CONTENTS GENERAL INFORMATION 1.Information................................................................2 2.Maintenance...............................................................6 3.Engine Removal & Installation.....................................14 ENGINE 4. Lubrication System...................................................16 5. Fuel System.............................................................23 6. Cylinder HEAD & Cylinder Valve.................................34 7. Cylinder & Piston......................................................50 8. V-Belt driving system................................................58 9. Transmission............................................................72 10. ACG & Start one way clutch......................................84 11. Crankcase & Crank..................................................93 12. Cooling System.....................................................101 CHASSIS 13.Steering & Suspension..............................................113 14. Front Wheel & Brake System..................................121 15. Rear Wheel & Brake System...................................127 16. Fenders & Exhaust Pipe.........................................136 17. Electrical System..................................................142 18. Trouble Shooting..................................................151 1 1. INFORMATION 1.1 1.2 1.3 SAFTY NOTES SPECIFICATION 1.4 1.5 SERIAL NUMBER TORQUE VALUE 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. 1.3 SPECIFICATION ENGINE Type Displacement Bore and Stroke 4 Stroke¡A Single Cylinder, Water cooled 249c.c. 71 mm x 63 mm 2 Compression Maximum Hp Maximum Torque (Nm/rpm) Carburetor Ignition Starting Lubrication Transmission 10.6:1 19ps / 5600 22.3 Nm / 5500 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 1815mm 1062mm 1130mm 1193mm 150mm 225kg 12L SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear PRESSURE ¡i Front Rear Hydraulic Disc*2 Hydraulic Disc*1 21x7-10 22x10-10 psi ( kgf/cm2)¡j 12(0.8) 12(0.8) Double A-Arm & Adjustable Shocks Swing Arm & Adjustable Shock COLORING Specifications subject to change without notice. 3 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. Side Frame serial number Engine serial number Frame serial number 4 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 28 N.m (20.7 lbf.ft) 12 N.m (8.9 lbf.ft) 20 N.m (14.8 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) 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBLE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE AJUSTMENT 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 SYSTEM 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¡Ó 100 rpm 15-25 mm 10-25 mm 5¡Ó 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) 6 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 1000KM 3000KM 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 6000 KM 1 Year Every 12000KM 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. 7 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 8 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. 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 0.6-0.7mm With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading. Tighten the spark plug with 12-19 N.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) 9 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 damaging. Replace the chain, if it is worn excessively or damaged. Inspect the sprocket teeth, if it is excessive wearing or damaging, please replace it. 2.10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. Adjustable nut Brake level The parking brake is shown on the picture. The position of parking Off is on the left side. Turn parking brake to right side is parking on Parking Brake Parking Off Parking On 10 Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 15-25 mm. Brake level Adjustment NOTE: The second method to adjust brake level is under the driver seat and rear brake component. Because the brake system is different, ones need to adjust it to reach a proper brake level. Rear Brake Front Brake Adjustable nut Parking Brake Adjustable nut 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the each tire surface at cold tire condition. *The standard of tire pressure is 12(0.8) psi ( kgf/cm2) 11 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. STEERING SHAFT HOLDER BUSHING Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage. If the bushing is worn or damaged, please change a new one. Grease the steering shaft bushing and install the parts in the reverse order of removal. Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft) 2.13 TOE-IN Keep the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. 12 Carefully to move the vehicle 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 measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m Lock Nuts 13 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 3.2 ENGINE REMOVAL 3.3 ENGINE INSTALLATION 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3.2 ENGINE REMOVAL Before removing engine, you need to remove all of components such as seat, front and back fender, fuel tube, exhaust pipe, carburetor cable and drive chain...etc. You can then see three hanger bolts which have screwed on engine. Loosen these three hanger bolts. You have succeeded to remove this engine. There are some pictures to describe main step of removing engine. Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively. Remove the drive chain cover. Remove the drive chain retaining clip and master link, and remove the drive chain. Hanger bolt 14 Hanger bolt 3.3 ENGINE INSTALLATION The Engine installation is essentially in the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly. 15 4. ...