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
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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.
1-2
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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To this chapter contents
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
To this chapter contents
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
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1. GENERAL INFORMATION
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
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
1-12
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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
1-13
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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
1-14
To this chapter contents
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
1-15
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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
To this chapter contents
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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