PowerMax ROUGH-RIDER 700 UTV Maintenance Manual
1
ROUGH-RIDER 700 UTV
Maintenance Manual
2
Catalog
General Information……………………………...5
1 Description…………………………………………………..5
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……………………………….10
Engine………………………………………………………….11
2. Inspection and adjustment of engine…………….11
2.1 Inspection of cylinder head, intake
And exhaust valve………………………………………….11
2.2 Inspection of spark Plug………………………………….14
2.3 Inspection of cylinder, piston and piston ring…….15
2.4 Inspection of crankshaft………………………………….18
2.5 Inspection of clutch……………………………………….19
2.6 Inspection of carburetor………………………………….19
2.7 Inspection of air filter………………………………….20
2.8 Inspection of oil filter………………………………….21
2.9 Inspection of lubrication system……………………….21
2.10 Lubrication of engine…………………………………….22
2.11 Inspection of cylinder head…………………………….22
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3. Disassembly of engine……………………………………27
3.1 Cylinder head and block………………………………….27
3.2 Piston and connecting rod……………………………….32
3.3 starting mechanism………………………………………..33
3.4 Sensor………………………………………………….…….33
3.5 Left crankcase cover……………………………….…….33
3.6 Magneto…………………………………………………..….34
3.7 Oil pump………………………………………….……..….34
3.8 Clutch…………………………………………………...….36
3.9 Carburetor……………………………………………...….36
3.9.1 Structure of carburetor…...36
3.9.2 Inspection and adjustment of carburetor…....….37
4. Chassis
4.1 Direction system…...42
4.2 Brake system…………………………………………...….57
4.3 Wheels and tires……………………………………...….77
4.4 Transmission system…………………………….…...….81
4.5．Reverse mechanism parts………………………………89
4.6 Suspension……....91
4.7 Cooling System of Engine………………..97
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4.8 Lubrication points……….102
5. Electrical system…....105
5.1 Ignition system…....108
5.2 Magneto and charging system…....109
5.3 Battery…....110
5.4 Lighting system…....111
5.5 Meter and signal system…………………………..……112
5.6 Electrical starting system…………….……..…….113
6. Appendix…...115
6.1 Specification…....115
6.2 Requirements for torque of fastener……………….121
6.3 Electrical circuits……………………………....….122
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General Information
1. Description
6
1.1 Identification code
1.1.1. Frame No.
Frame No. is carved in the lower right side of Figure 1-1
7
Figure 1-1
1.1.2. Engine NO.
Engine NO. Is carved on the right side of the engine,
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
8
To gauge the height of various components
1.2.3 Venire
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
9
1.2.9 Multimeter
To check electrical circuits and parts
1.2.10 Barometer
To measure pressure of the tire
1.2.11 Magneto drawing device
To detach the magneto
1.2.12 Snap ring clamp
To install and detach snap rings
1．2．13 Steering wheel pull tool
10
1.3 Maintenance schedule
Maintenance schedule
ITEM
ROUTINE
Whichever
comes first
EVERY
INITAL
month 1 3 6 6
12
km
320
1,200
2,400
2,400
4,800
(mi)
(200)
(750)
(1,500)
(1,500)
(3,000)
hours
20
75
150
150
300
Valves
● Check valve clearance.
● Adjust if necessary.
○
○ ○
○
Sparkplug
● Check condition.
● Adjust gap and clean.
● Replace if necessary.
○
○ ○ ○
○
Air filter
element
● Clean.
● Replace if necessary.
Every20-40hours
（More often in wet of dusty areas.）
Carburetor*
● Check and adjust idle speed/starter
operation.
● Adjust if necessary.
○ ○ ○
○
Crankcase
breather system*
● Check breather hose for cracks of
damage.
● Replace if necessary.
○ ○
○
Exhaust system*
● Check for leakage.
● Tighten if necessary.
● Replace gasket(s) if necessary.
○ ○
○
Spark arrester
● Clean.
○ ○
○
Fuel line*
● Check fuel hose for cracks or damage.
● Replace if necessary.
○ ○
○
Engine oil
●Replace.(Warm engine before draining.)
○
○ ○
○
Engine oil filter
cartridge
●Replace.
○
○ ○
○
Engine oil strainer*
●Clean.
○
○ ○
○
Final gear oil
● Check for oil leakage.
● Replace every 12 months.
○
○
Differential gear oil
Front brake*
● Check operation/fluid leakage. (See
NOTE page 8).
● Correct if necessary.
○
○
○
○
○
Rear brake*
● Check operation.
● Adjust if necessary.
○
○
○
○
○
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Select lever safety
system cable
● Check operation.
● Adjust if necessary.
○
○
○
V-belt*
● Check operation.
● Check for cracks or damage.
○
○
○
○
Wheel
● Check balance/damage/
● Repair if necessary.
○
○
○
○
Wheel bearing*
● Check bearing assemblies for loose/
Damage.
● Replace if necessary.
○
○
○
○
Front and rear
suspension*
● Check operation.
● Correct if necessary.
○ ○
Steering system*
● Check operation./Replace if damaged
● Check toe-in. /Adjust if necessary.
○
○
○
○
○
Drive shaft universal
joint*
● Lubricate with lithium–soap–based
grease.
○
○
○
Axle boots*
● Check operation.
● Replace if damaged.
○
○
○
○
○
Fittings and
fasteners*
● Check all chassis fittings and fasteners.
● Correct if necessary.
○
○
○
○
○
Lights and
switches*
● Check operation.
● Adjust headlight beams.
○
○
○
○
○
Engine
2. Inspection and adjustment of engine
2.1 Inspection of cylinder head, intake
And exhaust 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
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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 temperature 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. (Figure
2-2)
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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.
14
Figure 2-4
2.2 Inspection of spark Plug
1. Unplug the Spark-Plug cap: remove
The spark plug by box key, look over
To see if 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
.
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3.Swirl the when spark plug and tighten to 18～20N.m by box
key ,then fix the spark plug cap when assembling.
2.3 Inspection of cylinder, piston and piston ring
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 adjust without dust permeated into the crank
case before assembly.
item
standard value:mm
limit value:mm
cylinder
bore diameter of cylinder
φ102～φ102.03
φ102.1
taper
0.0040
0.005
out of roundness
0.0035
0.005
degree of touristy
0.04
0.06
Piston,
piston ring
and piston
pin
external diameter of piston
φ101.95～φ101.97
φ101.92
bore diameter of piston pin
hole
φ22.002～φ22.010
φ22.010
gap between piston pin and
piston pin hole
0.007～0.020
0.02
Piston ring
end
clearance
Top ring/the
second ring
0.25～0.40
0.5
gap between
piston ring
and piston
groove
oil ring
0.3～0.9
1.2
top ring
0.3～0.07
0.10
the second
ring
0.02～0.06
0.09
gap between cylinder and
piston
0.03～0.08
0.09
external diameter of piston
pin
φ21.995～φ21.990
φ21.96
connecting
rod
bore diameter
φ22.016～φ22.027
φ22.03
Gap between small end of
connecting rod and piston
pin
0.016～0.033
0.035
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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
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;
17
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
18
Figure 2-9
3. Measure the external diameter 10mm
Above the bottom of the piston skirt.
Extreme position: The gap between
Cylinder and piston repairing
Limit value: 0.1mm See figure 2-10
Figure 2-10
7 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
Check 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.
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Figure 2-12-1 Figure 2-12-2
2.5 Inspection of clutch
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 raise the idle, anti- clockwise to lower.
When adjusting is unavailable, check
20
That if there is a jam in
Carburetor idle nozzle or a
Air leakage of intake pipe.
See figure 2-14
Figure 2-14
2.7 Inspection of air filter
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 Figures 2-16
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2．8 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
2.9 Inspection of lubrication system
Lubricant of engine: the vehicle is oiled with lubricant
of APISGSAE10W/40. Others are forbidden.
Capacity:
1. 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 look over 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:
22
r/min
1000
2000
3000
L/min
3.78
7.43
10.89
Measure clearance of the top of internal external rotor
Limit value: 0.20mm
2.10 Lubrication of engine
Check the oil level, start the engine and let it running
for a few 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
wheels in flat ground.
Figure 2-18
2.11 Inspection of cylinder head
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
clearance gauge.
Repairing limit value:
Indicator of oil
level
23
0.05mm.See figure 2-19
Figure 2-19
2 Remove and examine the width of valve.
Repairing limit value: 2.0mm.
See figure 2-20-1, 2-20-2, and 2-20-3.
Figure 2-20-1 Figure 2-20-2
Figure 2-20-3
If the mating surfaces are coarse, corrode or cannot
contact with valve seat normally.repalce it.
24
Measure the width of mating surfaces of valve
Repairing limit value: 1.5mm
If the valve seat is to wide or narrow or cracked, grind
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.
25
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.
26
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, examine
the peak of breaker cam
Measure the bore diameter of rocker arm
Repairing limit value: φ12.038mm.See figure 2-24
Figure 2-24
27
7. 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
3.1 cylinder head and block
① Unplug the intake pipe and spark plug.( Figure 2-26-1,
28
Figure 2-26-1
②Remove cylinder valve cover, cam chain wheel 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
29
⑤Remove vision hole cover of left front cover .See figure 2-29
Figure 2-29
Alignment: adjust these two ＂●＂symbols of the cam chain
wheel to be at the same level with cylinder cover.
Alignmentment of top dead center:
Rotate 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.
30
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 whole cover of left front
cover. That is to say the piston is at the compression top
dead center and there is 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.
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