SMC Networks ATV50, ATV100 Service Manual
SERVICE MANUAL
CF5/UR5/UR0
ATV 50/100 ATV with F/N/R
3 in 1 engine
Standard Motor Corporation
1-
01-01-01-01-01-0
1.
Thi
s
not
iackcha
1-
0
Sy
m
is
nand
1. Sym
b
2. Gene
r
3. Servi
c
4. Spec
i
5. Torq
u
6. Trou
b
General
chapter
o
ce, cautio
n
nowledge
pters.
1. Sym
b
bols an
d
eeded. In
marks,
e
Warni
n
Cauti
o
Engine
Greas
Gear
o
Oil se
a
Rene
w
Brake fl
Special t
o
ols and
al Safe
t
e Prec
a
fication
s
e Value
s
les Dia
g
Informa
ffer you t
h
and the
t
and skills
ols and
marks a
r
case su
p
xplanatio
g
Mfon M
oil
Li
oi
li
m
e C
il
G
r
e
l
Ap
R
uid U
ols S
p
S
MC
Marks
y
utions
nosis
tion
e general
ools tong
u
before sta
Marks
e used in
plement
a
ns will b
e
eans that
llowed.
eans that
mits to us
l. Warrant
ited engi
n
hassis gr
e
ear oil s
e
commend
ply with li
eplace wit
se recom
m
ecial tool
s
ATV5
0
informati
o
e setting,
rt to do an
this man
l informa
t
added to
serious i
n
equipmen
t
SAE #
2
will not
c
e oil.
ase is rec
o
rials are
ed )
thium-soa
a new p
a
ended br
a
/10
0
Se
n of SMC
please re
a
y repair/in
s
ual to ind
ion of pr
o
the text i
jury or e
v
damage
s
0 or JAS
O
over the
mmende
d
recomm
e
p base lu
b
rt before
i
ke fluid
D
rvice
M
1
2
3
10
12
14
ATV 50/1
0
d carefull
y
pection j
o
cate wha
t
cedures
i
stead of
en death
may resu
FC clas
s
damage t
h
.
nded. (
G
ricant.
nstallatio
n
OT4.
anua
l
Chapt
e
0 with 2
s
and mak
bs as me
n
and wh
e
s needed
using th
e
may resul
t
lt if proce
d
or simila
at cause
d
ear oil
S
.
er 1 Gen
troke eng
i
e sure yo
u
tioned at
re the sp
e
for thes
e
symbols
t if proce
d
ures are
n
r class 2
s
by not a
AE #40
-
ral Infor
m
ne, safety
have wel
furthering
cial serv
i
symbols
or marks
ures are
n
ot followe
d
troke eng
pply with
t
or above
1 -
ation
l
ce
.
ot
.
ine
he
is
1-
0
Bel
o
Ca
r
If y
o
are
ause
Ex
h
Ga
Ga
sspa
Ga
s
chil
Us
e
Pro
ver
iKee
Ho
Co
mThe
ser
v
Ba
t
Gene
r
w is som
e
bon mo
n
u must ru
. Run yo
u
an extrac
Cautio
n
aust cont
a
oline
oline is a
rk should
Cautio
n
oline is hi
ren.
d trans
m
Cautio
n
longed co
n
fied. We r
e
p the use
d
compo
n
Cautio
n
ponents
o
y remain
v
ice work
o
tery
Cautio
n
Batte
r
when
Batte
r
not b
e
imme
d
water
If you
veget
a
Keep
al infor
m
of the g
e
oxide
n your en
g
r engine i
n
tor.
ins toxic
g
low ignitio
n
be allowe
d
ghly flam
m
mission
tact with
u
commen
d
oil beyo
n
nents
f the eng
i
ery hot e
v
n these p
y emits e
x
charging
t
y contain
s
spray on
iately wit
h
and then
g
swallow it
ble oil an
electrolyt
e
S
MC
ation r
e
neral info
r
ine, ensu
r
an open
as which
point an
d
in the w
o
able, and
oil
sed tran
s
that you
w
d reach o
f
ne and e
x
en after t
h
arts, wear
plosive g
a
he battery
sulfuric a
c
your eyes
water. If
y
o to hos
p
by mistak
d then im
m
beyond r
e
ATV5
0
fer to y
mation to
e the pla
c
area, if yo
may caus
e
explosiv
e
rk place o
r
may expl
o
mission oi
ash you
r
children.
haust sys
t
e engine
h
insulated
ses; Flam
.
id (electr
o
or skin. If
ou get b
a
ital to see
e, drink a
l
ediately
g
ach of ch
/10
0
Se
our ow
n
your own
s
e is well v
e
u have to
one to lo
material.
where g
a
de under
l may cau
s
hands wi
t
em can b
e
as been
s
gloves an
d
e is strictl
y
lyte) whi
c
you get b
a
ttery acid
an ophth
a
ot of wate
o to see
a
ildren.
rvice
M
safety
afety duri
ntilated.
N
run your e
se consci
o
Work in a
soline is
b
some con
d
e skin ca
n
h soap an
come ext
r
topped fo
wait until
prohibite
d
h can cau
s
ttery acid
in your ey
e
lmologist.
r or milk,
a
doctor.
anua
l
Chapt
e
ng the rep
ever run
y
gine in a
usness a
n
well-ventil
eing store
itions, ke
e
cer altho
u
d water ri
g
emely hot
r some ti
m
cooling o
f
. Keeps t
h
e serious
on your s
k
s, flush it
nd take s
o
er 1 Gen
air/servic
e
your engi
n
closed ar
e
d even re
ated plac
e
d.
ep it awa
y
gh it mig
h
ht after c
o
after engi
e. When
p
f.
e place
w
burns so
b
in, flush i
t
off immed
me laxati
v
-
ral Infor
m
time.
e in a clo
s
a, be sur
e
sult in de
a
, no flam
e
from
t not be
ntacting.
ne runnin
g
erforming
ell ventila
t
e careful
off
iately with
e such a
s
2 -
ation
ed
to
th.
or
.
ed
do
Br
a
Do
cle
a
Inh
a
Br
a
Spi
l
cle
a
the
1-
0
1.
A
2.
3.
W
v
4.
5.
W
ke pad/
s
not use a
n
ner or th
e
Cautio
n
ling brake
ke fluid
Cautio
n
ling brake
n towel o
n
brake flui
d
3. Servi
c
lways us
Using n
o
ATV an
d
Special to
o
compone
n
Using wro
hen ser
v
interchan
g
ehicle.
Clean the
deposit a
c
cause da
m
ash and
dry with c
o
seals bec
a
on them.
hoe
air hose
o
equivale
n
shoe or pa
d
fluid on p
a
the abo
v
beyond r
e Preca
e with SM
C
n-genuin
e
out of S
M
ls are de
s
ts without
ng tools
m
icing this
A
eable wit
h
outside of
cumulate
d
age.
clean par
t
mpresse
d
use most
S
MC
r a dry br
t to avoid
ash may
c
inted, pla
e-mention
each of c
h
utions
genuine
parts for
S
C warran
t
igned for
damagin
g
ay result i
n
TV, use
o
the Engli
s
the parts
o
on the p
a
s with hig
h
air. Pay
s
cleaning
a
ATV5
0
sh to cle
a
dust flying
ause diso
r
stic, or ru
b
ed parts f
o
ildren.
parts and
MC ATV
y service.
remove a
n
the parts
parts da
m
nly metri
c
h system
,
r the cov
e
rt's surfac
e
ignition
p
pecial att
e
gents ha
v
/10
0
Se
n compo
n
.
ders and c
a
ber parts
r protecti
o
recomme
may dam
a
d install o
being wor
aged.
tools. M
e
, using wr
o
r before r
e
e may fall
oint solve
n
ntion to
O
e an adve
rvice
M
ents of th
e
ncer of th
e
ay caus
e
n when s
e
nded oils.
ge the
f
ked on.
tric bolts,
n
ng tools
a
moving it
into the e
n
t, and blo
-rings or
o
rse effect
anua
l
Chapt
e
brake sy
s
breathing
damage
t
rvicing th
e
uts, and
s
nd fasten
e
rom the
A
gine, cha
s
il
SMC
G
er 1 Gen
stem; use
system
to the par
t
brake sy
s
crews ar
e
rs may d
a
TV. Other
w
sis, or br
a
enuine Par
t
-
ral Infor
m
a vacuum
s. Place a
tem. Kee
not
mage thi
s
ise, dirt
a
ke syste
m
s
3 -
ation
p
nd
to
6.
7.
8.
W
9.
10.
11.
12.
13.
w
Never be
n
and prem
a
Rubber p
a
Check the
necessar
y
hen loo
s
pattern an
loosen fir
s
Store com
proper as
s
of installat
number ta
Note the r
e
ensure th
e
Compone
n
disassem
b
snap ring
s
he lengt
h
boxes is d
installed. I
compare i
t
he same
w
assembly
ighten a
s
ighten al
l
ith speci
a
important
c
appropriat
Bolts and
f
o the thre
d or twist
a
ture worn
rts may b
e
se parts b
e
.
ening a c
o
d work fro
m
t, small fa
s
plex com
p
emble or
d
ion later o
r
b for the s
assembl
e
y will be r
e
ts not to
b
led includ
, and split
of bolts
a
ifferent fro
n case of
c
s length
w
ith other
should ha
v
semblies
w
the faste
n
l tool first
ompone
n
e increme
n
asteners
s
ads.
S
MC
control
c
out.
come det
e
fore inst
a
mponent
inside o
teners m
a
onents su
er and tie
you can l
equence t
o
position
o
assembl
e
e reused
ing gaske
t
pins.
nd screw
s
m one an
o
onfusion,
ith other
b
bolts, it is
e the sa
m
ith differ
e
ers with fi
diagonall
y
ts should
ts to avoi
hould be
ATV5
0
able to pr
e
riorated
w
llation to
m
which has
ut. Loose
n
y receive
ch as tran
s
them tog
e
abel the a
s
avoid th
e
f the imp
o
d in corre
c
should be
s, metal s
e
for asse
m
ther, be s
Insert the
olts, if its l
a correct
b
e length.
nt dimen
s
ngers, the
from insi
d
e tighten
e
d warp un
l
kept clean
/10
0
Se
vent uns
m
hen old,
a
ake sure
different
s
the small
too much
mission
p
ther with
a
ssembly p
mistake.
rtant com
ct dimensi
replaced
w
al rings,
O
blies, cov
ure they a
bolt into t
h
ength out
s
olt. Bolts
f
ion fasten
n tighten t
e toward
d 2 to 3 ti
ess other
w
and dry.
D
rvice
M
ooth con
t
nd prone
t
that they
a
ized faste
fasteners
stress.
arts in th
e
wire for
e
arts by Ar
a
ponents b
e
ons (dept
h
hen
-rings, oil
er plates
o
e correctl
y
e hole to
ide the h
o
or the sa
m
ers as foll
o
he big on
e
outside,
mes with
ise indic
a
o not ap
p
anua
l
Chapt
e
rol
o be dam
a
re in goo
d
ners, ope
r
first. If th
e
ase
bic
fore disa
s
, distance
seals,
r
le is
e
ws:
s
ted.
ly oil
er 1 Gen
ged by s
o
conditio
n
ate with a
bigger o
n
sembling
or positio
n
-
ral Infor
m
lvent and
, replace i
f
diagonal
es are
them to
).
4 -
ation
oil.
14.
15.
16.
17.
18.
When oil
he oil se
a
outside, a
n
installed f
o
oil seal.
Remove r
e
reinstallati
has any d
a
he ends
o
should be
so that th
e
ightening
Rubber a
n
he origin
a
he beari
n
removing
a
inner race
bearing, u
s
seal is in
s
l with the
n
d check t
h
r smooth
n
sidues of
on, grind
w
mage.
f rubber
h
pushed a
s
re is eno
u
the clamp
d plastic
b
l correct
p
g tool sh
o
ball bea
r
or outer r
a
e equal f
o
(B
o
S
MC
talled, fill t
ame of th
e shaft o
n
ess and f
o
the old g
a
ith a grin
d
oses (for
far as th
e
gh room
b
s.
oots shou
ositions a
s
uld be pr
e
ing. Dam
a
ce). In thi
rce on b
o
th of the
s
ATV5
0
he groove
e manufa
c
which th
e
r burrs th
a
sket or se
a
stone if t
h
uel, vacu
u
y can go
t
elow the
e
ld be prop
designe
d
ssed agai
n
ge may r
e
s case, th
e
th races.
e exampl
e
/10
0
Se
with grea
s
turer faci
n
oil seal i
s
t may da
m
alant befo
r
e contact
m, or co
o
o their co
n
nlarged e
n
erly reinst
a
.
st two (in
sult if the
t
bearing
s
s can re
s
rvice
M
e, install
g
to be
age the
e
surface
lant)
nections
ds for
lled to
ner and o
u
ool is pre
s
hould be
r
ult in bea
r
anua
l
Chapt
e
ter) beari
n
sed again
eplaced.
T
ing dama
g
er 1 Gen
g races
w
st only on
e
o avoid d
ge)
-
ral Infor
m
hen
race (eit
h
amaging t
h
5 -
ation
er
e
he rotatio
n
points be
f
sitions a
n
service s
a
parts fall
d
oval/inst
a
attery re
m
(－) cabl
e
ith body
t
vice com
p
. Battery p
install the
two pole
s
re that th
e
.
Voltage
rate expl
o
stic sulfu
r
tective ey
e
atteries in
teries aw
a
).
SMOKE
w
S
MC
ball face
ore asse
m
d operati
o
fety for e
a
own.
llation.
oval oper
a
firstly. T
o
o prevent
leted, ma
k
ositive (+)
battery c
o
ide of bat
t
battery p
o
and cond
sive hydr
o
ic acid. T
h
gear wh
e
a well-ve
n
y from fir
e
hen char
g
ATV5
0
with spec
i
bling.
n for inst
a
ch other
w
tion, it ha
s
ols like o
p
from shor
t
e sure all
cable sho
rd. .
ery have t
o
st caps a
r
tion of c
h
gen gas
a
erefore,
a
n handlin
g
tilated a
r
e
, sparks o
r
ing or ha
n
/10
0
Se
fied lubric
a
lled parts
hen con
d
to remo
v
en-end w
r
-circuit an
connectio
uld be co
n
be grea
s
re located
arge in b
a
nd contai
lways foll
o
or worki
n
a.
open fla
m
dling batt
e
rvice
M
nt on the
is in corre
c
ucting by
e the batt
e
ench do n
o
create s
p
n points is
nected fir
s
ed after c
o
in properl
y
ttery
n electrol
y
w these p
g near b
a
es (e.g.,
w
ries.
anua
l
Chapt
e
t and
wo perso
n
ry
t
ark.
tly
nnected
t
after the
e which i
s
reventive
m
tteries.
elding e
q
er 1 Gen
s.
he cables
.
battery p
o
made of
p
easures:
uipment, l
-
ral Infor
m
sts had b
e
oisonous
ighted
6 -
ation
en
FI
REXT
IN
T
24.
25.
A
KEEP B
A
A
void bo
d
ST AID I
N
ERNAL
Skin —
W
Eyes —
F
ERNAL
Drink lar
g
vegetabl
e
If fuse bur
capacity f
u
Connecto
r
. When
s
compl
e
B. Do not
wires.
H
C. Make
s
D. Insert
t
locker
s
locker
s
loose.
E. Check
conne
c
TTERIES
ily conta
c
CASE O
F
ash with
w
lush with
e quantiti
e
oil. Get i
m
ned, it ha
s
se.
unlock/in
s
eparatin
g
tely, unlo
c
pull the w
old the c
o
ure if the
c
he conne
c
on two c
o
are locke
if the con
n
tor boot c
o
S
MC
AND EL
E
t with ele
c
BODILY
ater.
water for
1
s of wate
mediate
to find ou
ert
a connec
t
ked it firs
t
ires as re
m
nnector
b
onnector
tor compl
e
nnector s
i
d in prope
ector is c
o
mpletely
ATV5
0
CTROLY
T
trolyte as
CONTAC
5 minute
s
or milk f
o
medical a
t
the caus
e
or, it lock
e
.
oving a c
o
ody.
pins are b
e
tely. If th
e
des, mak
e
rly. Check
vered by
t
and secur
e
/10
0
Se
E OUT O
it can cau
s
T:
and get i
m
llowed wit
tention.
and solv
e
r has to I
n
onnector
o
nt, extru
d
re are tw
o
sure the
if any wir
e
he twin
d properl
y
rvice
M
F REACH
e severe
b
mediate
h milk of
m
d it. And
t
sert the t
e
r
ed or loo
s
.
anua
l
Chapt
e
OF CHIL
D
urns or p
e
medical a
t
agnesia,
b
hen repla
c
rminal
en.
er 1 Gen
REN.
rmanent
e
tention.
beaten eg
g
e with sp
e
-
ral Infor
m
ye injury.
or
cified
7 -
ation
26.
27.
W
28.
29.
30.
31.
F. Before
termin
a
Secure wi
r
locations.
harnesse
s
ire ban
d
properly.
Do not sq
u
Do not let
compone
n
Keep wire
Route wir
e
corners a
n
and scre
w
terminal
c
l is loose.
es and wi
Tighten th
.
and wire
eeze wir
e
the wire h
a
ts as routi
harnesse
s
harness
e
d also av
o
s.
S
MC
onnection
re harnes
s
e bands s
o
harness
h
s against
t
rness co
n
ng the ha
r
far away
s to avoid
id the pro
j
ATV5
0
check if t
es to the
f
that only
ave to b
e
he weld o
tact with
r
ness.
from the
h
sharp ed
g
ected en
d
/10
0
Se
he boot is
rame with
the insul
a
clamped
r its clam
p
otating, m
ot parts.
es or
s of bolts
rvice
M
crack or t
h
respectiv
e
ted surfac
secured
.
oving or v
i
anua
l
Chapt
e
e
wire ban
d
s contact
brating
er 1 Gen
s at the
d
the wires
-
ral Infor
m
esignated
or wire
8 -
ation
32.
33.
34.
35.
36.
37.
38.
W
39.
40.
W
f
Route har
n
slack.
Protect w
contact a
tape is to
Secure th
e
Never us
e
broken.
W
replace th
e
Never cla
m
compone
n
Do not let
ire harn
e
slack, be
r
Before op
e
instrumen
t
ith sand
ound. An
d
esses so
ires or wir
e
sharp ed
g
be applie
d
rubber b
o
wires or
h
rap electri
m.
p or squ
e
ts.
the wire h
a
sses rout
ubbed ag
a
rating a t
e
. And the
n
paper to
c
then con
S
MC
that they
n
harness
e
e or corn
e
.
ot firmly
a
arnesses
cal tape a
r
eze the
w
rness be
e
ed along t
h
inst or int
e
st instru
m
, conduct
lean rust
o
duct conn
e
ATV5
0
either pul
s with ele
c
r. Thorou
g
s applyin
g
which ins
u
ound the
d
ire harnes
n twisted
e handle
b
rfere with
ent, oper
a
test in ac
c
n connec
t
ction ope
/10
0
Se
l too tight
n
trical tap
e
hly clean
it on wir
e
lation ha
s
amaged
p
s as instal
as install
a
ar should
adjacent
o
tor shoul
d
ordance
w
or pins/te
r
ration late
r
rvice
M
or have
e
or tube i
f
he surfac
e
harness.
been
arts or
ling other
tion.
not be pu
r surroun
read the
o
ith the in
s
minals if
.
anua
l
Chapt
e
xcessive
they
where
led too tig
ding parts
peration
m
truction.
er 1 Gen
ht or have
in all stee
anual of
-
ral Infor
m
excessiv
e
ring positi
o
the
9 -
ation
n.
1-
0
1.
Di
mSeaWhe
Gro
Wei
En
g
Cyli
Bor
e
Dis
p
Co
m
Lub
Car
Sp
a
Sta
r
Igni
tGen
Bat
tEngEng
Air-
F
Tra
nGea
Fin
a
Fin
a
Ge
a
Ge
aFue
Fu
e
Ch
a
Fro
nRea
Bra
k
Bra
k
F.
B
R.
B
Tir
e
Fro
n
He
aRea
Fla
s
4 Speci
f
SMC CF5
ension (Lx
W
t height
el base
und Cleara
ght
ine
nde
r
* Stroke
lacement:
pression
R
ricant :
bureto
r
rk
ting
ion
erator
ery :
ine Oil
ine Oil
ilter
smission (
r Shifting :
l ratio
:
l Drive :
r box oil
:
r Ratio :
l : Unl
e
l tank: 8.1
L
ssis : Ste
e
t Suspens
r Suspensi
e (F/R)
e (F/R)
rake oper
a
rake oper
a
: Tubeles
s
t/Rear: (F
)
(
R
d Light (ty
p
r Light: 12
V
her Light :
ication
s
series A
T
xH): 165
5
: 845mm
: 1080mm
nce : 23
5
: Un-laden
: 2 Stroke,
A
: Single, H
o
: 40 x 39.2
m
49.3 cc
atio : 7.8:1
mixed with
: Mikuni V
M
: NGK BP
R
: Electrical
: C.D.I.
:
A
CG Fly
W
MF type,
F
: 2Stroke
E
: 1.1L
: Wet type
e
F-R): C.V.
T
F- R (shift
s
1.59(35/2
2
Chain Dri
v
SAE #40,
Forward:
4
aded gas
o
l tube fra
m
ion: Doubl
e
on: Single
s
: Front dua
: Front dua
tion: Front
tion: Front
pedal for
i
AT 21x7-1
) AT 21x1
0
e 1): 12V
3
5W* 1 (L
E
12V 10W*
4
S
MC
50, CV
T
mm/1028
m
mm
Mass = 14
2ir
Cooled
rizontal
m
fuel by oil
p
16 (18m
m
7HS x 1
starte
r
/Kic
k
heel Mag
n
actory def
a
ngine Oil,
S
lement
Automati
c
elector fu
n
T)
e, 428*88
0.12L
1.15~17.3
7
line
e
A-arm; sh
o
wing Arm;
l hydraulic
d
l drum bra
k
RH side ha
LH side h
a
ntegrate fr
o
0 or others
-8 or othe
r
5W/35W*1
D)
ATV5
0
with rev
e
m/1025m
m
kg; with fu
e
ump
), MJ:#65,
Starter
eto 90W
ult: YUAS
A
AE #20 or
with centri
f
ction in re
v
; Reverse:
ck absorb
e
shock abs
o
isc / Rear
e / Rear si
n
ndle brake
ndle brake
nt and rea
s
(Hi/Low-B
e
/10
0
Se
rse gear,
l Mass =
1
PJ:#17.5,
N
/GS Batte
r
JASO FC
c
ugal clutc
h
erse with
p
34.86- 14.
: 72 mm
t
rber: 63m
m
single hydr
gle drum
b
lever for fr
o
lever for r
e
r wheeler
a
am)
rvice
M
Chain dri
48 kg
J:E-1(#42
6
y YTX4L-B
lass or ab
o
.
edal brake
)
71
ravel, 5-Se
travel, 5-
S
ulic disc (
O
rake (optio
nt wheele
r
ar wheeler
/
t the same
anua
l
Chapt
e
e.
)
/GTX4L-
B
ve.
tion adjus
t
ection adj
u
ption 1)
2)
parking br
a
time
er 1 Gen
S
able pre-lo
ustable pre
ke; R side
-
ral Infor
m
aded
-loaded
footrest br
a
10 -
ation
ke
2.
Di
mSeaWhe
Gro
Wei
En
g
Cyli
Bor
e
Dis
pCom
Lub
Car
Sp
a
Sta
r
Igni
tGen
Bat
tEngEng
Air-
F
Tra
nGea
Fin
a
Fin
aGeaGeaFue
Fu
eCha
Fro
nRea
Bra
k
Bra
k
F.
B
R.
B
Tir
e
Fro
n
He
a
Re
a
Fla
s
SMC CF0
ension (Lx
W
t height
el base
und Cleara
ght
ine
nde
r
* Stroke
lacement:
pression
R
ricant :
bureto
r
rk
ting
ion
erator
ery :
ine Oil
ine Oil
ilter
smission
r Shifting :
l ratio
:
l Drive :
r box oil
:
r Ratio :
l : Unl
e
l tank: 8.1
L
ssis : Ste
e
t Suspens
r Suspensi
e (F/R)
e (F/R)
rake oper
a
rake oper
a
: Tubeles
s
t/Rear: (F
)
(
R
d Light (ty
p
r Light: 12
V
her Light:
1
series A
T
xH): 165
5
: 845mm
: 1080mm
nce : 23
5
: Un-laden
: 2 Stroke,
A
: Single, H
o
: 52 x 45m
m
95.2 cm3
atio : 5.8:1
mixed with
: Mikuni V
M
: NGK BP
R
: Electrical
: C.D.I.
:
A
CG Fly
W
MF type,
F
: 2 Stroke
E
: 1.1L
: Wet type
e
: C.V.T A
u
F-N- R (sh
i
1.59(35/2
2
Chain Dri
v
SAE #40,
Forward:
4
aded gas
o
l tube fra
m
ion: Doubl
e
on: Single
s
: Front dua
: Front dua
tion: Front
tion: Front
pedal for
i
AT 21x7-1
) AT 21x1
0
e 1): 12V
3
5W* 1 (L
E
2V 10W*
4
S
MC
100, CV
mm/1028
m
mm
Mass = 14
4ir
Cooled
rizontal
fuel by oil
p
16 (18m
m
7HS x 1
starte
r
/Kic
k
heel Mag
n
actory def
a
ngine Oil,
lement
tomatic wit
ft selector
f
T)
e, 428*88
0.12L
1.15~17.3
7
line
e
A-arm; sh
o
wing Arm;
l hydraulic
d
l drum bra
k
RH side ha
LH side h
a
ntegrate fr
o
0 or others
-8 or othe
r
5W/35W*1
D)
ATV5
0
with re
v
m/1025m
m
kg; with fu
e
ump
), MJ:#77.
5
Starter(op
t
eto 90W
ult: YUAS
A
AE #20 o
r
h centrifug
a
unction in
r
; Reverse:
ck absorb
e
shock abs
o
isc / Rear
e / Rear si
n
ndle brake
ndle brake
nt and rea
s
(Hi/Low-B
e
/10
0
Se
erse gea
r
l Mass =
1
, PJ:#17.5
ional)
/GS Batte
r
JASO FC
l clutch.
everse wit
h
34.86- 14.
: 72 mm
t
rber: 63m
m
single hydr
gle drum
b
lever for fr
o
lever for r
e
r wheeler
a
am)
rvice
M
, Chain d
r
50 kg
, NJ:E-1(#
4
y YTX5L-B
class or ab
pedal bra
k
71
ravel, 5-Se
travel, 5-
S
ulic disc (
O
rake (optio
nt wheele
r
ar wheeler
/
t the same
anua
l
Chapt
e
ive.
26)
/GTX5L-
B
ove.
e)
tion adjus
t
ection adj
u
ption 1)
2)
parking br
a
time
er 1 Gen
S
able pre-lo
ustable pre
ke; R side
-
ral Infor
m
aded
-loaded
footrest br
a
11 -
ation
ke
1-
0
Th
e
val
u
A.
5m
6m
8m
10
m12m
B.
Sp
a
Cyl
Cyl
A
ir
A
ir
Fa
n
Oil
Ca
rCar
A
ir
Int
a
Oil
Oil
Ge
a
Cr
a
ca
sL.R
Kic
Idl
eOne
Cl
uCluExhMufPro A.C
Ma
Ge
a
5. Tool
T
torque v
a
es for not
Standard
Ite
m
m Bolt, N
u
m Bolt, N
u
m Bolt, N
u
m Bolt,
N
m Bolt,
N
Engine T
o
rk Plug
inder hea
d
inder hea
d
Shroud
Shroud c
o
Bolt
pump bolt
buretor u
p
buretor fl
o
cleaner fi
x
ke bolt (r
e
plug cap
drop bolt
(
r box bol
t
nkcase c
o
e)
Crankca
s
k Nut
gear plat
e
way clut
c
tch
tch carrie
r
aust Pipe
fler bolt
tector, m
u
. Generat
o
gnet (A.C.
r shifting
orque
v
lues listed
listed in t
h
Toque V
a
t
t
t
ut
ut
rque
Item
/cylinder
s
nut
ver
per bolt
at bolt
ing bolt
ed valve)
drain bolt
)
ver bolt (t
r
e bolt
bolt
h bolt
(cylinder
s
ffler
r nut (fly
w
G. coil) sc
lever nut
S
MC
alue se
t
in table a
r
e table.
lue
Torqu
00135
tud bolt
ansmissi
o
ide)
heel/roto
r
rew
ATV5
0
ting
e for mor
e
e Value (
k
.45~0.60
.80~1.20
.80~2.00
.00~4.00
.00~6.00
Q
’
n
)
1443142242411
6161211122212
1
/10
0
Se
importan
t
g-m)
5m
6m
6m
8m
10
m
ty
Thr
e
(
m
1
1
4070706060504040606
1
4
0
806
1
1
0
6
0
6
0
6101028060806100606
rvice
M
tighten to
Item
m Screw
m Screw
m Screw
m Screw
m Screw
ad Dia.
m)
*1.22
*1.00
*1.00
*1.00
6.0
*1.00
*0.8
*0.7
*0.7
*1.00
*1.00
*1.50
*1.25
*1.00
*1.00
*1.00
*1.00
*1.00
*1.25
*1.00
*1.00
*1.00
*1.25
*1.00
*1.25
*1.00
*1.00
anua
l
Chapt
e
rque valu
e
T
o
Torqu
e
(kg
1.5
~
1.4
~
1.3
~
0.5
~
0.1
~
0.5
~
0.3
~
0.15
~
0
0.7
~
0.7
~
0.2
~
1.5
~
0.7
~
0.7
~
0.7
~
0.7
~
0.6
~
2.5
~
3.5
~
5
0.7
~
2.2
~
0.7
~
3.8
~
1.0
~
1
er 1 Gen
s. Please
rque Val
u
0.45~
0
1.00~
1
0.70~
1
2.00~
3
3.50~
4
Value
-m)
2.0
2.0
1.5
0.8
0.2
0.8
0.5
0.25
.2
1.0
1.0
0.4
2.0
1.0
1.0
1.0
1.0
1.0
3.5
4.5
.0
1.0
3.0
1.0
4.2
1.6
.0
-
ral Infor
m
see stand
a
e (kg-m)
.60
.40
.10
.00
.50
sugges
2.0
1.0
1.4
0.7
0.2
0.7
0.4
0.2
0.2
0.9
1.1
0.3
1.8
1.2
1.2
1.2
0.9
0.8
4.0
3.0
0.9
2.6
0.9
3.8
0.8
12 -
ation
rd
t
C.
Ste
Ste
Fro
Fro
Ste
Tie
-
Tie
-
Fro
Fro
Re
aRea
Fro
Re
a
En
g
F.e
n
Sw
iUndChaFooReaRea
Re
aRea
Fo
oFoo
Ex
hHan
Chassis
P
ering colu
m
ering colu
m
nt Shock
a
nt Arm (U
p
ering Knu
c
rod (lock
n
rod end a
nt hub
nt Wheel
r collar w
h
r Wheel
nt shield
b
r shield b
o
ine Moun
t
gine and
ng-Arm
er guard
in suppor
t
trest L&R
r Shock
A
r axles h
e
r axles h
e
r Brake H
t brake b
o
t brake b
o
aust Pipe
dlebar H
o
arts Tor
q
Item
n holder
n holder
bsorber (
u
per-Fram
kle and u
p
ut)
nd steerin
g
eel
olt
lt
ing
frame
er
bsorber (
u
xagon nu
t
xagon nu
t
ub Bolt
lt
lt
holder (fr
a
lder
S
MC
ue Value
and fram
e
and handl
pper & lo
w
e)
per arm
column
pper) bolt
(IN)
(EX)
me)
ATV5
0
Q
e bar
er)
2142244
2828411144411
1
4
1
2
2
2
/10
0
Se
’ty
Thr
e
(
1
1
1
1
1
1
1
1
0
810101010101014
1
0
1
410080810140810081028
2
810
1
008
0
808
rvice
M
ad Dia.
mm)
*1.25
*1.25
*1.25
*1.25
*1.25
*1.25
*1.25
*1.50
*1.25
*1.50
*1.25
*1.25
*1.25
*1.25
*1.50
*1.25
*1.25
*1.25
*1.25
*1.50
*1.50
*1.25
*1.25
*1.25
*1.25
*1.25
anua
l
Chapt
e
Torqu
(k
g
1.
82.24.0
34.023
7
4
1
42248
21.8
22.010
1
0
5
4.
01.0
1.
81.0
er 1 Gen
e Value
-m)
/2.3
/3.5
/3.0
.0
/6.0
.5
.0
.0
.5
2.0
.5
.6
.6
.5
.5
.3
/2.8
.6
/3.0
/16
/16
.0
/6.0
/1.6
/2.8
/1.5
-
ral Infor
m
Rema
r
13 -
ation
ks
1-
0
A.
E
6.Trou
b
ngine d
o
les Diag
es not st
a
S
MC
nosis
rt
ATV50/10
0
Se
rvice Manua
l
Chapteer 1 Gen- ral Infor
m
14 -
ation
B.
E
C.
E
ngine p
o
ngine p
o
or perfor
m
or perfor
m
S
MC
ance at
ance at
ATV5
0
ow and i
d
igh spe
e
/10
0
Se
le speed
d
rvice Manua
l
Chapteer 1 Gen- ral Infor
m
15 -
ation
D.
P
oor Performance
S
MC
ATV50/10
0
Se
rvice Manua
l
Chapteer 1 Gen- ral Infor
m
16 -
ation
A.
P
oor Steering
S
MC
ATV50/10
0
Se
rvice Manua
l
Chapteer 1 Gen- ral Infor
m
17 -
ation
2-
02-02-02-02-02-02-02-02-0
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-
0
1. Tech
n
2. Perio
d
3. Fuel
H
4. Throt
t
5. Air C
l
6. Spar
k
7. Idle
S
8. Drivi
n
9. Brak
e
0. Brak
e
1. Brak
e
2. Clutc
h
3. Susp
e
4. Steer
i
5. Whe
e
6. Nuts,
7. Toe-I
n
8. Gear
1 Tech
n
Cl
e
Spar
k
“
F
Tire
d
ical Da
t
ical Ma
oses
le Cabl
e
eaner
Plug
peed A
d
g Chai
n
Syste
m
Syste
m
Light S
Wear
nsion
ng Han
d
l/Tire
Bolts Ti
Oil
ical Dat
a
Fuel Tank
2T Eng
i
Gea
r
arance of
t
plug
Brake leve
r
” Mark in
s
Idling
s
imension
Tire pr
e
Batt
e
SMC
a
intenan
c
justme
n
(drum
b
(Disk
B
witch/St
le
ghtness
of Oil
&
Capacity
ne Oil
Oil
hrottle val
v
T
y
G
a
free play
tatic timing
peed
F
R
ssure
ry
ATV 5
0
e Sche
d
t
rake)
rake)
arting I
n
Pressu
r
e
pe
p
ront
ear
/10
0
S
ule
hibitor
S
e Capa
c
50 CC: 1
2
YT
100CC: 1
2
Y
T
ervice
M
C
witch
ity
1.
10.1NG0B
18
AT21
x
AT21
x
12 p
s
V3Ah (typ
e
4L-BS or
V4Ah (typ
e
X5L-BS or
anua
l
hapter 2
8.1L.
L, SAE 2
0
2L, SAE 4
0
4~6 mm
K BPR7H
S
.6~0.7 mm
3~5 mm
TDC 18º
0±100 rp
m
7-10 / or o
t
10-8 / or o
t
i (0.81 kgf/c
m
: MF batt
e
GS Battery
: MF batt
e
GS Batter
y
Maintena
n
15
16
18
18
18
19
19
20
21
22
24
24
24
25
25
25
26
26
hers
hers
2)
ry, default:
GTX4L-B
S
ry, default:
GTX5L-B
S
-
1
ce Inform
a
YUASA
)
YUASA
)
5-
tion
2-
0
Ha
v
A
ut
sch
It
1
2
3
4
5
6
7
8
9
1
1
1
1
1
4
1
1
1
1
1
2
2
2
2
2
4
2
2 Perio
d
e your A
T
horized D
e
edule is e
s
em
Ch
e
Ite
m
*
*
*
A
*
A
*
*
0 *
1 *
*
3 *
*
5 *
6 *
7 *
W
8 *
W
9 *
0 *
1 *
*
3 *
*
5
ical Ma
V checke
d
aler to m
a
tablished
ck
s
Ma
Kil
o
Ma
Engine oil (
2
Gear Oil
Engine idle
s
Fuel Filter(f
u
Spark plug
ir cleaner
e
ir Cleaner
t
Carburetor
Throttle ope
limiter
Fuel lines (c
cracks/dam
a
Upper and l
o
Steering Sh
a
in check)
Front and R
e
absorber ch
e
Front /Rear
check
Front / Rear
shoe/pad w
e
Front and R
e
Level/Leaka
Wheel rim c
h
Wheel Hub
B
looseness/d
a
Tire (Wear/
P
Nuts, Bolt,
B
check and l
u
Fr. & Rr. St
e
pivot
CVT driving
CVT driving
Driving Cha
i
Battery Volt
a
SMC
intenan
c
, adjuste
d
intain the
by taking
t
intenance
meter
intenance In
stroke)
peed
el cup)
lement (Re
m
ube
ration /Spee
heck or
ge)
Fram
ew A
-Arm
ft (lubricant
ar shock
ck
brake free p
l
brake or
ar
ar Brake Fl
ge Check
eck for da
m
earing
mage
ressure)
ush, fasten
e
bricant.
ering Knuc
k
belt/weight
r
Clutch
n
ge
ATV 5
0
e Sche
d
, and rec
o
ATV at th
e
he hours
o
30
0
terval 20
hEngFue
ark)
C
/Steering/S
u
, Toe
ay
uid
age
r
le
T
ollers
/10
0
S
ule
rded mai
n
optimum
r kilomet
e
KM
r
ine mainten
a
A
dd 2 strok
R
I
l and air sy
s
lean or repl
a
(more of
t
I
spension/B
r
I
Replac
e
I
I
ransmissio
ervice
M
C
tenance d
condition
.
rs as a re
Every 3
M
1000 KM
60 hr
nce
e oil into oil
t
I
tem
ce if neces
s
en when in
w
I
I
I
I
ake/ Wheel
L
I/
L
I
I
whenever
w
I
I
I
I
I
L
n
I/
L
I
anua
l
hapter 2
ata period
The abo
v
erence w
h
on. Ev
20
0120
ank, when
o
ary for Eve
r
et or dusty
& Tires
orn to the li
Maintena
n
ically by y
o
e mainten
ichever c
o
ery 6 Mon.
00 KM
0 hr
il warning l
a
R
I
I
I
y 1000 KM
areas)
I
I
I
I
L
I/L
I
I
mited
I
I
I
I
I
L
I
I
I/L
I
-
1
ce Inform
a
ur SMC
ance
mes first.
Remark
s
mp is “on”
6-
tion
2
2
2
Co
d
Re
m
1.
Are
2.
Man
3.
C
4.
P
a
b
- C
A
the
ma
i
pro
d
6 *
7 *
8 *
e: I ~ I
n
C ~
c
*Sh
o
arks:
ir cleane
r
placemen
aintenan
c
d after th
e
heck batt
e
reventive
. Ignition
s
after-bur
n
. Carbon
d
system w
h
UTION:
T
time, or h
a
ntenance
uct warr
a
Dashboard/
s
Lights /elect
Front and r
e
spection
,
leaning
(
uld be p
e
needs to
t after ridi
n
e should
ATV ha
s
ry before
maintena
n
ystem: pe
r
or overh
e
eposit re
m
en powe
r
he user
m
ve SMC
d
of your ve
h
nty.
SMC
peedomete
r
rical equipm
ar brake sw
i
cleanin
g
replaced
rform an
d
be clean
g on (1)
d
be perfor
m
accumul
a
riding AT
V
ce
form mai
n
ating occ
u
oval: re
m
is obviou
s
ust perfor
ealer for
a
icle will l
e
ATV 5
0
El
e
nt
tch
, and adj
u
if necess
a
settle b
y
very 100
0
usty rain
d
ed more
ted a high
. Re-cha
r
tenance
a
rs.
ove carb
lower th
a
m the peri
o
periodic
m
ad to poo
r
/10
0
S
ectrical Syst
I
I
I
stment
ry)
local de
a
0 KM driv
e
ays (2) s
a
often if th
e
er mileag
e
ge battery
nd check
w
on deposi
n ever.
d check
&
aintena
n
perform
a
ervice
M
C
em
I
I
I
R ~ Repl
a
L ~ Lubri
c
ler or se
r
and req
u
nd area (
3
ATV is f
r
.
or replac
e
hen con
t
ts in cylin
d
service
a
ce progra
m
nce, brok
e
anua
l
hapter 2
cement
ation
vice stati
o
ires mor
e
) snow d
a
equently
o
a new b
a
inuous ab
n
er head,
nd keep t
h
. Failure
n of your
v
Maintena
n
I
I
I
n
frequentl
y
ys.
perated i
n
ttery, if it
n
normal ig
n
piston he
a
e service
to follow t
h
ehicle an
d
-
1
ce Inform
a
cleaning
high sp
e
ecessary.
ition, misf
i
ds, exha
u
records a
l
e periodi
c
out of
7-
tion
or
ed
re,
st
l
2-
.
W
G
a
of
2-
Fr
e
2-
03 Fuel
/
Check fu
e
any dete
r
leaking.
R
necessa
r
Check th
e
tank to th
damage,
replace
w
arning
soline is
a
fire is stri
c
04 Thro
t
Have a
w
handle in
back orig
Check h
a
Lubricat
e
smooth.
Check th
e
cable/oil
p
Replace
i
damage
d
Measure
flange p
a
a. Rem
o
and t
h
adjus
t
b. Tight
e
accel
e
e play: 4
05. Air
C
Remove
t
with full
s
Remove
3
cover an
d
Clean th
e
high-flas
h
for dry.
Replace
w
Oil Hos
e
l tank, fu
e
ioration, d
eplace it
w
y.
oil tank,
e oil pum
p
bend or o
i
ith new o
n
low igniti
o
tly prohibi
t
tle Cabl
ide open
o
any positi
inal (full C
ndle if its
o
the cable
throttle
c
ump cabl
t if deterio
.
the throttl
e
rt.
ve rubber
en adjust
ment scre
n the fixin
ration op
e
~6 mm.
leaner
he LH fo
o
ize type.
screws
f
then re
m
element
w
point sol
v
ith new
o
SMC
s
l cock, an
amage, b
e
ith new
o
oil hose b
e
if any de
t
l leaking.
C
e if nece
s
n materi
a
ed as de
a
e
f throttle
v
on and rel
losed) po
s
peration
i
if operati
o
able/carb
u
e if functi
o
rated, twi
s
lever fre
e
boot, loos
it by turni
n
w.
g nut, and
ration co
n
trest guar
d
rom the ai
ove the c
o
ith non-fl
a
ent and t
h
ne if nece
ATV 5
0
d fuel hos
e
nd or fuel
ne if
tween oil
erioration,
orrect it
a
sary.
l so any ki
ling it.
alve as
ease it to l
ition.
s smooth.
n is not
retor
n correctl
y
ted or
play in it
s
en fixing n
g the
check
dition.
(if equip
p
cleaner
ver.
mmable
o
en squee
z
ssary
/10
0
S
if
nd
nd
et
.
ut,
ed
e it
ervice
M
C
anua
l
hapter 2 Maintena
n
-
1
ce Inform
a
8-
tion
C
a
N
e
to
S
othethecle
2-
R
eabcd
S
p
ef.g
Ti
g
2-
C
a
1.
2.
S
p
18
ution
ver use g
a
clean the
e
ap the el
e
n squeez
e
element
s
aner cov
e
06. Spa
r
commen
d
. Remove
. Clean di
r
. Remove
. Measur
e
ark plug
g
. Carefull
y
plug to
a
Hold sp
a
spark pl
u
. Tighten
t
with plu
g
hten tor
q
07. Idle
S
ution
Inspectio
have to
b
engine th
adjusted.
Idle spee
be done
a
is enoug
h
running f
o
Warm up
Turn the
in) to
g
clockwis
e
Start the
screw un
t
ecified id
00 ± 100
r
soline or
lement.
ment into
it out. In
s
eat and t
h
r.
k Plug
ed spark
p
spark plu
g
t around t
spark plu
g
spark plu
ap 0.6 ~
0
bend gro
u
djust the
g
rk plug w
a
g by scre
w
he plug b
y
socket a
ft
ue: 2.0 k
g
peed A
n & adjust
m
e perform
e
at needed
d check a
n
fter engi
n
that oper
r 10 min
u
the engin
e
Idle adju
s
et highe
r
(Turn ou
t
engine an
d
il around
1
le speed:
pm
SMC
acid orga
n
cleaning
e
tall the el
e
en install
lug : NG
K
cap.
he spark
p
.
g gap.
.7 mm
nd electr
o
ap if nec
e
sher and
ing it.
turning 1
/
er install
e
-m / 20N
-
djustm
e
ent for i
d
d after all
adjustme
n
d adjust
m
e is being
ates engi
n
tes.)
.
t screw c
l
Idle sp
e
) to get lo
w
adjust th
,750~18
5
ATV 5
0
ized solv
e
ngine oil
a
ment ont
o
the air
- BPR7H
S
lug hole.
de of the
ssary.
nstall the
2 turn mo
d.
m
nt
le speed
parts in
t have b
e
ent have
t
warm up.
e from sto
ockwise (
t
ed. Cou
n
er Idle sp
e throttle
s
0 rpm.
/10
0
S
nt
nd
re
en
o
(It
p to
urn
nter
eed
top
ervice
M
C
anua
l
hapter 2 Maintena
n
Adjust Scr
e
-
1
ce Inform
a
w
9-
tion
2-
a.
b.
1.
2.
c.
In
s
ex
08. Driv
i
Inspect t
h
The st
a
A
djust th
e
Loose th
e
connecti
o
rear hub,
by turn t
h
After adj
u
four lock
Clean th
e
When t
h
it shoul
d
lubricat
e
Using c
o
lubricat
e
Clean t
h
wipe it
d
Inspect
t
or dam
a
Replac
e
or dam
a
pect the
d
cessive w
e
ng Chai
e chain sl
ndard is
1
chain sl
a
lock bolt
s
n betwee
n
then adju
s
e adjustin
g
st to the s
bolts.
Driving
C
e drive ch
be remo
v
d by spe
c
mmercial
the drive
e drive ch
ry.
he drive
c
ge.
the chain
ged.
rive spro
c
ar or da
m
SMC
n
ack.
0-25mm.
ck.
(4 pcs) o
rear swi
n
t the driv
e
nut.
uitable sla
hain
ain beco
m
ed, clean
e
ify lubrica
t
chain lub
r
chain.
ain with k
e
hain for p
o
, if it is wo
r
ket teeth,
age, repl
a
ATV 5
0
n the
g arm an
d
chain sla
k, tighten
es very di
d and
or.
icant to
rosene a
n
ssible we
a
n excessi
v
f it is
ce it.
/10
0
S
ck
the
rty,
d
ar
ely
L
ervice
M
C
Adju
ock bolt
anua
l
hapter 2
st bolt
Maintena
n
-
2
ce Inform
a
0-
tion
2-
a.
M
e
en
pl
a
b.
M
ethemm
c.
M
ethe
09 Brak
e
Inspect t
h
excessiv
e
Replace
o
asure the
d of the b
r
y is 15-2
5
Inspect t
h
front /rea
excessiv
e
or repair
asure the
end of th
.
Inspect t
h
excessiv
e
or repair
asure the
end of th
Syste
m
e front br
a
free play
r repair if
free play
o
ake lever.
mm.
e integrat
r drum br
a
play or o
t
if necessa
free play
o
e lever. T
h
e rear br
a
play or o
t
if necessa
free play
o
e pedal.
SMC
(drum
b
ke lever
a
or other d
necessar
y
f the bra
k
The stan
d
e brake (f
o
ke and co
her dama
ry.
f the rear
e standar
d
ke pedal
a
her dama
ry.
f the rear
ATV 5
0
rake)
nd cable
f
amage.
.
e lever at
ard of fre
e
ot pedal)
f
trol cabl
e
ge. Repla
c
brake lev
e
is 10-20
nd cable
f
ge. Repla
c
brake lev
e
/10
0
S
or
the
or
for
e
r at
or
e
r at
ervice
M
C
anua
l
hapter 2
Maintena
n
-
2
ce Inform
a
1-
tion
\
2-
T
h
ac
co
th
e
co
a.
M
a
co
b.
C
hreslim
ch
le
v
C
a
In
in
un
D
o
ha
wi
lno
c.
abcde
f.
d.
Ad
R
e
(r
e
10. Bra
k
e Disk br
a
ive the th
r
mbine bra
right han
ntrolled b
y
Brake
S
ke sure t
h
rrosion or
Brake
F
eck brak
e
ervoir. If t
it, add br
a
eck brake
el found.
ution
order to
m
horizontal
til handle
s
not oper
a
d been re
m
l spread o
n-compati
Air Ble
e
Operati
. Open th
e
sufficient
bleed/oil
c
. Open th
e
the calip
e
. Connect
a
valve.
. Loose th
e
. Use a va
c
bubble/oi
fluid bec
o
Closed t
h
caliper.
Added
B
d brake fl
u
commen
d
commend
e Syste
m
ke versio
n
ee caliper
king syste
m
dle bar si
d
cable to t
ystem
H
e brake h
o
leaking oil
luid
fluid level
he level is
ke fluid to
system fo
r
aintain br
a
position,
d
top.
te the bra
oved. Ot
h
ut if opera
t
ble brake
f
d / Bra
k
on
brake flui
d
brake flui
d
hange.
rubber c
a
r.
transpar
drain val
v
uum dra
w
l brake flu
i
me clear
(
e drain v
a
rake Fl
id to UP
P
ed brake
f
) brake flu
SMC
(Disk
B
, apply by
(front 2 a
n
. The br
a
e is parki
n
he rear ca
ose
ses cont
a
.
in the bra
lower tha
n
UPPER li
leaking if
ke fluid in
o not rem
o
ke lever a
f
erwise, t
h
e the lev
e
luid toget
h
e fluid
C
reservoi
r
while doi
p of draini
ent hose t
o
e.
er to drai
n
d, until no
new).
lve on fro
n
uid
ER limit l
e
luid: DOT
3
id.
ATV 5
0
rake)
foot peda
d rear 1)
a
ke lever
o
g brake
liper side.
in no
ke fluid
the LO
W
it. Also
low brak
e
the reser
v
ve the c
a
ter the ca
p
e brake fl
u
r. Do not
m
er.
hange
cap. Add
ng the air
ng valve
o
draining
out the a
air bubbl
e
t/rear dis
k
vel.
or DOT4
/10
0
S
l, to
s a
n
ER
oir
p
id
ix
the
n
ir
or
ervice
M
C
anua
l
hapter 2
Maintena
n
-
2
ce Inform
a
2-
tion
C
a
N
efrobra
e.
B
r
T
hlimRema
C
a
T
ofro
It i
re
p
B
r
M
a
th
e
li
m
C
a
D
o
ca
pi
s
ba
on
ution
ver mix o
r
m damagi
ke perfor
m
Parking
b
A
pply th
then pu
s
release
brake.
To rele
a
lever ag
release.
Check t
h
parking
adjust t
h
side.
ake Lini
e indent
m
itation.
place the
rk closed
ution
check fro
nt wheel f
i
s not nec
e
lacing th
e
ake Pa
d
ke sure t
h
lining pa
d
itation gr
o
ution
not oper
a
liper bein
g
ton. In or
d
lance, the
e set.
use dirty
ng brake
s
ance.
rake
e right ha
n
h down t
h
the lever t
o
se the pa
r
ain and st
o
e brake f
o
brake. Adj
e adjustin
ng Wea
r
ark on br
a
brake lini
n
to the ed
g
nt brake li
n
rst.
ssary to r
e
brake lini
s Repla
c
e brake li
n
s if the b
r
ove close
te the bra
removed
er to mai
n
brake pa
d
SMC
brake flui
d
ystem or
r
d brake l
e
e button
s
activate
king brak
e
pper will
j
rce when
ust the br
a
g bolt on t
h
ke lining i
g pad if th
e of brak
e
ing must
move bra
ng.
ement
ing condi
t
ake lining
to the bra
k
ke pedal
a
to avoid p
tain brak
e
s must be
ATV 5
0
to preven
educing
ver and h
o
topper an
d
he parkin
g
, apply th
e
ump up a
n
set up th
e
ke force
b
e rear cal
s the wea
r
e wear li
m
disc.
e remov
e
ke hose w
ion. Repl
a
wear
e disc.
fter the
shing ou
t
power
replaced
b
/10
0
S
t
ld,
d
y
iper
it
hen
ce
y
ervice
M
C
A
dju
anua
l
hapter 2
st bolt
Maintena
n
-
2
ce Inform
a
3-
tion
2-
T
h
as
M
aop
2-
R
u
o
p
If
t
ch
2-
W
D
oLo
m
a
F
r
R
e
11. Bra
k
Inhibit
o
e brake li
g
brake pe
d
ke sure t
h
erated onl
12. Clut
c
n the AT
V
ening gra
d
he ATV is
eck clutch
13. Sus
p
arning
not ride t
h
oseness,
w
ke poor s
t
ont sus
p
Press d
o
several
t
Check i
f
bound
&
Replac
e
Tighten
ar sus
p
Press d
o
several
t
Check i
f
bound
&
Replac
e
e Light
S
r Switc
ht switch
i
al applied
at electri
c
y under b
r
h Wear
and incr
e
ually to c
h
in forwar
d
condition.
ension
e ATV wi
t
ear or d
a
ability an
d
ension
wn the fr
o
imes to c
h
it is dam
a
rebound)
relative p
all nuts a
n
ension
wn the re
imes to c
h
it is dam
a
rebound)
relative p
SMC
witch/
S
h
s to light
u
.
al starter
c
ake applyi
ase throttl
eck clutc
h
moving a
Replace i
h poor su
s
mage sus
drive-abi
l
nt suspe
n
eck its o
p
ged (oil le
arts if da
m
d bolts.
ar suspen
s
eck its o
p
ged (oil le
arts if da
m
ATV 5
0
tarting
p brake li
g
an be
ng.
e valve
operatio
n
d shakin
g
if need.
pension.
ension w
ity.
sion for
eration.
aking / ba
d
age foun
d
ion for
eration.
aking / ba
d
age foun
d
/10
0
S
ht
.
,
ill
.
.
ervice
M
C
anua
l
hapter 2
Adju
Maintena
n
st bolt
-
2
ce Inform
a
4-
tion
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