WD250U - L Service Manual PDF

WD250U Service Manual
For any questions please contact Baja Motorsports at 888-863-2252

Content
Content...........................................................................................................................2
Chapter I General description........................................................................................6
Section 2 Special tools, instruments & meters.............................................................. 7
(I) Special tools....................................................................................................7
Section 3 Identification code, label of model and engine No........................................9
Section 4 Points for attention in maintenance................................................................9
Section 5 Specification................................................................................................. 13
I. How to use conversion table of unit............................................................... 13
(1) How to use conversion table........................................................................ 13
(2) Definition of unit..........................................................................................13
II. Basic specification.........................................................................................14
III. ATV body..................................................................................................... 15
IV. Electric system............................................................................................. 16
V. Maintenance specification of engine............................................................. 18
Section 6 Wiring diagram of ATV................................................................................ 21
(I) Technical explanation and requirement, details of relative component........ 21
(II) Wiring diagram (1)...................................................................................... 23
(III) Wiring diagram (2)..................................................................................... 24
(IV) Wiring diagram (3)..................................................................................... 25
Section 7 Requirements for torque of fastener............................................................. 26
(1) ATV body..................................................................................................... 26
(2) Engine.......................................................................................................... 28
(3) General torque specification........................................................................ 30
Section 8 Lubrication................................................................................................... 31
(1) Lubrication oil way........................................................................................31
(2) Lubrication diagram..................................................................................... 32
Section 9 Lubrication point and type of lubricants...................................................... 34
(1) ATV body..................................................................................................... 34
(2) Engine.......................................................................................................... 35
Chapter II Maintenance and adjustment of vehicle...................................................... 36
Section 1 Periodic maintenance/lubrication................................................................ 36
Section 2 Disassembly and assembly of cushion, fender and fuel tank....................... 37
(I) Cushion......................................................................................................... 37
(II) Rear fender.................................................................................................. 38
(III) Fuel tank..................................................................................................... 40
(IV) Front fender................................................................................................ 42
2
Section 3 Maintenance and adjustment of vehicle body.................................................................... 44
(I) Wear inspection of front and rear brake............................................................................ 44
(II) Adjustment of front brake..................................................................................................44
(III) Adjustment of free clearance of left lever and rear brake pedal.......................................45
(IV) Position adjustment of steering lever............................................................................. 47
(V) Lubricating oil level inspection of rear driving gearcase................................................. 47
(VI) Replacement of engine oil of rear driving gearcase....................................................... 48
(VII) Rubber sleeve inspection of rear wheel fork................................................................. 49
(VIII) Inspection of steering system....................................................................................... 49
(IX) Adjustment of toe-in of front wheel............................................................................... 50
(X) Inspection of front/rear shock absorber........................................................................... 51
(XI) Adjustment of rear shock absorber............................................................................... 51
(XII) Inspection of tire.......................................................................................................... 52
(XIII) Inspection of rim........................................................................................................ 53
Section 4 Maintenance and adjustment of electrical appliance......................................................... 54
(I) Inspection of battery......................................................................................................... 54
(II) Inspection of fuse............................................................................................................ 55
(III) Replacement of headlight lamp.......................................................................................56
Section 5 Maintenance and adjustment of engine.............................................................................. 58
(I) Adjustment of clutch......................................................................................................... 58
(II) Cleaning of air filter.........................................................................................................58
(III) Inspection of spark plug................................................................................................. 60
(IV) Adjustment of idle speed.............................................................................................. 61
(V) Adjustment of free clearance of throttle grip................................................................. 61
(VI) Adjustment of speed limiter........................................................................................... 62
(VII) Adjustment of valve clearance.................................................................................... 63
(VIII) Adjustment of timing chain tension.............................................................................65
(IX) Inspection of ignition timing........................................................................................ 66
(X) Measuring of compressive force..................................................................................... 67
(XI) Inspection oil quantity of engine................................................................................... 68
(XII) Replacement of engine oil and inspection of oil flow.................................................. 69
Chapter III Repair and maintenance of vehicle body.........................................................................71
Section 1 Rear driving gearcase and driving shaft.............................................................................71
(I) Troubleshooting.................................................................................................................72
(II) Inspection.........................................................................................................................72
(III) Troubleshooting table.....................................................................................................73
(IV) Disassembly.................................................................................................................. 74
(V) Inspection.........................................................................................................................77
(VI) Pad choice of main driving gear and shift gear............................................................ 79
(VII) Installation....................................................................................................................80
3
Section 3 Rear wheel/Rear brake/Rear wheel axle................................................................ 81
(I) Removal steps....................................................................................................... 83
(II) Inspection stepes.................................................................................................. 85
(III) Installation steps................................................................................................. 88
Section 4 Steering operation system...................................................................................... 92
(I) Removal steps of steering bar................................................................................ 93
(II) Removal steps of steering vertical column welding............................................ 94
(III) Inspection content............................................................................................... 95
(IV) Installation steps................................................................................................. 96
(V) Installation steps of steering bar.......................................................................... 99
Section 5 Front shock absorber and front wheel fork............................................................ 100
(I) Disassembly........................................................................................................... 101
(II) Inspection steps.................................................................................................... 103
(III) Installment steps................................................................................................. 104
Section 6 Rear shock absorber and rear wheel fork............................................................... 107
(I) Disassembling steps.............................................................................................. 108
(II) Checking steps..................................................................................................... 110
(III) Mounting steps................................................................................................... 112
Chapter IV Electric appliance................................................................................................ 115
Section 1 Electric assembly.................................................................................................... 115
Section 2 Inspect switch......................................................................................................... 116
(I) Inspect switch........................................................................................................ 116
(II) Inspect the switch circuit..................................................................................... 117
Section 3 Check headlight lamp............................................................................................. 118
Wire diagram.............................................................................................................. 119
Section 4 Troubleshooting the ignition system failure........................................................... 120
Section 5 Running starting circuit.......................................................................................... 124
Section 6 Troubleshooting electric starting system................................................................ 125
Section 7 Starting motor......................................................................................................... 128
Section 8 Check starting motor............................................................................................... 129
Section 9 Battery will not hold charge.................................................................................... 131
Section 10 Troubleshooting.................................................................................................... 133
Section 11 Inspection of lighting system................................................................................ 135
(I) Headlight not working........................................................................................... 135
(II) Taillight not working............................................................................................ 136
Section 12 Troubleshooting.................................................................................................... 137
(I) If indicated lamp is out of work............................................................................. 137
Section 13 Inspection of signal system.................................................................................. 139
(I) If the neutral indicated lamp is out work............................................................... 139
(II) If the reverse indicated lamp is out work............................................................. 140
(III) If the HB indicated lamp is out work.................................................................. 141
Chapter V Engine................................................................................................................... 142
Section 1 Disassembly of Engine........................................................................................... 142
(I) Remove the engine from finished ATV.................................................................. 142
(II) Disassembly of engine......................................................................................... 145
4
Section 2 Inspection and maintanence of engine............................................................................... 159
Section 3 Assembly and adjustment of engine................................................................................... 183
(I) Closing assembly of left & right crankcase...................................................................... 183
(II) Assembly of right crankcase............................................................................................ 187
(III) Assembly of left crankcase............................................................................................. 196
(IV) Selection and installation of adjusting washer............................................................... 207
(V) Assembly of cylinder head.............................................................................................. 209
(VI) Manual starting mechanism and others.......................................................................... 209
(VII) Mount the engine on the finished vehicle..................................................................... 219
Chapter VI Vehicle Troubleshooting.................................................................................................. 220
(I) Starting trouble/difficulty................................................................................................... 227

5
Chapter I General Description
Section 1 Description
2 5 6 7 8
1
1. Front wheel
2. Headlight
3. Forward/Reverse lever
4. Shift pedal
5. Fuel valve
6. Hand-operated lever 3 4
7. Air choke
8. Taillight
9. Rear wheel 10 11 12 13 14 15
10. Rear luggage carrier
11. Exhaust silencer
12. Cushion
13. Fuel tank cover
14. Rear brake pedal
15. Front luggage carrier
16. Left rear brake lever
17. Hand-operated parking brake
18. Main switch lock
19. Throttle grip
18
20. Right front brake lever 16 17 19
21. Left switch unit
22. Left and right mirror 22
22
20
21
CAUTION:
The ATV you purchased may be slightly different from the pictures in the
manual due to improvements.
6
Section 2 Special tools, instruments and meters
(I) Special tools

There are special tools needed to properly adjust and assemble this unit. These tools are
intended to prevent maintenance defects and damage.
1. Wrench for valve adjustment, mainly used to adjusting the valve clearance. Specification:
3mm, 90890-01311
2. Puller for piston pin, used for removing piston pin.
3. Remover for rotator, mainly for pulling the magneto rotator from crank.
4. Clamp for rotator, for clamping magneto rotator when removing it to prevent it’s rotation due
to torque force.
5. Stop rotating meter for rotator, used for removing and assembling rotator of kick starter.
6. Puller for crank, for disassembling crank from crankcase.
7. Puller for rocker shaft, used for the removing rocker shaft.
8. Compressing tools for spring of valve, for fixing and compressing spring when assembling
valve lock clamp.
9. Assembling and disassembling tools for valve guide.
10. Assembling buffer, used for assembling crank and balancing gear.
11. Hollow sleeve, for assembling crank and balancing gear.
12. Assembling tool for crank, used for assembling crank and balancing gear.
13. Assembling and disassembling joint for universal coupling.
14. Assembling and disassembling disc, used for assembling and disassembling reverse gear.
15. Fixed puller for gear.
7
(II) Instruments and meters
The following instruments and meters can be selected with
reference to the same type of vehicle.
8
Section 3 Identification code, label
of model and engine No.
Identification code
Engraved in the left or right side of the front
supporting main tube of engine of frame
Engine No.
This is engraved on the top middle part of the
right crankcase of engine.
Section 4 Points for attention in maintenance

1. Preparation when disassembling
1.1 First clean the dirt and mud from the vehicle before removing or disassebmling.
1.2 Use proper cleaning device and tools.
1.3 Keep all the components away from fire. Pay attention to hot surfaces such as the engine,
exhuast etc.
1.4 When disassembling the ATV, keep alike parts such as gear pairs, cylinder, piston, etc.
together. When assembling or replacing these components they should be kept in pairs.
1.5 When disassembling the engine, clean all components and place in a tray in the order of dis-
assembly, not only increasing the assembling speed, but also ensuring the correct assembly.
2. Replace the components
When replacing components use only the products, lubricants and grease recommened by manu-
facturer.
3. Oil seal, shim, O-ring, clip, split pin, elastic washer
3.1 When disassembling to maintain the engine, to ensure that the reassembled engine has good
sealing and connected parts are fixed and reliable, the oil seal, shim, o-ring, clip, split pin and
elastic washer should be replaced, be sure to keep lip of oil seal, surface of shim and o-ring in a
clean condition.
3.2 When reassembling, apply lubricant to all the alike components and bearings,
apply grease for oil seal.
9
4. Clip
4.1 Before assembling, check all the clips carefully.
Replace with a new one after removing from piston
pin. When mounting clip ring (1), make the sharp
end face (2) on the opposite position of
impacted face (3) of clip. (see figure at left)
5. Locking washer/shim and location pin

5.1 When reassembling, replace all locking washer/
shim and location pin (a) . After bolt or nut is in the
lock position, bend and fix both ends of locking shim
along head of bolt or direction of nut.
6. Bearing and oil seal

6.1 When assembling bearing and oil seal, put the
mark (specification of manufacturer) outside. When
assembling oil seal, apply a thin layer of lithium-
based grease on the lip of oil seal.
CAUTION:
Do not dry inside of bearing by blowing out with
compressed air, this will cause damage to the surface
of the bearing.
10
7. Check of electric parts
7.1 Make sure there is no rust, dirt or moisture at the
connection, if there is blow it dry or clean.
7.2 The electrolyte inside the battery is corrosive,

take extra precautions as to not get this on your
body.
7.3 When repairing wires on electrical parts, remove

the wire on the terminal of negative pole of battery
(see figure 7.1). When tightening or loosening bolt
on terminal of battery, do not let the wrench contact
the engine or other metal parts of the vehicle body to
avoid electric shock.
7.4 When connecting the wire to battery, first con-

nect the positive pole then connect the negative pole.
After wires are connected, apply clean grease on the
terminal to increase resistence of rust.
7.5 Check the terminal of connector

A. Grip the two terminals of connector together,
check with the multimeter (see figures 7.3 and 7.4)
11
B. If there is slack in the joint, bend the plug pin
upward, then connect with connector plug (see figure
7.5)
7.6 Before mounting the new fuse, check if the load

of fuse on the components are correct, especially the
portion being broken regularly, then mount the fuse
having proper current value.
7.7 There are two kinds of wire connectors, a single-

head connector, another a multi-head connector.
Before connecting single-head connector, make sure
there are no defects on the housing of the joints.
When inserting the joint, after defects are fixed, put
plastic coating on.
In general, multi-head connectors are plastic and
designed to lock. When disassembling the connector,
first open lock; when connecting again make sure the
joints are in good condition and there are no bends
or twists. After connecting, align the lock device and
lock.
8. Use torque spanner to tighten screw and nut, and

as per specified torque. It should be tightened in
steps from big to small, from inside to outside and
along the direction of a diagonal line that intersects
(see figure 8.1).
12
Section 5 Specification
I. How to use conversion table of unit

(1) How to use a conversion table
All the specified documents in this manual are taken SI and Metric as unit. With the following
conversion table, metric unit could ne conversed into imperial unit.
Metric Multiply Imperial

mm 0.03937 in
2mm x 0.03937 = 0.08in
Conversion Table
Known Unit Multiply Product
Torque m•kg 7.233 ft.lb
m•kg 86.794 in•lb
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb
Weight kg 2.205 lb
g 0.03527 oz
Length km/hr 06.214 mph
km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
Volume/capacity cc(cm³) 0.03527 oz(IMP lig.)
cc(cm²) 0.06102 cu•in
lit(liter) 0.8799 qt(IMP lig.)
lit(liter) 0.2199 gal(IMP liq.)
Others kg/mm 55.997 lb/in
kg/cm² 14.2234 psi(lb/in2)
Centrigrade 9/5(˚C)+32 Fahrenheit(˚F)
(2) Definition of unit
Unit Read Definition Measurement
mm Millimeter 10ֿ³Meter Length
cm Centimeter 10ֿ²Meter Length
kg kilogram 10³Gram Weight
N Newton 1 lilo x meter/second Force
Nm Newton meter Newton x meter Torque
m•kg Meter kilogram Meter x kilo Torque
Pa Pascal Newton x meter² Pressure
N/mm Newton per millimeter Newton/centimeter Rigid of spring
L Liter
cm³ Cubic centimeter ¯ ¯
r/min Revolutions per minute − Rotational speed
13
II. Basic specification
Item Specifications Item Specifications
Dimension: Shifting type
Overall length 1960mm 1st speed 34/12(2.833)
Overall width 1010mm 2nd speed 34/19(1.789)
Overall height 1120mm 3rd speed 29/22(1.318)
Height of cushion 780mm 4th speed 26/25(1.040)
Axle base 1160mm 5th speed 23/28(0.821)
Front wheel distance 785mm Reverse gear 73/22x34/12x19/18x46/11(41.5)
Rear wheel distance 770mm Frame
Min.ground clearance 155mm Bracket Steel tube
Min.turning radius 2900mm Caster angle 13˚
Basic weight: Toe-in of tire 0-5mm
Engine oil(with full tank) 220kg Tire
Engine Single-cylinder, 4 Type Vacuum
stroke, air cooled Spec. of front wheel AT22x7-10
Displacement 229.6cm³ Spec. of rear wheel AT22x10-10
Cylinder bore x stroke 71 x 58mm Pressure of front wheel 20kpa
Compression ratio 8.7:1 Pressure of rear wheel 25kpa
Starting system Electric starter or Brake
handoperated starter Type of front brake Drum(full-closed)
Lubrication system Pressure splash Operation Right-hand
Engien oil SAE20W40, Type of rear brake Drum(full-closed)
SAE10W30, Operation Left-hand and right foot
SAE5W30 Front suspension Independent
Classification of Model SE,SF,SG or Rear suspension Center shock absorber
recommended engine oil above Spec. of shock absorber
Periodic oil replacement 1.5L Front shock absorber Spring/oil pressure
Replace filter 1.6L Rear shock absorber Spring/oil pressure
Overall capacity 1.8L Electric system
Oil capacity of gearbox 0.27L Ignition system C.D.I
Model: SAE80API”GL-4” Magneto system A.C. magneto
gear oil of standard Battery/capacity Free of maintenance,
double curved face 12N14-BS/12V, 14AH
Capacity of fuel tank 12L, Non-lead gas #90 Headlight 12V, 25W/25Wx2
Capacity of reserve fuel tank 1.6L Taillight 12V,10Wx1
Carburetor: Neutral indicator 12V,3Wx1
Type Vacuum film type Reverse indicator 12V,3Wx1
Type of spark plug D7RTC High-beam indicator 12V,3Wx1
Clearance of spark plug 0.6-0.7mm
Type of clutch Wet automatic
centrifugal type
Output
Primary reduction system Gear driving
Reduction ratio 73/22(3.318)
Secondary reduction system Axle driving
Reduction ratio 19/18x46/11(4.414)
Output type Non-cycle,5 gear
forward, gear back
Operation Left-foot operation
14
III. ATV body
Item Standard Limit

Steering system Powder metallurgy sliding
Type of steering bearing bearing
Type Spock rim, tubeless tire
Material of rim Steel plate
Front Size of tire AT22x7-10
Wheel
Size of rim AT 10x5.5
Radial runout of rim 2.0mm
Lateral swing of rim 2.0mm
Front Brake Type Hydraulic disc
Rear Type Spoke rim, tubeless tire
Wheel Material of rim Steel plate
Sixe of tire AT22x10-10
Size of rim AT 10x8.0
Radial runout of rim 2.0mm
Lateral swing of rim 2.0mm
Type Drum type
Rear
Outside diameter of brake drum 160mm 161mm
Brake
Thickness of friction piece 4.0mm 2.0mm
Free length of back spring of brake 71.0mm
shoe
Free play of brake lever (left) 5-7mm
Brake lever Free play of brake lever (right) 5-7mm
and brake Free play of rear brake pedal 20-30mm
pedal
Free play of throttle grip 3-5mm
15
III. ATV body
Item Specification Limit

Elastic coefficient of spring K1 10N/mm/0-117mm
Front suspension Free length of suspending spring 293mm
system Stroke of shock absorber 117mm
Pre-tension force of spring is Not adjustable
adjustable or not
Elastic coefficient K2 49N/mm/8-85mm
Rear suspension Free length of suspending spring 263mm
system Assembling length 244mm
Stroke of shock absorber 85mm
Pre-tension force of spring is Adjustable
adjustable or not
Rear wheel fork Assembling free play (left-end) 1.0mm
Assembling free play (right-end) 1.0mm
IV. Electric system
Item Standard
Voltage of electric system 12V
Spark plug Type D7RTC
Resistence 10Ω
Clearance of spark plug 0.6-0.7mm
Resistence of primary coil At 20˚C(68˚F), 0.5-1.5Ω
Ignition coil
Resistence of secondary oil At 20˚C(68 ˚F), 4.6-7.6Ω
Clearance of min. spark 6mm(0.24in)
Ignition timming (before upper 10˚/2300r/min
stop point
Ignition system Advancing angle of ignition (be- 30˚/4300r/min
fore ipper stop point)
Type of ignition advance
16
IV. Electric system
Item Standard
Resistence of induction coil/color At 20˚C (68˚F), 189-231Ω Blue-black
Magneto Resistence of source coil/color At 20˚C (68˚F), 470-530Ω yellow/green-red
Type of C.D.I. Electric capacity contactless type
Rectifier No-loading adjusting voltage 14.1-14.9V
Voltage-resisting value 200V
Type A·C magneto
Charging Rated output voltage At 2000r/min 14-15V
system
Coil resistence/color At 20˚C (68˚F) 1.0-1.2˚ white-white
Battery Specific gravity 1.28
Type/capacity 12N14-BS/12V, 14Ah
Broken Type Fuse
circuit of
system
Main fuse 20A
Reserved fuse 20A
Relay of cut- Coil resistence At 20˚C (68˚F), 72-88Ω
off current
Diode Yes
Electric start- Type Constant mesh type
ing motor Output power 0.35KW
system
Resistence of armature coils At 20˚C (68˚F), 0.004-0.005Ω
Electric Ampere 100A
starting relay
system
coils resistence At 20˚C (68˚F), 4.8-5.3Ω
17
V. Maintenance Specification of Engine
Item Standard Limit
Axle Drive
Meshing clearance of last end gear 0.1-0.2mm
Meshing clearance of middle gear (forward) 0.1-0.2mm
Meshing clearance of middle gear (backward) 0.10-0.25mm
Lubrication system:
Type of oil filter Wire filter net
Type of oil pump Rotor type, pressure splash type lubrication
Clearance of side 0.04-0.09mm
Endface clearance “A” or “B” 0.15mm 0.09mm
Releasing pressure of safety valve 80-120Kpa 0.20mm
Cylinder 70.97-71.02mm
(Distance between measuring point and
Bore size upper endface of cylinder is 40mm) 71.10mm
Cylinder head Measure the surface warp of every portion 0.10mm
Flatness of lower endface on the lower endface of cylinder head with
ruler.
Timing chain
Type of timing chain Roller chain
Tension type of timing chain Free adjustment
Pneumatic camshaft:
Driving method Chain driven
Roundness tolerance of camshaft 0.03mm
Outside diameter of camshaft 24.96-24.98mm
Cam size
Exhaust: A 36.582-36.682mm 36.482
B 30.252-30.352mm 30.152
C 6.572-6.692mm
Intake: A 36.537-36.637mm 36.437mm
B 30.131-30.231mm 30.031mm
C 6.527-6.647mm
Rocker arm/ Rocker arm shaft
Outside diameter of shaft 11.981-11.991
Inside diameter of rocker arm 12.000-12.018
Clearance between arm and shaft 0.009-0.037
Valve spring
Inside spring
Free length:intake/exhaust 35.5mm
Setting length when valve is closed:intake/exhaust 30.5mm
Compressing pressure when assembling:intake/exhaust 82.4-100.0N
Limit value of squareness:intake/exhaust 2.5˚/1.6mm
Twisting direction of spring(topview):intake/exhaust counterclockwise
18
Item Standard Limit
Valve spring:
Outside spring:
Free length: intake/exhaust 37.2mm
Setting length when valve is closed: 32.0mm
Compressing pressure when assembling:intake/exhaust 162.8-200.1N
Limit value of sqaureness:intake/exhaust 2.5˚/1.6mm
Twisting direction of spring (top view):intake/exhaust clockwise
Valve, valve seal, valve guide
Valve clearance (it’s cold): intake 0.05-0.09
exhaust 0.11-0.15
Size of valve
A-diameter of valve head exhaust 28.4-28.6mm

intake 33.9-34.1mm
B-width of valve face intake/exhaust 1.7-2.8mm
C-width of valve set intake/exhaust 0.9-1.1mm 1.6mm
D-limit thickness intake/exhuast 0.8-1.2mm
Outside diametes of valve stem exhaust 5.960-5.975mm
intake 5.975-5.990mm
Inside diameter of valve guide: intake/exhaust 6.000-6.012mm 0.10mm
Clearance between valve stem and guide:
exhaust 0.025-0.052mm 0.08mm
intake 0.10-0.037mm
Roundness of valve seem 0.03mm
Piston ring:
First ring
Type Bucket-shaped back round

Size (BxT) 1.2x2.8mm
Clearance of endface (in assembling) 0.15-0.30mm 0.4mm
Clearance of side (in assembling) 0.03-0.07mm 0.12mm
Second ring
Type Flat type

Clearance of endface (in assembling) 0.15-0.30mm 0.4mm
Clearnace of side (in assembling) 0.02-0.06mm 0.12mm
Oil ring

Clearance of endface (in assembling) 0.2-0.7mm
19
Item Standard Limit
Piston
Piston size “D” 70.92-70.97mm

Measuring point “H” (from bottom line of piston lower portion) 4.0mm
Piston offset 0.5mm
Direction of piston offset Inward
Clearance between piston and cylinder 0.04-0.006 0.15mm
Outside diameter of piston pin 15.991-16.000mm
Inside diameter of pin hole 16.002-16.013mm
Driving method of balancing block gear driving
Connecting rod of crank
Limit value of runout: C1 0.03mm

C2 0.06mm
Width of crank “A” 55.95-56.00mm
Small end free play of connecting rod “F” 0.8-1.0mm 2.0mm
Big end free play of connecring rod “D” 0.35-0.65mm
Big end radial clearance of connecting rod “E” 0.010-0.025mm
Automatic centrifugal clutch
Clutch shoe: quantity 3 pieces
thickness 2.0mm 1.5mm
Clutch messhing revolution 1800-2100r/min
Clutch stalled revolution 3200-3600r/min
Free length of back spring of brake shoe 32.47mm
Clutch:
Action method of clutch Outside pushing type
Clutch piece: quantity 4 pieces
thickness 1.45-1.75mm
Friction piece: quantity 5 pieces
thickness 2.94-3.06mm 2.8mm
Spring of clutch: quantity 4
free length 35.1mm 32.9mm
Shifting mechanism
shifting method shift gear cam drunk and
beding limit of fork guide fork 0.8mm
Transmission device
offset limit of spindle 0.08mm
offset limit of transmission output shaft 0.08mm
20
Section 6 Wiring diagram
(I) Technical explanation and requirements, details of relative component.
1. Technical explanation [W] After putting the fuel tank vent tube though
[A] Main switch wire, indicator wire, mileage the hole of main switch, lead it to the lower
meter wire (mounting digital mileage meter) right side of steering bar, then put it through the
must be put through the guide grip of holding wire hook on the frame. NOTE: Hose must be
seat of steering bar (see figure 1). unlocked (see figure E-E).
[B] Rear brake vent-pipe, carburetor vent-pipe [V] The leading wire on the switch units of
and vent-pipe of rear driving gearbox must be steering bar, must be bound with the band (see
inserted into the hole of supporting pad of vent- figure G-G).
pipe (see figure 1 also see view D). [E] After the vent-tube of the front brake is put
[C] Neutral and reverse switch wire, mileage through the plastic clip hole on the frame the
meter wire (moutning with digital mileage me- excess should be put in the proper position of
ter) should be fixed with bands (see figure 1). frame (see figure 2).
[D] After putting overflow pipe of carburetor [G] After the vent-pipe of battery is checked and
through two rear fixing part of engine (on the free of twists, insert it in the preset hole of rear
frame) put it ino the proper position between fender (If free of maintenance battery is used,
engine and rear arm. NOTE: overflow pipe then this item of requirement isn’t needed)
must not be blocked (see figure 1). [H] Wire of rear brake cable, rear brake vent-
[S] After putting rear brake cable, throttle pipe and mileage meter (mounted with a digital
cable, wire of starting motor and mileage meter mileage meter) should be put through the cable
(mounting with digital mileage meter) through frame welded on the frame. (see figure3).
wire hook 2, bend wire hook 2 according to the [F] Wire of starting motor must be first put
method of view A. through the plastic clip on the frame, then con-
[P] Starting motor wire and mileage meter wire nected with the matching units (see figure 3).
(mount with digital mileage meter) must be put [L] Vent-tube of battery should be put through
through the hole of the plastic grip in the fuel the plastic clip fixed on the frame. (see figure3).
tank support of frame (see figure B-B) [K] The throttle cable wire, rear brake cable and
[R] Rear brake cable, rear brake vent-pipe mileage meter (mounted using a digital mile-
and mileage wire (mount with digital mileage age meter) should be pout through the cable
meter) must be first put through wire hook 2, guide frame welded to the frame. (throttle cable
then connect with respective matching unit (see should be mounted on the inner side)
figure B-B). (see figure 4).
[Q] Wire of reverse switch, neutral switch and [J] Insert the starting relay into the rear fender
mileage meter (mount wih digital mileage me- (see figure 4).
ter) must be fixed with bands (see figure B-B). [M] After putting the vent-tube of battery
[T] When assembling the wire for ser. No.14 through the plastic clip mounted on the rear
and No.15 do not put through the guide clip of fender, insert into the hole on rear fender (com-
holding seat of steering bar See figure E-E). bine with G) (see figure [G]) (see figure 4).
21
[U] When assembling, mount supporting pad of 3. Details of relative component
vent-tube should be free of leaks, and pay at-
Ser. Code Name Qty
tention to let the direction of mark upward (see
#
view D).
33 SSA0-000512-0 Wire clip 4 3
[N] Taillight wire must be put through the slot 32 SSA0-000511-0 Wire clip 3 2
hole preset by tool kit from the bottom of tool 31 SSA0-000510-0 Wire clip 2 3
kit (see view F). 30 SSA0-000509-0 Wire clip 1 2
29 JS150.00-039 Cable band 6
2. Technical requirement
1) In this drawing the wiring condition and position for 28 JS150.00-03 Steering bar band 2
all wires are marked. When finished assembling, wiring 27 C.D.I magneto wire 1
should be done as per the drawing. 26 Vent tube-carb. 1
2) For the wiring and fixing method that cannot be 25 JS150.00-06 Cut-ff relay 1
marked in this drawing, necessary technical explanation 24 FG-802000-0 Starting relay 1
has been made and should be followed. 23 SSA5-320000-0 Cable 1
22 SSA0-000516-0 Vent tube-rear brake 1
21 Wire of starting motor 1
20 High voltage coils and wire 1
19 Vent tube-battery 1
18 SSA0-000515-0 Vent tube-front brake 1
17 Wire of headlight 1
16 SSA4-230000-0 Rear brake cable 1
15 Wire of handlebar switch 1
14 Wire of cltch wire 1

13 SSA4-210000-0 Throttle cable 1
12 SSA4-220000-0 Front brake cable units 1
11 Wire of mileage meter 1
10 Wire of neutral switch 1
9 Wire of reverse switch 1
8 Overflow hose-carb. 1
7 SSA0-000517-0 Vent tube of gearbox 1
6 SSA5-630000-0 Taillight unit 1
5 FG-803000-0 C.D.I 1
4 FG-805000-0 Rectifier 1
3 Vent tube of gearbox 1
2 SSA5-510000-0 Main switch lock 1
1 SSA0-012000-0 Wire clip unit 1
22
(II) Wiring diagram (1)
23
(III) Wiring diagram (2)
24
(IV) Wiring diagram (1)
25
Section 7 Requirements for torque fastening
(I) ATV Body
Torque value of fasteners

Locking component and location on ATV Hard- Size of Qty Nm m·kg ft·lb
ware thread
Front wheel rim & front brake hub Nut M10x1.25 8 55 5.5 40
Front brake hub & steering vertical post Nut M12x1.25 2 25 2.5 18
Front brake cam arm & cam shaft Nut M6x30 2 9 0.9 6.5
Front brake & front shock absorber Bolt M12x50 4 78 7.8 56
Front shock absorber & frame Nut M35x1.5 2 55 5.5 40
Steering veritcal post & pulling rod Nut M12x1.25 2 25 2.5 18
Pulling rod & nut Nut M12x1.25 4 30 3 22
Steering vertical post & end of pulling rod Nut M12x1.25 2 25 2.5 18
Steering vertical post (lower) & frame Nut M10 1 30 3 22
Holding seat of steering vertical post & frame Bolt M8x60 2 23 2.3 17
Steering vertical post & upper/lower holding seat of Bolt M8x60 4 20 2 14
steering bar
Front wheel fork & frame Bolt M10x70 4 45 4.5 32
Front wheel fork & brake Nut M12x1.25 2 25 2.5 18
Engine upper connecting plate & frame (upper) Bolt M8x16 2 33 3.3 24
Engine assy & engine upper connecting plate Bolt M8x55 1 33 3.3 24
Engine assy & frame (front) Bolt M8x65 1 48 4.8 35
Engine assy & frame (rear upper) Bolt M8x105 1 33 3.3 24
Engine assy & frame (rear lower) Bolt M8x105 1 33 3.3 24
Front fender & frame Bolt M6x16 2 7 0.7 5.1
Front fender flap & front fender supporting rod Screw M6x16 2 7 0.7 5.1
Bumper & frame Bolt M8x16 4 11 1.1 8
Front luggage carrier & bumper Bolt M6x16 2 11 1.1 8
Front luggage carrier & frame Bolt M8x16 2 34 3.4 25
Front fender & front luggage carrier Bolt M6x20 2 7 0.7 5.1
Rear fender & frame Bolt M6x16 2 7 0.7 5.1
Rear luggage carrier & frame Bolt M6x40 2 7 0.7 5.1
26
(I) ATV Body

Locking component and location on ATV Hard- Size of thread Qty Nm m·kg ft·lb
ware
Rear fender & rear luggage carrier Bolt M8x16 2 7 0.7 5.1
Left & right foot rest & frame Bolt M6x20 4 65 6.5 47
Left & right foot rest & frame Bolt M10x22 2 30 3 22
Supporting weld in foot rest & bracket weld Bolt M8x16 4 30 3 22
Rear rim & hub Nut M10x1.25 8 55 5.5 40
Rear wheel axle & nut Nut M16 2 150 15 110
Rear brake cam arm & cam shaft Nut M6x30 1 9 0.9 6.5
Rear brake show & rear axle housing Bolt M8x1.25 4 28 2.8 20
Rear wheel fork & frame (left) Bolt M22x1.5 1 130 13 94
Rear wheel fork & frame (right) Bolt M22x1.5 1 6 0.6 4.3
Rear arm ahst & nut (right) Nut M22x1.5 1 130 13 94
Rear wheel fork unit & rear driving gearbox Nut M10x1.25 4 55 5.5 40
Rear wheel axle bushing & rear driving gearbox Bolt M10x1.25x25 4 55 5.5 40
Rear shock absorber (upper) & frame Bolt M12x75 1 50 5 36
Lower cover of gearbox Bolt M8x12 2 17 1.7 12
Rear wheel axle bushing & rear wheel fork Bolt M12x1.25x25 4 103 10.3 74
Fuel tank & frame Bolt M6x35 2 10 1 7.2
Oil draining bolt of rear driving gearbox Bolt M12x1.25 1 23 2.3 17
Oiling bolt of rear driving gearbox Bolt M12x1.25 1 23 2.3 17
27
(II) Engine
Locking component and location on Hardware Size of Qty Nm m·kg ft·lb Remarks
engine thread
Observing screw hole of cylinder head cap nut M6 1 7 0.7 5.1
Cylinder head flange bolt M8 4 22 2.2 16 apply oil
to washer
Cylinder head & cylinder Bolt M8 2 22 2.2 26
Sprocket cover Screw M6 2 7 0.7 5.1
Valve cover Bolt M6 5 10 1 7.2
Bearing stop plate of camshaft Bolt M6 2 8 0.8 5.8 apply oil
to washer
Spark plug M12 1 17.5 1.75 12.5
Cylinder Bolt M6 2 10 1 7.2
Balancing shaft gear Nut M14x1.0 1 50 5 36 apply oil
to washer
Starting ratchet disc Bolt M10x1.25 1 50 5 36
Locking nut (adjusting screw of valve clear- Nut M6 2 14 1.4 10
nace)
Cam timing sprocket Bolt M10 1 60 6 43
Chain tensioner Bolt M6 2 10 1 7.2
Chain tensioner cover Bolt M6 1 7 0.7 5.1
Upper guide plate of chain Bolt M6 2 8 0.8 5.8
Oil pump Screw M6 3 7 0.7 5.1
Oil draining screw plug Plug M35 1 43 4.3 31
Fine filter cover of engine oil (draining oil) Bolt M6 1 10 1 7.2
Fine filter cover of engine oil Bolt M6 2 10 1 7.2
Carburetor seat & cylinder head Bolt M6 2 12 1.2 8.7 twist w/cable
guide part
Carburetor & carburetor seat Bolt M6 2 12 1.2 8.7
Carburetor & carb. connecting pipe Hose clip M5 1 2 0.2 1.4
Aif filter box & carb. connecting pipe Hose clip M5 1 2 0.2 1.4
Aif filter box & intake pipe Hose clip M5 1 2 0.2 1.4
Silencer & frame Bolt M8 2 34 3.4 25
Silencer & exhaust pipe Bolt M8 1 20 2 1.4
28
(II) Engine
Locking component and location on Hardware Size of Qty Nm m·kg ft·lb Remarks
engine thread
Exhaust pipe Bolt M6 2 10 1 7.2
Crankcase (closing case) Screw M6 11 7 0.7 5.1
Left side cover Screw M6 6 7 0.7 5.1
Left crankcase cover Screw M6 8 7 0.7 5.1
Right crankcase cover Screw M6 9 7 0.7 5.1
Bearing clamp of right crankcase cover Screw M6 3 7 0.7 5.1 apply tighten-
ing agent
Bearing clamp of left crankcase cover Screw M5 3 7 0.7 5.1 apply tighten-
ing agent
Right connecting box Screw M6 3 7 0.7 5.1
Main clutch Nut M22 1 78 7.8 56 Use lock
washer
Assitant clutch spring Bolt M5 4 6 0.6 4.3
Assitant clutch hub Nut M14 1 50 5 36 Use lock
washer
Shift cam star-shapped gear Screw M6 1 12 1.2 8.7 apply tighten-
ing agent
Locking nut (clutch releasing adjustable screw) Nut M8 1 15 1.5 11
Starting surpassing clutch Bolt M8 3 30 3 22 Apply tighten-
ing agent, rivet
to prevent
lossen
Connecting plate of starting motor Screw M6 2 7 0.7 5.1
Output gear Nut M16 1 60 6 43
Left case bearing clamp of driving shaft Screw M8 3 25 2.5 18 apply tighten-
ing agent
Rear cover bearing inner-hex- 2 50 5 36 apply tighten-
agonal screw ing agent
sleeve
Reverse gear Special-shaped 1 50 5 36 apply tighten-
nut (L.H) ing agent
Rear cover Bolt M8 4 23 2.3 17

Front joint Nut M12 1 60 6 43 apply tighten-
ing agent
Reverse gear lever unit Bolt M6 2 12 1.2 8.7
Reverse gear lever unit Bolt M14 1 15 1.5 11
Locking nut of length adjuster of connecting Nut M8 1 15 1.5 11
rod (reverse gear operation bar assy)
Locking nut of length adjuster of connecting Nut M8 1 15 1.5 11
rod (reverse gear operation bar assy)
Reverse gear operation rod & reverse gear Flange nut M6 1 10 1 7.2
lever mechanism
29
(II) Engine
Locking component and location on Hardware Size of Qty Nm m·kg ft·lb
engine thread
Shift pedal Bolt M6 1 10 1.0 7.2
Megneto stator Screw M6 3 7 0.7 5.1
Neutral switch M12 1 20 2.0 14
Reverse gear switch M12 1 20 2.0 14
Hand-started driving disc Screw pin M6 1 12 1.2 8.7
(III) General torque specification

General torque specification (standard screw)
This figure is a screw locking specification
drawn by International Standard Association.
In order to avoid twisting or unbalancing when
locking screw, cross lock as stated below.
* When measuring torque force, standard torque

force testing spanner must be used.
A (Nut) B (Screw) m·kg

10mm 6mm 0.6
12mm 8mm 1.5
14mm 10mm 3.0
17mm 12mm 5.5
19mm 14mm 8.5
22mm 16mm 13.0
30
Section 8 Lubrication
(I) Lubrication oil way
31
(II) Lubrication diagram
1. Oil draining plug 8. Oil pump driving gear

2. O-ring 9. Camshaft
3. Compressing spring 10. Crankcase
4. Rough filter 11. Crank
5.Oil pump washer 12. Spindle
6. Oil pump assy 13. Driving shaft
7. Oil pump driven gear 14. Fine filter
32
(II) Lubrication diagram
1. Single-direction valve 8. Single-direction bearing

2. Engine oil fine filter (automatic centrifugal clutch)
3. Engine oil fillter cover 9. Crank pin
4. O-ring 10. Crank pin
5. Clip 11. Spindle
6. Camshaft 12. Driving shaft
7. Rocker
33
Section 9 Lubrication point and type of lubricants
(I) Lubrication point and type of lubricants (ATV body)
Lubricant point Type of lubricants

Lip of oil seal (full) Light lithium-base grease
O-ring (full) Light lithium-base grease
Steering shaft (upper end, lower end) Light lithium-base grease
Ball connection of steering pushing rod Light lithium-base grease
Front wheel fork (ball-shaped joint) Light lithium-base grease
Front wheel bearing Grease used for bearing
Front & rear brake: Braking camshaft, Light lithium-base grease
Rotating pin seat, Lip of oil seal
Dust-proof ring of brake Light lithium-base grease
Joint of front brake cable Light lithium-base grease
Front brake lever axle & rear brake lever axle Light lithium-base grease
Adjusting nut & pin of front brake cable Light lithium-base grease
Adjusting nut & pin of rear brake cable Light lithium-base grease
Rear brake pedal pivot & brake pedal axle hole Light lithium-base grease
Throttle rotating frame shaft & end section of Light lithium-base grease
throttle cable
Reverse gear lever pivot Light lithium-base grease
Connection bolt of rear wheel fork & frame, Light lithium-base grease
rear wheel fork bearing
Rubber sleeve & rear wheel fork Seal gum
Rear shock absorber bushing Light lithium-base grease
34
(II) Lubrication point and type of lubricants (Engine)
Lubricant point (name of component) Type of Lubricant

Lip of oil seal (Crank,shift,gearshaft,spindle,shiftgear operation shaft) Light lithium-base grease
All bearing (Crank,spindle,driving shaft,output shaft,balancing Lubricating oil

shaft,shift gear camshaft,pneumatic camshaft)
O-ring (Contact position of o-ring) Light lithium-base grease
Stem end of intake & exhaust valve (Intake & exhaust valve, valve adjusting screw) Lubricating oil
Fastener of cylinder head (Bolt flange face, thread portion, washer endface) Lubricating oil
Outside surface of piston pin (Piston, piston pin, small end of connecting rod) Lubricating oil
Oustide surface of piston, piston ring (Cylinder block, piston, piston ring) Lubricating oil
Inner hole of main driving gear (Crank, main driving gear) Lubricating oil
of main clutch
Inner hole of assitant clutch gear (Assitant clutch gear unit,spindle) Lubricating oil
Assistant clutch releasing (Operation rocker & it’s contact portion) Lubricating oil
operation rocker unit
Upper cam plate guide rod (Upper cam plate unit, guide rod) Lubricating oil
Inner hole of upper cam plate unit (Shift gear shaft, upper cam plate unit) Lubricating oil
Steel ball bracket unit (Steel ball bracket unit, upper & lower cam plate) Lubricating oil
Surpassing clutch (Surpassing clutch, main clutch cover, inner spline sleeve) Lubricating oil
Outside surface of reverse gear (Reverse gear controlling rod, rear transmission) Lubricating oil
controlling rod
Outside surface of reverse gear (Reverse gear fork shaft, reverse gear fork, steel ball) Lubricating oil
fork shaft
Spindle & inside hole jointing (Spindle, right crankcase) Lubricating oil
face of right crankcase
Outside surface of reverse gear (Reverse gear controlling rod, crankcase) Lubricating oil
controlling rod
Contractor of reverse gear switch (Reverse gear switch, reverse gear fork) Lubricating oil
Outside surface of short fork shaft(Fork shaft, fork, crankcase) Lubricating oil
Outside sirface of long fork shaft (Fork shaft, fork, crankcase) Lubricating oil
Shift gear camshaft portion, slot (Fork, shift gear cam, crankcase) Lubricating oil
portion, contator
Outside surface of shift gear shaft (Shift gear shaft & it’s contacting portion) Lubricating oil
Outside surface of over-wheel shaft (Over-wheel shaft, crankcase) Lubricating oil
Bushing inner hole of big gear of (Bushing, left crankcase) Lubricating oil
electric starter
Electric starting clutch (Rolling post & the contacting portion) Lubricating oil
35
Chapter II Maintenance
adjustment of vehicle
NOTE:
The correct maintenance and adjustments are necessary to ensure the vechicle’s in normal driving
condition. The repair personnel should be familiar with the contents of this article.
Section 1 Periodic Maintenance/Lubrication

Everytime Every
Item Requirement 1MO 3MO 6MO 6MO 1YR
Valve Check the valve clearance. Adjust if necessary. ○ ○ ○
Spark plug Check the clearance & clean. Replace if necessary. ○ ○ ○ ○
Air filter Clean. Replace is necessary. Maintain every 20-40 hr’s of use
Carburetor Check the idle/starting state. Adjust if necessary. ○ ○ ○
Cylinder head Check for cracks/damage in gas tube. ○ ○
Replace if necessary
Exhaust system Check for leakage. Tighten if necessary. ○ ○
Replace gasket if necessary
Spark surpressor Clean ○ ○
Oil circuit Check for cracks/damage in oil tube. ○ ○
Replace gasket if necessary
Engine oil Replace (preheat engine before draining oil). ○ ○ ○
Oil filter Clean ○ ○ ○
Oil filter screen Clean ○ ○ ○
Gear case oil Check oil level and leakage. Replace ○ ○
Brake Check the operation. Adjust if necessary. ○ ○ ○ ○
Clutch Check the operation. Adjust if necessary. ○ ○ ○
Wheel Check the balance,damage,run-out etc. ○ ○ ○
Replace if necessary
Wheel bearing Check for looseness/damage. Replace if necessary. ○ ○ ○
Front & rear Check the operation & correct if necessary ○ ○
suspension system
Steering system Check the operation/correct if necessary, ○ ○ ○ ○
Check toe-in & adjust if necessary
Bearing of steering Lubricate every 6 MO (lithium soap grease). ○ ○
column
Connecting piece Check all connecting pieces & fasteners of ○ ○ ○ ○
& fastener chassis. Correct them if necessary.
36
Section 2 Disassembly and assembly of Cushion,
Fender and Fuel tank
1 (I) Cushion
1.Disassembly
1- Place the vehicle on level ground.
2- Disassemble the cushion (1) : Pull the
cushion lock lever (2) up, then raise the
rear of cushion.
2. Installation
First insert the support lug on the front end
of cushion into the plug of frame, press the
rear of seat down.
37
3 1
(II) Rear fender

1. Disassembly
1- Place vehicle on level ground.
2- Disassemble the rear luggage carrier

(1) and installing bushing (2)
2 3- Disassemble the cushion (3) (see cush-

ion disassembly in this section).
4- Disconnect the negative wire (5) and

5 7 positive wire (4) of battery.
8 CAUTION:
Disconnect the negative wire (5) first.
5- Disassemble the clamp plate (9) of

9 battery.
6- Disassemble the starting relay (6)
7- Disassemble the cut-off realy (7)

4
8- Take out the battery (8)
9- Disassemble the rear fender (10)
10
38
2 2. Installation
Reverse procedure for “Disassembly”. Pay at-
tention to the following points:
1- Install:
Rear fender (1)
1
Bolt (2) (rear fender and frame). The
torsion in 7N·m.
Bolt (3) and rubber hood of protecting plate
(rear fender and frame). The torsion is 7N·m.
3
2- Install:
5 3 a.Battery (1)
b.Battery clamp plate (2)
4
3- Install:
1 a. Cut-ff relay (3)
b.Starting relay (4)
c.Connect the positive wire (6) to battery
d.Connect the negative wire (5) to battery
2
6
4- Install the cushion (1)
1
2
CAUTION:
Insert the support lug (2) of cushion into the
plug seat (3) on the frame, then press down on
the seat.
3 1
5- Install rear luggage carrier (1)

Torque requirement for fasteners:
2 Bolt (2) fastening torque: 3N·m
Bolt (3) fastening torque: 9N·m
CAUTION:
Remember to install the bushing on the con-
3
necting point of luggage carrier and frame.
39
(III) Fuel tank
1. Disassembly
4 2- Remove the cushion (see “cushion disas-
sembly” section)
3- Remove the air hose on the fuel tank cover
4- Remove:
a.Bolt (2) , flat washer 30, installing bush-
ing of upper cover of fuel tank, washer and
rubber hood 2 of fuel tank.
b.Plastic expansion screw assy (3) all around
c.Fuel tank cover (4)
2 3
OFF
6- Turn the fuel shut off valve to the “OFF”

position
7- Remove the fuel inlet pipe (8)
CAUTION:
Place a cloth on the engine to absorb the
splashed gasoline.
WARNING:
The gasoline is flammable. Avoid splashing it
on the hot engine.
8 8- Remove:
4 Bolts (1) , flat washers 30, rubber hood of
fuel tank and installing bushing of fuel tank.
4 9- Remove the air inlet pipe (2) of air filter,
supporting pad (3) of air pipe (5) .
2 10- Remove the fuel tank (4) .
1
5
40
1
2. Installation
Reverse procedure for “Disassembly”. Pay
close attention to the following points:
1- Install the fuel tank (1)
2- Connect
a. Air inlet pipe (2) and hose (4)
b. Supporting pad (3) of air pipe and air rub-
ber pipe (4)
CAUTION:
The convext part on the ring should be facing
forward when installing the supporting pad
(3) of air pipe.
4 3 2
4- Install:
4 a. Fuel tank cover (4)
b. Plastic expansion screw assy (3)
c. Bolt (2) and related fasteners and
connecting pieces.
The fastening torque of bolt is 10N·m.
5- Connect:
• Air hose
6- Install:
2 3 • Cushion (see “Cushion installation”)
41
1
(IV) Front fender
1. Disassembly:
2- Disassemble the front luggage carrier (1)
3- Disassemble the front guarding plate (2)
2
4- Cut off the connecting wire (1) of head-
light (from connecting point).
5- Disassemble the bumper (2)
1
2
6- Disassemble the front fender (1)

1
42
2. Installation
1 Reverse procedure for “Disassembly”.
2
1- Install:
a. Front fender (1)
b. Bolt (2) . The fastening torque is 7N·m
c. Bolt (3) , rubber hood of protecting plate.
The fastening torque is 7N·m
2- Install the bumper (1) .

The fastening torque of bolt (bumper and
frame) is 16N·m.
2- Install the front guard plate (1) .
4- Install the front luggage carrier (1) .

Bolt (2) (front luggage carrier and frame). The
2 fastening torque is 34N·m.
1 Bolt (3) (front luggage carrier and bumper).
The fastening torque is 11N·m.
43
Section 3 Maintenance and Adjustment of
vehicle body
(I) Wear inspection of front and rear brake
1.Check the front brake
1- Stop the vehicle using the front brake
2- Check:
2 • Brake pad (1) between caliper (2) and disc
(3)
• If pads are worn, replace.
Refer to “Front wheel and front brake” sec-
tion in Chapter VII.
3
2.Check the rear brake

1- Tread down the rear brake pedal to rake
the vehicle.
2- Check
• Wear indication (1)
• If the wear reaches the limit mark (2)
replace the brake shoe assy.
Refer to “Rear wheel and rear brake” section
in Chapter VII.
(II) Adjustment of front brake
2 CAUTION:
Before adjusting, check the degree of wear
on the front brake according to the above
procedures.
CAUTION:
In order to avoid too large or too small brake
1
force when braking, make sure there is prop-
er free clearance of left/right brake lever and
rear brake pedal:
1. Check
If the free clearance of right lever does not
conform to (a) specification as shown in
firgure, adjust it according to following stan-
dard.
Standard free clearance (a) of right lever:
5-7mm
Calculate from the fulcrum ( (a) in figure).
44
2. Adjustment
Adjusting procedure of the free clearance of
right lever:
• Loosen the lock nut (1) , rotate the cable
adjusting screw (2) clockwise to reduce the
tension of front brake cable.
• Lift the front end from the ground, rotate the
two front wheels. Apply brake to verify it is
adjusted correctly.
2 1 • Rotate the adjusting screw (2) clockwise
or counterclocksiwe to gain proper free clear-
ance.
Clockwise: wear free clearance
Counterclockwise: decrease free
clearance
• Tighten the lock nut
(III) Adjustment of free clearance of left lever

and rear brake pedal.
CAUTION:
Before adjusting, check the wear condition of
rear brake.
CAUTION:
In order to avoid too large or too small brake
force of rear brake.
WARNING:
When braking after adjusting, must adjust the
left lever and rear brake pedal simultaneously.
45
1 2. Adjust
• Free clearance of left lever.
• Free clearance of rear brake pedal.
Adjusting procedure:
2 CAUTION:
Before adjusting, depress the rear brake pedal
2-3 times.
• Loosen the locking nut (1) completely, and
screw in the cable adjusting screw (2)
completely.
• Loosen adjusting nut (3) of the rear brake

cable and adjusting nut (4) of rear brake.
6 • Tighten the adjusting nut (4) of rear brake
3 pedal until correct clearance is met: Free
clearance (rear brake pedal):20-30mm.
5 4
• Rotate adjusting nut (3) of rear brake cable
until correct clearance is met :
0-1mm
5 Rear brake arm assy.
6 Pin
• Screw out the adjusting screw (2) of rear

brake cable untl gaining correct free clearance
(b) :Free clearance (b) (left lever):5-7mm
a
• Screw up the locking nut (1)
• Check the free clearance of left lever and
rear brake pedal.
If is does not meet the standard value, repeat
above procedures to adjust.
b
WARNING:
1
After adjusting, raise the rear wheels from the
ground and rotate them to confirm no brake
force to block the rotation.
2 Otherwise repeat above adjustment.
46
1 2 (IV) Position adjustment of steering lever
• Position adjusting procedure of steering lever.
• Place the vehicle on level ground.
• Change gears to 1st gear and pull the steering
lever (1) to reverse gear position.
• Loosen the locking nut (2)
• Screw in or out the adjusting nut (3) of steering
lever until the middle line (a) of the tension rod
plate aims at the alignment mark (b) on the rear
transmission cover (or the vehicle will not release
the gear).
3 4 • Screw tightly lock nut (2)
Torsion of lock nut: 15N·m
CAUTION:
After adjusting the steering lever, ensure the re-
verse gear indicator lights up when the steering
b lever is in the reverse position.
(V) Lubricating oil level inspection of rear driving
gear case.
Check the lubricating oil level of the gear case.
4 CAUTION:
The engine must be in a cold state
a Checking procedure:
• Place the vehicle on level ground.
• Placce oil catcher under the gear case.
• Remove the oil filling screw plug (1) and sealing
washer.
• Observe the oil level: the correct amount should
be on the bottom of oil filling hole.
• If the oil level is too low, refill the recommened
engine oil to specified oil level.
Refer to the section “replacement of engine oil of
rear driving gear case”.
• Check for any damages to the sealing washer, if
damaged replace it.
• Install the sealing washer and oil fill screw plug
(1).
CAUTION:
• Install the sealing washer before installing the oil
filling screw plug.
1 • After installing the oil fill screw plug, check for
leaks.
Torsion of oil fill screw plug: 23N·m
47
(VI) Replacing engine oil of rear driving gear case.
1. Place the vehicle on level ground.
2. Place an oil catcher under the rear driving gear
case.
3. Remove:
• Lower cover of gear case
• Oil fillin screw plug
• Oil drain screw plug (1)
Drain out the engine oil of the rear driving gear
case.
4. Check:
1 • Sealing washer (oil fill screw plug position)
• Sealing washer (oil drain screw plug position)
If damaged, replace it.
5. Install:
Oil drain screw plug (rear driving gear case)
Torsion of oil drain screw plug: 23N·m
6. Oil fill screw plug

CAUTION:
Avoid any forgein matter from entering the driving
gear case.
Recommended oil:
SAE80API “GL-4” engine oil of hypoid gear
If needed, you may use SAE80W90 engine oil of
hypoid gear
Period replacement:
0.12L
Total capacity:
0.27L
7. Install:
• Oil fill srew plug (rear drain gear case)
CAUTION:
After refilling, check for leaks.
Torsion of oil fill screw plug: 23N·m
48
(VII) Rubber sleeve inspection of rear wheel fork
check
• Rubber sleeve (1)
If damaged or worn, replace it.
Refer to chapter 3 section 6 “rear shock absorber
and rear wheel fork”.
(VIII) Inspection of steering system

1. Place the vehicle on level ground
2. Check:
1 • Clamp seat of steering column and
bearing on the lower end of the steering column,
upper & lower and front & rear moving section
steering bar.
If the clearance is too large, replace the bearing.
Refer to Chapter 3 section 4 ”Steering system”.
3. Check:
• Ball pin unit of steering tension rod.
Rotate the steering bar leftward and/or rightward,
then rotate from left to right. If the ball pin unit (1)
of steering tension rod has too much
1 vertical clearance, replace it.
Refer to Chapter 3 section 4 “Steering system”.
4. Lift the front end of vehicle to make the front

wheel not bear any load.
5. Check:
• Left/right front seat assy on front brake position,
and/or bearing 6005-2Z/bearing 6203. When
moving the wheel back and forth horizontally, if
the clearance is too large, replace the following
components:
1) Bearing 6005-2Z/bearing 6203
2) Left/right front seat assy (1)
3) Split pin (2)
4) Front fork ball connection (3)
5) Bushing assy (4)
Refer to Chapter 3 section 4 “Steering system.
49
(IX) Adjustment of toe-in on front wheels.
1. Rest the vehicle on level ground.
2. Measurement:
• Toe-in, adjust if not in specification.
Adjustment steps for toe-in
• Mark the center of tire thread on both front
wheels
• Lift the front end to keep force off wheels
• Point tires forward, measure the width between
the marks made on tire (A) .
• Rotate the front tires 180˚ in reverse.
• Measure the width B between two marks.
• Calculate the toe-in with the following formula
Toe-in= (B) - (A)
Standard value of toe-in:0.5mm

• If the toe-in is not correct, adjust
3. Adjustment
Adjustment steps of toe-in:
• Mark determination marks at the end of t left/
right tension rod (1)
• Loosen the locking nuts at the end of left/right
tension rod (2)
• Left/right tension rods (3) should turn the same
turns left or right up to obtain the specified toe-in
and make the lrft/right tension rods are the same in
strength.
Tighten up the locking nuts (2) at the end of left/
right tension rod.
Torque of locking nut: 30N·m
CAUTION:
• Make sure that the left/right tension rods have
been adjusted the same. Otherwise the vehicle will
still go forward left and right.
3 2
• After adjusting the toe-in correctly drive the
1
vehicle to test the toe-in adjustment. If the steering
is not normal as specified, adjust again.
50
(X) Inspection of front/rear shock absorbers
1. Rest the vehicle on level ground
1 2. Inspection:
• Ball joint assy (1) (upper part of front shock
absorber).
If broken or damaged, replace the front shock
3 absorber.
• Rear shock rod (2) (rear shock absorber)
If broken or damaged, replace the rear shock
absorber.
• Oil leakage (3)
If there is a heavy leak from the front/rear shock
absorber repalce it.
Refer to Chapter 3 section 5 and 6 “Front shock
2
absorber and front wheel fork” and “Rear shock
absorber and rear wheel fork”.
3
3. Inspection
• Operation:
• Move the front/rear shock absorbers up and
down.
If it is not operating correctly replacce the compo-
nent.
Refer to Chapter 3 section 5 and 6 “Front shock
absorber and front wheel fork” and “Rear shock
absorber and rear wheel fork”.
(XI) Adjustment of rear shock absorber

Adjustment of spring preload:
Turn the adjuster (1) to increase or decrease the
spring upload.
CAUTION:
The spring preload of rear shock absorber can be
adjusted to your needs, weight of the operator and
driving condition.
Standard Position: (B)
A-softest
E-hardest
51
(XII) Inspection of tire
WARNING:
This vehicle is equipped with low pressure tires,
so correct filling pressure and keeping the proper
pressure is very important.
• Tire characteristics
1) Quality charicteristics of tire will affect the driv-
ing reliability of ATV. The following types of tires
are approved by the manufacturer and can be used
safely. The use of any other tires is NOT
recommended.
Manufacturer Dimension
Front Zhengxin/Wuxi AT22x7-10
Rear Zhengxin/Wuxi AT22x10-10
• Tire pressure
1) Recommended tire pressure.
Front 20Kpa (0.20kg f/cm²)
Rear 25 Kpa (0.22kg f/cm²)
2) Low tire pressure will cause the tire to dislodge
from the rim in bad driving condition.
The Minimum tire pressure
Rear 22Kpa (0.22kg f/cm²)
3) When installing the tire to the rim, the tire pres-

sure should be no more than:
Rear 250Kpa (2.50kg f/cm²)
After installing the tire to the rim, fast pressure

will cause an explosion. Filling pressure should be
conducted slowly and carefully.
CAUTION:
The max load of the ATV is 165kg (including
driver)
52
1. Measurement
• Tire pressure (normal atmospheric temperature):
If out of specification, adjust.
CAUTION:
• The manometer (1) is included with the tool kit
(Nver use high pressure).
• If there is any dust or debris in the tire pressure
manometer you will not receive a correct reading.
Always take two measurements and the second
should be the one used.
WARNING:
• Uneven and improper tire pressure is not safe and
may cause the loss of control.
• Keep the proper tire pressure
• The tire pressure of both the front and rear tires
should be the same.
Normal
Temp. Front Rear
Tire Pressure
Standard 20kpa(0.20kgf/cm²) 25kpa(0.25kgf/cm²)
Min 17kpa(0.17kgf/cm²) 25kpa(0.22kgf/cm²)
Max 23kpa(0.23kgf/cm²) 28kpa(0.28kgf/cm²)
2. Inspection
• If wear or damage is found on the durface of the
tire, replace.
WARNING:
Using overworn tires is extremely dangerous.
If the tire is worn to the specified postion replace
immediately.
Wear Limit of tire:
Front and rear tires: 2.0mm (a)
(XIII) Inspection of rim

Inspection of rim (1) :
CAUTION:
Keep the rim in balance when replacing the rim or
tire.
WARNING:
Never attempt to repair the rim.
53
Section 4 Maintenanace and Adjustment of
Electrical Appliance
(I) Inspection of battery
WARNING:
The electrolyte is dangerous and includes sulphuric acid,
so it is poisonous and corrosive.
• Please operate by the following steps:
a. Avoid touching any part of your body with the
electrolyte especially your eyes.
1 b.Wear protective glasses when operating near battery.
• Avoid measures (external):
a. Wash the skin with water.
b. Wash eyes for 15 minutes with water, then conducte
treatment at hospital.
• Avoiding measures (internal):
3 Drink plenty of water or milk, magnesia oxide, egg or
rapeseed oil and seek treament as soon as possible.
• The battery can produce explosive gas, so follow the
protection measures below:
a. When changing the battery be in a well
4 ventilated area.
b. Keep away from flame or spark such as welding
equipment, burning cigarettes, etc.
c. Smoking is strictly prohibited when charging or
operating the battery.
d. Keep away from children
1. Removal (refer to Section 2 of this chapter)
• Cut off (refer to “Removal of cushion” of this chapter.
• Battery electrode (negative electrode (1) , positive
2
electrode (2)).
WARNING:
First remove the negative electrode (1)
3. Removal:
a. Battery clamp plate (4)
b. Battery (3)
CAUTION:
Before using a new battery, be sure to charge to ensure
optimum condition of vehicle.
4. Inspection of battery electrode
If dirt or dust is found clean with a brush, check
connections.
CAUTION:
After cleaning the elctrode apply a film of lubrication
54
2
5. Inspection of battery
If damaged, replace it
6. Installment of battery (3)

7. Connect
• Battery electrode (positive electrode (1) negative
3
electrode (2) )
First connect the positive electrode (1)
4 8. Installment:
a. Battery clamp plate (4)
b. Cushion
(II) Inspection of fuse

CAUTION:
Close the main switch when checking or replacing
the fuse, otherwise, it will cause a short circuit.
1
1. Inspection steps
• Remove the fuse (1)
• Connect the small size test instrument to measure
if the fuse is connected well.
1 CAUTION:
Set the test instrument at the position of “52x1”
Small sixe test instrument:

9/N·YU-.3112
90890-03112
• If the indicating needle points toward ∞, the fuse

is broken and needs to be replaced.
55
1 2. Replacement of bad/old fuse
Replacement steps:
• Cut off engine and circuit
• Install the new fuse.
• Start the power for electrical appliance inspection.
• If the fuse is not responding check the system
again (Refer to “Electrical Appliance” of chapter 4)
3. Installment of fuse cover
(III) Replacement of headlight lamp

1. Cut off engine
• Connecting wire terminal of headlight (1)
2. Removal
• Unit of headlight (2)
3. Take out the lens (1)

4. Remove the lens seat (2)
2
Rotate countereclockwise when taking out the lens
(1) .
CAUTION:
When removing the light head hold the front side
of the headlight with hand.
5. Removal:
• Lamp (1)
WARNING:
The lamp is very hot never touch before cooling.
56
6. Installment
• Lamp (1)
CAUTION:
Be sure that the projective part of the lamp (2) is
engaged with the convex groove (3) on the light
seat.
CAUTION:
Never touch the glass part otherwise the lamp will
loose illuminating value. If there are some oils on it
clean off with cloth mixed with alcohol.
7. Connect
• Light seat (1)
CAUTION:
Be sure that the projective part of the lamp is
engaged with the convex groove on the light seat.
8. Install the lens to the light seat.
9. Installment
• Headlight
CAUTION:
Install the rubber hole-guard ring of the headlight
connecting wire to the headlight.
10. Connect
• Connecting wire terminal of headlight.
57
Section 5 Maintenance and Adjustment of
Engine
(I) Adjustment of clutch

Adjustment steps:
a. Loosen the locking nut (1)
b. Turn the adjusting screw rod (2) counterclock-
wise slowly up to be unable to turn, then turn 1/8
clockwise, and fasten the adjusting screw rod 2 to
this position and tighten up the locking nut 1 with
the torque of N ·m.
CAUTION:
1 2
Turn the adjusting screw rod (2) counterclock-
1 wise to decrease the clearance of clutch, Turn the
adjusting screw rod (2) clockwise to increase the
clearance of clutch.
(II) Clean the air filter

CAUTION:
There is an inspection cup (1) on the bottom of
the air filter, if there is dust or water deposits in the
cap clean the filter core and filter box of air filter.
1. Remove the cushion (Refer to “Cushion Remov-

al” of this chapter).
2. Remove the air filter box cover (1) , air filter
components.
58
3. Removal
a. Air filter core (1)
b. Foam supporting cylinder (2)
CAUTION:
Never start the engine without filter, otherwise the
piston and cylinder will be overworn.
4. Inspection
a. Air filter core (1)
b. Foam supporting cylinder (2)
If damaged replace it.
5. Clean the foam supporting cylinder. Clean off

the dust on the inner surface with compressed air.
6. Clean the foam filter core

a. Clean with water completely and slightly.
b. Squeeze the surplus water of the foam and dry it.
NOTE:
When squeezing the water on the foam.
7. Installament
a. Install the foam filter core to the foam supporting
cylinder to combine an air filter assy.
b. Install the air filter assy.
c. Install the air filter cover.
CAUTION:
Make sure that the close fit surface of air filter is
engaged with the close fit surface of air filter box,
and there is no air leakage.
9. Installment of cushion (Refer to section 2

“Cushion Installment” of this chapter.
59
1
(III) Inspection of spark plug

1. Rest the vehicle on level ground and clean the
spark plug with compressed air to avoid the dust
entering the engine.
2. Remove the spark plug (1)
The standard spark plug: DTRTC, if not correct,
replace it.
3. Inspection of spark plug

a. Electrode (1)
Worn or damaged, replace it
b. Insulator (2) color
Brown or light brown is normal condition
If the color is clearly different, check the engine.
4. Clean the spark plug

Clean the spark plug with spark plug cleaner.
5. Measure the spark plug clearance (1) .

Measure with feeler gauge. If out of specification,
adjust.
Spark plug standard clearance: 0.6-0.7mm
6. Installment of spark plug

a. Clean the washer surface and spark plug surface
before installing the spark plug.
b. Tighten up the spark plug with hand before in-
stalling it according to specification.
Torque of Spark plug: 17.5N ·m
60
(IV) Adjustment of idle speed
1. Rest the vehicle on level ground
2. Start the engine and warm it at idle speed of
1000-2000r/min, after several minutes, increase the
engine speed to 4000-5000r/min.
3. Set the specified idle speed through adjusting the
throttle adjusting screw (1) . Screw in to increase
the engine speed and screw out to decrease the
speed.
Specified idle speed: 1450-1550r/min
4. Measure the engine speed with measuring meter.
5. Make sure that the free clearance of the throttle

grip is within 3-5mm, otherwise readjust the idle
speed.
(V) Adjustment of free clearance of throttle grip

CAUTION:
First adjust the engine idle speed when adjusting
throttle grip.
1. Rest the vehicle on level ground.
2. Inspection
• Free clearance of throttle grip (a) . If out of
specifications adjust free clearance of throttle grip:
3-5mm
3. Adjustment
Adjustment steps of free clearance of throttle grip.
a. Loosen the locking nut (2) .
b. Turn the adjusting bolt (1) up to the free clear-
ance of throttle grip a is 3-5mm.
c. Tighten up the locking nut (2) .
1 2 a
CAUTION:
After adjusting the free clearance, move the lever
forward and backward to make sure that the engine
will not lift.
61
(VI) Adjustment of speed limiter:
The speed limiter can limit the throttle in full open-
ing condition when the throttle grip is pulled to
the max position, screwing the adjuster inward can
stop increasing the speed.
1. Adjust speed limiting length (a)
Adjustment steps:
a. Loosen the locking nut (1)
b. Adjust the adjusting screw (2) clockwise or
counter-clockwise to make a obtain the specified
length of 12mm.
1 2 c. Lock the locking nut (1)
WARNING:
a. For the beginner driver, pay extra attention to
screw the limiter inward and screw out with im-
provement of driving skills. Never remove the
adjusting screw of speed limitor.
b. For the correct throttle grip operation, never
screw out the adjuster to exceed 12mm, and adjust
the free clearance of throttle grip to 3-5mm.
62
1
(VII) Adjustment of valve clearance
CAUTION:
The valve clearance should be adjusted only after
the engine is cold, the valve clearance should be
adjusted when the piston is at the end point posi-
tion of compress stroke.
1. Removal:
1) Rest the vehicle on level ground
2) Remove
a. Cushion (Refer to section 2 “Cushion removal”
of this chapter)
b. Fuel tank (Refer to section 2 “Fuel tank remov-
al” of this chapter)
3) Remove:
2
a. Timing observation hole scsrew (1)
b. Manual operation start mechanism (2)
4) Remove:
a. Valve cap (1) (the side of exhaust valve)
2 1
b. Valve cap (2) (the side of intake valve)
2. Adjustment
1) Measure the valve clearance
a. Turn the crankshaft counterclockwise with
wrench.
63
1 2
b. Make the mark “T” on the rotor align with the
mark on the crankcase. When aligned the piston
ties in Top Dead Center (TDC)
c. Inspection of top dead center in pressure stroke:
(i) When the mark (1) on the rotor is align with
mark (2) on the crankcase, the two arms must be
clear.
(ii) If there is no clearance, turn the crankcase
counterclockwise to meet the above requirement.
d. Measure the valve clearance (3) with a plug

gauge. Adjust the clearance if it is out of specifica-
tion.
Intake valve clearance: 0.05-0.09mm (normal
temp.)
Exhaust valve clearancee: 0.11-0.15mm (normal
temp.)
(2) Adjustment of valve clearance:

a. Loosen lock nut (1)
b. Insert the plug gauge spanner (2) between
adjusting screw (3) and valve rod.
c. Turn the adjusting screw 3 clockwise with
valve adjusting spanner until the right clearance
has been met.
Size of valve adjusting spanner: 3mm
Code: 90890-01311
d. Fix the adjusting screw (3) to avoid turning,
and fasten the lock nut (1) .
Torque of lock nut: 14N ·m
3. Adjust the valve clearance again: If the clearance

is not correct adjust it again by using the above
procedures.
64
2 1
3. Installation:
Follow the opposite steps of “Removal”.
(1) Mount:
a. Valve cap (1) (side of outlet door)
b. Valve cap (2) ( side of inlet door)
CAUTION:
(i) Project of valve cap (1) (2) should be up
(3)
(ii) Check if the o-ring (4) is damaged, if so re-
place immediately.
Torque of valve cap: 10N·m
(2) Mount:
a. Oil tank (see oil tank installation in this section)
b. Upper cover of oil tank
c. Seat (see installation of seat in section 2)
(VIII) Adjustment of timing chain tension

The engine has an automatic adjusting tensioner on
the chain, so manual adjustment is not neccessary.
65
(IX) Inspection of ignition timing
Notice:
Before you check the correct timed ignition,
adjust the engine idle speed and free clearance of
the throttle grip to the correct position.
1. Put the vehicle on level ground
2. Start the engine for pre-heating, and then stop
the engine.
3. Mount the induction engine tachometer (90890-
1 03113)
4. Mount the correct timed ignition meter on the
connection line of the spark plug cap (90890-
003141)
5. Inspection of ignition timing

Inspection steps:
a. Remove the plug (1)
b. Start the engine, run engine at 1450r/min-1550r/
min idle speed.
WARNING:
When the engine is running, the mcahines oil may
splash out, be careful.
c. Check if the the mark (2) on the crankcase is

3 2 in range (3) of ignition under the magneto rotor
indication. If it is out of range, check if the rotor or
pulse coil are loose or damaged (refer to chapter 4
electricity)
CAUTION:
Ignition timing can’t be adjusted
6. Mount the plug (1)
7. Take the ignition timing meter induction engine

tachometer off.
66
(X) Measurement of compressive force
CAUTION:
Inadequate compressive force will reduce the en-
gine performance.
Before measuring the compressive force, the valve
clearance should be adjusted first (refer to “Adjust-
ment of valve clearance” section).
1. Put vehicle on level ground
2. Take the spark plug off
3. The following are steps for measuring compres-
sive force:
a. Install pressure gauge (1) and change connec-

tor.
b. Turn the throttle lever to max position.
Start engine with power (battery has been charged
fully) until there is no increase on the pressure
gauge.
WARNING:
When starting the engine, the spark plug must be
connected to ground to avoid sparks.
c. Reading the pressure gauge
Compressive foce on sea level:
Standard value: 900Kpa (9.0kg/cm²)
Min. value: 800Kpa (8.0kg/cm²)
Max value: 1000Kpa (10.0kg/cm²)
66
d. If pressure drops below min. value:
(i) Drop some oil to active cylinder.
(ii) Measure the pressure again
Compressing force (The machine oil has been
filled in the cylinder)
Compressure read Reason
Read is higher Piston or ring is
than filling before worn/damaged
Read is equal when Piston ring, throttle,
no oil cylinder head,washer
may be damage
Read is over max value Check if cylinder head
throttle surface or
piston top end are
carbon laydown
4. Remove pressure gauge
5. Mount spark plug, torque of mount equals

17.5N∙m
(XI) Inspection of oil quantity of engine

CAUTION:
No foreign matter in crankcase
1. Place vehicle on flat ground
2. Check engine oil quantity and fill it if it is
inadequate.
Inspection steps:
a. Pre-heat then turn off engine after several
minutes. Return the machine oil into crankcase
after waiting ten minutes.
67
2 b. Completely remove the dipstick (1) and
clean it before inserting it back into the oil hole.
c. Remove the dipstick (1) . Make certain that
the oil level is between the max value (2) and
3
min value (3) .
d. Put some engine oil in to get te proper oil

quantity if it was too small. See diagram to the
left for recommended oil quantity.
1 CAUTION:
Recommended oil type:
U∙S∙A Petrol Association offers:
“SE” and “SF” type oil such as:
“SF-SE-CC”, “SF-SE-SD”, etc.
(XII) Inspection of oil flow and replacement of

engine oil.
CAUTION:
The clutch can be lubricated with engine oil, but
do not use any chemical additive in machine oil
because it can cause the clutch to breakdown.
Foreign matter should not be permitted in the
crankcase.
1. Put vehicle on flat ground
2. Pre-heat the engine and stop after several min-
utes.
3. Place a container under the engine.
4. Remove oil dipstick and draining plug (1) to
drain engine oil.
WARNING:
It is easy to lose the draining plug, compressor
spring (3) , rough filter (4) , and O-ring (2)
when they have been removed. Pay attention to
these parts.
5. Remove fire-filter cap (5) , fine filter (6) ,
and O-ring (7) .
68
6. Inspection
If O-ring (1) , compressor spring (2) , rough
filter (3) , or fine filter (4) is damaged, it
should be replaced.
7. Cleaning
Use cleanser to clean the compressor spring (2)
, filter (3), filter net (4), crankcase filter plug
(5), and filter nut cap (6) .
8. Slightly coat the O-ring with engine oil.
9. The fire filter (1), fire filter cap with O-ring

(2), rough filter (3), and draining plug (4)
should be installed.
WARNING:
Be definite that th draining plug, mount O-ring
(5), compressor spring (6), and fine filter are in
the correct mounting order prior to installation.
Mounting torque: fine filter cap:10N∙m
Draining plug: 43N∙m
10. Fill the crankcase with machine oil

Refer to: “Inspection of Engine Oil Quantity”
Appendix: Total: 2.2 L
Periodic change oil: 1.8L
When cleaning or replacing filter net, oil quan-
tity should be 1.7L
69
11. Mount dipstick
12. Stop pre-heating engine after 5 minutes or
1
more.
13. Check the oil level and if it is leaking
14. Check oil flow
Inspection steps:
a. Lightly loosen bolt (1) of cylinder head.
b. start engine for racing until oil runs from the
oil tunnel. Stop the engine immediately if no
machine oil comes out to avoid damaging the
engine.
c. Start the engine again after fixing step b. and
check the oil pressure.
d. The oil tunnel bolt should be fastened ac-
cording to standard.
Fasten the torque of oil tunnel bolt: 7N∙m
70
Chapter III Repair and Maintenance of Vehicle Body
Section 1 Rear driving gearcase and driving shaft
1. Driving gear case cover 8. Bearing 13. Bearing 18. Trans. shaft
2. O-ring 9. Oil seal 14. Bearing gasket 19. Circlip
3. Oil seal 10. Bearing 15. O-ring 20. Rear joint
4. Bearing 11. Main driving gear 16. Bearing 21. Bearing
5. Pad 12. Thrust pad 17. Bushing 22. Oil seal
6. Shift gear 23. Bearing
7. Thrust plain pad
71
(I) Trouble
• Trouble judging guidance
Performance Possible Reason
1. The vehicle appears to stop or there is irregular A. Damaged bearing
axial run-out with an abnormal noise while the B. Improper clearance
vehicle accelerates, decelerates, or is in idle state. C. Damaged gear
(Make sure not to confuse with engine trouble) D. Driving shaft breaks
2. The vehicle makes an obvious boom sound at E. Gear teeth break
low speed and “Wu Wu” sound when decelerating F. Jam caused by
or accelerating. There is also a regular snap from shortage of lubricating
the case body. oil
3. The rear wheel can not rotate and the G. The gear is jammed
transmission shaft jams by foreign matter
CAUTION:
“A”, “B”, and “C” are difficult to judge because the performance is very subtle and it’s difficult
to distinguish them from normal operating noise. Remove these parts for special inspection if
you think they may have been damaged.
(II) Inspection
1. Check abnormal noise:
The following noises may indicate mechanism trouble
a. Boom when vehicle is sliding, accelerating, or decelerating. The noise is not direct ratio with
higher engine and transmission case speed, but is direct ratio with rear wheel speed.
b. “Wu Wu” noise is different when accelerating or decelerating.
Cause: Incorrect assembly or teeth clearance is too small.
CAUTION:
Noise must differentiate from normal operating noise of vehicle.
Judgment: Teeth of gear cracked
WARNING:
You should stop driving immediately if there is any doubt that the gear teeth cracked. This could
mean that the transmitting components are jammed by gear fragment and it is possible to lose
control of the vehicle, possibly injuring the driver.
2. Check following condition:

a. Drain the lubricating oil
72
It is necessary to check the rust of bearing if there is a great deal of metal or metal corpuscle on
the oil draining screw plug so it does not cause a jam.
CAUTION:
It is normal for some metal corpuscle to be in the oil.
3. Check oil leakage
Check according to following procedures.
a. Completely clean, wipe, and dry the entire vehicle.
b. Dry powder on the transmission shaft or paint inspecting solvent of oil leakage.
c. To be able to examine the leakage you need enough examining distance, (Suggestion ≥5km).
If leaking, check component
If damaged, replace component
CAUTION:
1. Improper installation or damage of oil seal causes oil leakage in new vehicles.
2. To avoid unnecessary disassembly, check and confirm the oil leakage carefully.
(III) Trouble-shooting table

Check following points if there is basic trouble condition.
To check if the wheel bear-

YES Refer to “Front wheel and front
ings are damaged, lift the brake” of this chapter to replace the
front end of vehicle and front wheel bearings
rotate the front wheels.
NO
Recheck or remove single com-

Check the rear wheel shaft NO ponent. May not be damage to the
to see if the bearings are rear wheel bearing or driving shaft
damaged. bearing.
YES
To check if the bearing is Refer to “Rear wheel and rear

YES
damaged, remove the rear wheel shaft” of this chapter to re-
wheel shaft place the rear wheel shaft bearing.
NO
Remove the transmission

shaft components
73
(IV) Disassembly
WARNING:
Ensure that the vehicle does not turn over by
firmly supporting it.
1. Drain the rear driving gear case oil

Refer to section 3, chapter 2, “Replacement of
engine oil of rear driving gear case”
2. Disassemble
1) Cushion
2) Rear luggage carrier
1 3) Rear fender
2 Refer to “rear fender”
3. Disassemble
1) Rear wheel (left)
2) Connecting plate of rear wheel
3) Rear wheel (right)
4) Rear brake and rear brake hub
5) Rear wheel shaft
Refer to “Rear wheel/rear brake/rear wheel
shaft”
4. Disconnect:
Air pipe (1) (rear driving gear case)
5. Disassemble
Rear driving gear case body (2)
CAUTION:
1) The transmission shaft (3) could possibly
drop out while driving gear case is removed
from the rear wheel fork.
2) Do not lose these components.
74
1
1. Disassembly
a. Remove: bolt (1) M6
2 bolt (2) M8
CAUTION:
Loosen each bolt by ¼ circle and remove bolts
alternately.
1 b. Disassemble:
1) Rear driving gear case body (1)
2) Annular gear pad
3) Shift gear
4) Thrust plain pad
c. Disassemble:
Bearing gasket (transmission shaft-last grade)
CAUTION:
On the bearing there is left-handed thread.
The bearing gasket may be loosened if rotated
clockwise.
CAUTION:
Use special wrench when reinstalling the bear-
ing gasket.
75
d. Disassemble
With a soft hammer lightly tap the main driv-
ing gear (1) and remove (with thrust pad (2)
and bearing (3))
CAUTION:
Remove the main driving gear first if it is nec-
essary to replace the gear. Replace the original
bearing thrust pad, do not reuse.
e. Disassemble:
1) Oil seal (1)
2) Bearing (2) (shift gear)
Properly support rear driving gear case and use
proper pressure assemble tool (3)
f. Disassemble:
Bearing (1) (main driving gear)
Procedures for disassembly:
1) Heat up the rear driving gear case to 150°C
2) With a proper punching pin (2) , remove
the outer circle of bearing.
3) On the main driving gear remove the inner
circle of bearing.
CAUTION:
Removing the inner circle of the main driving
gear bearing is difficult and generally unneces-
sary.
76
(V) Inspection
1. Replace the main driving gear and shift gear
if there are any caving, scratches, or wearing on
the gear teeth of bevel gear pair (1)
2. Check oil seal (2)
3. Check the O-ring (3)
Replace if damaged
4. Check the bearing (4)
Replace if damaged
CAUTION:
(a) The bearing can be used repeatedly;
however, the Jianshe group advises that it be
replaced. The oil seal should not be used repeat-
edly.
(b) Be sure to adjust the main driving gear
and/or shift gear when replacing them. Turn to
“Choice of Main Driving and Shift Gear Pad”
5. If the transmission shaft (5) (spline) has any

wear or damage, replace it.
6. If there are any cracks or damage on the driv-

ing gear case body (6) and cover (7) replace
them.
CAUTION:
Be sure to adjust the pad of main driving and
shift gear while replacing the driving gear case
body and cover. Turn to “Choice of Main Driv-
ing and Shift Gear Pad”
50
07
77
(VI) Choice of main driving and shift gear pad
1. Main driving gear pad (1) choice:
Use “A” = (a) - (b) to work out main driving
gear pad thickness
(a) =84 +/- engraved number on main driving
gear
(b) =83.5 +/- engraved number on driving gear
case body
CAUTION:
The unit of numbers on the main driving gear and
case body =1/100mm
Example:
1) If “+01” is engraved on the main driving gear
then:
(a) is 84+0.01=84.01
2) If “10” is engraved on the main driving gear
then:
(b) is 83.5+0.10=83.60
3) “A”=0.41
4) Chose the proper pad and correct the percent
digit The resulted value in the example is 0.41,
but the meter specifies to change 1 of the per-
centage digit to 0. The pad thickness will then be
0.40mm
Number on Amending
percent digit value
0,1,2 0
3,4,5,6,7 5
8,9 10
Pad thickness
Main driving gear pad
Thickness 0.15 0.50
(mm) 0.30 0.60
1 0.40
78
2. Choice of shift gear pad
Shift gear pad (1)
Choosing procedures:
Work out the pad thickness “B” from following
formula
“B”= (c) + (d) - ( (e) + (f) )
(c) =45.5 adds or subtracts the number en-
graved on the driving gear case body.
(d) =1 adds or subtracts the number engraved
on the driving gear case cover.
(e) =35 adds or subtracts the number on the
shift gear
(f) =bearing thickness (regarding unchange-
able)= “11.00mm”
For example:
1) The number engraved on the driving gear
case body is “07”
(c) =45.5+0.07=45.57
2) The number engraved on the driving gear
case cover is “06”
(d) =1+0.06=1.06mm
3) The number engraved on the shift gear is
“-05”
(e) =35-0.05=34.95
4) f =11.00
5) Pad thickness
“B” =(45.57+1.06)-(34.95+11)=0.68
c
50 d Number on Amending
90
07 Percent value value

0,1,2 0
3,4,5,6,7 5
8,9 10
The pad has following thickness
Shift gear pad
Thickness 0.25 0.40
(mm) 0.30 0.50
-05 e
79
(VII) Installation:
Reversal of “disassembly.” Make sure to pay
attention to the following points:
1. Install the needle bearing (small) on main
driving gear:
Procedures:
a. Warm the case body to 150°C
b. Assemble the out circle of bearing with
proper hold-down.
c. Install the inner circle of the needle bearing
onto the shift gear.
2. Install oil seal (1)
3. Install the outer circle of the needle bearing
(bigger) (2) of shift gear onto the driving gear
case body.
Warning
Must use new oil seal
4. Install main driving gear (1) (pad (2) and

bearing (3) ), and install bearing gasket (4) .
Calculate the size of the pad.
CAUTION:
(a) The bearing gasket is left-handed, so
tighten it by rotating counter clockwise.
(b) Before installing the bearing gasket, ap-
ply grease on O-ring.
(c) When installing the bearing gasket, tight-
en it with special tool.
80
Section 3 Rear wheel, rear brake, rear wheel axle
Technical Parameter
No. Item Parameter
1 Tire specification AT22x10-10

2 Rim Dimension 8.5x10
3 Tire air pressure
(Normal Temperature) Standard value 25KPa
Min. value 22KPa
Max. value 28KPa
4 Runout
Radial runout 2mm
End face runout 2mm
5 Wear limit of tire 2mm
6 Wear limit of friction disk 2mm
7 Rear brake hub wear limit 161mm
81
B. Right end of rear wheel
1 Rear brake hub 2 Brake shoe 3 Bearing block
4 Dust-proof seal 5 Air pipe 6 Rear brake cover assembly
7 Rear brake cam shaft 8 Brake indicating plate
9 Rear brake arm assembly
82
(I) Removal steps
1. Rest the motorcycle on a flat ground. Press
the brake clip (1) .
2. Loosen the connecting nuts of front and rear
wheels.
3. Stop up the front wheel with wood, then put
a proper supporting article under the frame
so as to lift the rear wheel and make the rear
wheel leave the earth.
WARNING:
In order to avoid the parts falling, (which will
cause danger), during the removal process, rest
the vehicle firmly.
4. Removal (the Ser. No. is corresponding to
the Ser. No. on the drawing)
(1) Connecting nut of front and rear wheels
(2) Left rear wheel
(3) Split pin
(4) Rear wheel axle nut
(5) Washer
(6) Rear wheel connecting plate
5. Removal (the Ser. No. is corresponding to

the Ser. No. on the drawing)
(1) Connecting nut if front and rear wheels
(2) Right rear wheel
(3) Split pin
(4) Rear wheel axle nut
(5) Washer
6. Loosen the rear brake clip
7. Removal:
Brake shoe assy (1)
83
8. Removal: (the Ser. No. as shown on the
drawing)
(1) Adjusting nut, pin and spring of rear
brake arm and rear brake tension rod assy.
9. Removal:
(2) Rear brake cable
(3) Rear brake tension rod assy
(4) Air pipe of rear brake
10. Removal:
(1) Rear brake bearing block
(2) Rear brake hub
11. Removal
(1) Tension spring
(2) Rear brake arm
(3) Brake indicating plate
(4) Rear brake cam shaft
12. Removal:
(1) O-ring 30x1.8G
(2) Plain pad of rear brake cover
13. Removal:
(1) Rear wheel axle: Beat the right end of
the rear wheel axle, slightly pull the rear wheel
axle from left end.
CAUTION:
Take out the rear wheel axle from the end of
rear wheel axle bushing and gear box with soft
hammer.
WARNING:
While taking out the rear wheel axle, in order
to protect the thread
and gear groove from damage, do not beat the
rear wheel axle directly with hammer.
84
(II) Inspection steps:
1. Inspection
When inspecting the real wheel, refer to “Tire
Inspection”, “Rim Inspection” Section of chap-
ter 2.
2. Measurement:
a: radial run-out of rim
b: Tire surface
Refer to “Front wheel and Front Brake Inspec-
tion” Section of this chapter
3. Inspection
(1) Rear wheel connection plate (1) , if
cracks or damage is found, replace it.
(2) Involute splint on rear wheel connecting
plate (2) . If worn or damaged, replace it.
4. Inspection:
Friction plate of rear brake
5. Measurement
Thickness of brake friction plate
See the “Front wheel and Front brake inspec-
tion” section of this chapter.
Attached: The thickness of brake friction plate
is: 4.0mm (0.16in)
<Wear limit>: 2.0mm (0.08in)
6. Inspection
Tension spring of brake shoe
See the “Front wheel and Front brake Inspec-
tion” section of this chapter
7. Measurement
Internal diameter of rear brake hub (a)
If out of specification, replace the hub
Attached: Internal diameter of rear brake hub:
160mm
<Wear limit>: 161mm
85
8. Inspection (The Ser. No. as shown on the
drawing)
1 Inner surface of rear brake hub
If there is some engine oil or scraped markings,
remove it and treat it. The method of treat is as
follows:
Removal of engine oil: Clean with cloth dipped
in volatile dilute or volatile solvent.
Removal of scraped marking: wipe slightly and
with even force the scraped marking to remove
it.
(2) Gear groove of rear brake hub
If worn or damaged, replace it.
9. Inspection
(1) If there are any cracks, bends, or damage
on the brake cover, replace it.
(2) If the dust-proof seal is worn or damaged,
replace it.
10. Inspection
(1) If there is worn, scraped marking, or dam-
age on the cam shaft of rear brake, replace it.
(2) If the air pipe of rear brake is clogged,
remove this pipe and clean the dirt, if damaged,
replace it.
11. Clean the air hole on the rear brake cover
with compressed air.
12. Inspection of rear wheel axle (1)

a: If the rear wheel axle is heavily scraped or
broken, replace it.
b: If the thread or gear groove on the rear wheel
axle is worn or damaged, replace it.
86
13. Measurement
The radial run-out of the piston (a) on the rear
wheel axle, if out of specification, replace it.
Attached: The radial run-out limit of rear wheel

axle: 1.5mm
WARNING:
If the axle is bent, do not straighten it force-
fully.
14. Inspection:
(1) Bearing on the rear wheel axle
Rotate the rear wheel axle, if the axle shakes
left and right in the bearing or run-out it indi-
cates that the bearing is heavily worn and needs
to be replaced.
(2) If the oil seal is worn or damaged, replace
it.
Replacement steps of bearing and oil seal:
a: Clean around the bearing of gear case end.
b: Remove the oil seal (1) with plain screw-
driver.
CAUTION:
In order to protect the oil seal out edge from
damage during the removal process, place a
wood block (2) under the screwdriver.
Remove the bearing (3) with corresponding
tool.
The installment of new bearing and oil seal is in
reverse.
Caution
During the installment, the pressing tool of
bearing (4) should be matched with the outer
diameter of bearing outer race (7) and that of
oil seal.
WARNING:
Never beat the inner race (5) and bearing ball
(6) , the pressing tool needs to touch the bearing
outer race (7) .
87
(III) Installment steps:
The reversal steps of “removal steps” are in-
stallment steps. Pay attention to the following
points when installing:
1. Lubrication part
(1) Oil seal lip of rear wheel axle.
(2) Bearing of rear wheel axle.
The corresponding splint tooth of rear wheel
axle.
The lubrication oil is lithium base grease.
2. Installment
Installment of rear wheel axle (1)
CAUTION:
Before installing the rear wheel axle, loosen
all bolts on the driving gear case (2) ; hold
the rear wheel axle with hand to make it enter
the gear groove of gear case, apply on the left
end of the axle slightly with soft hummer.
WARNING:
In order to protect the axle thread and splint
tooth of axle, never beat the end face of axle
directly with hummer.
3. Installment
Plain pad of rear brake cover
O-ring 30x1.8G
4. Lubrication of rear brake cam shaft.

The lubrication oil is lithium base grease.
88
5. Installment
Cam shaft of rear brake (1)
Indicating plate of brake (2)
Rear brake arm assy (3)
CAUTION:
When installing the brake indicating plate (2)
to rear brake cam shaft (1) , be sure to align
the projective part (a) of brake indicating
plate (2) with the concave part (b) of rear
brake cam shaft (1) .
At the same time, align the punch mark (c)

on the rear brake cam shaft with that (d) of
the rear brake arm assy (3) .
The torque of rear arm assy; 9Nm
6. Application
Sealing agent: Be suitable for the rear brake
cover assy and rear wheel axle bushing sur-
face.
Attached: Sealing agent: P/N: ACC-QUICK-
GS-KT
7. Installment
Rear brake cover assy (1)
Bearing block of rear brake (2)
CAUTION:
Install the rear brake cover with bolt (3) , the
torque of bolt installment is: 28N∙m۪
89
8. Installment
Brake shoe assy
9. Lubrication
Dust-proof seal
Lubrication oil for dust-proof seal: lithium
base grease.
Warning
The lubrication oil is not allowed to be used
for brake shoe assy, the lithium base grease is
used for rear brake hub splint groove.
WARNING:
The lubrication oil is not allowed to be used
for splint on the right end of rear wheel axle,
other wise, during the work, the surplus lubri-
cation oil will leave on the brake shoe, affect-
ing the brake performance.
10. Installment:
Rear brake hub
11. Installment (The Ser No. as shown on the
drawing)
(1) Air pipe (1) of rear brake
(2) Rear brake tension rod assy
(3) Rear brake cable
12. Installment
Spring
Pin
Adjusting nuts (4) of rear brake tension rod
assy and rear brake cable.
13. Installment
(1) Washer 16
(2) Nut M16
14. Tighten up nut M16
Attached: (2) Torque of nut M16: 150Nm
90
15. Installment
split pin 4x30 (1)
CAUTION:
After fastening the torque, the nut on the rear
axle is not allowed to be loose. If the nut con-
cave groove is not aligned with the splint hole
on the screw rod, align it by tightening up the
nut.
WARNING:
Always use the new splint pin
16. Installment
Right rear wheel (1)
Connecting nut of front and rear wheels (2)
Attached: The torque of the connecting nut of
front and rear wheels is 55Nm.
CAUTION:
The rotating direction of the wheel is the arrow
marking direction on the tire. For this, refer to
“Front wheel and Front Brake” section of this
chapter.
WARNING:
When installing the core nut to the rear wheel,
be sure to face its core edge to the wheel.
18. Installment
Connecting plate of rear wheel (1)
Washer 16 (2)
Rear wheel axle nut M16 (3)
Split pin 4x30 (4)
Left rear wheel (5)
Connecting nut of front and rear wheels (6)
Refer to “Rear wheel” section of this chapter.
19. Adjustment
Rear brake pedal clearance
Rear brake cable clearance
Refer to “Adjustment of left Lever and Rear
Brake Pedal Free Clearance” Section of chap-
ter 2.
Attached:
Rear brake pedal clearance: 20-30mm
Clearance of left lever center: 5.0-8.0mm
91
Section 4 Steering Operation system
(1) Upper holder of steering bar (2) Lower holder of steering bar
(3) Steering vertical column welding (4) Steering vertical column holder (5) Seal ring
(6) Bushing (7) Clip assy (8) Locking pad (9) Steering tension rod ball pin assy
(10) Tension rod
92
(I) Removal steps of steering bar
1. Removal
Front luggage carrier
Bumper
Front fender
Refer to chapter 2, section 2
2. Removal
Main switch lock wire
“Neutral” indicating light wire
1 “Reverse” indicating light wire
“High beam” indicating light wire
Clutch switch wire
3. Removal
(1) Front brake cable
4. Removal
(2) Throttle grip assy
5. Removal
After stopping the vehicle, remove the rear
brake cable (1)
6. Removal
Handlebar
Handlebar bracket
93
(II) Removal steps of steering vertical column
welding
1. Plain move
(1) The locking part of locking pad as shown
2. Removal
(2) Bolt M8x60
(3) Locking washer
(4) Clip assy
3. Removal
Install the steering vertical column with split pin
2.5x24
Nut M10
Washer 10
4. Removal
Split pin 3.2x24
Nut M12x1.25
1 Tension rod (1)
CAUTION:
When removing the tension rod end and steering
ball pin from the steering vertical column weld-
ing assy and front seat assy of front brake with
common bearing tension tool and other tools,
pay attention not to damage the relevant parts.
5. Removal
Remove the steering vertical column weld-
ing assy together with steering vertical column
holder.
6. Removal
(1) Steering vertical column holder
(2) Bushing
(3) Oil seal
94
(III) Inspection content
1. Check if the steering bar cracked, bent, or
damaged. If it is, replace it.
2. Inspect the steering vertical column welding

assy for any bends or damage. If there is, re-
place it.
WARNING:
In order to avoid decreasing the performance of
the steering vertical column, do not straighten it
forcefully if it is bent.
3. Inspection
Check the steering vertical column holder (1)
and seal ring (2) . If they are worn or damaged
replace them.
4. Inspection:
If the tension rod (1) is bent or damaged re-
place them.
5. Correcting:
If the free clearance is found on the ball pin
head, replace the ball pin. If the part around the
ball pin head is uneven, replace the ball pin.
If there is convex point, wear, or damage on the
core surface of ball pin end head, replace it.
95
6. Adjustment
Assembly length of tension rod
Adjustment steps of tension rod assembly length
1- Loosen the connecting nut [A] [B]
2-Adjusting the assembly length of tension rod
by rotating the tension rod.
Attached: Tension rod assembly length @:
297mm
[A] Right-handed thread
[B] Left-handed thread
Connect [C] position to the steering vertical col-
umn welding assy.
Connect [D] position to the front seat assy, the
front brake.
CAUTION:
The connection nut [A] [B] can be tightened up
only when the revealed thread length (b) of two
ends of tension rod are the same.
Attached: Connecting nut torque of tension rod:
30Nm
7. Inspection
If the bearing (1) and O-seal (2) under the
steering vertical welding are worn or damaged,
replace them.
(IV) Installment steps

The reversal steps of “Removal” steps are the
“Installment” steps. Pay attention to the follow-
ing points during installment.
1. When installing steering vertical column
welding, lubricate the bearing (1) and seal ring
2 under the steering vertical column welding.
96
2. Lubricate the steering vertical column hold-
er (1) and seal ring (2) during installation
of the steering vertical column welding.
3. Installment
Install the seal ring (1) to the steering verti-
cal column welding, then install bushing (2).
Finally, install the steering vertical column
holder (3).
CAUTION:
Never damage the seal ring when installing.
4. Installment
When installing the steering vertical column
holder and steering vertical column welding
take them as a unit.
WARNING:
In order to ensure that the correct circuit of
brake cable and wire, never damage and wind
the cables and wires.
5. Installment of left and right tension rod (2)

CAUTION:
Make sure that the ball pin (1) at the side of
scraped marking connects with the front seat
assy of front brake.
1
6. Tighten up the nut (1) of ball
97
7. Mounting split pin (1)
CAUTION:
Don’t loosen the nut after the torque is fixed.
If the nut recess does not correspond with split
pin hole on the double-screw bolt, tighten the
nut to align them.
WARNING:
Always use new split pin
8. Tightening
After mounting the washer, nut, split pin under
the steering vertical column.
Nut torque: 30Nm
9. Install
Clip (1) , locking washer (2) , bolt (3)
Attached: bolt torque: 23Nm
WARNING:
Always use new locking washer.
10. Bent showing supporting lug of locking

washer to lock lightly the bolt.
11. Fill the lubrication oil at the oil cup to

lubricate the bearing under the steering vertical
column. Lubrication oil is Lithium base grease.
98
(V) Installation steps of steering bar
1. Install the lower holding seat (1) , steering
tube (2) and upper holding seat (3) .
WARNING:
When tightening the bolt of holding seat, make
sure clearance (b) is clear.
Attached: bolt torque: 20Nm
2. Install the throttle grip unit

CAUTION:
The projection (1) of throttle grip must cor-
respond with the sunken part (2) on the right
lever seat when installed.
WARNING:
Correct installation of cable and wire is very
necessary to ensure the safe operation of ve-
hicle.
Refer to chapter 1 “Wiring diagram of vehicle”
3. Adjusting the free clearance of brake cable

Refer to “Adjustment of Front Brake” and
“Adjustment of free clearance about left handle
lever and rear brake pedal” in chapter 2.
4. Adjusting the toe-in of front wheel

Refer to “Adjustment of front wheel Toe-in” in
chapter 2.
99
Section 5 Front shock absorber
and Front wheel fork
(1) Front shock absorber (2) Left/right front seat assy

(3) Left/right front wheel fork welding (4) Bushing unit
100
(I) Disassembly:
1. Take off front luggage carrier, bumper, and
front fender.
Refer to the second section of chapter 2
Disassemble the front wheel front brake hub,
brake shoe unit, and front brake cap unit.
Refer to “Dischargement of front wheel and
front brake” of this chapter
2. Take off split pin (1) , nut (2) , and steer-
ing rod ball pin assembly (3) .
3. Take off the bolt (3) under the front

shock absorber nut of front shock absorber
(2) and front shock absorber (4) .
4. Loosen the front shock absorber nut (2) .
5. Take off the bolt (3) under the front

shock absorber nut of front shock absorber
(2) and front shock absorber (4) .
6. Take off split pin (5) , nut (6) on the left/

right front seat assy, and left/right front seat
assy (7) .
101
7. Check the free clearance of left/right front
wheel fork
Inspection step:
a: Check the parts (1) of left/right front
wheel fork on the frame. If it is bent, cracked,
or worn, repair or replace the frame.
b: Check the torque value of locking nut (2)
on the left/right front wheel fork
Attached: Nut torque: 45Nm
c: Move the left/right front wheel fork from

one side to another to check it’s side clearance.
If the side clearance is very obvious replace
bushing sub-assembly or a set of front wheel
fork.
d: Move the left/right front wheel fork up and

down to check its vertical clearance. If the
vertical moving is tight, limited, or uneven, re-
place the bushing sub-assembly or whole front
wheel fork.
8. Take off nut (1) , bolt (2) , left/right front

wheel fork (3) and bushing sub-assembly
(4) .
102
(II) Inspection step
1. Check the front shock absorber. If there is
leakage, replace it. Check the universal joint.
If it is cracked or damaged, replace the front
shock absorber.
Check spring, if it is fatigued or damaged, re-
place the front shock absorber. (When check-
ing, move the spring up and down).
2. Check the front seat assy of front brake, if it

is cracked, sunk, or damaged, replace it.
WARNING:
If the front axle is bent, don’t straighten it.
This is to avoid reducing the performance of
the front axle on the front brake.
3. Check the left/right front wheel fork weld-

ing. If it is cracked, bent, or damaged, replace
it.
WARNING:
If the left/right front wheel fork welding is
bent, don’t straighten it sedulously in order to
avoid reducing its performance.
4. Check the bushing sub-assembly (1) , if it

is worn or damaged, replace it.
103
(III) Installment steps
The opposite steps of “Disassembly” are the
mounting steps. The following must be paid
attention to when mounting:
1. Lubricate the inner surface of bushing sub-
assembly (1) . (lubrication oil is lithium base
grease).
2. Fix nut (2)

Nut torque: 45Nm
CAUTION:
Must ensure that the correction of bolt mount-
ing of left/right front wheel fork, bolt head
position showing on the drawing (1) front,
behind (2) that make the bolt head is out-
ward.
[A] means the vehicle is forward.
3. Mount left/right front seat assy (1)
4. Fix the nut (2) of left/right front seat assy
104
5. Mount the split pin (3)
CAUTION:
Don’t loosen the nut after marking the standard
torque. If the recess on the nut does not corre-
spond with split pin hole on the bolt, correct it
by tightening the nut.
WARNING:
Must use new split pin.
6. Mount:
Front shock absorber (4) , front shock absorb-
er nut (5) , bolt (6) under the front shock
absorber.
CAUTION:
Before fixing the front shock absorber nut (5)
you must ensure that the side plane (8) of
universal joint (7) is limited by frame limited
block.
The head of bolt should be forward. The cor-
rection of bolt mounting direction (6) under
the front shock absorber should be guaranteed.
7. Tighten the nut (5) , bolt of front shock
absorber (6)
Attached: Nut torque of front shock absorber:
5Nm
Bolt torque: 78Nm
8. Mount circlip (7)
9. Mount steering lever ball pin assembly (1) ,

nut (2) and split pin (3)
105
CAUTION:
Don’t loosen the nut after marking the standard
torque. If the recess on the nut does not cor-
respond with the split pin on the bolt, correct it
by fixing the nut.
WARNING:
Must use new split pin (3)
10. Mount front brake cap assy, brake shoe

assy, front brake hub, and front wheel.
Refer to “Installation of front wheel and front
brake” of this chapter.
11. Adjust front wheel toe-in

Refer to “Adjustment of front wheel toe-in” in
chapter.
12. Mount front fender, safety lever, and front

carrier.
Refer to the second section of chapter 2.
106
Section 6 Rear shock absorber and Rear wheel fork
(1) Rear shock absorber (6) Oil sealing

(2) Rubber washer assy of rear shock absorber (7) Bearing 30203
(3) Rear arm nut M22 (8) Rear wheel fork Assy
(4) Rear arm joint bolt (9) Rubber tube
(5) Axle bushing (10) Lower cap of gear case
107
(I) Disassembling steps
1. Take off left rear wheel, rear wheel joint
plate, right rear wheel, rear brake hub, rear
brake, and rear axle.
Refer to “Disassembly of rear wheel/rear
brake and rear wheel axle” section in this
chapter.
2. Take off lower cap (2) of gear case.
3. Take off the rear driving gear case sub-as-

sembly (1)
1 Refer to “Dischargment of rear driving gear
case sub-assembly and driving shaft” section
of this chapter.
2
4. Take off split pin 3.2x24 (1) , washer 12

(2) and rear shock absorber pin shaft (3) .
CAUTION:
When taking off rear shock absorber pin shaft
(3) , hold rear wheel fork so that rear wheel
fork does not drop.
108
5. Take off nut (1) on the rear shock absorber,
bolt (2), rear shock absorber (3) .
6. Take off rear brake tension spring (1) .
7. Take off dusty cap on rear arm axle.
8. Check the free clearance of rear wheel fork

1 checking steps.
a: Check the torque value of rear arm joint bolt
and the torque value of rear arm bolt (2), and
nut of rear wheel fork right side.
Attached: Torque of rear arm joint bolt and nut

is 130N ∙ m
Torque of rear arm joint nut (2) is 6N ∙ m
b: Move the rear wheel fork across to check

2
the side clearance [A]. If the clearance is big,
check the relevant parts of bush bearing 30203
and frame.
Attached: Free clearance value is less than
1.00mm
c: Move the rear wheel fork up and down to
check the vertical clearance. If the clearance is
too tight, limited, or uneven, check the relevant
parts of bush bearing 30203 and frame.
109
9. Take off rear bush (1)
10. Take off driving axle clamp assy (front)

(1), rear arm nut (right side) and rear arm joint
bolt.
1
11. Take off rear wheel fork assy (1) .
(II) Checking steps

1. Check
a: If rear shock absorber is leakage, if any,
replace it.
b: If rear shock absorber is bent or damaged, if
any, replace it.
c: Pull the spring up and down to check if
spring is fatigued or damaged, if it is, replace
rear shock absorber.
110
2. Check if the rear wheel fork assy is cracked,
bent, and damaged. If any, replace it.
Check if the rear wheel bush is cracked, bent,
and damaged. If there is one of these problems,
replace it.
3. Check the gear case lower cap. If there are

any cracks, bends, or damage, replace this part.
4. Check the rear arm joint bolt (1) , rear arm

joint bolt (2) , and bush (3) . If one of these
parts are worn or damaged, replace it.
5. Check the bearing 30203 (1) of rear wheel

fork assy, if there is free clearance during the
bearing match with the rear wheel fork, or un-
even swirl, replace the bearing. Check the oil
sealing (2) . If it is worn or damaged, replace
it.
Replacing steps of bearing 30203 and oil seal-

ing.
a. Clean the bearing round
b. Take off the oil sealing (1) with flat screw-
driver.
CAUTION:
Put a wooden block (2) at the outer side in
order to protect the outer side.
111
Take off bearing (3) with usually bearing tool.
The reverse step of “bearing and oil sealing
replacing step” is the mounting step of new
bearing and new oil sealing.
CAUTION:
Use a pressure tooling (4) which is matched
with outer diameter of bearing race (7) and
oil sealing.
WARNING:
Don’t strike the bearing inner race (5) and
roller. The pressure tooling (4) is only in
contact with outer race (7) .
(III) Mounting steps:

The reverse step of “disassembly” is the
mounting step, but the following points must
be paid attention to during the installation:
1. Lubricate the bearing (10, oil sealing (2)),
bush (3) , and rear arm joint bolt (4) .
Lubrication oil is Lithium base grease.
2. Mount the real wheel fork assy, rear wheel

fork bushing and rear arm joint bolt.
112
3. Fix the rear arm joint bolt (1) (left), rear
arm joint bolt (2) (right) and bush (3) .
Fixing steps:
a: Fix the left rear arm joint bolt (1) by stan-
dard torque.
Attached: Bolt torque value: 130Nm
b: Fix the right rear arm joint bolt (2) until it
makes contact with its bush (3) .
Attached: Bolt torque value: 6Nm
c: Fix right rear arm nut (4) by standard torque.
Attached: Rear arm nut torque: 130Nm
4. Check rear wheel fork free clearance.

Refer to step 8 in “disassembly”
5. Lubricate the upper and lower end surface of

rear shock absorber (see figure)
Use Lithium base grease as lubrication oil
6. Mount rear shock absorber

Upper nut torque of rear shock absorber: 50Nm
7. Mount slip pin
113
8. Mount the rear driving gear case sub-assem-
bly (1)
Refer to “Installation of rear driving gear case
sub-assembly and driving shaft” section of this
chapter.
9. Mount the rear wheel axle, rear brake hub,

right rear wheel, rear wheel joint plate and left
rear wheel.
Refer to “Installation of rear wheel/rear brake/
rear wheel axle” section of this chapter.
1
114
Chapter IV Electric Appliance
Section 1 Electric Assembly
1. CDI assembly 15. Battery
2. Rectifier 22. Main switch lock
5. Safety. starting relay 24. Neutral indicating assembly
6. Power off relay 26. Reverse indicator assembly
7. High voltage coil 28. High beam indicator assembly
11. Reverse switch 32. Cable
13. Neutral switch
115
Section 2 Inspect switch
(I) Inspect switch

Make certain the wire end is on the pocket mul-
timeter. If there are any problems replace the
switch
Pocket multimeter
• Turn the multimeter to “O”

• Turn the multimeter to “Ωx1” when inspecct-
ing the circuit
• Turn the switch on and off many times while
inspecting
The left figure indicates the wire position of

switch. The vertical line indicates switch posi-
tion. The first row indicates color of wire. “O-O”
indicates the circuit between the wire ends.
1 When the switch is turned to “OFF” the
black and black/white wire are on
2 When the switch is turned to “ON” the red
and brown wire are on.
116
(II) Inspect the switch circuit
Refer to “Inspect switch”. Inspect if the circuit between wire and wire end is on.
If the contact is poor or the circuit is off-repair or replace
1 Light switch 6 Reverse switch

2 Engine stop switch 7 Neutral switch
3 Starting switch 8 Protecting device
4 Main switch
5 Rear brake switch
117
Section 3 Check Lamp (headlight)
Check the lamp condition
1. Remove the lamp
CAUTION:
Pay attention to support the lamp. Do not pull the lead wire, otherwise it will brake.
WARNING:
When the headlight illuminates, remove your hand from the lamp, it will be very hot. Do not
touch until it has cooled down.
2. Check if the circuit of lamp terminal in on

• Adjust the choice knob of the pocket multime-
ter to “Ωx1”
• Connect the multimeter pen to correspond-
ing lamp wire end, First connect the multimeter
pen (+) to wire end (1) and pen (-) to wire end
(2) to check the circuit between (1) and (2) .
Then connect the multimeter pen (+) to wire end
1 pen (-) to wire end 3 to check the circuit be-
tween (1) and (3). If it displays “∞” one time,
replace the lamp.
3. Mount a checked lamp to check the lamp
seat. The same as checking the lamp, connect
the multimeter pen to related lamp seat wire and
check the circuit by the same method as above.
Color indication:
Br-brown O-orange
R-red Sb-sky blue
B-black G/Y-green/yellow
B/W-black/white W-white
Bl-blue G/Bl-green/blue
G-green Y/R- yellow/red
Y-yellow Y/G-yellow/gree
Br/W-brown/white B/Y-black/yellow
R/W-red/white
118
119
Section 4 Troubleshooting the
Ignition System failure
If the ignition system does not work (No spark)
Check:
1. Spark plug 6. Main switch
2. Ignition spark clearance 7. Resistence value of triggering coil
3. Resistence value of spark plug cap 8. Resistence value of charge coil
4. Resistence value of ignition coil 9. Circuit connection (entire ignition system)
5. Engine stop switch
•Remove the following parts before trouble-

shooting Power spark tester:
1) Cushion Igntion tester:
2) Front frame Pocket multimeter:
3) Front fender
• Check and repair with the following tools
1. Spark plug
• Check the spark plug condition Standard spark plug
• Check the spark plug type D8RTC
• Check the spark plug clearance
Refer to chapter 3 “Check the spark plug”
Spark plug clearance Incorrect

0.6~0.7mm (0.024~0.028in)
Correct Repair or replace spark plug
120
2. Ignition spark clearance
• Remove the spark plug cap
• Connect as shown in figure
(1) Spark testing instrument
(2) Spark plug cap
(3) Spark plug
• Turn the main switch to the “ON” position
• Check the ignition spark clearance
• Press the starting switch to start the engine.
Increase the spark clearance until the engine
can not be started.
Min spark clearance Conforming to specification

6.0mm (0.24in)
No spark Ignition system has no problem
3. Resistence of spark plug cap

• Remove the spark cap
• Connect the pocket multitester to spark plug
cap
• Inspect if resistence of spark plug conform to

specification
Resistence of spark plug cap: 20˚C
(68˚F) 4-7KΩ Not conforming to specification
Conforming to specification Replace spark plug cap
4. Resistence of ignition coil

• Remove the ignition coil connector from
cable
• Connect the pocket multimeter (Ωx1) to igni-
tion coil.
121
• Inspect if the resistence of primary coil con-
forms to specification
Primary coil resistence

At 20˚C(68˚F), 0.43~0.5Ω
• Connect the multitester (Ωx1K) to ignition
coil
• Inspect if the second coil resistence conforms FAIL

to specification
Secondary coil resistence Replace ignition coil

At 20˚C(68˚F), 4.6~7.6KΩ
PASS
5. Engine stop switch Abnormal

Refer to “Check switch”

Normal Replace left handlebar switch
6. Main switch
Refer to “Check switch”
Normal
7. Resistence value of triggering coil

• Remove CDI magneto connector from cable
• Connect the multitester (Ωx100) to wire end
of triggering coil
Multitester pen (+) - blue wire end (1)
Multitester pen (-) - black wire end (2)
• Inspect if the resistence of triggering coil con- FAIL

forms to specification
Resistence value of triggering coil Replace triggering coil

At 20˚C(68˚F), 180~220KΩ
122
8. Resistence value of charge coil
• Remove the corresponding connector of
charge coil from cable.
• Connect the multitester (Ωx100) to wire end
of charge oil
Multitester pen (+) - yellow/green wire end(1)
Multiteser pen (-) - red wire end (2)
Inspect if the resistence value is not at the FAIL

specification

Coil resistence value Replace charge coil
At 20˚C (68˚F), 450~550Ω
PASS
9. Wire connection
• Check the connection of entire igntion sys- Poor contact
tem
Refer to “Electric diagram”
Connect the ignitionsystem correcly
PASS
Replace CDI assembly
123
Section 5 Running of Starting circuit
The starting circuit of this vehicle including
starting motor, cut-off relay, rear brake switch
and neutral switch. If the main switch is in
position, the starting motor could be operated
only at the following conditions:
• Driving device is in the neutral postion

(neutral switch is closed)
OR
• Rear brake switch (rear switch is closed)
When the vehicle is in drive or reverse, and

the rear brake is in idle, then the cut-off relay
will prevent starting device from running. In
this state the cut-off relay is closed.
When drive device is in neutral
When rear brake is tensioned
(1) Battery
(2) Start motor
(3) Start relay
(4) Cut-off relay
(5) Start switch
(6) Rear brake switch
(7) Neutral switch
[A] To main switch
[B] From main switch
124
Section 6 Troubleshooting electric starting system
If starting motor does not work
• Check
1. Safety 6. Main switch
2. Battery 7. Neutral switch
3. Starting motor 8. Rear brake switch
4. Cut-off relay 9. Starting switch
5. Starting relay 10. Circuit connection
(entire startinf system)
• Remove the following parts before trouble-

shooting Pocket multimeter
1) Cushion
2) Front frame
3) Front fender
No electricty
1. Safety
Refer to “Check of switch”
Replace the safety
PASS
2. Battery
• Check the condition of the battery FAIL
Refer to “Check battery” chapter 3
Voltage of open circuit •Clean the battery terminal
At 20˚C (68˚F), 12.8V or much more • Recharge or replace the battery
PASS
WARNING:
• Jumper wire must have the same or bigger
3. Starting motor loading capability than battery wire, other-
• Connect the positive terminal (1) of the wise it will burn
battery to cable (2) of starting motor by • This kind of testing is similar to making
wire (3) electric spark, therefore, no inflammable air
• Inspect the running condition of starting or liquid should be kept near.
motor
125
No rotation
Repair or replace starting motor
Operation
4. Power off relay

• Remove relay from cable
• Connect portable multitester (Ωx1) and bat-
tery (12V) to end of wire on relay
Battery end (+) - red/white wire end (1)
Battery end (-) - green/yellow wire end (2)
Mutlitester pen (+) - red/white wire end (1)
Multitester pen (-) - blue/white wire end (3) The circuit is NOT on
• Inspect if the power off relay is on Replace power off relay
The circuit is on
5. Starting relay
• Remove the connector of the starting relay
from cable.
• Connect the multimeter (Ωx1) and battery
(12V) to end of wire on relay.
Battery end (+) - blue/white wire end (1)
Battery end (-) - black wire direction (2)
Mutlitester pen (+) - red wire end (3) The circuit is NOT on
Multitester pen (-) - black wire end (4)
Inspect if the starting relay is on Replace the starting off relay
The circuit is on
126
6. Main switch FAIL
Refer to “Check system”
Replace main switch
PASS
7. Neutral switch FAIL

Replace neutral switch
PASS
8. Rear brake switch FAIL

Replace rear brake switch
PASS
9. Starting switch FAIL

Replace left handlebar switch
PASS
10. Circuit connection FAIL

• Check the circuit connetion of entire starting
sytem Connect entire starting system correctly
Refer to “Electric diagram”
127
Section 7 Starting Motor
Sequence Name of Part QTY Remark

Starting motor disassembly
Starting motor wire 1 Remove the components
Starting motor connecting wire 1 according to sequence.
Starting motor o-ring 1/1
Same disassembly as above
1 Bracket 1 1
2 Washer/pad 1/1 Refer to “Starting motor”
3 Bracket 2 1 installation
4 Pad
5 Electrice brush/spring 2/2
6 Armature winding 1 Installing sequence in re-
7 Magnet steel 1 versed of disassembly
128
Section 8 Check Starting Motor
1. Check
• Reverser
If dirty clean with #600 sand paper
2. Measure
• Reverser diameter (a)
Does not meet specification-change the starting
motor
Outer diameter 28mm(1.10in)

(Wear range) 27mm(1.06in)
3. Measure
• Mica cut sheet (b)
Does not meet specification- scrape the mica with
square scraper
Mica cut sheet: 0.7mm(0.028in)
Scrape the mica with square scraper to get proper

dimension to fit the reverser.
4. Check
• Armature winding (insulation/power on)
Fail-replace starting motor
Check procedure of armature winding

• Connect the multitester to check power on (1)
and insulation (2) condition
• Measure the armature resistence
Inner resistence of armature winding

Power on condition check 1 :At
20˚C(68˚F), 0.004~0.005Ω
Insulation check: At 20˚C(68˚F),
exceed 1MΩ
• If the resistenance is incorrect, replace the mo-

tor.
129
5. Measure
• Length of brush
Out of specification-replace it
Length of brush:10mm(0.39in)
Range of wear: <6mm(0.14in)
6. Measure
• Brushing spring force
Fatigue/out of specifications-replace entire
device
Brushing spring
force:326~970g(3.2~3.8N)
7. Check
• Oil sealing
• Bushing
• O-ring
Worn or damaged-replace
Installation of starting motor:
1. Mount
• Magnetic steel
• Bracket
Make the matching mark (a) on the magnetic

steel is in align to that on the bracket.
130
Section 9 Battery will not hold charge
Check:
1. Safety 4. Stator coil
2. Battery 5. Coupling of circuit
3. Charging voltage (entire charging system)
• Remove parts before maintenance

1) Cushion Coil techometer
• Repair with special tools Engine tachometer
Pocket multimeter
1. Safety
Refer to “Inspection of switch”
No electricity
PASS
2. Battery Replace the safety

• Check the condition of battery
Refer to “Inspection of battery” in chapter 3
Voltage:
12.8V or more at 20˚C (68˚F) FAIL
PASS
3. Charging voltage • Clean the battery terminal

• Connect engine tachometer to the wire to • Recharge or replace battery
spark plug
• Connect pocket tester (DC 20V) to the battery
Pocket multimeter (+) - white terminal
Pocket multimeter (-) - white terminal
131
• Start engine and accelerate to 2000r/m
Charging Voltage: 14-15V at 2000r/m
Use fully charged battery Specification met
Out of specification No failure on charging circuit
4. Resistence value for stator coil

• Remove the lighting coil of AC magneto
• Connect pocket multimeter to stator coil
(Ωx1)
Pocket multimeter (+) - white terminal 1
Pocket multimeter (-) - white terminal 2
Pocket multimeter (+) - white terminal 3
Pocket multimeter (-) - white terminal 4
Measure the resistence value of stator coil Out of specification
At 20˚C (68˚F), 1.10-1.50Ω

Replace parts of stator coil
Specification met
Poor connection
5. Coupling of circuit
• Circuit the whole coupling of charging wire.
Refer to “Electric diagram” Connect the charging system correctly
Correct
Replace rectified adjuster
132
Section 10 Troubleshooting
If the headlight or taillight is out
Check:
1. Safety 4. Lamp switch
2. Battery 5. Coupling of wires
3. Main switch (entire lighing system)
• Remove the following parts before starting Pocket multimeter: P/N

troublingshooting maintenance YU-03112 90890-03112
1) Cushion
2) Front luggage carrier
3) Front covering parts
•Use special tools for troubleshooting
1. Safety
Refer to “Inspection of switch” No electricity
PASS
Replace fuse
2. Battery
• Check the condition of battery
Refer to “Inspection of battery” in chapter 3 FAIL
Voltage of open circuit
12.8V or more at 20˚C (68˚F)
• Clean terminal of battery
PASS • Recharge or replace the battery
3. Main switch FAIL

PASS Replace main switch
133
4. Change lamps FAIL
PASS If the lamp switch fails, replace the switch on

left handle
5. Coupling of wires
• Check the wire coupling for entire lighting
system
Refer to “Diagram” Poor coupling
PASS
Connect whole lighting system correctly
Check the returning condition of each lighting

system.
Refer to “Inspection of lighting system”.
134
Section 11 Inspection of Lighting System
(II) If headlight is out
No electricity
1. Bulb and socket
• Check if the bulb and socket are correct
Replace bulb and socket
PASS
2. Voltage
• Connect the pocket tester (DC 20V) to the
headlight
A B
Multimeter (+) - green terminal (1) or yel-

low terminal (2)
Multimeter (-) - black terminal (3)
[A] When switch is in “LOW” position
[B] When switch is in “HI” position
• Turn main switch to “ON” position

•Turn lamp switch to “LOW” or “HI” position Out of specification
• Check the voltage of green and yellow wires
in coupler of bulb socket
If there is failure on the cicuit from main
PASS switch to bulb socket coupler, repair it
No failure on this circuit
135
(II) If taillight is out
No electricity
1. Bulb and socket
• Check if the bulb and socket are correct
Replace bulb and socket
PASS
2. Voltage
• Connect the pocket tester (DC 20V) to the
taillight terminal
Multimeter (+) - blue terminal (1)
Multimeter (-) - black terminal (2)
• Turn main switch to “ON” position

•Turn lamp switch to “LOW” or “HI” position Out of specification
• Check the voltage of blue wire in coupler of
bulb socket (12V)
If there is failure on the cicuit from main
PASS switch to bulb socket coupler, repair it
136
Section 12 Troubleshooting
(I) If indicator lamp is out

Check:
1. Safety 4. Coupling of wires
2. Battery (whole signal system)
3. Front switch
• Remove the following parts before trouble-

shooting Picket multimeter
1) Cushion
2) Front frame
3) Front pedal
• Use specific tools for troublshooting
1. Safety No electricity
PASS Replace fuse
2. Battery FAIL
• Check the condition of the battery
Refer to “Inspection of battery” in chapter 3.
Voltage of open circuit • Clean battery terminal
12.8V or more at 20˚C (68˚F) • Recharge or replace the battery
PASS
137
3. Main switch FAIL
PASS Replace main switch
4. Coupling of wires
• Check the coupling of whole signal system Poor connection
wires
Refer to “Diagram of wires”
Connect it correctly
PASS
Check the condition of each signal system

Refer to “Inspection of signal system”
138
Section 13 Inspection of Signal System
(I) If the neutral indicator lamp is out No electricity
1. Bulb and socket

•Check if the bulb and socket circuit B are Replace bulb and socket
correct.
PASS
No electricity
2. Neutral switch
• Refer to “Inspection of switch” Replace neutral switch

PASS
3. Voltage
• Connect pocket tester (DC 20V) to the tail-
lamp terminal
Pocket tester (+) - brown terminal (2)
Pcoket tester (-) - sky blue terminal (1)

• Adjust main switch to “ON” position Out of specification
• Check voltage (12V)

Meet specification If there is failure on the circuit from the main
switch to the bulb socket, repair it.
139
(II) If the reverse indicator lamp is out No electricity
1.Bulb and socket

• Check if the bulb and socket are in good Replace bulb and socket
condition.
PASS No electricity
2. Reverse switch Replace reverse switch

• Refer to “Inspection of switch”
PASS
3. Voltage
• Connect pocket multimeter (DC 20V) to the
taillight terminal
Multimeter (+) - brown terminal (2)
Multimeter (-) - green/blue terminal (1)

Out of specification
• Adjust main switch “ON” position
• Check the volts (12V)

140
(III) If the HB indicator light is out No electricity
1. Bulb and socket

•Check if the bulb and socket circuit B are Replace bulb and socket
correct.
PASS
No electricity
2. High or low beam switch

• Refer to “Inspection of switch” Replace handlerbar switch (left)

PASS
3. Voltage
• Connect pocket tester (DC 20V) to the tail-
lamp terminal
Pocket tester (+) - brown terminal (1)
Pcoket tester (-) - yellow terminal (2)

• Adjust main switch to “ON” position Out of specification
• Check voltage (12V)

141
Chapter V Engine
Section I Disassembly of Engine
(I) Remove the engine from finished ATV
1. Remove
• Cushion
• Front luggage carrier
• Front bumper
• Front fender
• Rear luggage carrier
• Rear fender
The disassembling method refers to “Fender,
fuel tank disassembly” of chapter II.
2. Oil draining
Screw out oil draining screw plug. Drain off
the lubricating oil of the engine from the oil
draining hole.
3. Exhaust pipe and silencer
1) Remove
• Exhaust pipe (1)
2) Remove
• Silencer (2)
4. Carburetor and air intake pipe

2
Place the throttle cock grip on “OFF”
position, and remove:
1 • Throttle cable (1)
• Oil pipe (2)
• Hoop (3)
3
4 • Carburetor, carburetor seat and hook hitch
assy (4)
CAUTION:
Before disassembling, drain off the gasoline
of the carburetor float cabinet firstly. Wrap
the overflow pipe with cloth to absorb the
splashed gasoline. The gasoline is
inflammable. Pay attention not to splash
gasoline on a hot engine.
5. Starting motor
1) Remove
• Starting motor line (1)
142
2) Remove
• Connecting plate of starting motor (2)
• Starting motor (3)
6. Rear brake cable and footrest

1) Remove
• Adjusting nut (1)
• Pin (2)
• Spring (3)
• Rear brake cable and tension rod (4)
(Remove from rear brake arm)
2) Remove
• Left footrest (1)
• Shift pedal (2)
• Supporting rod of front fender (3)
3) Remove
• Right footrest (1)
• Spring (2)
7. Wire and hose

1) Remove
• Spark plug cap
• CDI magneto wire (1)
• Reverse switch wire (2)
• Neutral switch wire (3)
• Air pipe (4)
143
8. Rear diving unit and rocker (rear wheel fork
and shock absorber)
1) Remove
• Remove the air (1) (gear case of last grade
and rear brake hub) from the clip on the frame
• Fix the front wheel and raise up the rear wheel
(place the supporter on the frame)
2) Remove
• Bolt (1) (Upper end of the rear shock
absorber)
3) Remove
• Hoop (1) (rubber hood)
• Dustproof cap of rear arm shaft (2)
• Rear arm nut (3) (right)
• Connecting screw column of rear arm (4)
(right)
• Connecting bolt of rear arm (5) (left)
4) Remove
• Rear wheel driving unit/rocker assy
CAUTION:
• When disassembling the rocker assy, support
the shock absorber to avoid dropping down.
• When removing the rocker from the rubber
hood, the driving shaft may drop down. Pay
attention not to lose components.
9. Disassembly of engine
1) Remove
• Bolt (1) (top supporting of engine)
• Bolt (2) (bottom supporting of engine)
• Bolt (3) (rear upper supporting of engine)
• Bolt (4) (rear lower supporting of engine)
2) Remove the engine unit from right side
144
(II) Disassembly of engine
1. Remove
• Hand starting unit (1)
2. Remove
• Screw (1) (2) (3)
• Reverse controlling bar unit (4)
• Washer
Pay attention not to lose washer
3. Remove
1
• Sprocket cabinet cover (1)
4. Remove
• Spark plug (1)
2 • Upper valve cap (intake) (2)
3 • Lower valve cap (exhaust) (3)
145
2
1
5. Remove
• Chain tensioner (2)
CAUTION:
Before removing the chain tensioner, loosen the
screw (1) firstly.
6. Remove
• Bolt (1)
• Timing sprocket (2)
CAUTION:
1 • When loosening the bolt, it is needed to fix
2 the hand starting ratchet (4)
• Use a wire to hold chain so the timing chain
4 does not drop into crankcase.
7. Remove
• All the bolts and nut on the cylinder cover.
CAUTION:
Loosen every bolt and nut by ¼ circle, then
disassemble
• Loosen them from big to small according to
the numbers marked on the cylinder cover.
8. Remove
• Cylinder cover unit (1)
• Cylinder cover pad (2)
• Location pin (3)
• Oil seal (4)
• Lower guide plate (5) (exhaust side)
146
2
9. Remove
• Screw (1) (cylinder body)
• Cylinder body assy (2)
4 5 • Cylinder body pad (3)
1 3 • O-ring (5)
10. Remove
• Circlip (1)
2 3 • Piston pin (2)
• Piston unit (3)
CAUTION:
• Before disassembling the piston pin circlip,
cover the crankcase with a clean cloth to avoid
the circlip suddenly dropping into the case.
• Before disassembling the piston pin,
remove the burr of circlip groove and piston pin.
1
If it is still difficult to remove the piston pin,
remove it with drawing aid.
2 • Do not remove the piston pin with wood
hammer.
11. Remove
• Starting ratchet (1)
CAUTION:
Fix the starting ratchet with special tool, and
loosen the bolt on the starting ratchet.
12. Remove
• Left crankcase cover (2)
147
2
13. Remove
• Gasket of left crankcase cover (1)
• Intermediate gear shaft (3)
1 • Washer (4)
2 • Duplex intermediate gear (5)
(starting motor)
4
5
14. Remove
• Magneto (1)
CAUTION:
Disassemble the magneto rotator with special
tool.
1
15. Remove
• Semicircle key (1)
2 • Electric starting gear assy (2)
• Washer (3)
1
2
16. Remove
• Upper guide plate (1) (air intake side)
• Timing chain (2)
17. Remove
1
• 4 screws (1) (rear cover)
148
18. Remove
• Screw (1) (rear driving cover)
• Rear driving cover (2)
19. Remove
• Output shaft unit (1)
20. Remove
• Output shaft assy (1)
• Bearing (2)
1 • Washer (3)
2 3 • Forward gear (4)
4
2 21. Remove
5 4 • Fine filter cover of engine oil (1)
• Fine filter of engine oil (2)
• O-ring (3)
1 • Right crankcase cover (4)
• Gasket of right crankcase cover (6)
3
6
22. Remove
1 • Compressing spring (1)
• Upper cam plate assy (2)
2 • Steel ball bracket assy (3)
• Lower cam plate (4)
3
149
23. Remove
• Main clutch nut (2)
CAUTION:
Loosen the locking pad (1) before removing
the nut, and fix the main clutch shoe (3), then
remove the nut.
24. Remove
• Locking pad (1)
5 3 1 • Main clutch shoe unit (2)
4 2
• Washer (3)
• Main clutch housing unit (4)
1 • Washer (5)
CAUTION:
The two grooves (1) on auxiliary clutch
when installing the main drive gear (2) .
So when removing the main clutch unit, you
must aim any one of the two grooves at the
main driving gear firstly.
2
25. Remove:
• Nut (1)
2 • Output gear (2)
CAUTION:
1 • Slap flat the self-locking part of the nut
• Place the engine to 1st gear to operate
• When loosening the nut (output gear), must
fix the auxiliary hub assy (4) with special
tool.
4
26. Remove
3
• Clutch post rod (1)
2 1 • Bearing (2)
• Compressing cover (3)
• Clutch spring (4)
150
27. Remove
• Nut (2) (clutch hub assy)
CAUTION:
Slap the locking washer (1) flat before
removing the nut. Must fix the clutch hub assy
(3) with special tool when screwing the nut.
2 6 28. Remove:
• Locking washer (1)
• Clutch hub assy (2)
• Friction washer (3)
1 4 5 7 • Clutch piece (4)
3 • Compressing plate (5)
• Spline washer (6)
• Clutch gear assy (7)
1
29. Remove:
• Right connecting case (1)
• Gasket of right connecting case (3)
3
1
30. Remove
• Oil pump unit (1)
• Pad
151
31. Remove:
• Shift lever unit (1)
• Washer (2)
• Limit torsion spring (3)
• Limit lever unit (4)
CAUTION:
Pull the limit lever unit and shift lever unit
along the arrow direction, then you can remove
them from the star-shaped gear.
32. Remove
• Star-shaped gear (1) (on shift cam)
CAUTION:
• The location pin is easy to drop down. Pay
attention not to lose it.
1
33. Remove
• Nut (2) (balance shaft gear)
CAUTION:
• Slap the locking washer (1) flat before
removing the nut
• Put a cloth (3) folded thickly between the
balance gear (4) and balance shaft driving
gear (5) for seizing to prevent the rotation of
the two gears when removing the nut.
5 4 2 1 3
152
3 1
34. Remove
2
• Balance shaft gear (2)
• Flat key (3)
35. Remove
•All the closing case screw.
CAUTION:
Loosen and remove every screw ¼ circle with
phillipshead screwdriver.
36. Remove
• Left crankcase (1)
CAUTION:
• Disassemble the left crankcase with crankcase
separator.
• Tighten up the screw of separator, and must
keep the separator body parallel with crankcase
face. If necessary, screw the screw in reverse
direction to adjust the separator body level.
• When applying force to case body
separator, knock the front supporter of engine,
shift shaft and balance shaft alternately and
continually.
37. Remove
• Long fork shaft (1)
• Short fork shaft (2)
7 • Shift cam shaft (3)
• Fork 3 (4)
• Fork 2 (5)
1 • Fork 1 (6)
CAUTION:
4 Pay attention to position of every part,
6
5 especially the position and direction of every
2 fork.
3
153
38. Remove
• Main shaft assy and driving shaft unit (1)
2 • Washer (2) (driving shaft unit)
1
39. Remove
• Circlip (1)
• Balance shaft driving gear (2)
• Crankshaft (3)
• Semicircle key (4)
CAUTION:
•Press out the crankshaft with pressure device.
40. Remove
• Stop plate (2)
2
• Pressing plate (3)
CAUTION:
3 Knock the locking part (1) of stop plate flat (1)
before removing the stop plate.
1
41. Remove
• Distribution cam shaft (1)
CAUTION:
• Screw in the bolt (2) 10mm to cam shaft
screw hole to draw out the distribution cam
shaft.
154
42. Remove
• Rocker shaft (1)
• Air intake and exhaust rocker (2)
CAUTION:
• Screw the slip hammer assy into rocker shaft,
then pull out the rocker.
43. Remove
• Valve lock clip (1)
CAUTION:
• Disassemble the valve lock clip with valve
spring compressing device.
44. Remove
• Valve spring cover (1)
• Valve outer spring (2)
• Valve inner spring (3)
• Valve (4)
• Oil seal of valve rod (5)
• Spring seat of valve (6)
CAUTION:
• Pay attention to position of each component
for installation to original position.
45. Remove
• Starting lever cap (1)
2
• Starting lever (2)
CAUTION:
• Before untying the knot (3) , pull out the
rope long enough to tie a knot to avoid to be
1 3 pulled into the cap
46. Remove
• Screw pin (1)
3 • Guide plate (2)
• Compressing spring (3)
6
• Circlip (4)
• Driving jaw (5)
5 • Torsion spring (6)
2
4
1
155
4 47. Remove
3 • Coiling spring (1)
•Coiling spring backboard (2)
• Driving plate assy (3)
• Left side cover assy (4)
1
48. Remove
2
• Pressure plate (1)
CAUTION:
• Remove the screw with impact
screwdriver
49. Remove
• Bearing (1)
• Washer (2)
50. Remove
• Circlip (1)
• Rear joint (2)
CAUTION:
The disassembling method of rear joint is as
follows:
• Pull and press the driving fork downward
• Use a sleeve with the proper diameter below
the front joint, and press the bearing into the
sleeve as shown in figure.
• Repeat the procedure to corresponding bearing
• Remove the driving fork and rear joint (2)
156
51. Remove
• Nut
• Washer
• Front joint
CAUTION:
Clamp the front joint with gymbal, then loosen
the nut.
2 1
52. Remove
• Output shaft (1)
• Connecting jaw (2)
1
53. Remove
• Inner-hexagon screw bushing (1)
• Bearing (3)
• Washer
3
CAUTION:
Use inner-hexagon screw bushing wrench
54. Remove
• Irregular left handed nut
• Reverse gear
• Washer
CAUTION:
• The irregular left handed nut is left
handed screw thread. Rotate the nut clockwise
when loosening it.
• Use irregular nut wrench
157
55. Remove
• Nut
• Bearing
CAUTION:
Use inner-hexagon screw bushing wrench
56. Remove
4 • Reverse fork shaft (1)
• Reverse fork (2)
• Steel ball (3)
3 2 CAUTION:
When disassembling the reverse fork shaft, the
steel ball is easy to roll out. Make sure not to
lose it.
57. Remove
2 • Circlip (1)
3 • Reverse controlling rod (2)
• Reverse controlling rod (3)
1 • Reverse controlling shaft (4)
158
Section 2 Inspection and Maintenance of Engine
1. Cylinder cover
1) Clean
• Carbon deposit
Use circular scraper (1)
CAUTION:
Please do not use sharp tool to avoid scraping
• Nut of spark plug
• Valve seat ring
• Bottom face of cylinder
2) Measure
• Flatness of cylinder cover bottom face
Recorrect the bottom face or replace if
unqualified
Flatness of cylinder bottom face is less than
0.10mm (0.004in)
2. Intake and exhaust valve

1) Check
• Valve surface
• Valve rod end
Replace it if it is worn, exfoliation corroded or
unqualified
Min thickness (working limit)
(a) 0.8mm (0.031in)
Slope
(b) 0.5mm(0.020in)
Min length (working limit)
(c) 4.0mm(0.157in)
2) Check
• Valve rod end (1)
Replace the valve, valve guide pipe and valve
rod oil seal if it is mushroom-shaped or its
diameter is bigger than other rod diameter.
CAUTION:
Remove the deformation of valve rod end (1)
by polishing the valve end with oilstone.
159
3) Measure
• Rod part run-out of valve rod
Replace it if unqualified
The rod part run-out of valve rod is less than
0.03mm (0.0012in)
4) Measure
• Clearance between valve rod and valve guide
pipe
Clearance=[A]-[B]
Inner diameter of valve guide pipe [A]
Valve rod diameter [B]
Replace the valve or valve guide pipe if
unqualified.
Measure with micrometer and inner diameter
gauge (1)
Clearance between Valve Limit
rod and valve Guide pipe
Intake 0.010~0.037mm 0.08mm
valve (0.0004~0.0015in) (0.0031in)
Exhaust 0.025~0.052mm 0.10mm
valve (0.0010~0.0020in) (0.0039in)
CAUTION:
• When replacing the valve, replace the valve
guide pipe and valve rod oil seal
together.
3. Valve guide pipe

1) Check
• Valve guide pipe
Replace it if it is worn or the oil leaks into the
cylinder
2) Disassemble
• Valve guide pipe
Use valve guide pipe disassembling device (1)
CAUTION:
Place the cylinder cover in the furnace to heat
to 100°C (212F) for the convenience of
disassembly and installation of valve guide
pipe. And it can ensure correct installing
clearance.
160
3) Install
• Circlip (1)
• Valve guide pipe (2)
Use the installing and disassembling device of
valve guide pipe
4) Ream the inner diameter of valve guide pipe

to get proper valve rod clearance.
CAUTION:
Regrind the valve race after installing valve
guide pipe
4. Valve race
1) Clean
• Carbon deposit (valve race and valve face)
2) Check
• Valve seat ring
Regrind the valve race if it is exfoliation
corroded.
3) Measure
• Contacting width of valve and valve race.
Regrind the valve race if unqualified
• Paint red lead powder on the valve fit
pyramidal force of valve race
• Place the valve into the cylinder cove
161
• Press the valve on the valve race through
valve guide pipe to leave clear trace on the
valve.
• Remove the valve from cylinder cover
• When the valve contacts with valve race,
the reddle is marked on the valve from valve
race. Then can measure the contacting width of
valve and valve race.
Contacting width of Limit
Valve and valve race
Intake 0.9~1.1mm 1.6mm
Exhaust (0.035~0.043mm) (.063in)
• If the contacting width is too wide, too

narrow or not in the middle, it is necessary to
recorrect valve race.
4) Correct
• Valve race
Use reamers of 30°, 45°, and 60°
CAUTION:
Rotate the reamer with even force to avoid
cutting mark. And remove surplus part to get
ideal valve race.
Reamer used on each part

Part Reamer
A 30°
B 45°
C 60°
Valve race correcting procedure
The contacting part [A] is in the middle
of valve face. But the contacting width is too
wide.
Reamer assy of valve race Reamer
Operate Reamer 30° Reduce the
lightly Reamer 60° contacting width to 1.0mm
(0.04in)
162
The contacting part [B] is in the middle of valve
face. But the width is too narrow
Reamer assy of valve rale Result
USE Reamer 45˚ Get unified contacting width
1.0mm (0.04in)
The contacting part [C] is too narrow, and on
the upper edge of valve face
Reamer 35˚ Make the contacting part in
USE middle and get the
Reamer 45˚ contacting width 1.0mm
(0.04in)
[D] The contacting part is too narrow and on
bottom of valve.
USE Use reamer of 60˚ first Make the contracting part in
Reamer of 45˚ the middle and increase the
width
5) Grind
• Valve face
• Valve race
CAUTION:
Should grind the valve face and valve race after
correcting the valve race or replacing valve and
valve guide pipe.
Grinding procedure of valve face

• Paint a layer of grinding powder (1)
CAUTION:
Ensure no grinding powder enters the clearance
between the valve and valve guage.
163
• Paint molybdenum disulfide oil on the valve
rod part.
• Place the valve in to the cylinder cover
• Rotate the valve to grind in with seat fully on
the valve face, then clean the dirt
• Repeat procedure until the contacting width
of valve face and valve seat
CAUTION:
In order to get the best grinding quality, you
may slap the valve lightly when rotating the
valve forward and backward. Be sure to clean
all the dirt on the valve face and valve race
after every grinding.
6) Measure the contacting width again after
correcting and grinding
• Measure the contacting width and
position of valve and valve race again
according to method explained in 3)
• If the contacting width and position do not
conform to specification yet, recorrect and
grind the valve race
5. Valve spring
1) Measure
• If the free length (a) (inner and outer spring)
of valve spring is unqualified, replace it.
Free length of valve spring

Inner spring Outer spring
(intake/exhaust) (intake/exhaust)
35.5mm(1.4 in) 37.2mm(1.46in)
164
2) Measure
• Installing pressure of valve spring
If unqualified, replace the inner and outer
spring totally.
Inner spring When it is 30.5mm (1.2 in), the pressure
(intake/exhaust) 8.4~10.2kg(18.5~22.5 lbs)
Outer spring When it is 32.0mm (1.26 in), the pres-
(intake/exhaust) sure is 16.6~20.4kg (36.6~45.0lbs)
6. Seal check of valve

1) Installation of valve
Lubricate
• Valve rod part (1)
• Valve rod oil seal (2)
Install
• Valve spring seat (1) (lower part)
• Oil seal of valve rod (2)
• Valve (3)
• Inner spring (4) of valve
• Outer spring (5) of valve
• Spring cover (6) of valve
• Locking clip (7) of valve
165
CAUTION:
Must install the long pitch end of all valve
spring upward
2) Check the valve seal

If there is leakage on the valve face, repair
again and regrind or replace the valve and
regrind.
Inspecting procedure of valve seal
• Inject the clean solvent (1) into intake way
and exhaust way respectively.
• Check the valve seal. There should be no
leakage on valve race (2)
3) Regrinding procedure
• Remove components of the cylinder cover
again
• Grind repeatedly with fine grinding
powder
• Clean totally
• Reassemble and check the leakage with
solvent
• Repeat above procedures until getting ideal
seal
7. Distribution cam
1) Check
• Distribution cam
Replace if there is cave, scratch, or
discoloration
2) Measure
• Distribution cam (use micrometer)
Unqualified→ Replace
166
Limit value “A” of Limit value“B”
distribution cam of distribution cam
Intake 36.437mm 30.031mm
cam (1.435 in) (1.182 in)
Exhaust 36.482mm 30.152mm
cam (1.436 in) (1.187 in)
8. Valve rocker and rocker shaft

1) Check
• Rocker hole
• Contacting surface with distribution cam
If ever worn, replace it
2) Check
• Rocker shaft surface
Replace or check lubrication if there are dents,
scratches, or discoloration
3) Measure
• Measure inner diameter of valve rocker hole
Inner diameter of rocker hole:12.000~12.018mm

(0.4724~0.4731 in)
• Measure the outer diameter (b) of rocker

shaft
Outer diameter of rocker

11.985~11.991mm (0.4718~0.4721 in)
167
• Subtract the outer diameter of rocker shaft
from inner diameter of valve rocker hole to
calculate clearance.
Clearance between rocker hole and shaft= (a) - (b)

Inner diameter of valve rocker hole (a)
Outer diameter of rocker shaft (b)
Replace a set if unqualified
Clearance between rocker shaft and hole:

0.009~0.037mm (0.0004~0.0031 in)
Limit:
0.037mm (0.0015 in)
9. Timing chain
Check
• Timing chain
Replace it if the chain is stretched, or not
flexible or broken.
10. Timing sprocket and crankshaft sprocket

Check
• Timing chain
• Crankshaft sprocket (on crankshaft)
If there is wear and damage, replace the
sprocket and chain totally
11. Guide plate

1) Check
• Lower guide plate (1) (exhaust side)
• Upper guide plate (2) (intake side)
Replace it if it is worn or damaged
12. Chain tensioner

1) Check
• Pushing rod of chain tensioner (1)
• Washer (2)
Replace it if it is worn or damaged
168
2) Check
Flexibility of chain tensioner
Checking procedure
• Press the tensioner pushing rod lightly with
finger, and rotate it clockwise with thin
screwdriver to screw it in.
• Press the pushing rod lightly with finger and
remove screwdriver, then the pushing rod screws
out stably
• If the operation is unflexible, replace chain
tensioner.
13. Valve cover and sprocket cabinet cover
1) Check
• Valve cover (upper valve cover (1) and lower
valve cover (2))
• Sprocket cabinet cover (3)
• O-ring (4)
Replace it if there is cracks and damage
14. Cylinder and piston
1) Check
• Carbon deposit (from piston top to ring slot)
2) Check
• Surface of cylinder and piston
Rebore cylinder or replace cylinder and piston if
there is vertical scratch
3) Measure
• Clearance between cylinder and piston
Measuring method is as follows
• Measure the inner diameter “C” of cylinder with
inner diameter gauge (a) is the measuring
position (a) is 40mm(1.6 in) far away from
cylinder top
Remark:
Measure twice the inner diameter “C” of cylinder
from two directions vertical with each other in the
same face. The find out average value.
Standard value wear limit

value
Inner diameter 70.97-71.02mm 71.10mm
“C” of cylinder (2.794~2.796in) (2.799in)
x+r
C=
2
169
If out of specification, rebore or replace the
cylinder and piston (replace in a set)
• Measure the diameter “P” of piston lower part
with micrometer, (b) is the measuring position
(b) is 4mm away from piston bottom (0.16 in)
Piston lower part diameter “P”

Standard 70.92~70.97mm (2.792~2.794in)
If out of specification, replace the piston and
piston ring as a set at the same time.
•Calculate the mating cylinder clearance with

the following formulas
Mating cylinder clearance=“C”-“P”
Inner diameter of cylinder “C”
Piston lower part diameter “P”
Mating cylinder clearance: 0.04~0.06mm

(0.0016~0.0024 in)
Limit:
0.15mm (0.0059 in)
•If out of specification, rebore or replace the
cylinder, and replace the piston and piston ring
as a set at the same time.
15. Piston ring and piston pin

Piston ring
1) Measure
• Clearance between piston ring and ring groove
• Use feeler gauge (1)
If out of specification, replace piston and a set
of rings
CAUTION:
First clean the carbon deposits inside the piston
ring and ring groove, followed by measuring the
clearance between piston ring and ring groove.
170
Clearance between piston ring and ring groove
Standard Limit
First 0.03~0.07mm 0.12mm
Ring (0.001~0.003 in) (0.005in)
Second 0.02~0.06mm 0.12mm

Ring (0.008~0.024in) (0.005in)
2) Measurement:
• Closed clearance of piston ring
• Install the piston ring to the cylinder, pull
forward about 20mm (0.8in), then pull the pis-
ton ring with piston top to make it vertical with
cylinder wall.
• Use feeler gauge (1)
If out of specification replace a set of ring
Closed clearance
Standard Limit
Piston 0.15~0.30mm 0.4mm
ring 1 (0.006~0.012in) (0.016in)
Piston 0.15~0.30mm 0.4mm
ring 2 (0.006~0.012in) (0.016in)
Oil ring 0.2~0.7mm
(0.008~0.028in)
CAUTON:
You cannot measure the closed clearance of
scraping plate of oil ring assy, if the clearance
of scraping plate is bigger, replace a set of oil
ring
171
Piston pin
1) Inspection
• If the color is changed, or indent is found,
replace piston pin, then inspect to
Lubrication system.
2) Measurement:
• Outer diameter (a) (piston pin)
Out of specification, replace it
Outer diameter (piston pin): 15.991~16.00mm

(0.6296~0.6299 in)
3) Measurement:
• Inner diameter (b) of piston pin
Out of specification, replace it
Inner Diameter of piston pin hole
16.002~16.013mm(0.63~0.6304in)
4) Measurement:
• Clearance between piston pin and piston pin
hole
Clearance between piston pin and piston pin

hole= (b) - (a)
Inner diameter of piston pin hole (b)
Outer diameter of piston pin (a)
Clearance between piston pin and piston pin

hole
0.002~0.022mm(0.0001~0.0009in)
Limit 0.07mm(0.003 in)
172
16. Crankshaft
1) Measurement
• Dimension A of crankshaft assy
If out of specification replace it or repair it
Dimension of crankshaft assy
55.95-56.00mm(2.203-2.205 in)
• Runout C
If out of specification, replace it or repair it
Runout Limit
C1: 0.03mm (0.0012 in)
C2: 0.06mm (0.0024 in)
• Side clearance D of big head of

connecting rod
Max side clearance
0.35mm-0.65mm(0.014- 0.026 in)
• Runout E of big head of connecting rod

Runout amount of big head of connecting rod
0.010-0.025mm(0.0004-0.0010 in)
• Clearance F of small end

Clearance of small end:
0.8mm-1.0mm(0.032-0.040 in)
Limit: 2.0mm(0.08 in)
2) Inspection:
• Crankshaft bearing
If there is some noise or it is not active in

operation or overbig clearance, replace it.
173
Main points of reassembly of crankshaft:
The oil traces on crankshaft (1) and crank pin
(2) should be connected correctly, the malposi-
tion of two oil traces should be within 1mm (0.04
in)
17. Driving gear of balance shaft and gear of
balance shaft
Inspection:
• Driving gear of balance shaft (1)
• Gear of balance shaft (2)
If worn or damaged, replace two gears at the
same time.
18. Primary gear and electric starting gear

1) Inspection
• Main driving gear (1)
• Clutch gear assy (2)
If scraped, worn, damaged, replace it
If the noise is overhigh during operation replace
two gears at the same time.
2) Inspection
• Duplex Intermediate gear (1)
• Intermediate gear axle (2)
If scraped, worn, or damaged, replace it.
• Electric starting gear assy (3)
• Contact surface of overrunning clutch (4)
• Bimetallic bushing (5)
If scraped, worn, or damaged, replace duplex
intermediate gear, intermediate gear axle, electric
starting gear assy as a set.
3) Inspection of overrunning:
• Install the electric starting big gear to the run-
ning clutch and fasten the running clutch
• Turn the starting big gear counterclockwise in
direction A as shown on the drawing, the
starting big gear will drive the overrunning
clutch, if out, it indicates the running clutch is out
of operation, replace it.
• Turn the electric starting big gear clockwise in
direction B as shown or the drawing, the starting
big gear will run in idle speed if not, it indicates
that the overrunning clutch is out of operation,
replace it.
174
• Inspection
• Bolt (1) (overrunning clutch)
• Loosen then replace with new one and
apply fastening agent
CAUTION:
Fastening torgue of bolt (overrunning clutch) is
30Nm(3.0m·kg22yd·pound)
Apply the fastening agent on the bolt
19. Main clutch

Clutch case
1) Inspection:
• Clutch case assy (1) (inner surface)
Abrasion, wear, or damaged, replace it
• Single direction (2) (inside the clutch case
assy)
If scraped, worn, or damaged, replace it
2) Inspection the operation of single direction
clutch
Make sure that the inner spline cover (1) can
only rotate clockwise in direction A, if the inner
spline cover functions unsmoothly or rotates.
Counterclockwise, replace the inner spline
cover (1) and main clutch case assy (2) at
the same time.
Main clutch shoe

1) Inspection
• Clutch shoe
If abrasion is found, replace it
Wear limit of main clutch shoe: (a)

1.5mm (0.06 in)
2) Measurement
• Thickness of main clutch shoe
If out of specification, replace it.
20. Vice clutch
Clutch case
Inspection
• Split groove of clutch case
If there is pressing mark, worn, or damaged on
the groove face, remove the burr, or replace it.
175
Clutch hub assy and pressing plate
Inspection
• Tooth groove on the clutch hub (1)
• Tooth groove on the pressing plate (2)
If there is scraped, worn, or damaged, replace
the clutch hub or pressing plate.
Friction plate
1) Inspection
• Friction plate (1)
If damaged, worn replace a set of friction plates
2) Measurement:
• Friction plate thickness
• Measure four positions
If out of specification, replace a set of friction
plate.
Wear Limit:
2.8mm (0.110 in)
Clutch plate
Measurement:
• Planeness of clutch plate
Use flat plate and feeler gauge (1)
Planeness Limit:
0.2mm (0.008 in)
Clutch post rod and earing

Inspection:
• Bearing (1) (Post rod)
If rough in surface or jammed in rotation, re-
place it
• Pressing cover (3)
176
Clutch spring
1) Inspection
• Clutch spring
If worn or damaged, replace it
2) Measurement
• Freelength of clutch spring (a)
If out of specification replace set of springs
Min Limit of clutch spring length

32.9mm (1.30 in)
Clutch operating rocker assy

Inspection
• Operation rocker assy (1)
• Adjusting screw (2)
• O-ring (3)
If cracks, wear, or damage, replace it.
21. Oil Pump

1) Measurement
• Clearance a between oil pump and outer
rotor (2) with feeler gauge
If out of specification, replace oil pump
Clearance Limit
0.09mm (0.004 in)
2) Measurement
• Side clearance between outer rotor (1) and
inner rotor (2)
If out of specification, replace oil pump
Side clearance limit
0.2mm (0.008 in)
3) Inspection
• Gear of driving oil pump on driving gear of
balance shaft
• Oil pump gear assy (2)
If worn, scraped, or damaged, replace it
177
22. Shift fork and fork shaft
1) Inspection:
• Fork
Connecting surface to gear and shift cam
If worn, scraped, bent, or damaged, replace it.
2) Inspection
• Fork shaft
(Roll the fork shaft on a plane)
If bent replace it.
WARNING:
Never attempt to straighten a bent fork shaft
3) Inspection
• Movement of fork on the fork shaft (1)
If not smooth in operation, replace fork or fork
shaft
23. Shift cam

Inspection
• Groove of shift cam (1)
If worn, damaged, or scraped, replace it.
• Start wheel (2)
If damaged or worn, replace it
• Needle bearing (3)
If rough on surface or not active in operation,
replace it.
24. Main/vice shaft and gear

1) Measurement
• Runout of shaft (1) (Main/vice shaft)
Measure with bracket and runout meter
Runout Limit
0.08mm(0.0031 in)
178
2) Inspection
• Gear (refer to shift mechanism and
output gear (2))
• Engaging jaw position
If cracks, damage, wear, replace it.
CAUTION:
When replacing the output gear, be sure to
adjust the adjusting washer of output gear.
3) Inspection
• Movement of gear (shift mechanism)
If not smooth in operation, replace.
25. Shift shaft and limit lever

1) Inspection
• Shift shaft (1)
• Hook plate (2)
If bent, worn, damaged, replace it.
2) Inspection:
• Limit lever (3)
If not smooth in operation, replace it
If bent or damaged, replace it.
3) Inspection
• Shift torsion spring (4) (on the shift shaft)
• Tension spring (5) (Hook plate)
• Limit torsion spring (6) (On Limit
Lever)
179
27. Bearing and oil seal
1) Inspection
• Bearing
If jammed in operation or there are pits and
damage, replace it.
2) Inspection
• Oil seal
If damaged or worn replace it.
28. Circlip and washer

Inspection:
• Circlip
• Washer
If damaged, loose, or bent, replace it.
29. Crankcase
1) Clean crankcase with soft agent completely
2) Clean all sealing surfaces and closing
surfaces completely
3) Inspection:
• Crankcase
Cracks/damage, replace it.
• Oil trace
If jammed, blow with compressed air.
CAUTION:
When replacing the crankcase be sure to
readjust the output gear washer.
180
30. Hand operated mechanism
1) Inspection
• Inspection (1)
If cracked, bent, or damaged, replace it.
• Driving jaw (2)
• Compressing Spring (3)
• Torsion spring (4) (Driving jaw position)
Wear/cracks/damage, replace it.
2) Inspection:
• Rolling spring (1) (Starting)
• Tension wire (2)
• Driving plate assy (3)
Cracks/damage, replace it.
31. Output Mechanism

1) Inspection
• All gears (1)
If pressing mark/abrasion/wear is found,
replace it.
• Connecting jaw (2)
If pressing mark/abrasion/wear is found,
replace it
• Driving shaft (3)
• Output shaft (4)
If damaged or bent, replace it.
CAUTION:
When replacing any gear or output shaft be
sure to readjust core gear washer, refer to
“Selection of adjusting washer” section.
2) Inspection
• Bearing (5)
If pressing mark or abrasion is found, replace
it.
3) Inspection
• Front joint and rear joint (1)
• Driving for (2)
• Needle bearing (3)
181
4) Inspection
• Reverse fork (1)
If wear/abrasion/bend/damage is found on the
surface connecting with connecting jaw and
reverse operating shaft, replace it.
If the elasticity is lost, or worn, replace it
• Steel ball (3)
If wear, damage, or scratch marks are found,
replace it.
5) Inspection:
• Reverse fork shaft
Roll the reverse fork shaft on the flat surface, if
bent, replace it.
CAUTION:
Never straighten a bent shaft and reuse it
6) Inspection
• Flexibility of fork movement
Install the reverse fork 1 to fork shaft, if not
active or smooth in operation, replace fork and
fork shaft.
7) Inspection
• Reverse control lever (1)
• Operating plate (2)
• Reverse operating shaft (3)
If bends, cracks, or damage is found, replace it.
8) Inspection
• Rear cover (1)
If cracks or damage on the position connecting
with left crankcase, rear driving cover is found,
replace the rear cover.
• O-ring (2)
If damaged or deformed, replace it
CAUTION:
When replacing the rear cover, be sure to read-
just the gear core washer, refer to “Selection of
adjusting washer” section.
182
Section 3 Assembly and Adjustment of Engine
(I) Closing assembly of left & right crankcase
Crank/balance shaft 5. Needle bearing

1. Crank sprocket 6. Connecting lever
2. Bearing 6305 7. Right crank assy
3. Left crank 8. Bearing 6306/C4
4. Crank pin 9. Bearing 6304
10. Balance shaft
183
Shift gear mechanism
1. Bearing 6202 15. Long fork shaft

2. Washer 16. Needle bearing
3. 1st gear of driven gear assy 17. Shift cam shaft assy
4. 5th gear of driven gear 18. Fork 3
5. Circlip 19. Short fork shaft
6. Inner spline washer 20. Bearing 6204
7. 3rd gear of driven gear 21. Spindle assy
8. 4th gear of driver gear 22. 5th gear of driving gear
9. Circlip 26 23. Spline pad
10. Inner spline washer 24. Circlip
11. 2nd gear of driven gear 25. 3rd gear of driving gear
12. Driving shaft assy 26. 4th gear of driving gear
13. Fork 2 27. 2nd gear of driving gear
14. Fork 1 28. Oil seal
184
1. Installment:
1
• Crankshaft (1) (Install to right crankcase)
CAUTION:
When installing the crankshaft, fasten the
connecting rod to the installing hole of cylinder
with hand.
2. Installment
Spindle assy and driving shaft assy (1)
3. Installment:
1 • Balance shaft (1)
5 • Fork 1 (2)
4 3 2 6 • Fork 2 (3)
• Fork 3 (4)
• Shift cam (5)
7
• Short fork shaft (6)
• Long fork shaft (7)
CAUTION:
• Lubricate each gear and bearing.
• Before closing, be sure to set the shift
mechanism at neutral and active in operation
185
Apply seal agent
4. Applying:
1 • Seal agent (1)
Apply the seal agent on the closing surface of
left crankcase.
Seal agent: Letai 518 anaerobic plane seal
glue.
1 5. Installment:
• Locating pin (1)
6. Install the left crankcase to the right crank-
case.
Beat with soft hammer slightly.
CAUTION:
Before installing the closing screw, be sure to
2 rotate shaft at random direction so as to check
7 if the function of shifting mechanism is
4
normal.
6
7. Tighten up:
• Screw (crankcase)
3 CAUTION:
Tighten up the screw as the order shown on the
1 8 9 drawing.
5
8. Applying oil:
• 4-stroke engine oil
Applying to the bearing and oil hole
11
9. Inspection:
• Operation of crankshaft and shift
mechanism
10 Not active then replace
186
(II) Assembly of right crankcase
Shift shaft, balance shaft gear, lubrication system.

1. Oil pump 16. Oil seal
2. Oil pump gear assy 17. Right connecting case
3. Driving pin 18. Pin 99530-12016
4. Oil pump pad 19. Right connecting case
5. Screw M6x20 20. Woodruff key
6. Oil rough filter 21. Balance shaft gear
7. Compressing spring 22. Locking washer
8. O-ring 23. Nut
9. Oil drain plug 24. Right crankcase cover gasket
10. Woodruff key 25. Right crankcase cover
11. Driving gear of balance shaft 26. O-ring
12. Circlip 26 27. Oil dipstick
13. Screw M6x18 28. Oil fine filter
14. Pressure plate spring 29. O-ring
15. Bearing 6203 30. Oil fine filter cover
187
Clutch and disengaging mechanism
1. Main clutch case assy 18. Screw with washer 35. Washer 8
2. Overruning clutch 19. Bearing 6000 36. Locking nut
3. Inner spline cover 20. Clutch post rod 37. Shift shaft assy
4. Washer 21. Locking washer 38. Torsion spring pin
5. Main clutch shoe assy 22. Nut 39. Torsion spring
6. Tension spring 23. Guide rod 40. Shift lever assy
7. Washer 24. Lower cam plate 41. Shift torsion spring
8. Locking washer 25. Steel ball stand assy 42. Washer
9. Nut 26. Upper cam plate assy 43. Limit lever assy
10. Clutch gear assy 27. Operating swing arm assy 44. Limit torsion spring
11. Spline washer 28. Compressing spring 45. Oil seal
12. Clutch drum assy 29. Connecting pin 46. Screw M6x20
13. Friction plate 30. Bracket seat 47. Shift pedal lever
14. Clutch plate 31. Washer 8 48. Shift pedal lever cover
15. Pressure plate 32. Splint pin 1.2x4 49. Shift gear locating pin
16. Clutch spring 33. Adjusting screw 50. Shift pin
17. Pressure cover 34. O-ring 51. Star gear
52. Screw
188
1. Balance shaft gear and driving gear
1) Installment:
• Woodruff key (1)
• Driving gear of balance shaft (2)
• Circlip (3)
CAUTION:
Use the gear puller.
2) Installment:
• Balance shaft gear (1) (be driven)
• Flat key (2)
CAUTION:
The mark (3) of driving gear should align
3
2 with the mark (4) of driven gear.
1
4
3) Installment:
• Nut (2) (Driven gear)
CAUTION:
• Be sure to use new locking washer.
4
2 • Install the locking washer locating plate (3)
inside the key groove of balance shaft (4) .
1
3
4) Tighten up:
• Nut (1) (Driven gear)
CAUTION:
Place a fold cloth (2) between the balance
shaft gear (3) and the gear of driving gear (4)
so as to avoid turning of shaft, then tighten up
the nut.
5) Bend the locking plate of locking washer.
4 3 1 2
189
2. Shift shaft and oil pump
1) Installment:
• Star gear (1)
• Locating pin (2) (long)
• Shift pin (3) (short)
CAUTION:
Install the locating pin (2) (long) to the filt-
2 1 ing mark (4) position.
2) Installment:
• Star gear (install to shift cam)
CAUTION:
The hole of shift cam should be aligned with
the locating pin (2) (long) of star gear.
3) Tighten up:
• Screw (1) (star gear)
• Apply the thread fastening agent on the
screw (1) .
1 4) Installment:
• Shift torsion spring (1) (install to shift
shaft)
• Washer (2)
• Limit lever (3) and limit torsion spring
assy (4)
• Washer (5)
5) Installment:
• Shift shaft (1)
CAUTION:
• Before installing the shift shaft, apply the
grease to the oil seal lip (left crankcase).
• Pull the hook plate (2) in arrow direction
and limit lever (3) and press and install
them to the star gear.
• Make sure that the torsion spring pin (4) in
within spring hook (4)
190
6) Apply engine oil
(Apply the parts inside the oil pump)
7) Installment:
• Oil pump seat (1)
• Outer rotor (2)
• Inner rotor (3)
• Oil pump gear assy (5)
• Driving pin (6)
• Oil pump cover (7)
• Screw (8)
8) Applying engine oil
(Apply to the lubrication oil trace of crank-
case)
CAUTION:
4-stroke engine oil should be applied to
lubrication oil trace of crankcase, otherwise
the engine would be damaged.
9) Applying engine oil
(Apply on the lubrication oil trace of oil
pump)
10) Installment
• Oil pump pad
• Oil pump (to crankcase)
• Tighten 3 screws 7 Nm
CAUTION:
• Be sure to use new pad
3. Right connecting case
3 1) Installment:
• Right connecting case gasket (1) (new)
• Locating pin
• Right connecting case (3)
1 CAUTION:
• Be sure to use new gasket.
2) Tighten up:
Screw (right connecting case)
191
4. Main, vice clutch
2
1) Installment:
• Clutch gear assy (secondary)
• Spline washer (2)
2) Installment:
• Friction plate (1)
• Clutch plate (2) (Install the clutch hub (3))
CAUTION:
Install the clutch plate and friction plate to the
3 2 1
clutch hub alternately, from friction plate to
friction plate.
3) Installment:
• Clutch hub
(Install to pressure plate)
CAUTION:
The arrow mark (3) of clutch hub should align
with the arrow mark (4) on the pressure plate.
3
4
4) Installment:
• Clutch hub, pressure plate, clutch plate, and
2 1 friction plate assy (1) (to main shaft (2))
• Nut (4)
CAUTION:
Be sure to use new locking
• Be sure to install the locking washer inside
the indent of clutch hub.
5) Tighten up:
• Nut (4) (Clutch hub)
CAUTION:
Fasten the clutch hub, then tighten up the
192
6) Bend the locking plate (5) of locking washer.
7) Installment:
• Clutch spring (1)
• Pressure cover (2)
• Bearing (3)
1 2 3 4
8) Installment:
• Output gear (1)
• Nut (2) 60 Nm
CAUTION:
Be sure to use new nut.
2 1
9) Tighten up:
• Nut (2)
CAUTION:
Fasten the clutch hub of vice clutch, and tighten
up the nut.
10) Lock the nut (2) with screwdriver.
193
11) Installment:
• Washer (1)
• Main clutch case assy (2)
• Washer (3)
• Clutch shoe assy (4)
1 2 3 4 CAUTION:
• There are two indents (1) on the vice clutch
case.
When installing the main clutch case, one of
the indents should align with the main clutch
gear (2) .
2
12) Installment:
1 • Nut (2) (main clutch)
3
CAUTION:
• Be sure to use new locking washer
• The locating plate of locking washer should
be installed n the indent of clutch shoe assy.
13) Tighten up:

• Nut (2) (main clutch)
CAUTION:
Fasten the clutch shoe assy, then tighten up
nut.
14) Bend the locking plate (3) of locking

2 washer.
194
4
5. Clutch disengaging mechanism and right
case cover
3 1) Installment:
• Lower cam plate (1)
2 • Steel ball stand assy (2)
• Upper cam plate assy (3)
1 • Compressing spring (4)
CAUTION:
• The locating notch of lower cam plate
should align with convex block of shift shaft
• The locating notch of upper cam plate
should align with guide rod.
7
3 1
2) Installment:
5 • Right crankcase gasket (2)
• Right crankcase gasket (3)
6 • Oil fine filter (5)
2 • O-ring (6)
• Oil fine filter cover (7)
• Clutch operating rocker assy
CAUTION:
• Be sure to use new gasket.
• The hole of clutch operating rocker assy
should align with shift shaft.
3) Tighten up:
• Screw (right crankshaft cover)
195
(III) Assembly of left crankcase
Output mechanism 10. Screw bushing 18. Nut

1. Output gear 11. Irregular left hand nut 19. Rear cover
2. Forward gear assy 12. Output shaft 20. O-ring
3. Reverse gear 13. Washer 21. Bolt M8x15
4. Nut 14. Bearing 22. Reverse fork
5. Bearing 15. Inner hexagonal screw 23. Compressing spring
6. Washer bushing 24. Steel ball 6.35G100b
7. Connecting jaw 16. Front connecting fork 25. Reverse fork shaft
8. Washer 17. Washer 26. Reverse control lever assy
9. Bearing 27. Reverse operating shaft
28. Circlip 14
196
Electric starting system
1. Circlip 12 10. Spring cover

2. Washer 11. Spring
3. Wheel axle 12. Timing chain
4. Double wheel 13. Up guide plate assembly
5. Woodruff key 14. Magneto rotor
6. Washer 15. Magneto starter
7. Electric starting gear assy 16. Left crankcase cover
8. Electric starting clutch 17. Starting ratchet assy
9. Roller
197
1. Reverse operation system
1) Mount:
• Reverse operation shaft (1)
• Operation plate (2)
• Reverse control lever (3)
• Circlip (4)
Mount the above on the rear driving cover.
2) Mount:
• Compressing spring (1) (on reverse gear
fork (4))
• Steel ball (2)
CAUTION:
1 Mount a positioning set pin into the fork first
for fixing the steel ball and spring, that is
4
easy to mount the fork pin into fork.
2
3) Lubrication:
Apply lubrication oil (SAE20W/40) in the
inner diameter of fork and pin.
3 4) Mount:
• Reverse gear fork shaft (1) (With
1 2 O-ring)
• Mount the reverse gear fork pin (1) into
the hole of rear driving cover (3)
• Reverse gear fork (2)
CAUTION:
• Mount the reverse fork shaft into the hole of
the reverse fork and then pull out the locating
pin and take it out.
• Check if the fork is working
198
2. Output shaft assy
1) Mount:
• Bearing (to rear cover)
• Nut collar
CAUTION:
Use the nut collar spanner to tighten the collar.
3) Mount:
• Washer
• Reverse gear
• Compromise left-turning nut
CAUTION:
• Fasten the compromise left-turning nut by
counterclockwise direction, because it is left-
turning thread.
• Use special-shaped nut spanner
4) Fasten:
• Special-shaped left-handed nut
2 3 5) Mount:
• Washer
• Bearing (2)
• Nut collar (3)
CAUTION:
• Use allen wrench
• Coat “518 anaerobic sealing gun” or equal
substitute on outer end surface of
bearing (2) which side is near to washer.
• Coat thread fastening agent on allen nut col-
lar (3)
6) Fasten:
• Allen nut collar
199
7) Mount:
• Output shaft
• Connecting claw
• Front splice
• Washer
• Nut
8) Fasten
• Nut (5)
CAUTION:
• Fix the front splice with universal joint
holder and connect the locking nut.
• Apply the thread fastening agent on the nut
when mounting it.
9) Mount:
• Rear joint and driving fork.
1 Mounting steps
• Mount the relative driving fork into the splice
• Coat grease on the needle bearing
• Press every needle bearing (1) into the front
splice with proper tube to ensure that the
driving fork is inserted into the needle bearing
hole
• Fix the hog ring into every bearing groove
CAUTION:
• Check every needle because the needle may
drop out from bearing cone to lose. If it is like
this the universal joint can’t be turned flexibly.
• Insert the needle bearing into universal joint
entirely to ensure the hog ring can be mounted.
200
4 5 3. Mount:
• Washer (2)
• Bearing (3)
• Forward shift gear assy (4)
3 2 6 • Output shaft assy (5)
CAUTION:
Apply sealing gum Apply grease on O-ring (6)
4. Coat:
• Sealing agent
(Coat on the matching surface of rear driving
cover.)
• Brand of sealing agent is 518 anaerobic seal-
ing gum or equal substitute
5. Mount:
• Rear driving cover (1)
• Tighten bolt (2)
Caution
Before running the rear driving cover on the
crank, make the gear on the forward shaft
position.
6. Tighten:
• 4 Bolts 23Nm (1) (rear cover)
CAUTION:
When mounting rear cover to the crankcase,
1 the arrow must be upward.
7. Electric starting system.
201
1 7. Electric starting system
2
1) Mount:
• Timing chain (1)
• Up guide plate (2)
CAUTION:
Tighten the shaft wire of timing chain to avoid
dropping it into the crankcase.
2) Mount:
1 • Washer (1)
• Electric Starting gear assy (2)
3 • Woodruff key (3)
2 • Magnets rotor (4)
CAUTION:
• Clean the conical part of crank and magneto
2 • When installing the magneto key must be in
4
the key groove of crank for avoiding it.
• Mount the magneto (4) drops out on the
crank, and then fix the electric starting gear
assy (2) turn the magneto by counterclock-
wise to make it into the electric starting big
gear
4 3) Mount:
• Double wheel (1)
• Washer
• Wheel axle (3)
5 • Sealing washer (5) of left crankcase cover
CAUTION:
1 Must use new washer
202
4) Mount:
• Left crankcase cover (1)
• Fasten screw (8 pieces 7Nm)
5) Mount:
• Starting click pulley assy (1)
CAUTION:
• Fix the click pulley with rotor seat and tighten
1 the bolt
• Before mounting the starting click
pulley, apply grease on oil sealing and O-ring
(3).
(IV) Selection and installation of adjusting

washer when mounting the crankcase.
50 Nm When mounting the crankcase, output gear and
output shaft, the applied washer thickness is
determined by the actual machining dimension of
the following parts. Adjust the correct break-in of
he level gear and the clearance of every moving
1 parts by washer thickness.
3
• Crankcase
• Output gear
• Reverse gear
• Rear cover
• Forward gear
• Output shaft
When replacing above parts, must select the ad-

justing washer again.
1. Mounting position of washer

[A] =Washer of output gear
[B] =Washer of forward gear
[C] =Washer of reverse gear
[D] =Washer of output shaft
203
[A] =a-b
[B] =d-c-e-f
[C] =d-g-h-i
[D] =j+c-e-B-k-l-0.25
(1) Left crankcase
(2) Output gear
(3) Forward shift gear
(4) Output shaft
(5) Reverse gear
(6) Rear cover
Changed parts Washer needed to be
adjusted
Crankcase [A] [B] [C] [D]
Output gear [A]
Forward gear [B] [D]
Reverse gear [C] [D]
Rear cover [C] [D]
Output shaft [D]
2. Choose washer [A]
• When changing the crankcase or output
gear, adjust output gear washer [A]
10 Calculate the washer thickness of output
gear by following formula “A”:
Washer thickness of output gear:
A= (a) - (b)
(a) =Theory installing distance42 of output
gear adds the value engraved on the output
gear.
(b) is the value engraved on crankcase
CAUTION:
All the units about the value is mm
2) For example
• If “+0.02” is engraved on the output gear
that is: a =42+0.02=42.02
• If “41.45” is engraved on the left crankcase
• So the washer thickness is:
A=42.02-41,45=0.57mm
3_ The following is prepared thickness of
washer (mm):
0.2 0.4
0.3 0.5
204
Washer selection table
Range of A Selected washer
0.25≤A≤0.32 0.3
0.35<A≤0.42 0.4
0.42<A≤0.52 0.5
0.52<A≤0.62 0.6
0.62<A≤0.72 0.7
0.72<A≤0.75 0.8
The washer thickness is 0.57mm, by calculation,

the washer thickness should select 0.60mm ac-
cording to above table.
3. Select washer [B]
When replacing left crankcase or forward gear,
the forward gear washer [B] needs to be
adjusted.
1) Calculate the washer thickness of forward

gear by following formula.
Washer thickness of forward gear:
[B]= (d) - (c) - (e) - (f)
(d) and (c) are the value engraved on the left
crankcase
(e) = (at the forward gear) bearing thickness
(no change)
“13.00mm”
(f) =Theory installing distance “37.5” of for-
ward gear adds value engraved on forward gear.
2) For example:
• If “d=110.08” is engraved on left
crankcase, “c=59.02”
• If “=0.02” is engraved on the forward gear,
(f) =37.5+0.02=37.52
[B]=110.08-59.02-13.00-37.52=0.54mm
3) The following is the prepared washer thick-
ness (mm)
0.2 0.4
0.3 0.5
205
Range of B Selected washer
0.25≤B≤0.28 0.2
0.28<B≤0.38 0.3
0.38<B≤0.48 0.4
0.48<B≤0.58 0.5
0.58<B≤0.68 0.6
0.68<B≤0.78 0.7
The washer thickness is 0.54mm by calculation,

the washer thickness should select 0.50mm ac-
cording to above table.
4. Select washer [C]
When replacing left crankcase, reverse gear, and
rear cover, reverse gear washer [C] needs to be
adjusted.
1) Calculate the washer thickness of reverse
gear by following formula.
Washer thickness of reverse gear:
C= (c) - (g) - (h) - (i)
(c) is the value engraved on left crankcase
(g) is the value engraved on rear cover
(h) is the bearing thickness “12.00” (at the
reverse gear)
(i) means that the theroy installing distance
“39” of reverse gear adds value engraved on
reverse gear.
2) For example
• “ (c) =58.98” is engraved on left crankcase
• “ (g) =7.49” is engraved on rear cover
• If “-0.02” is engraved on reverse gear,
(i) =39+(-0.02)=38.98
• So washer C thickness is the prepared
thickness of washer (mm):
0.2 0.4
0.3 0.5
The way selected washer C is same with the
way of washer B. The washer thickness is
0.51mm by calculation. So the washer thickness
should select 0.50mm according to washer C
selection way.
205
5. Select Washer [D]
When replacing left crankcase forward gear,
reverse gear, rear cover and output shaft, washer
[D] of output shaft needs to be adjusted.
10 Calculate the washer “D” thickness of output
shaft by following formula
Washer thickness of output shaft:
[D]= (d) + (j) - (e) -B-k-1-0.25
(d) is the value engraved on left crankcase
(j) is the value engraved on rear cover
(e) is the bearing (at output gear) thickness
“13.00”
“k” is the value engraved on forward gear
“l” is the value engraved on output shaft
2) For example:
• If “0.97” is engraved on rear cover
• “110.05” is engraved on left crankcase
• “14.4” is engraved on forward gear
• “80.45” is engraved on output shaft
[D]=110.05-0.97-13.00-0.50-14.4-80.45-
0.25=2.42mm
3)The following us the prepared washer thick-
ness (mm)
1.0 1.3 1.7
1.1 1.5
Range of washer thickness Selected washer
1.8≤D≤1.9 1.7
1.9<D≤2.0 2.0
2.0<D≤2.1 2.1
2.1<D≤2.2 2.2
2.2<D≤2.3 2.3
2.3<D≤2.4 2.4
2.4<D≤2.5 2.5
2.5<D≤2.6 2.6
2.6<D≤2.7 2.7
2.7<D≤2.8 2.8
2.8<D≤2.9 2.9
2.9<D≤3.0 3.0
The washer thickness is 2.42mm by calculation.
So the washer thickness should select 2.5mm
according to above table.
206
6. Installation of adjusting washer
1) Washer A
Mount
• Washer A (1)
• Bearing (2)
CAUTION:
This step is carried out before assembly with
closing case.
Mount:
• Clamp plate (1)
CAUTION:
This step is carried out before assembly with
case.
2) Washer B
Mount:
• Forward gear (1)
• Washer B (2)
• Bearing (3)
2 1
3
207
3) Washer C
Mount:
• Washer
• Reverse gear
• Special-shaped left-handed nut
CAUTION:
• The special-shaped left-handed nut
left-handed thread, so tighten it in counter
clockwise direction.
• Use special-shaped nut wrench
3 2
4) Washer D
Mount:
• Washer
• Bearing (2)
• Bushing (3)
CAUTION:
• Use inner allen bushing wrench
• Coat 518 anaerobic sealing gum or equal
substitute on outer end surface of bearing
(2) which side is near to washer.
208
(V) Assembly of cylinder head
Cylinder cover assy
1. Locking nut 12. Bolt M6x12

2. Adjusting screw 13. Locking plate
3. Throttle arm 14. Clamp plate
4. Arm axle 1 15. Rolling bearing 6005-RS/C3
5. Valve locking 16. Driving pin
6. Valve spring cover 17. Valve cam shaft
7. Valve recoil sealing 18. Rolling bearing 6202-Z
8. Valve spring 19. Rocker axle 2
9. Valve outer spring 20. O-ring
10. Valve spring seal 21. Exhaust valve
11. Inlet valve
209
Cylinder head 1
1. Cylinder head cover assy 13. Screw M8x45-10.9 25. O-ring

2. Steel wire circlip 14. Washer 8 26. Screw M6x18-06025
3. Throttle guide tube 15. Sprocket wheel cover assy 29. Chain tensioner
4. Bolt 95026-06010 16. Oil shield assy 30. Tensioner washer
5. Washer 17. Breather tube 31. Upper guide plate assembly
6. Shock absorbing block 18. Work carrier 32. Bolt 95026-06014
7. Cylinder cover washer assy 19. O-ring 33. Bolt M10V1.25x25
8. Locating pin 99510-14016 20. Screw 98512-06012 34. Washer
9. Locating pin 21. O-ring 35. Timing sprocket wheel
10. Oil sealing 22. Screw 98512-06012 36. Lower guide plate
11. Canopy nut 23. Upper valve cover 37. Timing chain
12. Washer 24. Lower valve cover
210
Cylinder head 2
1. Cylinder body assy 7. Piston ring 2

2. Screw M6 x 25-10.9 8. Oil ring subassembly
3. Cylinder body washer 9. Circlip
4. Locating pin 99530-14016 10. Piston
5. O-ring 11. Piston Pin
6. Piston ring 1 12. Double end bolt
211
1. Mount:
• Double end bolt (1)
2. Mount:
1
• Piston (1)
• Piston pin (2)
• Circlip (3)
CAUTION:
• Arrow (4) on the piston must point to the
forward engine
4 • Before mounting the piston pin, cover
crankcase hole with cleaning towel or clothes
for avoiding circlip and other small parts
2
dropping into crankcase.
• Be sure to use new circlip.
3. Apply oil:
• Apply 4-stroke machine oil on the piston
pin, piston ring groove, and piston edge.
4. Installation of piston ring

1
3 Assemble the piston ring split clearance stag-
geringly according to showing figure.
(1) Top ring
(2) Oil Ring (lower ring)
(3) The second ring
(4) Oil ring (upper ring)
5. Install:
• Cylinder body washer
• O-ring (3)
CAUTION:
Be sure to use new sealing washer and o-ring.
CAUTION:
• Be sure to check the standard of manufac-
2 ture and engraved figure on the ring. The
marking sufure is toward the piston top.
3 • Before mounting cylinder, apply a layer of
4-stroke engine oil on piston ring.
212
6. Mount:
• Cylinder (1)
• Tighten bolt (cylinder ) temporarily
CAUTION:
• When pressing the piston ring with one
hand, assemble the cylinder with the other.
1
• The timing chain should through the
bending locking end (2) of chain chamber.
7. Lubricate:
• Valve rocker
• Rocker shaft
• Lubrication oil : SAE 10W30
machine oil
8. Install:
• Valve rocker
• Rocker shaft
CAUTION:
• Thread hole on the rocker shaft is toward
out
• Mount rocker shaft (With O-ring), at
the side of outlet and the long rocker shaft
(with slot) at the side of inlet.
• The slot direction needs to be adjusted
when mounting inlet rocker shaft to make
the slot align with hole of cylinder cover
bolt
213
10. Mount:
• Valve cam
CAUTION:
The driving pin on the end of valve cam must
align to the timing mark on the cylinder cover.
9. Mount:
1 • Bearing (1) (to valve cam)
• Bearing (2) (to valve cam)
CAUTION:
The bearing (1) with oil sealing is toward out
when assembling it, and the bearing (2) with
dust cap is toward inside when assembling it.
2 11. Mount:
• Clamp plate (1) (Bearing)
• Locking plate (2) (new)
12. Fasten:
• Bolt (1)
1
13. Bend locking plate end (2)
2
214
14. Mount:
• Lower guide plate (1)
• Oil sealing (2)
• Cylinder cover washer assy (4)
• Cylinder head (5)
• Washer (7)
• Cylinder head nut (6)
• Washer (8)
• Screw (9)
CAUTION:
• Apply 4-stroke engine oil on the
washer (7)
15. Fasten the bolt and nut according to the

order in the figure.
2 3
1 16. Mount:
4
• Timing sprocket pulley
Mounting step of timing sprocket pulley:
• Turn the camshaft to make sure the cam
pin (1) is correspondence with the matching
6 5 mark (2) of cylinder head.
215
• Turn the crank until the mark TDC (3) is
5 2 correspondence with the mark on the crankcase
4
T cover (4) .
3 • Mount the timing chain to the timing sprocket
pulley.
• Mount the timing sprocket pulley to the cam-
shaft for ensuring the mark of timing sprocket
pulley (5) is correspondence with the mark
(2) on the cylinder head, then fasten the
sprocket pulley bolt with hand.
(make sure the tension of the timing chain at
the outlet when mounting the timing sprocket
pulley)
60 Nm
• Insert the special tooling into the tension hole
of timing chain and pull the tensioner timing
6 chain toward inside.
• The matching mark (5) of timing sprocket
is sure to correspond to the matching mark (2)
of cylinder head when pulling the timing chain
tensioner.
• Change the matching position between
sprocket pulley chain if the marks are not
aligned.
• After the marks are aligned, fasten the bolt of
timing sprocket.
CAUTION:
Fix the starting ratchet (6) and tighten the bolt
of timing sprocket.
17. Mount:
Tensioner of timing chain
Mounting steps:
• Take off bolt (1) from the tensioner of tim-
ing chain.
216
• Insert the small screwdriver into the groove
of tension rod and turn the screwdriver clock-
wise. A the same time press tension rod until
4 the screwdriver can’t be turned.
2 • Hold the screwdriver at this position, and

mount the tensioner assy (2) (with washer)
on the cylinder, then turn the locking bolt (4)
of tensioner sub-assembly.
• Take off the screw drive from the tensioner,
and then tighten the locking bolt of tensioner
assy.
• Mount tension bolt (1) with washer 10Nm.
1
CAUTION:
Always use new washer.
18. Adjust:
• The valve clearance
There is a valve clearance between two
rocker when the mark (3) of timing sprocket
is align with the mark (4) of cylinder cover.
• Inlet valve clearance (cool):
0.05-0.09mm
• Outlet clearance (cool):
2 0.11-0.15mm
T
1
19. Apply 4-stroke engine oil

(On the up side of cam shaft)
• Oil quantity is 0.05L
217
20. Mount:
• Valve cover (1) (mount o-ring in the sealing
1 2 groove of throttle cover first)
• Valve cover (2) (mount o-ring in the sealing
groove of throttle cover first)
• Spark plug (3)
CAUTION:
Check the o-ring. If it is deformed or damaged,
replace it.
3
21. Mount:
• Sprocket chamber cover (1) (mount o-ring in
the sealing groove of sprocket chamber cover
1 first).
CAUTION:
Check the o-ring. If it is deformed or damaged,
replace it.
22. Mount:
• O-ring
• Carburetor seat
• Washer
• Carburetor Mount o-ring in sealing groove
first).
CAUTION:
Check the o-ring. If it is damaged, replace it.
23. Mount:
• Carburetor seat and carburetor (on cylinder
cover)
• Wire clamp
CAUTION:
The carburetor seat and the o-ring in the sealing
groove of the cylinder cover connecting surface
can’t be forgotten to mount.
218
(VI) Manual starting mechanism and others
Starting system (manual)
1. Left side cover assy 8. Torsion spring

2. Guy 9. Drive jaw
3. Starting lever 10. Circlip
4. Starting lever cover 11. Screw pin
5. Washer 12. Guide plate
6. Coil spring backboard assy 13. Pressure spring
7. Driver disc assy
219
1
1. Mount:
• Coil spring backboard assy
2
CAUTION:
Hang the coil spring hook hanger (2) into the
split of spring backboards, and wind the coil
spring in counterclockwise.
2. Install:
• Washer (1)
• Coil spring backboard assy (2)
CAUTION:
4 End of the coil spring is hung on the inner race
of left side–cover coil spring.
3
3. Wind the rope in the drive disc groove 4 ½
2
circles by clockwise.
1 4. Lubricate:
• Coil spring backboard assy
• Drive disc
1
4
5. Mount:
2 • Drive disc (1)
CAUTION:
The projection need to be mounted into two
hole groove (2) and the coil spring hook hang-
er also need to be mounted into the hole groove
(4) .
220
6. Mount:
4
• Torsion spring (starting ratchet pawl) (1)
• Starting ratchet pawl (2)
• Hog Ring (3)
• Compress spring (4)
• Guide plate (5)
• Screw pin (6)
CAUTION:
When mounting torsion spring (starting ratchet
pawl), make the end (7) of torsion spring
align to groove A on the drive disc.
2 1 3 6 5
7. Turn the drive disc 3 circles by clockwise,

and pre-tighten the coil spring.
8. Mount:
1 • Starting lever (1)
• Cover (2)
CAUTION:
Make the rope across the hole of left side, and
knit it so that the rope is not pulled into left
side cover.
• After knitting (4), and untie.
4 2
221
9. Mount:
• Washer (1)
• Washer (2)
• Reverse lever system (4)
CAUTION:
Coat sealing gum on the bolt (3)
10. Mount:
• Manual starting system (1)
7Nm
6 places
(VII) Reverse procedure for “Engine Assembly”

CAUTION:
Support motorcycle firmly to avoid turning over.
1. Mount:
1
• Engine
Mount the engine from right side of frame.
2. Mount:
• Bolt (1)
(Installation position of engine -- rear lower)
• Bolt (2)
(Installation position of engine -- rear upper)
• Bolt (3)
(Installation position of engine -- front)
• Bolt (4)
(Installation position of engine -- top)
CAUTION:
• Mount all the installing bolts from right side of
motorcycle.
• Turn the nut and bolt temporarily, but don’t
fasten them at this time.
222
3. Mount:
• Drive assy of rear wheel and rear wheel
fork
Assembly steps:
10 Lubricate following parts before mounting
the rear wheel fork
• Bearing (1)
• Oil sealing (2)
• Bushing (3)
• Coupling bolt of rear arm (4)
• Spline of drive shaft (5)
• Spline of main drive gear (6)
Lubrication oil:
Lithium base lubrication oil
2) Mount the drive shaft (7) on the spline (6)
of main drive gear.
3) Pull rear wheel fork forward and mount drive
shaft (7) on the rear joint of direction knot (8).
4. Connect:
• Rubber bushing etc. (1)
5. Mount:
• Coupling bolt (2) of rear arm
• Rear arm nut (3)
• Coupling bolt (4) of rear arm
CAUTION:
Turn the rear shaft bolt and rear arm shaft nut
temporarily, and don’t fasten them at this time.
6. Check:
• Operation of drive shaft
Checking steps:
• Hold the front wheel and put the proper
bracket on the frame for lifting rear wheel
• Front and rear turning wheel
• Check the operation of driving shaft. If the
operation is not good, check the installation of
drive shaft again
223
7. Fasten:
• Bolt (1)
• Bolt (2)
• Bolt (3)
(Installation position of engine -- front)
• Bolt (4)
(Installation position of engine -- top)
(Rear arm shaft -- left)
(rear arm shaft -- right)
• Rear arm nut (7)
Bolt (Installation position of engine -- rear lower)
33Nm(3.3m*bg*24ft*lb)
Bolt (Installation position of engine -- rear lower)
Bolt (Installation position of engine --front)
Bolt (Installation position of engine -- top)
Coupling bolt of rear arm (rear arm shaft – left)
130Nm(13m*bg*94ft*lb)
Coupling bolt of rear arm (rear arm shaft – right)
0.6Nm(0.6m*bg*4.3ft*lb)
Rear arm nut:
130Nm(13m*bg*94ft*lb)
Bolt (rear shock absorber – top):
8. Mount:
• Dust cap (9) of rear arm shaft
9. Connect:
• Breather tube (1) (rear drive)
Refer to “Diagram of vehicle” in section 6 of
chapter 1
224
10. Connect:
• Spark plug terminal
• CDI magneto terminal (1)
• “Reverse” switch terminal (2)
• “Neutral” switch terminal (3)
• Breather tube (4) (crankcase)
• Brake cable (5)
Refer to “Diagram of vehicle” in section 6 of
chapter 1
11. Mount:
• Starting motor (1)
• Coupling plate (2) of staring motor
• Wire of starting motor (3)
CAUTION:
Lubricate o-ring before mounting the starting
motor
12. Mount:
• Spring (1)
• Foot rest (2) (right)
Bolt (foot rest)
65Nm(6.5m*47ft*lb)
Bolt (Shifting Pedal)
10Nm(1m*7.2ft*lb)
Bolt (foot rest)
65Nm(6.5m*47ft*lb)
Bolt (foot rest)
30Nm(3.0m*22ft*lb)
13. Mount:
• Bracing (1) of front fender
• Shifting pedal (2)
• Foot rest (3) (left)
14. Connect:
• Rear brake cable (1)
• Rear brake rod (2)
15 Adjust:
• Rear brake
Refer to “Adjustment of rear brake lever and
brake pedal” in chapter 3
225
16. Mount:
• Exhaust Pipe (1)
• Silencer (2)
17. Fill oil:

• Crankcase
Total:2.2L
Refer to relevant part in section 5 of chapter 2.
18. Adjust:
• Free clearance of plunger (clutch)
19. Adjust:
• Position of drive selection lever
Refer to relevant part in section 5 of chapter 2
20. Adjust:
• Idle speed
Idle speed: 1400-1500r/min
21. Adjust:
• Idle stroke of throttle cable
Idle stroke of throttle cable 3-5mm
226
Chapter VI Vehicle Ordinary
Trouble and it’s judgement
Trouble • Wrong spark plug heat value
CAUTION: • Inefficient spark plug cap
Please refer to relevant contents for the in-
spection, adjustment and replacement of (2) Ignition coil
parts. • Primary coil/secondary coil is broken
(I) Starting trouble/difficulty or shortened
1. Fuel system • Inefficient high voltage wire
(1) Fuel tank • Ignition coil is broken
• No oil
• Fuel filter is clogged (3) CDI magneto system
• Fuel filter net is clogged • CDI is failure
• Breather tube is clogged • Coil is failure
• Fuel is deteriorated or polluted • Charging coil is failure
• Woodruff key is bad
(2) Fuel cock
• Intel tube is clogged (4) Switches and wires
• Fuel cock is not opened • Main switch is bad
• The engine is off and switch is
(3) Carburetor inefficient
• Fuel is deteriorated or polluted • Wires are broken or shortened
• Starting nozzle is clogged • Neutral switch is bad
• Air tube is clogged • Starting switch is bad
• Float is distorted • Rear brake switch is bad
• Needle valve is worn
• Improper valve sealing (5) Staring motor
• Improper installation of starting nozzle • Starting motor is bad
• Starting nozzle is clogged • Starting relay is bad
• Improper work of starting plug • Off power relay is bad
• Super clutch is bad
(4) Air filter
• Core of air filter is clogged 3. Cylinder
(1) Cylinder body and cylinder head
2. Electric system • Spark plug is loose
(1) Spark plug • Cylinder head or cylinder body is loose
• Improper spark plug clearance • Cylinder head washer is damaged
(standard clearance is 0.6-0.7mm) • Cylinder body is worn or damaged
• Terminal is worn
• Spark plug is polluted
227
(2) Piston and piston ring (1) Carburetor
• Improper piston ring installation • Wrong needle valve position
• Piston ring is worn and out of elasticity • Main jet is clogged or loosened
• Piston ring is broken • Fuel is deteriorated or polluted
• Piston is damaged or cracked • Wrong float chamber oil level
(3) Valve, camshaft and crank shaft (2) Air filter

• Valve didn’t close entirely • Core of air filter is clogged
• Improper match between valve and valve
seat (IV) Shifting trouble
• Wrong port timing 1. Shifting difficulty
• Valve spring is damaged Refer to “slipping of clutch” and “ablation of
• Valve camshaft is damaged clutch” in this chapter
• Crank shaft is damaged
2. Shifting peddle is clogged
(II) Poor idle speed performance (1) Shifting shaft groups
(1) Carburetor • Shifting shaft is bent
• Starting plug is not closed entirely • Shifting lever group is damaged
• Idle metering jet is loose
• Idle air metering jet is clogged (2) Shifting cam, shifting fork
• Improper idle adjustment • There is foreign matter in shifting camshaft
• Improper adjustment of throttle stroke recess
• Leakage of carburetor • Shifting fork is clogged
• Shifting fork is bent
(2) Electric system
• Spark plug is bad (3) Driving system
• CDI is bad •Driving gear is clogged
• Coil is bad • Foreign matter is clogged
• Charging coil is bad • Incorrect driving system installation
• Ignition coil is bad
3. Shift is out of gear
(3) Valve system (1) Shifting shaft groups
• Improper adjustment of valve clearance • Improper adjustment of limited lever
•Core of air filter is clogged position
• Limited lever can’t back
(III) Poor middle and high speed
performance (2) Fork
Refer to “starting trouble/ deficiency” and •Fork is worn
“poor idle speed performance” section in
this chapter. (3) Shifting cam
• Recess of shifting cam is worn
228
(4) Driving system (2) Fuel System
• Claw of gear end is down • Main jet of carburetor is wrong
• Improper oil level
(V) Clutch slips • Core of air filter is clogged
(1) Clutch
• Improper adjustment of clamp plate release (3) Cylinder system
rod clearance of clutch • Serious carbon disposition
• Clutch spring is loosen (primary clutch
and/secondary clutch) (4) Engine oil
• Clutch spring is fatigue (primary clutch • Improper oil level
and/ secondary clutch) • Improper oil toughness
• Friction disc is worn • Poor oil quality
• Clamp plate is worn or deformed
• Main clutch shoe lining is worn (5) Brake
• Brake is stagnant
(2) Engine oil
• Low oil level (VIII) Brake trouble
• Poor quality (viscosity is low) Troubles: Poor brake efficient
• Deteriorated oil • Brake shoe lining is worn
• Serious wear of brake shoe
(VI) Clutch is locked • Brake shoe oil is too much
(1) Clutch • Improper adjustment of brake clearance
•Clutch is out of control or the clearance is • Improper brake arm position
too big • Returning spring is fatigue and damaged
• Improper match between release lever and • Brake cable is broken
release rod
• Deformed clutch clamp plate (IX) Shock absorber failure/ improper
• Friction disc is deformed operation
• Clutch hub is broken 1. Shock absorber failure:
• Damping rod is bent or damaged
(2) Engine oil • Bad oil sealing lip
• High oil level • Spring of shock absorber is fatigue
• Poor oil quality (viscosity is high)
• Deteriorated oil 2. Improper operation
(1) Handle bar
(VII) Engine is overheated • Improper installation or handlebar is bent
(1) Ignition system
• Improper spark plug clearance (2) Steering system
• Wrong spark plug heating value • Wrong toe-in
• CDI failure • Steering pillar is bent
229
• Improper installation of steering 2. Bulb is off
pillar bearings • Bulb is out of specification
• Holding seat of steering pillar or • Battery fails
sealing ring is damaged • Rectifier fails
• Rod is bent • Wrong connection of ground
• Spherical connection is bent • Main switch or lighting switch fail
• Use-life of bulb is end
(3) Wheel tire
• Uneven pressure on two sides of tire
• Wrong tire pressure
• Uneven tire wear
(4) Front/ Rear tire

• Deformed rim
• Loosen bearing front wheel axle is
bent or loosen
• Radial run out of front/rear wheel is
too big
(5) Frame
• Bend
• Damaged frame
(6) Rear wheel fork

• Bearing is bushing or worn
• Rear wheel fork is bent or damaged
(X) Lighting System

1. Head light is out of work
• Bulb is trouble
• Too big load
• Charging difficulty (Lighting coiler
rectifier is failure)
• Wrong connection of wire
• Wrong connection of ground
• Poor connection (Main switch or
lighting switch)
• Use-life of belt is end
230

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WD250U Service Manual

For any questions please contact Baja Motorsports at 888-863-2252

(I) Special tools

Section 4 Points for attention in maintenance

5. Locking washer/shim and location pin

6. Bearing and oil seal

7.2 The electrolyte inside the battery is corrosive,

7.3 When repairing wires on electrical parts, remove

7.4 When connecting the wire to battery, first con-

7.5 Check the terminal of connector

7.6 Before mounting the new fuse, check if the load

7.7 There are two kinds of wire connectors, a single-

8. Use torque spanner to tighten screw and nut, and

I. How to use conversion table of unit

Metric Multiply Imperial

Item Standard Limit

Item Specification Limit

IV. Electric system

A-diameter of valve head exhaust 28.4-28.6mm

Type Bucket-shaped back round

Type Flat type

Size (BxT) 2.5x2.8mm

Piston size “D” 70.92-70.97mm

Limit value of runout: C1 0.03mm

14 Wire of cltch wire 1

Torque value of fasteners

Torque value of fasteners

Rear cover Bolt M8 4 23 2.3 17

(III) General torque specification

* When measuring torque force, standard torque

A (Nut) B (Screw) m·kg

1. Oil draining plug 8. Oil pump driving gear

1. Single-direction valve 8. Single-direction bearing

Lubricant point Type of lubricants

Lubricant point (name of component) Type of Lubricant

All bearing (Crank,spindle,driving shaft,output shaft,balancing Lubricating oil

Section 1 Periodic Maintenance/Lubrication

(II) Rear fender

2- Disassemble the rear luggage carrier

2 3- Disassemble the cushion (3) (see cush-

4- Disconnect the negative wire (5) and

5- Disassemble the clamp plate (9) of

6- Disassemble the starting relay (6)

7- Disassemble the cut-off realy (7)

9- Disassemble the rear fender (10)

5- Install rear luggage carrier (1)

6- Turn the fuel shut off valve to the “OFF”

3- Disassemble the front guarding plate (2)

6- Disassemble the front fender (1)

2- Install the bumper (1) .

2- Install the front guard plate (1) .

4- Install the front luggage carrier (1) .

2.Check the rear brake

(III) Adjustment of free clearance of left lever

• Loosen adjusting nut (3) of the rear brake

• Screw out the adjusting screw (2) of rear

6. Oil fill screw plug

(VIII) Inspection of steering system

4. Lift the front end of vehicle to make the front