KEEWAY ATV300 User Manual
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KEEWAY ATV300 User Manual

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CONTENTS
1.Information... ... ... ... ...................................................2 2 2 2
2.Maintenance.....................................................6
3.EngineRemoval&Installation...... ... ... ... .......................13
ENGINE
4.LubricationSystem..........................................15
5.FuelSystem....................................................19
6.CylinderHEAD&CylinderValve...........................30
7.Cylinder&Piston............................................46
8.V-Beltdrivingsystem.......................................54
9.ACG&Startonewayclutch................................67
10.CoolingSystem............................................76
CHASSIS
11.SteeringSuspension.......................................84
12.FrontWheel&BrakeSystem............................90
13.RearWheel&BrakeSystem.............................95
14.ElectricalSystem.........................................97
15.TroubleShooting.........................................107
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  • Page 1 CONTENTS GENERAL INFORMATION 1.Information… … … … …………………………………..…….…2 2 2 2 2.Maintenance………………………………………...…..6 3.EngineRemoval&Installation…… … … … ……………...…..13 ENGINE 4.LubricationSystem………...…………………………15 5.FuelSystem…………………………………………….19 6.CylinderHEAD&CylinderValve………...……….…..30 7.Cylinder&Piston……………………………………..46 8.V-Beltdrivingsystem…………………………………54 9.ACG&Startonewayclutch……………...…………..67 10.CoolingSystem……………...……………………..76 CHASSIS 11.SteeringSuspension…………..………....84 12.FrontWheel&BrakeSystem……………...……….90 13.RearWheel&BrakeSystem…………………….….95 14.ElectricalSystem…………………………………..97 15.TroubleShooting…………………………………..107...
  • Page 2 1. INFORMATION 1.1 SAFTY 1.4 SERIAL NUMBER 1.2 NOTES 1.5 TORQUE VALUE 1.3 SPECIFICATION 1.1 SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE ●...
  • Page 3 Compression 10.5:1 OutputPower 14KW/6000rpm Maximum Torque (Nm/rpm) 22.3 Nm / 5500rpm Carburetor Vacuum film Ignition Starting Electric Lubrication 15W-40 Transmission Automatic (C.V.T. V-belt Shafts CHASSIS Overall Length 2170mm Overall Width 1200 Overall Height 1210mm Wheel base 1275mm Ground Clearance 260mm Dry Weight 330kg Fuel Tank Capacity...
  • Page 4 1.4 SERIAL NUMBER Vehicle Identification Number (VIN) and Engine No. are used for registration. When you order parts or need special service, these numbers can help you receive the best service from our Authorized Dealers. We recommend copying your vehicle identification date in your operation and maintenance manual and on a sheet that you should keep in a safe place, separately from the vehicle.
  • Page 5 1.5 TORQUE VALUES STANDARD 5 N.m (3.5 lbf.ft) ● 5 mm bolt and nut 10 N.m (7.2 lbf.ft) 6 mm bolt and nut ● 22 N.m (16 lbf.ft) 8 mm bolt and nut ● 35 N.m (25 lbf.ft) 1 0 mm bolt and nut ●...
  • Page 6 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBLE 2.9 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.10 WHEELS AND TIRES 2.5 THROTTLE CABLE AJUSTMENT 2.11 STEERING SYSTEM 2.6 AIR CLEANER 2.12 TOE-IN 2.7 SPARK PLUG 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG SPARK PLUG GAP...
  • Page 7 2.2 MAINTENANCE SCHEDULE To keep the performance good, the motorcycle should be checked and maintained at certain interval. The meanings of capital in following table are: I: Inspection, including check, clean, lubricate, refuel, repair or replacing if necessary. A: Adjusting C: Cleaning R: Replacing T: Tightening...
  • Page 8 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damaging or leakage and replace if necessary. 2.4 THROTTLE OPERATION Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink in the throttle cable, replace it if necessary.
  • Page 9 2.7 SPARK PLUG This spark plug is located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the condition of spark plug electrodes wear. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
  • Page 10 Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 5-15 mm. The second method to adjust brake level is under the Parking BRAKE Adjustabie nut driver seat and rear brake component.
  • Page 11 STEERING SHAFT HOLDER BUSHING Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage. If the bushing is worn or damaged, please change a new one. Grease the steering shaft bushing and install the parts in the reverse order of removal.
  • Page 12 If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m...
  • Page 13 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3.2 ENGINE REMOVAL Before removing engine, you need to remove all of components such as seat, front and back fender, fuel tube, exhaust pipe, carburetor cable and drive shafts e tc.
  • Page 14 3.3 ENGINE INSTALLATION The Engine installation is essentially in the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly.

  • Page 15: Table Of Contents

    4. LUBRICATION SYSTEM 4-1 Mechanism Diagram 4-5 Engine Oil Strainer Clean 4-2 Precautions in Operation 4-6 Gear Oil 4-3 Troubleshooting 4-4 Engine Oil 4-1 Mechanism Diagram...
  • Page 16 4-2 Precautions in Operation General Information: This chapter contains maintenance operation for the engine oil pump and gear oil replacement. Specifications Engine oil quantity Disassembly: 1200 c.c. Change: 1000c.c. 單 位 單 位 單 位 單 位 Oil viscosity SAE 10W-40 (Recommended King serial oils) : mm Gear oil Disassembly: 750c.c.

  • Page 17: Engine Oil

    4-4 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.

  • Page 18: Gear Oil

    Gear oil drain bolt 4-6 Gear Oil Gear Oil Change Remove oil join bolt. Remove drain bolt and drain gear oil out. Install the drain bolt after drained. Torque value: 1.0~1.5kgf-m Make sure that the drain bolt washer can be re-used.
  • Page 19 5. FUEL SYSTEM 5-1 Mechanism Diagram 5-6 Throttle Valve 5-2 Precautions in Operation 5-7 Float Chamber 5-3 Trouble Diagnosis 5-8 Adjustment of Idle Speed 5-4 Carburetor Remove / Install 5-9 Fuel Tank 5-5 Air Cut-Off Valve 5-10 Air Cleaner 5-1 Mechanism Diagram...
  • Page 20 5-2 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 D o not bend off throttle cable. Damaged throttle cable will make ●...
  • Page 21 5-3 Trouble Diagnosis Poor engine start Mixture too lean No fuel in fuel tank Clogged fuel injector Clogged fuel tube Vacuum piston stick and closed Too much fuel in cylinder Malfunction of float valve No spark from spark plug(malfunction of ignition Fuel level too low in float chamber system ) Clogged fuel tank cap vent...
  • Page 22 5-4 Carburetor Remove / Install Removal Drain out fuel in the float chamber. DRAIN BOLT Disconnect the fuel hose. Release the clamp strip of air cleaner. CLAMP Remove the carburetor upper parts from the carburetor. Release the 2 nuts of carburetor insulator, and then remove the carburetor.
  • Page 23 5-5 Air Cut-Off Valve Disassembly 1 - 真 空 活 塞 阀 盖 2 - 弹 簧 3 - 柱 赛 组 件 4 - 电 加 浓 阀 座 5 - 密 封 圈 6 - 截 气 阀 盖 7 - 弹 簧 8 - 截 气 阀 9 - 下 壳 体 1 0 - 密...
  • Page 24 5-6 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.
  • Page 25 5-7 Float Chamber Disassembly Remove 4 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.
  • Page 26 Remove main jet, needle jet holder, needle jet, Needle jet holder Main jet slow jet and air adjustment screw. Caution Take care not to damage jets and adjust screw. ˙ ˙ ˙ ˙ B efore removing adjustment screw, turn it all the way down and note the number of turns.
  • Page 27 5-8 Adjustment of Idle Speed Parking brake Caution A ir 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. ˙...
  • Page 28 5-9 Fuel Tank Fuel unit removal Open the seat. Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender. (Covers remove please refer chapter Disconnect fuel unit coupler. Remove fuel unit (4 bolts). Caution D o not bend the float arm of fuel unit ˙...
  • Page 29 5-10 Air Cleaner Removal Loosen the clamp strip of air cleaner and carburetor,and then remove the vapor hose. Loosen the clamp strip of air cleaner, and then remove the air cleaner vapor hose. Remove the air cleaner (2 bolts). CLAMP Installation Install the tank in the reverse order of removal.
  • Page 30 6. CYLINDER HEAD/VALVE 6-1 Mechanism Diagram 6-6 Valve Stem Replacement 6-2 Precautions in Operation 6-7 Valve Seat Inspection and Service 6-3 Troubleshooting 6-8 Cylinder Head Reassembly 6-4 Cylinder Head Removal 6-9 Cylinder Head Installation 6-5 Cylinder Head Inspection 6-10 Valve Clearance Adjustment 6-1 Mechanism Diagram...
  • Page 31 6-2 Precautions in Operation General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as rocker arm. Cylinder head service can be carried out when engine is in frame Specification Item Standard Limit Compression pressure 12+/2 kg/cm2 Camshaft...
  • Page 32 6-3 Troubleshooting Engine performance will be affected by troubles on engine top parts. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve ˙ ˙ ˙ ˙ I mproper valve adjustment ˙...
  • Page 33 6-4 Cylinder Head Removal Remove engine. (Refer to chapter 5) Remove the inlet pipe (2 nuts). 2 NUTS Remove 1 bolt of thermostat and then remove the thermostat. Remove hole bolt and spring for the cam chain TENSIONER BOLTS tensioner. Loosen 2 bolts, and then remove tensioner.
  • Page 34 TIMING MARK Timing mark Remove left crankcase cover, and turn the Turn the drive face, and align the timing mark on the sprocket with that of cylinder head, piston is at TDC position. Remove cam sprocket bolts and then remove the sprocket by prying chain out. BOLTS Remove cam shaft setting plate (1 bolt).
  • Page 35 Remove the 2 cylinder head mounting bolts from cylinder head right side, and then remove 4 nuts and washers from cylinder head upper side. Remove the cylinder head. Remove cylinder head gasket and 2 dowel pins. Remove chain guide. Clean up residues from the matching surfaces Gasket of cylinder and cylinder head Caution...
  • Page 36 Remove valve stem seals Clean carbon deposits in combustion chamber. Clean residues and foreign materials on cylinder head matching surface. Caution Do not damage the matching surface of cylinder head. 6-5 Cylinder Head Inspection Check if spark plug and valve holes are cracked. Measure cylinder head warp with a straightedge and thickness gauge.
  • Page 37 Rocker Arm Measure the cam rocker arm I.D., and wear or damage, oil hole clogged? Service Limit: Replace when it is less than 12.10 mm. Rocker Arm Shaft Measure the active O.D. of the cam rocker arm shaft and cam rocker arm. Service Limit: Replace when it is less than 11.91 mm.
  • Page 38 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.
  • Page 39 6-6 Valve Stem Replacement Heat up cylinder head to 100~150 ℃ ℃ ℃ ℃ with heated plate or toaster. Caution Do not let torch heat cylinder head ˙ ˙ ˙ ˙ directly. Otherwise, the cylinder head may be deformed as heating it. W ear on a pair of glove to protect your ˙...
  • Page 40 6-7 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 ˙ ˙ ˙ ˙ D o not let emery enter into between valve stem and valve guide.
  • Page 41 Use 60° cutter to cut a quarter lower parts out. Old valve seat width Remove the cutter and check new valve seat. Use 45° cutter to grind the valve seat to specified Width Caution 60° Make sure that all roughness and uneven faces had been ground 1.0mm Grind valve seat again if necessary.
  • Page 42 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 6-8 Cylinder Head Reassembly Lubricate valve stem with engine oil, and then insert the valve into valve guide.
  • Page 43 6-9 Cylinder Head Installation Gasket Clean up all residues and foreign materials onto the matching surfaces of both cylinder and cylinder head. Install chain guide, dowel pins and a new cylinder head gasket onto the cylinder. Caution Do not damage the matching surfaces of Chain guide Dowel pins cylinder and cylinder head.
  • Page 44 Install cam chain on to sprocket and align the timing mark on the sprocket with that of cylinder head. Align sprocket bolt hole with camshaft bolt hole. Tighten the sprocket mounting bolts Caution Make sure timing marks are matched. Install cylinder head side cover (3 bolts). Install thermostat (2 bolts).
  • Page 45 6-10 Valve Clearance Adjustment Remove cylinder head cover Remove the cylinder head side cover. Remove left crankcase cover, and turn the drive face, and align the timing mark on the cam sprocket with that of cylinder head, piston is at TDC position. Loosen valve clearance adjustment nuts and bolts located on valve rocker arm.

  • Page 46: Table Of Contents

    7. CYLINDER/PISTON 7-1 Mechanism Diagram 7-5 Piston Ring Installation 7-2 Precautions in Operation 7-6 Piston Installation 7-3 Trouble Diagnosis 7-7 Cylinder Installation 7-4 Cylinder and Piston Removal 7-1 Mechanism Diagram...
  • Page 47 7-2 Precautions in Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame Specification Unit ： Item Standard Limit Cylinder Bend Piston/ Top ring Clearance between Piston ring piston rings ring Ring-end gap Top ring ring Oil ring side rail...

  • Page 48: Cylinder And Piston Removal

    7-4 Cylinder and Piston Removal Remove cylinder head (refer to chapter 6). Remove coolant hose from cylinder. Remove cylinder. Cover the holes of crankcase and cam chain with a piece of cloth. Remove piston pin clip, and then remove piston pin and piston Remove cylinder gasket and dowel pin.
  • Page 49 Check cylinder if warp. Service limit: 0.05 mm 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.
  • Page 50 Measure the outer diameter of piston pin. Service Limit: 17.00 mm Measure the inner diameter of connecting rod small end. Service Limit: 17.02 mm Measure the inner diameter of piston pin hole. Service Limit: 17.02 mm Calculate clearance between piston pin and its hole.

  • Page 51: Piston Ring Installation

    7-5 Piston Ring Installation Clean up piston top, ring groove, and piston surface. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side. Make sure that all piston rings can be rotated freely after installed.

  • Page 52: Piston 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.

  • Page 53: Cylinder Installation

    7-7 Cylinder Installation Install dowel pins and new gasket Coat some engine oil to inside of cylinder, piston and piston rings. Care to be taken when installing piston into cylinder. Press piston rings in one by one as installation. Caution Do not push piston into cylinder forcefully because piston and piston rings will be damaged.
  • Page 54 8. V-BELT DRIVING SYSTEM 8-1 Mechanism Diagram 8-5 Drive Belt 8-2 Maintenance Description 8-6 Drive Face 8-3 Trouble Diagnosis 8-7 Clutch Outer/Driven Pulley 8-4 Left Crankcase Cover 8-1 Mechanism Diagram...
  • Page 55 8-2 Maintenance Description Precautions in Operation General Information Drive face, clutch outer, and driven pulley can be serviced on the motorcycle. Drive belt and drive pulley must be free of grease. Specification Unit ： Item Standard value (mm) Limit (mm) Drive belt width ID of drive face boss OD of drive face...
  • Page 56 8-4 Left Crankcase Cover Left crankcase cover removal Release the 2 clamp strips of left crankcase cover ducts, and then remove the ducts. Remove left crankcase cover. (10 bolts) Remove 2 dowel pin and gasket. Left crankcase cover install Install left crankcase cover in the reverse procedures of removal...
  • Page 57 8-5 Drive Belt Removal Universal holder Remove left crankcase cover. Hold drive face with universal holder, and remove nut and drive face. Special Tool u niversal holder ： Hold clutch outer with universal holder, and remove nut, bearing stay collar and clutch outer Caution Universal holder Bearing stay collar...
  • Page 58 Installation Driven face Caution ˙ ˙ ˙ ˙ P ull out driven face to avoid it closing. ˙ ˙ ˙ ˙ Cannot oppress friction plate comp in order to avoid creates the distortion or the damage. Install drive belt onto driven pulley. Install the driven pulley that has installed the belt onto drive shaft.
  • Page 59 8-6 Drive Face Universal holder Removal Remove left crankcase cover. Hold drive face with universal holder, and then remove drive face nut. Remove drive face and drive belt. Movable drive face Remove movable drive face comp and drive face boss from crankshaft. Remove ramp plate.
  • Page 60 Weight roller 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.
  • Page 61 Install ramp plate. With 4~5g grease spreads wipes drives in the movable drive face axis hole. Install drive face boss. Caution The movable drive face surface has to be free of grease. Clean it with cleaning solvent. Drive face boss Install movable drive face comp.
  • Page 62 8-7 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.
  • Page 63 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 Driven pulley Check following items: ·...
  • Page 64 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.
  • Page 65 Install snap ring and mounting plate onto setting pin. Replacement of Driven Pulley Bearing Remove inner bearing. Caution · · · · I f the inner bearing equipped with oil seal on side in the driven pulley, then remove the oil seal firstly. If the pulley equipped with ball ·...
  • Page 66 Installation of Clutch OUTER/Driven Pulley Assembly Install new oil seal and O-ring onto movable driven face. Apply with specified grease to lubricate the inside of movable driven face. Install the movable driven face onto driven face. Install the guide pin and guide pin roller. Install the collar.

  • Page 67: Table Of Contents

    9. ALTERNATOR/STARTING CLUTCH 9-1 Mechanism Diagram 9-6 Flywheel Removal 9-2 Precautions in Operation 9-7 Starting Clutch 9-3 Right Crankcase Cover Removal 9-8 Flywheel Installation 9-4 A.C.G. Set Removal 9-9 A.C.G. Set Installation 9-5 Right Cover Bearing 9-10 Right Crankcase Cover Installation 9-1 Mechanism Diagram...
  • Page 68 9-2 Precautions in Operation General information Refer to chapter 17: The troubleshooting and inspection of alternator Refer to chapter 17: The service procedures and precaution items of starter motor Specification Item Standard value (mm) Limit (mm) ID of starting clutch gear 25.026~25.045 25.100 OD of starting clutch gear...

  • Page 69: Right Crankcase Cover Removal

    9-3 Right Crankcase Cover Removal Remove left footrest. Drain out the engine oil and coolant, and then remove coolant hoses. Remove water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. 9-4 A.C.G.

  • Page 70: Flywheel Removal

    Check the oil seal for wear or damage. Replace it if necessary. Install a new one bearing (6201LU) by bearing driver. Special tool: Bearing driver 9-6 Flywheel Removal Remove right crankcase cover. Remove left crankcase cover. Hold the flywheel by drive face with universal holder.

  • Page 71: Starting Clutch

    Remove starter reduction gear and shaft. Pull out flywheel with A.C.G. flywheel puller. Special tool: A.C.G. Flywheel puller Remove flywheel and starting driven gear. 9-7 Starting Clutch Starting Clutch Inspection Remove starting clutch driven gear. Check the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear.
  • Page 72 Install starting clutch driven gear onto one way clutch. Hold flywheel and rotate starting clutch gear. The starting clutch gear should be rotated in C.C.W direction freely, but not C.W direction. (View as shown in this figure.) One way clutch removal Remove starting driven gear.

  • Page 73: Flywheel Installation

    One way clutch Installation Install the components in the reverse procedures of removal. Caution Tape a tightening tape onto the thread of hexagon bolt. Torque value: 1.0~1.4kgf-m Install starting driven gear. 9-8 Flywheel Installation Align the key on crankshaft with the flywheel groove, and then install the flywheel Hold the flywheel by drive face with universal holder, and tighten flywheel nut.
  • Page 74 Install reduction gear shaft and reduction gear 9-9 A.C.G. Set Installation Install the A.C.G. coil set onto right crankcase cover (3 screws). Install pulse generator (2 screws). Tie the wire harness securely onto the indent of crankcase. Caution Make sure that the wire harness is placed under pulse generator.
  • Page 75 Install right crankcase cover (11 screws). Install the dowel pin, new gasket and water pump cover onto crankcase cover. Connect water hoses to the right crankcase cover and water pump cover...

  • Page 76: Table Of Contents

    10. COOLING SYSTEM 10-1 Mechanism Diagram 10-4 Trouble Diagnosis for Cooling System 10-2 General Information 10-5 System Test 10-3 Trouble Diagnosis 10-6 Radiator 10-1 Mechanism Diagram...

  • Page 77: General Information

    10-2 General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down.
  • Page 78 10-3 Trouble Diagnosis The engine temperature is too high The water thermometer and the temperature sensor do not work properly. The thermostat is stuck to close. Insufficient coolant. The water hose and jacket are clogged. Fan motor malfunction. The filler cap of the radiator malfunction. The engine temperature is too low The water thermometer and the temperature sensor malfunction.
  • Page 79 10-4 Trouble Diagnosis for Cooling System...

  • Page 81: System Test

    10-5 System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low.
  • Page 82 air bubble in the radiator coolant, also the coolant liquid level is stable. S top the engine. Add coolant to proper level if necessary. · · · · S crew and tighten up the radiator filler cap · · · · Caution In order to avoid the water tank rusting, please do not use the unclear trade mark...
  • Page 83 Loosen the radiator 4 bolts. Remove coolant upper side pipes. Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. Disassembly Loosen the 3 bolts from the fan duct, and then remove the fan duct.
  • Page 84 11. STEERING AND SUSPENSION 11.1 PARTS DRAWING 11.4 THROTTLE HOUSING 11.2 TROUBLESHOOTING 11.5 STEERING SYSTEM 11.3 HANDLENAR 11.1 PARTS DRAWING...
  • Page 85 11.2 TROUBLESHOOTING HARD STEERING Faulty tire ★ Steering shaft holder too tight ★ Insufficient tire pressure ★ Faulty steering shaft bushing ★ Damaged steering shaft bushing ★ FRONT WHEEL WOBBLING Faulty tire ★ Worn front brake drum bearing ★ Bent rim ★...
  • Page 86 Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. SCREWS BOLTS Remove the handle cover and instrument panel by four screws at right and left side as shown in picture SCREWS Remove the bolts attaching the handlebar upper holder. Remove the handlebar.
  • Page 87 INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch marks match with the top end of the handlebar of lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts.
  • Page 88 11.4 THROTTLE HOUSING SCREWS DISASSEMBLY · · · · L oosen the screws on the throttle housing cover. R emove throttle housing cover and gasket. · · · · · · · · D isconnect throttle cable from the throttle arm and remove from the throttle housing.
  • Page 89 Steering Shaft Removal Remove the handle bar cover and handle bar. Remove the front fender. Remove handlebar lower holder. Loosen the steering shaft holder bolt and remove steering shaft holder. Take off the cotter pin below steering shaft. Loosen the steering shaft fixed out below shaft. Pull steering shaft carefully.
  • Page 90 12. FRONT WHEEL AND BRAKE SYSTEM 12.1 PARTS DRAWING 12.4 HYDRAULIC BRAKE 12.2 TROUBLESHOOTING 12.5 SUSPENSION SYSTEM 12.3 FRONT WHEEL 12 .1 PARTS DRAWING FRONT WHEEL BRAKE...
  • Page 91 12.2 TROUBLESHOOTING HARD STEERING Faulty tire ★ Insufficient tire pressure ★ FRONT WHEEL WOBBLING ★ Faulty tire ★ Worn front brake drum bearing ★ Bent rim Axle nut not tightened properly ★ BRAKE DRAG Incorrect brake adjustment ★ ★ ★ ★ Sticking brake cable ★...
  • Page 92 12 .4 HYDRAULIC BRAKE This type of brakes are applying in front of two wheels of REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures.
  • Page 93 Then using the power tools to take the screw out from brake stopping plate. You can take the brake disc off. When change brake shoe wear, you must push the master piston to rearward. After removal the front brake assembly, you must fabricate in reverse sequence.
  • Page 94 12 .5 SUSPENSION SYSTEM Suspension system in this type of AVT can be adjustable. There are two ways to adjust suspension: 1. You can raise the all ATV body up by using a repair platform. The four wheel are in the free position, you can easy to adjust the suspension.
  • Page 95 13. REAR WHEEL AND BRAKE SYSTEM 13.1 PARTS DRAWING 13.2 TROUBLESHOOTING Suspension adjustment 13.3 13.1 PARTS DRAWING REAR WHEEL FR./RR. AXLE...
  • Page 96 13.2 TROUBLESHOOTING Bad Brake Performance Brake shoes are worn ★ Bad brake adjustment ★ Brake linings are oily, greasy or dirty ★ Brake drums are worn ★ Brake arm setting is improperly engage ★ Vibration or Wobble ★ Axle is not tightened well Bent rim ★...
  • Page 97 14. ELECTRICAL SYSTEM 14.1 TROUBLESHOOTING 14.5 ELECTRIC STARTER 14.2 IGNITION COIL 14.6 LIGHT BULBS REPLACEMENT 14.3 IGNITION TIMING 14.7 INSTRUMENT PANEL 14.4 BATTERY INFORMATION 14.8 WIRING DIAGRAM 14.9Electrical starter switch 14.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING ★ FAULTY SPARK PLUG ★...
  • Page 98 14.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3 ( 20 Ω ℃ Measure the secondary coil resistance with the spark plug cap in place STANDARD : 3 –...
  • Page 99 BATTERY INSTALLATION Install the battery in the reverse order of removal. After installing the battery, coat the terminals with clean grease. CHARGING Firstly, connect the charged positive cable to the battery positive terminal. Secondly, connect the charged negative cable to the battery negative terminal. Using 0.9A-charging current about 11 hours.
  • Page 100 After loosen these three screws, users can find a connector. Please disjoin the connector in order to replace an electrical bulb conveniently and safely. The steps show on pictures. SCREWS Installation is in the reverse order of disassembly. Front Direction lights remove To replace the direction lights must loosen the screws as shown in picture.
  • Page 101 Front position light removes There are two screws inside the cap. Please disassemble first then push the cap upward. You could replace the electrical bulb Front position lights Turn around the cap, you could see the connector. Turn the seat to replace the electrical bulb TAILLIGHT The taillight combines a position and a rear brake light.
  • Page 102 Rear Direction lights remove The same disassembling procedure like front direction light. Please use the pliers to remove the seat. Then the bubble could be see and replaced Rear Direction lights 14.7 Instrument Panel The instrument panel includes fuel gauge, speed meter, water Temperature gauge, right and left turn signal, trip do-meter, and indicator camp.
  • Page 104 14.9 Electrical starter switch With main switch ‘ON’, press electrical starter switch , the engine will start. “ ” WARNING: Release the button after the engine has started. To avoid engine damage, do not engage starter with engine running. Turn signal switch Turn signal lights are used when turning left or right, or used to change lanes.
  • Page 105 Indicator and warning lights 1. Speed indicator in MPH. 2. left turning indicator High light indicator 4. Low light indicator 5. Right turning indicator 6. temperature indicator 7. Fuel indicator 8. Four wheel drive 、 、 、 、 t wo wheel drive indicator. 9.
  • Page 106 Fuse 、 、 、 、 Ignition system fuse (10 A) 、 、 、 、 Fan system fuse(10A) 、 、 、 、 light system fuse (15 A) 、 、 、 、 charging system fuse(15A) 、 、 、 、 Auxiliary DC jack fuse (10 A) 、...
  • Page 107 15.TROUBLESHOOTING 15.1 ENGINE CAN NOT WORK 15.4 LOSS POWER 15.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 15.5 POOR HANDLING 15.3 POOR PERFORMANCE AT HIGH SPEED 15.1 ENGINE CAN NOT WORK...
  • Page 108 15.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 15.3 POOR PERFORMANCE AT HIGH SPEED...
  • Page 109 15.4 LOSS POWER...
  • Page 110 15.5 POOR HANDLING...

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