SYM Quad Lander 250 User Manual

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Quad Lander 250
SERVICE MANUAL
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This service manual contains the technical data of each component inspection and repair for the SANYANG Quad Lander 250 ATV. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.
If the style and construction of the ATV, Quad Lander 250, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
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Contents
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and system inspection & service for SANYANG Quad Lander 250 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information and special tools manual. The third to the 11th chapters cover engine and driving systems. The 12th chapter is cooling system. The 13th to the 16th chapter is contained the parts set of assembly frame body. The 17th chapter is electrical equipment. The 18th chapter is wiring diagram. Please see index of content for quick having the special parts and system information.
There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and “Mechanism Illustrations” on the CD-R version, and can be access to these items by click the mouse.
If user wants to look for the content of each chapter, selecting the words of each chapter on the contents can reach to each chapter. There are two buttons, “Homepage and contents, onto the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this chapter contents” button at the second page of each contents so that clicking the button can back to the contents of this chapter.
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Page Content Index
1-1 ~ 1-18 2-1 ~ 2-14 3-1 ~ 3-8 4-1 ~ 4-12 5-1 ~ 5-6 6-1 ~ 6-16
7-1 ~ 7-8
GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD/VALVE
CYLINDER/PISTON
CONTENTS
1 2 3 4 5 6
7
8-1 ~ 8-14
9-1 ~ 9-12 10-1 ~ 10-10 11-1 ~ 11-8 12-1 ~ 12-12 13-1 ~ 13-14 14-1 ~ 14-14
15-1 ~ 15-10 16-1 ~ 16-18
17-1 ~ 17-22
“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER
FINAL DRIVING MECHANISM ALTERNATOR CRANKSHAFT/ CRANKCASE COOLING SYSTEM BODY COVER FRONT BRAKE AND FRONT WHEEL
STEERING/FRONT SUSPENSION
REAR BRAKE/REAR WHEEL/REAR CUSHION ELECTRICAL EQUIPMENT
8
9 10 11 12 13 14
15 16
17
18-1 ~ 18-2
ELECTRICAL DIAGRAM
18
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Contents
SERIAL NUMBER
Frame number
Engine number
Homepage
Contents
Symbols and Marks............................. 1-1
General Safety..................................... 1-2
Service Precautions............................ 1-3
Specifications......................................1-9
Specifications..................................... 1-10
Torque Values.................................... 1-11
Troubles Diagnosis............................ 1-13
Lubrication Points ............................. 1-18
1. GENERAL INFORMATION
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.
Warning
Caution
Engine oil
Means that serious injury or even death may result if procedures are not followed.
Means that equipment damages may result if procedures are not followed. Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil)
1
Grease King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Correct
Wrong
Indication Indication of components.
# 140) Apply sealant; medium strength sealant should be used unless otherwise specified.
Apply with lubricant.
Replace with a new part before installation.
Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools
Meaning correct installation.
Meaning wrong installation.
Directions
Indicates position and operation directions
Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
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1. GENERAL INFORMATION
General Safety
Carbon monoxide
If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area. Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an extractor.
Caution
Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode under some conditions, keep it away from children.
Used engine oil
Caution
Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might not be verified. We recommend that you wash your hands with soap and water right after contacting. Keep the used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system can become extremely hot after engine running. They remain very hot even after the engine has been stopped for some time. When performing service work on these parts, wear insulated gloves and wait until cooling off.
Battery
Caution
Battery emits explosive gases; flame is strictly prohibited. Keeps the place well ventilated when charging the battery.
Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with water. If you get battery acid in your eyes, flush it off immediately with water and then go to hospital to see an ophthalmologist.
If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such as castor oil or vegetable oil and then go to see a doctor.
Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake fluid beyond reach of children.
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Service Precautions
y Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts for SANYANG ATV may damage the ATV.
y Special tools are designed for remove and
install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.
y When servicing this ATV, use only metric tools.
Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.
1. GENERAL INFORMATION
y Never bend or twist a control cable to prevent
unsmooth control and premature worn out.
y Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.
y When loosening a component which has
different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.
y Store complex components such as
transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.
y Clean the outside of the parts or the cover
before removing it from the ATV. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause damage.
y Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.
y Note the reassemble position of the important
components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).
y Components not to be reused should be
replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins.
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1. GENERAL INFORMATION
y The length of bolts and screws for assemblies,
cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.
y Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners with fingers, then tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.
y Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if the contact surface has any damage.
y The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.
Groove
Clamp
Connector
y Rubber and plastic boots should be properly
reinstalled to the original correct positions as designed.
y When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the manufacturer facing outside, and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.
Manufacturer's name
1-4
Boots
y The tool should be pressed against two (inner
and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.
Both of these examples can result in bearing damage.
To this chapter contents
y Lubricate the rotation face with specified
lubricant on the lubrication points before assembling.
y Check if positions and operation for installed
parts is in correct and properly.
y Make sure service safety each other when
conducting by two persons.
1. GENERAL INFORMATION
y After service completed, make sure all
connection points is secured. Battery positive (+) cable should be connected firstly.
y And the two posts of battery have to be greased
after connected the cables.
y Make sure that the battery post caps are
located in properly after the battery posts had been serviced.
y Note that do not let parts fall down.
y Before battery removal operation, it has to
remove the battery negative (-) cable firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
y If fuse burned, it has to find out the cause and
solved it. And then replace with specified capacity fuse.
Capacity verification
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1. GENERAL INFORMATION
y When separating a connector, it locker has to
be unlocked firstly. Then, conduct the service operation.
y Do not pull the wires as removing a connector
or wires. Hold the connector body.
y Make sure if the connector pins are bent,
extruded or loosen.
y Insert the terminal completely.
Check if the terminal is covered by the boot. Do not let boot open facing up.
y Secure wires and wire harnesses to the frame
with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.
y Insert the connector completely.
If there are two lockers on two connector sides, make sure the lockers are locked in properly. Check if any wire loose.
y Check if the connector is covered by the twin
connector boot completely and secured properly.
y Wire band and wire harness have to be
clamped secured properly.
y Do not squeeze wires against the weld or its
clamp.
y Before terminal connection, check if the boot is
crack or the terminal is loose.
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y Do not let the wire harness contact with rotating,
moving or vibrating components as routing the harness.
y Keep wire harnesses far away from the hot
parts.
Never Touch
1. GENERAL INFORMATION
y Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied.
y Secure the rubber boot firmly as applying it on
wire harness.
y Route wire harnesses to avoid sharp edges or
corners and also avoid the projected ends of bolts and screws.
y Route harnesses so that they neither pull too
tight nor have excessive slack.
y Never use wires or harnesses which insulation
has been broken. Wrap electrical tape around the damaged parts or replace them.
y Never clamp or squeeze the wire harness as
installing other components.
Never clamp or squeeze the wire harness
Never too tight
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1. GENERAL INFORMATION
y Do not let the wire harness been twisted as
installation.
y Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.
y With sand paper to clean rust on connector
pins/terminals if found. And then conduct connection operation later.
Clean rust
y Before operating a test instrument, operator
should read the operation manual of the instrument. And then, conduct test in accordance with the instruction.
Do you know how to set the instrument to its measurement position and the insert locations of its two probes?
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Specifications
MAKER SANYANG MODEL UA25A
Overall Length 1890 mm Front Double arm
Overall Width 1055 mm
Overall Height 1115 mm Front AT22x7-10 (off road)
Wheel Base 1200 mm
Dimension
Wheel tread
Curb Weight
Passengers/Weight Two /150 kg
Weight
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement
1. GENERAL INFORMATION
Suspension
System
Tire Specifications
Front 810 mm Rim Aluminum
Rear 805 mm Front Disk (ψ175mm)
Front 109 kg
Rear 114 kg Max. Speed Above 80 km/hr
Total 223 kg
Front 142 kg
Rear 231 kg
Total 373 kg
Vertical, below center,
incline
Brake System
Performance
Climb Ability Below 25°
Reduction
Transmission
Rear Unit Swing
Rear AT22x10-9 (off road)
Rear Disk (ψ220mm)
Primary
Reduction
Secondary
Reduction
C.V.T., auto speed
Belt
Gear / Sprocket
change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore Ø71 mm Muffler
Stroke 63 mm
Cylinder
Number/Arrange
Engine
Displacement 249.4 cc Solid Particulate
Compression Ratio 10.5 : 1 CO Below 7.0 g/ km
Max. Torque 20.6Nm / 5500rpm
Starting System Electrical starter P.C.V.
ment
Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km
Ignition C.D.I. E.E.C.
Air filtration Sponge
Single Cylinder Lubrication System
Exhaust Pipe Position and
Direction
Exhaust
Concentration
Catalytic reaction control
Nox Below 0.4g/ km
system
Expansion & Pulse
Type
Left side, and
Backward
Forced circulation &
splashing
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1. GENERAL INFORMATION
Specifications
MAKER SANYANG MODEL UA25A1
Overall Length 1890 mm Front Double arm
Overall Width 1055 mm
Overall Height 1115 mm Front AT22x7-10 (on road)
Wheel Base 1200 mm
Dimension
Wheel tread
Curb Weight
Passengers/Weight Two /150 kg
Weight
Total Weight
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and
arrangement
Front 810 mm Rim Aluminum
Rear 805 mm Front Disk (ψ175mm)
Front 109 kg
Rear 114 kg Max. Speed Above 80 km/hr
Total 223 kg
Front 142 kg
Rear 231 kg
Total 373 kg
Vertical, below center,
incline
Suspension
System
Tire Specifications
Brake System
Performance
Climb Ability Below 25°
Reduction
Secondary
Reduction
Reduction
Transmission
Rear Unit Swing
Rear AT22x10-9 (on road)
Rear Disk (ψ220mm)
Primary
C.V.T., auto speed
Belt
Gear / Sprocket
change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Bore Ø71 mm Muffler
Stroke 63 mm
Cylinder
Number/Arrange
Engine
Displacement 249.4 cc Solid Particulate
Compression Ratio 10.5 : 1 CO Below 7.0 g/ km
Max. Torque 20.6Nm / 5500rpm
Starting System Electrical starter P.C.V.
ment
Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km
Ignition C.D.I. E.E.C.
Air filtration Sponge
Single Cylinder Lubrication System
Exhaust Pipe Position and
Direction
Exhaust
Concentration
Catalytic reaction control
Nox Below 0.4g/ km
system
Expansion & Pulse
Type
Left side, and
Backward
Forced circulation &
splashing
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1. GENERAL INFORMATION
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4 Cylinder head nut 4 8 3.6~4.0 Cylinder head right bolt 2 8 2.0~2.4 Cylinder head side cover bolt 2 6 1.0~1.4 Cylinder head cover bolt 4 6 1.0~1.4 Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4 Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0 Air inject pipe bolt 4 6 1.0~1.4 Air inject reed valve bolt 2 3 0.07~0.09 Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread Spark plug 1 10 1.0~1.2 Tensioner lifter bolt 2 6 1.0~1.4 Carburetor insulator bolt 2 6 0.7~1.1 Oil pump screw 2 3 0.1~0.3 Water pump impeller 1 7 1.0~1.4 Engine left cover bolt 9 6 1.1~1.5 Engine oil draining bolt 1 12 3.5~4.5 Engine oil strainer cap 1 30 1.3~1.7 Mission draining bolt 1 8 1.1~1.5 Mission filling bolt 1 12 3.5~4.5 Shift drum fixing bolt 1 14 3.5~4.5 Clutch driving plate nut 1 28 5.0~6.0 Clutch outer nut 1 14 5.0~6.0 Drive face nut 1 14 8.5~10.5 ACG. Flywheel nut 1 14 5.0~6.0 Crankcase bolts 7 6 0.8~1.2 Mission case bolt 7 8 2.6~3.0
0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
6 mm screwSH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
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1. GENERAL INFORMATION
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Handlebar upper holder bolt Steering shaft nut Steering tie-rod nut Knuckle nut Steering shaft holder bolt Tie rod lock nut Handlebar under holder nut Front wheel nut Front axle castle nut Rear axle castle nut Rear wheel nut Engine hanger nut Rear axle holder bolt Drive gear bolt Driven gear nut Swing arm pivot bolt
Front suspension arm nut 4 10 5.00 Front / Rear cushion mounting bolt 6 10 4.60
Brake lever nut Brake hose bolt Brake caliper bolt Brake disk mounting bolt Air-bleed valve Exhaust muffler mounting bolt Exhaust muffler connection nut
4 6 2.40 1 10 5.00 4 10 5.00 2 10 5.00 2 8 3.40 4 10 3.60 2 8 4.00 8 10 2.40 2 14 5.00 2 14 5.00 8 10 2.40 4 12 8.50 4 12 9.20 2 10 4.6 4 10 4.6 1 14 9.20
2 6 1.00
13 10 3.50
6 6 3.25
11 8 4.25
3 5 0.50 2 8 3.00 2 7 1.20
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1. GENERAL INFORMATION
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to check if there is gasoline inside the carburetor
Fuel supplied tom carburetor sufficient
Remove spark plug, install it into spark plug cap, and perform a spark test against engine
round.
Check if sparks Weak sparks, no spark at
Perform cylinder compression pressure test.
No fuel is supplied to carburetor
all
y No fuel in fuel tank y Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
y Float valve clogged y Lines in fuel tank evaporation system
clogged
y Malfunction of fuel pump y Loosen or damaged fuel pump vacuum
hose
y Fuel filter clogged
y Malfunction of spark plug y Spark plug foul y Malfunction of CDI set y Malfunction of AC generator y Ignition coil is in open or short circuit y Ignition coil leads open or short circuit y Malfunction of main switch
Cylinder compression pressure normal
Re-start by following the starting procedures
No ignition T here are some signs of
Remove the spark plug again and check it.
Dry spark plug Wet spark plug
Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit. Then blow the hose with air
Low compression pressure or no pressure
ignition; nut engine can
y Piston ring seized y Malfunction of cylinder valves y Worn cylinder and piston ring y Cylinder gasket leak y Sand hole in compression parts
y Malfunction of throttle valve operation y Air sucked into intake manifold y Incorrect ignition timing
y Fuel level in carburetor too high y Malfunction of throttle valve operation y Throttle valve opening too wide
Blowing in normal Blowing clogged
y Malfunction of automatic by- starter
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1. GENERAL INFORMATION
B. Engine run sluggish (Speed does not pick up, lack of power)
Check and adjustment Fault condition Probable causes
Try gradual acceleration and check engine speed
Engine speed can be increased.
Check ignition timing (Using ignition lamp)
Ignition timing correct Incorrect ignition timing
Check cylinder compression pressure (using compression
Compression pressure correct
Check if carburetor jet is clogged
Engine speed can not be increased.
No compression pressure
y Air cleaner clogged y Poor fuel supply y Lines in fuel tank evaporation system
clogged
y Exhaust pipe clogged y Fuel nozzle clogged in carburetor. y Fuel nozzle clogged in carburetor.
y Malfunction of CDI y Malfunction of AC alternator
y Cylinder & piston ring worn out y Cylinder gasket leaked y Sand hole in compression parts y Valve deterioration y Seized piston ring
No clogged Clogged
Remove spark plug
No foul or discoloration Fouled and discoloration
Check if engine over heat
Normal Engine overheat
Continually drive in acceleration or high speed
No knock Knock
y Remove foreign
y Remove dirt y Incorrect spark plug heat range
y Piston and cylinder worn out y Lean mixture y Poor fuel quality y Too much carbon deposited in
combustion chamber
y Ignition timing too advanced y Poor circuit on the cooling system
y Too much carbon deposited in
combustion chamber
y Lean mixture y Poor fuel quality y Ignition timing too advanced
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1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment Fault condition Probable causes
Check ignition timing (using ignition lamp)
Normal
Adjust the air screw of carburetor
Good Poor
Air sucked through carburetor gasket
No air sucked Air sucked
Remove spark plug, install spark plug into spark plug cap and perform spark test against engine ground
Good spark Poor
Abnormal
y Incorrect ignition timing (malfunction of
CDI or AC alternator)
y Rich mixture (loosen the screw) y Lean mixture (tighten the screw)
y Poor heat insulation gasket y Carburetor lock loose y Poor intake gasket y Poor carburetor O-ring y Vacuum hose crack
y Spark plug fouled y Malfunction of CDI y Malfunction of AC generator y Malfunction of ignition coil y Open or short circuit in spark plug leads y Malfunction of main switch
D. Engine runs sluggish (High speed)
Check and adjustment Fault condition
Check ignition timing
Check for fuel supplying system in automatic fuel cup
Check if carburetor clogged
Normal Abnormal
Good Abnormal
No clogged Clogged
Probable causes
y Malfunction of CDI y Malfunction of AC alternator
y Insufficient fuel in fuel tank y Fuel filter clogged y Restricted fuel tank vent
y Cleaning
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1. GENERAL INFORMATION
E. Clutch, driving and driving pulley
FAULT CONDITIONS
Engine can be started but motorcycle can not be moved.
Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)
Poor initial driving (Poor climbing performance)
PROBABLE CAUSES
y Drive belt worn out or deformation y Ramp plate of movable drive face damaged y Driving pulley spring broken y Clutch weights broken y Drive slide-shaft gear groove broken y Transmission gear damaged
y Clutch weights spring broken y Clutch outer stuck with clutch weights y Connection parts in clutch and shaft worn out or burned
y Drive belt worn out or deformation y Weight roller worn out y Movable drive face shaft worn out y Driven pulley spring deformation y Driven pulley shaft worn out y Greased in drive belt and driven face.
F. Poor handling
Steering is heavy
One wheel is wobbling
Vehicle pulls to one side
FAULT CONDITIONS
PROBABLE CAUSES
y Damaged steering bearing y Damaged steering shaft bushing
y Bent rim y Improperly installed wheel hub y Excessive wheel bearing play y Bent swing arm y Bent frame y Swing arm pivot bushing excessively y Worn
y Bent tie-rod y Incorrect tie-rod adjustment y Rear tie air pressure incorrect y Improper wheel alignment y Bent frame
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1. GENERAL INFORMATION
G. Loss power
Check and adjustment Fault condition Probable causes
Raise wheels off ground and spin by hand
Spin freely
Check tire pressure
Normal Abnormal
Accelerate lightly, engine speed can be increase
Normal Abnormal
Check ignition timing
Normal Abnormal
Test cylinder compression
Normal Abnormal
Check carburetor
Normal Clogged
Check spark plug
Normal Fouled or discolored
Check for engine overheating
Normal Overheating
Accelerate or run at high speed
Normal Knocks
Abnormal
y Brake dragging y Drive chain too tight y Damaged wheel bearing y Wheel bearing needs lubrication
y Punctured tire y Faulty tire valve
y Fuel / air mixture ratio too rich or lean y Clogged in air cleaner y Clogged in muffler y Restricted fuel flow y Clogged fuel tank cap breather hole
y Faulty pulse generator y Faulty CDI unit
y Leaking head gasket y Worn cylinder and piston rings
y Clean
y Clean the spark plug y Spark plug is incorrect heat range
y Excessive carbon deposited in
combustion chamber
y Wrong type of fuel y Fuel / air mixture ratio is lean y Use of poor quality fuel
y worn piston and cylinder y Fuel / air mixture ratio is lean y Wrong type of fuel y Ignition timing too advanced y Excessive carbon deposited in
combustion chamber
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1. GENERAL INFORMATION
Lubrication Points
Drive chain Acceleration cable/ Front & rear brake
lever pivot
1-18
Speedometer gear Wheel bearing
Home page
Contents
Precautions in Operation···················· 2-1 Periodical Maintenance Schedule······ 2-2 Fuel Lines············································· 2-3 Acceleration Operation ······················· 2-3 Air Cleaner············································ 2-3 Spark Plug············································ 2-3 Valve Clearance ··································· 2-4 Carburetor Idle Speed Adjustment····· 2-5 Ignition System···································· 2-6 Cylinder Compression Pressure ········ 2-6 Drive Belt·············································· 2-7
Precautions in Operation
2. MAINTENANCE INFORMATION
Drive Chain··········································· 2-7 Brake System (Disk Brake) ·················2-8 Brake Light Switch/Starting Inhibitor
Switch ··················································· 2-9 Headlight Beam Distance····················2-10 Clutch Disc Wear ·································2-10 Cushion················································· 2-10 Steering Handle···································· 2-11 Wheel/Tire·············································2-11 Nuts, Bolts Tightness·························· 2-11 Special Tools List ································2-12
2
Specification
Fuel Tank Capacity 12000 c.c.
Engine Oil
Transmission Gear oil
Capacity of coolant
Clearance of throttle valve 1~3 mm
Spark plug
“F” Mark in idling speed BTDC 10º / 1700 rpm
Full timing advanced BTDC 27º / 4000 rpm
Cylinder compression pressure 12.0 ±2 kgf/cm²
Capacity 1400 c.c.
Change 1200 c.c.
Capacity 750 c.c.
Change 650 c.c.
Engine + radiator 850 c.c.
Reservoir upper 420 c.c.
Type NGK CR8E
Gap 0.8 mm
Idling speed 1700±100 rpm
Valve clearance IN:0.10 ± 0.02 mm EX:0.15 ± 0.02 mm
Tire dimension
Tire pressure (cold) 3.8±2 psi
Battery 12V10Ah (MF battery) type: YTX12-BS
Front AT22x7-10
Rear AT22x10-9
2-1
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2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
Maintenance
Code
1 Air cleaner 2 Fuel filter 3 Oil filter 4 Engine oil change 5 Tire pressure 6 Battery inspection 7 Brake & free ply check 8 Steering handle check
9 Cushion operation check 10 Every screw tightening check 11 Gear oil check for leaking 12 Spark plug check or change 13 Gear oil change 14 Frame lubrication 15 Exhaust pipe 16 Ignition timing 17 emission check in Idling 18 Throttle operation 19 Engine bolt tightening 20 CVT driving device(belt) 21 CVT driving device(roller) 22 Drive chain
23 24 Fuel lines
25 Cam chain 26 Valve clearance 27 28 Coolant reservoir 29 Coolant
Lights/electrical equipment/multi-meters
Lines & connections in cooling
Item
Every
300KM
I / L I / L
1 Month
every
1,000KM
I C R
I I R C C R Replacement for every 1000 km
I I
I I
I I
I I
I I
I I
I I
I I R R Replacement for every 5000 km
L
I I
I I A I
I I
I I
I R
C
I I
I I
I I
I A
I I
I I
I I R
3 month
every
3,000KM
C
6 month
every
6000KM
1 year
every
12,000KM
15 month
every
14,500KM
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first. Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in
the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and after the ATV has accumulated a higher mileage.
3. Preventive maintenance a. Ignition systemPerform maintenance and check when continuous abnormal ignition, misfire,
after-burn, overheating occur.
b. Carbon deposit removalRemove carbon deposits in cylinder head, piston heads, exhaust system
when power is obvious lower. Than ever
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Fuel Lines
Remove the seat.
Loosen 2 screws and 2 bolts Remove the tank cover
Check all lines, and replace it when they are deterioration, damage or leaking
Warning
Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.
Acceleration Operation
Have a wide open of throttle valve as handle in any position and release it to let back original (full closed) position. Check handle if its operation is smooth. Check acceleration cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth. Measure the throttle lever free play in its flange part. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment screw. Tighten the fixing nut, and check acceleration operation condition.
Free play: 1~3 mm.
Air Cleaner
Remove seat. loosen 4 hooks from the air cleaner cover and then remove the cover. Loosen the clamp strip and 1 screw of air cleaner element, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.
2. MAINTENANCE INFORMATION
Fuel tank
Fuel hose
Vacuum hose
Fuel filter
Lock nut
Throttle adjustment screw
Clamp
Element
Caution
Never use gasoline or acid organized solvent to clean the element.
Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.
Spark Plug
Recommended spark plug: CR8E Remove spark plug cap. Clean dirt around the spark plug hole. Remove spark plug. Measure spark plug gap.
Spark plug gap0.8 mm
Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed.
Tighten torque: 1.0
~1.2kgf-m
Ground electrode
0.8~0.9mm
Central electrode
2-3
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2. MAINTENANCE INFORMATION
Valve Clearance
Caution
Checks and adjustment must be performed when the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank. Remove cylinder head cover. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.
Valve clearance inspection and adjustment. Check & adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
Timing mark
2 bolts
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for adjustment.
Caution
Re-check the valve clearance after tightened the fixing nut.
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Carburetor Idle Speed Adjustment
Caution
y Inspection & adjustment for idle speed have to
be performed after all parts in engine that needed adjustment have been adjusted.
y Idle speed check and adjustment have to be
done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.)
Park the ATV with main stand and warm up engine. Connect tachometer (the wire clamp of tachometer is connected to the high tension cable). Turn the throttle valve stopper screw to specified idle speed. Specified idle speed: 1700 ± 100 rpm
Emission adjustment in idle speed
Warm up the engine for around 10 minutes and then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let engine runs in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe. Adjust the air adjustment screw so that emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and release it immediately. Repeat this for 2~3 times.
5. Read engine RPM and value on the exhaust analyzer. Repeat step 2 to step 4 procedures until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm
2. MAINTENANCE INFORMATION
Ignition cable
Stopper screw
Air adjustment screw
2-5
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2. MAINTENANCE INFORMATION
Ignition System
Caution
y C.D.I ignition system is set by manufacturer so
it can not be adjusted.
y Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Connect tachometer and ignition light. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition light. Then, it is means that ignition timing is correct. Increase engine speed to 6000 rpm to check ignition advance degree. If indent is located within the ignition advance degrees, it is means that the ignition advance degree is in normal. If ignition timing is incorrect, check CDI set, pulse rotor and pulse generator. Replace it if malfunction of these parts is found.
Cylinder Compression Pressure
Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.
CDI unit
Caution
Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
y Incorrect valve clearance. y Valve leaking. y Cylinder head leaking, piston, piston ring and
cylinder worn out. If the pressure is too high, it means carbon deposits in combustion chamber or piston head.
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Drive Belt
Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Remove 9 bolts of the engine left side cover and the cover.
Check if the belt is crack or worn out. Replace the belt if necessary or in accord with the periodical maintenance schedule to replace it.
Width limit: 22.5 mm or above
Drive Chain
2. MAINTENANCE INFORMATION
Clamp strips
9 bolts
Teeth
Width
Check the drive chain
Park the ATV on a level ground, and shift the transmission onto neutral. Measure the drive chain slack midway between the sprockets.
Chain slack: 15~25mm (5/8~1 inch)
Adjust the chain slack
Loosen the axle holder lock nuts and bolts Loosen drive chain adjusting bolt lock nut and turn drive chain adjusting bolt until get the correct slack. Tighten the axle holder nuts and bolts.
Torque: 3.25kgf-m
2 nuts
Lock nut
Adjustment bolt
2-7
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2. MAINTENANCE INFORMATION
Brake System (Disk Brake)
Brake System Hose
Make sure the brake hoses for corrosion or leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found
Caution
y In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
y Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
y Do not mix non-compatible brake fluid together.
Filling Out Brake Fluid
Tighten the drain valve, and add brake fluid. Operate the brake lever so that brake fluid contents inside the brake system hoses.
Screws
Master cylinder cap
Air Bleed Operation
Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release the brake lever.
Added Brake Fluid
Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.
Air bubble
Diaphragm plate
Diaphragm
Upper
Drain valve
Transparent hose
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Brake Lining Wear
The indent mark on brake lining is the wear limitation. Replace the brake lining if the wear limit mark closed to the edge of brake disc.
Caution
y To check front brake lining must be remove
front wheel first.
y It is not necessary to remove brake hose when
replacing the brake lining.
Brake Lining Replacement (refer chapter
14)
Make sure the brake lining condition. Replace the lining if the brake lining wear limitation groove close to the brake disc.
Caution
y Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
y In order to maintain brake power balance, the
brake lining must be replaced with one set.
Brake Light Switch/Starting Inhibitor Switch
The brake light switch is to light up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying.
2. MAINTENANCE INFORMATION
Front brake
Lining
Brake lining wear limitation groove
Brake disk
Rear brake
Brake lining wear limitation groove
Brake switch
Brake switch
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2. MAINTENANCE INFORMATION
Headlight Beam Distance
Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high.
Caution
y To adjust the headlight beam follows related
regulations.
y Improper headlight beam adjustment will
make in coming driver dazzled or insufficient lighting.
Clutch Disc Wear
Run the ATV and increase throttle valve opening gradually to check clutch operation. If the ATV is in forward moving and shaking, check clutch disc condition. Replace it
Cushion
Adjust screw
Clutch weight
Drive plate
Warning
y Do not ride the ATV with poor cushion. y Looseness, wear or damage cushion will make
poor stability and drive-ability.
Front cushion
Press down the front cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found. Tighten all nuts and bolts.
Rear Cushion
Press down the rear cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found.
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Steering Handle
Caution
Check all wires and cables if they are interfered with the rotation of steering handle bar.
Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then check the handle top bearing.
Wheel/Tire
Caution
Tire pressure check should be done as cold engine.
2. MAINTENANCE INFORMATION
Check if tire surface is ticked with nails, stones or other materials.
Appointed tire pressure
Tire size Front tire Rear tire
Tire pressure as cold
Check if front and rear tires’ pressure is in normal. Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:
Front tire: 1.5 mm Rear tire: 2.0 mm
3.8±2
psi
Nuts, Bolts Tightness
Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose clamp, and wire holders for security.
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2. MAINTENANCE INFORMATION
Special Tools List
NAME
NO SYM-1445100 NO SYM-9001200 NO SYM-1472100
Rocker arm pin puller
NAME
Tappet adjusting wrench
NAME
Tappet adjusting wrench
NAME
NO SYM-9001209 NO SYM-1471110/20 NO SYM-3110000-HMA
Tappet adjuster
NAME
Valve cotter remove & assembly tool
NAME
AC.G. Flywheel puller
NAME
NO SYM-1332100-HMA NO SYM-2341110-HMA NO SYM-9120200-HMA
Left crank seal driver
NAME
Drive shaft puller
NAME
Driver shaft install bush & seal driver
NAME
NO SYM-9100410/440 NO
Bearing driver 6205LLU
2-12
NAME
Rear axle bearing driver
SYM-9100100 RA1 A3017
NAME
NO SYM-9100200-HMA
Counter shaft needle bearing drive HK1516
To this chapter contents
2. MAINTENANCE INFORMATION
NAME
NO SYM-9100300-RB1 NO SYM-2341110 NO SYM-9615000-RA1 6000
Counter shaft needle bearing driver HK2016
NAME Bearing driver 6305 NAME
Left crank case cover bearing driver 6000
NAME
NO SYM-9615000 NO SYM-9120600 RB1 RA1 NO SYM-9120100-RA1
Bearing driver 6205
NAME
(12*20*5)
NAME Water pump oil seal driver NAME Water pump bearing driver NAME
NO SYM-9120500-H9A NO SYM-9100100 NO SYM-1721700-H9A
Seal driver 14x28x7 &14x26x6
(6901)
NAME
Seal driver 30x40x5
Water pump mechanical seal driver
(6301)
NAME
NO SYM-9610000 NO SYM-9110400 NO SYM-9020100
BEARING DRIVER
NAME
(6204)
BEARING DRIVER
NAME Lock nut driver
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2. MAINTENANCE INFORMATION
NAME Inner bearing puller NAME Inner bearing puller NAME
NO SYM-6204002 NO SYM-6204022 NO SYM-6204001
Outer bearing puller
NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor
NO SYM-2210100 NO SYM-9020200 NO SYM-2301000
(55mm)
NAME Rear axle nut wrench NAME
NO SYM-HT06007 NO SYM-HT07004-RA1 NO
Torque wrench
NAME
(55mm)
Rear axle nut torque wrench
SYM-4230200
NAME NAME NAME
NO NO NO
2-14
Home page
Contents
Mechanism Diagram······························3-1 Precautions in Operation······················ 3-2 Troubleshooting ····································3-2 Engine Oil···············································3-3
Mechanism Diagram
Press-In Lubrication
Oil Route
3. LUBRICATION SYSTEM
Engine Oil Strainer Clean······················3-3 Oil Pump·················································3-4 Gear Oil···················································3-7
Valve Rocker Arm
Cam Shaft
Spray Lubrication
3
Con-Rod
Spray Lubrication
Press-In Lubrication
Oil Route
Rotate Direction
Oil Pump
Oil Strainer
3-1
To this chapter contents
3. LUBRICATION SYSTEM
Precautions in Operation
General Information:
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1400 c.c.
Change: 1200c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils)
單位:mm
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Oil pump
Clearance between outer rotor and body 0.15~0.20 0.25 Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil strainer cap 1.3~1.7kgf-m Engine oil drain bolt 3.5~4.5kgf-m Gear oil drain bolt 1.1~1.5kgf-m
Gear oil join bolt 3.5~4.5kgf-m Oil pump connection screw 0.1~0.3kgf-m
Troubleshooting
Low engine oil level
y Oil leaking y Valve guide or seat worn out y Piston ring worn out
Low oil pressure
y Low engine oil level y Clogged in oil strainer, circuits or pipes y Oil pump damage
Dirty oil
y No oil change in periodical y Cylinder head gasket damage y Piston ring worn out
3-2
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Engine Oil
Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick. So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that makes sure oil can be drained smoothly and completely.
Place an oil pan under the ATV, and remove oil drain bolt. After drained, make sure washer can be re-used. Install oil drain bolt.
Torque value3.5~4.5kgf-m
Engine Oil Strainer Clean
3. LUBRICATION SYSTEM
Drain bolt
Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap.
Torque value1.3~1.7kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30) Recommended using King serial oil.
Engine oil capacity: 1200c.c. when replacing
Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks.
Oil strainer cap
O-ring
Oil strainer
3-3
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3. LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to chapter 10)
Remove cir clip and take out oil pump driving chain and sprocket.
Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.
Oil Pump Disassembly
Remove the screws on oil pump cover and remove the cover. Remove oil pump shaft roller and shaft.
Clip
2 screws
1 screw
3-4
Roller
To this chapter contents
Oil Pump Inspection
Check the clearance between oil pump body and outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer rotors. Limit: 0.20 mm
Check clearance between rotor side face and pump body
Limit: 0.12 mm
Oil Pump Re-assembly
Install inner and outer rotors into the pump body. Align the indent on driving shaft with that of inner rotor. Install the oil pump shaft and roller. Install the oil pump cover and fixing pins properly.
3. LUBRICATION SYSTEM
Pins
3-5
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3. LUBRICATION SYSTEM
Tighten the oil pump screw.
Oil Pump Installation
Install the oil pump, and then tighten screws.
Torque value0.1~0.3kgf-m
Make sure that oil pump shaft can be rotated freely.
Install oil pump drive chain and sprocket, and then install cir clip onto oil pump shaft.
Install starting gear and generator. (Refer to chapter 10)
1 screw
Roller
2 screws
Clip
3-6
To this chapter contents
Gear Oil
Gear Oil Change
Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained.
Torque value: 1.1~1.5kgf-m
Make sure that the drain bolt washer can be re-used. Add oil to specified quantity from the join hole.
Gear Oil Quantity: 650c.c. when replacing
Make sure that the join bolt washer can be re-used, and install the bolt.
Torque value: 3.5~4.5kgf-m
Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking.
3. LUBRICATION SYSTEM
Gear oil join bolt
Gear oil drain bolt
3-7
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3. LUBRICATION SYSTEM
Notes:
3-8
Home page
Contents
Mechanism Diagram ............................ 4-1
Precautions in Operation..................... 4-2
Trouble Diagnosis................................ 4-3
Carburetor Remove / Install ................ 4-4
Air Cut-Off Valve .................................. 4-5
Mechanism Diagram
Fuel tank cap
Fuel tank
4. FUEL SYSTEM
Throttle Valve.......................................4-6
Float Chamber......................................4-7
Adjustment of Idle Speed....................4-9
Fuel Tank..............................................4-10
Air Cleaner............................................4-11
Fuel unit
4
Inlet pipe
Auto fuel cock
Carburetor
Fuel strainer
4-1
To this chapter contents
4. FUEL SYSTEM
Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline.
Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability. y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
y There is a drain screw in the float chamber for draining residual gasoline. y Do not disassemble air cut valve arbitrarily.
Specification
ITEM UA25A
Carburetor diameter Ø22mm I.D. number PTG 050 Fuel level 14.8mm Main injector # 110 Idle injector # 35 Idle speed 1700 ± 100rpm Throttle handle clearance 1~3 mm Pilot screw 2 turns
Tool Special service tools
Vacuum/air pressure pump Fuel level gauge
4-2
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Trouble Diagnosis
Poor engine start
y No fuel in fuel tank y Clogged fuel tube y Too much fuel in cylinder y No spark from spark plug(malfunction of ignition
system )
y Clogged air cleaner y Malfunction of carburetor chock y Malfunction of throttle operation
Stall after started
y Malfunction of carburetor chock y Incorrect ignition timing y Malfunction of carburetor y Dirty engine oil y Air existing in intake system y Incorrect idle speed
4. FUEL SYSTEM
Mixture too lean
y Clogged fuel injector y Vacuum piston stick and closed y Malfunction of float valve y Fuel level too low in float chamber y Clogged fuel tank cap vent y Clogged fuel filter y Obstructed fuel pipe y Clogged air vent hose y Air existing in intake system
Mixture too rich
y Clogged air injector y Malfunction of float valve y Fuel level too high in float chamber y Malfunction of carburetor chock y Dirty air cleaner
Rough idle
y Malfunction of ignition system y Incorrect idle speed y Malfunction of carburetor y Dirty fuel
Intermittently misfire as acceleration
y Malfunction of ignition system
Late ignition timing
y Malfunction of ignition system y Malfunction of carburetor
Power insufficiency and fuel consuming
y Fuel system clogged y Malfunction of ignition system
4-3
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4. FUEL SYSTEM
Carburetor Remove / Install
Removal
Drain out fuel in the float chamber.
Loosen the choke cable fixed iron sheet screw from plate. Remove the choke cable.
Disconnect the fuel hose. Release the clamp strip of air cleaner.
Remove the carburetor upper parts from the carburetor. Release the 2 nuts of carburetor insulator, and then remove the carburetor.
Drain bolt
Vacuum pipe
1 screw
Choke cable
Fuel pipe
Clamp
Installation
Install in reverse order of removal procedures.
4-4
2 nuts
To this chapter contents
Air Cut-Off Valve
Disassembly
Remove 2 screws.
Remove air cut-off valve cover, spring and valve.
Inspection
Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restricting, replace carburetor assembly. Check the vacuum pipe o-ring is in normal.
2 screws
O-ring
4. FUEL SYSTEM
Air cut-off valve
Spring
Cover
Assembly
Install in reverse order of removal procedures.
4-5
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4. FUEL SYSTEM
Throttle Valve
Disassembly
Remove carburetor upper parts, and then remove throttle valve and throttle cable.
Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle.
Assembly
Place the fuel needle onto the throttle valve and clip it with needle clamp. Install the sealed cap, carburetor upper part, and throttle valve spring. Connect the throttle valve cable to the throttle valve. Install the throttle valve into the carburetor body.
Throttle valve
Throttle cable
Spring
Needle clamp
Fuel needle clip Fuel needle
Caution
Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.
Tighten the carburetor upper part. Adjust the free play of throttle valve cable.
4-6
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Float Chamber
Disassembly
Remove 3 mounting screws and remove float chamber cover.
Remove the fuel level plate, float pin, float and float valve.
Inspection
Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.
Float
Fuel level plate
4. FUEL SYSTEM
3 Screws
Float valve
Pin
Pin
Caution
In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one.
Float
Check for wear or damage
Float valve
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4. FUEL SYSTEM
Remove main jet, needle jet holder, needle jet, slow jet and air adjustment screw.
Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
the way down and note the number of turns.
y Does not turn adjust screw forcefully to avoid
damaging valve seat face.
Clean jets with cleaning fluid. Then use compressed air to blow the dirt off. Blow carburetor body passages with compressed air.
Assembly
Install main jet, needle jet holder, needle jet, slow jet and air adjustment screw.
Caution
Needle jet holder
Needle jet
Main jet
Slow jet
Set the air adjustment screw in according to number of turns noted before it was removed.
Install the float valve, float, and float pin.
Checking fuel level
Caution
y Check again to ensure float valve, float for
proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber face is vertical to the main jet.
Fuel level: 14.8mm
Installation of carburetor
Install carburetor in the reverse order of removal. Following adjustments must be made after installation.
˙Throttle cable adjustment. ˙Idle adjustment
Air adjustment screw
Float gauge
Lock nut
4-8
Throttle adjustment screw
To this chapter contents
Adjustment of Idle Speed
Caution
y Air screw was set at factory, so no adjustment
is needed. Note the number of turns it takes to screw it all the way in for ease of installation.
y The parking brake must be used to stop the
ATV to perform the adjustments.
Use a tachometer when adjusting engine RPM. Screw in air adjustment screw gently, then back up to standard turns.
Standard turns: 2 turns
Warm up engine; adjust the throttle stopper screw of throttle valve to standard RPM.
Idle speed rpm: 1700 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust front end. Press test key on the analyzer. Adjust the pilot screw and read CO reading on the analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments; make sure rpm and CO value are in standard value after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above for adjusting to standard value.
Parking brake
Air adjustment screw
4. FUEL SYSTEM
Throttle valve stopper screw
4-9
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4. FUEL SYSTEM
Fuel Tank
Fuel unit removal
Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please Disconnect fuel unit coupler. Remove fuel unit (4 bolts).
Caution
˙Do not bend the float arm of fuel unit ˙Do not fill out too much fuel to fuel tank.
Fuel unit inspection (Refer to electrical equipment
chapter 17).
Fuel unit installation
Install the gauge in the reverse order of removal.
refer chapter 13)
4 bolts
Coupler
Caution
Do not forget to install the gasket of fuel unit or damage it.
Fuel tank removal
Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Remove the fuel tube. Remove the
Remove fuel tank front and rear side 4 bolts, and then remove fuel tank.
vacuum tube.
refer chapter 13)
Vacuum tube
FRONT
Fuel tube
Installation
Install the tank in the reverse order of removal.
4-10
REAR
4 bolts
To this chapter contents
Air Cleaner
Removal
Loosen the clamp strip of air cleaner and carburetor, and then remove the vapor hose.
Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (4 bolts).
Installation
Install the tank in the reverse order of removal.
Cleaning air cleaner element
Remove the air cleaner cover (4 catch hooks).
Remove element mounting screw. Loosen the clamp strip of air cleaner element, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.
Clamp
Clamp
4. FUEL SYSTEM
Clamp
4 bolts
4 hooks
1 screw
Caution
Never use gasoline or acid organized solvent to clean the element.
Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.
4-11
To this chapter contents
4. FUEL SYSTEM
Notes:
4-12
Home page
Contents
Precautions in Operation..................... 5-1
Engine Installation................................ 5-6
5. ENGINE REMOVAL
Removal of Engine ............................... 5-2
Precautions in Operation
General Information
y The engine has to be supported with special service tools that can be lifted or adjustable. y Engine shall be removal in the conditions of necessary repair or adjustment to the only. y The following parts can be serviced as engine mounted on frame:
Carburetor. Drive pulley, drive belt, clutch, and movable drive face assembly. Start motor. AC. Generator, oil pump and start one way clutch. Transmission.
Specification
5
Item Capacity
Replacement 1200 c.c.
Engine oil capacity
Disassembly 1400 c.c.
Replacement 650 c.c.
Gear oil capacity
Disassembly 750 c.c.
Engine & radiator 780 c.c.
Coolant capacity
Reservoir 420 c.c. AS indicator shown
Total 1200 c.c.
Torque Value
Engine hanger bolt 7.5~9.5kgf-m Exhaust muffler mounting bolt 2.8~3.2kgf-m
Exhaust muffler connection nut 1.0~1.4kgf-m
5-1
To this chapter contents
5. ENGINE REMOVAL
Removal of Engine
Remove the seat.
Remove battery negative post (-). Remove battery positive (+) post.
Remove front fender and the footrest (refer chapter 13).
Remove starter motor wire.
Remove the spark plug cap.
Disconnect A.C. Generator wire couplers.
Positive
Spark plug cap
A.C.G wire couplers
Negative
Starter motor wire
5-2
To this chapter contents
Remove muffler protect (2 bolts).
Loosen muffler front side bolt.
Remove 2 bolts, and then remove the exhaust muff ler.
Remove 2 nuts, and then remove exhaust pipe.
5. ENGINE REMOVAL
2 bolts
2 bolts
2 bolts
2 nuts
5-3
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5. ENGINE REMOVAL
Loosen 1 screw and disconnect the choke cable.
Remove fuel pipe and vacuum pipe. Release the clamp strip of air cleaner duct.
Disconnect the carburetor upper parts and cable.
Release the 2 nuts of carburetor insulator, and then remove the carburetor.
Release the clamp strips of left crankcase cover ducts, and then remove the ducts.
Vacuum pipe
2 nuts
Clamps
1 screw
Choke cable
Fuel pipe
Clamp
5-4
To this chapter contents
Remove coolant drain bolt, and drain out coolant. Remove coolant inlet hoses from water pump.
Remove the thermo-sensor wire, by-pass pipe and coolant outlet hose.
Remove gear change lever (1 bolt).
Remove change switch couplers.
Water hoses clamp
Drain bolt
By-pass pipe
Thermo-sensor wire
5. ENGINE REMOVAL
Outlet hose
1 bolt
Change switch couplers
5-5
To this chapter contents
5. ENGINE REMOVAL
Loosen speedometer cable mounting nut, and then remove the cable. Remove 3 bolts and remove drive chain protector. Turn the socket bolt clockwise, and then remove speedometer gear box.
Caution
The socket bolt is provided with left turn thread.
Remove 2 bolts, and then remove the drive sprocket fixing plate, drive chain and drive sprocket.
Remove the rear side engine hanger mounting nuts and bolts.
Remove the front side engine hanger mounting nut and bolt Remove left side engine hanger, and then remove engine by left side.
Speedometer cable
Socket bolt
2 bolts
3 bolts
Engine Installation
Check if the bush of engine hanger parts for damage. Install engine in the reverse procedures of removal.
Caution
y Pay attention of foot & hand safety as engine
installation to avoid hurting.
y Do not bend or twist wires. y Cables wires have to be routed in accordance
with normal layout.
Engine hanger Bolt: Torque value: 7.5~9.5kgf-m
5-6
2 nuts
1 nut
Home page
Contents
Mechanism Diagram··························· 6-1 Precautions in Operation··················· 6-2 Troubleshooting·································· 6-3 Cylinder Head Removal······················ 6-4 Cylinder Head Inspection··················· 6-7
Mechanism Diagram
1.0~1.4kgf-m
6. CYLINDER HEAD/VALVE
Valve Stem Replacement··················· 6-10 Valve Seat Inspection and Service··· 6-11 Cylinder Head Reassembly··············· 6-13 Cylinder Head Installation················· 6-14 Valve Clearance Adjustment············· 6-16
6
1.0~1.4kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m
0.7~1.1kgf-m
1.0~1.4kgf-m
3.6~4.0kgf-m
2.4~3.0kgf-m
1.0~1.2kgf-m
1.0~1.2kgf-m
6-1
To this chapter contents
6. CYLINDER HEAD/VALVE
Precautions in Operation
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm. y Cylinder head service can be carried out when engine is in frame.
Specification
Item Standard Limit
Compression pressure 12±2 kg/cm2 ---
Camshaft Height of cam lobe
ID of valve rocker arm 11.982~12.000 12.080
Rocker arm
OD of valve rocker arm shaft 11.966~11.984 11.936
OD of valve stem
Intake 34.880 34.860 Exhaust 34.740 34.725
Intake 4.975~4.990 4.900 Exhaust
4.950~4.975
4.900
ID of valve guide 5.000~5.012 5.030 Clearance between
valve stem and guide
Valve
Free length of valve spring
Valve seat width 1.600 ---
Valve clearance
Tilt angle of cylinder head --- 0.050
Intake 0.010~0.037 0.080 Exhaust 0.025~0.062 0.100 Inner 38.700 35.200 outer 40.400 36.900
Intake 0.10±0.02mm --­Exhaust 0.15±0.02mm ---
Torque Value
Cylinder head cover bolt 1.0~1.4kgf-m Exhaust pipe stud bolt 2.4~3.0kgf-m Cylinder head bolt 1.0~1.4kgf-m Cylinder head Nut 3.6~4.0kgf-m Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m Bolt of cam chain auto-tensioner 1.2~1.6kgf-m Cylinder side cover bolt 1.0~1.4kgf-m Cam sprocket bolt 1.0~1.4kgf-m Tappet adjustment screw nut 0.7~1.1kgf-m Spark plug 1.0~1.2kgf-m
Tools Special service tools
Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor
6-2
To this chapter contents
6. CYLINDER HEAD/VALVE
Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure
1. Valve
y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston ring worn out.
High compression pressure
y Too much carbon deposit on combustion chamber or piston head
Noise
y Improper valve clearance adjustment y Burnt valve or damaged valve spring y Camshaft wear out or damage y Chain wear out or looseness y Auto-tensioner wear out or damage y Camshaft sprocket y Rocker arm or rocker arm shaft wear out
6-3
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6. CYLINDER HEAD/VALVE
Cylinder Head Removal
Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts).
Remove 1 bolt of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain tensioner. Loosen 2 bolts, and then remove tensioner. Remove thermostat (2 bolts).
Remove Air Injection system (AI) pipe mounting bolts. Remove spark plug.
Remove the side cover mounting blots of cylinder head, and then take out the side cover.
2 nuts
Tensioner bolts
4 bolts
3 bolts
Thermostat bolts
Spark plug
6-4
To this chapter contents
Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out.
Remove cam shaft setting plate (1 bolt).
Remove rocker arm shafts and rocker arms.
Special Service Tool: Rocker arm and cam shaft puller
Remove cam shafts.
Special Service Tool: Rocker arm and cam shaft puller
6. CYLINDER HEAD/VALVE
Timing mark
2 bolts
Cam shaft setting plate
Rocker arm shafts
Rocker arm shaft and
cam shaft puller
Cam shafts
Rocker arm
shaft and cam shaft puller
6-5
To this chapter contents
6. CYLINDER HEAD/VALVE
Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head.
Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.
Caution
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Use a valve cotter remove & assembly tool to press the valve spring, and then remove valves.
4 Nuts
2 bolts
Gasket
Chain guide
Dowel pins
Caution
y In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.
Special Service Tool: Valve cotter remove & assembly tool
Valve cotter remove
and assembly tool
Inlet valve
Exhaust valve
Inner spring
Outer spring
Spring retainer
Cotter
6-6
To this chapter contents
Remove valve stem seals.
Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.
Caution
Do not damage the matching surface of cylinder head.
Cylinder Head Inspection
Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm EX: Replacement when less than 34.725mm
Inspect the camshaft bearing for looseness or wear out. If any damage, replace whole set of camshaft and bearing.
6. CYLINDER HEAD/VALVE
Valve stem seals
6-7
To this chapter contents
6. CYLINDER HEAD/VALVE
Rocker Arm
Measure the cam rocker arm I.D., and wear or damage, oil hole clogged?
Service Limit: Replace when it is less than
12.080 mm.
Rocker Arm Shaft
Measure the active O.D. of the cam rocker arm shaft and cam rocker arm.
Service Limit: Replace when it is less than
11.936 mm.
Calculate the clearance between the rocker arm shaft and the rocker arm.
Service Limit: Replace when it is less than 0.10 mm.
Valve spring free length
Measure the free length of intake and exhaust valve springs.
Service limit: Inner spring 35.20 mm Outer spring 36.90 mm
Valve stem
Check if valve stems are bend, crack or burn. Check the operation condition of valve stem in valve guide, and measure & record the valve stem outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
6-8
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Valve guide
Caution
Before measuring the valve guide, clean carbon deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide.
Service Limit: IN0.08 mm
EX0.10 mm
6. CYLINDER HEAD/VALVE
5.0 mm valve guide reamer
Caution
If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide.
Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve guide.
6-9
To this chapter contents
6. CYLINDER HEAD/VALVE
Valve Stem Replacement
Heat up cylinder head to 100~150 with heated plate or toaster.
Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
y Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Caution
y Check if new valve guide is deformation after
pressed it in.
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150
.
Valve guide driver
5.0mm
Valve guide driver
5.0 mm
Adjust the valve guide driver and let valve guide height is in 13 mm. Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.
Caution
y Using cutting oil when correcting valve guide
with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated. Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm
Valve guide reamer 5.0 mm
6-10
To this chapter contents
Valve Seat Inspection and Service
Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.
Caution
y Do not let emery enter into between valve stem
and valve guide.
y Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is roughness, wear out, or incomplete contacted with valve seat.
Valve seat inspection
If the valve seat is too width, narrow or rough, corrects it.
Valve seat width
Service limit: 1.6mm
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve seat chamfer cutter. Refer to operation manual of the valve seat chamfer cutter. Use 45° valve seat chamfer cutter to cut any rough or uneven surface from valve seat.
Caution
After valve guide had been replaced, it has to be ground with 45° valve seal chamfer cutter to correct its seat face.
Use 32° cutter to cut a quarter upper parts out.
6. CYLINDER HEAD/VALVE
Valve seat width
Roughness
45°
Old valve seat width
32°
6-11
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6. CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat.
Use 45° cutter to grind the valve seat to specified width.
Caution
Make sure that all roughness and uneven faces had been ground.
Grind valve seat again if necessary.
Coat the valve seat surface with red paint. Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a seal track will be created on contact surface.
Contact surface too high
Old valve seat width
60°
1.0mm
Old valve seat width
45°
Caution
The contact surfaces of valve and valve seat are very important to the valve sealing capacity.
If the contact surface too high, grind the valve seat with 32° cutter. Then, grind the valve seat to specified width.
If the contact surface too low, grind the valve seat with 60° cutter. Then, grind the valve seat to specified width.
6-12
Contact surface too low
32°
Old valve seat width
60°
V
To this chapter contents
After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground.
Cylinder Head Reassembly
Lubricate valve stem with engine oil, and then insert the valve into valve guide. Install new valve stem oil seal. Install valve springs and retainers.
Caution
The closed coils of valve spring should face down to combustion chamber.
Use a valve cotter remove & assembly tool to press the valve spring, and then remove valves.
6. CYLINDER HEAD/VALVE
Valve spring retainer
alve cotter
Valve spring
Valve stem seal
Inlet valve
Exhaust valve
Caution
In order to avoid damaging the valve stem and the cylinder head, in the combustion chamber place a rag between the valve spring remover/installer as compressing the valve spring directly.
Special Service Tool: Valve cotter remove & assembly tool
Tap the valve stems gently with a plastic hammer to make sure valve retainer and valve cotter is settled.
Caution
Place and hold cylinder head on to working table so that can prevent from valve damaged.
Valve cotter remove
and assembly tool
6-13
To this chapter contents
6. CYLINDER HEAD/VALVE
Cylinder Head Installation
Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder.
Caution
Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.
Install 4 washers and tighten 4 nuts on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head right side.
Torque value: Nut 3.6~4.0kgf-m Bolt 1.0~1.4kgf-m
Install camshaft into cylinder head, and install rocker arm, rocker arm shaft.
Install rocker arm pin mounting plate.
Gasket
Chain guide
Dowel pins
4 Nuts
2 bolts
Cam shaft setting plate
6-14
To this chapter contents
Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts.
Caution
Make sure timing marks are matched.
Install cylinder head side cover (3 bolts). Install thermostat (2 bolts).
Loosen auto tensioner adjustment bolt and remove bolt and spring. Install tensioner and install spring and adjustment bolt.
Install cylinder cover (4 bolts).
6. CYLINDER HEAD/VALVE
2 bolts
3 bolts
Tensioner adjustment bolt
Thermostat bolts
Timing mark
4 bolts
6-15
To this chapter contents
6. CYLINDER HEAD/VALVE
Install Air Injection system (AI) pipe. (4 bolts) Install inlet pipe onto cylinder Install and tighten spark plug
Torque value: 1.0~2.0kgf-m
Caution
This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.
Install the engine onto frame (refer chapter 5).
Valve Clearance Adjustment
Loosen Air Injection system (AI) pipe upper side bolt (2 bolts). Remove cylinder head cover.
Remove the cylinder head side cover. Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position. Loosen valve clearance adjustment nuts and bolts located on valve rocker arm. Measure and adjust valve clearance with feeler gauge. After valve clearance had been adjusted to standard value, hold adjustment bolt and then tighten the Adjustment nut.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Install the cylinder head side cover. Start the engine and make sure that engine oil flows onto the cylinder head. Stop the engine after confirmed, and then install the cylinder head cover and AI pipe.
4 bolts
Spark plug
Timing mark
Caution
y If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
y When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.
6-16
Home page
Contents
7. CYLINDER/PISTON
Mechanism Diagram···························· 7-1 Precautions in Operation ···················· 7-2 Trouble Diagnosis································ 7-2 Cylinder and Piston Removal ············· 7-3
Mechanism Diagram
Piston Ring Installation ···················7-6 Piston Installation ···························· 7-7 Cylinder Installation························· 7-7
1.0~1.4kgf-m
7
0.8~1.2kgf-m
7-1
To this chapter contents
7. CYLINDER/PISTON
Precautions in Operation
General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.
UA25A
Specification Unitmm
Item Standard Limit
Cylinder
Piston/ Piston ring
OD of piston pin 16.994~17.000 16.960 Clearance between piston and piston pin 0.002~0.014 0.020 ID of connecting rod small-end 17.016~17.034 17.064
ID 70.995~71.015 71.100 Bend - 0.050
Clearance between piston rings
Ring-end gap
OD of piston (2nd) 70.430~70.480 70.380 Clearance between piston and cylinder 0.010~0.040 0.100 ID of piston pin boss 17.002~17.008 17.020
Top ring 0.015~0.050 0.090
nd
ring 0.015~0.050 0.090
2 Top ring 0.150~0.300 0.500 2nd ring 0.300~0.450 0.650 Oil ring side rail 0.200~0.700 -
Trouble Diagnosis
Low or Unstable Compression Pressure
y Cylinder or piston ring worn out
Knock or Noise
y Cylinder or piston ring worn out y Carbon deposits on cylinder head top-side y Piston pin hole and piston pin wear out
7-2
Smoking in Exhaust Pipe
y Piston or piston ring worn out y Piston ring installation improperly y Cylinder or piston damage
Engine Overheat
y Carbon deposits on cylinder head top side y Cooling pipe clogged or not enough in coolant
flow
To this chapter contents
7. CYLINDER/PISTON
Cylinder and Piston Removal
Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder.
Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston.
Remove cylinder gasket and dowel pin. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.
Coolant hose
Dowel pins
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out or damaged. In the 3 positions, top, center and bottom, of cylinder, measure the X and Y values respective in the cylinder.
Service limit: 71.100 mm
Top Center
Bottom
7-3
To this chapter contents
7. CYLINDER/PISTON
Check cylinder if warp.
Service limit: 0.05 mm
Measure clearance between piston rings and grooves.
Service Limit: Top ring: 0.09 mm
nd
2
ring: 0.09 mm
Remove piston rings
Check if the piston rings are damaged or its grooves are worn.
Caution
Pay attention to remove piston rings because they are fragile.
Place piston rings respective into cylinder below 20 mm of cylinder top. In order to keep the piston rings in horizontal level in cylinder, push the rings with piston.
Service Limit: Top ring: 0.50 mm
nd
ring: 0.65 mm
2
7-4
To this chapter contents
7. CYLINDER/PISTON
Measure the outer diameter of piston pin.
Service Limit: 16.96 mm
Measure the inner diameter of connecting rod small end.
Service Limit: 17.064 mm
Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.
Service Limit: 0.02 mm
Measure piston outer diameter.
Caution
The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin.
Service limit70.380 mm
Compare measured value with service limit to calculate the clearance between piston and cylinder.
7-5
To this chapter contents
7. CYLINDER/PISTON
Piston Ring Installation
Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation. y All marks on the piston rings must be forwarded to up side. y Make sure that all piston rings can be rotated freely after installed.
Top ring
nd
2
ring
Oil ring
Top groove
nd
2
groove
Oil groove
7-6
To this chapter contents
7. CYLINDER/PISTON
Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase.
Caution
Soap the residues into solvent so that the residues can be removed more easily.
Piston Installation
Install piston and piston pin, and place the IN marks on the piston top side forward to inlet valve.
Install new piston pin clip.
Caution
y Do not let the opening of piston pin clip align
with the piston cutout.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from falling into crankcase as operation.
IN mark
Clip end gap
Cylinder Installation
Install dowel pins and new gasket.
Cutout
Dowel pins
7-7
To this chapter contents
7. CYLINDER/PISTON
Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.
Caution
Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
Install coolant hose onto cylinder. Install cylinder head (refer to Chapter 6).
Coolant hose
7-8
Home page
Contents
Mechanism Diagram ··························· 8-1 Maintenance Description···················· 8-2 Trouble Diagnosis······························· 8-2 Left Crankcase Cover ························· 8-3
Mechanism Diagram
8. V-BELT DRIVING SYSTEM
Drive Belt··············································8-5 Drive Face·············································8-7 Clutch Outer/Driven Pulley··················8-10
8
5.0~6.0kgf-m
8.5~10.5kgf-m
5.0~6.0kgf-m
8-1
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8. V-BELT DRIVING SYSTEM
Maintenance Description
Precautions in Operation General Information
y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. y Drive belt and drive pulley must be free of grease.
Specification
Item Standard value Limit Driving belt width 24.000 mm 22.500 mm OD of movable drive face boss 29.946~29.980 mm 29.926 mm ID of movable drive face 30.000~30.040 mm 30.060 mm OD of weight roller 19.500~20.000 mm 19.000 mm ID of clutch outer 144.850~145.150 mm 145.450 mm Thickness of clutch weight 6.000 mm 3.000 mm Free length of driven pulley spring 102.400 mm 97.400 mm OD of driven pulley boss 40.950~40.990 mm 40.930 mm ID of driven face 41.000~41.050 mm 41.070 mm Weight of weight roller 17.700~18.300 g 17.200 g
Torque value
y Drive face nut: 8.5~10.5kgf-m y Clutch outer nut: 5.0~6.0kgf-m y Drive plate nut: 5.0~6.0kgf-m
Special Service Tools
Clutch spring compressor: SYM-2301000 Inner bearing puller: Clutch nut wrench 39 x 41 mm: Universal holder: Bearing driver:
SYM-6204002
SYM-9020200
SYM-2210100
SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can not be moved
1. Worn drive Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
Insufficient horsepower or poor high speed performance
1. Worn drive belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
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Left Crankcase Cover
Left crankcase cover removal
Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (9 bolts) Remove 2 dowel pin and gasket.
Left crankcase cover install
Install left crankcase cover in the reverse procedures of removal.
8. V-BELT DRIVING SYSTEM
Clamp strips
9 bolts
Dowel pins
Left cover plate
Dowel pins
Bearing setting plate
Drive shaft holder bearing
Left cover plate gasket
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8. V-BELT DRIVING SYSTEM
Left crankcase cover inspection
Remove 2 bolts to remove left crankcase cover bearing setting plate.
Check bearing on left crankcase cover. Rotate bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on cover tightly.
2 bolts
9 bolts
If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
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Drive Belt
Removal
Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face.
Special Tooluniversal holder
Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer.
Caution
y Using special service tools for tightening or
loosening the nut.
8. V-BELT DRIVING SYSTEM
Universal holder
Universal holder
Bearing stay collar
y Fixed rear wheel or rear brake will damage
reduction gear system.
Push the drive belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley. Do not remove drive belt. Remove the drive belt from the groove of driven pulley.
Inspection
Check the drive belt for crack or wear. Replace it if necessary. Measure the width of drive belt as diagram shown.
Service Limit: 22.5 mm
Replace the belt if exceeds the service limit.
Caution
y Using the genuine parts for replacement. y The surfaces of drive belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.
Belt tooth
Width
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8. V-BELT DRIVING SYSTEM
Installation
Caution
z Pull out driven face to avoid it closing. z Cannot oppress friction plate comp in order
to avoid creates the distortion or the damage.
Install drive belt onto driven pulley.
Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.
Install the clutch outer and bearing stay collar.
Driven face
Universal holder
Bearing stay collar
Hold the clutch outer whit universal holder, and then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m
Install the drive face, washer and drive face nut. Hold drive face with universal holder, and then tighten nut to specified torque value.
Torque value: 8.5~10.5kgf-m
Universal holder
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Drive Face
Removal
Remove left crankcase cover. Hold drive face with universal holder, and then
remove drive face nut. Remove drive face and drive belt.
Remove movable drive face comp and drive face boss from crankshaft.
Remove ramp plate.
Crankshaft
8. V-BELT DRIVING SYSTEM
Universal holder
Movable drive face
Drive face boss
Ramp plate
Remove weight rollers from movable drive face.
Movable drive face
Weight roller
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8. V-BELT DRIVING SYSTEM
Inspection
The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter. Replace it if exceed the service limit.
Service limit: 19.0 mm Weight: 17.2g
Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face boss, and replace it if it exceed service limit.
Service limit: 29.962 mm
Weight roller
Movable drive face
Drive face boss
Measure the inner diameter of movable drive face, and replace it if it exceed service limit.
Service limit: 30.060 mm
Reassembly/installation Install weight rollers.
Caution
The weight roller two end surfaces are not certainly same. In order to lengthen the roller life and prevented exceptionally wears the occurrence, Please end surface of the closure surface counter clockwise assembles onto movable drive face.
Install ramp plate.
Weight roller
Ramp plate
Closure surface
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Guide collar
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With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss.
Caution
The movable drive face surface has to be free of grease. Clean it with cleaning solvent.
Install movable drive face comp. onto crankshaft.
Driven pulley installation
Press drive belt into pulley groove, and then pull the belt onto drive shaft.
Install drive face, washer and nut.
8. V-BELT DRIVING SYSTEM
Movable drive face
Crank shaft
Press down
Drive belt
Drive face boss
Drive face boss
Caution
Make sure that two sides of pulley surfaces have to be free of grease. Clean it with cleaning solvent.
Hold drives face with universal holder. Tighten nut to specified torque.
Torque value: 8.5~10.5kgf-m
Install left crankcase cover.
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8. V-BELT DRIVING SYSTEM
Clutch Outer/Driven Pulley
Disassembly
Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily.
Caution
Do not press the compressor too much.
Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool. Release the clutch spring compressor and remove friction plate, clutch weight and spring from driven pulley.
Remove seal collar from driven pulley.
Remove guide pin, guide pin roller, and movable driven face, and then remove O-ring & oil seal seat from movable driven face.
Clutch nut wrench
Movable driven face
Clutch spring compressor
Seal
Guide pin
Collar
Inspection Clutch outer
Measure the inner diameter of clutch outer. Replace the clutch outer if exceed service limit.
Service limit: 145.450 mm
O-ring
Inner diameter
Guide pin
Guide pin roller
Clutch outer
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Clutch lining
Measure each clutch weight thickness. Replace it if exceeds service limit.
Service limit: 3.0 mm
Driven pulley spring
Measure the length of driven pulley spring. Replace it if exceeds service limit.
Service limit: 97.4 mm
8. V-BELT DRIVING SYSTEM
Clutch lining
Clutch weight
Driven pulley
Check following items:
y If both surfaces are damaged or worn. y If guide pin groove is damaged or worn.
Replace damaged or worn components. Measure the outer diameter of driven face and the inner diameter of movable driven face. Replace it if exceeds service limit.
Service limit: Outer diameter 40.93 mm
Inner diameter 41.07 mm
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage. Replace it if necessary. Check if needle bearing is damage or too big clearance. Replace it if necessary. Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary.
Free length
Driven face
Movable driven face
Guide pin groove
Needle bearing
Outer ball bearing
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8. V-BELT DRIVING SYSTEM
Clutch weight Replacement
Remove snap ring and washer, and then remove clutch weight and spring from driving plate.
Caution
Some of models are equipped with one mounting plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins.
Spring
Clutch weight
Shock absorption rubber
Driving plate
Snap ring
Setting pin
Install new clutch weight onto setting pin and then push to the specified location. Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.
Caution
Grease or lubricant will damage the clutch weight and affect the block’s connection capacity.
Install the spring into groove with pliers.
Shock absorption rubber
Clutch weight
Spring
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Install snap ring and mounting plate onto setting pin.
Replacement of Driven Pulley Bearing
Remove inner bearing.
Caution
y If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
y If the pulley equipped with ball bearing, it has to
remove snap ring and then the bearing.
8. V-BELT DRIVING SYSTEM
Snap ring
Outer bearing
Clipper
Inner needle bearing
Remove snap ring and then push bearing forward to other side of inner bearing. Place new bearing onto proper position and its sealing end should be forwarded to outside. Apply with specified oil.
Install new inner bearing.
Caution
y Its sealing end should be forwarded to outside
as bearing installation.
y Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Snap ring
Snap ring
Outer bearing
Bearing end
Install snap ring into the groove of drive face. Align oil seal lip with bearing, and then install the new oil seal (if necessary).
Inner bearing
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