Kolpin Powersports 180cc Service Manual

Kolpin Powersports

180cc Service

Manual

CONTENTS

FIG.-01

INFORMATION.……………………….…………….

………………………………

1

FIG.-02

VEHICLE INSPECTION………………………….......

………………………………

6

FIG.-03

OVERVIEW…………………………………….……..

………………………………

18

FIG.-04

FENDER..……………………………………...……...

………………………………

19

FIG.-05

FUEL &OIL TANK……………..……………………..

………………………………

22

FIG.-06

MUFFLER…………………………………………….

………………………………

23

FIG.-07

HANDLEBAR………………………………………...

………………………………

24

FIG.-08

ENGINE REMOVAL…….……………………………

………………………………

26

FIG.-09

TIRE AND RIM……………….………………………

………………………………

27

FIG.-10

FRONT BRAKE………………………………………

………………………………

28

FIG.-11

REAR BRAKE………………………………………...

………………………………

30

FIG.-12

SUSPENSION…………………………………………

………………………………

32

FIG.-13

SUSPENSION ARM& KNUCKLE…..……………….

………………………………

33

FIG.-14

REAR AXLE ASS’Y……...…………………………..

………………………………

34

FIG.-15

STEERING SHAFT…..…………….…………………

………………………………

35

FIG.-16

FRAME COMP………………………..………………

………………………………

36

FIG.-17

LIGHT………………………………..………………..

………………………………

37

FIG.-18

ENGINE DISASSEMBLY .……..…………………….

………………………………

39

FIG.-19

ELECTRIC SYSTEM……….………………………..

………………………………

68

FIG.-20

TROUBLE SHOOTING………………………………

………………………………

73

FIG.-21

MAIN WIRE DRAWING…………………………….

………………………………

85

1

FIG-01 INFORMATION

SAFETY

GASOLINE
Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or
flames in your work area.

CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss
of consciousness and lead to death.

BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you come into contact with
the electrolyte, flush the area thoroughly with water. If you get the electrolyte in your eyes, flush with water and
contact a doctor immediately.

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 after repeated contact with the skin for long periods. Keep out
of reach of children.

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.

No part of this publication may be reproduced without written permission.

2

FIG-01 INFORMATION

SPECIFICATIONS

TYPE

OVERLAND – 180CC

ENGINE TYPE

Air-Cooled 4-stroke, with Oil Cooler, Horizontal Stroke

CYLINDER NUMBER

1

DISPLACEMENT

169 cc

BORE STROKE

∮ 61×57.8mm

COMPRESSION RATIO

9.1:1

MAX. TORQUE

6.37 Nm@4403 rpm

CARBURETOR

MIKUNI 180

STARTING

Electric/ Kick back-up

LUBRICATE

Forced pressure and wet sump

LUBR. CAPABILITY

1 Liter

TRANSMISSION

Automatic (C.V.T V-belt system)

SUSPENSION

FRONT

Single A-Arm

REAR

Single Swing Arm

BRAKE

FRONT

Drum

REAR

Disc

TIRE

FRONT

21× 7- 10”

REAR

21× 10- 8”

OVERALL DIMENSION

1740×990×1060 mm

WHEELBASE

1065 mm

DRY WEIGHT

165 kg

FUEL

Unleaded Gasoline

FUEL CAPABILITY

8 Liter

Ignition

Capacitor Discharge

Air Cleaner

AE-9

*Specifications subject to change without notice.

3

FIG-01 INFORMATION

SERIAL NUMBER

The frame serial number is stamped on the front frame.

The engine number is stamped under the crankcase.

4

FIG-01 INFORMATION

TORQUE VALUES
STANDARD

5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm 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
Steering shaft holder bolt
Wheel rim bolt
Tie rod lock nut
King pin nut
Handlebar lower holder nut
Front wheel bolt
Front axle nut
Front brake arm nut
Rear brake arm nut
Rear axle nut
Rear wheel bolt
Exhaust muffler mounting bolt
Engine hanger bolt
Rear axle holder bolt
Swing arm pivot nut
Rear shock absorber mounting nut

5 N.m (3.5 lbs.ft)
10 N.m (7.2 lbs.ft)
22 N.m (16 lbs.ft)
35 N.m (25 lbs.ft)
55 N.m (40 lbs.ft)

28 N.m (20.7 lbs.ft)
12 N.m (8.9 lbs.ft)
20 N.m (14.8 lbs.ft)
8 N.m (5.9 lbs.ft)

24 N.m (17.7 lbs.ft)
4 N.m (2.9 lbs.ft)
50 N.m (36.9 lbs.ft)
33 N.m (24 lbs.ft)
18 N.m (13.3 lbs.ft)
35 N.m (25.8 lbs.ft)
40 N.m (29 lbs.ft)
40 N.m (29.5 lbs.ft)
24 N.m (17.7 lbs.ft)
60 N.m (44 lbs.ft)
4 N.m (3.0 lbs.ft)
7 N.m (5.2 lbs.ft)
60 N.m (44.3 lbs.ft)
24 N.m (17.7 lbs.ft)
30 N.m (22.1 lbs.ft)
30 N.m (22 lbs.ft)
90 N.m (65 lbs.ft)
90 N.m (65 lbs.ft)
45 N.m (33 lbs.ft)

5

6

FIG-02. Vehicle Inspection

MAINTENANCE DATA
SPARK PLUG

Spark plug cap
Recommended spark plugs
Throttle lever free play:
Idle speed
Brake lever free play:
Drive chain slack
Front/rear tire size
Front/rear tire pressure
Toe-in

TORQUE VALUES

Spark plug
Tie-rod lock nut

ENGINE OIL

Viscosity:

GEAR LUBRICATION OIL

Viscosity:

0.6-0.7mm
NGK C7HSA or CR7HSA
5-10mm
1800rpm
10~20mm
15-25mm
21x7-10” / 21x10-8”
3±0.3psi (0.15 kgf/cm2)
5±10mm

12-19 N.m
35-43 N.m

SAE 15W-40

SAE 85W-140

7

FIG-02. Vehicle Inspection

MAINTENANCE SCHEDULE

The maintenance intervals in the follow table are based
upon average riding conditions. Riding
in unusually dusty areas requires more frequent
servicing.

Service Item

Initial Service

(First 30 hours)

Every 100 hours

Every 200 hours

Every 300 hours

ENGINE OIL

R R

GEAR OIL

R R

FUEL FILTER

R

AIR VLEAN FILTER

R

ENGINE OIL

FILTER

C

CARBURETOR

I

SPARK PLUG

C

VALVE GAP

A

IGNITION TIMING

A CHAIN

A

BATTERY

I

DRIVE BATTERY

I CLUTCH

I

THROTTLE

OPERATE

I

TIRE PRESSURE

Check before riding each time

BRAKE SYSTEM

Check before riding each time

NUTS/BOLTS

T

A: Adjust C: Clean I: Inspection R: Replace T: Tighten

8

FIG-02. Vehicle Inspection

FUEL TUBE

Inspect the fuel lines for deterioration, (a-1)
damage or leakage and replace if necessary.
(Photo 1)

THROTTLE OPERATION

1. Inspect for smooth lever operation, full opening and
automatic full closing in steering positions.

2. Inspect for deterioration, damage, cuts and nicks, or
kink in the throttle cable, replace it if necessary.

3. Check the throttle lever, free play should be not more
than 5-10 mm at the tip of the throttle lever. (a-1)

4. Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to
prevent premature wear.
(Photo 2)

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. (a-1)
(Photo 3)

AIR CLEANER MAINTENANCE

1. Loosen the screw and remove the air cleaner from
carburetor. (a-1)

2. Disassemble the air cleaner cover and body.

3. Remove the air cleaner element and screen.
Install the new one. (a-2)

4. Assemble the air cleaner body and cover and
re-attach to the carburetor with screw.
(Photo 4,5)

9

FIG-02. Vehicle Inspection

SPARK PLUG

The spark plug is located at the front of the engine.

1. Disconnect the spark plug cap and remove the spark
plug (a-1)

2. Visually inspect the spark plug electrode for wear or
cranks in insulator. Replace if needed

3. The center electrode should have square edges and
the side electrode should have a constant thickness.

4. Discard the spark plug if there is apparent wear or if
the insulator is cracked or chipped.

5. Measure the gap with a wire-type feeler gauge and
adjust if necessary by carefully bending the side
electrode.

6. Check the sealing washer and replace with a new one
if damaged.

7. With the sealing washer attached thread the spark
plug in by hand to prevent cross threading. Tighten the
spark plug. TORQUE: 12-19 N-m

SPARK PLUG GAP: 0.6~0.7 mm
RECOMMENDED REPLACEMENT PLUG:
NGK CR7HSA
(Photo 6)

IDLE SPEED SETTING

1. Inspect and adjust the idle speed after all other engine
maintenance items have been performed and are
within specifications. The engine must be warm for
accurate idle speed inspection and adjustment.

2. Warm up the engine for about ten minutes and
connect a tachometer.

3. Turn the throttle stop screw as required to obtain the
specified idle speed. (a-1)

IDLE SPEED: 1700 ± 100 rpm
(Photo 7)

10

FIG-02. Vehicle Inspection

DRIVE CHAIN ADJUSTMENT

Stop ATV and shift transmission into neutral. Inspect
the chain slack midway between the sprockets. The
standard is 10-25 mm (5/8-1 inch).

If needed remove the chain protectives cover and adjust
the chain slack. (a-1)
(Photo 8)

Loosen the axle holder lock nut then adjust the drive
chain slack by turning the adjusting nut. Tighten the
axle holder lock nut. (a-1)
Torque = 90N.m (65 Ft. lbs)
(Photo 9)

When the drive chain becomes very dirty, it should be
removed, cleaned and lubricated with the specified
lubricant.

1. Clean the drive chain with kerosene and wipe it dry

2. Inspect the drive chain for possible wear or damage.

3. Replace the chain, if it is worn excessively or
damaged.

4. Inspect the sprocket teeth, if it has excessive wear or
damage, replace if needed.

5.Use a commercial chain lubricant to lubricate the
drive chain, replace and adjust the slack as described
above. (a-1)
(Photo 10)

11

FIG-02. Vehicle Inspection

FRONT BRAKE ADJUSTMANT

The front brake has two cables to control right and
left side brake simultaneously.
You could adjust the gap of the front brake (a-1).
(Photo 11)

Loosen the fix nut (a-1) and adjust the position of cable
to proper situation.
(Photo 12)

Inspect the front brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the end of
the lever. The standard is 10~20 mm.
Adjust the free play of the front brake lever by turning
the adjuster on the brake lever assembly.

The brake shoe uses an arrowhead on the front brake
plate to indicate pad condition.
When the arrowhead is beyond the wear limits shown,
the brake shoes need to be changed. (a-1)
(Photo 14)

REAR BRAKE ADJUSTMENT

Install the rear brake cable fixing nut set & adjust the
brake cable.

1. Spin the gap adjuster on the left lever to the shortest
position. (a-1)

2. Adjust the adjusting screw and keep the gap within
2-3 mm. (a-2)
(Photo 15,16)

12

FIG-02. Vehicle Inspection

REAR BRAKE ADJUSTMENT

Remove the rear brake locking nut set and the brake

cylinder mounting bolts (a-1)

(Photo 17)

The setup of the adjusting nut of the brake pump(a-1):

1. The brake pedal should be in the highest location
with the returning spring functioning correctly.

2. The adjusting nut changes the distance between the
brake master cylinder and the hydraulic
cylinder-driving rod. Make sure the nut touches the
surface of the rod and revolve back 1 turn (360˚).
Confirm the nut location and spin the rod until the
nut is locked (a-2).

(Photo 18,19)

NOTICE:
Do not over-adjust, it might result in the
brake pump malfunction and cause the brake to activate.

1. Remove any air in the brake line to prevent

the brake from losing power(a-1).

2. Open the brake oil tank (a-2) and loosen the drain

screw of the brake caliper without pumping the brake.
In normal operation the brake oil could drain
automatically; please try this for couple times for
confirmation. If it doesn’t work, adjustment of the brake
pump may be required.
(Photo 20,21)

NOTICE:
Verify oil amount is above the minimum level.

Press on the brake pedal or pull the brake lever several
times then hold pressure, release the drain screw and
lock it on immediately until no air bubbles are found in
the brake oil.
Be careful for splashing oil when bleeding the brakes.

13

FIG-02. Vehicle Inspection

REAR BRAKE FLUID REFILLING METHOD

1. Remove the oil tank cover (a-1).

2. Refill with the recommended DOT-3 brake fluid until

the level reaches the upper limit.
(Photo 22)

CAUTION
Be careful when filling the brake oil tank to
to avoid spilling the oil

14

FIG-02. Vehicle Inspection

FRONT SUSPENSION

1. Check the R. and L. side suspension, the front

suspension should be adjusted to the same preload (a-1).

2. Inspect the shocks for oil leakage; if any is present,

replace shocks.

3. Check the welding of frame bracket, which is

connected to front suspension.

4. Also, check the swing arm for cracks or dents (a-2).

(Photo 23)

REAR SUSPENSION

1. Check the rear suspension for proper spring preload

(a-1). Inspect the shock for oil leakage; if any is present,
replace shock

2. Check the welding of frame bracket that connects

with rear shock and the condition of swing arm.
(Photo 24)

MANUAL CHOKE CABLE

There is an adjustment screw under the master cylinder
to control the amount of choke opening for proper
starting (a-1).
(Photo 25)

WHEELS AND TIRES
Inspect the tire surface for cuts, nails or other sharp
objects. (a-1).
Check the tire pressure at cold tire conditions.
The standard tire pressure is 3psi. (0.15kgf/cm2 )
(Photo 26)

15

FIG-02. Vehicle Inspection

STEERING SYSTEM
Check the free play of the steering shaft with the front
wheels turned straight ahead. When there is excessive
play, inspect the tie-rod, kingpin bushing and ball joint.
(a-1).
(Photo 27)

STEERING SHAFT HOLDER BUSHING
Remove the front fender.
Remove the steering shaft holder and check the steering
shaft bushing for wear or damage.
If the bushing is worn or damaged, replace the bushing.
Grease the steering shaft bushing and install the parts in
the reverse order of removal. (a-1)
(Photo 28)

Torque: steering shaft holder bolt: 33N.m ( 24 Ft. lbs)

TOE-IN
Park the vehicle on level ground with 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 move the vehicle back, let the wheels turn
180° so the marks on the tires are aligned with the axle
center height.
(Photo 29)

Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.
(Photo 30)
Toe-in: 5±10 mm

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 (a-1)
Torque: 35-43 N.m
(Photo 31)

16

FIG-02. Vehicle Inspection

GEAR OIL MAINTENANCE
Gear oil needs to be changed every 200 hours.
There is a gear oil drain hole bolt at the rear of the
engine.

1. Unscrew this drain hole bolt and let the dirty oil flow

out, catching the oil in a proper container for later
disposal.

2. Reinstall the drain hole bolt and tighten.

3. Fill with new gear oil through the oil fill hole located

on the engine case beside the gearbox.
(Photo 32)

LUBRICATE
There is a grease valve on the R. and L. suspension arm
and swing arm sub ass’y (a-1).
Please lubricate the grease frequently on the grease
valve.
(Photo 33)

17

0.6~0.7
mm

18

FIG-03. Overview

Parts Description

11. MAIN SWITCH ASS'Y

12. NEUTRAL INDICATOR

13. REVERSE INDICATOR

14. FUEL GAUGE ASS'Y

15. TRANSMISSION LEVER

16. REAR SUSPENSION

17. SEAT

18. TAIL LIGHT ASS’Y

19. REVERSE LIGHTS

20. REFLECTOR

21. REAR METAL RACK

22. TRAILER HITCH MOUNT

01. HANDLE BAR COVER

02. FRONT FENDER CARRIERS

03. HEAD LIGHT ASS’Y

04. POSITION LIGHT ASS’Y

05. MASTER CYLINDER SUB(L)

06. FRONT METAL RACK

07. BUMPER

08. FRONT SUSPENSION

09. RIGHT LEVER ASS'Y

(Including parking brake)

10. L. SWITCH ASS'Y

19

FIG-04. Fender

BUMPER

Loosen the bolts (a-1) and Remove the bumper (a-2)
from the frame body
(Photo 1)

FRONT METAL RACK

Loosen the bolts (a-1)
and Remove the front metal rack (a-2)
from the frame body
(Photo 2)

REAR METAL RACK

Loosen the screws (a-1)
Loosen the bolts (a-3)
Remove the rear rack bracket (a-2)
Loosen the bolts (a-3)
Remove the rear metal rack (a-4)
(Photo 3)

Note:

Refer to the preceding disassembly instructions for
re-assembly.

20

FIG-04. Fender

FRONT FENDER COVER

Loosen the screws (a-1)
Remove the front fender cover (a-2)
(Photo 4)

BUMPER COVER

Loosen the screws (a-1)
Loosen the screws (a-2)
Take off the main wire connect with the lights wire (a-3)
Remove the front fender cover (a-4)
(Photo 5)

LICENSE PLATE

Loosen the screws (a-1)
Loosen the screws (a-2)
Take off the main wire connect with the lights wire (a-3)
Remove the license plate (a-4)
(Photo 6)

SEAT ASS'Y

Pull the “Seat Release Bar” to take off the seat. (a-1)
This seat release bar is under the right side of the rear
fender. Remove the seat ass’y
(Photo 7)

FRONT FENDER

Loosen the screws (a-1)
Loosen the hex bolt with plain washer (a-2)
Take off the fuel tank cap
Remove the front fender (a-4)
(Photo 8)

FRONT FENDER

Loosen the screws (a-1)
Loosen the hex bolt with plain washer (a-2)
Remove the front fender (a-3)
(Photo 8)

CAUTION

1. The battery and the toolbox are put under the seat.

21

FIG-04. Fender

FOOTREST

Loosen the bolts (a-1)
Remove the footrest ass’y (a-2)
(Photo 10)

Note:

Refer to the preceding disassembly instructions for
re-assembly.

22

FIG-05. Fuel & Oil Tank

FUEL TANK

Loosen the bolts (a-1)
Take off the main wire connect with the fuel gauge wire
(a-2)
Loosen the bolts (a-3)
Remove the petcock ass’y, vacuum shut-off (a-4)
Remove the fuel tube (a-5) with the fuel filter ass’y(a-6)
Remove the air tube (a-7)
Remove the fuel tank (a-8) leave the frame body
(Photo 11,12)

CAUTION

1. There are rubbers on the frame body to reduce the

vibration and to protect the fuel tank.

2. There is a breather tube in the fuel cap.

Note:

Refer to the preceding disassembly instructions for
re-assembly.

23

FIG-06. Muffler

MUFFLER

Loosen the bolts (a-1) and make it connected to the
cylinder (a-2).
(Photo 13)

CAUTION

1. The muffler is hot during operation.

2. Do not touch the muffler or the heat shields.

3. Please check the gasket of muffler before mounting

the muffler.

Loosen the bolts (a-1) of the muffler (a-2)
on the frame body (a-3).
(Photo 14)

Note:

Refer to the preceding disassembly instructions for
re-assembly.

24

FIG-07. HANDLEBAR

HANDLE BAR COVER

Loosen the screws (a-1)
Remove the head light cover (a-2)
Take off the main wire connect with the head light wire
(Photo 15)

Remove the fuel gauge ass’y (a-1)
Loosen the nut remove the neutral indicator (a-2)
Loosen the nut remove the reverse indicator (a-3)
Remove the main switch clip and take off the main
switch (a-4)
(Photo 16)

Loosen the bolts (a-1)
Remove the protect cover mounting plate (a-2)
(Photo 17)

25

FIG-07. HANDLEBAR

REAR BRAKE CABLE

Remove the rear brake cable (a-1)
(Photo 18)

FRONT BRAKE CABLE

Remove the R. and L. front brake cable (a-1)
(Photo 19)

THROTTLE CABLE

Right lever ass’y loosen the screws (a-1)
open the cover and mount the throttle cable (a-2)
in the box
(Photo 20)

CAUTION

1. Smear grease on the throttle wire before mounting it

in the throttle box.

2. There is a park brake on the R. level.

3. It is design for safety assurance. When the vehicle

stopped on the slope ground, please operate the park
brake.

MANUAL CHOKE WIRE

Remove the manual choke wire on the L. Switch (a-1)
(Photo 21)

The L. Switch includes the engine start switch (a-2),
Horn switch (a-3)
Engine stop switch (a-4),
Headlight (high/low beam) switch (a-5).
(Photo 21)

HANDLE BAR CLAMP COVER

Loosen the bolts (a-1)
Remove the handle bar ass’y (a-2)
(Photo 22)

Note:

Refer to the preceding disassembly instructions for
re-assembly.