Sym Quad Lander 300 Service Manual

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HOW TO USE THIS MANUAL SERIAL NUMBER

Quad Lander 300

SERVICE MANUAL

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Contents

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This service manual contains the technical data of each component inspection and
repair for the SANYANG Quad Lander 300 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 300, 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 300ATV. 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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CONTENTS

Page Content Index

1-1 ~ 1-18

GENERAL INFORMATION

1

2-1 ~ 2-14

SERVICE MAINTENANCE INFORMATION

2

3-1 ~ 3-8

LUBRICATION SYSTEM

3

4-1 ~ 4-12

FUEL SYSTEM

4

5-1 ~ 5-6

ENGINE REMOVAL

5

6-1 ~ 6-16

CYLINDER HEAD/VALVE

6

7-1 ~ 7-8

CYLINDER/PISTON

7

8-1 ~ 8-16

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

8

9-1 ~ 9-19

FINAL DRIVING MECHANISM

9

10-1 ~ 10-10

ALTERNATOR

10

11-1 ~ 11-8

CRANKSHAFT/ CRANKCASE

11

12-1 ~ 12-12

COOLING SYSTEM

12

13-1 ~ 13-14

BODY COVER

13

14-1 ~ 14-14

FRONT BRAKE AND FRONT WHEEL

14

15-1 ~ 15-10

STEERING/FRONT SUSPENSION

15

16-1 ~ 16-18

REAR BRAKE/REAR WHEEL/REAR CUSHION

16

17-1 ~ 17-22

ELECTRICAL EQUIPMENT

17

18-1 ~ 18-2

ELECTRICAL DIAGRAM

18

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Contents

SERIAL NUMBER

Frame number

Engine number

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Contents

1. GENERAL INFORMATION

1-1

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............................ 1-14

Lubrication Points ............................. 1-19

1

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

Means that serious injury or even death may result if procedures are not
followed.

Caution

Means that equipment damages may result if procedures are not followed.

Engine oil

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)

Grease

King Mate G-3 is recommended.

Gear oil

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
# 140)

Locking sealant

Apply sealant; medium strength sealant should be used unless otherwise
specified.

Oil seal

Apply with lubricant.。

Renew

Replace with a new part before installation.

Brake fluid

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools

Special tools

Correct

Meaning correct installation.

Wrong

Meaning wrong installation.

Indication Indication of components.

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).

To this chapter contents

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.

1-2

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.

To this chapter contents

1. GENERAL INFORMATION

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.

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 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 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.

1-3

To this chapter contents

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.

1-4

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 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.

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.

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.

Manufacturer's name

Both of these examples can result in
bearing damage.

To this chapter contents

1. GENERAL INFORMATION

y Lubricate the rotation face with specified

lubricant on the lubrication points before
assembling.

1-5

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.

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 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 If fuse burned, it has to find out the cause and

solved it. And then replace with specified
capacity fuse.

Capacity
verification

To this chapter contents

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 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 Before terminal connection, check if the boot is

crack or the terminal is loose.

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 Wire band and wire harness have to be clamped

secured properly.

y Do not squeeze wires against the weld or its

clamp.

1-6

To this chapter contents

1. GENERAL INFORMATION

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.

1-7

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 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.

Never Touch

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

To this chapter contents

1. GENERAL INFORMATION

y Do not let the wire harness been twisted as

installation.

1-8

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 Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.

y With sand paper to clean rust on connector

pins/terminals if found. And then conduct
connection operation later.

Clean rust

Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?

To this chapter contents

1. GENERAL INFORMATION

Specifications

MAKER SANYANG MODEL UA30A

Overall Length 1920 mm Front Double arm

Overall Width 1065 mm

Suspension

System

Rear Unit Swing

Overall Height 1110 mm Front AT22x7-10 (off road)

Wheel Base 1190 mm

Tire Specifications

Rear AT22x10-9 (off road)

Front 825 mm Rim Aluminum

Dimension

Wheel tread

Rear 805 mm Front Disk (ψ 175mm)

Front 130 kg

Brake System

Rear Disk (ψ 220mm)

Rear 105 kg Max. Speed Above 80 km/hr

Curb Weight

Total 235 kg

Performance

Climb Ability Below 25°

Passengers/Weight Two /150 kg

Front 166 kg

Primary

Reduction

Belt

Rear 219 kg

Weight

Total Weight

Total 385 kg

Secondary

Reduction

Gear / Sprocket

Type 4-Stroke Engine Clutch Centrifugal, dry type

Installation and

arrangement

Vertical, below center,

incline

Reduction

Transmission

C.V.T., auto speed

change

Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr

Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A

Bore Ø75 mm Muffler

Expansion & Pulse

Type

Stroke 65 mm

Exhaust Pipe Position and

Direction

Left side, and

Backward

Cylinder

Number/Arrange

ment

Single Cylinder Lubrication System

Forced circulation &

splashing

Displacement 2857.2cc Solid Particulate

Compression Ratio 8.8: 1 CO Below 7.0 g/ km

Max. HP 19.2ps / 6500rpm HC Below 1.5g/ km

Max. Torque 2.45 Kg m / 5500rpm

Exhaust

Concentration

Nox Below 0.4g/ km

Ignition C.D.I. E.E.C. ─

Starting System Electrical starter P.C.V. ─

Engine

Air filtration Sponge

Catalytic reaction control

system

─

1-9

To this chapter contents

1. GENERAL INFORMATION

Specifications

MAKER SANYANG MODEL UA25A1

Overall Length 1,890 mm Front Double arm

Overall Width 1,055 mm

Suspension

System

Rear Unit Swing

Overall Height 1,115 mm Front AT22x7-10 (on road)

Wheel Base 1,200 mm

Tire Specifications

Rear AT22x10-9 (on road)

Front 810 mm Rim Aluminum

Dimension

Wheel tread

Rear 805 mm Front Disk (ψ 175mm)

Front 109 kg

Brake System

Rear Disk (ψ 220mm)

Rear 114 kg Max. Speed Above 80 km/hr

Curb Weight

Total 223 kg

Performance

Climb Ability Below 25°

Passengers/Weight Two /150 kg

Front 142 kg

Primary

Reduction

Belt

Rear 231 kg

Weight

Total Weight

Total 373 kg

Secondary

Reduction

Gear / Sprocket

Type 4-Stroke Engine Clutch Centrifugal, dry type

Installation and

arrangement

Vertical, below center,

incline

Reduction

Transmission

C.V.T., auto speed

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

Expansion & Pulse

Type

Stroke 63 mm

Exhaust Pipe Position and

Direction

Left side, and

Backward

Cylinder

Number/Arrange

ment

Single Cylinder Lubrication System

Forced circulation &

splashing

Displacement 249.4 cc Solid Particulate

Compression Ratio 10.5 : 1 CO Below 7.0 g/ km

Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km

Max. Torque 20.6Nm / 5500rpm

Exhaust

Concentration

Nox Below 0.4g/ km

Ignition C.D.I. E.E.C. ─

Starting System Electrical starter P.C.V. ─

Engine

Air filtration Sponge

Catalytic reaction control

system

─

1-10

To this chapter contents

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

0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m

6 mm bolt、nut

0.8~1.2kgf-m

6 mm screw、SH nut

0.7~ 1.1kgf-m

8 mm bolt、nut

1.8~2.5kgf-m

6 mm bolt、nut

1.0 ~1.4kgf-m

10 mm bolt、nut

3.0~4.0kgf-m

8 mm bolt、nut

2.4 ~3.0kgf-m

12 mm bolt、nut

5.0~6.0kgf-m

10 mm bolt、nut

3.5~4.5kgf-m

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

1-11

1. GENERAL INFORMATION

1-12

To this chapter contents

1. GENERAL INFORMATION

Frame Torque Values

Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks

Handlebar upper holder bolt

4 6 2.40

Steering shaft nut

1 10 5.00

Steering tie-rod nut

4 10 5.00

Knuckle nut

2 10 5.00

Steering shaft holder bolt

2 8 3.40

Tie rod lock nut

4 10 3.60

Handlebar under holder nut

2 8 4.00

Front wheel nut

8 10 2.40

Front axle castle nut

2 14 5.00

Rear axle castle nut

2 14 5.00

Rear wheel nut

8 10 2.40

Engine hanger nut

4 12 8.50

Rear axle holder bolt

4 12 9.20

Drive gear bolt

2 10 4.6

Driven gear nut

4 10 4.6

Swing arm pivot bolt

1 14 9.20
Front suspension arm nut 4 10 5.00
Front / Rear cushion mounting bolt 6 10 4.60

Brake lever nut

2 6 1.00

Brake hose bolt

13 10 3.50

Brake caliper bolt

6 6 3.25

Brake disk mounting bolt

11 8 4.25

Air-bleed valve

3 5 0.50

Exhaust muffler mounting bolt

2 8 3.00

Exhaust muffler connection nut

2 7 1.20

1-13

To this chapter contents

1. GENERAL INFORMATION

Troubles Diagnosis

A. Engine hard to start or can not be started

1-14

Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to
check if there is gasoline inside
the carburetor

y No fuel in fuel tank
y Check if the pipes, fuel tank to carburetor

and intake vacuum, are clogged.

y F loat valve clogged
y Lines in fuel tank evaporation system

clogged

y Malfunction of fuel pump

Fuel supplied tom
carburetor sufficient

No fuel is supplied to
carburetor

y Loosen or damaged fuel pump vacuum

hose

Remove spark plug, install it
into spark plug cap, and perform
a spark test against engine

g

round.

y F uel 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

Check if sparks W eak sparks, no spark at

all

Perform cylinder compression
pressure test.

Cylinder compression
pressure normal

Low compression
pressure or no pressure

y Piston ring seized
y Malfunction of cylinder valves
y W orn 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

Re-start by following the starting
procedures

No ignition There are some signs of

ignition; nut engine can

Remove the spark plug again
and check it.

y F uel level in carburetor too high

Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air

Dry spark plug Wet spark plug

y Malfunction of throttle valve operation
y Throttle valve opening too wide

Blowing in normal Blowing clogged

y Malfunction of automatic by- starter

To this chapter contents

1. GENERAL INFORMATION

B. Engine run sluggish (Speed does not pick up, lack of power)

1-15

Check and adjustment Fault condition Probable causes

Try gradual acceleration and
check engine speed

y Air cleaner clogged
y Poor fuel supply

Engine speed can be
increased.

Engine speed can not be
increased.

y Lines in fuel tank evaporation system

clogged

y Exhaust pipe clogged
y F uel nozzle clogged in carburetor.

Check ignition timing (Using
ignition lamp)

y F uel nozzle clogged in carburetor.

Check cylinder compression
pressure (using compression

Ignition timing correct Incorrect ignition timing

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

y Remove foreign

y Remove dirt
y Incorrect spark plug heat range

Compression pressure
correct

No compression pressure

Check if carburetor jet is
clogged

No clogged Clogged

Remove spark plug

No foul or discoloration Fouled and discoloration

Check if engine over heat

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

No knock Knock

y Poor circuit on the cooling system

Normal Engine overheat

Continually drive in acceleration
or high speed

y Too much carbon deposited in

combustion chamber

y Lean mixture
y Poor fuel quality
y Ignition timing too advanced

To this chapter contents

1. GENERAL INFORMATION

C. Engine runs sluggish (especially in low speed and idling)

1-16

Check and adjustment Fault condition Probable causes

Check ignition timing (using
ignition lamp)

D. Engine runs sluggish (High speed)

Normal

Abnormal

y Incorrect ignition timing (malfunction of

CDI or AC alternator)

Adjust the air screw of
carburetor

Good Poor

y Rich mixture (loosen the screw)
y Lean mixture (tighten the screw)

Air sucked through carburetor
gasket

Check for fuel supplying system
in automatic fuel cup

Check if carburetor clogged

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

y Insufficient fuel in fuel tank
y F uel filter clogged
y Restricted fuel tank vent

Good Abnormal

Good spark Poor

No air sucked Air sucked

Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground

Fault condition

Probable causes

Check and adjustment

Check ignition timing

y Malfunction of CDI
y Malfunction of AC alternator

Normal Abnormal

No clogged Clogged

y Cleaning

To this chapter contents

1. GENERAL INFORMATION

E. Clutch, driving and driving pulley

1-17

F. Poor handling

y Clutch weights spring broken
y Clutch outer stuck with clutch weights
y Connection parts in clutch and shaft worn out or burned

Engine can be started but
motorcycle can not be moved.

FAULT CONDITIONS

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

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)

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.

Steering is heavy

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

One wheel is wobbling

y Bent tie-rod
y Incorrect tie-rod adjustment
y Rear tie air pressure incorrect
y Improper wheel alignment
y Bent frame

Vehicle pulls to one side

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1. GENERAL INFORMATION

G. Loss power

1-18

Fault condition Probable causes Check and adjustment

Raise wheels off ground and
spin by hand

y Brake dragging

Abnormal

y Drive chain too tight
y Damaged wheel bearing
y Wheel bearing needs lubrication

Spin freely

Check tire pressure

Normal Abnormal

Accelerate lightly, engine speed
can be increase

Normal Abnormal

Check ignition timing

y Punctured tire
y Faulty tire valve

y F uel / 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

Normal Abnormal

Test cylinder compression

Normal Abnormal

y F aulty pulse generator
y F aulty CDI unit

y Leaking head gasket
y W orn cylinder and piston rings

Check carburetor

Normal Clogged

y Clean

Check spark plug

Normal Fouled or discolored

y Clean the spark plug
y Spark plug is incorrect heat range

Check for engine overheating

y Excessive carbon deposited in

combustion chamber

y W r ong type of fuel
y F uel / air mixture ratio is lean
y Use of poor quality fuel

y worn piston and cylinder
y F uel / air mixture ratio is lean
y W r ong type of fuel
y Ignition timing too advanced
y Excessive carbon deposited in

combustion chamber

Normal Overheating

Accelerate or run at high speed

Normal Knocks

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1. GENERAL INFORMATION

Lubrication Points

Drive chain Acceleration cable/ Front & rear brake

lever pivot

1-19

Speedometer gear Wheel bearing

Home page

Contents

2. MAINTENANCE INFORMATION

Precautions in Operation···················· 2-1
Periodical Maintenance Schedule······ 2-2

2-1

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

Drive Chain···········································2-7
Brake System (Disk Brake) ·················2-10
Brake Light Switch/Starting Inhibitor

Switch ··················································· 2-11
Headlight Beam Distance···················· 2-12
Clutch Disc Wear ·································2-12
Cushion················································· 2-12
Steering Handle···································· 2-13
Wheel/Tire·············································2-13
Nuts, Bolts Tightness··························2-13
Special Tools List ································2-14

2

Precautions in Operation

Specification

Fuel Tank Capacity 12000 c.c.

Capacity 1400 c.c.

Engine Oil

Change 1200 c.c.

Capacity 1300 c.c.

Transmission Gear oil

Change 1200 c.c.

Gear box oil 150 c.c.

Engine + radiator 850 c.c.

Capacity of coolant

Reservoir upper 420 c.c.

Clearance of throttle valve 1~3 mm

Type NGK CR8E

Spark plug

Gap 0.8 mm

BTDC 10º / 1700 rpm “F” Mark in idling speed
BTDC 27º / 4000 rpm Full timing advanced

Idling speed 1700±100 rpm

Cylinder compression pressure 12.0 ±2 kgf/cm²

Valve clearance IN:0.10 ± 0.02 mm EX:0.15 ± 0.02 mm

Front AT22x7-10

Tire dimension

Rear AT22x10-9

Tire pressure (cold) 3.8±2 psi

Battery 12V10Ah (MF battery) type: GTX12-BS

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2. MAINTENANCE INFORMATION

Periodical Maintenance Schedule

Maintenance

Code

Item

Every

300KM

1 Month

every

1,000KM

3 month

6 month

every

6000KM

1 year

every

12,000KM

15 month

every

14,500KM

every

3,000KM

1 Air cleaner

I C R

2 Fuel filter

I I R

3 Oil filter

C C

4 Engine oil change

R Replacement for every 1000 km

5 Tire pressure

I I

6 Battery inspection

I I

7 Brake & free ply check

I I

8 Steering handle check

I I

9 Cushion operation check

I I

10 Every screw tightening check

I I

11 Gear oil check for leaking

I I

12 Spark plug check or change

I I R

13 Gear oil change

R Replacement for every 12000 km

14 Frame lubrication

L

15 Exhaust pipe

I I

16 Ignition timing

I I

17 emission check in Idling

A I

18 Throttle operation

I I

19 Engine bolt tightening

I I

20 CVT driving device(belt)

I R

21 CVT driving device(roller)

C

22 Drive chain

I / L I / L

C

Lights/electrical
equipment/multi-meters

I I

23
24 Fuel lines

I I

25 Cam chain

I I

26 Valve clearance

I A

Lines & connections in cooling

I I

27
28 Coolant reservoir

I I

29 Coolant

I I R

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.
Rema rks: 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 system－Perform maintenance and check when continuous abnormal ignition, misfire,

after-burn, overheating occur.

b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system

when power is obvious lower. Than ever

2-2

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2. MAINTENANCE INFORMATION

2-3

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.

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 gap：0.8 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

Fuel tank

Fuel hose

Fuel filter

Fuel valve

carburetor

Lock nut

Throttle adjustment screw

Element

Clamp

Ground electrode

Central electrode

0.8~0.9mm

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2. MAINTENANCE INFORMATION

2-4

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

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.

Timing mark

2 bolts

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2. MAINTENANCE INFORMATION

2-5

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 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 0,8~1.5%

HC: below 900ppm

Ignition cable

Stopper screw

Air adjustment screw

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2. MAINTENANCE INFORMATION

2-6

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.

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.

CDI unit

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2. MAINTENANCE INFORMATION

2-7

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

Shaft Propulsion System

Check the drive shaft

Park the ATV on a level ground and remove brake
pedal and change rod gear shaft.
Loosen the rear drive shaft boot screw.
Remove 6 bolts them remove mission gear box.

Take out drive shaft and shaft universal joint.

Caution

Don’t lose the drive shaft spring.
Assemble drive shaft and shaft universal joint
ago with grease coating.

Teeth

Width

6 bolts

shaft universal joint

Clamp strips

9 bolts

drive shaft

2. MAINTENANCE INFORMATION

2-8

Check The Rear Gear box

Remove rear wheels and rear axle.
Loosen 3 bolts and remove rear axle gear box
under protector.

Loosen the 4 bolts of Rear Gear Box from the drive
shaft side.
Loosen 4 bolts from rear gear box by inner-left side
of the bottom of vehicle.
Then remove the rear gear box..

Use your hand to rotate and check the Rear Gear
Box for abnormal noise or cloggy rotation.

Caution

y Do not attempt to disassemble the Rear

Gear Box. Please exchange the whole
assembly if necessary.

3 bolts

4 bolts

4 bolts

Rear axle
side.

Drive shaft
side.

2. MAINTENANCE INFORMATION

2-9

Chain Propulsion System

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 bolts and turn drive
chain adjusting nuts until get the correct slack.
Tighten the axle holder bolts.

Torque: 3.25kgf-m

Caution

y This type ATV has a chain tensioner to

adjust and protect drive chain.

4 bolts

Adjustment nut

Tensioner

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2. MAINTENANCE INFORMATION

2-10

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.

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.

Screws

Transparent hose

Air bubble

Drain valve

Diaphragm plate

Upper

Master cylinder cap

Diaphragm

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2. MAINTENANCE INFORMATION

Brake Lining Wear

2-11

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.

Brake lining wear
limitation groove

Rear brake

Lining

Brake disk

Brake lining wear
limitation groove

Front brake

Brake switch

Brake switch

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2. MAINTENANCE INFORMATION

2-12

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

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.

Drive plate

Adjust screw

Clutch weight

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2. MAINTENANCE INFORMATION

2-13

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.

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

3.8±2psi

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

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

Rocker arm pin puller

NAME

Tappet adjusting wrench

NAME

Tappet adjusting wrench

NO SYM-1445100 NO SYM-9001200 NO SYM-1472100

NAME

Tappet adjuster

NAME

Valve cotter remove &
assembly tool

NAME

AC.G. Flywheel puller

NO SYM-2301000-HMA NO SYM-1471110/20 NO SYM-3110000-HMA

NAME

Left crank seal driver

NAME

Drive shaft puller

NAME

Driver shaft install bush & seal
driver

NO SYM-1332100-HMA NO SYM-2341110-HMA NO SYM-9120200-HMA

NAME

Bearing driver 6205LLU

NAME

Rear axle bearing driver

NAME

Counter shaft needle bearing
drive HK1516

NO SYM-9100410/440 NO

SYM-9100100 RA1
A3017

NO SYM-9100200-HMA

2-14

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2. MAINTENANCE INFORMATION

NAME

Counter shaft needle bearing
driver HK2016

NAME Bearing driver 6305 NAME

Left crank case cover bearing
driver 6000

NO SYM-9100300-RB1 NO SYM-2341110 NO SYM-9615000-RA1 6000

NAME

Bearing driver 6205

NAME

Seal driver 14x28x7 &14x26x6

NAME

Seal driver 30x40x5

NO SYM-9615000 NO SYM-9120600 RB1 RA1 NO SYM-9120100-RA1

(12*20*5)

(6901)

NAME Water pump oil seal driver NAME Water pump bearing driver NAME

Water pump mechanical
seal driver

NO SYM-9120500-H9A NO SYM-9100100 NO SYM-1721700-H9A

(6301)

(6204)

NAME

BEARING DRIVER

NAME

BEARING DRIVER

NAME Lock nut driver

NO SYM-9610000 NO SYM-9110400 NO

2-15

SYM-9020100

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2. MAINTENANCE INFORMATION

NAME Inner bearing puller NAME Inner bearing puller NAME

Outer bearing puller

NO SYM-6204002 NO SYM-6204022 NO SYM-6204001

NAME Universal holder NAME Clutch nut wrench NAME

Swing arm bearing 6007
puller

NO SYM-2210100 NO SYM-9020200 NO

SYM-2310000
RB1 RFA A6007

(55mm)

(55mm)

NAME Rear axle nut wrench NAME

Torque wrench

NAME

Rear axle nut torque wrench

NO SYM-HT06007 NO SYM-HT07004-RA1 NO

SYM-4230200

NAME ARM SUSPENSION NAME NAME

NO SYM-2300000 NO NO

2-16

2. MAINTENANCE INFORMATION

2-17

3. LUBRICATION SYSTEM

3-1

Mechanism Diagram······························ 3-1
Precautions in Operation······················3-2
Troubleshooting ····································3-2
Engine Oil··············································· 3-3

Engine Oil Strainer Clean······················3-3
Oil Pump·················································3-4
Gear Oil···················································3-7

Mechanism Diagram

Valve Rocker Arm

Cam Shaft

Spray Lubrication

Spray Lubrication

Press-In Lubrication

Press-In Lubrication

Oil Route

Con-Rod

Oil Route

Oil Pump

Rotate Direction

Oil Strainer

3

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Contents

3. LUBRICATION SYSTEM

3-2

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
Clearance between outer rotor and body 0.15~0.20 0.25

Oil pump

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

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3. LUBRICATION SYSTEM

3-3

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 value：3.5~4.5kgf-m

Engine Oil Strainer Clean

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 value：1.3~1.7kgf-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.

Drain bolt

Oil strainer cap

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Oil strainer

O-ring

3. LUBRICATION SYSTEM

3-4

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.

2 screws

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Clip

1 screw

Roller

3. LUBRICATION SYSTEM

3-5

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.

Pins

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3. LUBRICATION SYSTEM

3-6

Tighten the oil pump screw.

Oil Pump Installation

Install the oil pump, and then tighten screws.

Torque value：0.1~0.3kgf-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)

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1 screw

Roller

2 screws

Clip

3. LUBRICATION SYSTEM

3-7

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.

Gear oil drain bolt

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Gear oil join bolt

3. LUBRICATION SYSTEM

3-8

Notes:

To this chapter contents

4. FUEL SYSTEM

4-1

Mechanism Diagram ........................................... 1

Precautions in Operation..................................... 3

Trouble Diagnosis................................................4

Carburetor Remove / Install(for UA30A-6) .......... 5

Air Cut-Off Valve.................................................. 6

Vacuum Chamber ................................................ 7

Float Chamber..................................................... 8

Adjustment of Idle Speed.................................. 10

Carburetor Remove / Install(for

UA30A-A&UA30A1-6) ....................................... 11

Air Cut-Off Valve................................................

12

Throttle Valve.....................................................

13

Float Chamber...................................................

14

Adjustment of Idle Speed...................................

16

Fuel Tank...........................................................

17

Air Cleaner.........................................................

18

Mechanism Diagram

UA30A-6

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Contents

Fuel tank cap

Fuel tank

Carburetor

Fuel valve

Fuel Strainer

4. FUEL SYSTEM

4-2

UA30A-A&UA30A1-6

Fuel tank cap

Fuel tank

Carburetor

Fuel valve

Fuel Strainer

4. FUEL SYSTEM

4-3

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

yDo not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
yWhen disassembling fuel system parts, pay attention to O-ring position, replace with new one as

re-assembly

yThere is a drain screw in the float chamber for draining residual gasoline.
yDo not disassemble air cut valve arbitrarily.

Specification

ITEM UA30A – 6(RFA) UA30A-A(RFB) UA30A1-6(RFE)

Carburetor diameter 32.5 mm 20 mm 20 mm
I.D. number AG8 PTG 065 PTG 064
Fuel level 17 mm 14.8 mm 14.8 mm
Main injector #132 #108 #108
Idle injector #35 #35 #35
Idle speed 1700±100 rpm 1600±100 rpm
Throttle handle clearance 1~3
Pilot screw 1 1/2

Tool
Special service tools

Vacuum/air pressure pump
Fuel level gauge

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4. FUEL SYSTEM

4-4

Trouble Diagnosis

Poor engine start

yNo fuel in fuel tank
yClogged fuel tube
yToo much fuel in cylinder
yNo spark from spark plug(malfunction of ignition

system )

yClogged air cleaner
yMalfunction of carburetor chock
yMalfunction of throttle operation

Stall after started

yMalfunction of carburetor chock
yIncorrect ignition timing
yMalfunction of carburetor
yDirty engine oil
yAir existing in intake system
yIncorrect idle speed

Rough idle

yMalfunction of ignition system
yIncorrect idle speed
yMalfunction of carburetor
yDirty fuel

Intermittently misfire as acceleration

yMalfunction of ignition system

Late ignition timing

yMalfunction of ignition system
yMalfunction of carburetor

Power insufficiency and fuel consuming

yFuel system clogged
yMalfunction of ignition system

Mixture too lean

yClogged fuel injector
yVacuum piston stick and closed
yMalfunction of float valve
yFuel level too low in float chamber
yClogged fuel tank cap vent
yClogged fuel filter
yObstructed fuel pipe
yClogged air vent hose
yAir existing in intake system

Mixture too rich

yClogged air injector
yMalfunction of float valve
yFuel level too high in float chamber
yMalfunction of carburetor chock
yDirty air cleaner

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4. FUEL SYSTEM

4-5

Carburetor Remove / Install(for
UA30A-6)

Removal

Drain out fuel in the float chamber.

Turn the fuel valve lever on off.

Remove 1 screw from throttle lever cap them
remove throttle lever cap.
Loosen throttle cable adjustment nut and remove
throttle cable

Disconnect the fuel hose and by-starter and drain
tube
Release 2 clamps strip of air cleaner and inner
pipe.
Remove the carburetor.

Installation

Install in reverse order of removal procedures.

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fuel val ve lever

Drain bolt

adjustment nut

1 screw

By-starter

Drain tube

Fuel hose

2 clamps

4. FUEL SYSTEM

4-6

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.

Assembly

Install in reverse order of removal procedures.

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2 screws

O-ring

Spring

Air cut-off valve

Cover

4. FUEL SYSTEM

4-7

Vacuum Chamber

Disassembly

Removal

Loosen drain screw, and drain out residual fuel in
float chamber.
Remove screws (4 screws) of vacuum chamber
cover and the cover.

Remove compress spring and vacuum piston.
.

Remove fuel needle seat, spring, and injector
needle.
Check if the vacuum piston for wear out, crack or
other damage.
Check if the diaphragm for damage or crack.

Cautions

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Throttle valve

Spring

Do not damage vacuum diaphragm.

needle
seat

needle

Spring

vacuum
piston

4. FUEL SYSTEM

4-8

Float Chamber

Disassembly

Remove 4 mounting screws and remove float
chamber cover.

Remove the 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.

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

Pin Float valve

Check for wear or damage

4 Screws

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Float

Pin

Float valve

4. FUEL SYSTEM

4-9

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

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

yCheck again to ensure float valve, float for

proper installation.

yTo 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

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Needle jet

Needle jet holder

Main jet

Slow jet

Lock nut

Throttle adjustment screw

4. FUEL SYSTEM

4-10

Adjustment of Idle Speed

Caution

yAir 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.

yThe 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.

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Parking brake

Throttle valve stopper screw

Air adjustment screw

4. FUEL SYSTEM

4-11

Carburetor Remove / Install(for
UA30A-A&UA30A1-6)

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.

Installation

Install in reverse order of removal procedures.

Drain bolt

1 screw

Choke cable

Fuel pipe

Clamp

2 nuts

4. FUEL SYSTEM

4-12

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.

Assembly

Install in reverse order of removal procedures.

2 screws

O-ring

Spring

Air cut-off valve

Cover

4. FUEL SYSTEM

4-13

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.

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.

Throttle valve

Throttle
cable

Spring

Needle clam

p

Fuel needle clip

Fuel needle

4. FUEL SYSTEM

4-14

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.

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.

3 Screws

Float

Float valve

Fuel level plate Pin

Float

Pin

Float valve

Check for wear or damage

4. FUEL SYSTEM

4-15

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

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

yCheck again to ensure float valve, float for

proper installation.

yTo 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

Needle jet

Needle jet holder

Main jet

Slow jet

Air adjustment screw

Float gauge

Lock nut

Throttle adjustment screw

4. FUEL SYSTEM

4-16

Adjustment of Idle Speed

Caution

yAir 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.

yThe 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: 1600 ± 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: 0.8~1.5 %

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

stopper screw

4. FUEL SYSTEM

4-17

Fuel Tank

Fuel tank removal

Open the seat.
Remove the front cover and front top center cover.
Remove the side covers and lower side covers.
Remove the front fender.
Remove 2 bolts from tank cover BRKT.
(Covers remove please

refer chapter 13)

Remove the tank cap rubber.

remove 2 fuel tubes from fuel valve.

Remove 4 bolts from tank rear side & front side
and then remove fuel tank.
.

Installation

Install the tank in the reverse order of removal.

2 bolts

4 bolts

Fuel tube

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Fuel tank

FRONT

REAR

2 bolts

4. FUEL SYSTEM

4-18

Air Cleaner

Removal
FOR UA30A-6

Loosen the clamp strip of air cleaner and
carburetor, and then remove the vapor hose.

FOR UA30A1-6 and UA30A-A

Remove two nut from inner pipe and Loosen the
clamp strip of air cleaner 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).

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Clamp

4 bolts

4 hooks

Clamp

Clamp

4. FUEL SYSTEM

4-19

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.

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.

1 screw

Clamp

4. FUEL SYSTEM

4-20

Notes:

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5. ENGINE REMOVAL

5-1

Precautions in Operation..................... 5-Fel!

Bokmärket är inte definierat.

Removal of Engine ............................... 5-Fel!

Bokmärket är inte definierat.

Engine Installation................................ 5-Fel!

Bokmärket är inte definierat.

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

Item Capacity

Replacement 1200 c.c.

Engine oil capacity

Disassembly 1400 c.c.

Replacement 1200 c.c.

Gear oil capacity

Disassembly 1300 c.c.

Engine & radiator 780 c.c.

Reservoir 420 c.c. AS indicator shown

Coolant capacity

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

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Contents

5. ENGINE REMOVAL

5-2

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.

Starter motor wire

A.C.G wire couplers

Spark plug cap

Negative

Positive

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5. ENGINE REMOVAL

5-3

Remove muffler protect (2 bolts).

Loosen muffler front side bolt.

Remove 2 bolts, and then remove the exhaust muffler.

Remove 2 nuts, and then remove exhaust pipe.

2 bolts

2 bolts

2 nuts

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bolt

5. ENGINE REMOVAL

5-4

Remove fuel pipe and by-starter .

Loosen 1 screw from throttle lever side cover them
remove the side cover.
Loosen throttle cable adjustment nut. remove the
throttle cable.

Release the clamp stripes and remove the carburetor .

Release the clamp strips of left crankcase cover
ducts, and then remove the ducts.

by-starter

clamps

Clamps

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fuel pipe

Clamp

1 screw

5. ENGINE REMOVAL

5-5

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 brake pedal and change rod.

Remove 2 c clips from brake pedal.
Remove brake spring & stop switch spring
Remove brake penal.

1 bolt

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Thermo-sensor wire

Drain bolt

Outlet hose

Water hoses clamp

By-pass pipe

2 bolts

5. ENGINE REMOVAL

5-6

Remove 1 screw from duct band then remove it

Remove gear box cover bolts (6bolts) and then
remove the cover.

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.

Remove left side engine hanger, and then remove
engine by left side.

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

2 nuts

left side engine

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duct band

6 bolts

6. CYLINDER HEAD/VALVE

6-1

Mechanism Diagram··························· 6-1
Precautions in Operation··················· 6-2
Troubleshooting·································· 6-3
Cylinder Head Removal······················ 6-4
Cylinder Head Inspection··················· 6-7

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

Mechanism Diagram

6

0.7~1.1kgf-m

1.0~1.4kgf-m

1.0~1.4kgf-m

1.0~1.2kgf-m

3.6~4.0kgf-m

Home page

Contents

2.4~3.0kgf-m

1.0~1.4kgf-m

1.0~1.4kgf-m

1.0~1.4kgf-m

1.0~1.2kgf-m

6. CYLINDER HEAD/VALVE

6-2

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 ---

Intake 34.880 34.860

Camshaft Height of cam lobe

Exhaust 34.740 34.725

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

Intake 4.975~4.990 4.900

OD of valve stem

Exhaust

4.950~4.975

4.900

ID of valve guide 5.000~5.012 5.030

Intake 0.010~0.037 0.080

Clearance between
valve stem and guide

Exhaust 0.025~0.062 0.100
Inner 38.700 35.200

Free length of valve
spring

outer 40.400 36.900

Valve seat width 1.600 ---

Intake 0.10±0.02mm ---

Valve

Valve clearance

Exhaust 0.15±0.02mm ---

Tilt angle of cylinder head --- 0.050

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

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6. CYLINDER HEAD/VALVE

6-3

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

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6. CYLINDER HEAD/VALVE

6-4

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

4 bolts

Tensioner bolts

Thermostat bolts

3 bolts

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Spark plug

6. CYLINDER HEAD/VALVE

6-5

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:
Tool no:SYM-1445100
TOOL number: rocker arm and cam shaft puller

Remove cam shafts.

Special Service Tool:
Tool no:SYM-1445100
TOOL number: rocker arm and cam shaft puller

Cam shafts

Cam shaft setting plate

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2 bolts

Timing mark

Rocker arm

shaft and cam
shaft puller

Rocker arm shafts

Rocker arm shaft and

cam shaft puller

6. CYLINDER HEAD/VALVE

6-6

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.

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:
Tool no:SYM-1471110/20-4v
TOOL number: valve cotter remove &

assembly tool

4 Nuts

2 bolts

Spring retainer

Cotter

Exhaust valve

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Dowel pins

Gasket

Chain guide

Valve cotter remove

and assembly tool

Inner spring

Outer spring

Inlet valve

6. CYLINDER HEAD/VALVE

6-7

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.

To this chapter contents

Valve stem seals

6. CYLINDER HEAD/VALVE

6-8

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

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6. CYLINDER HEAD/VALVE

6-9

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: IN→ 0.08 mm

EX→ 0.10 mm

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.

5.0 mm valve guide reamer

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6. CYLINDER HEAD/VALVE

6-10

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

℃.

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 driver

5.0 mm

Valve guide driver

5.0mm

Valve guide reamer 5.0 mm

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6. CYLINDER HEAD/VALVE

6-11

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.

45°

Roughness

Old valve seat width

Valve seat width

32°

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6. CYLINDER HEAD/VALVE

6-12

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.

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.

Old valve seat width

60°

1.0mm

60°

45°

32°

Old valve seat width

Contact surface too high

Old valve seat width

Contact surface too low

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6. CYLINDER HEAD/VALVE

6-13

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.

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.

Exhaust valve

Inlet valve

Valve stem seal

Valve spring

Valve spring retainer

V

alve cotter

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Valve cotter remove

and assembly tool

6. CYLINDER HEAD/VALVE

6-14

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.

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Dowel pins

Gasket

Chain guide

4 Nuts

2 bolts

Cam shaft setting plate

6. CYLINDER HEAD/VALVE

6-15

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).

4 bolts

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2 bolts

Timing mark

3 bolts

Tensioner adjustment bolt

Thermostat bolts

6. CYLINDER HEAD/VALVE

6-16

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.

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.

To this chapter contents

4 bolts

Spark plug

Timing mark

7. CYLINDER/PISTON

7-1

Mechanism Diagram···························· 7-1
Precautions in Operation ···················· 7-2
Trouble Diagnosis································ 7-2
Cylinder and Piston Removal ············· 7-3

Piston Ring Installation ··················· 7-6
Piston Installation ···························· 7-7
Cylinder Installation························· 7-7

Mechanism Diagram

7

Home page

Contents

0.8~1.2kgf-m

1.0~1.4kgf-m

7. CYLINDER/PISTON

7-2

Precautions in Operation

General Information

y Both cylinder and piston service cannot be carried out when engine mounted on frame.

UA25A

Specification Unit：mm

Item Standard Limit

ID 74.995~75.015 75.100

Cylinder

Bend - 0.050

Top ring 0.015~0.050 0.090

Clearance between piston
rings

2

nd

ring 0.015~0.050 0.090
Top ring 0.150~0.300 0.500
2nd ring 0.300~0.450 0.650

Ring-end gap

Oil ring side rail 0.200~0.700 -

OD of piston (2nd) 74.430~75.480 75.380
Clearance between piston and cylinder 0.010~0.040 0.100

Piston/
Piston ring

ID of piston pin boss 17.002~17.008 17.020
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

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

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

7-3

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.

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: 75.100 mm

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Dowel pins

Top

Bottom

Center

7. CYLINDER/PISTON

7-4

Check cylinder if warp.

Service limit: 0.05 mm

Measure clearance between piston rings and
grooves.

Service Limit: Top ring: 0.09 mm

2

nd

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

2

nd

ring: 0.65 mm

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7. CYLINDER/PISTON

7-5

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 limit：75.380 mm

Compare measured value with service limit to
calculate the clearance between piston and
cylinder.

To this chapter contents

7. CYLINDER/PISTON

7-6

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

2

nd

ring

Oil ring

Top groove

2

nd

groove

Oil groove

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7. CYLINDER/PISTON

7-7

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.

Cylinder Installation

Install dowel pins and new gasket.

Dowel pins

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Clip end gap

IN mark

Cutout

7. CYLINDER/PISTON

7-8

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).

To this chapter contents

Coolant hose

8. V-BELT DRIVING SYSTEM

8-1

Mechanism Diagram ··························· 8-1
Maintenance Description···················· 8-2
Trouble Diagnosis······························· 8-2
Left Crankcase Cover ························· 8-3

Drive Belt··············································8-7
Drive Face·············································8-9
Clutch Outer/Driven Pulley··················8-12

Mechanism Diagram

5.0~6.0kgf-m

Home page

Contents

8

5.0~6.0kgf-m

8.5~10.5kgf-m