User manual ETON VSL-300ST - SERVICE MANUAL

VECTOR 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 1815mm 1062mm 1130mm 1193mm 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. PNEUMATIC TAKING BRG. 6205 TOOL (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 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. 20 2-10 Brake System Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the brake lever free play at the end of the brake lever trip. Front Brake lever free play is 15-25 mm. Brake lever Adjustable nut Parking Brake Turn the parking brake to the left side is "parking off", while turn to right side is "parking on". As you found out the parking brake which has been decreased its brake ability, you might screw the adjustable nut to modify the clearance of brake shoe to the correct position. Also, another method of adjustment of parking brake, please refer to next page. Parking Off Adjustable nut Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the rear brake lever free play at the end of the lever trip. Parking On Rear Brake lever free play is 15-25 mm. 21 Adjustment Brake level NOTE: The second method to adjust brake level is under the driver seat and rear brake component. In order to avoid a pre-load occurred between brake disk and lining. After all adjusting of brake system are completed, please check the small clearance between brake disk and lining. Rear Brake Front Brake Adjustable nut Loosen the adjustable nut near the rear brake caliper. Screw the adjustable bolt by hand with C.W. turn to the end, then back to a quarter turn. Tighten the nut to complete the parking brake adjustment. Also, as you fount out the brake ability which is a bit insufficient, you can screw the adjustable nut of parking Brake. Parking Brake Adjustable nut 22 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) 2-12 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. 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 23 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 24 3. ENGINE REMOVE AND INSTALLATION 3-1 General Information 3-2 Engine Removal 3-3 Engine Installation 3.1 General Information 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 25 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. 26 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 4-1 Mechanism Diagram Valve Rocker Arm Press-In Lubrication Cam Shaft Oil Route Spray Lubrication Con-Rod Oil Route Spray Lubrication Press-In Lubrication Rotate Direction Oil Pump Oil Strainer 27 4-2 Precautions In Operation General Information: This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 1400 c.c. Change: 1200c.c. Oil viscosity SAE 10W-30 (Recommended King serial oils) Gear oil Disassembly: Change: 750c.c. 650c.c. Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils) :mm Items Inner rotor clearance Oil pump Clearance between outer rotor and body Clearance between rotor side and body Torque value Torque value oil strainer cap Engine oil drain bolt Gear oil drain bolt Gear oil join bolt Oil pump connection bolt Standard (mm) 0.15 0.15~0.20 0.04~0.09 Limit (mm) 0.20 0.25 0.12 1.5~3.0kgf-m 1.9~2.5kgf-m 1.0~1.5kgf-m 1.0~1.5kgf-m 0.8~1.2kgf-m 4-3 Troubleshooting Low engine oil level Oil leaking Valve guide or seat worn out Piston ring worn out Low oil pressure Low engine oil level Clogged in oil strainer, circuits or pipes Oil pump damage Dirty oil No oil change in periodical Cylinder head gasket damage Piston ring worn out 28 4-4 Engine Oil Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level. Oil Change Drain bolt Caution Drain oil as engine warmed up so that makes sure oil can be drained smoothly and completely. Place an oil pan under the ATV, and remove oil drain bolt. After drained, make sure washer can be re-used. Install oil drain bolt. Torque value1.9~2.5kgf-m 4-5 Engine Oil Strainer Clean Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap. Torque value1.5~3.0kgf-m Add oil to crankcase (oil viscosity SAE 10W-30) Recommended using King serial oil. Engine oil capacity: 1200c.c. when replacing Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks. Oil strainer cap O-ring Oil strainer 29 4-6 Oil Pump Oil Pump Removal Remove generator and starting gear. (Refer to chapter 10) Clip Remove cir clip and 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. 2 screws Oil Pump Disassembly Remove the screws on oil pump cover and remove the cover. Remove oil pump shaft roller and shaft. 1 screw Roller 30 Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: 0.25 mm Check clearance between inner and 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 shaft with that of inner rotor. Install the oil pump shaft and roller. Install the oil pump cover and fixing pins properly. Pins 31 Tighten the oil pump screw. 1 screw Roller Oil Pump Installation Install the oil pump, and then tighten screws. Torque value0.8~1.2kgf-m Make sure that oil pump shaft can be rotated freely. 2 screws Clip Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft. Install starting gear and generator. (Refer to chapter 10) 32 4-7 Gear Oil Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.0~1.5kgf-m Gear oil join bolt Make sure that the drain bolt washer 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. Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking. Gear oil drain bolt 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 5-1 Mechanism Diagram Fuel tank cap Fuel unit Fuel tank Auto fuel cock Carburetor Fuel strainer Inlet pipe 5-2 Precautions In Operation General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. When disassembling fuel system parts, pay attention to O-ring position, replace with new one as re-assembly There is a drain screw in the float chamber for draining residual gasoline. Do not disassemble air cut valve arbitrarily. Tool Special service tools Vacuum/air pressure pump Fuel level gauge Specification of CARBURETOR ITEM Carburetor diameter I.D. number Fuel level Main injector Idle injector Idle speed Throttle lever clearance Air screw UA25A Ø22mm PTG 050 14.8mm # 110 # 35 1700 ± 100rpm 1~3 mm 2 turns 5-3 Trouble Diagnosis Poor engine start No fuel in fuel tank Clogged fuel tube Too much fuel in cylinder No spark from spark plug(malfunction of ignition system ) Clogged air cleaner Malfunction of carburetor chock Malfunction of throttle operation Mixture too lean Clogged fuel injector Vacuum piston stick and closed Malfunction of float valve Fuel level too low in float chamber Clogged fuel tank cap vent Clogged fuel filter Obstructed fuel pipe Clogged air vent hose Air existing in intake system Stall after started Malfunction of carburetor chock Incorrect ignition timing Malfunction of carburetor Dirty engine oil Air existing in intake system Incorrect idle speed Mixture too rich Clogged air injector Malfunction of float valve Fuel level too high in float chamber Malfunction of carburetor chock Dirty air cleaner Rough idle Malfunction of ignition system Incorrect idle speed Malfunction of carburetor Dirty fuel Intermittently misfire as acceleration Malfunction of ignition system Late ignition timing Malfunction of ignition system Malfunction of carburetor Power insufficiency and fuel consuming Fuel system clogged Malfunction of ignition system 5-4 Carburetor Remove / Install Removal Drain out fuel in the float chamber. Drain bolt 1 screw Loosen the choke cable fixed iron sheet screw from plate. Remove the choke cable. Choke cable Disconnect the fuel hose. Release the clamp strip of air cleaner. Vacuum pipe Fuel pipe Remove the carburetor upper parts from the carburetor. Release the 2 nuts of carburetor insulator, and then remove the carburetor. Clamp Installation Install in reverse order of removal procedures. 2 nuts 5-5 Air Cut-Off Valve Disassembly Remove 2 screws. 2 screws Remove air cut-off valve cover, spring and valve. O-ring Spring 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. Air cut-off valve Cover Assembly Install in reverse order of removal procedures. 5-6 Throttle Valve Disassembly Remove carburetor upper parts, and then remove throttle valve and throttle cable. Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle. Throttle valve Assembly Place the fuel needle onto the 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 into the carburetor body. Spring Needle clamp Fuel needle clip Throttle cable Fuel needle Caution Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body. Tighten the carburetor upper part. Adjust the free play of throttle valve cable. 5-7 Float Chamber Disassembly Remove 3 mounting screws and remove float chamber cover. Remove the fuel level plate, float pin, float and float valve. Float 3 Screws Float valve Inspection Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt. Fuel level plate Pin Pin Caution In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one. Float valve Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw. Needle jet holder Main jet Caution Take care not to damage jets and adjust screw. Before removing adjustment screw, turn it all the way down and note the number of turns. Does not turn adjust screw forcefully to avoid damaging valve seat face. Needle jet Slow jet Clean jets with cleaning fluid. Then use compressed air to blow the dirt off. Blow carburetor body passages with compressed air. Assembly Install main jet, needle jet holder, needle jet, slow 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. Air adjustment screw Checking fuel level Caution Check again to ensure float valve, float for proper installation. To ensure correct measurement, position the float meter in such a way so that float chamber face is vertical to the main jet. Fuel level: 14.8mm Installation of carburetor Install carburetor in the reverse order of removal. Following adjustments must be made after installation. Throttle cable adjustment. Idle adjustment Float gauge Lock nut Throttle adjustment screw 5-8 Adjustment Of Idle Speed Caution Inspection & adjustment for idle speed have to be performed after all parts in engine that needed adjustment have been adjusted. Idle speed check and adjustment have to be done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.) Park the ATV warm up engine. Connect tachometer (the wire clamp of tachometer is connected to the high tension cable). Turn the throttle valve stopper screw to specified idle speed. Specified idle speed: 1700 ± 100 rpm Ignition cable 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 valve stopper screw and let engine runs in 1600±100 rpm. 3. Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe. Adjust the air adjustment screw so that emission value in idle speed is within standard. 4. Slightly accelerate the throttle valve and release it immediately. Repeat this for 2~3 times. 5. Read engine RPM and value on the exhaust analyzer. Repeat step 2 to step 4 procedures until measured value within standard. Emission standard CO: below 0,8~1.5% HC: below 900ppm Stopper screw Air adjustment screw 5-9 Fuel Tank Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter 13) Disconnect fuel unit coupler. Remove fuel unit (4 bolts). 4 bolts Caution Do not bend the float arm of fuel unit Do not fill out too much fuel to fuel tank. Coupler Fuel unit inspection (Refer to electrical equipment chapter 17). Fuel unit installation Install the gauge in the reverse order of removal. Caution Do not forget to install the gasket of fuel unit or damage it. Fuel tube Fuel tank removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter 13) Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Remove the fuel tube. Remove the vacuum tube. Remove fuel tank front and rear side 4 bolts, and then remove fuel tank. Installation Install the tank in the reverse order of removal. Vacuum tube FRONT REAR 4 bolts 5-10 Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose. Clamp Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts). Installation Install the tank in the reverse order of removal. Cleaning air cleaner element Remove the air cleaner cover (4 catch hooks). Clamp 4 bolts 4 hooks Remove element mounting screw. Loosen the clamp strip of air cleaner element, and then remove the air cleaner element. 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 cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover. Clamp 1 screw 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 6-1 Mechanism Diagram 1.0~1.4kgf-m 1.0~1.4kgf-m 3.6~4.0kgf-m 2.4~3.0kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m 1.0~1.2kgf-m 0.7~1.1kgf-m 1.0~1.4kgf-m 1.0~1.2kgf-m 6-2 Precautions In Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame. Specification of CYLINDER HEAD Item Compression pressure Camshaft Rocker arm Height of cam lobe ID of valve rocker arm OD of valve rocker arm shaft OD of valve stem ID of valve guide Clearance between valve stem and guide Valve Free length of valve spring Valve seat width Valve clearance Tilt angle of cylinder head Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Standard 12±2 kg/cm2 5.90 5.70 11.982~12.000 11.966~11.984 4.975~4.990 4.950~4.975 5.000~5.012 0.010~0.037 0.025~0.062 38.700 40.400 3.400 0.10±0.02mm 0.15±0.02mm --- Limit --5.85 5.65 12.080 11.936 4.900 4.900 5.030 0.080 0.100 35.200 36.900 4.000 0.050 Torque Value Cylinder head cover bolt Exhaust pipe stud bolt Cylinder head bolt Cylinder head Nut Sealing bolt of cam chain auto-tensioner Bolt of cam chain auto-tensioner Cylinder side cover bolt Cam sprocket bolt Tappet adjustment screw nut Spark plug Tools Special service tools Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor 1.0~1.4kgf-m 2.4~3.0kgf-m 1.0~1.4kgf-m 3.6~4.0kgf-m 0.8~1.2kgf-m 1.2~1.6kgf-m 1.0~1.4kgf-m 1.0~1.4kgf-m 0.7~1.1kgf-m 1.0~1.2kgf-m 6-3 Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage Valve carbon deposit. 2. Cylinder head Cylinder head gasket leaking or damage Tilt or crack cylinder 3. Piston Piston ring worn out. High compression pressure Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt valve or damaged valve spring Camshaft wear out or damage Chain wear out or looseness Auto-tensioner wear out or damage Camshaft sprocket Rocker arm or rocker arm shaft wear out 6-4 Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). 2 nuts Remove 1 bolt of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts). Thermostat bolts Tensioner bolts 4 bolts Remove Air Injection system (AI) pipe mounting bolts. Remove spark plug. Spark plug Remove the side cover mounting blots of cylinder head, and then take out the side cover. 3 bolts Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out. Timing mark 2 bolts Cam shaft setting plate Remove cam shaft setting plate (1 bolt). Rocker arm shafts Remove rocker arm shafts and rocker arms. Special Service Tool: Rocker arm and cam shaft puller Rocker arm shaft and cam shaft puller Cam shafts Remove cam shafts. Special Service Tool: Rocker arm and cam shaft puller Rocker arm shaft and cam Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. 4 Nuts 2 bolts Gasket Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution Chain guide Dowel pins Do not damage the matching surfaces of cylinder and cylinder head. 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. Valve cotter remove and assembly tool Caution In order to avoid loosing spring elasticity, do not press the spring too much. Thus, press length is based on the valve cotter in which can be removed. Special Service Tool: Valve cotter remove & assembly tool Inlet valve Inner spring Spring retainer Exhaust valve Outer spring Cotter