HSUN ATV 4X4 User Manual

700ATV Maintenance Manual

Catalogue

General Information

1 Description

1.1 Identification code………..……………………………..6

1.1.1. Frame No. …………………………………………………6

1.1.2. Engine No.…………………………………………………7

1.2 Special tools, instruments and meters…………………7

1.3 Periodic maintenance chart……………………………….9

Engine

………………………………………………………….11

2. Inspection and adjustment of engine

2.1 Inspection of cylinder head, intake

…………………………………………………..5

……………………………...5

…………….11

and exhaust valve………………………………………….11

2.2 Inspection of spark Plug………………………………….12

2.3 Inspection of cylinder, piston and piston ring…….14

2.4 Inspection of crankshaft………………………………….17

2.5 Inspection of clutch……………………………………….18

2.6 Inspection of carburetor………………………………….18

2.7 Inspection of air filter………………………………….19

2.8 Inspection of oil filter………………………………….20

2.9 Inspection of lubrication system……………………….20

2.10 Lubrication of engine…………………………………….21

2.11 Inspection of cylinder head…………………………….21

3.Disassembly of engine

……………………………………27

3.1 Cylinder head and block………………………………….27

3.2 Piston and connecting rod……………………………….31

3.3 Manual starting mechanism……………………………….32

3.4 Sensor………………………………………………….…….32

3.5 Left crankcase cover……………………………….…….33

3.6 Magneto…………………………………………………..….33

3.7 Oil pump………………………………………….……..….34

3.8 Clutch…………………………………………………...….35

3.9 Carburetor……………………………………………...….36

3.9.1 Structure of carburetor………………………...…..36

3.9.2 Inspection and adjustment of carburetor…....….37

4.Chassis

4.1 Steering operation system………………………...…..39

4.2 Brake system…………………………………………...….51

4.3 Wheels and tires……………………………………...….67

4.4 Transmission system…………………………….…...….70

4.5．gear

4.6

gear

shift mechanism……………………………………..77

geargear

Suspension…………………………..……....….。。。。。.79

5. Electrical system

………………………..……....….84

5.1 Ignition system…………………………..……....….87

5.2 Magneto and charging system…………..……....….88

5.3 Battery……………………………………..……....….88

5.4 Lighting system…………………………..……....….90

5.5 Meterand signal system…………………………..……91

5.6 Electrical starting system…………….……..…….92

6.Appendix

6.1 Specification………..…………………..……....….93

6.2 Requirements for torque of fastener……………….99

6.3 Electrical circuits……………………………....….100

………………..…………………..……....…93

1 Description

General Information

1.1 Identification code

1.1.1. Frame No.

The frame No. is engraved in the right bottom of the supporting

frame. See Figure 1-1.

1.1.2.Engine No.

The engine No. is engraved in the right side of the engine. See

Figure 1-1

figure 1-2

Figure 1-2

1.2 Special tools, instruments and meters

1.2.1 Oil filter detacher

To fasten and detach the oil filter

1.2.2 Height gauge

To gauge the height of various components

1.2.3 Vernier

To measure the length of various components

1.2.4 Outside micrometer

To accurately measure external

diameter of a column

1.2.5 Inside micrometer

To accurately measure internal

diameter of a hole

1.2.6 Dial indicator

To accurately measure a small distance

1.2.7 Torque Spanner

To measure torque force

1.2.8 Feeler gauge

To measure gap-width

1.2.9 Multimeter

To check electrical circuits and parts

1.2.10 Barometer

To measure pressure of the tyre

1.2.11 Magneto drawing device

To detach the magneto

1.2.12 Snap ring clampTo install

and detach snap rings

1.3 Pe

ITEM

Valves

Sparkplug

Air fiter element

Carburetor*

Crankcase

breathersystem*

Exhaust system*

Spark arrester

riodic maintenance chart

ROUTINE

● Check valve clearance.

● Adjust if necessary.

● Check condition.

● Adjust gap and clean.

● Rep;ace if necessary.

● clean.

● Replace if necessary.

● Checkandadjustidlespeed/starteroperation.

● Adjust if necessary.

● Check breather hose for cracks of

damage.

● Replace if necessary.

● Check for lecakage.

● Tighten if necessany.

● Replace gasket(s) if necessary.

● Clean.

Whicheve

comes first

EVERY INITAL

month

km 320 1,200 2,400

(mi) (200) (750) (1,500) (1,500) (3,000)

hours 20 75 150 150 300

1 3 6 6 12

2,400 4,800

○ ○ ○ ○

○ ○ ○ ○ ○

Every20-40hours

（More often in wet of dusty areas.）

○

Fuel line*

● Check fuel hose for cracks or damage.

● Replace if necessaly.

○

Engine oil

●Replace.(Wamenginebefore draining.)

○ ○ ○ ○

Engine oil filter

cartridge

Engine oil strainer*

Final gear oil

Differential gear oil

Front brake*

Rear brake*

Select lever safety system cable

V-belt*

Wheel

Wheel bearing*

Front and rear

suspendion*

Steering system*

Drive shaft universal

joint*

Axle boots*

Fittings and

fasteners* Lights and

switches*

●Replace.

●Clean.

● Check for oil leakage.

● Replace eveny 12 months.

● Check operation/fuid leakage.(See NOTE

page 8).

● Correct if necessary.

● Check operation.

● Adjust if necessary.

● Check operation.

● Adjust if necessary.

● Check operation.

● Check for cracks or damage.

● Check balance/damage/

● Repair if necessary.

● Check bearing assemblies for lossenss/

damage.

● Replace if necessary.

● Check operation.

● Correct if necessary.

● Checkoperation./Replace if damaged

● Check toe-in./Adjust if necessaly.

● Lubricate with lithium–soap–bassed

grease.

● Check operation.

● Replace if damaged.

● Check all chassis fittings and fastenrs.

● Correct if necessary.

● Check operation.

● Adijust headinght beams.

○ ○ ○ ○

○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○

○ ○

○

○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○

○

○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Engine

2. Inspection and adjustment of engine

2. 2.

2.1

Inspection of cylinder head, intake and exhaust

2.1 2.1

valve

Preheat the engine ,then misfire and unplug the spark

plug.Fix pressure gauge into the hole, open the choke and

throttle handle,and start for 4-6 times.

Note: Giving a leakage check to the pressure

gauge.Rotate the engine until the pressure gauge

stop rising.The maximum reading would be greater

than 0.7-0.9Mpa after starting for 4-6 times.

See figure 2-1.

Figure 2-1

check the valve lash

Note:when adjust valve lash,the engine must be cooled.

(The tempreture should be less than 35℃ )

Remove the seat cushion and fuel tank,unplug the vision

hole cover ,round the flywheel of magneto anti-clockwise to aim

“T”at the signal of fore cover on the left.

Note: The piston must be fixed to the dead enter.

2-2)

(Figure

Figure 2-2

Remove cylinder valve cover,check the lash between the

valve stem by feeler gauge .

Valve clearance:inlet and exhaust valve: 0.05～0.08mm.

See figure 2-3.

Figure 2-3

Loose the lock nut,rotate the adjusting screw until it

appears that the feeler gauge be pulled .Then fasten the

adjusting screw by valve adjuster,tighten the lock nut and

check the valve lash .Afterword install the cylinder valve

cover , vision hole cover,the fuel tank and cushion.

See figure 2-4.

Figure 2-4

2.2222 Inspection of spark Plug

2.2.

1. Unplug the Spark-Plug cap:remove

the spark plug by box key,look over

whether the spark-plug insulator and

electrode is damaged or sooting.

If so ,see figure 2-5. Figure 2-5

2． Check the spark clearance

by feeler gauge whether it

is between 0.6～0.7mm.Or adjust

the gap,clean incrustation

with spark-plug cleaner and steel

wire brush and check if

the spark plug sealing washer(Figure 2-6). Figure 2-6

gap between

item

cylinder

Piston,piston

ring and

piston pin

connecting

rod Gap between small end of

bore diameter of cylinder

taper 0.0040 0.005 out of roundness 0.0035 0.005 degree of toruosity 0.04 0.06

external diameter of piston

bore diameter of piston pin

hole

gap between piston pin and

piston pin hole

Piston ring

end

clearance

piston ring

and piston

groove

gap between cylinder and

external diameter of piston

bore diameter

connecting rod and piston

Top ring/the

piston

second ring

oilring

top ring

the second

ring

standard value:mm limit value:mm

φ102～φ102.03 φ102.1

φ101.95～φ101.97 φ101.92 φ22.002～φ22.010 φ22.010

0.007～0.020

0.25～0.40

0.3～0.9

0.3～0.07

0.02～0.06

0.03～0.08

φ21.995～φ21.990 φ21.96 φ22.016～φ22.027 φ22.03

0.016～0.033 0.035

0.02

0.5

1.2

0.10

0.09

3.Swirl the when spark plug and tighten to 18～20N.m by box

key ,then fix the spark plug cap when assembling.

2.3333 Inspection of cylinder, piston and piston ring

2.2.

Camshaft lube is injected by a hole of engine body into

cylinder ,so the hole must not jam.It is necessary to fix

the cushion and adjer without dust permeated into the crank

case before assembly.

diagnosing and eliminating of malfunction:

●●●●

Emission of black smoke for abrasion of cylinder

or piston,

1. Cylinder , piston of piston ring is worn out.

2.The piston ring is not properly assembled.

3. The piston or cylinder wall is scraped.

●●●●

overheated

overheatedoverheated

1、

Excessive incrustation of piston.

2、Blast and abnormal noise.

3、Abrasion of cylinder or piston.

Inspection of cylinder.

1.Check whether the cylinder is damaged.

2.Measure the bore diameter of cylinder at three spots.

3.At the top,the middle and the bottom of the piston stroke .And

measure the bore diameter at directions of right-angle

intersection.

repairing limit value:

out of roundness: 0.005 mm

taper ：0.005mm

Inspection of piston and piston ring

Measure the gap between piston ring and piston groove.

1.unplug the piston ring;

Note:It is forbidden to damaging the piston ring when

assembling.Check whether the piston and the piston groove

is cracked and abraded.See figure 2-7

Figure 2-7

2.Insert piston ring into

cylinder,and measure the

end gap.repairing limit

value:the first ring/the

second ring: 0.5mm

See figure 2-8. Figure 2-8

Measure the bore diameter of piston pin hole.

repairing limit value: see figure 2-9

Figure 2-9

3.Measure the external diameter 10mm

above the bottom of the piston skirt.

Extreme position :the gap between

cylinder and pistonrepairing

limit value: 0.1mm See figure 2-10 Figure 2-10

Measure the external diameter of piston pin:

the gap between piston and piston pin:

repairing limit value: 0.02mm .See figure 2-11

Figure 2-11

2.4 Inspection of crankshaft

heck that whether crank and connecting rod can rotate

without stuck and whether the clearance between crank and

connecting rod is 0.5～0.6mm.The hop of crank shaft should be

0.05mm.If not so,replace it. See figure 2-12-1, figure 2-12-2.

Figure 2-12-1 Figure 2-12-2

2.5555

Inspection of clutch

2.2.

The wear condition of shoe block and friction plate:See

figure 2-13

Figure 2-13

2.6 Inspection of carburetor

1、Inspect the idle of carburetor

The engine speed should be 1500±150r/min 10 minutes after

starting at normal idle and will not misfire when briskly

accelerate.If not so, rotate the carburetor idle adjusting

screw clockwise to rise the idle ,anti- clockwise to lower.When

adjusting is unavailable,check that if there is a jam in

carburetor idle nozzle or a

air-leakage of intake pipe.

See figure 2-14

Figure 2-14

2.7777 Inspection of air filter

2.2.

1、Disassemble the air cleaner,remove cartridge,clean the

cartridge with non-flammable cleaning solvent,and then

make it dry.

Note: Petrol is forbidden.

2.Dip the air filter cartridge into 20# oil,then take it

out and squeeze the excessive oil,assemble it

orderly.Impermeability is necessary.See figure 2-15,

figure 2-16.

Figure 2-15 Figure 2-16

2222．．．．8888 Inspection of oil filter

Cleaning of lubricator oil strainer:remove clarifier

(Figure 2-17),clean it to ensure a well work- condition.Then

fix it up.

Note:Clean the clarifier

before injecting oil

into crankcase.

Figure 2-17

2222.9

.9 Inspection of lubrication system

.9.9

Lubricant of engine:the vehicle is oiled with lubricant

of APISGSAE10W/40

APISGSAE10W/40.... Others are forbidden.

APISGSAE10W/40APISGSAE10W/40

capacity :

The capacity is 1.9L after disassembly and assembly.

2、The capacity is 1.8L when fueling up after drain.

Inspection of lubricant:locate the dune buggy on the

ground to lookover the capacity with dip stick.If the

level is lower than the bottom indicator,fuel up with

recommended lubricant to the upper indicator.

Inspection of oil pump:

flow of oil pump:

r/min 1000 2000 3000 L/min 3.78 7.43 10.89

measure clearance of the top of internal external rotor

level

Limit value: 0.20mm

2.10

10 Lubrication of engine

2.2.

1010

Check the oil level,start the engine and let it running for

a fow minutes to make it heated and lubricated completely ,then

misfire.Unplug the dip stick to do cleaning and dip it into the

oil case again.Then unplug the dip stick and look whether oil

level is lower than the indicator. See figure 2-18

Note:Ensure that the engine is landed by both four wheel

in flat ground.

Figure 2-18

2.11

11 Inspection of cylinder head

2.2.

1111

1.Check whether the spark plug and valve seat is cracked and

whether the cylinder head is out of shape.Examine the

flatness of cylinder head by flat or knife edge gauge and

Indicator of oil

clearance gauge .

Repairing limit value:

0.05mm.See figure 2-19

rse,corrode or cannot

Figure 2-19

2 Remove and examine the width of valve .

Repairing limit value: 2.0mm.

See figure 2-20-1 ,2-20-2, 2-20-3.

If the mating surfaces is coa

contact with valve seat normally.repalce it.

Figure 2-20-1 Figure 2-20-2

Figure 2-20-3

Measure the width of mating surfaces of valve

repairing limit value: 1.5mm

cracked,grind

If the valve seat is to wide or narrow or

it to ensure impermeability.

4、Measure bore diameter of valve guide with internal micrometer

and special gauge.At last calculate clearance between valve

stem and valve guide.

Repairing limit value: intake : 0.12mm exhaust: 0.14mm

Note :Eliminate carbon in the pipe before

measuring.If the pipe will be replaced,grind the

valve seat again .

5、Inspection of valve and valve pipe:

Check whether the valve is bent,burn or the valve stem is

worn out.

Check the motion of valve and measure external diameter.

Repairing limit value: intake : 5.95mm exhaust: 5.95mm

See figure 2-21.

Fix valve into guide,and look over the motion.

Figure 2-21

Inspection of valve spring

Measure the free height and squareness

Repairing limit value:(intake and exhaust)

See figure 2-22-1, 2-22－2

free height of inlet valve spring: 32.5mm,

squareness:0.10mm

free height of exhaust valve spring: 36.2mm

squareness:0.10mm

Figure 2-22-1 Figure 2-22-2

6、Examining lifting distance of breaker cam.

Measure the length of fillet with micrometer and check

If it is worn out.

Repairing limit value:inlet lifting distance: 5.73mm

Exhaust lifting distance: 6.53mm.See figure 2-23.

examine

Figure 2-23

7、Check whether the crankshaft journal is worn out and

measure the external diameter of crankshaft journal.

Repairing limit value: φ22.939mm

Inspection of rocker arm.

Check whether the rocker arm is worn out,or damaged and

whether the oil hole is blocked.

Note:If there is a rocker arm to be replaced,

the peak of breaker cam

measure the bore diameter of rocker arm

Repairing limit value: φ12.038mm.See figure 2-24

Figure 2-24

Inspection of rocker arm shaft.

Examine if the rocker arm if worn out or cracked.

Measure the external diameter of rocker arm shaft with

micrometer.

Repairing limit value: φ11.96mm

The repairing limit value of clearance between rocker arm

shaft and hole : 0.05mm ,See figure 2-25

Figure 2-25

3. disassembly of engine

3.3.

3.1111 cylinder head and block

3.3.

① Unplug the intake pipe and spark plug.( Figure 2-26-1,

2-26-2)

Figure 2-26-1 Figure 2-26-2

② Remove cylinder valve cover,cam chainwheel cover and

Figure 2-27-1

③remove valve chain wheel Figure 2-27-2

Figure 2-27-1 Figure 2-27-2

④remove lower rocker arm shaft.See figure 2-28

Figure 2-28

⑤Remove vision hole cover of left front cover .See figure 2-29

Figure 2-29

Alignment: asjust these two ＂●＂symbols of the cam chain

wheel to be at the same level with cylinder cover.

alignmentment of top dead center:

Rorate the crankshaft with “T” sleeve anti-clockwise

until these two ＂●＂symbols of the cam chain wheel to be

at the same level with cylinder cover .That is to say the

piston of cylinder is at the top dead center.

Inspection of compression top dead center:

See figure 2-30-1 and figure 2-30-2.

figure 2-30-1 figure 2-30-2.

When inlet valve spring rise,rotate the crankshaft until

the “T” indicator on the magneto rotor to be at the same

level with the center of vision hole cover of left front

cover.That is to say the piston is at the compression top

dead center and there are valve clearance in these four

rocker arms of cylinder head. See figure 2-31

Figure 2-31

Remove chain tensioner adjuster.See figure 2-32.

Figure 2-32

remove the cylinder head

Loosen the bolt by intersection manner before remove the

bolt.see figure 2-33.

Figure 2-33

remove adjuster cotter sealed ring

of cylinder headtensioner

adjuster guide board

See figure 2-34.

remove cylinder block0-seal

adjuster cotter

Figure 2-34

sealed ring of cylinder head

See figure 2-35.

3. 2 piston and connecting rod

Figure 2-35

+ 71 hidden pages

HSUN ATV 4X4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual