TRACKRUNNER 200
HOW TO USE THIS MANUAL
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CONTENTS
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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
7
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
8
9
10
11
12
13
14
15
16
17
18-1 ~ 18-2
ELECTRICAL DIAGRAM
18
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Contents
SERIAL NUMBER
Frame number
Engine number
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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
1
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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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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To this chapter contents
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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To this chapter contents
1. GENERAL INFORMATION
y Do not let the wire harness been twisted as
installation.
y Wire harnesses routed along the handlebar
should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
y With sand paper to clean rust on connector
pins/terminals if found. And then conduct
connection operation later.
Clean rust
y Before operating a test instrument, operator
should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its
measurement position and
the insert locations of its
two probes?
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Specifications
MAKER SANYANG MODEL 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
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
─
1-10
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
1-13
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To this chapter contents
1. GENERAL INFORMATION
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
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
1-16
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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
1-17
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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
1-18
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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
1-19
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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
2
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
2-1
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2. MAINTENANCE INFORMATION
Periodical Maintenance Schedule
Maintenance
Code
1 Air cleaner
2 Fuel filter
3 Oil filter
4 Engine oil change
5 Tire pressure
6 Battery inspection
7 Brake & free ply check
8 Steering handle check
9 Cushion operation check
10 Every screw tightening check
11 Gear oil check for leaking
12 Spark plug check or change
13 Gear oil change
14 Frame lubrication
15 Exhaust pipe
16 Ignition timing
17 emission check in Idling
18 Throttle operation
19 Engine bolt tightening
20 CVT driving device(belt)
21 CVT driving device(roller)
22 Drive chain
23
24 Fuel lines
25 Cam chain
26 Valve clearance
27
28 Coolant reservoir
29 Coolant
Lights/electrical
equipment/multi-meters
Lines & connections in cooling
Item
Every
300KM
I / L I / L
1 Month
every
1,000KM
I C R
I I R
C C
R Replacement for every 1000 km
I I
I I
I I
I I
I I
I I
I I
I I R
R Replacement for every 5000 km
L
I I
I I
A I
I I
I I
I R
C
I I
I I
I I
I A
I I
I I
I I R
3 month
every
3,000KM
C
6 month
every
6000KM
1 year
every
12,000KM
15 month
every
14,500KM
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the ATV at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever
comes first.
Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in
the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and
after the ATV has accumulated a higher mileage.
3. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire,
after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system
when power is obvious lower. Than ever
2-2
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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
2-3
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2. MAINTENANCE INFORMATION
Valve Clearance
Caution
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove 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.
2-4
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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
2-5
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