SYM TRACKRUNNER 200 User Manual

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Track Runner 200

SERVICE MANUAL

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This service manual contains the technical data of each component inspection and repair for the SANYANG Track Runner 180 ATV. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the ATV, Track Runner 180, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice.

Service Department

SANYANG INDUSTRY CO., LTD.

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Contents

HOW TO USE THIS MANUAL

This service manual describes basic information of different system parts and system inspection & service for SANYANG Track Runner 180 ATV. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.

The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information and special tools manual. The third to the 11th chapters cover engine and driving systems. The 12th chapter is cooling system. The 13th to the 16th chapter is contained the parts set of assembly frame body. The 17th chapter is electrical equipment. The 18th chapter is wiring diagram. Please see index of content for quick having the special parts and system information.

There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and “Mechanism Illustrations” on the CD-R version, and can be access to these items by click the mouse.

If user wants to look for the content of each chapter, selecting the words of each chapter on the contents can reach to each chapter. There are two buttons, “Homepage and contents, onto the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this chapter contents” button at the second page of each content so that clicking the button can back to the contents of this chapter.

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Page Content Index

1-1 ~ 1-20 2-1 ~ 2-14 3-1 ~ 3-8 4-1 ~ 4-12 5-1 ~ 5-6 6-1 ~ 6-14

7-1 ~ 7-8

GENERAL INFORMATION SERVICE MAINTENANCE INFORMATION LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL CYLINDER HEAD/VALVE

CYLINDER/PISTON

CONTENTS

1 2 3 4 5 6

8-1 ~ 8-14

9-1 ~ 9-12 10-1 ~ 10-8 11-1 ~ 11-8 12-1 ~ 12-14 13-1 ~ 13-10 14-1 ~ 14-14

15-1 ~ 15-12 16-1 ~ 16-18

17-1 ~ 17-22

“V” TYPE BELT DRIVING SYSTEM/KICK-STARTER

FINAL DRIVING MECHANISM ALTERNATOR CRANKSHAFT/ CRANKCASE COOLING SYSTEM BODY COVER FRONT BRAKE AND FRONT WHEEL

STEERING/FRONT SUSPENSION

REAR BRAKE/REAR WHEEL/REAR CUSHION ELECTRICAL EQUIPMENT

9 10 11 12 13 14

15 16

18-1 ~ 18-2

ELECTRICAL DIAGRAM

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Contents

SERIAL NUMBER

Frame number

Engine number

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Contents

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

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

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

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

Specifications....................................... 1-11

Torque Values...................................... 1-12

Troubles Diagnosis.............................. 1-14

Parts to Be Greased............................. 1-19

1. GENERAL INFORMATION

Specifications......................................1-10

Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

Warning

Caution

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

Means that equipment damages may result if procedures are not followed. Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the

Engine oil

Grease King Mate G-3 is recommended.

Gear oil

Locking sealant

Oil seal

Renew

Brake fluid

Special tools

Correct

Wrong

damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil)

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL # 140) Apply sealant; medium strength sealant should be used unless otherwise specified.

Apply with lubricant.。

Replace with a new part before installation.

Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools

Meaning correct installation.

Meaning wrong installation.

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).

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To this chapter contents

1. GENERAL INFORMATION

General Safety

Carbon monoxide

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

Caution

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

Gasoline

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

Caution

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

Used engine oil

Caution

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

Hot components

Caution

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

Battery

Caution

• Battery emits explosive gases; flame is strictly prohibited. Keeps the place well ventilated when charging the battery.

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

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

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

• Keep electrolyte beyond reach of children.

Brake shoe

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

Caution

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

Brake fluid

Caution

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

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Service Precautions

y Always use with SANYANG genuine parts and

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

y Special tools are designed for remove and

install of components without damaging the parts being worked on. Using wrong tools may result in parts damaged.

y When servicing this ATV, use only metric tools.

Metric bolts, nuts, and screws are not interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.

1. GENERAL INFORMATION

y Never bend or twist a control cable to prevent

unsmooth control and premature worn out.

y Rubber parts may become deteriorated when

old, and prone to be damaged by solvent and oil. Check these parts before installation to make sure that they are in good condition, replace if necessary.

y When loosening a component which has

different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.

y Store complex components such as

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

y Clean the outside of the parts or the cover

before removing it from the ATV. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause damage.

y Wash and clean parts with high ignition point

solvent, and blow dry with compressed air. Pay special attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.

y Note the reassemble position of the important

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

y Components not to be reused should be

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

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1. GENERAL INFORMATION

y The length of bolts and screws for assemblies,

cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.

y Tighten assemblies with different dimension

fasteners as follows: Tighten all the fasteners with fingers, then tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.

y Remove residues of the old gasket or sealant

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

y The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.

Groove

Clamp

Connector

y Rubber and plastic boots should be properly

reinstalled to the original correct positions as designed.

y When oil seal is installed, fill the groove with

grease, install the oil seal with the name of the manufacturer facing outside, and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.

Manufacturer's name

1-4

Boots

y The tool should be pressed against two (inner

and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.

Both of these examples can result in bearing damage.

To this chapter contents

y Lubricate the rotation face with specified

lubricant on the lubrication points before assembling.

y Check if positions and operation for installed

parts is in correct and properly.

y Make sure service safety each other when

conducting by two persons.

1. GENERAL INFORMATION

y After service completed, make sure all

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

y And the two posts of battery have to be greased

after connected the cables.

y Make sure that the battery post caps are

located in properly after the battery posts had been serviced.

y Note that do not let parts fall down.

y Before battery removal operation, it has to

remove the battery negative (-) cable firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.

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

solved it. And then replace with specified capacity fuse.

Capacity verification

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1. GENERAL INFORMATION

y When separating a connector, it locker has to

be unlocked firstly. Then, conduct the service operation.

y Do not pull the wires as removing a connector

or wires. Hold the connector body.

y Make sure if the connector pins are bent,

extruded or loosen.

y Insert the terminal completely.

Check if the terminal is covered by the boot. Do not let boot open facing up.

y Secure wires and wire harnesses to the frame

with respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

y Insert the connector completely.

If there are two lockers on two connector sides, make sure the lockers are locked in properly. Check if any wire loose.

y Check if the connector is covered by the twin

connector boot completely and secured properly.

y Wire band and wire harness have to be

clamped secured properly.

y Do not squeeze wires against the weld or its

clamp.

y Before terminal connection, check if the boot is

crack or the terminal is loose.

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y Do not let the wire harness contact with rotating,

moving or vibrating components as routing the harness.

y Keep wire harnesses far away from the hot

parts.

Never Touch

1. GENERAL INFORMATION

y Protect wires or wire harnesses with electrical

tape or tube if they contact a sharp edge or corner. Thoroughly clean the surface where tape is to be applied.

y Secure the rubber boot firmly as applying it on

wire harness.

y Route wire harnesses to avoid sharp edges or

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

y Route harnesses so that they neither pull too

tight nor have excessive slack.

y Never use wires or harnesses which insulation

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

y Never clamp or squeeze the wire harness as

installing other components.

Never clamp or squeeze the wire harness

Never too tight

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1. GENERAL INFORMATION

y Do not let the wire harness been twisted as

installation.

y Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive slack, be rubbed against or interfere with adjacent or surrounding parts in all steering positions.

y With sand paper to clean rust on connector

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

Clean rust

y Before operating a test instrument, operator

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

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

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To this chapter contents

Specifications

MAKER SANYANG MODEL UA18A-6

Overall Length 1765 mm Front Unit Swing

Overall Width 1040 mm

Overall Height 1135 mm Front AT21x7-10 (off road)

Dimension

Weight

Wheel Base 1115 mm

Curb Weight

Passengers/Weight Two /150 kg Max. Speed Above 70 km/hr

Total Weight

Type 4-Stroke Engine Clutch Centrifugal, dry type

Installation and

arrangement

1. GENERAL INFORMATION

Suspension

System

Tire Specifications

Front 102 kg Rim Aluminum

Rear 97 kg Front Disk (ψ175mm)

Total 199 kg

Front 132 kg

Rear 217 kg

Total 349 kg

Vertical, below center,

incline 80°

Brake System

Performance

Climb Ability Below 20°

Reduction

Transmission

Rear Unit Swing

Rear AT22x10-10 (off road)

Rear Disk (ψ190mm)

Primary

Reduction

Secondary

Reduction

C.V.T., auto speed

Belt

Gear / Sprocket

change

Fuel Used Unleaded Speedometer 0 ~ 90 km/hr

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

Bore 61 mm Muffler

Stroke 58.8 mm

Cylinder

Number/Arrange

Engine

Displacement 171.2 cc Solid Particulate

Compression Ratio 10.8 : 1 CO Below 7.0 g/ km

Max. Torque 15.2Nm / 5500rpm

Starting System Electrical starter & Foot P.C.V. ─

ment

Max. HP 10.3kw / 7000rpm HC Below 1.5g/ km

Ignition C.D.I. E.E.C. ─

Air filtration Sponge

Single Cylinder Lubrication System

Exhaust Pipe Position and

Direction

Exhaust

Concentration

Catalytic reaction control

Nox Below 0.4g/ km

system

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

─

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To this chapter contents

1. GENERAL INFORMATION

Specifications

MAKER SANYANG MODEL UA18A1-6

Overall Length 1765 mm Front Unit Swing

Overall Width 1040 mm

Overall Height 1135 mm Front AT21x7-10 (on road)

Dimension

Weight

Wheel Base 1115 mm

Front 102 kg Rim Aluminum

Curb Weight

Passengers/Weight Two /150 kg Max. Speed Above 70 km/hr

Total Weight

Type 4-Stroke Engine Clutch Centrifugal, dry type

Installation and

arrangement

Rear 97 kg Front Disk (ψ175mm)

Total 199 kg

Front 132 kg

Rear 217 kg

Total 349 kg

Vertical, below center,

incline 80°

Suspension

System

Tire Specifications

Brake System

Performance

Climb Ability Below 20°

Reduction

Secondary

Reduction

Transmission

Rear Unit Swing

Rear AT22x10-10 (on road)

Rear Disk (ψ190mm)

Primary

C.V.T., auto speed

Belt

Gear / Sprocket

change

Fuel Used Unleaded Speedometer 0 ~ 90 km/hr

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

Bore 61 mm Muffler

Stroke 58.8 mm

Cylinder

Number/Arrange

Engine

Displacement 171.2 cc Solid Particulate

Compression Ratio 10.8 : 1 CO Below 7.0 g/ km

Max. Torque 15.2Nm / 5500rpm

Starting System Electrical starter & Foot P.C.V. ─

ment

Max. HP 10.3kw / 7000rpm HC Below 1.5g/ km

Ignition C.D.I. E.E.C. ─

Air filtration Sponge

Single Cylinder Lubrication System

Exhaust Pipe Position and

Direction

Exhaust

Concentration

Catalytic reaction control

Nox Below 0.4g/ km

system

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

─

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To this chapter contents

Specifications

MAKER SANYANG MODEL UA18A2-6

Overall Length 1765 mm Front Unit Swing

Overall Width 1040 mm

Overall Height 1135 mm Front AT21x7-10 (off road)

Dimension

Weight

Wheel Base 1115 mm

Curb Weight

Passengers/Weight Two /150 kg Max. Speed Above 70 km/hr

Total Weight

Type 4-Stroke Engine Clutch Centrifugal, dry type

Installation and

arrangement

1. GENERAL INFORMATION

Suspension

System

Tire Specifications

Front 102 kg Rim Steel

Rear 97 kg Front Disk (ψ175mm)

Total 199 kg

Front 132 kg

Rear 217 kg

Total 349 kg

Vertical, below center,

incline 80°

Brake System

Performance

Climb Ability Below 20°

Reduction

Transmission

Rear Unit Swing

Rear AT22x10-10 (off road)

Rear Disk (ψ190mm)

Primary

Reduction

Secondary

Reduction

C.V.T., auto speed

Belt

Gear / Sprocket

change

Fuel Used Unleaded Speedometer 0 ~ 90 km/hr

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

Bore 61 mm Muffler

Stroke 58.8 mm

Cylinder

Number/Arrange

Engine

Displacement 171.2 cc Solid Particulate

Compression Ratio 10.8 : 1 CO Below 7.0 g/ km

Max. Torque 15.2Nm / 5500rpm

Starting System Electrical starter & Foot P.C.V. ─

ment

Max. HP 10.3kw / 7000rpm HC Below 1.5g/ km

Ignition C.D.I. E.E.C. ─

Air filtration Sponge

Single Cylinder Lubrication System

Exhaust Pipe Position and

Direction

Exhaust

Concentration

Catalytic reaction control

Nox Below 0.4g/ km

system

Expansion & Pulse

Type

Right side, and

Backward

Forced circulation &

splashing

─

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1. GENERAL INFORMATION

Torque Values

The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table.

Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque

5 mm bolt、nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut 12 mm bolt、nut

Engine Torque Values

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

Cylinder head nut 4 8 2.0~2.4 Cylinder head right bolt 2 8 2.0~2.4 Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.1 Cylinder head stud bolt (EX. pipe) 2 7 0.5~1.0 Tappet adjustment hole cap bolt 6 6 1.0~1.4 Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread Spark plug 1 10 1.0~1.2 Carburetor insulator bolt 2 6 0.7~1.1 Cylinder stud bolt 4 8 0.7~1.1 Engine left cover bolt 7 6 1.1~1.5 Engine oil draining bolt 1 12 1.1~1.5 Engine oil strainer cap 1 30 1.3~1.7 Mission draining bolt 1 12 1.1~1.5 Mission filling bolt 1 12 1.1~1.5 Clutch driving plate nut 1 28 5.0~6.0 Clutch outer nut 1 12 5.0~6.0 Drive face nut 1 12 5.0~6.0 ACG. Flywheel nut 1 12 5.0~6.0 Crankcase bolts 7 6 0.8~1.2 Mission case bolt 7 8 2.0~2.4

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

0.8~1.2kgf-m

1.8~2.5kgf-m

3.0~4.0kgf-m

5.0~6.0kgf-m

6 mm screw、SH nut 6 mm bolt、nut 8 mm bolt、nut 10 mm bolt、nut

0.7~ 1.1kgf-m

1.0 ~1.4kgf-m

2.4 ~3.0kgf-m

3.5~4.5kgf-m

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1. GENERAL INFORMATION

Frame Torque Values

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

Handlebar upper holder bolt Steering shaft nut Steering tie-rod nut Knuckle nut Steering shaft holder bolt Tie rod lock nut Handlebar under holder nut Front wheel nut Front axle castle nut Rear axle castle nut Rear wheel nut Engine hanger nut Rear axle holder bolt Drive gear bolt Driven gear nut Swing arm pivot bolt

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

Brake lever nut Brake hose bolt Brake caliper bolt Brake disk mounting bolt Air-bleed valve Exhaust muffler mounting bolt Exhaust muffler connection nut

4 6 2.40 1 10 5.00 4 10 5.00 2 10 5.00 2 8 3.40 4 10 3.60 2 8 4.00 8 10 2.40 2 14 5.00 2 14 5.00 8 10 2.40 4 10 4.50 4 12 9.20 2 10 4.6 4 10 4.6 1 14 9.20

2 6 1.00

13 10 3.50

6 6 3.25

11 8 4.25

3 5 0.50 2 8 3.00 2 7 1.20

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1. GENERAL INFORMATION

Troubles Diagnosis

A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

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

Fuel supplied tom carburetor sufficient

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

round.

Check if sparks Weak sparks, no spark at

Perform cylinder compression pressure test.

No fuel is supplied to carburetor

all

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

and intake vacuum, are clogged.

y Float valve clogged y Lines in fuel tank evaporation system

clogged

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

hose

y Fuel filter clogged

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

Cylinder compression pressure normal

Re-start by following the starting procedures

No ignition T here are some signs of

Remove the spark plug again and check it.

Dry spark plug Wet spark plug

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

Low compression pressure or no pressure

ignition; nut engine can

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

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

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

Blowing in normal Blowing clogged

y Malfunction of automatic by- starter

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1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Try gradual acceleration and check engine speed

Engine speed can be increased.

Check ignition timing (Using ignition lamp)

Ignition timing correct Incorrect ignition timing

Check cylinder compression pressure (using compression

Compression pressure correct

Check if carburetor jet is clogged

Engine speed can not be increased.

No compression pressure

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

clogged

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

y Malfunction of CDI y Malfunction of AC alternator

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

No clogged Clogged

Remove spark plug

No foul or discoloration Fouled and discoloration

Check if engine over heat

Normal Engine overheat

Continually drive in acceleration or high speed

No knock Knock

y Remove foreign

y Remove dirt y Incorrect spark plug heat range

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

combustion chamber

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

y Too much carbon deposited in

combustion chamber

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

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1. GENERAL INFORMATION

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

Check and adjustment Fault condition Probable causes

Check ignition timing (using ignition lamp)

Normal

Adjust the air screw of carburetor

Good Poor

Air sucked through carburetor gasket

No air sucked Air sucked

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

Good spark Poor

Abnormal

y Incorrect ignition timing (malfunction of

CDI or AC alternator)

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

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

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

D. Engine runs sluggish (High speed)

Check and adjustment Fault condition

Check ignition timing

Check for fuel supplying system in automatic fuel cup

Check if carburetor clogged

Normal Abnormal

Good Abnormal

No clogged Clogged

Probable causes

y Malfunction of CDI y Malfunction of AC alternator

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

y Cleaning

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E. Clutch, driving and driving pulley

FAULT CONDITIONS

Engine can be started but motorcycle can not be moved.

Engine running and misfire as motorcycle initial forward moving or jumping suddenly (rear wheel rotating as engine in running)

Poor initial driving (Poor climbing performance)

1. GENERAL INFORMATION

PROBABLE CAUSES

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

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

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

F. Poor handling

Steering is heavy

One wheel is wobbling

Vehicle pulls to one side

FAULT CONDITIONS

PROBABLE CAUSES

y Damaged steering bearing y Damaged steering shaft bushing

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

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

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1. GENERAL INFORMATION

G. Loss power

Check and adjustment Fault condition Probable causes

Raise wheels off ground and spin by hand

Spin freely

Check tire pressure

Normal Abnormal

Accelerate lightly, engine speed can be increase

Normal Abnormal

Check ignition timing

Normal Abnormal

Test cylinder compression

Normal Abnormal

Check carburetor

Normal Clogged

Check spark plug

Normal Fouled or discolored

Check for engine overheating

Normal Overheating

Accelerate or run at high speed

Normal Knocks

Abnormal

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

y Punctured tire y Faulty tire valve

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

y Faulty pulse generator y Faulty CDI unit

y Leaking head gasket y Worn cylinder and piston rings

y Clean

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

y Excessive carbon deposited in

combustion chamber

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

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

combustion chamber

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Parts to Be Greased

Rear swing arm Front suspension arm front side

1. GENERAL INFORMATION

And steering shaft

Front suspension arm rear side Right and left Knuckle

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1. GENERAL INFORMATION

Drive chain Acceleration cable/ Front & rear brake

lever pivot

1-20

Speedometer gear Wheel bearing

Home page

Contents

Precautions in Operation···················· 2-1 Periodical Maintenance Schedule······ 2-2 Fuel Lines············································· 2-3 Acceleration Operation ······················· 2-3 Air Cleaner············································ 2-3 Spark Plug············································ 2-3 Valve Clearance ··································· 2-4 Carburetor Idle Speed Adjustment····· 2-5 Ignition System···································· 2-6 Cylinder Compression Pressure ········ 2-6 Drive Belt·············································· 2-7

Precautions in Operation

2. MAINTENANCE INFORMATION

Drive Chain··········································· 2-7 Brake System (Disk Brake) ·················2-8 Brake Light Switch/Starting Inhibitor

Switch ··················································· 2-9 Headlight Beam Distance····················2-10 Clutch Disc Wear ·································2-10 Cushion················································· 2-10 Steering Handle···································· 2-11 Wheel/Tire·············································2-11 Nuts, Bolts Tightness·························· 2-11 Special Tools List ································2-12

Specification

Fuel Tank Capacity 8000 c.c.

Engine Oil

Transmission Gear oil

Capacity of coolant

Clearance of throttle valve 5~10 mm

Spark plug

“F” Mark in idling speed BTDC 13º / 1000 rpm

Full timing advanced BTDC 27º / 6000 rpm

Cylinder compression pressure 12.0 ±2 kgf/cm²

Capacity 1000 c.c.

Change 800 c.c.

Capacity 750 c.c.

Change 650 c.c.

Engine + radiator 780 c.c.

Reservoir upper 420 c.c.

Type NGK CR8E

Gap 0.8 mm

Idling speed 1600±100 rpm

Valve clearance: IN/EX 0.12 ± 0.02 mm

Tire dimension

Tire pressure (cold) 0.8 kgf/cm² (12psi )

Battery 12V8Ah (MF battery) type: YTX9-BS

Front AT21x7-10

Rear AT21x10-10

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2. MAINTENANCE INFORMATION

Periodical Maintenance Schedule

Maintenance

Code

1 Air cleaner 2 Fuel filter 3 Oil filter 4 Engine oil change 5 Tire pressure 6 Battery inspection 7 Brake & free ply check 8 Steering handle check

9 Cushion operation check 10 Every screw tightening check 11 Gear oil check for leaking 12 Spark plug check or change 13 Gear oil change 14 Frame lubrication 15 Exhaust pipe 16 Ignition timing 17 emission check in Idling 18 Throttle operation 19 Engine bolt tightening 20 CVT driving device(belt) 21 CVT driving device(roller) 22 Drive chain

23 24 Fuel lines

25 Cam chain 26 Valve clearance 27 28 Coolant reservoir 29 Coolant

Lights/electrical equipment/multi-meters

Lines & connections in cooling

Item

Every

300KM

I / L I / L

1 Month

every

1,000KM

I C R

I I R C C R Replacement for every 1000 km

I I

I I R R Replacement for every 5000 km

I I

I I A I

I I

I R

I I

I A

I I

I I R

3 month

every

3,000KM

6 month

every

6000KM

1 year

every

12,000KM

15 month

every

14,500KM

Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement

C ~ Cleaning (replaced if necessary) L ~ Lubrication

Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain the ATV at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first. Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in

the Heavily- polluted environment.

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

3. Preventive maintenance a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire,

after-burn, overheating occur.

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

when power is obvious lower. Than ever

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Fuel Lines

Remove the seat. Loosen 2 screws and 2 bolts Remove the tank cover Check all lines, and replace it when they are deterioration, damage or leaking

Warning

Gasoline is a low ignition material so any kind of fire is strictly prohibited as dealing it.

Acceleration Operation

Have a wide open of throttle valve as handle in any position and release it to let back original (full closed) position. Check handle if its operation is smooth. Check acceleration cable and replace it if deteriorated, twisted or damaged. Lubricate the cable if operation is not smooth. Measure the throttle lever free play in its flange part. Remove rubber boot, loosen fixing nut, and then adjust it by turning the adjustment screw. Tighten the fixing nut, and check acceleration operation condition.

Free play: 5~10 mm.

Air Cleaner

Remove 3 screws from the air cleaner cover and then remove the cover. Loosen the clamp strip of air cleaner element, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

2. MAINTENANCE INFORMATION

Fuel tank

Fuel hose

Vacuum hose

Fuel filter

Lock nut

Throttle adjustment screw

Clamp

Element

Caution

Never use gasoline or acid organized solvent to clean the element.

Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.

Spark Plug

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

Spark plug gap：0.8~0.9 mm

Carefully bend ground electrode of the plug to adjust the gap if necessary. Hold spark plug washer and install the spark plug by screwing it. Tighten the plug by turning 1/2 turn more with plug socket after installed.

Tighten torque: 1.0~1.2kgf-m

Ground electrode

0.8~0.9mm

Central electrode

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2. MAINTENANCE INFORMATION

Valve Clearance

Caution

Checks and adjustment must be performed when the engine temperature is below 35℃.

Remove trunk. Remove central cover. Remove valve adjustment cap. Remove cylinder head side cover. Turn camshaft bolt in C.W. direction and let the “T” mark on the camshaft sprocket align with cylinder head mark so that piston is placed at TDC position in compression stroke.

Caution

Do not turn the bolt in C.C.W. direction to prevent from camshaft bolt looseness.

Valve clearance inspection and adjustment. Check & adjust valve clearance with feeler gauge.

Valve clearance (IN/EX): 0.12 ± 0.02 mm

Loosen fixing nut and turn the adjustment nut for adjustment.

Timing mark

Caution

Re-check the valve clearance after tightened the fixing nut.

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Carburetor Idle Speed Adjustment

Caution

y Inspection & adjustment for idle speed have to

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

y Idle speed check and adjustment have to be

done after engine is being warm up. (It is enough that operates engine from stop to running for 10 minutes.)

Park the ATV with main stand and warm up engine. Connect tachometer (the wire clamp of tachometer is connected to the high tension cable). Turn the throttle valve stopper screw to specified idle speed. Specified idle speed: 1600 ± 100 rpm

Emission adjustment in idle speed

Warm up the engine for around 10 minutes and then conduct this adjustment.

1. Connect the tachometer onto engine.

2. Adjust the throttle valve stopper screw and let engine runs in 1600±100 rpm.

3. Insert the exhaust sampling pipe of exhaust analyzer into the front section of exhaust pipe. Adjust the air adjustment screw so that emission value in idle speed is within standard.

4. Slightly accelerate the throttle valve and release it immediately. Repeat this for 2~3 times.

5. Read engine RPM and value on the exhaust analyzer. Repeat step 2 to step 4 procedures until measured value within standard.

Emission standard CO: below 2.5~3.5%

HC: below 2000ppm

2. MAINTENANCE INFORMATION

Ignition cable

Air adjustment screw

Stopper screw

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2. MAINTENANCE INFORMATION

Ignition System

Caution

y C.D.I ignition system is set by manufacturer so

it can not be adjusted.

y Ignition timing check procedure is for checking

whether CDI function is in normal or not.

Connect tachometer and ignition light. Start engine. As engine in idle speed: 1600 rpm, aim at the mark “F” with the ignition light. Then, it is means that ignition timing is correct. Increase engine speed to 6000 rpm to check ignition advance degree. If indent is located within the ignition advance degrees, it is means that the ignition advance degree is in normal. If ignition timing is incorrect, check CDI set, pulse rotor and pulse generator. Replace it if malfunction of these parts is found.

Cylinder Compression Pressure

Warm up engine. Turn off the engine. Remove the trunk. Remove the central cover. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of starter motor.

Caution

Rotate the engine until the reading in the gauge no more increasing. Usually, the highest pressure reading will be obtained in 4~7 seconds.

Compression pressure: 12 ± 2 Kg/cm²

Check following items if the pressure is too low:

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

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

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Drive Belt

Loosen the 2 clamp strips of left crankcase cover, and then remove the left crankcase cover vapor hose. Remove 7 bolts of the engine left side cover and the cover.

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

Width limit: 18.5mm or above

Drive Chain

Check the drive chain

Park the ATV on a level ground, and shift the transmission onto neutral. Measure the drive chain slack midway between the sprockets.

Chain slack: 15~25mm (5/8~1 inch)

Adjust the chain slack

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

2. MAINTENANCE INFORMATION

7 bolts

Teeth

Width

4 bolts

Adjustment nut

Torque: 3.25kgf-m

Caution

y This type ATV has a chain tensioner to adjust

and protect drive chain.

Tensioner

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2. MAINTENANCE INFORMATION

Brake System (Disk Brake)

Brake System Hose

Make sure the brake hoses for corrosion or leaking oil.

Brake Fluid

Check brake fluid level in the brake fluid reservoir. If the level is lower than the LOWER limit, add brake fluid to UPPER limit. Also check brake system for leaking if low brake level found

Caution

y In order to maintain brake fluid in the reservoir

in horizontal position, do not remove the cap

until handle stop.

y Do not operate the brake lever after the cap

had been removed. Otherwise, the brake fluid

will spread out if operated the lever.

y Do not mix non-compatible brake fluid together.

Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid. Operate the brake lever so that brake fluid contents inside the brake system hoses.

Screws

Master cylinder cap

Air Bleed Operation

Connect a transparent hose to draining valve. Hold the brake lever and open air bleeding valve. Perform this operation alternative until there is no air inside the brake system hoses.

Caution

Before closing the air bleed valve, do not release the brake lever.

Added Brake Fluid

Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 WELL RUN brake fluid.

Caution

Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

Air bubble

Diaphragm plate

Diaphragm

Upper

Drain valve

Transparent hose

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Brake Lining Wear

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

Caution

y To check front brake lining must be remove

front wheel first.

y It is not necessary to remove brake hose when

replacing the brake lining.

Brake Lining Replacement (refer chapter

14)

Make sure the brake lining condition. Replace the lining if the brake lining wear limitation groove close to the brake disc.

Caution

y Do not operate the brake lever after the clipper

removed to avoid clipping the brake lining.

y In order to maintain brake power balance, the

brake lining must be replaced with one set.

Brake Light Switch/Starting Inhibitor Switch

The brake light switch is to light up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying.

2. MAINTENANCE INFORMATION

Front brake

Lining

Brake lining wear limitation groove

Brake disk

Rear brake

Brake lining wear limitation groove

Lining

Brake switch

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2. MAINTENANCE INFORMATION

Headlight Beam Distance

Turn on main switch Headlight beam adjustment. Turn the headlight adjustment screw to adjust headlight beam high.

Caution

y To adjust the headlight beam follows related

regulations.

y Improper headlight beam adjustment will

make in coming driver dazzled or insufficient lighting.

Clutch Disc Wear

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

Cushion

Adjust screw

Clutch weight

Drive plate

Warning

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

poor stability and drive-ability.

Front cushion

Press down the front cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found. Tighten all nuts and bolts.

Rear Cushion

Press down the rear cushion for several times to check it operation. Check if it is damage Replace relative parts if damage found.

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Steering Handle

Caution

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

Lift the front wheel out of ground. Turn handle from right to left alternative and check if turning is smoothly. If handle turning is uneven and bending, or the handle can be operated in vertical direction, then check the handle top bearing.

Wheel/Tire

Caution

Tire pressure check should be done as cold engine.

2. MAINTENANCE INFORMATION

Check if tire surface is ticked with nails, stones or other materials.

Appointed tire pressure

Tire size Front tire Rear tire

Tire pressure as cold

Check if front and rear tires’ pressure is in normal. Measure tire thread depth from tire central surface. Replace the tire if the depth is not come with following specification:

Front tire: 1.5 mm Rear tire: 2.0 mm

0.8

kg/cm² (12psi )

Nuts, Bolts Tightness

Perform periodical maintenance in accord with the Periodical Maintenance Schedule Check if all bolts and nuts on the frame are tightened securely. Check all fixing pins, snap rings, hose clamp, and wire holders for security.

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2. MAINTENANCE INFORMATION

Special Tools List

NAME

NO SYM-1120000-H9A NO SYM-1130000-H9A NO SYM-9100200-H9A

R/L. CRANK DISASS. TOOL

NAME

CRANK SHAFT PULLER

NAME

L. CRANK SHAFT BRG. DRIVER

NAME

NO SYM-9100210-H9A NO SYM-1120310 NO SYM-1120320

CRANK SHAFT BRG. FIXING SOCKET

NAME

(ψ30mm)

CRANK CASE BUSH PULLER

NAME

(ψ22mm)

CRANK CASE BUSH PULLER

NAME

NO SYM-1471110/20 NO SYM-9001200 NO SYM-9001209

Valve cotter remove & assembly tool

NAME Tappet adjusting wrench NAME Tappet adjuster

NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor

NO SYM-2210100 NO SYM-9020200 NO SYM-2301000

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2. MAINTENANCE INFORMATION

NAME Inner bearing puller NAME Outer bearing puller NAME AC.G. Flywheel puller

NO SYM-6204002 NO SYM-6204001 NO SYM-3110A00

(12*20*5)

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

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

(6901)

(6301)

NAME

NO SYM-9610000 NO SYM-9110400 NO SYM-9620000

BEARING DRIVER

NAME

(6204)

BEARING DRIVER

Water pump mechanical seal driver

(6203/6004UZ)

NAME

BEARING DRIVER Ø17mm

(20*32*6)

NAME Oil seal driver NAME Oil seal driver NAME Oil seal driver

NO SYM-9120200 NO SYM-9121600 NO SYM-9125500

(25*40*8)

(27*42*7)

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2. MAINTENANCE INFORMATION

NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush (long)

NO SYM-1130000-L NO SYM-1130010 NO SYM-1130031

NAME Extension bush (short) NAME

NO SYM-1130032 NO SYM-HT07004-RA1 NO

Torque wrench

NAME

(55mm)

NAME Rear axle nut wrench NAME NAME

NO SYM-HT06007 NO NO

(55mm)

Rear axle nut torque wrench

SYM-4230200

NAME NAME NAME

NO NO NO

2-14

Home page

Contents

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

Mechanism Diagram

Press-In Lubrication

Oil Route

3. LUBRICATION SYSTEM

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

Valve Rocker Arm

Cam Shaft

Spray Lubrication

Con-Rod

Spray Lubrication

Press-In Lubrication

Oil Route

Oil through

Rotate Direction

Oil Strainer

Oil Pump

3-1

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3. LUBRICATION SYSTEM

Precautions in Operation

General Information:

z This chapter contains maintenance operation

for the engine oil pump and gear oil

replacement.

Specifications

Engine oil quantity Disassembly: 1000 c.c.

Change: 800 c.c.

Oil viscosity SAE 10W-30 (Recommended

King serial oils)

Gear oil Disassembly: 750c.c.

Change: 650c.c.

Gear oil viscosity SAE 140 (Recommended SYM Hypoid gear oils)

單位:mm

Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20

Oil pump

Clearance between outer rotor and body 0.15~0.20 0.25 Clearance between rotor side and body 0.04~0.09 0.12

Torque value

Torque value oil strainer cap 1.5~3.0kgf-m Engine oil drain bolt 1.9~2.5kgf-m Gear oil drain bolt 1.0~1.5kgf-m

Gear oil join bolt 1.0~1.5kgf-m Oil pump connection bolt 0.8~1.2kgf-m

Troubleshooting

Low engine oil level

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

Low oil pressure

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

Dirty oil

y No oil change in periodical y Cylinder head gasket damage y Piston ring worn out

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Engine Oil

Turn off engine, and park the ATV in flat surface with main stand. Check oil level with oil dipstick So not screw the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

Oil Change

Caution

Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely.

Place a 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：1.9~2.5kgf-m

3. LUBRICATION SYSTEM

Drain bolt

Engine Oil Strainer Clean

Drain engine oil out. Remove oil strainer and spring. Clean oil strainer. Check if O-ring can be re-used. Install oil strainer and spring. Install oil strainer cap.

Torque value：1.5~3.0kgf-m

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

Engine oil capacity: 0.8L when replacing

Install dipstick, start the engine for running several minutes. Turn off engine, and check oil level again. Check if engine oil leaks.

Oil strainer cap

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3. LUBRICATION SYSTEM

Oil Pump

Oil Pump Removal

Remove generator and starting gear. (Refer to chapter 10) 。

Remove snap ring and take out oil pump driving chain and sprocket.

Make sure that pump shaft can be rotated freely. Remove 2 screws on the oil pump, and then remove oil pump.

Clip

Oil Pump Disassembly

Remove the screws on oil pump cover and disassemble the pump as illustration shown.

Oil Pump Inspection

Check the clearance between oil pump body and outer rotor.

Limit: 0.25 mm

2 screws

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Check clearance between inner and outer rotors. Limit: 0.20 mm

Check clearance between rotor side face and pump body

Limit: 0.12 mm

Oil Pump Re-assembly

Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor. Install the driving shaft Install fixing pin

Install the oil pump cover and fixing pin properly

3. LUBRICATION SYSTEM

1 Screw

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3. LUBRICATION SYSTEM

Oil Pump Installation

Install the oil pump, and then tighten bolts.

Torque value：0.8~1.2kgf-m

Make sure that oil pump shaft can be rotated freely.

Install oil pump driving chain and sprocket, and then install snap ring onto oil pump shaft.

Install starting gear and generator. (Refer to chapter 10)

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Gear Oil

Oil level inspection

Park the ATV on flat surface. Check gear oil inspection window, gear oil level whether above scale division.

Gear lubrication oil quantity has to be measured with measure device. If oil level is too low, add gear oil. Recommended using King series oils. Install oil join bolt.

Gear Oil Change

Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained.

Torque value: 1.0~1.5kgf-m

Make sure that the drain bolt washer can be re-used. Add oil to specified quantity from the join hole.

Gear Oil Quantity: 1000 c.c. when replacing

Make sure that the join bolt washer can be re-used, and install the bolt. Start engine and run engine for 2-3 minutes. Turn off engine and make sure that oil level is in correct level. Make sure that no oil leaking.

Gear oil join bolt

3. LUBRICATION SYSTEM

Gear oil Inspection window

Gear oil drain bolt

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3. LUBRICATION SYSTEM

Notes:

3-8

Home page

Contents

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

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

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

Carburetor Remove / Install ................ 4-4

Air Cut-Off Valve .................................. 4-5

Mechanism Diagram

Fuel tank cap

Fuel tank

4. FUEL SYSTEM

Throttle Valve.......................................4-6

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

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

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

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

Fuel unit

Insulator

Auto fuel cock

Carburetor

Fuel strainer

Inlet pipe

4-1

To this chapter contents

4. FUEL SYSTEM

Precautions in Operation

General Information

Warning

Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline.

Cautions

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

re-assembly

y There is a drain screw in the float chamber for draining residual gasoline. y Do not disassemble auto by-starter and air cut valve arbitrarily.

Specification

ITEM UA18A

Carburetor diameter Ø22mm I.D. number PTC 049 Fuel level 14.8mm Main injector # 98 Idle injector # 35 Idle speed 1600 ± 100rpm Throttle handle clearance 5~10 mm Pilot screw 1 1/2 turns

Tool Special service tools

Vacuum/air pressure pump Fuel level gauge

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Trouble Diagnosis

Poor engine start

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

system )

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

Stall after started

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

4. FUEL SYSTEM

Mixture too lean

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

Mixture too rich

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

Rough idle

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

Intermittently misfire as acceleration

y Malfunction of ignition system

Late ignition timing

y Malfunction of ignition system y Malfunction of carburetor

Power insufficiency and fuel consuming

y Fuel system clogged y Malfunction of ignition system

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4. FUEL SYSTEM

Carburetor Remove / Install

Removal

Drain out fuel in the float chamber. Loosen the choke cable fixed iron sheet screw from plate.

Remove the choke cable

Remove the carburetor top parts from the carburetor. Disconnect the fuel hose.

Release the clamp strip of air cleaner. Release the 2 nuts of carburetor insulator, and then remove the carburetor.

Choke cable

2 nuts

Screw

Choke cable

Clamp screws

Installation

Install in reverse order of removal procedures.

4-4

Fuel pipe

To this chapter contents

Air Cut-Off Valve

Disassembly

Remove 2 screws.

Remove air cut-off valve cover, spring and valve.

Inspection

Check the valve is in normal. If the valve is in normal, it will restrict air-flow. If air-flow is no restrict, replace carburetor assembly. Check the vacuum pipe o-ring is in normal.

2 screws

O-ring

4. FUEL SYSTEM

Air cut-off valve

Spring

Cover

Assembly

Install in reverse order of removal procedures.

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4. FUEL SYSTEM

Throttle Valve

Disassembly

Remove carburetor upper parts, and then remove throttle valve and throttle cable.

Disconnect the throttle cable from the throttle valve and remove the valve spring. Remove the fuel needle clamp and fuel needle.

Assembly

Place the fuel needle onto the throttle valve and clip it with needle clamp. Install the sealed cap, carburetor upper part, and throttle valve spring. Connect the throttle valve cable to the throttle valve. Install the throttle valve into the carburetor body.

Throttle valve

Throttle cable

Spring

Needle clamp

Fuel needle clip Fuel needle

Caution

Align the groove inside the throttle valve with the throttle stopper screw of the carburetor body.

Tighten the carburetor upper part. Adjust the free play of throttle valve cable.

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Float Chamber

Disassembly

Remove 3 mounting screws and remove float chamber cover.

Remove the fuel level plate, float pin, float and float valve.

Inspection

Check float valve and valve seat for damage, blocking. Check float valve for wearing, and check valve seat face for wear, dirt.

Float

Fuel level plate

4. FUEL SYSTEM

3 Screws

Float valve

Caution

In case of worn out or dirt, the float valve and valve seat will not tightly close causing fuel level to increase and as a result, fuel flooding. A worn out or dirty float valve must be replaced with a new a new one.

Float

Check for wear or damage

Float valve

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4. FUEL SYSTEM

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

Caution

Take care not to damage jets and adjust screw.

y Before removing adjustment screw, turn it all

the way down and note the number of turns.

y Do not turn adjust screw forcefully to avoid

damaging valve seat face.

Clean jets with cleaning fluid. Then use compressed air to blow the dirt off. Blow carburetor body passages with compressed air.

Assembly

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

Caution

Needle jet holder

Needle jet

Main jet

Slow jet

Set the air adjustment screw in according to number of turns noted before it was removed.

Install the float valve, float, and float pin.

Checking fuel level

Caution

y Check again to ensure float valve, float for

proper installation.

y To ensure correct measurement, position the

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

Fuel level: 14.8mm

Installation of carburetor

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

˙Throttle cable adjustment. ˙Idle adjustment

Air adjustment screw

Float gauge

Lock nut

4-8

Throttle adjustment screw

To this chapter contents

Adjustment of Idle Speed

Caution

y Air screw was set at factory, so no adjustment

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

y The parking brake must be used to stop the

ATV to perform the adjustments.

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

Standard turns: 1 1/2turns

Warm up engine, adjust the throttle stopper screw of throttle valve to standard RPM.

Idle speed rpm: 1600 ± 100 rpm

Connect the hose of exhaust analyzer to exhaust front end. Press test key on the analyzer. Adjust the pilot screw and read CO reading on the analyzer

CO standard value: 1.0~1.5 %

Accelerate in gradual increments, make sure rpm and CO value are in standard value after engine running in stable. If rpm and CO value fluctuated, repeat the procedures described above for adjusting to standard value.

4. FUEL SYSTEM

Parking brake

Throttle valve stopper screw

Air adjustment screw

4-9

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4. FUEL SYSTEM

Fuel Tank

Fuel unit removal

Open the seat. Remove the front cover (2 screws). Remove the front body cover (6 screws and 5 bolts). Remove the tank cover (2 bolts). Disconnect fuel unit coupler. Remove fuel unit (4 bolts).

Caution

˙Do not bend the float arm of fuel unit ˙Do not fill out too much fuel to fuel tank.

Fuel unit inspection. (Refer to electrical equipment

chapter 17)

Fuel unit installation

Install the gauge in the reverse order of removal.

4 bolts

Caution

Do not forget to install the gasket of fuel unit or damage it.

Fuel tank removal

Open the seat. Remove the front cover (2 screws). Remove the front body cover (6 screws and 5 bolts). Remove the tank cover (2 bolts). Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Remove the fuel tube. Remove the Remove 2 bolts, and then remove fuel tank.

vacuum tube.

Installation

Install the tank in the reverse order of removal.

Vacuum tube

Fuel tube

4-10

2 bolts

To this chapter contents

Air Cleaner

Removal

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

Remove the air cleaner (2 bolts).

Installation

Install the tank in the reverse order of removal.

4. FUEL SYSTEM

Clamp

Cleaning air cleaner element

Loosen the clamp strip of left crankcase cover, and then remove the left crankcase cover vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner cover (3 screws).

Loosen the clamp strip of air cleaner element, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze it for dry.

Clamp

2 bolts

3 screws

Element

Caution

Never use gasoline or acid organized solvent to clean the element.

Soap the element into cleaning engine oil and then squeeze it out. Install the element onto the element seat and then install the air cleaner cover.

4-11

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4. FUEL SYSTEM

Notes:

4-12

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Contents

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

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

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

Removal of Engine Hanger Bush ........ 5-6

5. ENGINE REMOVAL

Precautions in Operation

General Information

y The engine has to be supported with special service tools that can be lifted or adjustable. y Engine shall be removal in the conditions of necessary repair or adjustment to the transmission system

only.

y The following parts can be serviced as engine mounted on frame:

Carburetor. Drive pulley, drive belt, clutch, and movable drive face assembly. Start motor.

Specification

Item Capacity

Replacement 800 c.c.

Engine oil capacity

Disassembly 1000 c.c.

Replacement 650 c.c.

Gear oil capacity

Disassembly 750 c.c.

Engine & radiator 780 c.c.

Coolant capacity

Reservoir 420 c.c. AS indicator shown

Total 1200 c.c.

Torque Value

Engine hanger bolt 4.5kgf-m Exhaust muffler mounting bolt 3.0kgf-m

Exhaust muffler connection nut 1.2kgf-m

5-1

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5. ENGINE REMOVAL

Removal of Engine

Remove the seat.

Remove battery negative post (-). Remove battery positive (+) post.

Remove front fender , rear fender and the footrest (refer chapter 13).

Remove starter motor wire from start relay.

Remove the spark plug cap and remove ignition cable by mounting clamp.

Disconnect A.C. Generator wire couplers.

Negative

Spark plug cap

A.C.G wire coupler

Negative

Starter motor wire

Clamp

5-2

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Remove the exhaust muffler (2 bolts, 2 nuts).

Disconnect the choke cable. Disconnect the carburetor upper parts and cable.

Remove fuel pipe and vacuum pipe.

Release the clamp strip of air cleaner duct. Release the 2 nuts of carburetor insulator, and then remove the carburetor.

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

5. ENGINE REMOVAL

2 bolts

2 nuts

Fuel pipe

Clamps

Clamp screws

5-3

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5. ENGINE REMOVAL

Remove gear change lever (1 bolt).

Remove coolant drain bolt, and drain out coolant. Remove water hoses from water pump.

Remove the thermo-sensor wire and coolant by-pass pipe.

Loosen speedometer cable mounting nut, and then remove the cable.

Water hoses clamp

Thermo-sensor wire

Drain bolt

1 bolt

By-pass pipe

5-4

Mounting nut

To this chapter contents

Remove the drive chain retaining clip and master link, and then remove the drive chain.

Remove the rear side engine hanger mounting nuts and bolts.

Remove the front side engine hanger mounting nut and bolt, then remove engine.

5. ENGINE REMOVAL

Clip

2 nuts

Engine Installation

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

Caution

y Pay attention of foot & hand safety as engine

installation to avoid hurting.

y Do not bend or twist wires. y Cables wires have to be routed in accordance

with normal layout.

Engine hanger Bolt: Torque value: 4.0~5.0kgf-m

1 nut

5-5

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5. ENGINE REMOVAL

Removal of Engine Hanger Bush

Check if engine hanger bush for damage. Remove the engine hanger bush, must be disassemble crankcase and transmission cover first.

Pressing out

If engine hanger and the rear cushion rubber bush damaged. Then, with the bush remover / presser, Ø 30mm, to press the bush out, and replace it with new one. Engine hanger bush: ψ 30mm

Place the detent section of the bush remover toward the bush, and drive both the pressing ring and bolt in to press the bush out.

Pressing In

Bush

Place the flat section of the remover toward the bush, and then drive the bush, pressing ring, and bolt in to install the bush.

5-6

Home page

Contents

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

Mechanism Diagram

0.8~1.2kgf-m

6. CYLINDER HEAD/VALVE

Valve Stem Replacement··················· 6-8 Valve Seat Inspection and Service··· 6-9 Cylinder Head Reassembly··············· 6-11 Cylinder Head Installation················· 6-12 Valve Clearance Adjustment············· 6-14

0.8~1.2kgf-m

2.0~2.4kgf-m

1.0~1.2kgf-m

2.0~2.4kgf-m

6-1

To this chapter contents

6. CYLINDER HEAD/VALVE

Precautions in Operation

General Information

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

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

Specification

Item Standard Limit

Compression pressure 12+/2 kg/cm2 ---

Intake 30.800~30.920 3.075 Camshaft Height of cam lobe

Exhaust 30.411~30.531 30.26 ID of valve rocker arm 12.000~12.018 12.10 Rocker arm OD of valve rocker arm shaft 11.966~11.984 11.910

Valve

Guide seat 5.000~5.012 5.030

Intake 4.975~4.990 4.900 OD of valve stem

Exhaust 4.955~4.970 4.900

Intake 0.010~0.037 0.080 Clearance between valve stem and guide

Free length of valve spring 35.000 31.500 Valve seat width 1.000 1.6

Tilt angle of cylinder head --- 0.05

Exhaust 0.030~0.057 0.100

Torque Value

Cylinder head bolt (LH) 2.0~2.4kgf-m Cylinder head Nut 2.0~2.4kgf-m Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m Bolt of cam chain auto-tensioner 1.2~1.6kgf-m Cam sprocket cover bolts 0.8~1.2kgf-m Cam sprocket bolt 0.8~1.2kgf-m Spark plug 1.0~1.2kgf-m

Tools Special service tools

Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor

6-2

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6. CYLINDER HEAD/VALVE

Troubleshooting

Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated.

Low compression pressure

1. Valve

y Improper valve adjustment y Burnt or bent valve y Improper valve timing y Valve spring damage y Valve carbon deposit.

2. Cylinder head

y Cylinder head gasket leaking or damage y Tilt or crack cylinder

3. Piston

y Piston ring worn out.

High compression pressure

y Too much carbon deposit on combustion chamber or piston head

Noise

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

6-3

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6. CYLINDER HEAD/VALVE

Cylinder Head Removal

Remove seat, luggage box and body cover. Remove engine. (Refer to chapter 5) Remove the clamp strip bolt of carburetor, and disconnect vacuum tube from the carburetor insulator. Remove Air Injection system (AI) pipe mounting bolt.

Remove 1 bolt of thermostat and then remove the thermostat. Remove hole cap for the adjustment bolt of cam chain tensioner, and then loosen the tensioner by turning a flat-driver in C.W direction.

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

Remove cam sprocket bolts and then remove the sprocket by prying chain out.

Vacuum tube

AI. Pipe bolt

Whole cap of adjustment

Clamp strip

Thermostat bolt

2 bolts

6-4

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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 2 bolts of carburetor insulator and then take the insulator out.

Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces of cylinder and cylinder head.

6. CYLINDER HEAD/VALVE

2 Insulator bolts

Cylinder head mounting

Carburetor insulator

4 Nuts

Dowel pin

Caution

y Do not damage the matching surfaces of

cylinder and cylinder head.

y Avoid residues of gasket or foreign materials

falling into crankcase as cleaning.

Chain guide

Gasket

6-5

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6. CYLINDER HEAD/VALVE

Cylinder Head Disassembly

Remove the hole cap of intake & exhaust valve clearance adjustment. There are 6 bolts. Then, remove the cap.

Remove the rocker arm pin stopper plate, and then screw a 5mm bolt into the rocker arm pin. Finally, remove the pin and the rocker arm.

Screw a 6 mm bolt into cam sprocket mounting bolt hole, and then pull the camshaft out.

Use a valve compressor to press the valve spring.

Stopper plate bolt

Caution

y In order to avoid loosing spring elasticity, do not

press the spring too much. Thus, press length is based on the valve cotter in which can be removed.

Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120)

Remove valve stem guide seal. Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface.

Caution

Do not damage the matching surface of cylinder head.

6-6

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Cylinder Head Inspection

Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.

Service limit: 0.5 mm

Valve spring free length

Measure the free length of intake and exhaust valve springs.

Service limit: 28.90 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

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

6. CYLINDER HEAD/VALVE

5.0 mm valve guide reamer

6-7

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6. CYLINDER HEAD/VALVE

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.

Valve Stem Replacement

Heat up cylinder head to 100~150 ℃ with heated plate or toaster.

Caution

y Do not let torch heat cylinder head directly.

Otherwise, the cylinder head may be deformed as heating it.

y Wear on a pair of glove to protect your hands

when operating.

Hold the cylinder head, and then press out old valve guide from combustion chamber side.

Valve guide driver

5.0mm

Tool: Valve guide driver: 5.0 mm

Caution

y Check if new valve guide is deformation after

pressed it in.

y When pressing in the new valve guide, cylinder

head still have to be kept in 100~150

Adjust the valve guide driver and let valve guide height is in 13 mm. Press in new valve guide from rocker arm side.

Tool: Valve guide driver: 5.0 mm

Wait for the cylinder head cooling down to room temperature, and then correct the new valve guide with reamer.

℃.

Caution

y Using cutting oil when correcting valve guide

with a reamer.

y Turn the reamer in same direction when it be

inserted or rotated.

Correct valve seat, and clean up all metal residues from cylinder head.

Tool: Valve guide reamer: 5.0 mm

Valve guide driver

5.0 mm

Valve guide reamer 5.0 mm

6-8

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Valve Seat Inspection and Service

Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool.

Caution

y Do not let emery enter into between valve stem

and valve guide.

y Clean up the emery after corrected, and apply

with engine oil onto contact faces of valve and valve seat.

Remove the valve and check its contact face.

Caution

Replace the valve with new one if valve seal is roughness, wear out, or incomplete contacted with valve seat.

Valve seat inspection

If the valve seat is too width, narrow or rough, corrects it.

Valve seat width

Service limit: 1.6mm

Check the contact condition of valve seat.

Valve seat grinding

The worn valve seat has to be ground with valve seat chamfer cutter. Refer to operation manual of the valve seat chamfer cutter. Use 45° valve seat chamfer cutter to cut any rough or uneven surface from valve seat.

Caution

After valve guide had been replaced, it has to be ground with 45° valve seal chamfer cutter to correct its seat face.

Use 32° cutter to cut a quarter upper parts out.

6. CYLINDER HEAD/VALVE

Valve seat width

Roughness

45°

Old valve seat width

32°

6-9

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6. CYLINDER HEAD/VALVE

Use 60° cutter to cut a quarter lower parts out. Remove the cutter and check new valve seat.

Use 45° cutter to grind the valve seat to specified width.

Caution

Make sure that all roughness and uneven faces had been ground.

Grind valve seat again if necessary.

Coat the valve seat surface with red paint. Install the valve through valve guide until the valve contacting with valve seat, slightly press down the valve but do not rotate it so that a seal track will be created on contact surface.

Contact surface too high

Old valve seat width

60°

1.0mm

Old valve seat width

45°

Caution

The contact surfaces of valve and valve seat are very important to the valve sealing capacity.

If the contact surface too high, grind the valve seat with 32° cutter. Then, grind the valve seat to specified width.

If the contact surface too low, grind the valve seat with 60° cutter. Then, grind the valve seat to specified width.

6-10

Contact surface too low

32°

Old valve seat width

60°

To this chapter contents

After the valve seat ground, coat valve seat surface with emery and then slightly press the ground surface. Clean up all emery coated onto cylinder and valve after ground.

Cylinder Head Reassembly

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

Caution

The closed coils of valve spring should face down to combustion chamber.

Use valve spring compressor to press valve spring.

6. CYLINDER HEAD/VALVE

Intake valve

Valve spring retainer

Exhaust valve

alve cotter

Valve stem seal

Valve spring

Caution

In order to avoid damaging the valve stem and the cylinder head, in the combustion chamber place a rag between the valve spring remover/installer as compressing the valve spring directly.

Special Service Tool: Valve spring remover (SYM-1471110) Valve spring installer (SYM-1471120)

Tap valve stem to make valve retainer and valve stem sealing properly.

Caution

Place and hold cylinder head on to working table so that can prevent from valve damaged.

6-11

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6. CYLINDER HEAD/VALVE

Cylinder Head Installation

Install a new O-ring into the indent of carburetor insulator, and then install the insulator onto cylinder head with 2 bolts.

Install camshaft into cylinder head, and align rocker pin with rocker arm pin hole. Then, insert the rocker arm pin. Install rocker arm pin mounting plate.

Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide. Install 2 set pins and cylinder head gasket.

Caution

Do not damage the matching surfaces of cylinder and cylinder head. Avoid residues of gasket or foreign materials falling into crankcase as cleaning.

Loosen the tensioner by turning a flat-driver in C.W direction. Install cylinder head.

Chain guide

Carburetor insulator

Stopper plate bolt

Dowel pin

Gasket

6-12

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Tighten 4 nuts and washers on the cylinder head upper side, and then tighten 2 cylinder head mounting bolts of cylinder head side cover.

Torque value: 2.0~2.4kgf-m

Install and tighten spark plug

Torque value: 2.0~2.4kgf-m

Caution

This model is equipped with more precision 4-valve mechanism so its tighten torque can not be exceeded standard value in order to avoid causing cylinder head deformation, engine noise and leaking so that motorcycle’s performance be effected.

Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolt.

6. CYLINDER HEAD/VALVE

2 Insulator bolts

Cylinder head mounting bolts

4 Nuts

Caution

Make sure timing marks are matched.

Install a new O-ring onto thermostat and tighten its mounting bolts. Loosen sprocket chain tensioner and let it contact with chain plate tightly. Tighten the bolt cap of tensioner adjustment hole.

Install Air Injection system (AI) pipe. (2 bolts) Install carburetor insulator onto carburetor and tighten clamp strip bolt. Install the vacuum hose of carburetor insulator.

Whole cap of adjustment

Vacuum tube

Timing mark

Thermostat bolt

Clamp strip

AI. Pipe bolts

6-13

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6. CYLINDER HEAD/VALVE

Valve Clearance Adjustment

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 0.12 ± 0.02 mm

EX 0.12 ± 0.02 mm

Install the valve clearance adjustment hole cap. (3 bolts)

Caution

The gasket is paper type. In case of broken, replace it and clean the Remnant gasket.

Start the engine after assembly. Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head. Stop the engine after confirmed, and then install the intake valve adjustment hole cap.

Install the seat, luggage box and the body cover.

Caution

y If lubricant does not flow to cylinder head,

engine components will be worn out seriously. Thus, it must be confirmed.

y When checking lubricant flowing condition, run

the engine in idle speed. Do not accelerate engine speed.

6-14

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Contents

7. CYLINDER/PISTON

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

Mechanism Diagram

Piston Removal ··································7-4 Piston Ring Installation ·····················7-6 Piston Installation ······························7-7 Cylinder Installation···························7-7

7-1

To this chapter contents

7. CYLINDER/PISTON

Precautions in Operation

General Information

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

UA18A

Specification Unit：mm

Item Standard Limit

Cylinder

Piston/ Piston ring

OD of piston pin 14.960~15.000 14.930 Clearance between piston and piston pin 0.002~0.014 0.020 ID of connecting rod small-end 15.016~15.034 15.060

ID 60.995~61.015 61.016 Bend - 0.050

Clearance between piston rings

Ring-end gap

OD of piston 60.985~61.005 60.900 Clearance between piston and cylinder 0.010~0.040 0.100 ID of piston pin boss 15.002~15.008 15.040

Top ring 0.015~0.050 0.090

ring 0.015~0.050 0.090

2 Top ring 0.150~0.300 0.500 2nd ring 0.300~0.450 0.650 Oil ring side rail 0.200~0.700 -

Trouble Diagnosis

Low or Unstable Compression Pressure

y Cylinder or piston ring worn out

Knock or Noise

y Cylinder or piston ring worn out y Carbon deposits on cylinder head top-side y Piston pin hole and piston pin wear out

7-2

Smoking in Exhaust Pipe

y Piston or piston ring worn out y Piston ring installation improperly y Cylinder or piston damage

Engine Overheat

y Carbon deposits on cylinder head top side y Cooling pipe clogged or not enough in coolant

flow

To this chapter contents

7. CYLINDER/PISTON

Cylinder Removal

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

Remove cylinder gasket and dowel pin. Cover the holes of crankcase and cam chain with a piece of cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase.

Coolant hose

Caution

y Soap the residues into solvent so that the

residues can be removed more easily.

Inspection

Check if the inner diameter of cylinder is wear out or damaged. In the 3 positions, top, center and bottom, of cylinder, measure the X and Y values respective in the cylinder.

Service limit: 61.016 mm

Check cylinder if warp.

Service limit: 0.05 mm

Top Center

Bottom

7-3

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7. CYLINDER/PISTON

Piston Removal

Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other foreign materials falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.

Inspection

Measure clearance between piston rings and grooves.

Service Limit: Top ring: 0.09 mm

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

ring: 0.65 mm

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7. CYLINDER/PISTON

Measure the outer diameter of piston pin.

Service Limit: 15.040 mm

Measure the inner diameter of connecting rod small end.

Service Limit: 15.06 mm

Measure the inner diameter of piston pin hole. Service Limit: 15.04 mm Calculate clearance between piston pin and its hole.

Service Limit: 0.02 mm

Measure piston outer diameter.

Caution

The measurement position is 10 mm distance from piston bottom side, and 90° to piston pin.

Service limit：60.90 mm

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

7-5

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7. CYLINDER/PISTON

Piston Ring Installation

Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown.

Caution

y Do not damage piston and piston rings as installation. y All marks on the piston rings must be forwarded to up side. y Make sure that all piston rings can be rotated freely after installed.

Top ring

ring

Oil ring

Top groove

groove

Oil groove

7-6

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7. CYLINDER/PISTON

Piston Installation

Install piston and piston pin, and place the IN marks on the piston top side forward to intake valve. Install new piston pin snap ring.

Caution

y Do not let the opening of piston pin snap ring

align with the opening piston ring.

y Place a piece of cloth between piston and

crankcase in order to prevent snap ring from falling into crankcase as operation.

Cylinder Installation

Clean up all residues and foreign materials on the matching surface of crankcase. Pay attention to not let these residues and foreign materials fall into crankcase.

Caution

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

Install dowel pins and new gasket.

Coat engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation.

Caution

Do not push piston into cylinder forcefully because piston and piston rings will be damaged.。

Install coolant hose onto cylinder. Install cylinder head (refer to Chapter 6).

Coolant hose

7-7

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7. CYLINDER/PISTON

Notes:

7-8

Home page

Contents

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

8. V-BELT DRIVING SYSTEM/KICK STARTER

Mechanism Diagram

Kick Starter···········································8-4 Drive Belt··············································8-5 Drive Face·············································8-7 Clutch Outer/Driven Pulley··················8-10

5.0~6.0kgf-m

8-1

To this chapter contents

8. V-BELT DRIVING SYSTEM/KICK STARTER

Maintenance Description

Precautions in Operation General Information

y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. y Driving belt and driving pulley must be free of grease.

Specification Unit：mm

Item Standard value (mm) Limit (mm) Driving belt width 19.000 17.500 ID of drive face boss 27.000~27.021 27.060 OD of drive face 26.970~26.990 26.940 OD of roller 19.950~20.100 19.500 ID of clutch outer 130.000~130.200 130.500 Thickness of clutch weight 4.000~4.100 2.000 Free length of driven pulley spring 88.300 83.200 OD of driven pulley 33.965~33.985 33.940 ID of drive face 34.000~34.025 34.060

Torque value

y Driven face nut: 5.0~6.0kgf-m y Clutch outer nut: 5.0~6.0kgf-m

Special Service Tools

Clutch spring compressor: SYM-2301000 Inner bearing puller: Clutch nut wrench 39 x 41 mm: Universal holder: Bearing driver:

SYM-6204002

SYM-9020200

SYM-2210100

SYM-9100100

Trouble Diagnosis

Engine can be started but motorcycle can not be moved

1. Worn driving Belt

2. Worn drive face

3. Worn or damaged clutch weight

4. Broken driven pulley

Insufficient horsepower or poor high speed performance

1. Worn driving belt

2. Insufficient spring force of driven pulley

3. Worn roller

4. Driven pulley operation un-smoothly

Shudder or misfire when driving

1. Broken clutch weight

2. Worn clutch weight

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Left Crankcase Cover

Left crankcase cover removal

Release the clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (7 bolts) Remove 2 dowel pin and gasket.

Left crankcase cover install

Install left crankcase cover in the reverse procedures of removal.

Clamps

7 bolts

Driven gear

Kick tarter spindle

Return spring

Bush

Dowel pins

Snap clip

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Kick Starter

Removal

Remove left crankcase cover.

Disassembly of kick starter

Remove 4 screws, and remove the kick starter plate. Remove snap clip and thrust washer from left crankcase cover. Install kick start arm, rotate the lever slightly, and then remove driven gear and washer. Remove the kick starter arm, kick starter spindle, and return spring as well as socket.

Inspection

Check if starter spindle, driven gear for wear or damage.

Reassembly of Kick Starter

Install bush, return spring and starter spindle as diagram shown. Install thrust washer and snap clip onto starter spindle. Install Kick starter lever temporary. Slightly rotate the lever and then align driven gear with width-tooth on the starter spindle. Install the friction spring of drive gear onto convex part of the cover. Install kick starter plate.

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Drive Belt

Removal

Remove left crankcase cover Hold drive face with universal holder, and remove nut and drive face.

Special Tool：universal holder Tools number：SYM-2210100

Hold clutch outer with universal holder, and remove nut and clutch outer.

Caution

y Using special service tools for tightening or

loosening the nut.

y Fixed rear wheel or rear brake will damage

Drive belt

Universal holder

reduction gear system.

Push the driving belt into belt groove as diagram shown so that the belt can be loosened, and then remove the driven pulley. Remove driven pulley. Do not remove driving belt. Remove the driving belt from the groove of driven pulley.

Inspection

Check the driving belt for crack or wear. Replace it if necessary. Measure the width of driving belt as diagram shown.

Service Limit: 17.5 mm

Replace the belt if exceeds the service limit.

Caution

Universal holder

Belt tooth

Width

y Using the genuine parts for replacement. y The surfaces of driving belt or pulley must be

free of grease.

y Clean up all grease or dirt before installation.

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Installation

Caution

z Pull out driven face to avoid it closing. z Cannot oppress friction plate comp in order

to avoid creates the distortion or the damage.

Install driving belt onto driven pulley.

Install the driven pulley that has installed the belt onto drive shaft. On the drive belt another end to the movable drive face.

Install the clutch outer with universal holder, and then tighten nut to specified torque value.

Torque value: 5.0~6.0kgf-m

Install the drive face with universal holder, and

Drive belt

Driven face

Friction plate comp

Universal holder

Nut

then tighten nut to specified torque value.

Torque value: 5.0~6.0kgf-m

8-6

Universal holder

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Drive Face

Removal

Remove left crankcase cover. Hold drive face with universal holder, and then

remove drive face nut. Remove drive face.

Remove driving belt and movable drive face comp from crankshaft.

Crankshaft

Universal holder

Movable drive face

Drive face boss

Remove ramp plate.

Remove weight rollers from movable drive face.

Ramp plate

Movable drive face

Weight roller

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Inspection

The weight rollers are to press movable drive face by means of centrifuge force. Thus, if weight rollers are worn out or damaged, the centrifuge force will be affected. Check if rollers are worn or damaged. Replace it if necessary. Measure each roller’s outer diameter. Replace it if exceed the service limit.

Service limit: 19.50 mm Weight: 14.5g

Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face, and replace it if it exceed service limit.

Service limit: 26.94 mm

Weight roller

Movable drive face

Drive face boss

Measure the inner diameter of movable drive face, and replace it if it exceed service limit.

Service limit: 27.06 mm

Reassembly/installation Install weight rollers.

Caution

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

Install ramp plate.

Weight roller

Guide collar

Closure surface

8-8

Ramp plate

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With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss.

8. V-BELT DRIVING SYSTEM/KICK STARTER

Caution

The movable drive face surface has to be free of grease. Clean it with cleaning solvent.

Install movable drive face comp. onto crankshaft.

Driven pulley installation

Press driving belt into pulley groove, and then pull the belt onto drive shaft.

Install drive face, washer and nut.

Movable drive face

Crank shaft

Press down

Drive belt

Drive face boss

Nut

Caution

Make sure that two sides of pulley surfaces have to be free of grease. Clean it with cleaning solvent.

Hold drives face with universal holder. Tighten nut to specified torque.

Torque value: 5.0~6.0kgf-m

Install left crankcase cover.

Drive face

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch Outer/Driven Pulley

Disassembly

Remove drive belt, clutch outer and driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let the wrench be installed more easily.

Caution

Do not press the compressor too much.

Hold the clutch spring compressor onto bench vise, and then remove mounting nut with special service tool. Release the clutch spring compressor and remove friction plate, clutch weight and spring from driven pulley.

Remove seal collar from driven pulley.

Remove guide pin, guide pin roller, and movable driven face, and then remove O-ring & oil seal seat from movable driven face.

Clutch nut wrench

Movable driven face

Clutch spring compressor

Seal

Guide pin

Collar

Inspection Clutch outer

Measure the inner diameter of clutch outer. Replace the clutch outer if exceed service limit.

Service limit: 130.5 mm

O-ring

Inner diameter

Guide pin

Guide pin roller

Clutch outer

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch lining

Measure each clutch weight thickness. Replace it if exceeds service limit.

Service limit: 2.0 mm

Driven pulley spring

Measure the length of driven pulley spring. Replace it if exceeds service limit.

Service limit: 83.2 mm

Clutch lining

Clutch weight

Driven pulley

Check following items:

y If both surfaces are damaged or worn. y If guide pin groove is damaged or worn.

Replace damaged or worn components. Measure the outer diameter of driven face and the inner diameter of movable driven face. Replace it if exceeds service limit.

Service limit: Outer diameter 33.94 mm

Inner diameter 34.06 mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage. Replace it if necessary. Check if needle bearing is damage or too big clearance. Replace it if necessary. Rotate the inside of inner bearing with fingers to check if the bearing rotation is in smooth and silent. Check if the bearing outer parts are closed and fixed. Replace it if necessary.

Outer ball bearing

Free length

Driven face

Movable driven face

Guide pin groove

Needle bearing

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch weight Replacement

Remove snap ring and washer, and then remove clutch weight and spring from driving plate.

Caution

Some of models are equipped with one mounting plate instead of 3 snap rings.

Check if spring is damage or insufficient elasticity.

Check if shock absorption rubber is damage or deformation. Replace it if necessary. Apply with grease onto setting pins.

Spring

Clutch weight

Shock absorption rubber

Driving plate

Snap ring

Setting pin

Install new clutch weight onto setting pin and then push to the specified location. Apply with grease onto setting pins. But, the clutch block should not be greased. If so, replace it.

Caution

Grease or lubricant will damage the clutch weight and affect the block’s connection capacity.

Install the spring into groove with pliers.

Shock absorption rubber

Clutch weight

8-12

Spring

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Install snap ring and mounting plate onto setting pin.

8. V-BELT DRIVING SYSTEM/KICK STARTER

Replacement of Driven Pulley Bearing

Remove inner bearing.

Caution

y If the inner bearing equipped with oil seal on

side in the driven pulley, then remove the oil seal firstly.

y If the pulley equipped with ball bearing, it has to

remove snap ring and then the bearing.

Snap ring

Outer bearing

Clipper

Inner needle bearing

Remove snap ring and then push bearing forward to other side of inner bearing. Place new bearing onto proper position and its sealing end should be forwarded to outside. Apply with specified oil.

Install new inner bearing.

Caution

y Its sealing end should be forwarded to outside

as bearing installation.

y Install needle bearing with hydraulic presser.

Install ball bearing by means of hydraulic presser.

Snap ring

Outer bearing

Bearing end

Install snap ring into the groove of driving face. Align oil seal lip with bearing, and then install the new oil seal (if necessary).

Inner bearing

8-13

SYM TRACKRUNNER 200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual