lbf.ft) 8 N.m (5.9 lbf.ft) FRAME Handlebar upper holder bolt Throttle housing cover screw Steering shaft nut Steering shaft holder bolt Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle castle nut Front brake arm nut Rear brake arm nut Rear axle castle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt Rear axle holder bolt Swing arm pivot nut Rear shock absorber mounting nut 24 N.m (17.7 lbf.ft) 4 N.m (2.9 lbf.ft) 50 N.m (36.9 lbf.ft) 33 N.m (24 lbf.ft) 18 N.m (13.3 lbf.ft) 35 N.m (25.8 lbf.ft) 40 N.m (29 lbf.ft) 40 N.m (29.5 lbf.ft) 24 N.m (17.7 lbf.ft) 40-60 N.m (30-45 lbf.ft) 4 N.m (3.0 lbf.ft) 7 N.m (5.2 lbf.ft) 40-60 N.m (30-45 lbf.ft) 24 N.m (17.7 lbf.ft) 30 N.m (22.1 lbf.ft) 30 N.m ( 22 lbf.ft) 90 N.m (65 lbf.ft) 90 N.m (65 lbf.ft) 45 N.m (33 lbf.ft) Nuts, Bolts Tightness Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose clamp, and wire holders for security. 1.6 Special Tools For Frame 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. 10 For Engine 1. TACKING ACG FLY WHEEL TOOL (C1110-RB1-FT1) 2. COUNTER SHIFT IMPLEMENT (I1003-RB1-FT1) 3. ADJUST TAPPET IMPLEMENT (A4721-HMA-FT1) 4. SLEEVE OF FABRICATING TRANSMISSION SHAFT & OIL SEAL (I1202-RB1-FT1) 11 5. SLEEVE OF FABRICATING L CRANK & OIL SEAL (I1201-HMA-FT1) 6. TAKING 6205 BRG. TOOL (I6150-6205-FT1) 7. 6205 BRG. KNOCK TOOL (I6150-6205-FT2) 8. L CRANK CASE COVER 6006 BRG. FABRICATING TOOL (I6150-6006-FT1) 12 9. FABRICATING R CRANK CASE COVER 6201 BRG. TOOL (I6140-6201-FT1) 10. TAKING BRG. RB1 TOOL (I6150-RB1-FT1) 11. (I6150-6205-FT3) 12. TAKING TAPPET PIN TOOL (A4451-HMA-FT1) 13 13. ASSEMBLING DRIVE SHAFT TOOL (B3411-RB1-FT1) 14. TAKING TRANSMISSION SHAFT BRG. 6305 TOOL (I6100-6305-FT1) 15. KNOCKING BRG.(6901) WATER PUMP IMPLEMENT (I1001-KJ9-FT1) 14 16. KNOCKING WATER PUMP OIL SEAL IMPLEMENT (INSIDE) (I1205-KF0-FT1 ) 17. KNOCKING WATER PUMP OIL SEAL(IRON) IMPLEMENT (A9217-H9A-FT1) 18. TAKING & LOCKING SPECIAL NUT 36MM SLEEVE (I0202-HMA-FT1) 19. TAKING & FABRICATING IN. VALVE TOOL (A4711-HMA-FT1) 15 20. TAKING BRG. 62040 LARGE-SIZE TOOL (I6100-6204-FT3 ) 21. ALL-PURPOSE FIXER (B2101-HMA-FT1) 22. KNOCKING BRG.(6204) IMPLEMENT (I6100-6204-FT2) 16 2. MAINTENANCE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 Maintenance Data Maintenance Schedule Fuel Tube Throttle Operation Throttle Cable Adjustment Air Cleaner Spark Plug 2-8 Idle Speed 2-9 Drive Chain 2-10 Brake System 2-11 Wheels And Tires 2-12 Steering Shaft Holder Bushing 2-13 Toe-In 2-1 Maintenance Data SPECIFICATION SPARK PLUG SPARK PLUG GAP RECOMMENDED SPARK PLUGS THROTTLE LEVER FREE PLAY IDLE SPEED BRAKE LEVER FREE PLAY DRIVE CHAIN SLACK TOE-IN 0.8 mm NGK CR8E 5-10 mm 1700±100 rpm 15-25 mm 10-25 mm 5±10 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT ENGINE OIL GEAR LUBRICATION OIL 12-19 N.m 35-43 N.m 1.4 Liter (1.2Liter for change) 750cc (650cc for change) 17 2-2 Maintenance Schedule The internal maintenance in the following table is based on average riding, normal conditions. Riding in unusually dusty areas, require more frequent servicing. 300KM 1 Month I I I I I, L I I I I I I I R R I C I I I I I Every Every 3 Months 6 Months I I C R I I I R I I I I I R Replace for every 3,000km or 6 Months Replace for every 3,000km or 6 Months I,C I,C C I I R I I Every 1 Year Every 2 Years R Notes Fuel Lines Throttle Operation Air Filter Fuel Filter Spark Plug Drive Chain Brake Shoes Brake System Brake Fluid Nuts, Bolts & Fasteners WHEEL/TIRES Wheels Steering System Suspension System C.V.T Drive belt Transmission Oil Engine Oil Battery Oil Filter (Screen) Valve Clearance Coolant Cooling Fan Carburetor (Idle Speed) Choke R R Lubricate for every 1 month Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace 2-3 Fuel Tube Inspect the fuel lines for deterioration, damaging or leakage and replace if necessary. 18 2-4 Throttle Operation Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever. Disconnect the throttle cable at the upper end. Lubricate the cable with commercially lubricant to prevent premature wear. Throttle 2-5 Throttle Cable Adjustment Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free 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 inside the air cleaner case. Pull out the air filter element from the air cleaner case. Washing the element in non-flammable solvent, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil. Install the every component into air cleaner in the reverse order of removal. Note: for more detail please check chapter 5-10 2-7 Spark Plug This spark plug is located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the condition of spark plug electrodes wear. 19 Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.8mm With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading. Tighten the spark plug with 1.0~1.2kgf-m 2-8 Idle Speed Connect an engine speed meter. Warm up the engine, 10 minutes are enough. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) will get higher speed. "Turn out" (counter clockwise) 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 =15~25mm (5/8~1 inch) Adjust the chain slack. Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack. Tighten the axle holder bolts. Torque = 90N.m (65 lbf.ft) When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Please use special chain oil to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for any possible wearing or dama ...