ATV ATV110-M Service Manual

BRIEF INTRODUCTION TO FOUR-WHEELED

CROSS-COUNTRY VEHICLE MODEL ATV110-M

Four-wheeled cross -country vehicle, model A TV1 10-M 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 A TV1 10-M (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 A TV1 10-M

First edition Aujust 2005

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

V. Maintenance specification of engine ..................................................................................11

Section 6 Wiring diagram of A TV........................................................................................................14

Section 7 Requirements for torque of fastener .................................................................................... 15

Section 8 Lubrication ..........................................................................................................................16

Section 9 Lubrication point and type of lubricants .............................................................................17

(1) Lubrication point and type of lubricants(ATV body).........................................................17

(2) Lubrication point and type of lubricants(Engine)...............................................................18

Chapter II Maintenance and adjustment of vehicle ............................................................................19

Section 1 Periodic maintenance/ lubrication .......................................................................................19

Section 2 Disassembly and assembly of cushion, fender and fuel tank..............................................20

(I) Cushion...............................................................................................................................20

(II) Rear fender......................................................................................................................... 20

(III) Front fender ..................................................................................................................... 22

(IV)Fuel tank ............................................................................................................................23

Section 3 Maintenance and adjustment of vehicle body .................................................................... 26

(I) Wear inspection of front and rear brake ..............................................................................26

(II) Adjustment of front brake..................................................................................................26

(III)Adjustment of free clearance of left lever and rear brake pedal .........................................27

(IV) Inspection of steering system ..........................................................................................29

(V) Adjustment of toe-in of front wheel..................................................................................30

(VI) Adjustment of rear shock absorber ..................................................................................31

(VII)Inspection of tire ..............................................................................................................32

(VIII) Inspection of rim ............................................................................................................33

Section 4 Maintenance and adjustment of electrical appliance...........................................................34

(I) Inspection of battery...........................................................................................................34

(II) Inspection of fuse ..............................................................................................................35

Section 5 Maintenance and adjustment of engine .............................................................................. 36

(I) Adjustment of clutch ..........................................................................................................36

(II) Clean of air filter .................................................................................................................36

(III) Inspection of spark plug ................................................................................................... 37

(IV) Adjustment of idle speed..................................................................................................38

(V) Adjustment of free clearance of throttle grip ..................................................................... 38

(VI) Adjustment of speed limitator ..........................................................................................39

(VII) Adjustment of valve clearance ........................................................................................39

(VII) Inspection of ignition timing ...........................................................................................41

(IX) Measuring of compressive force ......................................................................................42

(X) Inspection oil quantity of engine.......................................................................................43

(XI) Replacement of engine oil and inspection of oil flow .......................................................44

Chapter III Repair and maintenance of vehicle body .......................................................................... 46

Section 1 Rear driving gearcase and driving shaft..............................................................................46

(I) Disassembly ........................................................................................................................ 46

(II) Inspecting procedures .......................................................................................................48

(III) Installation procedure.......................................................................................................51

Section 2 Rear wheel/Rear brake/Rear wheel axle...............................................................................54

(I) Removal steps....................................................................................................................54

(II) Inspection steps ...............................................................................................................55

Section 3 Steering operation system..................................................................................................57

(I) Removal steps of steering bar............................................................................................57

(II) Removal steps of steering vertical column welding ..........................................................58

(III) Inspection content...........................................................................................................59

(IV) Installment steps..............................................................................................................60

(V) Installation steps of steering bar ......................................................................................63

Section 4 Front shock absorber and front wheel fork ........................................................................64

(I) Disassembly .......................................................................................................................64

(II) Inspection steps ...............................................................................................................65

(III) Installment steps..............................................................................................................66

Section 5 Rear shock absorber and rear wheel fork............................................................................69

Chapter IV Electric appliance ............................................................................................................. 70

Section 1 Inspect switch ....................................................................................................................7 0

(I) Inspect switch....................................................................................................................70

Section 2 check lamp(headlight) ........................................................................................................71

Section 3 Troubleshooting the ignition system failure ...................................................................... 75

Section 4 Troublshooting electric starting system ............................................................................76

Section 5 Check starting motor ..........................................................................................................79

Section 6 No charging in the battery .................................................................................................81

Section 7 Troubleshooting ................................................................................................................83

Section 8 Inspection of lighting system.............................................................................................85

Chapter V Engine ............................................................................................................................... 86

Section 1 Disassembly of engine ....................................................................................................... 86

(I) Remove the engine from finished A TV .............................................................................. 86

(II) Disassembly of engine......................................................................................................88

section 2 Inspection and maintenance of engine ............................................................................... 96

Chapter VI Vecicle ordinary trouble and its judgement ...................................................................... 116

(I) Starting trouble/difficulty................................................................................................... 116

(II) Poor idle speed performance............................................................................................. 117

(III) Poor middle and high speed performance........................................................................ 117

(IV) Shifting troubler............................................................................................................... 117

(V) Clutch slips ....................................................................................................................... 118

(VI) Clutch is locked ............................................................................................................... 118

(VII) Engine is overheat .......................................................................................................... 118

(VIII) Brake trouble ................................................................................................................. 118

(IX) Shock absorber failure/improper operation ..................................................................... 118

(X) Lighting system ................................................................................................................ 119

Chapter I General description

Section 1Description

12345

1. Front wheel

2. Shift pedal

3. Fuel cock

4. Cushion

5. Rear wheel

67 8 109

11 12 13 14 15

6. Exhaust silencer

7. Rear fender

8. Rear brake pedal

9. Front fender

10. Bumper

11. Left lever of rear brake

12. Left switch unit

13. Fuel tank cover

14. Throttle grip

15. Right lever of front brake

Caution:

The ATV you purchased maybe slightly differ from the pictures in the manual due to im-

provement 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 take of engine of frame.

Engine N0.

The engine No. engrave onthe narrow point position.

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

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.

Fig.7.5

According to intersecting

Fig.8.1Tightening method of screw and nut.

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.

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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

km/hr

m m

mm cc(cm3) cc(cm3) lit(liter) lit(liter)

kg/mm

kg/cm

Centigrade

Multiply

7.233

86.794

0.0723

0.8679

2.205

0.03527

0.6214

3.281

1.094

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

mph

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

cm kg

m.kg

N/mm

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

Measurement

Length Length Weight

Force Torque Torque

Pressure

Rigid of spring

Volume or capacity

Rotational speed

II.Basic specification

-9-

III.ATV body

Front

wheel

Front brake

Rear

wheel

Rear

brake

Item

Type Material of rim Size of tire Radial runout of rim Lateral swing of rim Type

Standard Limit

Spock rim, tubeless tire Steel plate AT 19¡Á7-8

2.0mm

Drum type

Spoke rim, tubeless tire Steel plate AT 18¡Á8-8

2.0mm

Disce

Brake

lever and

brake pedal

-10-

Free play of brake lever (left) Free play of brake lever (right) Free play of rear brake pedal

Free play of throttle grip

5-7mm 5-7mm 20-30mm 3-5mm

IV.Maintenance specificationof engine

-11-

-12-

-13-

Section 6 W iring diagram of ATV

12345678910

1. Front brake cable

2. Throttle cable

3. Rear brake cable

4. Wire of handle bar switch

5. Hight voltage coils and wire

6. Wire of starting motor

7. Wire of gear indicator

8. Rectifier

9. Cable

10. Taillight unit

-14-

Section 7 Requirements for torque of fastener

(I) General torque specification

General torque specification (standard screw) This table is screw locking specification drawn

up by International Standard Association.

In order to avoid the twist or unbalancing phenomenon when locking screw. please cross lock or londuit as per appointed orders.

*When measuring torque force, standard torque force testing spanner must be used.

(Nut)

10mm 12mm 14mm 17mm 19mm 22mm

(Screw)

6mm

8mm 10mm 12mm 14mm 16mm

Specification of general

lorque

m.kg

0.6

1.5

3.0

5.5

8.5

13.0

A.Size of nut B. Size of thread

-15-

Standard Item

(I) Lubrication oil way

:Pressure

:Splashing oil

Section 8 Lubrication

Piston/cylinder

Automatic centrifugal clutch

Spindle

Driving shaft

Middle gearbox

Piston pin

Crank

Oil pump

Rough filter

Connecting rod

Camshaft

Branch valveFine filter

V alve

Rocker

Bearing

Sprocket chamber

-16-

Section 9 Lubrication point and type of lubricants

(I)Lubrication point and type of lubricants(A TV body)

Lubrication point

Lip of oil seal (full)

O-ring (full)

Steering shaft(upper end,lower end)

Ball connection of steering pushing rod

Front wheel fork (ball-shaped joint)

Front wheel bearing

Braking camshaft

Front & rear

Rotating pin seat

brake

Lip of oil seal

Dust-proof ring of brake

Joint of front brake cable

Type of lubricants

Light lithium-base grease

Grease used for bearing

Light lithium-base grease

Front brake lever axle and rear brake lever axle

Adjusting nut and pin of front brake cable

Adjusting nut and pin of rear brake cable

Rear brake pedal pivot and brake pedal axle hole

Throttle rotating frame shaft and end section of throttle cable

Connection bolt of rear wheel fork and frame,rear wheel fork bearing

Rubber sleeve and rear wheel fork

Rear shock absorber bushing

Light lithium-base grease

Seal gum

Light lithium-base grease

-17-

(II)Lubrication point and type of lubricants(Engine)

Lubrication point(name of component)

Lip of oil seal

All bearing

O-ring

Stem end of intake and exhaust valve

Fastener of cylinder head

Outside surface of piston pin

Outside surface of piston.piston ring

Clutch

Upper cam plate guide rod

Inner hole of upper cam plate unit

Type of lubricant

(Crank,shift gear shaft,spindle,shift gear operation shaft)

(Crank spindle, driving shaft, shift gear camshaft,

pneumatic canshaft)

(Contact position of o-ring)

(Intake and exhaust valve, vale adjsuting screw )

(Bolt flange face,thread portion,washer endface)

(Piston piston pin,small connecting rod)

(Cylinder block ,piston, piston ring)

(Crank main drivinggear)

(Upper cam plate unit guide rod)

(Shift gear shaft, upper cam plate unit)

Light lithium-base grease

Lubricating-oil

Light lithium-base grease

Lubricating-oil

Steel ball bracket unit

Spindle and inside hole jointing face of right crankcase

Outside surface of short fork shaft

Outside surface of long fork shaft

Shift gear camshaft portion,slot portion,contactor

Outside surface of shift gear shaft

Outside surface of over-wheel shaft

Bushing inner hole of big gear of electric stater

Electric starting clutch

(Steel ball brakcket unit, upper&lowr cam plate)

(Spindle ,right crankcase)

(Fork shaft ,fork crankcase)

(Fork shaft ,fork ,crankcase )

(Fork, shift gear cam ,crankcase)

(Shift gear shaft and it’s contacting portion)

(Over-wheel shaft ,crankcase)

(Bushing,left crankcase)

(Rolling post and it’s contacting portion)

-18-

Lubricating-oil

Chapter II MAINTENANCE AND

ADJUSTMENT OF VEHICLE

Note:

The correct maintenance and adjustment are necessary to ensure vehicles, normal

driving.The repair personnel should be familiar with the contents of this article.

Section 1 Periodic Maintenance/Lubrication

Item

Valve

Spark plug

Air filter

Carburetor

Cylinder head

Exhaust system

Spark surpressor

Oil circuit Engine oil

Oil filter

Oil filter screen

Gear case oil

Brake

Requirement

Check the valve clearance.Adjust it if necessary.

Check the clearance and clean the plug. Replace it if necessary.

Clean it. Replace it if necessary.

Check the idle or starting state.Adjust it if necessary.

Check it there is crack or damage in gas tube.Replace it if necessary.

Check the leakage.Tighten it again if necessary.Replace the gasket if necessary.

Clean

Check the cracks or damage of oil tube.Replace it if necessary.

Replace.(Preheat the engine before draining the oil)

Clean

Check the oil level and leakage.Replace.

Check the operation.Adjudt it if necessary.

Every time

month6month6month1year

month

¡ð

Every

¡ð

Clutch Wheel

Wheel bearing

Front&Rear suspension system

Steering system

Bearing of steering

verticle column

Connecting piece and fastener

Check the operation.Adjudt it if necessary.

Check the balance,damage,run-out etc.Replace it if necessary.

Check the looseness and damage.Replace it if necessary.

Check the operation and correct it if necessary.

Check the operation and corrcet it if necessary.Check the toe-in and adjust it if necessary.

Lubricate every 6 months (lithium soap grease)

Check all the connecting piece and fasteners of chassis correct them if necessary.

¡ð

a¡ð

¡ð

.W e advise that the maintenance of these items should be conducted by our saler .

¡ð

-19-

Section 2 Diassembly and assembly of

Cushion, Fender and Fuel fank

(1) Cushion

1.Disassembly (1) Place the vehicle on the horizontal ground. (2) Disassemble the cushion; Pull the cushion lock lever upward, then raise the tail part of cushion. By that, you can disassemble the cushion.

2.Installation Firstly insert the support lug on the front end of cushion into the spigot of frame, then press down the rear part. Pay attention to confirm if the cushion is installed firmly.

-20-

(II) Rear fender

1.Disassembly (1)Place the vehicle on the horizsontal ground. (2)Disassemble the cushion (3)Disconnect the negative wire and positive wire of battery.

Caution

Should disconnect the negative wire fistly. (4)Take out the battery. (5)Disassemble the rear fender.

2.Installation Operate according to reverse procedure of “Disassembly”.Pay attention to following points: (1)Install: Rear fender

(2)Install: Battery

-21-

(3)Install the cushion

Caution

Insert the support lug ¢Ú of cushion into the plug seat ¢Ûon the frame, then press down the cushion.

(III)Front fender

1. Disassembly: (1) Place the vehicle on the horizontal ground. (2) T ake off bolt

(3) Dismantle the connecting pipe.

(4)Disassemble the front fender.

2.Installation: Operate according to reverse procedures of “Disassembly”.

-22-

(1)Install: Front fender

(2)Install: Assembly of the connecting pipe.

(3)Install: Bolt

(IV)Fuel tank

1.Disassembly (1)Place the vehicle on the horizontal ground. (2)Disassemble the cushion

-23-

(3) Demove the front fender. (4) Demove the fuel tank bolt. (5)Pull the fuel cock lever to “OFF”position. (6)Remove the fuel inlet pipe

Caution

Place a cloth on the engine to absorb the splashed gasoline.

Warning

The gasoline is inflammable. Avoid to splash it on the hot engine. (7)Remove the fuel tank.

2.Installation Operate according to reverse procedure of “Disassembly”,and pay attention to followig points: (1)Install the fuel tank (2)Connect a.Air inlet pipe and hose

-24-

+ 97 hidden pages

ATV ATV110-M Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual