VECTOR ST-300
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 Mechanism Diagram
7-2 Precautions In Operation
7-3 Trouble Diagnosis
7-4 Cylinder And Piston Removal
7-5 Piston Ring Installation
7-6 Piston Installation
7-7 Cylinder Installation
8. V-BELT DRIVING SYSTEM
8-1 Mechanism Diagram
8-2 Maintenance Description
8-3 Trouble Diagnosis
8-4 Left Crankcase Cover
8-5 Drive Belt
8-6 Drive Face
8-7 Clutch Outer/Driven Pulley
9. FINAL DRIVING MECHANISM
9-1 Mechanism Diagram - Transmission Cover
9-2 Precautions In Operation
9-3 Trouble Diagnosis
9-4 Disassembly Of Transmission
9-5 Inspection Of Mission Mechanism
9-6 Bearing Replacement
9-7 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 Mechanism Diagram
12-2 General Information
12-3 Trouble Diagnosis
12-4 Trouble Diagnosis For Cooling System
12-5 System Test
12-6 Radiator
12-7 Water Pump
12-8 Thermostat
13. STEERING AND SUSPENSION
13-1 Parts Drawing
13-2 Troubleshooting
13-3 Handlebar
13-4 Throttle Housing
13-5 Steering System
14. FRONT WHEEL AND BRAKE SYSTEM
14-1 Parts Drawing
14-2 Troubleshooting
14-3 Front Wheels
14-4 Hydraulic Brake
14-5 Suspension Adjustment
15. REAR WHEEL AND BRAKE SYSTEM
15-1 Parts Drawing
15-2 Troubleshooting
15-3 Remove Rear Wheel And Rear Brake
15-4 Swingarm & Rear Axle Holder
15-5 Suspension Adjustment
16. FENDERS AND EXHAUST PIPE
16-1 Fenders Drawing
16-2 Rear Fenders Removal
16-3 Front Fender Removal
16-4 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 Safety
1-2 Notes
1-3 EngineSpecifications
1-4 Serial Number
1-5 Torque Values
1-6 Special Tools
1-1 Safety
GASOLINE
Gasoline is extremely flammable and is explosive under certain conditio n.
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.
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1-3 EngineSpecifications
Type
Displacement 287.2c.c.
Bore and Stroke 75 mm x 65 mm
Compression 10.0:1
Maximum Hp 20ps / 6500
Maximum Torque (Nm/rpm) 24.6 Nm / 5000
Carburetor
Ignition DC-CDI
Starting Electric
Lubrication Auto oil injection
Transmission Automatic (C.V.T. V-belt + Reverse)
CHASSIS
Overall Length
Overall Width
Overall Height
Wheel base
Ground Clearance
Dry Weight
Fuel Tank Capacity
SUSPENSION
Front
Rear
BRAKES
Front
Rear
TIRES
Front
Rear
PRESSURE【 psi ( kgf/cm2)】
Front
Rear
COLORING
Specifications subject to change without notice.
4 Stroke，Sin gle Cylinder, Water cooled
1815mm
1062mm
1130mm
1193mm
150mm
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)
225Kg
12L
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
5 N.m (3.5 lbf.ft)
● 6 mm bolt and nut
● 8 mm bolt and nut
●10 mm bolt and nut
●12 mm bolt and nut
ENGINE
● Cylinder head nut
● Spark plug
● Cylinder head bolt
● Alternator bolt
FRAME
● Handlebar upper holder bolt
● Throttle housing cover screw
● Steering shaft nut
● S te ering shaft holder bolt
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)
38 N.m (27.4 lbf.ft)
12 N.m (8.9 lbf.
15 N.m (10.1 lbf.ft)
8 N.m (5.9 lbf.ft)
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)
ft)
● Wheel rim bolt
● Tie rod lock nut
● King pin nut
● Handlebar lo wer holder nut
● Front wheel bolt
● Front axle castle nut
● Front brake arm nut
● Rear brake arm nut
● Rear axl e castle nut
● Rear wheel bolt
● Exhaust muffler mounting bolt
● Engine hanger bolt
● Rear axle holder bolt
Nuts, Bolts Tightness
● Swing arm pivot nut
● Rear shock absorber mounting nut
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)
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.
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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)
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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)
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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)
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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)
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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)
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2. MAINTENANCE
2-1 Maintenance Data 2-8 Idle Speed
2-2 Maintenance Schedule 2-9 Drive Chain
2-3 Fuel Tube 2-10 Brake System
2-4 Throttle Operation 2-11 Wheels And Tires
2-5 Throttle Cable Adjustment 2-12 Steering Shaft Holder Bushing
2-6 Air Cleaner 2-13 Toe-In
2-7 Spark Plug
2-1 Maintenance Data
SPECIFICATION
SPARK PLUG
SPARK PLUG GAP 0.8 mm
RECOMMENDED SPARK PLUGS NGK CR8E
THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1700±100 rpm
BRAKE LEVER FREE PLAY 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
TOE-IN 5±10 mm
TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL 1.4 Liter (1.2Liter for change)
GEAR LUBRICATION OIL 750cc (650cc for change)
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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 Every Every Every Every Notes
1 Month 3 Months 6 Months 1 Year 2 Years
Fuel Lines I I R
Throttle Operation I I
Air Filter I C R
Fuel Filter R
Spark Plug I I R
Drive Chain I, L Lubricate for every 1 month
Brake Shoes I
Brake System I I
Brake Fluid I R
Nuts, Bolts & Fasteners I
WHEEL/TIRES I I
Wheels I I
Steering System I I
Suspension System I I
C.V.T Drive belt I R
Transmission Oil R Replace for every 3,000km or 6 Months
Engine Oil R Replace for every 3,000km or 6 Months
Battery I I,C I,C
Oil Filter (Screen) C C
Valve Clearance I I
Coolant I I R
Cooling Fan I I
Carburetor (Idle Speed) I I
Choke I
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.
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.
Throttle
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.
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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.
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.
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.
Rear Brake lever free play is 15-25 mm.
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Brake lever
Adjustable nut
Parking Brake
Parking Off
Adjustable nut
Parking On
Adjustment
Brake level
NOTE:
y The second method to adjust brake level is under the driver
seat and rear brake component.
y 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.
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
.
Rear Brake
Adjustable nut
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 3-3 Engine Installation
3-2 Engine Removal
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
4-5 Engine Oil Strainer Clean
4-6 Oil Pump
4-7 Gear Oil
4-4 Engine Oil
4-1 Mechanism Diagram
Press-In Lubrication
Oil Route
Con-Rod
Valve Rocker Arm
Cam Shaft
Spray Lubrication
Oil Route
Spray Lubrication
Press-In Lubrication
Rotate Direction
Oil Pump
Oil Strainer
27
4-2 Precautions In Operation
General Information:
z 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: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Oil pump
Torque value
Torque value oil strainer cap 1.5~3.0kgf-m
Engine oil drain bolt 1.9~2.5kgf-m
Gear oil drain bolt 1.0~1.5kgf-m
Gear oil join bolt 1.0~1.5kgf-m
Oil pump connection bolt 0.8~1.2kgf-m
Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12
單位:mm
4-3 Troubleshooting
Low engine oil level
y Oil leaking
y Valve guide or seat worn out
y Piston ring worn out
Low oil pressure
y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage
Dirty oil
y No oil change in periodical
y Cylinder head gasket damage
y 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
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.
Drain bolt
Torque value：1.9~2.5kgf-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 value：1.5~3.0kgf-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
29
Oil strainer
4-6 Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
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.
Oil Pump Disassembly
Remove the screws on oil pump cover and
remove the cover.
Remove oil pump shaft roller and shaft.
Clip
2 screws
1 screw
Roller
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