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

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a

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Fu

e

Ch

a

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Bra

k

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k

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B

R.

B

Tir

e

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n

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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

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(

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

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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

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pCom

Lub
Car
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a

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r

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tGen

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Bra

k

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n

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a

Re

a

Fla

s

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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

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a

5. Tool

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torque v

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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

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1.0

3.0

1.0

4.2

1.6

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-

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

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Tie

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g

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n

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Chassis

P

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m

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nt Shock

a

nt Arm (U

p

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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

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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

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(IN)
(EX)

me)

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0

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e bar

er)

2142244

2828411144411

1

4

1

2

2

2

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0

Se

’ty

Thr

e

(

1

1

1
1

1
1
1

1

0

810101010101014

1

0

1

410080810140810081028

2

810

1

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0

808

rvice

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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

2-

C

a

C

h

int
ba
Li

fTu

ch

2-

C

a

Ti

r

rid
C

h

or

A

p

12

C

hnoMe

su
R

e

Fr

oRe

2-

P

ethe

all
se

C

h

an

14. Stee

ution

eck all wi

r

erfered wi

t

r.

the front

rn handle

eck if turni

15. Whe

ution

e pressur

e

ing.

eck if tire

other mat

e

pointed t

psi (Off-r

o

eck if fron

rmal.

asure tire

rface.

place the

nt tire: 1

ar tire: 2.

0

16. Nut

s

rform peri

o

Periodic

a

bolts and

curely.

eck all fixi

d wire hol

d

ring Ha

n

es and ca

h the rota

t

wheel out

from right
ng is smo

o

el/Tire

check s

h

surface is

rials.

ire press

u

ad reco

m

t and rear

thread de

tire if the

d

.5 mm

mm

, Bolts T

dical mai

l Mainten

a

nuts on th

ng pins, s

n

ers for s

e

SMC

dle

bles if the

y

ion of ste

e

of ground

.

to left alte

thly.

ould be d

o

ticked wit

h

re:

mended)

tires’ pres

pth from ti

epth is s

m

ightnes

s

ntenance

i

nce Sch

e

e frame a

r

ap rings,

curity.

ATV 5

0

are

ring hand

native an

d

ne before

nails, sto

sure is in
re central

aller than

n accord

w

dule. Che

c

e tightene

d

hose cla

m

/10

0

S

le

nes

:

ith

k if

d

p,

ervice

M

C

anua

l

hapter 2 Maintena

n

-

2

ce Inform

a

5-

tion

2-

a.
b.
c.

d.

e.
f.

T

o

g.

T

o

2.

G

eTh

en
U

n

oil
T

h

be

C

aSA

17 Toe-i

Let the

v

front wh
Mark th

e

the axle
Measur

e

Carefull

y

wheels

h

on the ti
center h
Measur

e

Calcula

t

rear me

a

e-in: 5±1

0

If the to

e

changin

g

by turni

n

j

oint. Ti

g

rque: 35-

4

18 GEA

R

ar oil nee

d

ere is a g

e

gine.

screw thi

s

flow out.

e re-add

o

side gear

b

pacity of

E #40, 0.

1

n

ehicle on

eels facin

g

centers

o

center he

i

the dista

n

move th

e

ave turn

e

res are ali

g

eight.

the dista

n

e the diffe

suremen

t

mm

-in is out

o

the leng

t

g the tie-

r

hten the l

o

3 N.m

OIL

s to be c

h

ar oil rele

a

release

b

il hole is

o

ox.

Gear Oil

:

2L

SMC

level grou

straight

a

f the tires

ght.

ce betwe

vehicle

b

d 180 °, s

o

ned with
ce betwe

rence in t

h

s.

f standar

d

h of the ti

e

od while h

ck nuts.

anged ev

e

se bolt a

t

olt and ca

n the engi

ATV 5

0

d and th

e

head.
to indicat

e

en the ma

ack, let th

e

the mar

k

he axle
en the ma

e front an

d

, adjust it

-rods equ

olding the

ry year.

the rear

o

let the di

ne case

/10

0

S

rks.

s

rks.

by
ally
ball

f

rty

ervice

M

C

Oi

anua

l

hapter 2

l filler cap

Maintena

n

Drain bol

t

-

2

ce Inform

a

6-

tion

Note:

SMC

ATV 50/10

0

S

ervice

M

C

anua

l

hapter 2 Maintena

n

-

2

ce Inform

a

7-

tion

3-

03-03-0

3-

0

Ge




Sp

To

r

En

gExhExh

Ex

h

1. Prec

a

2. Rem

o

3. Engi

n

1. Prec

a

neral In

f

The engi

n

The follo

w

Carburet

o

Drive pul

l

Start mot

A

C. Gen

e

AIR clea

cificati

o

que

ine hang

e

aust Pipe
aust muffl

aust muffl

Engin

e

utions i

n

val of E

n

e Instal

l

utions i

n

ormatio

n

e has to b

e

ing parts c

a

ey, drive b

e

or.

rator, oil p

u

ner

n

r bolt
mounting

er mounti

n

er connec

t

oil capacit

y

SM

C

Opera

t

gine

ation

Opera

t

supported

n be servi

c

lt, clutch,

a

mp and st

bolt

g bolt

ion nut

Ite

m

ATV 5

0

ion

ion

with speci

a

ed as eng

i

nd movabl

rt one-wa

y

4.5 k

g

0.9 kg

2.6 k

g

1.2 k

g

R2T

/10

0

S

l service t

o

ine being

m

e drive fac

e

clutch.

-m/ 45N

m

-m/ 9Nm

-m/ 26N

m

-m/ 12N

m

eplacemen

t

Gear Oil

T engine oil

ervice

M

28
29
35

ols that ca

n

ounted on

assembly

anua

l

Chapt

e

be lifted

o

frame:

er 3 Engin

r adjustabl

e

Capacit

y

49.3 c.c.
120 c.c.

1.1L

-

2

e Remova

l

.

8 -

3-

0

En

gnec

tra

n

a.

R






b.

R





c.

R




d.

R




2. Engi

n

ine shall

b

essary re

p

smission

a

emove t

h

Shift the

s

below th

e

Remove
Remove

emove t

h

Remove

Firstly r

e

them re

m

terminal

.

Remove
rear fend

emove t

h

Remove
side of th
Remove

emove t

h

Remove
cleaner

c

Remove
rear fend
fender st

a

fender.

e Remo

v

e remove
air or adj

u

nd comb

u

e seat, r

e

eat open

seat to r

e

the seat
the rear c

a

e battery

the batter

y

move ne

g

ove the

b

.
the cord a
er throug

h

e R and

L

the 6 tapp

e side co

v

the R and

e air cle

a

4 pan hea

d

ap, and r

e

the 10 pa

n

er side (u

n

y side) a

n

.

SM

C

al

d in the c

o

stment in

stion sys

t

ar carrier

lever on t

h

lease the

rrier if an

y

and batt

e

cord.

ative term

attery po

s

nd fuse c

a

the side

h

side of

s

ing screw

s

er

L side co

v

ner cap

&

screws

o

move the

head scr

e

der the s

e

d remove

ATV 5

0

nditions o

f

the

em only.

e rear sid

seat catc

h

.

ry fuse.

inal (-) an

d

itive (+)
se out fro

m

ole.

ide cover

at R and

er.

rear fen

d

n the air

cap

ws on th

e

at side an
the rear

/10

0

S

e

.

L

er

d

ervice

M

SCR

E

anua

l

Chapt

e

WS

er 3 Engin

CLE A N E R C

A

-

2

e Remova

l

SE CAP

9 -

e.

Rcov







f. s

c

sid

e



g.

Rcab

h.

R




emove R

er

Screw o

u

mudguar

d

footrest

m

Remove
stay and
stay.

Remove
footrest

b

bar from

rew out

t

, remov

e

Remove
tapping

s

cooling s

emove o

le assy)

a

emove t

h

Remove
Pull out t

h

& L footr

e

t 3 bolts o

cover, a

n

udguard

c

out 3 bolt

s

then rem

o

2 bolts ea

c

ar, and th

e

frame.

he air co

o

(open) t

h

the 2 pan

crew, and

hroud

ut the oil

p

nd oil ho

s

e cylind

e

the deflec

t

e cylinde

r

SM

C

st stay

a

n each R

a

d then re

m

over

each R a

n

ve out the

h on R a

n

n remov

e

ling shr

o

e air shr

o

head scre

w

then rem

o

ump ca

b

e from o

r air shro

u

or

air shrou

d

ATV 5

0

nd mudg

u

nd L foot

r

ove out

t

d L mudg

mudguar

d

d L side

o

the footr

e

ud at rig

h

ud.

s and on

e

ve the air

le (throttl

l pump.

d

/10

0

S

ard

est

he

uard

f

st

t

e

e

ervice

M

SCR

E

anua

l

Chapt

e

W, TAPPI N

G

THROTTLE

C

er 3 Engin

ABLE

AIR SHRO U

D

-

3

e Remova

l

0 -

i. r

e




j. r

e




k.

R



Tig

Ex

h



Tig

Mu

f



l. r

e




move th

e

Screw o

u

Remove

move th

e

Remove
Remove

emove t

h

Remove
exhaust

s

hten torq

u

aust pipe

Remove
engine c

a

rear fram

hten torq

u

fler tighte

n

Remove

move th

e

Screw o

u

fixing pla

t

Remove

t

sprocket.

exhaust

t 2 fixing

s

the exhau

s

stop swi

t

the stop s

w

the stop s

w

e exhaus

out 2 flan

g

ide.

e:

tighten bo

the 2 han

g

se (conn

e

e side.

e:

bolt: : 2.

6

out the ex

h

drive ch

a

t the bolts

e

the sproc

k

SM

C

pipe prot

e

crew

t protect

o

ch & spr

i

itch spri

n

itch

t muffler

a

e nuts on

lt: : 0.9kg-

ing flang

e

cting with

kg-m/ 26

N

aust muf

f

in

on the dri

et and dri

v

ATV 5

0

ctor.

ng

g

ssy

the cylind

e

m/ 9Nm

bolts on t

bracket)

a

m

ler assy.

e sprock

e

ing chain

/10

0

S

r

he

nd

t

from

ervice

M

SPRING,

S

BOLTS

anua

l

Chapt

e

TOP SWITCH

er 3 Engin

PLATE W AS

H

PLATE W AS

H

SWITCH AS

BOLTS

GASKET,

PLATE, FIXI

N

-

3

e Remova

l

ER

ER

S'Y, R EAR STO

P

XHAUST P IP

E

G

1 -

m.

d

coi

l



n.

R

car





Tig

Ca

r




o.

D

wir

e





p.

D

e

Tig

Sp

e

isconne

c

)

Remove
cap) fro

m

emove c

a

buretor

Switch th
pan und

e

carburet

o

drain out
remove t

h

careful n

o

Remove
carburet

o

hten torq

u

buretor to

p

Remove

t

Disconn

e

wire har

n

isconne

c

harnes

s

Disconn

e

harness.
Disconn

e

wire har

n

Disconn

e

isconne

c

ngine ca

s

 Loo

s

LH

c

 Pull

o

hten torq

u

edometer

t the spa

out the ig

n

cylinder

h

bles and

e fuel coc

k

the carb

u

r fuel drai

n

the fuel.

A

e fuel ho

s

t to spill

o

the throttl

e

e:

cap bolt:

he oil pu

m

ct the aut

o

ess.

t the ele

c

.

ct the sta

r

ct the A.

C

ess

ct the sta

r

t the spe

e

e.

en the fixi

rankcase.

ut the sp

e

e:

cable bol

t

SM

C

rk plug c

a

ition coil (

s

ead

fuel/oil h

o

to off po

s

retor, loo

s

bolt at b

o

fter fuel b

e

e on the

c

ut the fuel

cable fro

m

: 0.2 kg-

m

p hose/ a

i

-by start

e

trical cou

t motor co
. Generat

o

t motor wi

r

dometer

ng bolt on

edomete

r

: : 1.1kg-

m

ATV 5

0

p (ignitio

park plug

se from

ition, put

a

e the

ttom side

ing drain

arburetor.

.

top of

/ 2Nm

r breathe

h

r coupler

f

plers fro

m

upler from

r coupler

f

e coupler

.

cable fro

m

the rear u

cable.

/11Nm

/10

0

S

n

to
out,
Be

ose

rom

wire

from

p of

ervice

M

S

anua

l

Chapt

e

PROC KET DR

I

er 3 Engin

V

E

-

3

e Remova

l

2 -

q.

Reng




r. r

e




s. r





Tig

Air

emove t

h

ine case.

Remove
the engi

n

Disconn

e

cable fro

m

move th

e

Disconn

e

Remove

emove th

e

Remove

t

case sid

e

Loosen t

h

carburet

o

Pull and

r

hten torq

u

cleaner b

o

e gear s

h

cotter pin

f

e case.

ct the re

m

engine

h

engine

ct the en

g

out the en

air clea

n

the 2 fixin

g

e air clea

emove th

e

e:

lt: 0.9kg-

m

SM

C

ifting lev

e

rom the s

h

ove the g

e

older

ine hange

gine from

t

er

screw o

n

ner air du

c

air clean

/ 9Nm

ATV 5

0

r from

ifting lev

e

ar shiftin

g

r bolts

he left sid

the LH e

n

t clamp fr

o

er assy.

/10

0

S

r on

e.

gine

m

B

O

ervice

M

LT

anua

l

Chapt

e

BOLT

er 3 Engin

-

3

e Remova

l

BOLT

3 -

t.

R




u.

R




Tig

AIR

v.

R




Tig

Sta

emove th

Remove
intake an
Remove

emove t

h

Remove
Remove
gasket.

hten torq

u

intake /R

e

emove t

h

Remove
Disconn

e

only) an

d

hten torq

u

rt Motor b

o

e carbure

the clamp

d carbure

t

the carbu

r

e intake

p

the 4 soc

k

the intake

,

e:

ed valve

e start m

o

the 2 fixin

g

ct the ear

t

remove

o

e:

lt: 1.3kg-

m

SM

C

tor

in connec

t

or

etor.

ipe and

r

et bolts

reed valv

bolt: 1.1k

g

tor

bolts

h cord (1

0

ut the sta

r

/13Nm

ATV 5

0

ing betwe

eed valv

e

e assy an

d

-m/11Nm

0CC mod

e

t motor.

/10

0

S

en

l

B

O

ervice

M

SO

R

LTS

C

anua

l

Chapt

e

CKET BOLT

EED VALVE

A

ORD COMP

er 3 Engin

SSEMBL

Y

GASKET

-

3

e Remova

l

4 -

5-

0

Ch

edam

Ins

trem

Ca

u






3. Engi

n

ck the bu

s

age.

all the en

g

oval.

tion

Be caref

u

engine.
Do not b

e

Cables

w

accorda

n

e Instal

l

h of engi

n

ine in the

l when re

m

nd or twi

s

ires have

t

ce with n

o

SM

C

ation

e hanger

reverse p

r

oving an

t the wire

s

o be rout

e

rmal layo

u

ATV 5

0

parts for

a

ocedures

installin

g

and tube

s

d in

t.

/10

0

S

ny

of

the

.

ervice Manua

l

Chapt

e

er 3 Engin

-

3

e Remova

l

5 -

N

O

TE:

SMC ATV 50/10

0

S

ervice Manua

l

Chapteer 3 Engin

-

3

e Remova

l

6 -

4-

04-04-04-04-04-04-0

4-

0

1. Mech

a

2. Prec

a

3. Trou

b

4. FUEL

5. Carb

u

6. Intak

e

7. Air C

l

1. Mec

h

anism D

utions i

n

le Shoo

TANK

retor
, Reed

V

eaner

anism

D

S

M

iagram

Opera

t

ting

alve

iagram

C AT

V

5

ion

/100S

e

rvice

M

3

3

3

4

0

4

4

4

anua

l

Chapt

e

7

8
9

0
2
3

er 4 Fuel

S

-

3

ystem

7 -

4-

0

A.

W

a

Ga

sand

Ca






B.

C

a

I.

D

M

a

Idl
Idl
T

h

Pil

C.

TSpe

Vac

Fu

e

2. Prec

a

General

rning

oline is a

strictly pr

o

utions

Do not b

e

When di

s

after re-

a

There is

a

Specific

rburetor d
. number
in injecto

r

e injector
e speed

rottle han

d

ot screw

ool

cial serv

i

uum/air

p

l level ga

utions i

n

Informa

t

low ignitio

hibit flam

nd off thr

o

assembli

n

ssembly

drain sc

r

ation

ITEM

iameter

le clearan

ce tools

ressure

p

uge

S

M

Opera

t

ion

n point an

d

e when w

o

ttle cable

.

g fuel sys

t

ew in the

f

ce

ump

C AT

V

5

ion

explosiv

e

rking with

Damage

d

em parts,
loat cham

/100S

e

material

s

gasoline.

throttle c

a

pay atten

t

ber for dr

a

rvice

M

, so alwa

y

ble will

m

ion to O-ri

ining resi

d

MIKUN

I

Ø18

m

VM

1#65#17

1800 ±

1

1~3

m

1 1/2

t

anua

l

Chapt

e

s work in

a

ake unsta

g positio

n

ual gasoli

n

VM16

m

6

.5

00rpm

m

urns

er 4 Fuel

S

a well-ven

ble drivab

i

, replace

w

ne.

-

3

ystem

tilated pla

c

lity.

ith new

o

8 -

e

ne

4-

0

Po







En








Le

a







Ri

c






Int

e



3. Trou

b

or engi

n

No fuel i

n

Clogged

f

Too muc

h

No spark
Clogged

gine idl

e

Improper
Ignition

m

Fuel/air

m

Air clean

e

Insulatio

n

Fuel tan

k

n Mixtu

Fuel jet

o

Fuel tan

k

Fuel flow
Float lev

e

Vacuum

h Mixtu

r

Float ne

e

Float lev

e

Air duct i

n

Air clean

e

rmitten

Malfuncti

le Shoo

e start

fuel tank

fuel tube

fuel in c

y

from spa

r

air cleane

r

s unste

a

adjustme

n

alfunctio

n

ixture rat

i

r dirty

leakage

cap brea

t

re

f carburet

o

cap brea

t

s in the tu

b

l in carbu

r

piston stic

k

e

dle valve

i

l too high

carburet

o

r elemen

t

tly misfi

on of ignit

i

S

M

ting

linder

k plug(ma

l

dy, stal

t to the

o not goo

d

hing hole

c

r clogged

hing hole

c

e unsmo

o

etor too l

o

and clos

e

n carbure

t

r is clogg

dirty

re as ac

c

on syste

m

C AT

V

5

function o

f

l or run

s

idle speed

logged

logged

th.

w.

d

or faulty

ed

elerati

o

/100S

e

f ignition

s

poorly

screw

n

rvice

M

ystem )

anua

l

Chapteer 4 Fuel

S

-

3

ystem

9 -

4.

4

a.










(for
ch

a

No

tspa

Wi

p

b.

c.

4-

0

a.

1.

R Rle L

r

2.

D

w

3.

L

c

Not

e

(bel

FUEL T

A

REMOVA

L

Remove
Remove
Turn the
Disconn

e

carburet

o

Remove
Remove
Unscrew

detail re

m

pter for e

a

e: Keep

rks.

e up spill

e

Fuel tank

/

need to r

e

 Chec

k

leaki

n

 Chec

k

on th

e

surfa

c

 Chec

k

crack
fuel c

o

Installati

o

Follow th

e

5. Carb

u

REMOVA

L

emove th

e

emove th

e

ft crankca

s

oosen the

a

move the

isconnect

t

ire.

oosen the

arburetor.

: Turn off

t

ow fuel tan

NK

the seat a

n

the side c

o

fuel cock

s

ct the

r.
the front p
the fuel ta

n

the fuel t

a

oving ste

p

ch mentio

gasoline

d gasolin

e

fuel coc

k

move th

e

the fuel t

g or dam

a

the fuel

c

body sid

e

e, seal d

a

the fuel

h

or fuel lea

ck and c

a

n

reverse

w

retor

air cleane

r

2 air clea

n

e.

air duct cla

m

air cleaner

he fuel lin

e

intake cla

m

he fuel pip

e

k) to “off” p

o

S

M

d rear fe

n

vers

witch to

O

fuel lin

e

anel, han

d

k cap an

d

nk fixed 4

, please

r

ned fram

e

away fro

at once.

/hose Ins

p

fuel tan

k

ank if any

ge.
ock, if an

y

, fuel tan

k

mage.

ose, if an

y

king, and

t

rburetor.

ay of rem

o

.
er mountin

p on carb

and auto-

c

p and rem

o

by turn th

sition.

C AT

V

5

der.

FF positi

o

from

le bar.

front fen

d

bolts.
efer to fur

t

parts)
m flame

s

ection(n

o

and cov

e

cracks,, f

u

fuel leaki
contact

bended,

ighten we

l

val.

bolt on th

uretor and

hoke elect
ve out the

fuel cup

/100S

e

n

the

er.

ther

or

rs)

el

ng

l on

e

ric

rvice Manua

l

Chapteer 4 Fuel

S

-

4

ystem

0 -

bly of Ca

r

r cap/ th

r

the throttl

e

le depres

s

the needl

e

jet needl

e

e throttle
r wear, s

c

needle c

l

jet needl

e

the throt

t

lve.

throttle v

a

just

d install t

h

r.

mber/adj

u

the floa

t

e float ch
bly the f
le valve.
bly the p

bly the i

air screw.

ll the jets

l based s

o

pressed a

i

e seat of

t

amage.

carbureto

r

ce betwe

e

ithout th

e

float.

ght :15.0

S

M

buretor

c

ottle valv

e

cable fro

m

ing the th

r

clip retai

n

and nee

d

valve and

ratches o

r

ip on the j

e

into the

t

le cable,

s

lve groov

e

e carbure

t

st screw

s

chambe

r

amber co

v

loat arm

p

ilot jet, m

a

dle speed

and scre

w

lvent and
with co

m

he float n

e

upside d

o

n the pla

n

gasket)

a

mm ~ 17.

0

C AT

V

5

ompone

n

/jet need

the thro

t

ottle valv

e

er (or spri
le clip.

jet needle

dirt.

t needle.

hrottle val

v

pring and

with the

or cap to

t

screws

er.

in, float

in jet, ne

e

adjust s

c

s for we

a

clean the

pressed

a

edle valv

e

wn, mea

s

e of the

b

nd the u

p

mm

/100S

e

ts

le.

tle

ng

e.

the

idle
he

and
and

dle

rew

r or
jets

ir.

for
ure

owl

per

rvice Manua

l

Chapteer 4 Fuel

S

-

4

ystem

1 -

parts in s

o

compre

s

ly the rev

e

bly.

r cover

b

2 Nm

able free

nt of Idle

meter wh

e

le speed a

d

standard t

u

: 1800 ± 1

e(Auto-b

ter plung

e

e other si

d

a 3.3 m

m

and blow

i

rter plun

g

ke unit.

I

the auto c

h

r five min

u

a 3.3 m

m

and blow
pens, rep

l

plunger cl

o

n of carb

u

y of remo

v

, Reed

V

the 4 soc

k

the air int

a

kcase.

S

M

lvent and

sed air. A

s

rse order

o

olt torqu

e

play adju

s

Speed

n adjustin

g

justing scr

e

rns.

00 rpm

y starter)

r is open,

e of the

s

hose to

nto the h

o

er open

s

f closed,

oke unit l

tes.

hose to

into the

h

ace the a

u

ses, auto

retor

al.

alve

et bolts o

n

ke and r

e

C AT

V

5

blow it dr

y

sembly is

f

:

tment (2

engine R

P

w gently,

t

air should
tarter air

he starte

r

se.

, replace

perform

s

eads to a

he starte

r

ose. If st

a

to choke

u

choke is

o

the air in

t

ed valve

a

/100S

e

~ 5

M.

hen

air

the
tep

12V

air

rter

nit.

k.

ake

ssy

rvice

M

SOC

K

anua

l

Chapt

e

ET BOLT

er 4 Fuel

S

-

4

ystem

2 -

stopper h

e

of specifi

c

the valve

nce of re

e

m. if out

lve.

y of remo

v

rque: 1.1

aner

l

the 2 air c

l

clamp on

nnect fro

m

3 screws

o

ve the air

the air cle

a

air cle

a

element

g

e excess

ry. Do no

t

ezing it.
element.

e motor

o

ould be w

e

he eleme

r access.

oline or

a

ent.

on

in the reve

olt torqu

e

S

M

ight shou

l

ation, adj

u

d valve

s

of specifi

c

al.

mgf • kg

/

eaner fixi

n

the air an

d

carburet

n the air

c

cleaner c

o

ner elem

e

ner ele

m

ently but

solvent

o

twist the

If damage

d

il to the

e

t but not

d

nt assem

b

cid organi

z

rse order o

f

: 0.9 mgf

C AT

V

5

d be 6.0 ~

st the sto

p

hould be

l

ation, rep

l

11 Nm

g bolts ,

breathe

t

or.

leaner co

v

ver

nt

ent

thoroughl

y

ut of the

f

filter ele

m

, replace

lement w

h

ripping.

ly and p

ed solve

n

removal.

• kg/ 9 N

m

/100S

e

6.4
per

less

ace

ube

er,

in

ilter

ent

it.

ich

arts

t to

rvice Manua

l

Chapteer 4 Fuel

S

-

4

ystem

3 -

N

o

tes:

S

M

C AT

V

5

/100Service Manua

l

Chapteer 4 Fuel

S

-

4

ystem

4 -

5-

05-05-05-05-05-05-0

5-

0

Th

ePum

cra

n

Th

e

1. Mech

a

2. Prec

a

3. Trou

b

4. Oil T

a

5. Oil g

a

6. Oil p

u

7. Air c

o

1. Mec

h

engine c

r

p gears

r

kcase to

oil drops

anism D

utions i

n

le Shoo
nk
uge

mp

oling S

y

anism

D

ankshaft

d

otate the

p

mix with t

h

and foam

SMC

iagram

Opera

t

ting

stem

iagram

rives the

p

lunger sh

a

e mixture

cover the

c

ATV5

0

ion

ump gea

r

ft in oil p

u

of air-fuel

ylinder in

/10

0

S

s of oil pu

mp. This

s

flow evenl

ner wall,

p

ervice

M

45
46
46

47

47

47

48

p.

haft sent
y.
iston surf

a

anua

l

Chapte

r

he lubric

a

ce and pi

s

5 Oil lub

r

ting oil int

o

ton rings.

-

4

icant Syst

e

the

5 -

m

5-

0

Ha

v

will
en

g

Also

5-

0

NO







OI

L






2. Prec

a

ing enou

g

be seriou

s

ine is seri

o

you nee

d

3. Trou

b

ENOUG

H

The oil le
Oil tube

w

Oil has l

e

Oil tube

w

Oil tube

w

PUMP C

A

Always i

n

External

o

Worn cyl

i

Worn pis

t

utions i

n

h oil supp

scratche

d

us scratc

to check

le Shoo

OIL SUP

vel in oil t

a

as not fix

akage fro

m

as broke

n

as clogg

e

NNOT

W

sufficient

il leaks i

n

nder hea

d

on rings

SMC

Opera

t

ly to engin

, and the

n

hed, you

n

the comb

u

ting

PLY TO E

nk is too l

ed well.

tube en

d

.

d. (Air bu

b

ORK.

oil level.

lubricant
gasket

ATV5

0

ion

e is very i

m

this engi

n

eed to ch

a

stion syst

NGINE

ow.

s.
ble, forei

g

oil tank.

/10

0

S

portant.

I

e will sto

p

nge the

p

em and lu

n materia

ervice

M

f the oil q

u

, even ca
iston, pist

o

rication s

l…)

anua

l

Chapte

r

antity is n

o

not work

n rings a

n

stem car

e

5 Oil lub

r

ot enough

again. W

h

d cylinde

r

fully.

-

4

icant Syst

e

, this engi

n

en this

together.

6 -

m

e

5.

0

a.







b.

c.

5-

0



Csp

u



R

5-

0

Th

e

inc

r

car

b

the
co

n

a.

b.

4 Oil Ta

n

Removal

Remove
tank, rig

h

shroud. (
Disconn

e

Disconn

e

Screw o
remove.

Oil tank/

h

 Chec

k

or da

m

 Chec

k

or fu

e

tighte
the oi

l

Installati

o

Follow th

e

5. Oil g

a

heck the f

u

peedomet

e

osition an

d

pper positi

o

eplace wit

h

6. Oil p

u

quantity

o

eased by

t

uretor th

r

right side

trol cable

o

Removal

 Rem

o

and o

 Rem

o

 Rem

o

out th

Inspectio

n

pump fro

m

 Rem

o

 Disco

side.

.

 Push

crank

s

k

the front t

o

t side of fl

Refer to c

h

ct the cou
ct the oil

h

ut two b

o

ose Insp

e

the oil ta

n

age.

the oil h

o

l leaking,

c

n well. Av

o

l hose.

n

reverse

w

uge ins

p

nction of

o

turn on

w

off when

o

n.
new if ou

t

mp

f oil that

d

he engin

e

ottle open
of the eng

f throttle.

ve the cla

il out hos

e

ve the thr

o

ve the sc

r

e oil pum

p

(no nee

d

crankc

a

ve the sp

a

nnect the

o

the electri

c

haft.

SMC

p cover,

f

oor panel,

apter 3 &

pler of oil

g

ose from

o

lts on th

e

ction

k if any c

r

se, if any

logged a

n

id any air

ay of rem

o

ection

il gauge, if
hen oil ga

u

il gauge s

e

of functio

n

eliver out
speed an
width. Oil

ine and c

o

mps on th

e

at oil pu

m

ttle cable

ew of oil

p

.

to remo

v

se)

rk plug c

a

il hose o

n

al start t

o

ATV5

0

ront fend

e

engine c

o

?)

auge.

il pump.

oil tan

k

acks, lea

k

bended, c

r

d if being

bubble in

s

val.

oil lamp on

ge at low
nsor shift t

o

.

from oil p

u

d the

pump is u
nnected b

oil in ho

s

p side.
from oil p

u

ump and

p

e the oil

p.

the carb

u

crank the

/10

0

S

r fuel

oling

and

ing
ack

ide

mp

nder

y a

e

mp.

ull

retor

ervice Manua

l

Chapte

r

5 Oil lub

r

-

4

icant Syst

e

7 -

m

c.

5-

0

Th

ecoo

is f

ohea

So,
Ma

k

shr

o

fun

c

 Chec

k

come

s

syste

m

Repl

a

Installatio

n

 Instal

l

crank

c

Make

 Conn

e

sure t
hose.

 Conn

e

 Apply

crank
come

s

 Conn

e

 Conn

e

plug

o

7 Air co

engine-c

o

ling fan is

rced to fl

o

d by air c

o

the cylind

e sure th

e

ud/cylind

e

tion well.

if the oil

b

out, ple

a

if air bu

b

ce with n

e

.

the oil pu

ase and

t

sure the

g

ct the oil

h

here is no

ct the oil

o

the electr

i

the oil pu

m

out by oi
ct the oil

o

ct the sp

a

n cylinde

r

oling sy

s

oling fan

on the rig

h

w through

oling shr

o

er and pis

t

air cooli

n

r air shro

u

SMC

eing pum

se check

t

ble or clo

g

w oil pum

p

mp onto t

h

ighten the

ears are

e

ose from

air bubbl

e

ut hose.

cal starte

r

p and co

l pump. (a

ut hose t

o

rk plug c

a

head.

tem.

sucks the

t side of

e

cylinder fi

ud and cy
on will no

t

g fan/ air

c

d are wel

ATV5

0

p out. If n

o

he oil flo

w

ged insid

e

if neces

s

e engine

fixing scr

e

ngaged

w

oil tank.

M

on the oil

/throttle t

o

nfirm the

o

ir bleedin

g

carburet

o

p to spar

k

air. The

ngine. Th

e

n and cyli

n

linder shr

o

over hea

t

ooling

l install an

/10

0

S

t oil

e.

ary.

w.

ell.

ake

il

)

r.

air

der

ud.

.

d

ervice Manua

l

Chapter 5 Oil lub

r

-

4

icant Syst

e

8 -

m

N

o

tes:

SMC

ATV50/10

0

S

ervice Manua

l

Chapter 5 Oil lub

r

-

4

icant Syst

e

9 -

m

6-

06-06-06-06-06-0

6-

0

1. Mech

a

2. Prec

a

3. Trou

b

4. Cylin

d

5. Parts

6. Cylin

d

1. Mec

h

anism D

utions i

n

leshoot

er / Pis

t

inspect

i

er/Pist

o

anism

D

SM

C

iagram

Opera

t

ing

on/ Rin

g

on

n/Ring

i

iagram

ATV5

0

ion

s Rem

o

nstallati

/10

0

S

val

on

ervice

M

anua

l

Chapt

e

50
51
51
52
54
56

er 6 Cylin

d

-

5

er Head/

V

0 -

alves

6-

0

G

e

●

C

Ppis

Ppis

T

o

C

y

Ex
Sp

6-

0

Lo

w





Hi

g



Ex

c




Ex

c





Ov

e






2. Prec

a

neral I

n

This chap

t

piston/pis

ylinder

iston &

ton ring

C

iston &
ton ping

Clearanc

e

rque V

a

linder head

haust pipe

s

ark plug

3. Troub

Compr

e

Cylinder
Cylinder
Cylinder

o

h compr

e

Excessiv

e

essive n

o

Piston a

n

Excessiv

e

ess smo

k

Cylinder

o

Improper
Piston or

rheating

Excessiv

e

Engine c

o

Oil suppl

y

Wrong ig

utions i

formati

o

er is cont

a

ton ring/pi

s

C

learance

b

and

Clearanc

e

pi

Clearanc

e

between

p

lue

Nut

tud bolt

leshoot

i

ssion

head gas

k

head war

p

r piston r

i

ssion

carbon

b

ise

d cylinder

carbon

b

e

r piston r

i

installatio

cylinder

w

carbon

b

oling sys

t

is out of

nition timi

n

SM

C

n Opera

n

ined main

ton pin a

n

Item

ID of Cylin

d

Cylind

e

Circular

d

ylinder hea

d

etween pis

t

ring groove

of the mo

u

ston ring

OD of

p

between

p

OD of pis

iston pin h

o

ng

et leaking

ed or cra

c

ngs worn

uild-up o

n

worn out

uild up

ngs worn

n of pisto

n

all scored

uild-up o

n

em (fan,

c

order.

g

ATV5

0

tion

tenance a

n

d clip.

er bore

ricity

egree

Warpage

on ring

fi

r

th of

f

iston

iston and c

y

ton pin
le and pisto

or damag

e

ked

out

piston he

a

out

rings

or scratc

h

the pisto

n

ylinder air

/10

0

S

d service

st ring

second

ring

first ring

second

ring

ylinder

n pin

1.4kgf-m

/

0.9kgf-m

/

2.0kgf-m

/

d

ad or in c

o

ed

or comb

u

shroud…

ervice

M

for cylind

e

Standar

d

40.0

0

0.0

3

0.0

3

0.1

0.1

39.9

5

0.0

3

9.99

6

0.0

0

14Nm
9Nm
20Nm

mbustion

stion cha

m

etc.) work

s

anua

l

Chapt

e

r head, C

y

value (m

0-40.015

----

----

----

－0.05
－0.05

5-0.35
5-0.35
8-39.972

4-0.047

-10.000

8-0.015

chamber

ber

badly.

er 6 Cylin

d

linder, an

d

m)

U

s

valu

40000

-

5

er Head/

V

reed valv

e

age

e (mm)

0.10
.05
.03

.03

0.1

0.1

0.6

0.6

--­.10

----

----

1 -

alves

6

R

a

b

c

d

e

f

.

g

-04. Cyl

i

emoval

. Refer t

o

proces

s

. Use sp

a

spark pl

. Remov

e

head. T
cylinder

. Remov

e

you can

. Remov

e

Remov

e

bearing

. Remov

e

residue

s

contact

nder /

P

the chap

t

to remov

e

rk plug w

r

ug.

the 4 fixi

n

hen remo

v

head gas

k

the cylin

d

see the

w

one pist

o

the pisto

n

at conne

c

the cylin

d

or foreig

n

surfaces

o

SM

C

iston/ R

i

er 3 for e

n

the engi

n

ench to r

e

g nuts fr

o

e the cyli

n

et..

er careful

hole pisto

n pin clip.

pin, pist

o

ting rod s

m

er gasket

material

s

f cylinder

a

ATV5

0

ngs

gine rem

o

e from fra

move the

m cylinde

r

der head

/

ly, and th

e

.

n and ne

e

all end si

d

. Clean up

from the

t

nd crank

c

/10

0

S

val

me.

n

dle

de.

all

wo

ase.

ervice Manua

l

Chapt

e

er 6 Cylin

d

-

5

er Head/

V

2 -

alves

C

Wre

h

C

D

i.

aution

et the re

s

sidues c

a

. Spread

remove
opposit

e

aution

on’t let th

e

Remov

e

 Use

nuts

)

two

n

dire

c



Use
on t

h

idues by

s

n be rem

o

each pist

o

it by liftin

g

the gap.

clip drop

the cylin

d

the two fl

a

to screw

uts by tu

r

tion.

wrench to

e crankc

a

SM

C

olvent so

t

ved more
n ring lub

r

up at a p

o

into engi

n

er stud b

o

nge nuts

(

in a little

b

n each by

remove o

u

se.

ATV5

0

hat the

easily.
icant and

int just

e crankca

s

lts.

cylinder h

e

it, and loc

k

reverse

t the stud

/10

0

S

se.

ad

the

bolts

ervice Manua

l

Chapteer 6 Cylin

d

-

5

er Head/

V

3 -

alves

6

a



b



T

O



S



S

-05. Par

t

. Cylinde

r

Check

distort.

Clean

t

cylind

e

Check

surfac

e

thickn

e

measu
cylind

e

If too

m

to scr

a

crisscr

o

. Cylinde

r

Inspec

dama

g

Measu

three l

e

aper limit:

ut of roun

Check

surfac

e

and fe

e

ervice lim

i

Insert

e

cylind

e

ervice lim

i

ts inspe

c

Head In

s

the cylind

e

Replace

w

he carbo

n

r head at

t

the cylind

e

if wrap,

u

ss gauge

re the ga

p

r head co

n

uch gap,

tch and m

ss patter

n

/piston/ri

t the cylin

d

e.

re the cyli

n

vels in X

0.05 mm
d: 0.03 m

m

the cylind

e

for warp

ler gaug

e

it: 0.10 m

m

ach pisto

n

r, and me

a

it: 0.10 m

m

SM

C

tion

pection

r head if

a

ith new if

residues
he combu

r head c

o

se 0.03

m

and straig
between

r

tact.

use thin s

a

odify. S

a

and gen

t

ng inspe

c

er bore f

o

der inner

and Y-axi

s

r head m

a

with a str

a

.

ring into

sure the

e

ATV5

0

ny dama

g

necessar

y

on the
stion area

.

ntact

m

htedge to

uler and

nd paper
nd it in a
le.

tion

r wear or

diameter

a

.

ting

ight edge

the

nd gap.

/10

0

S

e

,

.

t

ervice Manua

l

Chapt

e

er 6 Cylin

d

-

5

er Head/

V

4 -

alves



S



S35



P

9

1

P

1
1



S

Measu

and gr

o

ervice lim

i

Measu

10 m

m

ervice lim

i

9.9 mm (f

o

1.9 mm (f

o

Measu

piston

in outer d

i

.96 mm (f

o

1.6 mm (f

o

in bore s

e

0.04 mm

(

2.04 mm

(

Measu

inner

d

micro

m

ervice lim

i

14.06

m

15.06

m

re the cle

a

ove.

it: 0.06 m

m

re the pist

o

high fro

m

it:

r 50cc en
r 100cc e

re the pist

o

pin outer

d

ameter s

e

r 50cc en
r 100cc e

rvice limit:

for 50cc e
for 100cc

re the con

iameter w

eter.

it:

m (for 5

0

m (for 1

0

SM

C

rance bet

w

n outer d

the skirt’

s

gine)
ngine)

n pin bor

e

iameter.

rvice limit:

gine)
ngine)

ngine)
engine)

necting ro

d

ith an insi

d

cc engine
0cc engin

ATV5

0

een ring

iameter at

bottom.

, and the

small en

e

)

)

/10

0

S

d

ervice

M

anua

l

Chapt

e

er 6 Cylin

d

-

5

er Head/

V

5 -

alves

6in



T











T

-06 Cyli

n

stallati

o

Install

t

remov

e

he torque

Install

t

facing
by spr

e

Clean

t

careful
into th

e

Apply

s

rod s

m

bearin

g

Install

t

1. Ins

t

fac

i

2. Do
wit

h

Install

a

Apply

a

rings a
compr

e

Repla

c

Install

t

Tighte

n

he torque

der/Pis
n

he stud b

o

d.

is 10-14N

he piston

up. Do no

t

ading the

he cylind

e

not to dr

o

crankca

s

ome oil t

o

all end an

d

.

he piston,

all the pis

t

ng the ex

h

not align t

h

the pisto

n

new cyli

n

thin coat

nd cylind

e

ssing the

e a new c

y

he cylind

e

the cylin

d

is 10-14N

SM

C

ton/Rin

g

lt onto cr

a

.m

rings with

damage

t

ends too

f

r gasket

s

p any gas

e.

inside of

install th

piston pi

n

on with th

aust pipe

.

e piston

p

cutout.

der gask

e

of engine

r wall. Ins

t

piston rin

g

linder he

a

r head.

er-mount

.m

ATV5

0

nkcase if

the marks
he piston

ar.

urface bei

et materi

a

he conne

c

e new ne

e

and clip.

e arrow m

a

in clip en

d

t.

oil to the

p

all the cyli

n

s.

d gasket.

ng bolt.

/10

0

S

rings

ng

l

ting

dle

ark

gap

iston

der,

ervice Manua

l

Chapt

e

er 6 Cylin

d

-

5

er Head/

V

6 -

alves

Note:

SMC ATV50/10

0

S

ervice Manua

l

Chapteer 6 Cylin

d

-

5

er Head/

V

7 -

alves

7-

07-07-07-07-07-07-07-0

7-

0

Thi

s

tra

n

Wh
to

b

pit

c

dri

v

the
rati

o

rad

i

low

1. Mech

a

2. Main

t

3. Trou

b

4. Left

C

5. Drive

6. Move

7. Rear

D

8. Re-In

s

1. Mech

transmis

s

smission,

en engine

elt by the

h circle of

en pulley

i

radius of

p

is theref

o

us. (In th

e

speed)

anism

enance

D

le Diag

n

rankca

s

Belt

able Dri

v

riven

P

tallatio

n

anism D

ion is the

which ca

n

speed inc

centrifuga

l

belt in dri

v

s forced t

o

itch circle

re altere

d

drawing,

S

escrip

t

osis

e Cove

r

ing Fac

ulley A

s

of the

F

iagram

combinati

o

change t

h

rease, the

force fro

m

e pulley

w

move to

t

is decrea

s

by the alt

e

“H” mean

s

MC AT

V

ion

e(MDF)

sy

r. Driv

e

n of auto

m

e transmi

s

drive pull

e

six roller

s

ill be larg

e

he center

ed. The t

r

ration of

p

high spe

e

5/10

0

S

Assy

/R. driv

e

atic cent

ssion rati

o

y will be

p

s. Then th

e

r. The bel
of shaft, t

h

ansmissi

o

itch circl

e

d, “L” me

a

ervice

n pulle

y

rifugal clu

t

automati

c

ush
at

en
n
’s

ns

Chapt

e

Manual

5

8

5

9

5

9

6

0

6

0

6

1

6

2

6

3

ch and V-

b

ally.

r 7 CVT d

elt contin

u

-

5

riving Sys

t

ous varia

8-

em

ble

7-

0

Pr

e

Ge




Sp

I

tDO

I

T

F

To

r

Dr
Cl

u

Sp

e

Clu

t

Clu

t

Uni

v

7-

0

En

1.

2.

3.

4.

Sh

1.

2.

In

s

1.

2.

3.

4.

2. Main

t

caution

neral In

f

Drive fac

e

Drive bel

t

cificati

o

em

riving bel

t

D of weig

of

clutc

h

hickness

o

ree lengt

h

que valu

e

ive face n

u

tch outer

cial Serv

i

ch spring
ch nut wr

e

ersal hol

d

3. Trou

b

gine ca

n

Worn driv

e

Worn driv

e

Worn or d
Broken dr

udder o

r

Broken cl

u

Worn clut

c

ufficien

t

Worn driv

e

Insufficie

n

Worn roll

e

Driven pu

l

enance

s in Op

e

ormatio

n

, clutch o

and driv

e

n

width

ht roller

outer (ho

u

f clutch we

i

of driven

t: 4.5kgf-

m

nut: 4.0kg

f

ce Tools

compress

nch

er

le Diag

n

be star

t

Belt
face

amaged c

l

iven pulle

y

misfire

tch weig

h

h weight

horsep

o

belt

t spring fo
ley opera

t

S

Descrip

t

ration

uter, and

d

pulley m

u

sing)

ght

pulley spri

n

/ 45Nm

-m / 40N

m

or

osis

ed but

A

utch weig

h

when d

r

t

wer or

rce of driv

e

ion un-sm

o

MC AT

V

ion

riven pull

e

st be free

g

TV can

n

t

iving

poor hi

g

n pulley
othly

5/10

0

S

y can be

of any gr

e

S

ot be

m

h spee

d

ervice

serviced

o

ase.

tandard v

a

oved

perfor

m

Chapt

e

Manual

n the vehi

c

lue

16.6

m

15.0

m

112.0

m

2.0

94.0

m

ance

r 7 CVT d

le.

mm
mm
mm

mm

mm

-

5

riving Sys

t

Limit

14.

6

14.

5

112.

3

1

.

91.

0

9-

em

mm
mm
mm

0 mm

mm

7-

0

Le

f

Re

mRem

Le

f

Ins

t

pro

c

To

r

1.2

7-

0

Re

m

a.

b.

A

c.

Ins

p

Ch

e

it if
Me

asho

Se

r

Re

p

Ca

u




4. Left

C

t crank

c

ove left

c

ove 2 do

w

t crank

c

all left cra

n

edure of

r

que of cr

a

kgf-m/12

5. Drive

oval

Loosen 1

n

remove th

e

Remove t

h

ssy).

 Loos

e

Speci
one

w

 Rem

o

shea

v

face (

w

Remove t

h

sheave) a

n

ection

ck the dri

v

necessar

y

sure the

w

wn.

vice Limi

t

lace the

b

tion

Using the
The surfa

c

rankcas

ase co

v

rankcase

el pin an

ase co

v

kcase co

v

emoval.

nkcase

c

Nm

Belt

ut from th

e

clutch o

u

e movabl

e

n 1nut fro

al tool an

d

ay, conic

a

ve the dri

v

e) by rem

o

with fan),

M

e driven

p

d belt.

e belt for

.

idth of dr

: 14.6 m

m

elt if exce

e

genuine p

a

es of drive

SM

C

e Cover

er remo

v

cover bolt

s

d gasket.

er instal

er in the

r

over bolt

:

clutch o

u

ter.

drive fa

c

m the driv

e

take out

c

l spring w

a

e pulley

a

ving out

f

DF assy

,

ulley (sec

crack or

w

ive belt as

ds the s

e

rts for repl

a

belt or pull

ATV 5

0

al

(9 bolts).

lation

everse

ter, and t

h

e assy (M

D

pulley wi

law wash

e

sher and

ssy (prim

a

ixed drive

collar.

ondary

ear. Repl

a

diagram

rvice limit.

cement.

y must be

/10

0

S

en

F

th

,

nut.

rily

ce

free

ervice

M

Belt

t

anua

l

Chapt

e

ooth

r 7 CVT d

CLA W WASH

E

CONI CAL SP

R

Widt

-

6

riving Sys

t

ONE- WAY

ING WASHER

NU

T

h

0 -

em



7-

0

Du

epus

for

c

tur

n

the
bel

t

Ins

p

1.

Ins

e

dri

v

2.

W

Th

e

fac

e

wei
ce

n

are
ne

c

Me

a

if e

x

Se

r

of grease.
Clean up

a

6. Mov
(MDF

to the in

c

h the mov

e. Then t

h

ing radiu

s

exterior o

f

temperat

u

ection

MDF com

rt the MD

e face co

m

eight R

o

weight r

o

by mean

ht rollers

trifuge for

c

worn out

o

essary.

sure eac

h

ceed the

s

vice limit

:

ll grease

o

eable D

r

Assy)

reasing e

n

able drive

e belt is p

. The alu

m

fixed driv

e

re.

p movem

F boss (c

o

p, and c

h

ller

llers are t

o

s of centri

f

are worn

o

e will be

a

r damag

e

roller’s o

u

ervice li

m

14.50 m

m

SM

C

r dirt befor

e

iving F

a

gine spe

e

face by c

e

ressed an

d

inum fan

i

face. It

c

ent

llar) into t

h

eck for fr

e

press m

o

uge force

.

ut or da

m

ffected.

C

d. Replac

e

ter diam

e

it.

ATV 5

0

installatio

ce Assy

d, the roll

e

ntrifugal

enlarges

s installe

d

an reduce

e movea

b

e movem

e

vable driv

e

Thus, if
aged, the
heck if rol

l

it if

ter. Repla

c

/10

0

S

n.

rs

its

on

the

le
nt.

e

ers

e it

ervice

M

V

anua

l

Chapt

e

-BELT

r 7 CVT d

16~14.5 mm

-

6

riving Sys

t

1 -

em

7-

0

a.

b.

1.

2.

3.

NO
poli

4.

7. Drive
Assy

Disasse

m

Remove t

h

and remo

v

spring, sli

d

seat, oil s

e

Inspectio

n

Moveme

n

heave:

 Check

the sli

d

smoot

h

 Check

are da

m

 Check

damag

Clutch c

o

Measure t
Replace it

Standard

:

Service L
Clutch o

u

 Chec

k

crack

 Chec

k

housi

n

Clutch ho

u

(Wear Li

m

E :After

u

shed parti

c

Clutch w

e

 Chec

k

servi

c

Clutch we

i

(Wear Li

m

 Chec

k

sprin

g

new

s

n Pulley

bly

e fixing n

u

e the clut

c

ing shea

v

als.

.

t of fixed

turn and

c

ing sheav

e

ly.

the two s

h

aged or

w

the sheav

e

ed or wor

n

mpress s

he length

o

if exceed

s

94 mm.

imit : 91

m

ter housi

n

the clutc

h

or damag

e

the inne

r

g if we

a

sing insid

it : 112.3

m

sing the

s

les with

a

ight.

the clutc

h

e limit.
ght lining

t

it : 1.0mm

the clutc

h

, if crack

o

et if nece

s

SM

C

(secon

d

t on the

c

h weight

a

e and fix

s

sheave a

n

heck the

m

and fixe

d

eaves, if

b

orn.
guide pi

n

.

pring.

f sliding

s

service li

m

m

g.

outer ho

u

.

diameter

r to the li

m

e diamete

r

m)

and pape

r

cloth

weight, i

f

hickness

:

)

weight li

n

r damage

sary.

ATV 5

0

ary She

a

lutch weig

ssy, com

p

heave, sp

d sliding

ovement

sheave i

f

oth surfa

c

groove i

s

heave sp

r

it.

sing if w

e

of clutch

o

it.

: 112mm

, clean of

f

wear to t

h

2.0mm

ing and

. Replace

/10

0

S

ve)

ht,

ress

ring

on

es

ing.

ar,

uter

the

e

with

ervice Manua

l

Chapt

e

r 7 CVT d

-

6

riving Sys

t

2 -

em

5.

c.

Tig

h

7-

0









Tor

q


Tor

q



Driven sh

 Chec

k

dama

 Chec

k

big cl

e

 Rotat

e

finge

r

in sm

o

 Chec

k

close

d

ssembl

y

sheave A

s

 Chec

k

or da

m

nece

s

and s

l

 Instal

l

sprin

g

the s

p

the fi

x

ten Torqu

8.

Instal

pulle

y

Install th

e

to the cr

a

Press th

e

down, an
Install th

e

drive sh

a

front driv

e

Install th

e

claw wa

s

washer

a

ue for fix

e

Tighten t

h

ue for fix

e

Install th

e

crankcas
front cra

n

eave bea

r

if the inn

e

ge. Repla

c

if needle

arance.

R

the insid

s to chec

k

oth and

s

if the be

a

and fixe

d

of Drive

n

sy)

the beari

age, repl

sary) and

liding she

a

the rear

p

compres

s

ring and

c

ing nut wi

t

e: 5.0kgf-

m

lation o

f

and re

a

MDF as

s

nkshaft.

rear driv

e

d insert th

rear drivi

ft and put

pulley.

front fixe

d

her, one

w

nd tighten

d drive fa

e clutch

o

d drive fa
dowel pi

n

e cover g

a

kcase co

v

SM

C

ing Insp

e

r bearing

e it if nec

e

bearing is

eplace it i

f

e of inner
if the bea

r

ilent.

ring outer
. Replace

Pulley (s

ng, oil rin

g

ace with n

install to t

h

ve.

ulley ass’

y

or and w

r

lutch weig

h special

t

/ 50Nm

the fro

n

r drive

n

’y with dri

v

n pulley s

e belt.
ng pulley

a

the drive

b

driving f

a

ay, conic

a

the fixing

ce nut: 4.

5

uter nut.

ce nut: 4.

0

and put

o

sket and

t

er with fla

ATV 5

0

ction

oil seal is

ssary.

damage

o

necessa

r

earing wi

ing rotati

o

parts are
it if neces

econdary

/oil seal if

ew one (if

e fix she

a

with clut

c

ench. Pre

s

ht assy, ti

g

orque.

t drive

pulley.

e boss (c

o

liding she

a

ssy to th

e

elt onto t

h

ce (with f

a

l spring

nut.

kgf-m/ 45

N

kgf-m/ 40

N

n the ne

w

hen install
nge bolts.

/10

0

S

r too

y.

th

n is

sary.

wear

ve
h

sing

hten

llar)

ve

rear
e

n),

m

m

L.

the

C

LCO

O

ervice

M

AW WASHER

O

NICAL SPRI N

G

uter ball

b

anua

l

Chapt

e

NE-WA

Y

WAS HER

NUT

earing

r 7 CVT d

N

-

6

riving Sys

t

eedle bea

r

3 -

em

ing

N

O

TE:

SMC ATV 50/10

0

S

ervice Manua

l

Chapter 7 CVT d

-

6

riving Sys

t

4 -

em

8-

08-08-08-08-0

8-

0

Thi

s

thr

oone

8-

0

Ge



To

r

Sta
Idl

e

1. Mech

a

2. Main

t

3. One

W

4. Elect

r

5. Kick

s

1. Mech

ATV 50

e

ugh idle g

way clut

c

2. Main

t

neral In

f

Before th

que valu

e

rting moto

gear plat

e

anism

enance

D

ay Clu

t

ical Sta

r

tarter

anism D

quipped

w

ear or kic

k

h at the le

f

enance

ormatio

n

e service

o

r bolt: 1.3

k

bolt: 0.8

k

S

M

escrip

t

ch (Star

t

ting Mo

t

iagram

ith electri

c

start by

s

t side of

c

Descrip

t

f one wa

y

gf-m /13N
gf-m/8N

m

C ATV

ion

clutch)
or

al starter

pindle ge

a

rankcase.

ion

clutch, pl

e

m

50/100

and kick s

r and kick

ease refer

C

Servic

e

65
65
66

67

68

tarter (opt

i

pinion se

t

to chapte

r

hapter 8

E

Manua

l

onal). By

a

, to crank

t

8, the C

V

ngine St

a

pply the

s

the crank

s

T system

-

rting Syst

e

tarting m

o

haft throu

g

removal.

65-

m

tor

h

ay Clut

ing menti

o

r 7, for fr

o

ut 2 pan h

gear pla

t

e plate w

a

e idle ge

a

e start cl

u

ring, star

t

her.

gear toot

h

r, if Burrs/

C

with new.

art clutch

ckwise “

B

he start

c

t be mov

e

n. Repla

c

idle gear

s

. The sha

f

t be loose

h spare p

a

SMC

ch(Start

ned servi

c

nt pulley

/

ead scre

w

e.

sher on t

h

and plat

e

tch ass’y,
er boss a

n

of idle g

e

hips/Rou

(one way

c

”, and ch

e

lutch sho

u

d when tu

r

e with ne

w

haft on t

h

t should b

e

or move.

rts, if we

a

JMAX

70

Clutch)

e, please

MDF ass

y

, and rem

o

e idle ge

a

washe

r

starter wh

d starter

ar start cl

u

ghness/W

lutch)

ck if rotat

e

ld hold fir

m

n clockwi

s

set if bro

k

e L.

tightly fi

x

or dam

a

00 ATV

S

ve

r.

eel,

tch

ea

r

ly

e

en.

ed

ge.

ervice CManual

hapter 8

E

ngine St

a

-

6

rting Syst

e

6 -

m

c.







To

r

8-

0

Sta
en

g

left

a.







b.





c.

In r

e

plu

g

(idl

eeng

To

rSta

Re-install

Add gre

a

bearing.
Install th

e

disasse

m

Grease t

h

gear and
plate wa

s

Tighten t

h

screw in

s

que valu

e

4. Elect

r

rter Motor

ine. The

s

hand bra

k

Removal

Disconn

e

Remove
Disconn

e

model)
Pull out

a

Inspectio

n

Check th

e

power if

m

Check th

e

wear or

d

Replace

w

necessa

r

Installati

o

verse wa

in the st

a

gear cor

r

age well.

que:

rting mot

o

ation

se to the

s

start clut

c

bly.

e needle

then inst

a

her.

e idle ge

a

pecific to

r

: 0.8kgf-

m

ical Sta

r

is installe

d

tarter mot

o

e is appli

e

ct the ele

c

out the st

a

ct the ear

t

nd remov

e

.

motor fu

otor can

gear en

d

amage.

ith new

s

y.

n.

y of start

m

rt motor g

espond),

m

r bolt: 1.

SMC

tart clutch

h in reve

r

bearing in

s

ll the idle

g

r plate wi

t

que.

/8Nm

ting Mo

on the u

p

r can act

d.

tric coupl

e

rter moto

r

h cord (fo

r

the start

e

nction by

c

run corre

c

, if the ge

a

tart motor

otor rem

o

ear end t

o

ake sur

e

3kgf-m /1

3

JMAX

70

needle
se way of

ide the id

ear with

2

h 2 pan h

e

or

per side

o

only when

r.

fixing 2 b

o

100 CC

r motor.

onnects

w

tly.

r tooth ar

e

ass’y if

val. Whe

n

the engin

e

of the ge

a

Nm

00 ATV

S

le

ad

f

the

lts.

ith

e

e

r

B

O

ervice

C

LTS

C

Manual

hapter 8

E

RD CO MP

ngine St

a

-

6

rting Syst

e

7 -

m

tarter (

O

r is fixed

ompose

d

pring, bu

s

starter, fi

is engage

rankshaft

f

ly

the kick st

rew and t

h

.

the clamp

nkcase c

o

the spindl

e

the clip sp

inion ass

y

each pa

r

spring b

o

ormally.

e gear, s

p

rn spring

a

er onto th

stall the

f

cover.

pring ont

o

kick start

e

r.

ighten b

o

SMC

ptional

)

at the left

c

by kick st

h and pic

k

rst slightly
d, and the

or startin

g

arter by lo

o

en pull o

u

on spindl

e

ver.

gear, bo

s

ring, and t

.

ts if wear,

und/rebo

u

ring with

c

nd spindl

e

e left cran

k

ixing clip

a

the cran

k

r pinion g

e

lt: 0.9kg

f

-

JMAX

70

.

rankcase

arter, spin

d

pinion

push to

m

m kick ha

r

the engin

sing the

t the kick

at outsid

e

s, washe

r

hen remo

v

rusty or g

e

nd force i

are.

gear, col

case cov

e

t outside

o

case

ar and th

e

m / 9Nm

00 ATV

S

dle

ake
dly

e.

of

.

e

ar

f

lar,

r

f

ervice CManual

hapter 8

E

ngine St

a

-

6

rting Syst

e

8 -

m

N

O

TE:

SMC

JMAX 7000 ATV Service CManual

hapter 8 Engine St

a

-

6

rting Syst

e

9 -

m

9-

09-09-09-09-0

9-

0

1. Mech

a

2. Main

t

3. A.C.

G

4.

Oil p

u

5. Cran

k

1. Mech

anism D

enance

N

enerat

o

mp and

shaft

anism

D

SM

C

iagram

otice

r Assy

oil pu

m

iagram

ATV 5

0

p drive

g

/10

0

S

Chap

t

ear

rvice

M

er 9 A.C.

G

anua

l

enerator

/

70
71

72

73

75

Oil Pump

/C

-

7

rankshaf

t

0 -

9-

0

To

r

A

ir

Co

o

Fly

w

Sta

t

Oil
R.

C

Oil

Sp

e

A.C

Uni

v

Cr

aCra

2. Main

t

que valu

e

shroud fixi

ling fan fi

x

heel nut

or fixing

b

Pump Bol

t

rankcas

e

seal stop

p

cial tool

s

.G. flywh

e

ersal hol

d

nkshaft p

u

nkshaft in

s

enance

ng bolt:

ing bolt:

olt:

:
bolt
er bolt

el puller

er

ller

taller

SM

C

Notice

ATV 5

0

0.7kgf-m

/

0.7kgf-m

/

3.8 kgf-

m

0.8kgf-m

/

0.4kgf-m

/

1.2kgf-m

/

0.9kgf-m

/

/10

0

S

Chap

t

7Nm
7Nm

/38Nm
8Nm
4Nm
12Nm

9Nm

rvice

M

er 9 A.C.

G

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

1 -

9-

0

a.














3. A.C.

G

Remova

Remove
chapter

3

Remove
and rem

o

wheel.

Remove
the A.C.

G

Use flyw

h

flywheel,
clockwis

e

fly wheel

Remove
cranksh

a

Screw o

u

push do

w

and then
crankcas

Remove

enerat

o

l

the air co

o

, engine r

e

the 4 scre

w

ve out th

e

out the fla

n

. flywhee

l

eel puller

,

and then

u

the midd

l

from right

the KEY

W

ft.

t the 2 bol

n the sea

l

remove t

h

e.

the gaske

t

SM

C

r Assy.

ling shrou

moval)

s on the

cooling f

a

ge nut a

n

.

screw th

e

se wrenc

e push bo

side of cr

a

OODRU

F

ts on the

s

rubber o

n

e Stator

A

.

ATV 5

0

d. (refer t

o

air cooling

n from fly

d washer

puller int

o

to turn

lt to pull o

u

nkshaft.

F from th

e

tator plat

e

the stato

r

ssy from

R

/10

0

S

Chap

t

fan,

on

the

t the

, and

coil

.

rvice

M

er 9 A.C.

G

anua

l

enerator

/

WOODR UFF

K

Oil Pump

/C

EY

-

7

rankshaf

t

2 -

ation.

gasket

ase with l

i

wheel ca

b

tor asse

m

r assemb

l

odruff ke

y

flywheel

in washe

r

lywheel h

o

nd tighte

n

.

neto Nu

tgf

-m/38

N

cooling f

a

rews

crew

-m/7 N

m

mp an

d

A

.C. Gen

e

ft (refer to

t 2 screw

s

the cir-cli

p

then tak

e

SM

C

thium soa
le throug

h

bly

y): 0.8 kg





and nu

t

lding tool



flywheel

m

n onto fly

w

oil pu

m

rator Ass

y

9-03)
remove t

h

on the oil

out the oi

ATV 5

0

p base on

the cran

k

-m/8Nm



to hold t

(magneto

heel by

p drive

from

e oil pum

pump dri

v

l pump dri

v

/10

0

S

Chap

t

the

case

he

p.

e

e

rvice

M

er 9 A.C.

G

CIRCLIP

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

3 -

the pin an

d

ft

oil pump

d

eplace th

e

.

drive gear

orn or da

m

.

ation.

e lithium

s

side of oil

oil seal.

clip  &



r  in rev

e

oil pump

.

SM

C

cir-clip o

riven gear
oil pump

a

teeth of th

e

age. Repl

a

oap base

pump dri

v

, Pin a

n

rse way

o

Make su

r

ATV 5

0

n the

eeth if

W

ssy if

oil pump

d

ce it if

grease o

n

e / driven

d oil pum

p

f disasse

m

e the gea

r

/10

0

S

Chap

t

ear/

rive

to

gear,

bly.

is

rvice

M

er 9 A.C.

G

P

anua

l

enerator

/

IN

Oil Pump

/C

CIRCL

-

7

rankshaf

t

P

4 -

case/cr

a

sing cran

k

us chapte

and A.C.

G

ar remov

a

e air-inta

k

screw a

n

e 6 pan h

case sep

a

nuts of t

h

dy is para

, slightly l

o

body of t

h to turn

c

cranksh

a

right cra

n

e rubber

h

for easie

r

me steps

from L. C

ent on c

r

dial gaug

ft width "

A

limit " C

"

ng rod big

free pla

y

value, rep

l

t bearing

c

earing in

n

play/Rou

mage

C

SM

C

nkshaf

t

shaft rem

rs for engi

enerato

r

,

l.

e/reed va

l

d remove

ead bolts

o

rate tool,

f

e tool, bu

t

llel with th

e

osen one

he tool.

lockwise

a

ft, then s

e

kcase. W

ammer t

o

crankcas

e

above, to

rankcase.

ankshaft

:

es and thi

c

" : 37.90

: 0.03m

m

end side

“

" F" : 0.4

~

ace with

n

heck

er race

ghness

C

hange

ATV 5

0

oval, plea

s

ne remov

a

oil pump/

o

ve/gasket

the oil se

a

n R.

ully tighte

n

ensure th

box. If

of the scr

e

nd apply
parate an

hen press

u

strike the

case

push out t

kness ga

u

~37.95 m

m

D”: 0.2~0.

0.8 mm

ew crank

s

hange

/10

0

S

Chap

t

e

l,

oil

.

l

the
at

ws

d

re is

he

ge.

5

haft.

rvice

M

er 9 A.C.

G

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

5 -

n.

tching the

procedu

r

e and ea

c

case sid

e

nkshaft.

Cranksh

ft through

connectin

g

h one ha

n

shaft inst

a

crankshaf

t

ft assemb

l

seal at o

u

ith new

o

ium soap

b

.

uide  a

n

al

SM

C

cranksha

f

e, lubricat

h bearing

.

aft Installi

n

the L cran

rod at to

p

d while tu

r

lling tool

w

installing
y bottoms

tside of

L

il seal on

e

ase grea

s

d seal dri

v

ATV 5

0

and to e

a

e the oil s

e

with engi

n

g tool to t

kcase hol

e

dead ce

n

ning the

n

ith the ot

h

tool until t

h

against t

h

. Crankc

a

ach time

e onto th

e

er  to in

/10

0

S

Chap

t

se

al

e oil.

he

.

ter

ut of

er.

e

e

ase

oil

stall

rvice

M

er 9 A.C.

G

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

6 -

nkcase

wel pins

a

lant (pac

k

of both ca

Cranksh
ft through
ll the right
ft and cra

n

e Crankc

-m/12 N

Cranksh

h, operat

e

oil seal,

a

install the

oil seal s

t

.

-m/ 9 N

m

Gasket,

R

-m/11N

m

SM

C

nd engin

e

ing paste

)

se helves.

aft Installi

n

the R cra

n

crankcas

e

kcase.

ase holdin

m

aft operati

the repai

r

pply grea

s

oil seal.

opper pla

t

eed valv

e

ATV 5

0

mount sp

a

to the m

a

g tool to t

kcase hol

e

onto

g screws.

on. If

process.

e on oil s

e

e and tig

h

and air I

n

/10

0

S

Chap

t

acer

ting

he
e

al lip

ten

take

rvice

M

er 9 A.C.

G

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

7 -

N

O

TE:

SMC ATV 50/10

0

S

Chap

t

rvice

M

er 9 A.C.

G

anua

l

enerator/Oil Pump

/C

-

7

rankshaf

t

8 -

10

-10-10-10-10-10-10-

10

-

01. Mec

h

02. Mai

n

03. Tro

u

04. Tra

n

05. Tra

n

06. Bea

r

07. Tra

n

01. Me

c

anism

tenanc

e

ble Dia

g

smissio
smissio

ing Rep

smissio

hanism

SM

C

Notice

nosis

n Disas

s

n Inspe

c

laceme

n

n Reass

Diagra

m

ATV 5

0

embly

tion

t

embly

/10

0

S

ervice

M

79
80
80

81
82
83
83

anua

l

Chapter 10 Transmi

s

-

7

sion Gear

s

9 -

10

-

Thi

sRem

－

E－C

S

p

It

e

OID

S

T

o

G

eGe

B

o

B

oBo

T

oSp

B

eNeDrDrInn

1

0

E

n





N

o





G

e




02. Mai

n

Section

c

ove follo

w

ngine re

m

VT syste

m

ecifica

m

D of shift

of shift f

o

hift fork cl

rque val

u

ar oil drai

n

ar oil fill b

lt for tran

s

lts for idle
lts for dri

v

ols
ecial t

o

o

aring driv

e

edle bear

i

ive shaft

a

ive shaft

p

er bearin

g

-03. Tro

gine ca

n

Damag

e

Burnt o

u

Damag

e

ise

Worn o

r

Worn g

e

ar oil l

e

a

Excessi

v

Worn o

r

tenanc

e

oncerns

d

ing com

p

ove

tion

fork shaft

rk

aw thickn

e

e

bolt:

olt:

0

mission c

a

gear seat

e axle co

v

ls

ng driver

nd oil sea

l

uller:

puller

uble D

i

a

be start

e

d drive g

e

t drive ge

a

d gear sh

burnt gea

ar

ks

e gear oil

damage

o

SM

C

Notice

isassemb

l

onents be

ss

1.8kgf-m/

1

.3 kgf-m/

3

se cover:

(for spee

d

er: 1.2kgf

-

driver

gnosis

d but

v

e

ar

r

ift system

r

.

il seal

ATV 5

0

y-assemb

fore disas

s

c

h

S

8Nm

Nm

1.2kgf-m/
ometer g

e

m/12Nm

hicle c

a

n

/10

0

S

ly of the tr

a

embling

c

apter 3

ection 7

S

t

13.

9

14.

05.9

12Nm

ar):

not mo

v

ervice

M

nsmissio

n

rankcase.

andard v

a

84~14.00
00~14.01

30~6.000

e

.

anua

l

Chapter 1

0

gears fo

r

lue

mm
mm

mm

Transmi

s

repair pu

Limi

13.9

14.0

5.7

3

-

sion Gear

s

pose.

t (mm)

66 mm
34 mm

0 mm

80 -

10

-

a.

1.

t

Tor

2.

f

f

3.

t

4.

f

5.

t

6.

04.Tran

ransmis

s

Remove t

h

ransmissi

gear oil. A

f

que:
Remove t

h

rom trans
ixing bolt.

Screw out

he compr

e

shift fork

s

Remove t

h

rom the g

Remove t

h

gear box

c

ransmissi

Remove t

h

crankcas

e

smissio

n

ion cov

e

e drain b

o

on cover

a

ter drain

o

e speedo

mission c

a

the flang

e

ssion sp

r

haft.

e flange

n

ear shift c

a

e 11 scre

w

over and

t

on case c

o

e gasket

a

.

SM

C

Disass

e

r remova

l

lt on the

b

nd then d

r

ut the oil,

meter gea

se cover

b

bolt, was

h

ing, steel

b

ut and ge

a

m axle.

s on the

hen open

ver.

nd dowel

ATV 5

0

mbly

ottom of t

h

ain out th

e

ighten th

e

r body/ge

a

y loosen

t

er and re

m

all for ge

a

r shifting

transmissi

the

pin from l

e

/10

0

S

e

bolt.

he

ove

r

lever

on

ft

ervice Manua

l

Chapter 1

0

Transmi

s

-

sion Gear

s

81 -

ion gear

s

chain sp

e dowel

p

hift fork t

o

.

primary

d

e main a

x

ase (hol

d

or speed

e 2 flang

e

idle gear,

r.

ear or da

m

smissio

function

fork, shift

ear and tr

and chec

k

gears, s

h

age.

SM

C

remova

l

rocket dri

v

in from g

e

ward the

t

rive gear

le assem

b

er) and i

d

ometer g

e

bolt from

idle gear

p

age.

n Gear I

n

of main a

x

the dog c

l

ansmissio

n

if smoot

h

aft, shift

f

ATV 5

0

e axle ( fi

n

ar shift ca

op of

ly and shi

f

le gear

ar)

idle gear

b

in and idl

e

specti

o

le assy wi

utch towa

r

gear

ly.

ork if

/10

0

S

al

m

ft

ase

n

th

d

ervice Manua

l

Chapter 10 Transmi

s

-

sion Gear

s

82 -

10

-cas

a.

1.

2.

t

3.

w

b.

10

-

ge

a

1.

2.

3.

t

06. L. C

r

e cove

r

Inspection
Screw out
cover and
gasket, ch
damage.
Check the

ransmissi

smoothly

w

Check the
drive gear

ith new i

f

Bearing &
Use the b

e

installer t

o

07 Inst

a

rs.

Check the
smoothly.

Install the
Install the

he shift w

ankcas

e

the 3 flan

g

remove d

r

eck the oi

l

bearings

o

on case c

o

ithout ro

u

oil seals

o

if oil leaki

n

necessa

r

seal rem

o

aring re

m

replace t

h

llation

o

gear shift

primary d

r

main axle

ork with d

o

SM

C

/ Tran

s

e bolt on

ive axle c

o

seal, if oil

n the left

ver, turn

a

gh feeling

n the driv

e

g or dam

a

y

val and in

s

over/insta

l

e bearing

f trans

m

cam axle

ive gear

assy with

g clutch.

ATV 5

0

mission

the drive

a

ver and

leaking o

r

crankcas

e

nd check

.

axle, pri

m

ge. Repl

a

tall

ler and oil

and seal.

ission

if turn

shift folk.

A

/10

0

S

xle

and
if

ary

ce

seal

lign

ervice Manua

l

Chapter 1

0

Transmi

s

-

sion Gear

s

83 -

4.

A

5.

6.

To

r

7.

t

To

r

8.

9.

A

Tor

10.

To

r

lign the

g

and then i

n

cam axle.
Install the

Install the
screws.

que: 1.2k

g

Install the

ighten wit

que: 1.2k

g

Install the

lign the

g

position a

n

que: ???

Fill in the

g

que of oil

ear shift

c

stall the

d

(final) driv

transmiss

i

-m/12N

m

drive axle

h bolts.

-m / 12

N

gear shifti

n

ear shift l

e

d then tig

ear box o

bolt: 0.3

SM

C

am with g

e

owel pin

o

e shaft wit

on gear c

o

cover wit

h

m

g lever a

n

ver for F/

N

hten the b

o

il and tigh

t

kgf-m/3 N

ATV 5

0

ar shift f

o

nto gear

s

h sprocke

t

ver with

gasket a

n

d grease

/R gear

lt.

en the oil

m

/10

0

S

rk,

hift

.

d

it.

bolt.

ervice Manua

l

Chapter 1

0

Transmi

s

-

sion Gear

s

84 -

N

O

TE:

SMC ATV 50/10

0

S

ervice Manua

l

Chapter 10 Transmi

s

-

sion Gear

s

85 -