Sym Quad Raider 600 Service Manual

FOREWORD CONTENTS

HOW TO USE THIS MANUAL SERIAL NUMBER

Quad Raider 600

SERVICE MANUAL

FOREWORD

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Contents

This service manual contains the technical data of each component inspection and
repair for the SANYANG QuadRaider 600 ATV. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment”, providing technician with service guidelines.

If the style and construction of the ATV, QuadRaider 600, are different from 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 QuadRaider 600ATV. 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 and special tools information.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter contain the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content to acquire the special parts and system information
quickly.

There are 4 buttons, “Foreword”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the PDF version, and can be access to these items by
clicking on them.

If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can link 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 to
the homepage or contents. The content of each chapter can be selected too.
Therefore, when the user needs to check the content 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 on the top of the following
pages; clicking the button can back to the contents of this chapter.

CONTENTS

Homepage

Page Content Index

1-1 ~ 1-17

GENERAL INFORMATION

1

2-1 ~ 2-17

MAINTENANCE INFORMATION

2

3-1 ~ 3-8

LUBRICATION SYSTEM

3

4-1 ~ 4-13

FUEL SYSTEM

4

5-1 ~ 5-6

ENGINE REMOVAL

5

6-1 ~ 6-17

CYLINDER HEAD/ VALVE

6

7-1 ~ 7-8

CYLINDER/ PISTON

7

8-1 ~ 8-17

“V” BELT DRIVING SYSTEM

8

9-1 ~ 9-14

TRANSMISSION

9

10-1 ~ 10-16

WHEEL DRIVE SHAFT/ PROPELLER SHAFT

10

11-1 ~ 11-11

A.C. GENERATOR/ STARTING CLUTCH

11

12-1 ~ 12-8

CRANKCASE/ CRANKSHAFT

12

13-1 ~ 13-14

COOLING SYSTEM

13

14-1 ~ 14-8

BODY COVER

14

15-1 ~ 15-12

FRONT BRAKE AND FRONT WHEEL

15

16-1 ~ 16-13

STEERING/ FRONT SUSPENSION

16

17-1 ~ 17-18

REAR BRAKE/ REAR WHEEL/ REAR CUSHION

17

18-1 ~ 18-21

ELECTRICAL SYSTEM

18

19-1 ~ 19-2

ELECTRICAL DIAGRAM

19

SERIAL NUMBER

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Contents

Frame number

Engine number

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Contents

1. GENERAL INFORMATION

Symbols and Marks............................. 1-1

Torque Values .................................... 1-10

Troubles Diagnosis............................ 1-12

Lubrication Points ............................. 1-17

General Safety ..................................... 1-2

Service Precautions ............................ 1-3

Specifications ...................................... 1-9

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).

1

1-1

1. GENERAL INFORMATION

To this chapter contents

General Safety

Carbon monoxide

If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you have
to run your engine in a closed area, be sure to use
an extractor.

Caution

Exhaust contains toxic gas, which may cause one
to lose consciousness and even result in death.

Gasoline

Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.

Caution

Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.

Used engine oil

Caution

Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although
it might not be verified.
We recommend that you wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.

Hot components

Caution

Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.

Battery

Caution

• Battery emits explosive gases; flame is strictly

prohibited. Keeps the place well ventilated
when charging the battery.

• Battery contains sulfuric acid (electrolyte)

which can cause serious burns so be careful
do not be spray on your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery acid
in your eyes, flush it off immediately with
water and then go to hospital to see an
ophthalmologist.

• If you swallow it by mistake, drink a lot of

water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a
doctor.

• Keep electrolyte beyond reach of children.

Brake shoe

Do not use an air hose or a dry brush to clean
components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.

Caution

Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system

Brake fluid

Caution

Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.

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1. GENERAL INFORMATION

To this chapter contents

Service Precautions

 Always use with SANYANG genuine parts and

recommended oils. Using non-designed parts for
SANYANG ATV may damage the ATV.

 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.

 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.

 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.

 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.

 Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

 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.

 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.

 Store complex components such as transmission

parts in the proper assemble order and tie them
together with a wire for ease of installation later.

 Note the reassemble position of the important

components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).

 Components not to be reused should be

replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.

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1. GENERAL INFORMATION

1-4

 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.

 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.

 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.

 Remove residues of the old gasket or sealant

before reinstallation, grind with a grindstone if the
contact surface has any damage.

 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

 Rubber and plastic boots should be properly

reinstalled to the original correct positions as
designed.

Boots

 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.

1. GENERAL INFORMATION

To this chapter contents

 Lubricate the rotation face with specified

lubricant on the lubrication points before
assembling.

 Check if positions and operation for installed

parts is in correct and properly.

 Make sure service safety each other when

conducting by two persons.

 Note that do not let parts fall down.

 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.

 After service completed, make sure all

connection points is secured.
Battery positive (+) cable should be connected
firstly.

 And the two posts of battery have to be greased

after connected the cables.

 Make sure that the battery post caps are located

in properly after the battery posts had been
serviced.

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

solved it. And then replace with specified
capacity fuse.

Capacity
verification

1-5

1. GENERAL INFORMATION

To this chapter contents

 When separating a connector, it locker has to

be unlocked firstly. Then, conduct the service
operation.

 Do not pull the wires as removing a connector

or wires. Hold the connector body.

 Make sure if the connector pins are bent,

extruded or loosen.

 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.

 Check if the connector is covered by the twin

connector boot completely and secured properly.

 Before terminal connection, check if the boot is

crack or the terminal is loose.

 Insert the terminal completely.

Check if the boot covers the terminal.
Do not let boot open facing up.

 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.

 Wire band and wire harness have to be clamped

secured properly.

 Do not squeeze wires against the weld or its

clamp.

1-6

1. GENERAL INFORMATION

To this chapter contents

 Do not let the wire harness contact with rotating,

moving or vibrating components as routing the
harness.

 Keep wire harnesses far away from the hot

parts.

 Route wire harnesses to avoid sharp edges or

corners and also avoid the projected ends of
bolts and screws.

 Route harnesses so that they neither pull too

tight nor have excessive slack.

 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.

 Secure the rubber boot firmly as applying it on

wire harness.

Never Touch

 Never use wires or harnesses which insulation

has been broken. Wrap electrical tape around
the damaged parts or replace them.

 Never clamp or squeeze the wire harness as

installing other components.

Never clamp or
squeeze the wire
harness

Never too tight

1-7

To this chapter contents

1. GENERAL INFORMATION

 Do not let the wire harness been twisted as

installation.

 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.

 Before operating a test instrument, operator

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

 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?

1-8

1. GENERAL INFORMATION

To this chapter contents

Specifications

MAKER SANYANG MODEL UA60A-6

Overall Length 2110 mm Front Double arm

Overall Width 1150 mm

Suspension

System

Rear Unit Swing

Overall Height 1220 mm Front AT25x8-12 (off road)

Wheel Base 1300 mm

Tire Specifications

Rear AT25x8-12 (off road)

Front 900 mm Rim Aluminum

Dimension

Wheel tread

Rear 895 mm Front Disk (ψ220mm)

Front 180 kg

Brake System

Rear Disk (ψ180mm)

Rear 165 kg Max. Speed Above 80 km/hr

Curb Weight

Total 345 kg

Performance

Climb Ability Below 25°

Passengers/Weight Two /150 kg

Front 215 kg

Primary

Reduction

Belt

Rear 280 kg

Weight

Total Weight

Total 495 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 Ø92 mm Muffler

Expansion & Pulse

Type

Stroke 85 mm

Exhaust Pipe Position and

Direction

Left side, and

Backward

Cylinder

Number/Arrange

ment

Single Cylinder Lubrication System

Forced circulation &

splashing

Displacement 565cc Solid Particulate

Compression Ratio 10.2 CO Below 7.0 g/ km

Max. HP 20.4ps / 6000rpm HC Below 1.5g/ km

Max. Torque 3.6 Kg m / 2750rpm

Exhaust

Concentration

Nox Below 0.4g/ km

Ignition Full Transistor Ignition E.E.C. ―

Starting System Electrical Starter P.C.V. ―

Engine

Air filtration Sponge

Catalytic reaction control

system

―

1-9

1. GENERAL INFORMATION

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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

1-10

1. GENERAL INFORMATION

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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

1-11

To this chapter contents

1. GENERAL INFORMATION

Troubles Diagnosis

A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

Cylinder compression
pressure normal

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

Fuel supplied tom
carburetor sufficient

No fuel is supplied to
carburetor

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

g

round.

Perform cylinder compression
pressure test.

Check if sparks Weak sparks, no spark at

all

Low compression
pressure or no pressure

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.

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

Blowing in normal Blowing clogged

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

and intake vacuum, are clogged.

 Float valve clogged
 Lines in fuel tank evaporation system

clogged

 Malfunction of fuel pump
 Loosen or damaged fuel pump vacuum

hose

 Fuel filter clogged

 Malfunction of spark plug
 Spark plug foul
 Malfunction of CDI set
 Malfunction of AC generator
 Ignition coil is in open or short circuit
 Ignition coil leads open or short circuit
 Malfunction of main switch

 Piston ring seized
 Malfunction of cylinder valves
 Worn cylinder and piston ring
 Cylinder gasket leak
 Sand hole in compression parts

 Malfunction of throttle valve operation
 Air sucked into intake manifold
 Incorrect ignition timing

 Fuel level in carburetor too high
 Malfunction of throttle valve operation
 Throttle valve opening too wide

 Malfunction of automatic by- starter

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1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Try gradual acceleration and
check engine speed

Engine speed can be
increased.

Engine speed cannot be
increased.

Check ignition timing (Using
ignition lamp)

Check cylinder compression
pressure (using compression

Ignition timing correct Incorrect ignition timing

Compression pressure
correct

No compression pressure

Check if carburetor jet is
clogged

No clogged

Clogged

Remove spark plug

Check if engine over heat

No foul or discoloration

Fouled and discoloration

No knock

Knock

 Air cleaner clogged
 Poor fuel supply
 Lines in fuel tank evaporation system

clogged

 Exhaust pipe clogged
 Fuel nozzle clogged in carburetor.
 Fuel nozzle clogged in carburetor.

 Malfunction of CDI
 Malfunction of AC alternator

 Cylinder & piston ring worn out
 Cylinder gasket leaked
 Sand hole in compression parts
 Valve deterioration
 Seized piston ring

 Remove foreign

 Remove dirt
 Incorrect spark plug heat range

 Piston and cylinder worn out
 Lean mixture
 Poor fuel quality
 Too much carbon deposited in

combustion chamber

 Ignition timing too advanced
 Poor circuit on the cooling system

Normal

Engine overheat

Continually drive in acceleration
or high speed

 Too much carbon deposited in

combustion chamber

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

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1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

D. Engine runs sluggish (High speed)

Check ignition timing (using
ignition lamp)

Check for fuel supplying system
in automatic fuel cup

Check if carburetor clogged

 Incorrect ignition timing (malfunction of

CDI or AC alternator)

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

 Poor heat insulation gasket
 Carburetor lock loose
 Poor intake gasket
 Poor carburetor O-ring
 Vacuum hose crack

 Spark plug fouled
 Malfunction of CDI
 Malfunction of AC generator
 Malfunction of ignition coil
 Open or short circuit in spark plug leads
 Malfunction of main switch

 Insufficient fuel in fuel tank
 Fuel filter clogged
 Restricted fuel tank vent

Good

A

bnormal

Good spark Poor

No air sucked

A

ir sucked

Good Poor

Normal

A

bnormal

A

ir sucked through carburetor

gasket

A

djust the airscrew of

carburetor

No clogged Clogged

 Cleaning

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

Check and adjustment Fault condition

Probable causes

Check ignition timing

 Malfunction of CDI
 Malfunction of AC alternator

A

bnormal Normal

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1. GENERAL INFORMATION

E. Clutch, driving and driving pulley

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

Engine can be started but
motorcycle can not be moved.

FAULT CONDITIONS

PROBABLE CAUSES

 Drive belt worn out or deformation
 Weight roller worn out
 Movable drive face shaft worn out
 Driven pulley spring deformation
 Driven pulley shaft worn out
 Greased in drive belt and driven face.

Poor initial driving (Poor climbing
performance)

Engine running and misfire as
motorcycle initial forward moving or

j

umping suddenly (rear wheel

rotating as engine in running)

 Drive belt worn out or deformation
 Ramp plate of movable drive face damaged
 Driving pulley spring broken
 Clutch weights broken
 Drive slide-shaft gear groove broken
 Transmission gear damaged

F. Poor handling

Steering is heavy

FAULT CONDITIONS

PROBABLE CAUSES

One wheel is wobbling

Vehicle pulls to one side

 Bent rim
 Improperly installed wheel hub
 Excessive wheel bearing play
 Bent swing arm
 Bent frame
 Swing arm pivot bushing excessively
 Worn

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

 Damaged steering bearing
 Damaged steering shaft bushing

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1. GENERAL INFORMATION

G. Loss power

Check and adjustment Fault condition Probable causes

Raise wheels off ground and
spin by hand

 Brake dragging
 Drive chain too tight
 Damaged wheel bearing
 Wheel bearing needs lubrication

Spin freely

A

bnormal

 Punctured tire
 Faulty tire valve

 Fuel / air mixture ratio too rich or lean
 Clogged in air cleaner
 Clogged in muffler
 Restricted fuel flow
 Clogged fuel tank cap breather hole

 Faulty pulse generator
 Faulty CDI unit

 Leaking head gasket
 Worn cylinder and piston rings

 Clean

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

 Excessive carbon deposited in

combustion chamber

 Wrong type of fuel
 Fuel / air mixture ratio is lean
 Use of poor quality fuel

 Worn piston and cylinder
 Fuel / air mixture ratio is lean
 Wrong type of fuel
 Ignition timing too advanced
 Excessive carbon deposited in

combustion chamber

Check tire pressure

Normal

A

bnormal

A

ccelerate lightly, engine speed

can be increase

Normal

A

bnormal

Check ignition timing

Normal

A

bnormal

Test cylinder compression

Normal

A

bnormal

Check carburetor

Normal Clogged

Check spark plug

Normal Fouled or discolored

Check for engine overheating

Normal Overheating

A

ccelerate or run at high speed

Knocks Normal

1-16

1. GENERAL INFORMATION

Lubrication Points

Acceleration cable/ Front & rear brake/ Lever Pivot

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Wheel bearing

1-17

2. MAINTENANCE INFORMATION

2-1

Precautions in Operation ···················· 2-1

Periodical Maintenance Schedule ······ 2-2

Fuel Lines············································· 2-3

Acceleration Operation ······················· 2-3

Air Cleaner············································ 2-3

Spark Plug ············································ 2-4

Valve Clearance ··································· 2-4

Carburetor Idle Speed Adjustment····· 2-5

Ignition System ···································· 2-6

Cylinder Compression Pressure ········ 2-6

Drive Belt·············································· 2-7

Propeller Shaft ····································· 2-7

Front Differential ·································· 2-8

Rear Axle Gearbox······························· 2-8

Brake System ······································· 2-9

Brake Light Switch······························· 2-10

Headlight Beam Distance ···················· 2-11

Clutch Disc Wear ································· 2-11

Cushion················································· 2-11

Steering Handle···································· 2-12

Wheel/Tire············································· 2-12

Nuts, Bolts Tightness ·························· 2-12

Special Tools List ································ 2-13

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.

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

“F” Mark in idling speed BTDC 10º / 1700 rpm

Full timing advanced BTDC 27º / 4000 rpm

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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Contents

2

2. MAINTENANCE INFORMATION

2-2

Periodical Maintenance Schedule

Maintenance

Code

Item

Every

300KM

1 Month

Every

3 month

Every

6 month

Every

1 year

Every

15 month

Every

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

23

Lights/electrical
equipment/multi-meters

I I

24 Fuel lines

I I

25 Cam chain

I I

26 Valve clearance

I A

27

Lines & connections in cooling

I I

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.
Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in

the Heavily- polluted environment.

2. Maintenance should be performed more often if the ATV is frequently operated in high speed and
after the ATV has accumulated a higher mileage.

3. Preventive maintenance
a. Ignition 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.

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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 the lines when they
are deteriorated, damaged 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 adjusting screw.
Tighten the fixing nut, and check acceleration
operation condition.

Free play: 1~3 mm.

Air Cleaner

Remove the seat.
Loosen 5 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.

Fuel tank

Fuel hose

Fuel filter

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Lock nut

Throttle adjustment screw

Element

Clamp

Fuel valve

Carburetor

Screw

2. MAINTENANCE INFORMATION

2-4

Spark Plug

Recommended spark plug: CR8E
Remove the spark plug cap.
Clean the dirt around the spark plug hole.
Remove the spark plug.
Measure the spark plug gap.

Spark plug gap：0.8 mm

Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold the 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

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
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.

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2 bolts

Timing mark

0.8~0.9mm

Ground electrode

Central electrode

2. MAINTENANCE INFORMATION

2-5

Carburetor Idle Speed Adjustment

Caution

 Inspection & adjustment for idle speed have to

be performed after all parts in engine that
needed adjustment have been adjusted.

 Idle speed check and adjustment have to be

done after engine being warmed 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 coil

Idle speed adjust screw

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Air/fuel adjusting screw

2. MAINTENANCE INFORMATION

2-6

Ignition System

Caution

 Full transistor ignition system is setup by the

manufacturer so it cannot be adjusted.

 Ignition timing check procedure is for checking

whether ignition 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 which 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 means that the
ignition advance degree is normal.
If ignition timing is incorrect, check the full
transistor ignition set, 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:

 Incorrect valve clearance.
 Valve leaking.
 Cylinder head leaking, piston, piston ring and

cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.

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2. MAINTENANCE INFORMATION

2-7

Drive Belt

Loosen the 2 clamp strips of left crankcase cover,
and then remove the left crankcase cover
ventilation pipe.
Remove 17 bolts.
Remove the left crankcase cover.

Check if the belt is cracked or worn out.
Replace the belt if necessary or in accordance
with the periodical maintenance schedule to
replace it.

Width limit: 32.7 mm or above

Propeller Shaft

Remove 3 bolts from the propeller shaft connector.
Check the propeller shaft for any wear.
Check the rubber boots for any damage.

Caution

Don’t lose the propeller shaft spring.
Coat the propeller shaft gear with grease before
assembling the propeller shaft.

Teeth

Width

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Propeller shaft spring

9 bolts

Propeller shaft connector

Front propeller shaft

3 bolts

Rubber boot

2. MAINTENANCE INFORMATION

2-8

Front Differential

Check the front differential for abnormal noise or
unsmooth rotation.

Caution

 Do not attempt to disassemble the Front

Differential. Please exchange the whole
assembly if necessary.

Rear Axle Gearbox

Check the rear axle gearbox for abnormal noise or
unsmooth rotation.

Caution

 Do not attempt to disassemble the Rear

Gear Box. Please exchange the whole
assembly if necessary.

2 bolts

Front differential

Differential control unit

3 bolts

Rear axle gearbox

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2. MAINTENANCE INFORMATION

2-9

Brake System

Brake System Hose

Check 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

 In order to maintain brake fluid in the reservoir

in horizontal position, do not remove the cap

until handle stop.

 Do not operate the brake lever after the cap

had been removed. Otherwise, the brake fluid

will spread out if operated the lever.

 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.

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Transparent hose

Air bubble

Drain valve

Screws

Diaphragm plate

Upper

Diaphragm

Master cylinder cap

2. MAINTENANCE INFORMATION

2-10

Brake Lining Wear

The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.

Caution

 To check front brake lining must be remove

front wheel first.

 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

 Do not operate the brake lever after the clipper

removed to avoid clipping the brake lining.

 In order to maintain brake power balance, the

brake lining must be replaced with one set.

Brake Light 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

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Lining

Brake disk

Brake lining wear
limitation groove

Front brake

Brake switch

Brake switch

2. MAINTENANCE INFORMATION

2-11

Headlight Beam Distance

Turn on main switch.
Turn the headlight adjusting screw to adjust
headlight beam height.

Caution

 To adjust the headlight beam follows related

regulations.

 Improper headlight beam adjustment will

make in coming driver dazzled or insufficient
lighting.

Clutch Weight

Run the ATV and increase throttle valve opening
gradually to check the clutch operation.
If the ATV is in forward moving and shaking, check
clutch disc condition. Replace it

Cushion

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.

Warning

 Do not ride the ATV with poor cushion.
 Looseness, wear or damage cushion will make

poor stability and drive-ability.

Adj

ustingscrew

Clutch weight

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2. MAINTENANCE INFORMATION

2-12

Steering Handle

Caution

Check all wires and cables if they are interfered
with the rotation of steering handle bar.

Lift the front wheel off 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±2

psi

Check if front and rear tires’ pressure is 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 accordance
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

2-13

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

KNUCKLE BODY BRG.
6006 driver

NAME

Drive shaft puller

NAME

Driveshaft BRG. 6228 driver

NO

SYM-5024000-REA 6006

NO SYM-2341120-REA NO

SYM-2341110-REA 6228

NAME

BEVEL GEAR HOUSHING
BRG 6306 driver

NAME

WHEEL DRIVE SHAFT
BALL SET tool

NAME

Countershaft OIL SEAL
20*40*5

NO SYM-2343700-REA A6306 NO SYM-4423500-REA NO SYM-9121000-REA

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2. MAINTENANCE INFORMATION

2-14

NAME

NEEDLE BRG. 2220C driver

NAME MDF. Fixer NAME Final shaft gear stopper

NO SYM-9100400-REA 2220 NO

SYM-2211000-REA

NO

SYM-2343100-REA

NAME

Driveshaft BRG. 6328 driver

NAME

OUTPUT SHAFT OIL SEAL
42*52*7

NAME

OUTPUT SHAFT OIL SEAL
38*52*7

NO SYM-9100500-REA A6328 NO SYM-9120900-REA NO SYM-9120800-REA

(12*28*7)

(6901)

NAME Water pump oil seal driver NAME

WATER PUMP BRG. 6001
driver

NAME

Water pump mechanical seal
driver

NO SYM-9120200-REA NO SYM-6001300-REA A6001 NO SYM-1721700-H9A

NAME

CLUTCH COVER BRG. 6207
driver

NAME

R COVER OIL SEAL GUIDE

NAME Lock nut driver

NO SYM-9610000- REA A6207 NO SYM-1133000-REA NO SYM-9020100

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2. MAINTENANCE INFORMATION

2-15

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 Crankcase tool

NO SYM-2210100 NO SYM-9020200 NO SYM-1120000-ALL

(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

WHEEL KNUCKLE BODY
SEAL 40*55*8 driver

NAME

WHEEL KNUCKLE BODY
SEAL 40*50*6.5 driver

NO SYM-2300000 NO SYM-9123200-REA NO SYM-9123000-REA

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2. MAINTENANCE INFORMATION

2-16

NAME

MAIN BRG. UP/LWR
40*44*20 driver

NAME NAME

PULLEY DRIVEN FACE
41*44*4 OIL SEAL GUIDE

NO SYM-9100110-REA NO SYM-9100400 G5A ADA NO SYM-9121100-REA

NAME

ENG L COVER RADIAL BALL
BRG. 6006 driver

NAME

FINAL SHAFT BRG 6307
driver

NAME

PULLEY DRIVEN FACE
expander

NO SYM-9615010-REA 6006 NO SYM-2343110-REA 6307 NO SYM-2321000-REA

NAME

CLUTCH COVER 35*55*8
OIL SEAL

NAME

DRIVEN PULLEY
Disassemble tool

NAME

PULLEY DRIVEN FACE
SEAL COLLER tool

NO SYM-9120300-REA NO SYM-2301000-REA NO SYM-2323700-REA

NAME

R CASE PARK GEAR
CLIP GUIDE & installer

NAME

Driveshaft oil seal driver

NAME

OUTPUT SHAFT BRG
6307 driver

NO SYM-9060200-REA NO SYM-9120600-REA NO SYM-2346000-REA A6307

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2. MAINTENANCE INFORMATION

2-17

NAME

MAIN BRG. UP/LWR
40*44*20 assemble tool

NAME

L COVER FR. BRG. 6302
driver

NAME Drive plate fixer

NO SYM-9100100-REA NO SYM-9615000-REA 6302 NO

SYM-2230000-REA

NAME

NAME

NAME

NO NO NO

NAME NAME NAME

NO NO NO

NAME

NAME

NAME

NO NO NO

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Home page

3. LUBRICATION SYSTEM

Contents

Mechanism Diagram·································3-1

Precautions in Operation ·························3-3

Troubleshooting ·······································3-3

Engine Oil··················································3-4

Engine Oil Strainer Clean·························3-4

Oil Filter Unit ·············································3-5

Oil Pump ····················································3-6

Mechanism Diagram

3

3-1

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3. LUBRICATION SYSTEM

Cam Shaft

Spray Lubrication

Spray Lubrication

Press-In Lubrication

Con-Rod

Oil Route

Valve Rocker Arm

Oil Route

3-2

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3. LUBRICATION SYSTEM

Precautions in Operation

General Information:

 This chapter contains maintenance operation

for the engine oil pump and gear oil

replacement.

Specifications

Engine oil capacity Disassembly: 3000 c.c.

Replacement: 2400 c.c.

Replacement with oil filter replaced: 2700 c.c.
Oil viscosity SAE 10W-30 (Recommended

King serial oils)

Rear axle gear oil replacement: 100c.c.

Front differential gear oil replacement: 200c.c.

Gear oil viscosity SAE 80 or 90
(Recommended SYM Hypoid gear oil)

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

 Oil leaking
 Valve guide or seat worn out
 Piston ring worn out

Low oil pressure

 Low engine oil level
 Clogged in oil strainer, circuits or pipes
 Oil pump damage

Dirty oil

 No oil change periodically
 Cylinder head gasket damage
 Piston ring worn out

3-3

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3. LUBRICATION SYSTEM

Engine Oil

Turn off engine, and park the ATV in flat surface.
Check oil level with oil dipstick.
Do 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 the oil strainer and spring.
Clean the oil strainer.
Check if the `O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.

Torque value：1.3~1.7kgf-m

Refill oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.

Engine oil capacity: 2400c.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

Oil strainer

3-4

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3. LUBRICATION SYSTEM

3-5

Oil Filter Unit

Remove the oil filter unit with special tool.

Special Service Tool:
Tool No: SYM-1445100

Install the oil filter unit by hand.

Lock the oil filter unit with special tool.

Special Service Tool:
Tool No: SYM-1445100

Torque value：1.3~1.7kgf-m

Drain bolt

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3. LUBRICATION SYSTEM

3-6

Oil Pump

Oil Pump Removal

Remove the recoil starter and the AC Generator.

(Refer to chapter 10) 。

Remove the cir clip and take out the oil pump
sprocket.

Make sure that pump shaft can be rotated freely.
Remove 3 screws on the oil pump, and then
remove the oil pump.

Oil Pump Disassembly

Remove the screws on oil pump cover and
remove the cover.
Remove the oil pump shaft roller and shaft.

Cir Clip

3 screws

1 screw

Roller Pin

3. LUBRICATION SYSTEM

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 the 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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3-7

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3. LUBRICATION SYSTEM

3-8

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 the oil pump sprocket, and then install cir
clip onto oil pump shaft.

1 screw

Roller

3 screws

Cir Clip

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3. LUBRICATION SYSTEM

Notes:

3-9

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Contents

4. FUEL SYSTEM

`

Vacuum Chamber ............................. 4-6

Float Chamber................................... 4-7

Adjustment of Idle Speed................. 4-9

Fuel Tank........................................... 4-10

Air Cleaner ........................................ 4-11

Mechanism Diagram ......................... 4-1

Precautions in Operation ................. 4-2

Trouble Diagnosis............................. 4-3

Carburetor Removal / Installation.... 4-4

Air Cut-off Valve................................ 4-5

Mechanism Diagram

UA60A-6

Fuel tank

Carburetor

Fuel valve

Fuel Strainer

4

Fuel tank cap

4-1

4. FUEL SYSTEM

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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

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

re-assembly

There is a drain screw in the float chamber for draining residual gasoline.
Do not disassemble air cut valve arbitrarily.

Specification

ITEM UA60A-6

Carburetor diameter 35 mm

I.D. number AG8

Fuel level 17 mm

Main injector #132

Idle injector #92

Idle speed 1700±100 rpm

Throttle handle clearance 1~3

Pilot screw 1 1/2

Tool

Special service tools

Vacuum/air pressure pump
Fuel level gauge

4-2

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4. FUEL SYSTEM

Trouble Diagnosis

Poor engine start

No fuel in fuel tank
Clogged fuel tube
Too much fuel in cylinder
No spark from spark plug(malfunction of ignition

system )

Clogged air cleaner
Malfunction of carburetor chock
Malfunction of throttle operation

Stall after started

Malfunction of carburetor chock
Incorrect ignition timing
Malfunction of carburetor
Dirty engine oil
Air existing in intake system
Incorrect idle speed

Rough idle

Malfunction of ignition system
Incorrect idle speed
Malfunction of carburetor
Dirty fuel

Intermittently misfire as acceleration

Malfunction of ignition system

Late ignition timing

Malfunction of ignition system
Malfunction of carburetor

Power insufficiency and fuel consuming

Fuel system clogged
Malfunction of ignition system

Mixture too lean

Clogged fuel injector
Vacuum piston stick and closed
Malfunction of float valve
Fuel level too low in float chamber
Clogged fuel tank cap vent
Clogged fuel filter
Obstructed fuel pipe
Clogged air vent hose
Air existing in intake system

Mixture too rich

Clogged air injector
Malfunction of float valve
Fuel level too high in float chamber
Malfunction of carburetor chock
Dirty air cleaner

4-3

4. FUEL SYSTEM

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Carburetor Removal / Installation

Removal

Remove the fuel tank.
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

Remove the sleep adjustment wire.

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.

throttle cable

adjustment wire

By-starter

1 screw

Drain tube

Fuel hose

2 clamps

adjustment nut

4-4

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4. FUEL SYSTEM

4-5

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

Air cut-off valve

Spring

Cover

4. FUEL SYSTEM

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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

vacuum chamber cover

Spring

Do not damage vacuum diaphragm.

needle
seat

needle

Spring

vacuum
piston

4 bolts

4-6

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4. FUEL SYSTEM

4-7

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

PinFloat valve

Check for wear or damage

4 Screws

Pin

Float valve

Float

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4. FUEL SYSTEM

Remove main jet, needle jet holder, needle jet,
slow jet and air adjustment screw.

Caution

Take care not to damage jets and adjust screw.

 Before removing adjustment screw, turn it all

the way down and note the number of turns.

 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

Check again to ensure float valve, float for

proper installation.

To ensure correct measurement, position the

float meter in such a way so that float chamber
face is vertical to the main jet.

Fuel level: 14.8mm

Installation of carburetor

Install carburetor in the reverse order of removal.
Following adjustments must be made after
installation.

˙Throttle cable adjustment.
˙Idle adjustment

Air adjustment screw

Float gauge

Needle jet Needle jet holder

Slow jet

Main jet

Lock nut

Rubbe

Throttle adjustment screw

4-8

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4. FUEL SYSTEM

4-9

Adjustment of Idle Speed

Caution

Air screw was set at factory, so no adjustment is

needed. Note the number of turns it takes to
screw it all the way in for ease of installation.

The parking brake must be used to stop the ATV

to perform the adjustments.

Use a tachometer when adjusting engine RPM.
Screw in air adjustment screw gently, then back up
to standard turns.

Standard turns: 2 turns

Warm up engine; adjust the throttle stopper wire 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: 0.5~1.0 %

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.

Air adjustment screw

Parking brake

Throttle valve stopper wire

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4. FUEL SYSTEM

4-10

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 fuel unit wire from tank.
(Covers remove please

refer chapter 13)

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.

Fuel unit

4 bolts

Fuel tube

FRONT REAR

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4. FUEL SYSTEM

4-11

Air Cleaner

Removal

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

Loosen the clamp strip of air cleaner, and then
remove the air cleaner vapor hose.
Remove the air cleaner (4 bolts).

Installation

Install the tank in the reverse order of removal.

Cleaning air cleaner element

Remove the air cleaner cover (5 catch hooks).

Remove element mounting screw.
Loosen the clamp strip of air cleaner element.

Clamp

4 bolts

Clamp

Clamp

5 Catch hooks

4. FUEL SYSTEM

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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.

Element

4-12

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4. FUEL SYSTEM

4-13

Notes:

Contents

Home page

5. ENGINE REMOVAL

Precautions in Operation...................... 5-1

Engine Removal .................................... 5-2

Engine Installation ................................ 5-6

Precautions in Operation

General Information

 The engine has to be supported with special service tools that can be lifted or adjustable.

 The following parts can be serviced as engine being 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.

Specification

Item Capacity

Replacement 2400 c.c.

Replacement with oil filter changed 2700 c.c.

Engine oil capacity

Disassembly 3000 c.c.

Rear axle gear oil capacity Replacement 100 c.c.

Front differential gear oil capacity Replacement 200 c.c.

Engine & radiator 1980 c.c.

Reservoir 420 c.c.

Coolant capacity

Total 2400 c.c.

5

Torque Value

Engine hanger bolt 7.5~9.5kgf-m

Exhaust muffler mounting bolt 2.8~3.2kgf-m

Exhaust muffler connection nut 1.0~1.4kgf-m

5-1

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5. ENGINE REMOVAL

Engine Removal

Negative

Remove the seat.

Positive

Remove the battery negative terminal (-).
Remove the battery positive (+) terminal.
Remove front fender and the footrest (refer
chapter 13).

Remove the starter motor wire.

Remove the spark plug cap.

Disconnect A.C. Generator wire couplers.

Spark plug cap

A.C.G wire couplers

Starter motor wire

5-2

5. ENGINE REMOVAL

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Remove the front left and rear left tires.

Remove the idle speed adjustment nut.

Remove 2 bolt on the muffler.

Remove the muffler.

Remove the throttle cable.
Remove 2 nuts and 1 bolt.

Remove the exhaust pipe.

Remove the choke cable and ventilation tube.

Remove 2 nuts, and then remove exhaust pipe.

Idle speed adjustment nut

Throttle cable

Choke cable

Ventilation tube

5-3

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5. ENGINE REMOVAL

5-4

Remove 2 manifold clamps.

Remove the carburetor.

Remove 4 bolts.

Remove the air cleaner.

Remove 2 bolts.
Remove the muffler.

Remove 2 nuts and 1 bolt.

Remove the exhaust pipe.

Manifold clamps

4 bolts

2 bolts

2 nuts

Bolt

5. ENGINE REMOVAL

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Remove the coolant drain bolt and drain out

coolant.
Remove the coolant inlet pipe from the water

pump cover and the outlet pipe from the

thermostat cover.
Remove the PCV pipe.

Remove 2 bolts.

Remove the starter motor.

Remove 3 bolts on the front propeller shaft
connector.

Remove the front propeller shaft.

Remove 3 bolts on the rear propeller shaft
connector.

Remove the rear propeller shaft.

Be careful not to do any damage to the rubber
boot.

PCV pipe

Coolant pipe

Starter motor

Rubber boot

2 bolts

3 bolts

3 bolts

Rubber boot

5-5

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5. ENGINE REMOVAL

5-6

Remove the rear brake pedal.

Remove the coolant reserve tank.

Remove the front and rear side engine hanger

mounting nuts and bolts.

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

Engine Installation

Check the bush of engine hanger parts for any
damage.
Install the engine in the reverse procedures of
removal.

Caution

 Be careful when removing and installing the

engine.

 Do not bend or twist the wires and tubes.
 Cables wires have to be routed in accordance

with normal layout.

Engine hanger Bolt:
Torque value: 7.5~9.5kgf-m

3 bolts

2 bolts

Engine hanger

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

 This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as

rocker arm.
 Cylinder head service can be carried out when engine is in frame.

Specification

Item Standard Limit

Compression pressure 12±2 kg/cm2 ---

Intake 36.478 36.458

Camshaft Height of cam lobe

Exhaust 36.847 36.832

ID of valve rocker arm 13.000~13.018 13.098

Rocker arm

OD of valve rocker arm shaft 12.991~13.009 11.936

Intake 4.975~4.990 4.900

OD of valve stem

Exhaust 4.955~4.970 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 33.700 30.100

Free length of valve
spring

outer 38.800 35.200

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

 Improper valve adjustment

 Burnt or bent valve

 Improper valve timing

 Valve spring damage

 Valve carbon deposit.

2. Cylinder head

 Cylinder head gasket leaking or damage

 Tilt or crack cylinder

3. Piston

 Piston ring worn out.

High compression pressure

 Too much carbon deposit on combustion chamber or piston head

Noise

 Improper valve clearance adjustment
 Burnt valve or damaged valve spring
 Camshaft wear out or damage
 Chain wear out or looseness
 Auto-tensioner wear out or damage
 Camshaft sprocket
 Rocker arm or rocker arm shaft wear out

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6. CYLINDER HEAD/VALVE

6-4

Cylinder Head Removal

Remove the engine from the frame. (Refer to
chapter 5)
Remove the inlet pipe (2 nuts).

Remove 2 thermostat bolts and then remove the
thermostat.
Remove the bolt and spring of the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).

Remove Air Injection system (AI) pipe mounting
bolts.
Remove the spark plug.

Loosen 4 bolts from the head cover then remove
head cover.

2 nuts

4 bolts

Tensioner bolts

Thermostat bolts

4 bolts

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6. CYLINDER HEAD/VALVE

6-5

Remove the side cover mounting blots of cylinder
head, and then remove the side cover.

Remove left crankcase cover, and turn the drive
face.
Align the timing mark on the cam sprocket with
that of cylinder head to make the piston at TDC
position.

Loosen 2 bolts from the cam sprocket.
Remove the cam sprocket disk and washer.
Remove the cam sprocket.

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

Cam shafts

Timing Mark

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3 bolts

Rocker arm shaft

and camshaft

p

uller

2 bolts

Cam sprocket disk

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

 Do not damage the matching surfaces of

cylinder and cylinder head.

 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

 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

Dowel pins

Gasket

Chain guide

Valve cotter remove

and assembly tool

Inner spring

Outer spring

Inlet valve

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6. CYLINDER HEAD/VALVE

6-7

Remove the valve stem seals.

Clean carbon deposits in the 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.

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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 reame

r

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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

 Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed

as heating it.

 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

 Check if new valve guide is deformation after

pressed it in.

 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

 Using cutting oil when correcting valve guide

with a reamer.

 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

 Do not let emery enter into between valve stem

and valve guide.

 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 is too high, grind the valve
seat with 32° cutter.
Then, grind the valve seat to specified width.

If the contact surface is 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 being ground, coat the valve
seat surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto the cylinder and
valve after grind.

Cylinder Head Reassembly

Lubricate the valve stem with engine oil, and then
insert the valve into valve guide.
Install the new valve stem oil seal.
Install the 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 the
valves.

Caution

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 the cylinder head on working table
so that can prevent valve from being 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.
Prevent the 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 the two sprocket
bolt holes and the lower bolt hole of the cylinder
side cover.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.

Caution

Make sure timing marks are matched.

Install the cylinder head side cover (3 bolts).
Install the thermostat (2 bolts).

Loosen auto tensioner adjustment bolt and
remove bolt and spring.
Install tensioner and install spring and adjustment
bolt.

Install cylinder head 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 vehicle performance be
affected.

Install the engine onto frame (refer chapter 5).

Valve Clearance Adjustment

Loosen Air Injection system (AI) pipe upper side
bolt (2 bolts).
Remove the 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

 If lubricant does not flow to cylinder head,

engine components will be worn out seriously.

Thus, it must be confirmed.

 When checking lubricant flowing condition, run

the engine at idle speed. Do not accelerate

engine speed.

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4 bolts

Timing mark

6. CYLINDER HEAD/VALVE

6-17

Notes:

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Home page

Contents

7. CYLINDER/PISTON

Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6

Piston Installation ···························· 7-7

Cylinder Installation························· 7-7

Precautions in Operation ···················· 7-2

Trouble Diagnosis································ 7-2

Cylinder and Piston Removal ············· 7-3

Mechanism Diagram

1.0~1.4kgf-m

7

0.8~1.2kgf-m

7-1

7. CYLINDER/PISTON

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Precautions in Operation

General Information

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

UA25A

Specification Unit：mm

Item Standard Limit

ID 92.00 92.100

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

 Cylinder or piston ring worn out

Knock or Noise

 Cylinder or piston ring worn out

 Carbon deposits on cylinder head top-side

 Piston pin hole and piston pin wear out

Smoking in Exhaust Pipe

 Piston or piston ring worn out

 Piston ring installation improperly

 Cylinder or piston damage

Engine Overheat

 Carbon deposits on cylinder head top side

 Cooling pipe clogged or not enough in coolant

flow

7-2

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7. CYLINDER/PISTON

Cylinder and Piston Removal

Remove the cylinder head (refer to chapter 6).
Remove the coolant hose from cylinder.

Remove the cylinder.

Cover the holes of crankcase and cam chain with

a piece of cloth to prevent foreign material falling

into the crankcase.
Remove the piston pin clip, and then remove the

piston pin and piston.

Remove the cylinder gasket and dowel pin.
Clean up all residues or foreign materials from

the two contact surfaces of cylinder and

crankcase.

Caution

 Wet the residues by solvent so that the

residues can be removed more easily.

Inspection

Check if the inner diameter of cylinder is worn 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

Dowel pins

Top

Center

Bottom

7-3

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7. CYLINDER/PISTON

7-4

Check cylinder if warp.

Service limit: 0.05 mm

Measure the 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

7. CYLINDER/PISTON

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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 the 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.

7-5

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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

 Do not damage piston and piston rings as installation.
 All marks on the piston rings must be forwarded to up side.
 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

7. CYLINDER/PISTON

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Clean up all residues and foreign materials on

the contact surface of crankcase. Pay attention to

not let these residues and foreign materials fall
into crankcase.

Caution

Wet the residues into solvent so that the residues
can be removed more easily.

Piston Installation

Install the piston and piston pin, and place the IN
marks on the piston topside forward to inlet valve.

Install new piston pin clip.

Caution

 Do not let the opening of piston pin clip align

with the piston cutout.

 Place a piece of cloth between piston and

crankcase in order to prevent snap ring from
falling into crankcase during servicing.

Cylinder Installation

Install dowel pins and new gasket.

IN mark

Clip end gap

Dowel pins

Cutout

7-7

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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).

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 ·············································· 8-3

Drive Plate ············································8-4

Movable Drive Face Disassembly······· 8-6

Driven Pulley Disassembly ·················8-13

Mechanism Diagram

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Contents

8

5.0~6.0kgf-m

5.0~6.0kgf-m

5.0~6.0kgf-m

8. V-BELT DRIVING SYSTEM

8-2

Maintenance Description

Precautions in Operation
General Information

 Drive face, clutch outer, and driven pulley can be serviced on the vehicle.

 Drive belt and drive pulley must be free of any grease.

Specification

Item Standard value Limit

Driving belt width 30.700 mm 29.200 mm

OD of movable drive face boss 35.970~35.990 mm 35.950 mm

ID of movable drive face 36.010~36.035 mm 36.055 mm

OD of weight roller 29.992~30.008 mm 29.950 mm

ID of clutch outer 140.000~140.200 mm 140.500 mm

Thickness of clutch weight 6.000 mm 3.000 mm

Free length of driven pulley spring 124.5 mm 119.500 mm

OD of driven pulley boss 40.965~40.985 mm 40.945 mm

ID of driven face 41.000~41.050 mm 41.070 mm

Weight of weight roller 19.700~20.300 g 19.200 g

Torque value

 Drive face nut: 8.5~10.5kgf-m
 Clutch outer nut: 5.0~6.0kgf-m

 Drive plate nut: 5.0~6.0kgf-m

Special Service Tools

Clutch spring compressor: SYM-2301000
Inner bearing puller:

SYM-6204002

Clutch nut wrench 39 x 41 mm:

SYM-9020200

Universal holder:

SYM-2210100

Bearing driver:

SYM-9100100

Trouble Diagnosis

Engine can be started but vehicle can not
move

1. Worn drive Belt

2. Worn drive face

3. Worn or damaged clutch weight

4. Broken driven pulley

Shudder or misfire when driving

1. Broken clutch weight

2. Worn clutch weight

Insufficient horsepower or poor high
speed performance

1. Worn drive belt

2. Insufficient spring force of driven pulley

3. Worn roller

4. Driven pulley operation un-smoothly

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8. V-BELT DRIVING SYSTEM

8-3

Left Crankcase Cover

Left crankcase cover removal

Release 2 clamp strips of left crankcase cover

ducts, and then remove the ducts.

Remove left crankcase cover cap.
Remove left crankcase cover bolts (17bolts).

Remove 2 dowel pin and gasket.

Left crankcase cover installation

Install left crankcase cover in the reverse

procedure of removal.

Drive Belt

Loosen 1nut from the drive face with Special tool.

Tool name: Movable Drive Face Holder

Tool NO: SYM-2211000-REA

Remove the movable drive face.

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15 bolts

L case cap

SYM-2211000-REA

2 bolts

8. V-BELT DRIVING SYSTEM

8-4

Loosen 1nut from the driven pulley with Special
tool.

Tool name: Universal holder

Tool NO: SYM-2210100

Remove the drive pulley and belt.

Inspection

Check the drive belt for crack or wear. Replace it if

necessary.

Measure the width of drive belt as diagram shown.

Service Limit: 29.2 mm

Replace the belt if exceeds the service limit.

Caution

 Using the genuine parts for replacement.

 The surfaces of drive belt or pulley must be

free of grease.

 Clean up all grease or dirt before installation.

Drive Plate

Remove the drive face.

Loosen 5 bolts from the CVT cooling plate then

remove it.

Drive face

SYM-2210100

Belt tooth

Width

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8. V-BELT DRIVING SYSTEM

8-5

Loosen 10 bolts from the clutch cover.

Remove the clutch cover.

Remove the clutch outer.

One-way Clutch Inspection

Check each roller for wear or damage.

Hold the clutch outer and turning the one way

clutch for right side. .

Loosen the drive plate nut with special tool.

Remove the drive plate.

Tool name: drive plate holder

Tool NO: SYM-2230000-REA

10 Belts

SYM-2230000-REA

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8. V-BELT DRIVING SYSTEM

8-6

Movable Drive Face Disassembly

Loosen 4 bolts form the drive face.

Remove the drive face plate

Remove the drive face plate

Remove the ramp plate and weight roller (8pcs).

Inspection

The weight rollers are to press movable drive face

by means of centrifuge force.

Thus, if weight rollers are worn out or damaged,

the centrifuge force will be affected.

Check if rollers are worn out or damaged.

Replace it if necessary.

Measure each roller’s outer diameter. Replace it if

exceed the service limit.

Service limit: 29.50 mm

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8. V-BELT DRIVING SYSTEM

8-7

Check if drive face boss is worn or damaged and

replace it if necessary.

Measure the outer diameter of movable drive face

boss, and replace it if it exceed service limit.

Service limit: 35.950 mm

Measure the inner diameter of movable drive face,

and replace it if it exceed service limit.

Service limit: 36.055 mm

Reassembly/installation
Install weight rollers.

Caution

The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.

Install ramp plate.

Movable drive face

Drive face boss

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8. V-BELT DRIVING SYSTEM

8-8

Left crankcase cover inspection

Remove cir clip with inner cir clip pliers

Check bearing on left crankcase cover.

Rotate bearing’s inner ring with fingers.

Check if bearings can be turned in smooth and

silent, and also check if bearing outer ring is

mounted on cover tightly.

If bearing rotation is uneven, noising, or loose

bearing mounted, then replace it.

Remove the bearing 6302 with inner bearing

puller.

Tools number: SYM-6204025

Tools name: INNER BEARING PULLER.

Remove the bearing 6006 with inner bearing

puller.

Tools number: SYM-6204025

Tools name: INNER BEARING PULLER.

Cir clip

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SYM-6204025

SYM-6204025