ATV 250 Service Manual
BRIEF INTRODUCTION TO FOUR-WHEELED
CROSS-COUNTRY VEHICLE MODEL 250ATV
Four-wheeled cross -country vehicle, model 250A TV is a full road condition vehicle which
can be driven on every kinds of road conditions such as sand beach, grassland, forest,village,
construction site country road , This maintenance manual of four-wheeled vehicle model
250A TV (Hereafter called cross -country vehicle for short) compiled by Chongqing Industries
Co., Ltd is specially provided for saler and technical staff of our Group. This manual mainly
introduce the maintenance, removing and repairing method of cross-country vehicle and provide some relative technology and performance data. Because this manual can’t collect the
whole content of cross-country vehicle, it can only help maintainer of our group and it’s saler
have a basic understanding on working principle, maintenance procedure and repairing technology of cross-country vehicle. If you don’t have this knowledge, when repairing cross-country vehicle, the condition of improper assembling and danger occurs after assembling are easily
happened. Proper operation and maintenance are the advance of your safely driving crosscountry vehicle, it also can reduce the troubles of cross-country vehicle and keep the best
performance of it. The specification, performance and explanation stated in the manual are
determined according to newly design of the vehicle, which are subject to changes without
notce.
In this manual, for specially important requirement, the words of “W arning ” “Caution ” are
labelled to prompt relative maintainer to abide it.
In the manual
Warning
Caution
Show that if the content of “W arning ”isn’t obeyed, the driver, maintainer ,
checker will be heavily injuried, even dead.
Show that you must be careful to prevent the vehicle from being damaged.
Maintenance manual of four-wheeled cross-country vehicle model 250A TV
First edition July 2003
This manual is published by publishing factory. maintain the copyright of
publishing. Without permitted, publishing is prohibited.
Content
Content ...............................................................................................................................................I
Chapter I General description..............................................................................................................1
Section 1 Description .......................................................................................................................... 1
Section 2 Special tools, instruments & meters ....................................................................................2
(I) Special tools ........................................................................................................................ 2
(II) Instruments & tools ........................................................................................................... 3
Section 3 Identification code, label of model and engine No. .............................................................4
Section 4 Points for attention in maintenance.....................................................................................4
Section 5 Specification........................................................................................................................8
I. How to use conversion table of unit ....................................................................................8
(1)How to use conversion table...............................................................................................8
(2)Definition of unit ................................................................................................................. 8
II. Basic specification...............................................................................................................9
III. A TV body...........................................................................................................................10
IV. Electric system ...................................................................................................................11
V. Maintenance specification of engine ..................................................................................13
Section 6 Wiring diagram of ATV........................................................................................................16
(I) Technical explanation and requirement, details of relative component. .............................. 16
(II) Wiring diagram(1)...............................................................................................................18
(III) Wiring diagram(2) ............................................................................................................. 19
(IV) Wiring diagram(3) .............................................................................................................20
Section 7 Requirements for torque of fastener....................................................................................21
(1)ATV body............................................................................................................................21
(2) Engine.................................................................................................................................23
(3) General torque specification ............................................................................................... 25
Section 8 Lubrication ..........................................................................................................................26
(1)Lubrication oil way ..............................................................................................................26
(2) Lubrication diagram ............................................................................................................ 27
Section 9 Lubrication point and type of lubricants ............................................................................. 29
(1) Lubrication point and type of lubricants(ATV body) ......................................................... 29
(2) Lubrication point and type of lubricants(Engine)...............................................................30
Chapter II Maintenance and adjustment of vehicle ............................................................................ 31
Section 1 Periodic maintenance/ lubrication .......................................................................................31
Section 2 Disassembly and assembly of cushion, fender and fuel tank..............................................32
(I) Cushion...............................................................................................................................32
(II) Rear fender......................................................................................................................... 33
(III) Fuel tank ...........................................................................................................................35
I
(IV) Front fender ......................................................................................................................37
Section 3 Maintenance and adjustment of vehicle body ....................................................................39
(I) Wear inspection of front and rear brake ..............................................................................39
(II) Adjustment of front brake..................................................................................................39
(III)Adjustment of free clearance of left lever and rear brake pedal .........................................40
(IV) Position adjustmen of steering lever.................................................................................42
(V) Lubricating oil level inspection of rear driving gearcase ...................................................42
(VI) Replacement of engine oil of rear driving gear case .........................................................43
(VII) Inspection of steering system ......................................................................................... 44
(IX) Adjustment of toe-in of front wheel ................................................................................ 45
(X) Inspection of front/rear shock absorber ............................................................................46
(XI) Adjustment of rear shock absorber ..................................................................................46
(XII) Inspection of tire .............................................................................................................47
(XIII) Inspection of rim ............................................................................................................48
Section 4 Maintenance and adjustment of electrical appliance...........................................................49
(I) Inspection of battery...........................................................................................................49
(II) Inspection of fuse ..............................................................................................................50
(III) Replacement of headlight lamp .........................................................................................51
Section 5 Maintenance and adjustment of engine ..............................................................................53
(I) Adjustment of clutch ..........................................................................................................53
(II) Clean of air filter .................................................................................................................53
(III) Inspection of spark plug ................................................................................................... 55
(IV) Adjustment of idle speed..................................................................................................56
(V) Adjustment of free clearance of throttle grip .....................................................................56
(VI) Adjustment of speed limitator ..........................................................................................57
(VII) Adjustment of valve clearance ........................................................................................58
(VIII) Adjustment of timing chain tension ...............................................................................60
(IX) Inspection of ignition timing ............................................................................................ 61
(X) Measuring of compressive force .......................................................................................62
(XI) Inspection oil quantity of engine .....................................................................................63
(XII) Replacement of engine oil and inspection of oil flow ...................................................... 64
Chapter III Repair and maintenance of vehicle body ..........................................................................67
Section 1 Rear driving gearcase and driving shaft..............................................................................67
(I) Trouble................................................................................................................................67
(II) Inspection ..........................................................................................................................67
(III) Trouble-shooting table .....................................................................................................68
(IV) Disassembly .....................................................................................................................69
(V) Inspection ..........................................................................................................................72
(VI) Pad choice of main driving gear and shift gear ................................................................. 73
II
(VII) Installation......................................................................................................................75
Section 2 Front wheel and front brake ...............................................................................................76
(I) Disassembly .......................................................................................................................76
(II) Inspecting procedures ......................................................................................................78
(III) Installation procedures ....................................................................................................81
Section 3 Rear wheel/Rear brake/Rear wheel axle ...................................................................84
(I) Removal steps....................................................................................................................85
(II) Inspection steps ...............................................................................................................87
(III) Installment steps..............................................................................................................90
Section 3 Steering operation system..................................................................................................94
(I) Removal steps of steering bar............................................................................................94
(II) Removal steps of steering vertical column welding .......................................................... 95
(III) Inspection content...........................................................................................................96
(IV) Installment steps..............................................................................................................97
(V) Installation steps of steering bar ......................................................................................1 00
Section 4 Front shock absorber and front wheel fork ........................................................................101
(I) Disassembly .......................................................................................................................101
(II) Inspection steps ...............................................................................................................103
(III) Installment steps..............................................................................................................104
Section 5 Rear shock absorber and rear wheel fork............................................................................107
(I) Disassembling steps .......................................................................................................... 107
(II) Checking steps .................................................................................................................109
(III) mounting..........................................................................................................................111
Chapter IV Electric appliance .............................................................................................................114
Section 1 Inspect switch ....................................................................................................................114
(I) Inspect switch....................................................................................................................114
Section 2 check lamp(headlight) ........................................................................................................115
Section 3 Troubleshooting the ignition system failure ......................................................................117
Section 4 Running of starting circuit .................................................................................................122
Section 5 Troublshooting electric starting system ............................................................................123
Section 6 Check starting motor ..........................................................................................................126
Section 7 No charging in the battery .................................................................................................129
Section 8 Troubleshooting ................................................................................................................132
Section 9 Inspection of lighting system.............................................................................................134
(I) If the headlight is out of work ............................................................................................134
(II) If the taillight is out of work .............................................................................................. 135
Section 10 Troubleshooting...............................................................................................................137
(I) If indicated lamp is out of work .......................................................................................... 137
Section 11 Inspection of signal system.............................................................................................. 139
(I) If the neutral indicated lamp is out of work ........................................................................ 139
III
(II) If the reverse indicated lamp is out of work ...................................................................... 140
(III) If the HB indicated lamp is out of work............................................................................ 141
Chapter V Engine ............................................................................................................................... 142
Section 1 Disassembly of engine ....................................................................................................... 142
(I) Remove the engine from finished A TV .............................................................................. 142
(II) Disassembly of engine...................................................................................................... 145
section 2 Inspection and maintenance of engine ............................................................................... 159
Section 3 Assembly and adjustment of engine .................................................................................. 183
(I) Closing assembly of left & right crankcase........................................................................ 183
(II) Assembly of right crankcase ............................................................................................ 184
(III) Assembly of left crankcase.............................................................................................. 192
(IV) Selection and installation of adjusting washer ................................................................ 197
(V) Assembly of cylinder head ............................................................................................... 204
(VI) Manual starting mechanism and others........................................................................... 211
(VII) Mount the engine on the finished vehicle...................................................................... 211
Chapter VI Vecicle ordinary trouble and its judgement ...................................................................... 218
(I) Starting trouble/difficulty................................................................................................... 218
(II) Poor idle speed performance............................................................................................. 219
(III) Poor middle and high speed performance........................................................................ 219
(IV) Shifting troubler............................................................................................................... 219
(V) Clutch slips ....................................................................................................................... 220
(VI) Clutch is locked ............................................................................................................... 220
(VII) Engine is overheat .......................................................................................................... 220
(VIII) Brake trouble ................................................................................................................. 220
(IX) Shock absorber failure/improper operation ..................................................................... 220
(X) Lighting system ................................................................................................................ 221
IV
Chapter I General description
Section 1Description
12 3
10 1 1 12 13 14 15
45
6 78 9
1.Front wheel
2.Headlight
3.Steering lever
4.Shift pedal
5.Fuel cock
6.Hand-operated lever
7.Air chock
8.T ail light
9.Rear wheel
10.Rear luggage carrier
11.Exhaust silencer
12.Cushion
13.Fuel tank cover
14.Rear brake pedal
15.Front luggage carrier
16.Left lever of rear brake
17.Fixing clamp of rear brake
18.Main switch lock
19.Throttle grip
20.Right lever of front brake
21. Left switch unit
Caution:
The ATV you purchased maybe slightly differ from the pictures in the manual due to
improvement or other changement.
-1-
Section 2 Special tools, instruments and meters
(I) Special tools
Special tools is the necessary tools used for accurately adjustment and assembly, it is
helpful to prevent the maintenance defects and components damage caused by using improper
tools.
1.Wrench for valve adjustment mainly used for adjusting valve clearance. Specification:
3mm 90890-01311
2.Puller for piston pin, mainly used of removing pistion pin.
3.Remover for rotator, mainly used for pulling magneto rotator form crank.
4. Clamp for rotator, mainly used for clamping magneto rotator when removing it to pre-
vent it’s rotation due to torque force.
5.Stop rotating meter for rotator, mainly used for removing and assembling rotator of kick
starter.
6.Puller for crank, mainly used for disassembling crank from crankcase.
7.Puller for rocker shaft, mainly used for removing rocker shaft.
8.Compressing tools for spring of valve, mainly used for fixing and compressing spring
when assembling valve lock clamp.
9. Assembling and disassembling tool for valve guide, mainly used for assembling and
disassembling valve guide.
10.Assembling buffer, mainly used for assembling crank and balancing gear.
11.Hollow sleeve, mainly used for assembling crank and balancing gear .
12.Assembling toal for crank, mainly used for assembling crank and balancing gear.
13.Assembling and disassembling joint for universal coupling, mainly used for assembling
and dismsembling universal coupling.
14.Assembling and disassembling disc, mainly used for assembling and disassembling re-
verse gear.
15.Fixed puller for gear, mainly used for assembling and disassembling gear.
For the above tools, you can select with reference to special tools of the same type
of vehicle.
-2-
(II) Instruments and meters
The following instruments and meters can be selected with reference to the same type of
vehicle.
speedometer of engine
(90890-03113)
Ignition timing meter
(90890-03141)
multimeter
spark tester of spark plug
barometer ignition checker
measuring tool of gasoling
(90890-01312)
dial indicator
-3-
Section 3 Identification code, label of model and engine N0.
Identification code
It is engraved in the left or right side of front
supporting main tube of engine of frame.
¢Ù
Engine N0.
It is engravd on the lug of top middle part of
right crankcases of engine.
Section 4 Points for attention in maintenance
1.Preparation when disassembling
1.1 First clean the dirt, mud and attachment
on the vehicle befor removing or disassembling.
1.2 Use proper special too cleaning device
and means.
1.3 Keep all the components away from fire
source. Pay attention to the safety, Don’t be
burned by the high temperation portion of engine,
exhuaster and silencer etc. Be sure to take care
of each other when operation with other people.
1.4 When disassembling the ATV, put the
mated components, such as gear pairs, cylinder,
piston and other “mated” components by normal running in together, When assembling or
replacing these components, they should be in
pairs.
1.5 When disassembling the engine, clean
all the components and put in the tray in the or
der of disassembly, this in assembling, can
not only increase the assembling speed, but also
ensure the rightness of assembling.
2.Replace the components
When replacing the components, be sure to
use qualified products provided by use lubricants
and grease which brank is assigned by lubricate.
3.Oil seal, shim, o-ring clip split pin,
elastic washer.
3.1 When disassembling to maintain the
engine, in order to ensure that the reassembled
engine have good sealing and connecting part is
fixed and reliable, all the oil seal, shim, o-ring,
clip, split pin and elastic washer should be
replaced, be sure to keep lip of oil seal surface
of shim and o-ring in cleaning condition.
3.2 When reassembling, apply lubricants to
lubricate all the mated components and bearing,
apply grease for oil seal.
-4-
4. Clip
4.1Before assembling, be sure to check all
the clips carefully.Use a new one after removing the clip of piston pin. When mounting clip
ring ¢Ùmake the sharp face ¢Úon the opposite
position of impacted face ¢Ûof clip.(see left
fig)
5.Locking washer /shim and location pin
5.1When reassembling after disassembling.
be sure to replace all the locking washer /shim
and location pin @ After bolt or nut is fixed on
the locking position. be sure to bend and fix both
ends of locking shim along head of bolt or direction of nut.
6.Bearing and oil seal
6.1 When assembling bearing and oil seal
put the mark or specification of manufacturer
outside, When assembling oil seal apply a thin
film of lithium-base grease on the lip of oil seal.
Caution:
Don’t blow to dry the inside of bearing with
compressed air, this would damage the surface
of bearing.
-5-
Fig.7.1Removal of negative pole wire of battery
Fig.7.2 Connection of positive pole wire of battery
7.Check of electirc parts
7.1 Check the rust, dirt and moisture etc.
of connector, if there is moisture, please blow it
dry and clear the rust and dirt.
7.2 The eclectolyte inside the battery is a
kind of corrosive, when operation exercise shall
be taken not to let the electrolyte splash on the
body.
7.3 When repairing wire on electric parts,
first remove the wire on the termianl of negative pole of battery(see fig.7.1).When tightening or loosening bolt of terminal of big capacity
battery, don’t let the wrench contact with engine or other metal parts of vehicle body to
avoid the electric shock.
7.4 When connecting the wire of battery,
first connect the opositive pole wire of battery,
then connect the negative pole wire After connecting the wire, apply clean grease on the terminal to avoid the increasing of resistance due
to rust.
-6-
7.5 Check the terminal of connector
a Grip two terminals of connector together,
check with the multimeter.(see fig.7.3,fig.7.4)
Fig.7.3
Fig.7.4
Plug pin
Fig.7.5
According to
intersecting
Fig.8.1Tightening method of screw and nut.
b. If joint is slack, bend the plug pin
upward, then connect with connector plug(see
fig7.5)
7.6 Before mounting new fuse, check if the
load of fuse of components is right, especially
for the portion being burned broken regularly,
then mount the fuse having proper current value.
7.7Wire connector have two kinds, one is
single-head connector, another is multi -head
one.
Before connecting single-head connector ,
check if there is broken on the housing of joints,
the joint is fixed and if there is a broken phenomenon on it. When inserting the joint, it should
be fixed, then put in plastic coating after
inserting.
In general, multi-head connector is plastic
one, and locking catch is designed. When disassembling the connector, first open locking catch
when connecting again, first check if all the joint
is in good condition, if there is bent or twisted
on them. After connecting, align the locking
catch and lock them.
8. Use torque spanner to tighten screw and
nut, and as per specified torque to tighten them.
It should be tightened in steps from big ones to
small ones, from inside to outside and along the
direction of diagonal line to intersect. A s shown
in fig.8.1.
-7-
Section 5 Specification
(I) How to use conversion table of unit
(1)How to use conversion table
All the specified documents in this manual are taken SI and Metric as unit. With the follow-
ing conversion table, metric unit could be conversed into imperial unit.
METRIC MUL TIPLY IMPERIAL
m m 0.03937 in
2mm ¡À 0.03937 = 0.08in
Conversion table
Conversio between metric and imperial
Torque
Weight
Length
Volume/capacity
Others
Known unit
m.kg
m.kg
cm.kg
cm.kg
kg
g
km/hr
km
m
m
cm
mm
cc(cm3)
cc(cm3)
lit(liter)
lit(liter)
kg/mm
2
kg/cm
Centigrade
Multiply
7.233
86.794
0.0723
0.8679
2.205
0.03527
0.6214
0.6214
3.281
1.094
0.3937
0.3937
0.03527
0.06102
0.8799
0.2199
55.997
14.2234
9/5(¡æ)+32
produst
ft.lb
in.lb
ft.lb
in.lb
lb
oz
mph
mi
ft
yd
in
in
oz(IMP liq)
cu.in
qt(IMP liq)
gal(IMP liq)
1b/in
psi(1b/in2)
Fahrenheit(0F)
(2)Definition of unit
Unit
mm
cm
kg
N
Nm
m.kg
Pa
N/mm
L
3
cm
r/min
-8-
Read
Millimetre
Centimetre
Kilogram
Newton
Newton meter
Meter kilogram
Pascal
Newton per millimeter
Liter
Cubic centimeter
Revolutions per minute
Definition
10-3Meter
10-3Meter
103Gram
1 lilo ¡Ámeter /second
Newton ¡Ámeter
Meter ¡Ákilo
Newton/meter
Newton/centimeter
2
Measurement
Length
Length
Weight
Force
Torque
Torque
Pressure
Rigid of spring
Volume or capacity
Rotational speed
II.Basic specification
-9-
III.ATV body
Steering system
Type of steering bearing
Type
Material of rim
Front
wheel
Front
brake
Size of tire
Size of rim
Radial runout of rim
Lateral swing of rim
Type
Inside diameter of brake drum
Thickness of friction piece
Free length of back spring of brake shoe
Type
Material of rim
Item
Standard Limit
Powder metallurgy sliding bearing
Spock rim, tubeless tire
Steel plate
AT 23¡Á7-10
AT 10¡Á5.5
Drum type
160mn
4.0mm
71.0mm
Spoke rim, tubeless tire
Steel plate
2.0mm
2.0mm
161mm
2.0mm
Rear
wheel
Rear
brake
Brake
lever and
brake
pedal
Free play of throttle grip
-10-
Size of tire
Size of rim
Radial runout of rim
Lateral swing of rim
Type
Outside diameter of brake durm
Thickness of friction piece
Free length of back spring of brake shoe
Free play of brake lever (left)
Free play of brake lever (right)
Free play of rear brake pedal
AT 22¡Á10-10
AT 10¡Á8.0
Drum type
160mm
4.0mm
71.0mm
5-7mm
5-7mm
20-30mm
3-5mm
2.0mm
2.0mm
161mm
2.0mm
Item
Standard Limit
Elastic coefficient of spring K1
Front
suspen-
sion
system
Rear
suspen-
sion
system
Rear
wheel
fork
Free length of suspending spring
Stoke of shock absorber
Pre-tension force of spring is
adjsutable or not
Elastic coefficient K2
Free length of suspending spring
Assembling length
Stroke of shock absorber
Pre-tension force of spring is
adjustabe of not
Assembling free play(left-end)
Assembling free play (right-end)_
IV.Electric system
10N/mm/0-117mm
293mm
117mm
Can’t adjustable
49N/mm/0-85mm
263mm
244mm
85mm
Adjustable
1.0mm
1.0mm
Spark
plug
Ignition
coil
Ignition
system
Item
Voltage of electric system
Type
Resistance
Clearance of spark plug
Resistance of primary coil
Resistance of secondary coil
Clearance of min. spark
Ignition timing (Before upper stop point)
Advancing angle of ignition (Before upper stop point)
Type of ignition advance
Standard Limit
12V
D7RTC
10¦¸
0.6-0.7mm
At 20¡æ(680F),0.5-1.5¦¸
At 20¡æ(680F),4.6-7.6¦¸
6mm(0.24in)
10/2300r/min
30/4300r/min
Electric type
-11-
Item
Standard Limit
Magneto
Rectifier
Charging
system
Battery
Broken
circuit of
circuit
system
Belay of
cut-off
current
Resistance of induction coil/colour
Resistance of source coil /colour
T ype of C.D.I
No-loading adjusting volatage
Voltage-resisting value
Type
Rated ouput voltage
Coil resistance/colour
Specific gravity
Type/capacity
Type
Main fuse
Resaved fuse
Coil resistance
Diode
At 20¡æ(680F),189-231¦¸ Blue black
At 20¡æ(680F),470-530¦¸ Yellow/green-red
Electric capacity contactless type
14.1-14.9V
200V
A.C magneto
At 2000r/min 14-15V
At 20¡æ(680F),1.0-1.2¦¸ White -white
1.28
12N14-BS/12V.14Ah
Fuse
20A
20A
At 20¡æ(680F),72-88¦¸
Yes
Electric
starting
system
Electric
starting
system
-12-
Type
Starting
motor
Starting
relay
Output power
Resistance of armature coils
Ampere
Coils resistance
Constant mesh type
0.35KW
At 20¡æ(680F),0.004-0.005¦¸
100A
At 20¡æ(680F),4.8-5.3¦¸
V.Maintenance specificationof engine
-13-
-14-
-15-
Section 6 W iring diagram of ATV
(I)Thechnical explanation and requirement, details of relative compenent.
1.Technical explanation
A Main switch wire, indicator wire, mileage meter wire (mounting digital mileage meter)
must be put throught the guide grip of holding
seat of steering bar. (see fig.1)
B Rear brake vent-pipe, carburetor ventpipe and vent-pipe of rear driving gearbox must
be inserted into the hole of supporting pad of
vent-pipe.(see fig.1, also see view D)
C Neutral and reverse switch wire, mileage meter wire(mounting with digital mileage
meter) should be fixed with bands here.(see
fig.1)
D After putting overflowing pipe of carburetor through two rear fixing part of engine
(on thge frame), then put it in the proper position between engine and rear arm. Note: Overflowing pipe be unblocked.(see fig.1)
S After putting rear brake cable, throttle
cable, wire of starting motor and mileage meter
(mounting with digital mileage meter )through
wire hook2, wire hook 2should be bent according to the method of view A.
P In this position, starting motor wire and
mileage meter wire(mounting with digital mileage meter)must be put throughh the hole of plastic grip in the fuel tank support of frame..(see
view B-B)
R In here, rear brake cable, rear brake
vent-pipe and mileage wire(mountig with digital
mileage meter)must be first put through wire
hook 2, then connect with respective matching
unit.(see fig. B-B)
Q In here, wire of reverse switch neutral
switch, and mileage meter (mounting with digital mileage meter)must be fixed with bands.(see
fig.B-B)
T When assembling the wire of ser. No.
14 and No.15.don’t need to put through the guide
clip of holdig seat of steering bar.(see fig.E-E)
W After putting the vent-pipe of tank
through the hole of main switch, lead it to the
lower of right side of steering bar, then put it
through the wire hook on the frame.
Note: Hose must be unblocked.(see fig.
E-E)
V The leading wire on the switch units of
steering bar, must be bound with band,(see fig.
G-G)
E After the vent-pipe of front brake is put
through plastic clip hole on the frame, surplus
portion should be put in the proper position of
frame.(see fig.2)
G After the vent-pipe of battery is checked
and no twist is found here, then insert it in the
presetting hole of rear fedner.(If free of maintenance battery is used, then this item of requirement doesn’t need.)(see fig.3)
H Wire of rear brake cable, rear brake
vent-pipe and mileage meter(mounting with digital mileage meter)should be put through the cable
frame welded on the frame in here.(see fig.3)
F In here, wire of starting motor must
be first put through the plastic clip on the
frame, then connect with the matching units.
(see fig.3)
L Vent-pipe of battery should be put
through the plastic clip fixed on the frame.(see
fig..)(If free of maintenance battery is used, then
this item of requirement doesn’t need.)
K In here, wire of throttle cable, rear brake
cable and mileage meter(mounting with digital
mileage meter )should be put through the cable
guide frame welded on the frame.(Throttel cable
-16-
should be mounted on the inner side of guide
frame direction).(see fig.4)
J Insert the starting relay into the inserter
preset by the rear fender, the direction should be
ensured the convenience of inserting.(see fig.4)
M After putting the vent pipe of battery
through the plastic clip mounted on the rear
fender, instert it into the hole preset by the rear
fender, (Combine with G)(see fig.4)(If free of
maintenance battery is used. then this item of
requirement doesn’t need).
U When assembling, mounting supporting
pad of vent-pinpe shouldn’t be leaked, and pay
attention to let the direction of mark upward.
(see view D )
N In here, the wire of taillight must be put
through the slot hole preset by tool kit from the
bottom of tool kit.(see view F)
2.Technical requirement
¢ÙIn the drawing, the wiring condition and
position for all kinds of wires on the ATV body
is marked. When assembling the finished ATV,
wiring should be done as per the drawing in
principle.
¢ÚFor the wiring and fixing method which
can’t be marked in the drawing , necessary technical explanation has been made, you should abide
to execute in assembling.
¢ÛFor the place of using plastic clip stipulated in the drawing, if can’t be used temporarily,
you can use band to fix it.
¢ÜThe dimension in the drawing is only used
for reference in operation, while not be used as
checking data. In the details of marking the code
No. of component, the self-carrying component
(wire etc.)of units only be marked with name.
3.Details of relative component
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Ser.No.
SSA0-000512-0
SSA0-000511-0
SSA0-000510-0
SSA0-000509-0
150.00-0.39
150.00-03
150.00-06
FG-802000-0
SSA5-320000-0
SSA0-000516-0
SSA0-000515-0
SSA4-230000-0
SSA4-230000-0
SSA4-210000-0
SSA4-220000-0
SSA0-000517-0
SS45-630000-0
FG-803000-0
FG-805000-0
SSA5-510000-0
SSA0-012000-0
Code
Wire clip 4
Wire clip 3
Wire clip 2
Wire clip 1
Cable band
band of steering bar
C.D.I magneto wire
Vent-pipe of carburetor
Cut-off relay
Starting relay
Cable
Ven-pipe of rear brake
Wire of starting motor
High voltage coils and wire
Vent-pipe of battery
Vent-pipe of front
Wire of headlight
Rear brake cable
Wire of handle bar switch
Wire of clutch wire
Throttle cable
Front brake cable units
Wire of mileage meter
Wire of neutral switch
Wire of reverse witch
Overflowig hose of carburetor
Vent-pipe of garbox
Taillight unit
C.D.I
Rectifier
Vent-pipe of gearbox
Main swtich lock
Wire clip unit
Name
3
2
3
2
6
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Q’ty
Remark
-17-
(II)Wiring diagram(1)
E L
Fig.1
-18-
Fig.2
(III)Wiring diagram(2)
Fig.3
Fig.4
F
View F
-19-
(IV)Wiring diagram(3)
B-B
View C
-20-
V iew A
G-G
Section 7 Requirements for torque of fastener
(I)A TV body
Torque value of fastener
Locking component and
location of ATV body
Name of
component
Size of
thread
Q’ty
Tightening torque of
fastener of AT V body
Nm
m.kg
Remark
ft.lb
Front wheel rim and front brake hub
Front brake hub and steering vertical post units
Fornt brake cam arm and cam shaft
Front brake and front shock absorber
Front shock absorber and frame
Steering vertical post and pulling rod
pulling rod and nut
Steering vertical post and pulling rod
Steerig vertical post(lower)and frame
Holding seat of steering vertical post and frame
Steerig vertical post and upper & lower holding seat of steerig bar
Front wheel fork and frame
Front wheel fork and brake
Engine upper connection plate unit and frame(upper )
Engine assy and engine upper connecting plate unit
Engine assy and frame(front)
Nut
Nut
Nut
Bolt
Nut
Nut
Nut
Nut
Nut
Bolt
Bolt
Bolt
Nut
Bolt
Bolt
Bolt
M10¡Á1.25
M12¡Á1.25
M6 ¡Á30
M12¡Á50
M35¡Á1.5
M12¡Á1.25
M12¡Á1.25
M12¡Á1.25
M10
M8¡Á60
M8¡Á50
M10¡Á70
M12 ¡Á1.25
M8¡Á6
M8¡Á55
M8¡Á105
8
55
5.5
40
2
25
2.5
18
2
9
0.9
6.5
4
78
7.8
56
2
55
5.5
40
2
25
2.5
18
4
30
3
22
2
25
2.5
18
1
30
3
22
2
23
2.3
17
4
20
2
14
4
45
4.5
32
2
25
2.5
18
2
33
3.3
24
1
33
3.3
24
1
48
4.8
35
Engine assy and frame(rear upper)
Engine assy and frame(rear lower)
Front fender and frame
Front fender flap and front fender supporting rod
Bumper and frame
Front luggage carrier and bumper
Front luggage carrier and frame
Front fender and front luggage carrier
Rear fender and frame
Rear luggage carrier and frame
Bolt
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
M8¡Á105
M6¡Á16
M6¡Á16
M6¡Á16
M8¡Á16
M6¡Á16
M8¡Á16
M6¡Á20
M6¡Á16
M6¡Á40
1
33
3.3
24
1
33
3.3
24
2
7
0.7
5.1
2
7
0.7
5.1
4
11
1.1
8
2
11
1.1
8
2
34
3.4
25
2
7
0.7
5.1
2
7
0.7
5.1
2
7
0.7
5.1
-21-
Locking component and
location of ATV body
Name of
component
Size of
thread
Q’ty
Tightening torque of
fastener of ATV body
Nm
m.kg
ft.lb
Remark
Rear fender and rear luggage carrier
Left&right foot rest and frame
Left&right foot rest and frame
Supporting weldment in foot rest and bracket weldment
Rear rim and hub
Rear wheel axle and nut
Rear brake cam arm and cam shaft
Rear brake shoe and rear axle housing
Rear wheel fork and frame(left)
Rear wheel fork and frame(right)
Rear arm shaft and nut(right)
Rear wheel fork unit and rear driving gearbox units
Rear wheel axle bushing and driving gearbox units
Rear shock absorber(upper)and frame
Lower cover of gearbox
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Nut
Bolt
Bolt
Bolt
Nut
Nut
Bolt
Bolt
Bolt
M8¡Á16
M6¡Á20
M10¡Á22
M8¡Á16
M8¡Á16
M10 ¡Á1.25
M16
M6¡Á30
M8¡Á1.25
M22 ¡Á1.25
M22¡Á1.5
M22¡Á1.5
M22¡Á1.5
M12 ¡Á1.25 ¡Á25
M12¡Á75
M8¡Á12
2
34
3.4
25
2
7
0.7
5.1
4
65
6.5
47
2
30
3
22
4
30
3
22
8
55
5.5
40
2
150
15
110
1
9
0.9
6.5
4
28
2.8
20
1
130
13
94
1
6
0.6
4.3
1
130
13
94
4
55
5.5
40
4
55
5.5
40
1
50
5
36
2
17
1.7
12
Rear wheel axle bushing and rear wheel fork init
Fuel tank and frmae
Oil draining bolt of rear driving gearbox
Oiling bolt of rear driving gearbox
-22-
Bolt
Bolt
Bolt
Bolt
M12 ¡Á1.25 ¡Á25
M6¡Á35
M12 ¡Á1.25
M12 ¡Á1.25
4
103
10.3
74
2
10
1
7.2
1
23
2.3
17
1
23
2.3
17
(II) Engine
Torque value of fastener
Locking component and
location of ATV body
Name of
component
Size of
thread
Q’ty
Tightening torque of
fastener of AT V body
Nm
m.kg
Remark
ft.lb
Observing screw hole of cylinder head
Cylinder head
Cylinder head and cylinder
Sprocket cover
Valve cover
Bearing stop plate of camshaft
Spark plug
Cylinder
Balancing shaft gear
Starting ratchet disc
Locking nut(adjusting screw of valve clearance)
Cam timing sprocket
Chain tensioner
Chain tensioner cover
Upper guide plate of chain
Oil pump
Cap shaped nut
Flange bolt
Bolt
Screw
Bolt
Bolt
Nut
Bolt
Nut
Bolt
Nut
Bolt
Bolt
Bolt
Bolt
Screw
M6
M8
M8
M6
M6
M6
M12
M6
M14¡Á1.0
M10 ¡Á1.25
M6
M10
M6
M6
M6
M6
1
7
0.7
5.1
4
22
2.2
2
22
2.2
2
7
0.7
5
10
1
2
8
0.8
1
17.5
1.75
12.5
2
10
1
1
50
5
1
50
5
2
14
1.4
1
60
6
2
10
1
1
7
0.7
2
8
0.8
3
7
0.7
16
16
5.1
7.2
5.8
7.2
36
36
10
43
7.2
5.1
5.8
5.1
Apply oil
to washer
Apply oil
to washer
Apply oil
to washer
Oil draining screw plug
Fine filter cover of engine oil(drainingoil)
Fine filter cover of engine oil
Carburetor seat and cylinder head
Carburetor and carburetor seat
Carburetor and carbuetor connecting pipe
Air filter box and carburetor connecting pipe
Air filter box and intake pipe
Silencer and frame
Silencer and exhaust pipe
Plug
Bolt
Bolt
Bolt
Bolt
Hose clip
Hose clip
Hose clip
Bolt
Bolt
M35
M6
M6
M6
M6
M5
M5
M5
M8
M8
1
43
4.3
31
1
10
1
7.2
2
10
1
7.2
2
12
1.2
2
12
1.2
1
2
0.2
1
2
0.2
1
2
0.2
2
34
3.4
1
20
2
8.7
8.7
1.4
1.4
1.4
25
1.4
Twist with cable
guide part
-23-
Locking component and
location of ATV body
Name of
component
Size of
thread
Q’ty
Tightening torque of
fastener of ATV body
Nm
m.kg
Remark
ft.lb
Exhaust pipe
Crankcase(closing case)
Left side cover
Left crankcase cover
Right crankcase cover
Bearing clamp of right crankcase cover
Bearing clamp of left crankcase cover
Right connecting box
Main clutch
Assistant clutch spring
Assistant clutch hub
Shift cam star-shaped gear
Locking nut
(clutch releasig adjsutable screw)
Starting surpassig clutch
Connecting plate of starting motor
Output
Left case bearing clamp of driving shaft
Rear cover bearing
Rear cover bearing
Reverse gear
Rear cover
Front joint
Reverse gear lever unit
Bolt
Screw
Screw
Screw
Screw
Screw
Screw
Screw
Nut
Bolt
Nut
Screw
Nut
Bolt
Screw
Nut
Screw
Inner-hexagoral
screw sleeve
Inner-hexagoral
screw sleeve
Special-shaped
nut(L.H)
Bolt
Nut
Bolt
M6
M6
M6
M6
M6
M6
M5
M6
M22
M5
M14
M6
M8
M8
M16
M16
M8
M8
M12
M6
11
2
1
1
7.2
7
0.7
5.1
6
7
0.7
5.1
8
7
0.7
5.1
9
7
0.7
5.1
3
7
0.7
3
7
0.7
3
7
0.7
1
78
7.8
4
6
0.6
1
50
5
1
12
1.2
1
15
1.5
3
30
3
2
7
0.7
1
60
6
3
25
2.5
1
50
5
1
50
5
1
50
5
4
23
2.3
1
60
6
2
12
1.2
5.1
5.1
5.1
56
4.3
36
8.7
11
22
5.1
43
18
36
36
36
17
43
8.7
Apply tightening
agent
Apply tightening
agent
Use locking
washer
Use locking
washer
Apply tightening
agent
Apply tightening
agent, rivent to
prevent loosen
Rivel to prevent
loosen
Apply tightening
agent
Apply tightening
agent
Apply tightening
agent
Apply tightening
agent
Reverse gear lever unit
Locking nut of length adjuster of connecting rod
(Reverse gear operation bar assy)
Locking nut of length adjuster of connecting rod
(Reverse gear operation bar assy)
Reverse gear operation rod and reverse gear lever mechanism
-24-
Bolt
Nut
Nut
Flange nut
M14
M8
M8
M6
1
15
1.5
11
1
15
1.5
11
1
15
1.5
11
1
10
1
7.2
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