Quad Lander 250: Service Manual

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HOW TO USE THIS MANUAL SERIAL NUMBER
Quad Lander 250

SERVICE MANUAL
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This service manual contains the technical data of each component inspection and
repair for the SANYANG Quad Lander 250 ATV. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment” so that provides technician with service guidelines.
If the style and construction of the ATV, Quad Lander 250, are different from that
of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
Service Department
SANYANG INDUSTRY CO., LTD.
Homepage Contents
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for SANYANG Quad Lander 250 ATV. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.
There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the CD-R version, and can be access to these items
by click the mouse.
If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, onto the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back the
homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the content.
In addition, there is a “To this chapter contents” button at the second page of each
contents so that clicking the button can back to the contents of this chapter.
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CONTENTS
Page Content Index
1-1 ~ 1-18 GENERAL INFORMATION 1
2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-8 LUBRICATION SYSTEM 3
4-1 ~ 4-12 FUEL SYSTEM 4
5-1 ~ 5-6 ENGINE REMOVAL 5
6-1 ~ 6-16 CYLINDER HEAD/VALVE 6
7-1 ~ 7-8 CYLINDER/PISTON 7
8-1 ~ 8-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8
9-1 ~ 9-12 FINAL DRIVING MECHANISM 9
10-1 ~ 10-10 ALTERNATOR 10
11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11
12-1 ~ 12-12 COOLING SYSTEM 12
13-1 ~ 13-14 BODY COVER 13
14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL 14
15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15
16-1 ~ 16-18 REAR BRAKE/REAR WHEEL/REAR CUSHION 16
17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17
18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

Home page Contents
SERIAL NUMBER
Frame number
Engine number
Homepage Contents
1. GENERAL INFORMATION
Symbols and Marks............................. 1-1 Specifications..................................... 1-10 1

General Safety ..................................... 1-2 Torque Values .................................... 1-11
Service Precautions ............................ 1-3 Troubles Diagnosis............................ 1-13
Specifications ...................................... 1-9 Lubrication Points ............................. 1-18
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are needed, in
case supplemental information is procedures needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.
Means that serious injury or even death may result if procedures are not
Warning
followed.
Caution Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
Engine oil damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)
Grease King Mate G-3 is recommended.
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil # 140)
Apply sealant; medium strength sealant should be used unless otherwise
Locking sealant
specified.
Oil seal Apply with lubricant.。
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools Special tools
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
1-1
To this chapter contents
General Safety
Carbon monoxide Battery
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed Caution
area. Run your engine in an open area, if you • Battery emits explosive gases; flame is strictly
have to run your engine in a closed area, be sure prohibited. Keeps the place well ventilated
to use an extractor. when charging the battery.
Caution • Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
Exhaust contains toxic gas which may cause one do not be spray on your eyes or skin. If you
to lose consciousness and even result in death. get battery acid on your skin, flush it off
immediately with water. If you get battery acid
Gasoline in your eyes, flush it off immediately with
Gasoline is a low ignition point and explosive water and then go to hospital to see an
material. Work in a well-ventilated place, no flame ophthalmologist.
or spark should be allowed in the work place or • If you swallow it by mistake, drink a lot of
where gasoline is being stored. water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a
Caution doctor.
Gasoline is highly flammable, and may explode • Keep electrolyte beyond reach of children.
under some conditions, keep it away from
children. Brake shoe
Do not use an air hose or a dry brush to clean
Used engine oil components of the brake system; use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although Inhaling brake shoe or pad ash may cause
it might not be verified. disorders and cancer of the breathing system
We recommend that you wash your hands with
soap and water right after contacting. Keep the Brake fluid
used oil beyond reach of children.
Caution
Hot components
Spilling brake fluid on painted, plastic, or rubber
Caution parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
Components of the engine and exhaust system protection when servicing the brake system.
can become extremely hot after engine running. Keep the brake fluid beyond reach of children.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.
1-2
Service Precautions
y Always use with SANYANG genuine parts and y Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts unsmooth control and premature worn out.
for SANYANG ATV may damage the ATV.
y Rubber parts may become deteriorated when

y Special tools are designed for remove and old, and prone to be damaged by solvent and oil.
install of components without damaging the Check these parts before installation to make
parts being worked on. Using wrong tools may sure that they are in good condition, replace if
result in parts damaged. necessary.
y When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
y Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
y When servicing this ATV, use only metric tools. installation later.
Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
y Clean the outside of the parts or the cover
before removing it from the ATV. Otherwise, dirt
and deposit accumulated on the part's surface
may fall into the engine, chassis, or brake
system to cause damage.
y Note the reassemble position of the important
y Wash and clean parts with high ignition point
components before disassembling them to
solvent, and blow dry with compressed air. Pay
ensure they will be reassembled in correct
special attention to O-rings or oil seals because
dimensions (depth, distance or position).
most cleaning agents have an adverse effect on
them. y Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
y The length of bolts and screws for assemblies, y Remove residues of the old gasket or sealant
cover plates or boxes is different from one before reinstallation, grind with a grindstone if
another, be sure they are correctly installed. In the contact surface has any damage.
case of confusion, Insert the bolt into the hole to
compare its length with other bolts, if its length
out side the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.
y The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can go
to their connections so that there is enough
room below the enlarged ends for tightening the
clamps.
Groove
y Tighten assemblies with different dimension Clamp

fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with Connector
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise y Rubber and plastic boots should be properly
indicated. Bolts and fasteners should be kept reinstalled to the original correct positions as
clean and dry. Do not apply oil to the threads. designed.
Boots
y When oil seal is installed, fill the groove with y The tool should be pressed against two (inner
grease, install the oil seal with the name of the and outer) bearing races when removing a ball
manufacturer facing outside, and check the bearing. Damage may result if the tool is
shaft on which the oil seal is to be installed for pressed against only one race (either inner race
smoothness and for burrs that may damage the or outer race). In this case, the bearing should
oil seal. be replaced. To avoid damaging the bearing,
use equal force on both races.
Manufacturer's name
Both of these examples can result in

bearing damage.
1-4
y Lubricate the rotation face with specified y After service completed, make sure all
lubricant on the lubrication points before connection points is secured.
assembling. Battery positive (+) cable should be connected
firstly.
y And the two posts of battery have to be greased
after connected the cables.
y Check if positions and operation for installed

parts is in correct and properly.
y Make sure that the battery post caps are

located in properly after the battery posts had
been serviced.
y Make sure service safety each other when
conducting by two persons.
y If fuse burned, it has to find out the cause and

solved it. And then replace with specified
capacity fuse.
y Note that do not let parts fall down.
Capacity
verification
y Before battery removal operation, it has to

remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and
create spark.
1-5
y When separating a connector, it locker has to y Insert the terminal completely.
be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot.
operation. Do not let boot open facing up.
y Secure wires and wire harnesses to the frame

y Do not pull the wires as removing a connector with respective wire bands at the designated
or wires. Hold the connector body. locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
y Make sure if the connector pins are bent,

extruded or loosen.
y Wire band and wire harness have to be

clamped secured properly.
y Insert the connector completely.

If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
y Do not squeeze wires against the weld or its
clamp.
y Check if the connector is covered by the twin

connector boot completely and secured
properly.
y Before terminal connection, check if the boot is

crack or the terminal is loose.
1-6
y Do not let the wire harness contact with rotating, y Protect wires or wire harnesses with electrical
moving or vibrating components as routing the tape or tube if they contact a sharp edge or
harness. corner. Thoroughly clean the surface where
tape is to be applied.
y Keep wire harnesses far away from the hot y Secure the rubber boot firmly as applying it on
parts. wire harness.
Never Touch
y Route wire harnesses to avoid sharp edges or y Never use wires or harnesses which insulation
corners and also avoid the projected ends of has been broken. Wrap electrical tape around
bolts and screws. the damaged parts or replace them.
y Route harnesses so that they neither pull too y Never clamp or squeeze the wire harness as
tight nor have excessive slack. installing other components.
Never clamp or
squeeze the wire
harness
Never too tight
1-7
y Do not let the wire harness been twisted as y With sand paper to clean rust on connector
installation. pins/terminals if found. And then conduct
connection operation later.
Clean rust
y Wire harnesses routed along the handlebar

should not be pulled too tight or have excessive
slack, be rubbed against or interfere with
adjacent or surrounding parts in all steering
positions.
y Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.
Do you know how to set the

instrument to its
measurement position and
the insert locations of its
two probes?
1-8
Specifications
MAKER SANYANG MODEL UA25A
Overall Length 1890 mm Suspension Front Double arm
Overall Width 1055 mm System Rear Unit Swing
Dimension
Overall Height 1115 mm Front AT22x7-10 (off road)

Tire Specifications
Wheel Base 1200 mm Rear AT22x10-9 (off road)
Front 810 mm Rim Aluminum
Wheel tread
Rear 805 mm Front Disk (ψ175mm)
Brake System
Front 109 kg Rear Disk (ψ220mm)
Curb Weight Rear 114 kg Max. Speed Above 80 km/hr
Performance
Total 223 kg Climb Ability Below 25°
Weight
Passengers/Weight Two /150 kg Primary

Belt
Front 142 kg Reduction
Total Weight Rear 231 kg Secondary
Gear / Sprocket
Total 373 kg Reduction Reduction
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and Vertical, below center, C.V.T., auto speed
Transmission
arrangement incline change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Expansion & Pulse
Bore Ø71 mm Muffler
Type
Cylinder
Exhaust Pipe Position and Left side, and

Stroke 63 mm
Direction Backward
Engine
Number/Arrange Forced circulation &

Single Cylinder Lubrication System
ment splashing
Concentration
Displacement 249.4 cc Solid Particulate

Exhaust
Compression Ratio 10.5 : 1 CO Below 7.0 g/ km

Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km
Max. Torque 20.6Nm / 5500rpm Nox Below 0.4g/ km
Ignition C.D.I. E.E.C. ─
Starting System Electrical starter P.C.V. ─
Catalytic reaction control
Air filtration Sponge ─
system
1-9
Specifications
MAKER SANYANG MODEL UA25A1
Overall Length 1890 mm Suspension Front Double arm
Overall Width 1055 mm System Rear Unit Swing
Dimension
Overall Height 1115 mm Front AT22x7-10 (on road)

Tire Specifications
Wheel Base 1200 mm Rear AT22x10-9 (on road)
Front 810 mm Rim Aluminum
Wheel tread
Rear 805 mm Front Disk (ψ175mm)
Brake System
Front 109 kg Rear Disk (ψ220mm)
Curb Weight Rear 114 kg Max. Speed Above 80 km/hr
Performance
Total 223 kg Climb Ability Below 25°
Weight
Passengers/Weight Two /150 kg Primary

Belt
Front 142 kg Reduction
Total Weight Rear 231 kg Secondary
Gear / Sprocket
Total 373 kg Reduction Reduction
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and Vertical, below center, C.V.T., auto speed
Transmission
arrangement incline change
Fuel Used Above 92 unleaded Speedometer 0 ~ 100 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Expansion & Pulse
Bore Ø71 mm Muffler
Type
Cylinder
Exhaust Pipe Position and Left side, and

Stroke 63 mm
Direction Backward
Engine
Number/Arrange Forced circulation &

Single Cylinder Lubrication System
ment splashing
Concentration
Displacement 249.4 cc Solid Particulate

Exhaust
Compression Ratio 10.5 : 1 CO Below 7.0 g/ km

Max. HP 13.2kw / 7000rpm HC Below 1.5g/ km
Max. Torque 20.6Nm / 5500rpm Nox Below 0.4g/ km
Ignition C.D.I. E.E.C. ─
Starting System Electrical starter P.C.V. ─
Catalytic reaction control
Air filtration Sponge ─
system
1-10
Torque Values
The torque values listed in above table are for more important tighten torque values. Please see standard
values for not listed in the table.
Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque
5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
6 mm bolt、nut 0.8~1.2kgf-m 6 mm screw、SH nut 0.7~ 1.1kgf-m
8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m
10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m
12 mm bolt、nut 5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m
Engine Torque Values

Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 8 3.6~4.0
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head side cover bolt 2 6 1.0~1.4
Cylinder head cover bolt 4 6 1.0~1.4
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Tensioner lifter bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 3 0.1~0.3
Water pump impeller 1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 1.1~1.5
Mission filling bolt 1 12 3.5~4.5
Shift drum fixing bolt 1 14 3.5~4.5
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 14 5.0~6.0
Drive face nut 1 14 8.5~10.5
ACG. Flywheel nut 1 14 5.0~6.0
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
1-11
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Handlebar upper holder bolt 4 6 2.40
Steering shaft nut 1 10 5.00
Steering tie-rod nut 4 10 5.00
Knuckle nut 2 10 5.00
Steering shaft holder bolt 2 8 3.40
Tie rod lock nut 4 10 3.60
Handlebar under holder nut 2 8 4.00
Front wheel nut 8 10 2.40
Front axle castle nut 2 14 5.00
Rear axle castle nut 2 14 5.00
Rear wheel nut 8 10 2.40
Engine hanger nut 4 12 8.50
Rear axle holder bolt 4 12 9.20
Drive gear bolt 2 10 4.6
Driven gear nut 4 10 4.6
Swing arm pivot bolt 1 14 9.20
Front suspension arm nut 4 10 5.00
Front / Rear cushion mounting bolt 6 10 4.60
Brake lever nut 2 6 1.00
Brake hose bolt 13 10 3.50
Brake caliper bolt 6 6 3.25
Brake disk mounting bolt 11 8 4.25
Air-bleed valve 3 5 0.50
Exhaust muffler mounting bolt 2 8 3.00
Exhaust muffler connection nut 2 7 1.20
1-12
Troubles Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to

check if there is gasoline inside
the carburetor y No fuel in fuel tank
y Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
y Float valve clogged
Fuel supplied tom No fuel is supplied to
y Lines in fuel tank evaporation system
carburetor sufficient carburetor
clogged
y Malfunction of fuel pump
y Loosen or damaged fuel pump vacuum
Remove spark plug, install it
hose
into spark plug cap, and perform
y Fuel filter clogged
a spark test against engine
ground.
y Malfunction of spark plug
y Spark plug foul
Check if sparks Weak sparks, no spark at
y Malfunction of CDI set
all
y Malfunction of AC generator
y Ignition coil is in open or short circuit
Perform cylinder compression y Ignition coil leads open or short circuit
pressure test. y Malfunction of main switch
Cylinder compression Low compression y Piston ring seized

pressure normal pressure or no pressure y Malfunction of cylinder valves
y Worn cylinder and piston ring
y Cylinder gasket leak
Re-start by following the starting y Sand hole in compression parts
procedures
No ignition There are some signs of y Malfunction of throttle valve operation

ignition; nut engine can y Air sucked into intake manifold
not be started y Incorrect ignition timing
Remove the spark plug again

and check it.
y Fuel level in carburetor too high

Dry spark plug Wet spark plug y Malfunction of throttle valve operation
y Throttle valve opening too wide
Remove carburetor after 30

minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Blowing in normal Blowing clogged y Malfunction of automatic by- starter
1-13
B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration and

check engine speed
y Air cleaner clogged
y Poor fuel supply
Engine speed can be Engine speed can not be
y Lines in fuel tank evaporation system
increased. increased.
clogged
y Exhaust pipe clogged
Check ignition timing (Using y Fuel nozzle clogged in carburetor.
ignition lamp) y Fuel nozzle clogged in carburetor.
Ignition timing correct Incorrect ignition timing y Malfunction of CDI

y Malfunction of AC alternator
Check cylinder compression

pressure (using compression
pressure gauge)
y Cylinder & piston ring worn out
y Cylinder gasket leaked
Compression pressure No compression pressure y Sand hole in compression parts
correct y Valve deterioration
y Seized piston ring
Check if carburetor jet is
clogged
No clogged Clogged y Remove foreign
Remove spark plug
No foul or discoloration Fouled and discoloration y Remove dirt

y Incorrect spark plug heat range
Check if engine over heat

y Piston and cylinder worn out
y Lean mixture
y Poor fuel quality
Normal Engine overheat y Too much carbon deposited in
combustion chamber
y Ignition timing too advanced
y Poor circuit on the cooling system
Continually drive in acceleration
or high speed
y Too much carbon deposited in
combustion chamber
No knock Knock y Lean mixture
y Poor fuel quality
1-14
C. Engine runs sluggish (especially in low speed and idling)

Check ignition timing (using

ignition lamp)
Normal Abnormal y Incorrect ignition timing (malfunction of

CDI or AC alternator)
Adjust the air screw of

carburetor
Good Poor y Rich mixture (loosen the screw)

y Lean mixture (tighten the screw)
Air sucked through carburetor
gasket
y Poor heat insulation gasket
y Carburetor lock loose
No air sucked Air sucked y Poor intake gasket
y Poor carburetor O-ring
y Vacuum hose crack
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground y Spark plug fouled
y Malfunction of CDI
y Malfunction of AC generator
Good spark Poor y Malfunction of ignition coil
y Open or short circuit in spark plug leads
y Malfunction of main switch
D. Engine runs sluggish (High speed)
Check ignition timing
Normal Abnormal y Malfunction of CDI

y Malfunction of AC alternator
Check for fuel supplying system

in automatic fuel cup
y Insufficient fuel in fuel tank

Good Abnormal y Fuel filter clogged
y Restricted fuel tank vent
Check if carburetor clogged
No clogged Clogged y Cleaning
1-15
E. Clutch, driving and driving pulley
FAULT CONDITIONS PROBABLE CAUSES
y Drive belt worn out or deformation

y Ramp plate of movable drive face damaged
Engine can be started but
motorcycle can not be moved. y Driving pulley spring broken
y Clutch weights broken
y Drive slide-shaft gear groove broken
y Transmission gear damaged
Engine running and misfire as y Clutch weights spring broken

motorcycle initial forward moving or y Clutch outer stuck with clutch weights
jumping suddenly (rear wheel
y Connection parts in clutch and shaft worn out or burned
rotating as engine in running)
y Drive belt worn out or deformation

y Weight roller worn out
Poor initial driving (Poor climbing
performance) y Movable drive face shaft worn out
y Driven pulley spring deformation
y Driven pulley shaft worn out
y Greased in drive belt and driven face.
F. Poor handling
FAULT CONDITIONS PROBABLE CAUSES
Steering is heavy y Damaged steering bearing

y Damaged steering shaft bushing
y Bent rim
y Improperly installed wheel hub
One wheel is wobbling y Excessive wheel bearing play
y Bent swing arm
y Bent frame
y Swing arm pivot bushing excessively
y Worn
y Bent tie-rod
y Incorrect tie-rod adjustment
Vehicle pulls to one side y Rear tie air pressure incorrect
y Improper wheel alignment
y Bent frame
1-16
G. Loss power
Raise wheels off ground and

spin by hand
y Brake dragging
Spin freely Abnormal y Drive chain too tight
y Damaged wheel bearing
y Wheel bearing needs lubrication
Check tire pressure
Normal Abnormal y Punctured tire

y Faulty tire valve
Accelerate lightly, engine speed

can be increase
y Fuel / air mixture ratio too rich or lean
y Clogged in air cleaner
Normal Abnormal y Clogged in muffler
y Restricted fuel flow
y Clogged fuel tank cap breather hole
Check ignition timing
Normal Abnormal y Faulty pulse generator

y Faulty CDI unit
Test cylinder compression
Normal Abnormal y Leaking head gasket

y Worn cylinder and piston rings
Check carburetor
Normal Clogged y Clean
Check spark plug
Normal Fouled or discolored y Clean the spark plug

y Spark plug is incorrect heat range
Check for engine overheating

y Excessive carbon deposited in
combustion chamber
Normal Overheating y Wrong type of fuel
y Fuel / air mixture ratio is lean
y Use of poor quality fuel
Accelerate or run at high speed
y worn piston and cylinder
y Fuel / air mixture ratio is lean
Normal Knocks y Wrong type of fuel
y Excessive carbon deposited in
combustion chamber
1-17
Lubrication Points
Drive chain Acceleration cable/ Front & rear brake

lever pivot
Speedometer gear Wheel bearing
1-18
Home page Contents
2. MAINTENANCE INFORMATION
Precautions in Operation ···················· 2-1 Drive Chain ··········································· 2-7

Periodical Maintenance Schedule ······ 2-2 Brake System (Disk Brake) ················· 2-8
2
Fuel Lines ············································· 2-3 Brake Light Switch/Starting Inhibitor
Acceleration Operation ······················· 2-3 Switch ··················································· 2-9
Air Cleaner············································ 2-3 Headlight Beam Distance ···················· 2-10

Clutch Disc Wear ································· 2-10
Spark Plug ············································ 2-3
Cushion················································· 2-10
Valve Clearance ··································· 2-4
Steering Handle···································· 2-11
Carburetor Idle Speed Adjustment····· 2-5
Wheel/Tire············································· 2-11
Ignition System ···································· 2-6
Cylinder Compression Pressure ········ 2-6 Nuts, Bolts Tightness ·························· 2-11
Special Tools List ································ 2-12
Drive Belt ·············································· 2-7
Precautions in Operation
Specification
Fuel Tank Capacity 12000 c.c.
Capacity 1400 c.c.
Engine Oil
Change 1200 c.c.
Capacity 750 c.c.
Transmission Gear oil
Change 650 c.c.
Engine + radiator 850 c.c.
Capacity of coolant
Reservoir upper 420 c.c.
Clearance of throttle valve 1~3 mm
Type NGK CR8E
Spark plug
Gap 0.8 mm
“F” Mark in idling speed BTDC 10º / 1700 rpm
Full timing advanced BTDC 27º / 4000 rpm
Idling speed 1700±100 rpm
Cylinder compression pressure 12.0 ±2 kgf/cm²
Valve clearance IN:0.10 ± 0.02 mm EX:0.15 ± 0.02 mm
Front AT22x7-10
Tire dimension
Rear AT22x10-9
Tire pressure (cold) 3.8±2 psi
Battery 12V10Ah (MF battery) type: YTX12-BS
2-1
Periodical Maintenance Schedule

1 Month 3 month 6 month 1 year 15 month
Maintenance Every
Item every every every every every
Code 300KM
1,000KM 3,000KM 6000KM 12,000KM 14,500KM
1 Air cleaner I C R
2 Fuel filter I I R
3 Oil filter C C
4 Engine oil change R Replacement for every 1000 km
5 Tire pressure I I
6 Battery inspection I I
7 Brake & free ply check I I
8 Steering handle check I I
9 Cushion operation check I I
10 Every screw tightening check I I
11 Gear oil check for leaking I I
12 Spark plug check or change I I R
13 Gear oil change R Replacement for every 5000 km
14 Frame lubrication L
15 Exhaust pipe I I
16 Ignition timing I I
17 emission check in Idling A I
18 Throttle operation I I
19 Engine bolt tightening I I
20 CVT driving device(belt) I R
21 CVT driving device(roller) C
22 Drive chain I/L I/L C
Lights/electrical
23 I I
equipment/multi-meters
24 Fuel lines I I
25 Cam chain I I
26 Valve clearance I A
27 Lines & connections in cooling I I
t
28 Coolant reservoir I I
29 Coolant I I R
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your ATV checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to
maintain the ATV at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever
comes first.
Remarks: 1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or in
the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and
after the ATV has accumulated a higher mileage.
3. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire,
after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system
when power is obvious lower. Than ever
2-2
Fuel Lines Fuel tank

Remove
Loosen 2the seat.and 2 bolts
screws
Remove the tank cover
Check all lines, and replace it when they are
deterioration, damage or leaking Fuel hose
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it. Vacuum hose
Fuel filter
Acceleration Operation
Have a wide open of throttle valve as handle in
any position and release it to let back original (full Lock nut
closed) position.
Check handle if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth.
Measure the throttle lever free play in its flange
part.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment screw.
Tighten the fixing nut, and check acceleration
operation condition.
Free play: 1~3 mm.
Throttle adjustment screw
Air Cleaner
Remove seat. Clamp Element
loosen 4 hooks from the air cleaner cover and
then remove the cover.
Loosen the clamp strip and 1 screw of air cleaner
element, and then remove the air cleaner element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Caution
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and then
squeeze it out. Install the element onto the
element seat and then install the air cleaner cover.
Ground electrode
Spark Plug
Recommended spark plug: CR8E Central electrode
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap：0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it. 0.8~0.9mm
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0~1.2kgf-m
2-3
Valve Clearance Timing mark
Caution
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank. 2 bolts
Remove cylinder head cover.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.
Valve clearance inspection and adjustment.

Check & adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.
2-4
Carburetor Idle Speed Adjustment Ignition cable
Caution
y Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
y Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV with main stand and warm up
engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Stopper screw
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1700 ± 100 rpm
Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let
engine runs in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe. Air adjustment screw
Adjust the air adjustment screw so that
emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm
2-5
Ignition System CDI unit
Caution
y C.D.I ignition system is set by manufacturer so
it can not be adjusted.
y Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Connect tachometer and ignition light.
Start engine.
As engine in idle speed: 1600 rpm, aim at the
mark “F” with the ignition light. Then, it is means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it is means that the
ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if
malfunction of these parts is found.
Cylinder Compression Pressure

Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
y Incorrect valve clearance.
y Valve leaking.
y Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
2-6
Drive Belt Clamp strips
Loosen the 2 clamp strips of left crankcase cover,

and then remove the left crankcase cover vapor
hose.
Remove 9 bolts of the engine left side cover and
the cover.
9 bolts
Check if the belt is crack or worn out.

Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.
Width limit: 22.5 mm or above Teeth
Width
Drive Chain
Check the drive chain
Park the ATV on a level ground, and shift the
transmission onto neutral.
Measure the drive chain slack midway between
the sprockets.
Chain slack: 15~25mm (5/8~1 inch)
2 nuts
Adjust the chain slack

Loosen the axle holder lock nuts and bolts Lock nut
Loosen drive chain adjusting bolt lock nut and turn
drive chain adjusting bolt until get the correct
slack.
Tighten the axle holder nuts and bolts.
Torque: 3.25kgf-m
Adjustment bolt
2-7
Brake System (Disk Brake)

Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found
Caution
y In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
y Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
y Do not mix non-compatible brake fluid together.
Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid.
Screws
Operate the brake lever so that brake fluid
contents inside the brake system hoses. Master cylinder cap
Diaphragm plate
Air Bleed Operation Upper
Diaphragm
Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release
the brake lever.
Air bubble Drain valve
Added Brake Fluid

Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent from
damage brake system or reducing brake
performance. Transparent hose
2-8
Brake Lining Wear Front brake

The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark Lining
closed to the edge of brake disc.
Caution
y To check front brake lining must be remove Brake lining wear
front wheel first. limitation groove
y It is not necessary to remove brake hose when
replacing the brake lining.
Brake disk
Brake Lining Replacement (refer chapter Rear brake

14)
Make sure the brake lining condition. Replace
the lining if the brake lining wear limitation groove Brake lining wear
close to the brake disc. limitation groove
Caution
y Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
y In order to maintain brake power balance, the
brake lining must be replaced with one set.
Brake Light Switch/Starting Inhibitor

Brake switch
Switch
The brake light switch is to light up brake light as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.
Brake switch
2-9
Headlight Beam Distance

Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.
Caution
y To adjust the headlight beam follows related
regulations.
y Improper headlight beam adjustment will
make in coming driver dazzled or insufficient
lighting.
Adjust screw
Clutch weight
Clutch Disc Wear
Run the ATV and increase throttle valve opening
gradually to check clutch operation.
If the ATV is in forward moving and shaking, check
clutch disc condition. Replace it
Drive plate
Cushion
Warning
y Do not ride the ATV with poor cushion.
y Looseness, wear or damage cushion will make
poor stability and drive-ability.
Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear Cushion
Press down the rear cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
2-10
Steering Handle
Caution
Check all wires and cables if they are interfered
with the rotation of steering handle bar.
Lift the front wheel out of ground.

Turn handle from right to left alternative and check
if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
check the handle top bearing.
Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.
Check if tire surface is ticked with nails, stones or

other materials.
Appointed tire pressure
Tire size Front tire Rear tire
Tire pressure as cold 3.8±2psi
Check if front and rear tires’ pressure is in normal.

Measure tire thread depth from tire central surface.
Replace the tire if the depth is not come with
following specification:
Front tire: 1.5 mm
Rear tire: 2.0 mm
Nuts, Bolts Tightness

Perform periodical maintenance in accord with the
Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamp, and
wire holders for security.
2-11
Special Tools List
NAME Rocker arm pin puller NAME Tappet adjusting wrench NAME Tappet adjusting wrench
NO SYM-1445100 NO SYM-9001200 NO SYM-1472100
Valve cotter remove &

NAME Tappet adjuster NAME assembly tool
NAME AC.G. Flywheel puller
NO SYM-9001209 NO SYM-1471110/20 NO SYM-3110000-HMA
Driver shaft install bush & seal

NAME Left crank seal driver NAME Drive shaft puller NAME driver
NO SYM-1332100-HMA NO SYM-2341110-HMA NO SYM-9120200-HMA
Counter shaft needle bearing

NAME Bearing driver 6205LLU NAME Rear axle bearing driver NAME drive HK1516
SYM-9100100 RA1
NO SYM-9100410/440 NO NO SYM-9100200-HMA
A3017
2-12
Counter shaft needle bearing Left crank case cover bearing

NAME driver HK2016
NAME Bearing driver 6305 NAME driver 6000
NO SYM-9100300-RB1 NO SYM-2341110 NO SYM-9615000-RA1 6000
NAME Bearing driver 6205 NAME Seal driver 14x28x7 &14x26x6 NAME Seal driver 30x40x5
NO SYM-9615000 NO SYM-9120600 RB1 RA1 NO SYM-9120100-RA1
(12*20*5) (6901)
Water pump mechanical
NAME Water pump oil seal driver NAME Water pump bearing driver NAME
seal driver
NO SYM-9120500-H9A NO SYM-9100100 NO SYM-1721700-H9A
(6301) (6204)
NAME BEARING DRIVER NAME BEARING DRIVER NAME Lock nut driver
2-13
NAME Inner bearing puller NAME Inner bearing puller NAME Outer bearing puller
NAME Universal holder NAME Clutch nut wrench NAME Clutch spring compressor
(55mm) (55mm)
NAME Rear axle nut wrench NAME Torque wrench NAME Rear axle nut torque wrench
NO SYM-HT06007 NO SYM-HT07004-RA1 NO SYM-4230200
NAME NAME NAME

NO NO NO
2-14
Home page Contents
3. LUBRICATION SYSTEM
Mechanism Diagram ······························ 3-1 Engine Oil Strainer Clean ······················ 3-3
Precautions in Operation ······················ 3-2 Oil Pump ················································· 3-4
Troubleshooting ···································· 3-2 Gear Oil ··················································· 3-7
Engine Oil ··············································· 3-3 3
Mechanism Diagram
Valve Rocker Arm
Press-In Lubrication
Cam Shaft
Oil Route
Spray Lubrication
Con-Rod
Oil Route
Spray Lubrication
Press-In Lubrication
Rotate Direction
Oil Pump
Oil Strainer
3-1
General Information:
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1400 c.c.
Change: 1200c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)
單位:mm
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Oil pump Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil strainer cap 1.3~1.7kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Gear oil drain bolt 1.1~1.5kgf-m
Gear oil join bolt 3.5~4.5kgf-m
Oil pump connection screw 0.1~0.3kgf-m
Troubleshooting
Low engine oil level Dirty oil
y Oil leaking y No oil change in periodical
y Valve guide or seat worn out y Cylinder head gasket damage
y Piston ring worn out y Piston ring worn out
Low oil pressure

y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage
3-2
Engine Oil
Turn off engine, and park the ATV in flat surface
with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Drain bolt
Caution
Drain oil as engine warmed up so that makes
sure oil can be drained smoothly and completely.
Place an oil pan under the ATV, and remove oil

drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value：3.5~4.5kgf-m
Engine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil. Oil strainer cap
Engine oil capacity: 1200c.c. when replacing
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Oil strainer
O-ring
3-3
Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
Clip
Remove cir clip and take out oil pump driving
chain and sprocket.
Make sure that pump shaft can be rotated freely.

Remove 2 screws on the oil pump, and then
remove oil pump.
2 screws
Oil Pump Disassembly 1 screw

Remove the screws on oil pump cover and
remove the cover.
Remove oil pump shaft roller and shaft.
Roller
3-4
Oil Pump Inspection

Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer rotors.

Limit: 0.20 mm
Check clearance between rotor side face and

pump body
Limit: 0.12 mm
Pins
Oil Pump Re-assembly
Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner
rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.
3-5
Tighten the oil pump screw. 1 screw
Roller
Oil Pump Installation

Install the oil pump, and then tighten screws.
Make sure that oil pump shaft can be rotated
freely.
2 screws
Install oil pump drive chain and sprocket, and Clip
then install cir clip onto oil pump shaft.
Install starting gear and generator.

(Refer to chapter 10)
3-6
Gear Oil Gear oil join bolt
Gear Oil Change

Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.
Torque value: 1.1~1.5kgf-m
Make sure that the drain bolt washer can be
re-used.
Add oil to specified quantity from the join hole.
Gear Oil Quantity: 650c.c. when replacing
Make sure that the join bolt washer can be
re-used, and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
Gear oil drain bolt
3-7
Notes:
3-8
Home page Contents
4. FUEL SYSTEM
Mechanism Diagram ............................ 4-1 Throttle Valve .......................................4-6

Precautions in Operation..................... 4-2 Float Chamber......................................4-7
Trouble Diagnosis................................ 4-3 Adjustment of Idle Speed....................4-9
Carburetor Remove / Install ................ 4-4 Fuel Tank ..............................................4-10
Air Cut-Off Valve .................................. 4-5 Air Cleaner............................................4-11 4
Mechanism Diagram
Fuel tank cap
Fuel unit
Fuel tank
Auto fuel cock
Carburetor
Fuel strainer
Inlet pipe
4-1
4. FUEL SYSTEM
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.
Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
y There is a drain screw in the float chamber for draining residual gasoline.
y Do not disassemble air cut valve arbitrarily.
Specification
ITEM UA25A
Carburetor diameter Ø22mm
I.D. number PTG 050
Fuel level 14.8mm
Main injector # 110
Idle injector # 35
Idle speed 1700 ± 100rpm
Throttle handle clearance 1~3 mm
Pilot screw 2 turns
Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge
4-2
4. FUEL SYSTEM
Trouble Diagnosis
Poor engine start Mixture too lean
y No fuel in fuel tank y Clogged fuel injector
y Clogged fuel tube y Vacuum piston stick and closed
y Too much fuel in cylinder y Malfunction of float valve
y No spark from spark plug(malfunction of ignition y Fuel level too low in float chamber
system ) y Clogged fuel tank cap vent
y Clogged air cleaner y Clogged fuel filter
y Malfunction of carburetor chock y Obstructed fuel pipe
y Malfunction of throttle operation y Clogged air vent hose
y Air existing in intake system
Stall after started

y Malfunction of carburetor chock Mixture too rich
y Incorrect ignition timing y Clogged air injector
y Malfunction of carburetor y Malfunction of float valve
y Dirty engine oil y Fuel level too high in float chamber
y Air existing in intake system y Malfunction of carburetor chock
y Incorrect idle speed y Dirty air cleaner
Rough idle
y Malfunction of ignition system
y Incorrect idle speed
y Malfunction of carburetor
y Dirty fuel
Intermittently misfire as acceleration

Late ignition timing

y Malfunction of carburetor
Power insufficiency and fuel consuming

y Fuel system clogged
4-3
4. FUEL SYSTEM
Carburetor Remove / Install

Removal
Drain out fuel in the float chamber.
Drain bolt
Loosen the choke cable fixed iron sheet screw 1 screw

from plate.
Remove the choke cable.
Choke cable
Vacuum pipe Fuel pipe

Disconnect the fuel hose.
Release the clamp strip of air cleaner.
Clamp
Remove the carburetor upper parts from the

carburetor.
Release the 2 nuts of carburetor insulator, and
then remove the carburetor.
Installation
Install in reverse order of removal procedures.
2 nuts
4-4
4. FUEL SYSTEM
Air Cut-Off Valve 2 screws
Disassembly
Remove 2 screws.
Remove air cut-off valve cover, spring and valve. O-ring Spring
Air cut-off valve Cover
Inspection
Check the valve is in normal.
If the valve is in normal, it will restrict air-flow.
If air-flow is no restricting, replace carburetor
assembly.
Check the vacuum pipe o-ring is in normal.
Assembly
4-5
4. FUEL SYSTEM
Throttle Valve
Disassembly
Remove carburetor upper parts, and then remove
throttle valve and throttle cable.
Throttle valve
Disconnect the throttle cable from the throttle

valve and remove the valve spring.
Remove the fuel needle clamp and fuel needle. Spring
Assembly
Place the fuel needle onto the throttle valve and Needle clamp
clip it with needle clamp.
Install the sealed cap, carburetor upper part, and Fuel needle clip
throttle valve spring.
Connect the throttle valve cable to the throttle Fuel needle
Throttle
valve. cable
Install the throttle valve into the carburetor body.
Caution
Align the groove inside the throttle valve with the
throttle stopper screw of the carburetor body.
Tighten the carburetor upper part.

Adjust the free play of throttle valve cable.
4-6
4. FUEL SYSTEM
Float Chamber
Disassembly
Remove 3 mounting screws and remove float
chamber cover.
3 Screws
Remove the fuel level plate, float pin, float and Float Float valve
float valve.
Fuel level plate Pin
Inspection Pin
Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.
Caution
In case of worn out or dirt, the float valve and
valve seat will not tightly close causing fuel level
to increase and as a result, fuel flooding. A worn
out or dirty float valve must be replaced with a
Float Float valve
new a new one.
Check for wear or damage
4-7
4. FUEL SYSTEM
Remove main jet, needle jet holder, needle jet,
slow jet and air adjustment screw. Needle jet holder
Main jet
Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
the way down and note the number of turns.
y Does not turn adjust screw forcefully to avoid
damaging valve seat face.
Clean jets with cleaning fluid. Then use Needle jet Slow jet
compressed air to blow the dirt off.

Blow carburetor body passages with compressed
air.
Assembly
Install main jet, needle jet holder, needle jet, slow
jet and air adjustment screw.
Caution
Set the air adjustment screw in according to
number of turns noted before it was removed.
Install the float valve, float, and float pin.
Air adjustment screw
Checking fuel level

Caution
y Check again to ensure float valve, float for
proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber
face is vertical to the main jet.
Fuel level: 14.8mm
Float gauge
Installation of carburetor Lock nut
Install carburetor in the reverse order of removal.

Following adjustments must be made after
installation.
˙Throttle cable adjustment.
˙Idle adjustment
Throttle adjustment screw
4-8
4. FUEL SYSTEM
Adjustment of Idle Speed Parking brake
Caution
y Air screw was set at factory, so no adjustment
is needed. Note the number of turns it takes to
screw it all the way in for ease of installation.
y The parking brake must be used to stop the
ATV to perform the adjustments.
Use a tachometer when adjusting engine RPM.

Screw in air adjustment screw gently, then back up
to standard turns.
Standard turns: 2 turns
Warm up engine; adjust the throttle stopper screw
of throttle valve to standard RPM. Throttle valve stopper screw
Idle speed rpm: 1700 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust
front end. Press test key on the analyzer.
Adjust the pilot screw and read CO reading on the
analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments; make sure rpm
and CO value are in standard value after engine
running in stable. If rpm and CO value fluctuated,
repeat the procedures described above for
adjusting to standard value.
Air adjustment screw
4-9
4. FUEL SYSTEM
Fuel Tank 4 bolts
Fuel unit removal

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).
Caution
˙Do not bend the float arm of fuel unit Coupler
˙Do not fill out too much fuel to fuel tank.
Fuel unit inspection (Refer to electrical equipment

chapter 17).
Fuel unit installation

Install the gauge in the reverse order of removal.
Caution
Do not forget to install the gasket of fuel unit or
damage it.
Fuel tank removal Fuel tube

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).
Remove the fuel tube.
Remove the vacuum tube.
Vacuum tube
Remove fuel tank front and rear side 4 bolts, and FRONT
then remove fuel tank.
Installation
Install the tank in the reverse order of removal.
4 bolts
REAR
4-10
4. FUEL SYSTEM
Air Cleaner Clamp
Removal
Loosen the clamp strip of air cleaner and
carburetor, and then remove the vapor hose.
Loosen the clamp strip of air cleaner, and then

remove the air cleaner vapor hose.
Remove the air cleaner (4 bolts).
Installation
Install the tank in the reverse order of removal.
Clamp 4 bolts
Cleaning air cleaner element 4 hooks
Remove the air cleaner cover (4 catch hooks).
Remove element mounting screw.

Loosen the clamp strip of air cleaner element, and
Clamp 1 screw
then remove the air cleaner element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Caution
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and then
squeeze it out. Install the element onto the
element seat and then install the air cleaner cover.
4-11
4. FUEL SYSTEM
Notes:
4-12
Home page Contents
5. ENGINE REMOVAL
Precautions in Operation ..................... 5-1 Engine Installation ................................ 5-6

Removal of Engine ............................... 5-2
General Information
y The engine has to be supported with special service tools that can be lifted or adjustable.
y Engine shall be removal in the conditions of necessary repair or adjustment to the only. 5
y The following parts can be serviced as engine mounted on frame:
Carburetor.
Drive pulley, drive belt, clutch, and movable drive face assembly.
Start motor.
AC. Generator, oil pump and start one way clutch.
Transmission.
Specification
Item Capacity
Replacement 1200 c.c.

Engine oil capacity
Disassembly 1400 c.c.
Replacement 650 c.c.

Gear oil capacity
Disassembly 750 c.c.
Engine & radiator 780 c.c.
Coolant capacity Reservoir 420 c.c. AS indicator shown
Total 1200 c.c.
Torque Value
Engine hanger bolt 7.5~9.5kgf-m
Exhaust muffler mounting bolt 2.8~3.2kgf-m
Exhaust muffler connection nut 1.0~1.4kgf-m
5-1
5. ENGINE REMOVAL
Removal of Engine Negative

Remove the seat.
Remove battery negative post (-).
Remove battery positive (+) post.
Remove front fender and the footrest (refer chapter 13).
Positive
Remove starter motor wire. Starter motor wire
Remove the spark plug cap. Spark plug cap
Disconnect A.C. Generator wire couplers. A.C.G wire couplers
5-2
5. ENGINE REMOVAL
Remove muffler protect (2 bolts).
2 bolts
Loosen muffler front side bolt.
2 bolts
Remove 2 bolts, and then remove the exhaust muffler.
2 bolts
Remove 2 nuts, and then remove exhaust pipe.
2 nuts
5-3
5. ENGINE REMOVAL
Loosen 1 screw and disconnect the choke cable. 1 screw
Choke cable
Remove fuel pipe and vacuum pipe. Vacuum pipe Fuel pipe
Release the clamp strip of air cleaner duct.
Clamp
Disconnect the carburetor upper parts and cable.

Release the 2 nuts of carburetor insulator, and
then remove the carburetor.
2 nuts
Release the clamp strips of left crankcase cover

Clamps
ducts, and then remove the ducts.
5-4
5. ENGINE REMOVAL
Remove coolant drain bolt, and drain out coolant. Water hoses clamp
Remove coolant inlet hoses from water pump.
Drain bolt
Remove the thermo-sensor wire, by-pass pipe and By-pass pipe Outlet hose
coolant outlet hose.
Thermo-sensor wire
Remove gear change lever (1 bolt).
1 bolt
Remove change switch couplers.
Change switch couplers
5-5
5. ENGINE REMOVAL
Loosen speedometer cable mounting nut, and Speedometer cable

then remove the cable.
Remove 3 bolts and remove drive chain protector.
Turn the socket bolt clockwise, and then remove
3 bolts
speedometer gear box.
Caution
The socket bolt is provided with left turn
thread.
Socket bolt
Remove 2 bolts, and then remove the drive

sprocket fixing plate, drive chain and drive
sprocket.
2 bolts
Remove the rear side engine hanger mounting

nuts and bolts.
Remove the front side engine hanger mounting

nut and bolt
Remove left side engine hanger, and then remove
engine by left side.
Engine Installation
2 nuts
Check if the bush of engine hanger parts for
damage.
Install engine in the reverse procedures of 1 nut
removal.
Caution
y Pay attention of foot & hand safety as engine
installation to avoid hurting.
y Do not bend or twist wires.
y Cables wires have to be routed in accordance
with normal layout.
Engine hanger Bolt:
5-6
Home page Contents
6. CYLINDER HEAD/VALVE
Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10

Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11
Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13
Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-14
Cylinder Head Inspection··················· 6-7 Valve Clearance Adjustment············· 6-16
Mechanism Diagram
6
1.0~1.4kgf-m
1.0~1.4kgf-m
3.6~4.0kgf-m
2.4~3.0kgf-m
1.0~1.4kgf-m
1.0~1.4kgf-m 1.0~1.2kgf-m
0.7~1.1kgf-m
1.0~1.4kgf-m
1.0~1.2kgf-m
6-1
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
y Cylinder head service can be carried out when engine is in frame.
Specification
Item Standard Limit
Compression pressure 12±2 kg/cm2 ---
Intake 34.880 34.860
Camshaft Height of cam lobe
Exhaust 34.740 34.725
ID of valve rocker arm 11.982~12.000 12.080
Rocker arm
OD of valve rocker arm shaft 11.966~11.984 11.936
Intake 4.975~4.990 4.900
OD of valve stem
Exhaust 4.950~4.975 4.900
ID of valve guide 5.000~5.012 5.030
Clearance between Intake 0.010~0.037 0.080

valve stem and guide Exhaust 0.025~0.062 0.100
Valve
Free length of valve Inner 38.700 35.200
spring outer 40.400 36.900
Valve seat width 1.600 ---
Intake 0.10±0.02mm ---
Valve clearance
Exhaust 0.15±0.02mm ---
Tilt angle of cylinder head --- 0.050
Torque Value
Cylinder head cover bolt 1.0~1.4kgf-m
Exhaust pipe stud bolt 2.4~3.0kgf-m
Cylinder head bolt 1.0~1.4kgf-m
Cylinder head Nut 3.6~4.0kgf-m
Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cylinder side cover bolt 1.0~1.4kgf-m
Cam sprocket bolt 1.0~1.4kgf-m
Tappet adjustment screw nut 0.7~1.1kgf-m
Spark plug 1.0~1.2kgf-m
Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-2
Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise generated.
Low compression pressure

1. Valve
y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston ring worn out.
High compression pressure

y Too much carbon deposit on combustion chamber or piston head
Noise
y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Chain wear out or looseness
y Auto-tensioner wear out or damage
y Camshaft sprocket
y Rocker arm or rocker arm shaft wear out
6-3
Cylinder Head Removal 2 nuts
Remove engine. (Refer to chapter 5)

Remove the inlet pipe (2 nuts).
Remove 1 bolt of thermostat and then remove the Thermostat bolts

thermostat.
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Tensioner bolts
Remove Air Injection system (AI) pipe mounting 4 bolts Spark plug
bolts.
Remove spark plug.
Remove the side cover mounting blots of cylinder 3 bolts

head, and then take out the side cover.
6-4
Remove left crankcase cover, and turn the
Timing mark
Turn the drive face, and align the timing mark on
the sprocket with that of cylinder head, piston is at
TDC position.
Remove cam sprocket bolts and then remove the
sprocket by prying chain out.
2 bolts
Cam shaft setting plate

Remove cam shaft setting plate (1 bolt).
Rocker arm shafts

Remove rocker arm shafts and rocker arms.
Special Service Tool:
Rocker arm and cam shaft puller
Rocker arm shaft and

cam shaft puller
Remove cam shafts. Cam shafts

Rocker arm and cam shaft puller
Rocker arm
shaft and cam
shaft puller
6-5
Remove the 2 cylinder head mounting bolts from 4 Nuts
cylinder head right side, and then remove 4 nuts
and washers from cylinder head upper side.
Remove the cylinder head.
2 bolts
Gasket
Remove cylinder head gasket and 2 dowel pins.
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Caution
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide Dowel pins
Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.
Caution
y In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.
Valve cotter remove & assembly tool
Valve cotter remove
and assembly tool
Inlet valve Inner spring Spring retainer
Exhaust valve Outer spring Cotter
6-6
Remove valve stem seals.
Valve stem seals
Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of cylinder
head.
Cylinder Head Inspection

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm
EX: Replacement when less than 34.725mm
Inspect the camshaft bearing for looseness or
wear out. If any damage, replace whole set of
camshaft and bearing.
6-7
Rocker Arm
Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?
Service Limit: Replace when it is less than
12.080 mm.
Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm
shaft and cam rocker arm.
Service Limit: Replace when it is less than
11.936 mm.
Calculate the clearance between the rocker arm

shaft and the rocker arm.
Service Limit: Replace when it is less than 0.10
mm.
Valve spring free length

Measure the free length of intake and exhaust
valve springs.
Service limit:
Inner spring 35.20 mm
Outer spring 36.90 mm
Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
6-8
Valve guide
Caution 5.0 mm valve guide reamer
Before measuring the valve guide, clean carbon
deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner

diameters.
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.08 mm
EX→0.10 mm
Caution
If clearance between valve stem and valve guide
exceeded service limit, check whether the new
clearance that only replaces new valve guide is
within service limit or not. If so, replace valve
guide.
Correct it with reamer after replacement.

If clearance still exceeds service limit after
replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve
guide.
6-9
Valve Stem Replacement

Heat up cylinder head to 100~150 ℃ with heated Valve guide driver
plate or toaster. 5.0mm
Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
y Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old

valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Caution
y Check if new valve guide is deformation after Valve guide driver
pressed it in. 5.0 mm
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150℃.
Adjust the valve guide driver and let valve guide
height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve guide
with reamer.
Caution
Valve guide reamer 5.0 mm
y Using cutting oil when correcting valve guide
with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-10
Valve Seat Inspection and Service

Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other
manual grinding tool.
Caution
y Do not let emery enter into between valve stem
and valve guide.
y Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and
valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is
roughness, wear out, or incomplete contacted
with valve seat.
Valve seat width
Valve seat inspection

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

Service limit: 1.6mm
Check the contact condition of valve seat.
Valve seat grinding

The worn valve seat has to be ground with valve
Roughness
seat chamfer cutter.
Refer to operation manual of the valve seat
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any rough
or uneven surface from valve seat.
45°
Caution
After valve guide had been replaced, it has to be
ground with 45° valve seal chamfer cutter to
correct its seat face.
Use 32° cutter to cut a quarter upper parts out.
Old valve seat width
32°
6-11
Use 60° cutter to cut a quarter lower parts out.
Remove the cutter and check new valve seat.
Old valve seat width
60°
Use 45° cutter to grind the valve seat to specified

width.
1.0mm
Caution
Make sure that all roughness and uneven faces
had been ground.
Grind valve seat again if necessary.
45°
Coat the valve seat surface with red paint.

Install the valve through valve guide until the valve Contact surface too high
contacting with valve seat, slightly press down the
valve but do not rotate it so that a seal track will be Old valve seat width
created on contact surface.
Caution
32°
The contact surfaces of valve and valve seat are
very important to the valve sealing capacity.
If the contact surface too high, grind the valve seat

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

with 60° cutter.
Then, grind the valve seat to specified width.
60°
6-12
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and valve
after ground.
Cylinder Head Reassembly

Valve spring retainer
Lubricate valve stem with engine oil, and then Valve stem seal
insert the valve into valve guide.
Install new valve stem oil seal. Valve cotter
Install valve springs and retainers. Inlet valve
Caution
The closed coils of valve spring should face down
to combustion chamber.
Valve spring
Exhaust valve
Use a valve cotter remove & assembly tool to

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

Valve cotter remove & assembly tool Valve cotter remove
and assembly tool
Tap the valve stems gently with a plastic hammer

to make sure valve retainer and valve cotter is
settled.
Caution
Place and hold cylinder head on to working table
so that can prevent from valve damaged.
6-13
Cylinder Head Installation Gasket

Clean up all residues and foreign materials onto
the matching surfaces of both cylinder and
cylinder head.
Install chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.
Caution
Do not damage the matching surfaces of cylinder
and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning. Chain guide Dowel pins
Install 4 washers and tighten 4 nuts on the cylinder 4 Nuts

head upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head right side.
Torque value:
Nut 3.6~4.0kgf-m
Bolt 1.0~1.4kgf-m
2 bolts
Install camshaft into cylinder head, and install

rocker arm, rocker arm shaft.
Install rocker arm pin mounting plate. Cam shaft setting plate
6-14
Install cam chain on to sprocket and align the
Timing mark
timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.
Caution 2 bolts
Make sure timing marks are matched.
Install cylinder head side cover (3 bolts). 3 bolts

Install thermostat (2 bolts).
Thermostat bolts
Loosen auto tensioner adjustment bolt and

remove bolt and spring.
Install tensioner and install spring and adjustment
bolt.
Tensioner adjustment bolt
Install cylinder cover (4 bolts).
4 bolts
6-15
Install Air Injection system (AI) pipe. (4 bolts) 4 bolts Spark plug
Install inlet pipe onto cylinder
Install and tighten spark plug
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can not
be exceeded standard value in order to avoid
causing cylinder head deformation, engine noise
and leaking so that motorcycle’s performance be
effected.
Install the engine onto frame (refer chapter 5).
Valve Clearance Adjustment

Loosen Air Injection system (AI) pipe upper side
bolt (2 bolts).
Remove cylinder head cover.
Remove the cylinder head side cover.

Remove left crankcase cover, and turn the drive Timing mark
face, and align the timing mark on the cam
sprocket with that of cylinder head, piston is at
TDC position.
Loosen valve clearance adjustment nuts and bolts
located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Install the cylinder head side cover.
Start the engine and make sure that engine oil
flows onto the cylinder head.
Stop the engine after confirmed, and then install
the cylinder head cover and AI pipe.
Caution
y If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
y When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.
6-16
Home page Contents
7. CYLINDER/PISTON
Mechanism Diagram ···························· 7-1 Piston Ring Installation ··················· 7-6

Precautions in Operation ···················· 7-2 Piston Installation ···························· 7-7
Trouble Diagnosis································ 7-2 Cylinder Installation ························· 7-7
Cylinder and Piston Removal ············· 7-3
Mechanism Diagram
1.0~1.4kgf-m
7
0.8~1.2kgf-m
7-1
7. CYLINDER/PISTON
General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.
UA25A
Specification Unit：mm
Item Standard Limit
ID 70.995~71.015 71.100
Cylinder
Bend - 0.050
Clearance between piston Top ring 0.015~0.050 0.090
rings nd
2 ring 0.015~0.050 0.090
Top ring 0.150~0.300 0.500
nd
Piston/ Ring-end gap 2 ring 0.300~0.450 0.650
Piston ring Oil ring side rail 0.200~0.700 -
nd
OD of piston (2 ) 70.430~70.480 70.380
Clearance between piston and cylinder 0.010~0.040 0.100
ID of piston pin boss 17.002~17.008 17.020
OD of piston pin 16.994~17.000 16.960
Clearance between piston and piston pin 0.002~0.014 0.020
ID of connecting rod small-end 17.016~17.034 17.064
Trouble Diagnosis
Low or Unstable Compression Pressure Smoking in Exhaust Pipe
y Cylinder or piston ring worn out y Piston or piston ring worn out
y Piston ring installation improperly
y Cylinder or piston damage
Knock or Noise Engine Overheat

y Cylinder or piston ring worn out y Carbon deposits on cylinder head top side
y Carbon deposits on cylinder head top-side y Cooling pipe clogged or not enough in coolant
y Piston pin hole and piston pin wear out flow
7-2
7. CYLINDER/PISTON
Cylinder and Piston Removal

Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.
Coolant hose
Cover the holes of crankcase and cam chain with

a piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.
Remove cylinder gasket and dowel pin. Dowel pins
Clean up all residues or foreign materials from

the two matching surfaces of cylinder and
crankcase.
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective
Top
in the cylinder.
Center
Service limit: 71.100 mm Bottom
7-3
7. CYLINDER/PISTON
Check cylinder if warp.

Measure clearance between piston rings and

grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.
Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
7-4
7. CYLINDER/PISTON
Measure the outer diameter of piston pin.

Service Limit: 16.96 mm
Measure the inner diameter of connecting rod

small end.
Measure the inner diameter of piston pin hole.

Calculate clearance between piston pin and its
hole.
Measure piston outer diameter.

Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：70.380 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
7-5
7. CYLINDER/PISTON
Piston Ring Installation

Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.
Top ring
nd
2 ring
Oil ring
Top groove
nd
2 groove
Oil groove
7-6
7. CYLINDER/PISTON
Clean up all residues and foreign materials on

the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.
Piston Installation IN mark
Install piston and piston pin, and place the IN

marks on the piston top side forward to inlet
valve.
Install new piston pin clip.

Caution
Clip end gap
y Do not let the opening of piston pin clip align
with the piston cutout.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.
Cutout
Cylinder Installation
Install dowel pins and new gasket.
Dowel pins
7-7
7. CYLINDER/PISTON
Coat some engine oil to inside of cylinder, piston

and piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because piston and piston rings will be
damaged.。
Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).
Coolant hose
7-8
Home page Contents
8. V-BELT DRIVING SYSTEM
Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-5

Maintenance Description ···················· 8-2 Drive Face·············································8-7
Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley··················8-10
Left Crankcase Cover ························· 8-3
Mechanism Diagram
5.0~6.0kgf-m
8.5~10.5kgf-m
5.0~6.0kgf-m
8-1
Maintenance Description
General Information
y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
y Drive belt and drive pulley must be free of grease.
Specification
Item Standard value Limit
Driving belt width 24.000 mm 22.500 mm
OD of movable drive face boss 29.946~29.980 mm 29.926 mm
ID of movable drive face 30.000~30.040 mm 30.060 mm
OD of weight roller 19.500~20.000 mm 19.000 mm
ID of clutch outer 144.850~145.150 mm 145.450 mm
Thickness of clutch weight 6.000 mm 3.000 mm
Free length of driven pulley spring 102.400 mm 97.400 mm
OD of driven pulley boss 40.950~40.990 mm 40.930 mm
ID of driven face 41.000~41.050 mm 41.070 mm
Weight of weight roller 17.700~18.300 g 17.200 g
Torque value Special Service Tools

y Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000
y Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002
y Drive plate nut: 5.0~6.0kgf-m Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
Trouble Diagnosis
Engine can be started but motorcycle can Insufficient horsepower or poor high
not be moved speed performance
1. Worn drive Belt 1. Worn drive belt
2. Worn drive face 2. Insufficient spring force of driven pulley
3. Worn or damaged clutch weight 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly
Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight
8-2
Left Crankcase Cover Clamp strips
Left crankcase cover removal

Release the 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover. (9 bolts)
Remove 2 dowel pin and gasket.
9 bolts
Left crankcase cover install

Install left crankcase cover in the reverse
procedures of removal.
Dowel pins
Dowel pins
Left cover plate
Bearing setting plate
Drive shaft holder bearing
Left cover plate gasket
8-3
Left crankcase cover inspection 2 bolts

Remove 2 bolts to remove left crankcase cover
bearing setting plate.
9 bolts
Check bearing on left crankcase cover.

Rotate bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
8-4
Drive Belt Universal holder
Removal
Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.
Special Tool：universal holder
Hold clutch outer with universal holder, and

Universal holder Bearing stay collar
remove nut, bearing stay collar and clutch outer.
Caution
y Using special service tools for tightening or

loosening the nut.
y Fixed rear wheel or rear brake will damage
reduction gear system.
Push the drive belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive belt.
Remove the drive belt from the groove of driven
pulley.
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
Replace the belt if exceeds the service limit.
Caution
Belt tooth
y Using the genuine parts for replacement.
Width
y The surfaces of drive belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.
8-5
Installation
Caution
z Pull out driven face to avoid it closing. Driven face
z Cannot oppress friction plate comp in order
to avoid creates the distortion or the
damage.
Install drive belt onto driven pulley.
Install the driven pulley that has installed the belt

onto drive shaft.
On the drive belt another end to the movable drive
face.
Universal holder Bearing stay collar

Install the clutch outer and bearing stay collar.
Hold the clutch outer whit universal holder, and
then tighten nut to specified torque value.
Universal holder
Install the drive face, washer and drive face nut.
Hold drive face with universal holder, and then
tighten nut to specified torque value.
8-6
Drive Face Universal holder
Removal
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.
Remove movable drive face comp and drive face

Movable drive face
boss from crankshaft.
Crankshaft Drive face boss
Remove ramp plate.

Ramp plate
Remove weight rollers from movable drive face. Movable drive face
Weight roller
8-7
Inspection
Weight roller
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Weight: 17.2g
Check if drive face boss is worn or damaged and Movable drive face
replace it if necessary.
Measure the outer diameter of movable drive face
Drive face boss
boss, and replace it if it exceed service limit.
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Reassembly/installation
Install weight rollers. Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Closure surface
Install ramp plate. Ramp plate
Guide collar
8-8
With 4~5g grease spreads wipes drives in the

movable drive face axis hole.
Install drive face boss.
Caution
The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.
Drive face boss
Movable drive face Drive face boss

Install movable drive face comp. onto crankshaft.
Crank shaft
Press down
Driven pulley installation
Press drive belt into pulley groove, and then pull
the belt onto drive shaft.
Drive belt
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.
Hold drives face with universal holder.
Tighten nut to specified torque.
Install left crankcase cover.
8-9
Clutch Outer/Driven Pulley

Clutch nut wrench
Disassembly
Remove drive belt, clutch outer and driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.
Caution
Do not press the compressor too much.
Clutch spring compressor
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
friction plate, clutch weight and spring from driven
pulley.
Remove seal collar from driven pulley.
Collar
Remove guide pin, guide pin roller, and movable Movable driven face Guide pin
Seal
driven face, and then remove O-ring & oil seal
seat from movable driven face.
O-ring Guide pin Guide pin roller
Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Inner
diameter
Clutch outer
8-10
Clutch lining
Clutch lining
Measure each clutch weight thickness. Replace
it if exceeds service limit.
Clutch weight
Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Free length
Driven pulley
Check following items:
y If both surfaces are damaged or worn.
y If guide pin groove is damaged or worn.
Driven face
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 40.93 mm
Inner diameter 41.07 mm
Movable driven face Guide pin groove
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and silent.
Needle bearing
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Outer ball bearing
8-11
Clutch weight Replacement

Spring Driving plate
Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.
Caution
Some of models are equipped with one mounting
plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight
Check if shock absorption rubber is damage or

Shock absorption rubber
deformation. Replace it if necessary.
Setting pin
Apply with grease onto setting pins.
Install new clutch weight onto setting pin and then

Shock absorption rubber
push to the specified location.
Apply with grease onto setting pins.
But, the clutch block should not be greased. If so,
replace it.
Caution
Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity. Clutch weight
Install the spring into groove with pliers.

Spring
8-12
Install snap ring and mounting plate onto setting

pin.
Snap ring
Replacement of Driven Pulley Bearing

Remove inner bearing. Outer bearing
Clipper
Caution
y If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
y If the pulley equipped with ball bearing, it has to Inner needle
bearing
remove snap ring and then the bearing.
Snap ring
Remove snap ring and then push bearing forward

to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Snap ring
Apply with specified oil.
Outer bearing
Install new inner bearing.

Bearing end
Caution
y Its sealing end should be forwarded to outside
as bearing installation.
y Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of drive face.
Inner bearing
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
8-13
Installation of Clutch OUTER/Driven Pulley

Oil seal
Assembly
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.
Specified grease
O-ring
Install the movable driven face onto driven face.

Movable driven face Guide pin
Install the guide pin and guide pin roller. Oil seal
O-ring Guide pin Guide pin roller
Install the collar.
Collar
Install friction plate, spring and clutch weight into

clutch spring compressor, and press down the
assembly by turning manual lever until mounting Clutch nut wrench
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Install clutch outer/driven pulley and drive belt onto
drive shaft. Clutch spring compressor
8-14
Home page Contents
9. FINAL DRIVING MECHANISM
Mechanism Diagram - transmission cover Inspection of Mission Mechanism ···· 9-6

······························································ 9-1 Bearing Replacement ························ 9-8
Precautions in operation ···················· 9-2 Re-assembly of Final Driving Mechanism
Trouble Diagnosis ······························· 9-2 ····························································· 9-11
Disassembly of Transmission············ 9-3
Mechanism Diagram - transmission cover
Reverse shaft
Gear oil fill bolt
3.5~4.5kgf-m
Bearing (6205LLU)
Bearing
Bearing (6304) (6204) Oil seal (30x46x7)
Final shaft
Drive sprocket
Drive shaft
9
Gear oil drain bolt
0.8~1.2kgf-m
Cover bolt
2.6~3.0kgf-m
Bearing (6204)
Oil seal
(14x26x6) Shift fork
Bearing Oil seal

(6305) (25x40x7)
Shift spindle Shift drum
Counter shaft
Needle bearing
(K25x29x10) Needle bearing
(HK2016)
Dowel pin
Drive shaft bearing
setting plate
Gasket
Change switch
Shift drum fixed catch bolt

2.6~3.0kgf-m
9-1
9. TRANSMISSION
Precautions in operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 750c.c. (650c.c. when replacing)
Item Standard value Limit (mm)
OD of shift fork shaft 11.982~12.000 mm 11.970 mm
ID of shift fork 12.016~12.043 mm 12.010 mm
Shift fork claw thickness 5.930~6.000 mm 5.730 mm
Torque value
Gear box cover 2.6~3.0kgf-m
Gear oil fill bolt 3.5~4.5kgf-m
Tools
Special tools
Bearing driver (6204): SYM-9110400
Bearing driver (6205LLU): SYM-9100400-HMA
Bearing driver (6305): SYM-9100400-RB1
Needle bearing driver (HK2016): SYM-9100300-RB1
Drive shaft and oil seal driver: SYM-9120200-HMA
Drive shaft puller: SYM-2341100
Inner bearing puller: SYM-6204002
Trouble Diagnosis
Engine can be started but motorcycle can not be moved.
y Damaged drive gear
y Burnt out drive gear
y Damaged gear shift system
Noise
y Worn or burnt gear
y Worn gear
Gear oil leaks

y Excessive gear oil.
y Worn or damage oil seal
9-2
Disassembly of Transmission
Remove gear change lever (1 bolt).
1 bolt
Loosen speedometer cable mounting nut, and Speedometer cable
then remove the cable.

Remove 3 bolts and remove drive chain protector.
Turn the socket bolt clockwise, and then remove
speedometer gear box. 3 bolts
Caution
The socket bolt is provided with left turn
thread.
Socket bolt
Remove 2 bolts, and then remove the drive

sprocket fixing plate, drive chain and drive
sprocket.
2 bolts
Remove gear fill bolt.

Fill bolt
Place an oil pan under the ATV, and remove gear
oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value:
Gear oil fill bolt 3.5~4.5kgf-m
Drain bolt
9-3
9. TRANSMISSION
Remove gear box cover bolts (9 bolts) and then 9 bolts
remove the cover.
Remove shift drum catch ball, spring and bolt.
Shift drum
Remove shift spindle, shift fork shaft, shift fork and
shift drum.
Shift fork shaft and fork Shift spindle
Reverse shaft Drive shaft

Remove final shaft, counter shaft and reverse
shaft.
Final shaft Counter shaft
9-4

Remove drive shaft bearing setting plate (1 bolt).
Bearing setting plate
Remove the drive shaft.

Special tool:
Shaft protector
Remove gasket and dowel pin.
Caution
y If non- essential do not remove the drive
shaft from the case upper side.
y If remove the drive shaft from the gear box,
then its bearing and oil seal has to be
replaced.
Oil seal Bearing
9-5
9. TRANSMISSION
Inspection of Mission Mechanism

Check if the shift spindle is wear or damage.
Check if the shift drum is wear or damage.
Check if the shift fork and shaft is wear or damage.

Measure the outer diameter of shift fork shaft, and
replace it if it exceed service limit.
Measure the inner diameter of shift fork, and
Measure the claw thickness of shift fork, and
Check if the counter shaft is wear or damage.
9-6
Check if the reverse shaft is wear or damage.
Check if the final shaft and gear are burn, wear or

damage.
Check bearings on gear box and gear box cover. Gear box Drive shaft bearing
Rotate each bearing’s inner ring with fingers.
Reverse shaft
silent, and also check if bearing outer ring is bearing
mounted on gear tightly.
Check oil seal for wear or damage, and replace it
if necessary.
Caution
Counter shaft needle bearing
y If remove the drive shaft from the crankcase Final shaft bearing
upper side, then its bearing has to be

replaced. Final shaft bearing
Gear box cover
Reverse shaft bearing Counter shaft bearing
9-7
9. TRANSMISSION
Bearing Replacement Inner bearing puller
Caution
y Never install used bearings. Once bearing
removed, it has to be replaced with new one.
Crankcase side
Remove drive shaft bearing setting plate, and then
remove drive shaft bearing from left crankcase
using following tools.
Remove reverse shaft bearing and counter shaft
bearing from left crankcase using following tools.
Remove drive shaft oil seal.
Special tool:
Inner bearing puller Bearing driver
Install new final shaft, counter shaft and reverse

shaft bearings into left crankcase.
Special tool:
Bearing driver (6204)
Needle bearing driver (HK2016)
Install new drive shaft bearings and baring driver Clutch nut wrench Drive shaft and
into left crankcase. seal install bush
Drive shaft puller
Install the universal bearing puller and bearing Drive shaft and
driver. seal install bush
Turn the universal bearing puller to install drive
shaft bearing.
Special tool:
Universal bearing puller
9-8
Install drive shaft. Clutch nut wrench Drive shaft and
Special tool: seal install bush
Drive shaft puller
Drive shaft and oil seal install bush
Clutch nut wrench
Drive shaft puller
Apply with grease onto new drive shaft oil seal lip, Drive shaft and
seal install bush
and then install the oil seal.
Special tool:
Drive shaft and oil seal install bush
Install drive shaft bearing setting plate (1 bolt).
Gear box side

Use inner bearing puller to remove the final shaft
needle bearing, gear shift shaft bearing and
counter shaft bearing from the cover inner side.
Special tool:
Inner bearing puller
Cir clip
Remove cir clip of final shat out side bearing.
.
9-9
9. TRANSMISSION
Remove final shat out side bearing. Inner bearing puller
Special tool:
Remove oil seal from gear box cover and discard
the seal
Install new bearing and bearing driver into gear Universal

box cover outer side. bearing puller
Install the universal bearing puller and bearing
driver.
Bearing driver
Turn the universal bearing puller to install drive Universal

shaft bearing. bearing puller
Special tool:
Bearing driver
Universal
Install new oil seal and bearing driver into gear
bearing puller
box cover inner side.
Install the universal bearing puller and bearing
driver.
Turn the universal bearing puller to install drive
shaft oil seal.
Special tool:
9-10
Re-assembly of Final Driving Oil seal

Mechanism
Apply with grease onto the oil seal lip of final
driving shaft.
Install counter shaft, reverse shaft and final shaft Reverse shaft Drive shaft
onto gear box.
Final shaft Counter shaft
Shift drum
Install shift drum, shift fork and fork shaft onto gear
box.
Shift fork shaft and fork Shift spindle
Install shift drum fixed catch ball, spring and bolt

onto gear box.
9-11
9. TRANSMISSION
Align the position mark on the shift spindle Position mark
sprocket with that of shift drum, and then install
shift spindle.
Dowel pins
Install dowel pins and new gasket.
9 bolts
Install gear box cover and bolts, and tighten.
Install the shift spindle bracket, drive chain

protector, speedometer gear box and gear change
lever.
Add gear oil.
Gear oil quantity: 750c.c.
9-12
Home page Contents
10. ALTERNATOR/STARTING CLUTCH
Mechanism Diagram ··························· 10-1 Flywheel Removal ································ 10-4

Precautions in Operation···················· 10-2 Starting Clutch ····································· 10-5
Right Crankcase Cover Removal ······· 10-3 Flywheel Installation···························· 10-7
A.C.G. Set Removal····························· 10-3 A.C.G. Set Installation·························· 10-8
Right Cover Bearing···························· 10-3 Right Crankcase Cover Installation···· 10-8
Mechanism Diagram
10
0.8~1.2kgf-m
1.0~1.4kgf-m
5.0~6.0kgf-m
10-1
General information
y Refer to chapter 17: The troubleshooting and inspection of alternator
y Refer to chapter 17: The service procedures and precaution items of starter motor
Specification
Item Standard value (mm) Limit (mm)
ID of starting clutch gear 25.026~25.045 25.050
OD of starting clutch gear 42.192~42.208 42.100
Torque value
Flywheel nut 5.0~6.0kgf-m
Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive
8 mm bolts 0.8~1.2kgf-m
12 mm bolts 1.0~1.4kgf-m
Tools
Special tools
A.C.G. flywheel puller: SYM-3110A00
Universal holder: SYM-2210100
10-2
Right Crankcase Cover Removal 11 bolts
Remove left footrest.

Drain out the engine oil and coolant, and then
remove coolant hoses.
Remove water pump cover (4 bolts).
Remove 11 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.
Water pump cover bolts
2 screws
A.C.G. Set Removal
Remove 2 mounted screws from pulse generator
and then remove it.
Remove 3 screws from right crankcase cover and
then remove generator coil set.
3 screws
Right Cover Bearing Cir clip
Inspection
Rotate the bearing with finger to check if the
bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
Remove the cir clip, and then remove bearing.

Special tool:
10-3
Check the oil seal for wear or damage. Replace Oil seal
it if necessary.
Install a new one bearing (6201LU) by bearing

driver.
Special tool:
Bearing driver
Bearing driver
Flywheel Removal Reduction gear Flywheel nut
Remove right crankcase cover.

Hold the flywheel by drive face with universal
holder.
Remove flywheel nut.
Special tool:
Universal Holder
10-4
Remove starter reduction gear and shaft.
flywheel puller
Pull out flywheel with A.C.G. flywheel puller.
Special tool:
A.C.G. Flywheel puller
Remove flywheel and starting driven gear.
Starting Clutch
ID
Starting Clutch Inspection
Remove starting clutch driven gear.
Check the gear for wear or damage.
Measure the ID and OD of the starting clutch
driven gear.
Service Limit: ID: 25.050 mm
OD: 42.100 mm
OD
Check the starting reduction gear and shaft for

wear or damage.
Check each roller for wear or damage.
10-5
Install starting clutch driven gear onto one way
clutch.
Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
(View as shown in this figure.)
One way clutch removal Starting driven gear

Remove starting driven gear.
Remove 3 socket bolts, and then remove one way 3 socket bolts
clutch.
One way clutch
Starting driven gear
10-6
One way clutch Installation 3 socket bolts

Install the components in the reverse procedures
of removal.
Caution
Tape a tightening tape onto the thread of hexagon
bolt.
Starting driven gear

Install starting driven gear.
Groove
Flywheel Installation
Align the key on crankshaft with the flywheel
groove, and then install the flywheel.
Hold the flywheel by drive face with universal

holder, and tighten flywheel nut.
Special tool:
Universal Holder
10-7
Install reduction gear shaft and reduction gear. Reduction gear
A.C.G. Set Installation Wire 2 bolts
Install the A.C.G. coil set onto right crankcase

cover (3 screws).
Install pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed under
pulse generator.
3 screws
Right Crankcase Cover Installation

Install dowel pin and new gasket.
Dowel pin
Remove water pump cover.

Install right crankcase cover onto the crankcase.
Note: Align the water pump shaft indent with the oil
pump shaft.
10-8
Install right crankcase cover (11 screws). 11 bolts
Install the dowel pin, new gasket and water pump
cover onto crankcase cover.
Water pump cover bolts
Connect water hoses to the right crankcase cover

and water pump cover.
10-9
Note:
10-10
Home page Contents
11. CRANKCASE / CRANK
Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3

General information ···························11-2 Crankshaft Inspection ······················· 11-5
Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6
Mechanism Diagram
1.0~1.4kgf-m
0.8~1.2kgf-m
11
0.8~1.2kgf-m
Eng. Oil drain bolt

3.5~4.5kgf-m
11-1
General information
Operational precautions
y This Section concerns disassembly of the crankcase for repair purpose.
y Remove following components before disassembling crankcase.
－Engine remove Section 5
－Cylinder head Section 6
－Cylinder and piston Section 7
－Drive face and driven pulley Section 8
－AC generator/Start one way clutch Section 10
y In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing
chain, it is preferably to replace crankshaft as a unit.
Specification Unit: mm
Item Standard Limit
Connecting rod side clearance of the big end 0.100~0.400 0.600
Crankshaft
Vertical clearance of the big end of the connecting rod 0~0.008 0.050
Run-out - 0.100
Torque value
Bolts for crankcase 0.8~1.2kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Cylinder stud bolt 1.0~1.4kgf-m
Tools
Special tools
L. crank shaft oil seal driver (27*42*7): SYM-1332100-HMA
Trouble diagnosis
Engine noise
y Loose crankshaft bearing
y Loose crankshaft pin bearing
y Worn out piston pin and pin hole
11-2
Disassembly of crankcase Tensioner
Remove the cam chain setting plate, and then

remove cam chain.
Loosen the pivot bolt and remove the tensioner.
Cam chain setting plate
Loosen 2 bolts on the right crankcase.
2 bolts
Loosen 11 bolts on the left crankcase. 11 bolts
Place right crankcase downward and left

crankcase up.
Tap the left crankcase with a plastic hammer to
remove it.
Caution
Care should be taken not to damage the contact
surfaces.
11-3
Remove balance shaft from right crankcase. Balance shaft
Remove crankshaft from right crankcase.
Remove gasket and dowel pins.

Scrape gasket residues off the crankcase contact
surface.
Caution
Do not damage contact surface of the gasket.
It is better to moisten the gasket residue for
easy scrapping.
Drive out left crankcase oil seal.
11-4
Crankshaft Inspection
Use a thickness gauge to measure left and right
clearance of connecting rod big end.
Measure point for the crank

big end of the connecting rod.
Measure the clearance of the big end at the

vertical directions.
Place the crankshaft on a V-block, measure

run-out of the crankshaft.
90 mm 60 mm
Check crankshaft bearing

Use hand to crank the bearing to see it moves
freely, smoothly and noiseless.
Check the inner ring to see it links firmly on the
bearing.
If any roughness, noise and loose linkage are
detected, replace the bearing with new one.
Caution
The bearing shall be replaced in pair.
Special tool: outer bearing puller Crank bearing
11-5
Check balance shaft bearing Balance shaft bearings

Check bearings on right and left crankcase.
Rotate each bearings inner ring with fingers.
mounted on gear tightly.
Special tool: Inner bearing puller
Bearing driver
Assembly of crankcase
Install wave washer into right crank bearing seat.
Wave washer
Install crank shaft on the right crankcase.
Align the position mark on the balance shaft drive Position mark
gear with that of balance shaft driven gear, and
then install balance shaft onto right crankcase.
11-6
Install 2 dowel pins and new gasket.
Dowel pins
Install the left crankcase onto the right crankcase.
Tighten 11 bolts on the left crankcase. 11 bolts

Tighten 2 bolts on the right crankcase.

2 bolts
11-7
Clean the crankshaft.
Apply a layer of grease on the lip of oil seal, Puts
on the left crank shaft.
Install the oil seal in the left crankcase with care
not to damage the lip of the oil seal.
By oil seal driver (27×42×7), oil seal will knock into Oil seal
located. driver
Special tool:
Oil seal driver (27×42×7)
Install the tensioner and tighten the pivot bolt. Tensioner

Torque value: 0.8 ~1.2kgf-m
Install the cam chain.
Install the cam chain setting plate.
Cam chain setting plate
11-8
Home page Contents
12. COOLING SYSTEM
Mechanism Diagram ··························12-1 System Test········································ 12-5

General Information ···························12-2 Radiator ·············································· 12-6
Trouble Diagnosis ······························12-2 Water Pump ········································ 12-8
Trouble Diagnosis for Cooling System Thermostat ········································· 12-12
·····························································12-3
Mechanism Diagram
Radiator filler cap
Reserve tank
By-pass pipe
To cylinder head
12
Coolant outlet pipe
Radiator
Cooling fan
Coolant inlet pipe
Thermostat
Thermo switch (fan)
Water pump
12-1
12. COOLING SYSTEM
General Information
General
Warning:
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant
may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless
the engine is completely cooled down.
y Refill the radiator with distilled water or specified additives.

y Add coolant to the reservoir.
y The cooling system can be serviced on the ATV.
y Never spill the coolant to the painted surface.
y Test the cooling system for any leakage after the repair.
y Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.
Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 850c.c.
Reservoir upper 420c.c.
Begins to activate at 82~95℃
Thermostat
Stroke: 0.05~3mm
Thermos switch (fan) Begins to activate at 98±3℃
Not-pressure: 107.7℃
Boiling point
Pressurized: 125.6℃
Torque Value
For water pump impeller 1.0~1.4kgf-m
Tools Requirement
Special tools
Water pump bearing driver (6901): SYM-9100100
Water pump oil seal driver (Inner): SYM-9120500-H9A
Water pump mechanical seal driver: SYM-1721700-H9A
Trouble Diagnosis
The engine temperature is too high The engine temperature is too low
y The water thermometer and the temperature y The water thermometer and the temperature
sensor do not work properly. sensor malfunction.
y The thermostat is stuck to close. y The thermostat is stuck to open.
y Insufficient coolant.
y The water hose and jacket are clogged. Coolant is leaking
y Fan motor malfunction. y The water pump mechanical seal does not
y The filler cap of the radiator malfunction. function properly.
y The O ring is deteriorated.
y The water hose is broken or aged.
12-2
12. COOLING SYSTEM
Trouble Diagnosis for Cooling System
The temperature indicated is too high
A. Stop and waiting for the

A1.Refill the radiator with
engine is completely N coolant then check for any Y
cooled down, open cap to Water leaking problem
leakage?
check the capacity of
coolant in radiator.
N
Y
B. Turn on main switch and N B-1. Measure thermo unit to N

check the water Replace thermo unit
confirm voltage 6V↑?
temperature indicator
back to zero?
Y
Y
B-2. Inspect the circuits of Y
water temperature have Short or earth handle
short or earth?
N
Meter problem
C-1. Eng. stop and remove

C. Open radiator cap and N water pump cover, start
softly throttle, inspect Water pump repair
the motor to inspect pump
coolant have circulated? its rotation? N
Y Y
Water hose clogged
D. Close radiator cap,

measure thermo unit to N
confirm voltage reduced Replace thermo unit
comply with temperature
rise?
Y
Next page
12-3
12. COOLING SYSTEM
Preceding page
E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to

and inspect cooling fan was
N confirm voltage be
N
Replace thermal switch
operating after the changed (12→0V)?
temperature gauge over 3
checks?
Y
Y
E-2. Connect cooling fan
F. Confirm the cooling fan was terminals with battery N
convulsion? Replace cooling fan
(12V) directly to inspect
its operation?
Y
Meter unusual Y
E-3. Keep eng. 3000~4000

rpm and inspect coolant
If circuit connects reverse flow into reserve tank
cooling fan will forward, after the temperature
correct and check again. gauge over 3 checks?
E-4. Remove thermostat from N

holder then heats it by Replace thermostat
water directly to check its
operation?
Y Refill with coolant then

check again
For bleed the air bubbles

completely, open radiator cap Notice the water hose
and start engine while engine can’t any unsuitable
is cool then press water hose bend or twist and
softly by hand to bleeding. bleed the air bubbles
Turn the throttle repeatedly completely.
until the coolant surface
becomes stable.
12-4
12. COOLING SYSTEM
System Test
Test on the filler cap
Hermetically seal the filler cap, apply water and
pressure to the filler cap. Replace it with new one
if found failing to maintain the specified pressure
within a given time limit, or the opening pressure is
too high or too low. The specified pressure shall
be maintained at least for 6 seconds in the test
Relief pressure for the filler cap: 0.9-0.15
kgf/cm2 Pressure tester
Apply pressure to the radiator, engine and water Filler cap
hose to check for any leakage
Caution
Reserve tank cap
Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
If the system fails to maintain the specified
pressure for at least 6 seconds, repair or replace
parts.
Change of coolant
Warning
Never attempt to carry out service work on the
cooling system unless the engine is completely Radiator filler cap
cooled down, otherwise, you may get scalded.
Remove the front center cover, and then remove
filler cap.
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Refilling system with coolant and bleeding the air

bubbles.
y Run the engine, and remove by-pass pipe.
y Check by-pass hole whether has the air bubble
to emit.
y If emits without the air bubble, only has the
coolant to flow out, then backflow pipe joint on, Drain bolt
engine flameout.
y Remove radiator filler cap.
y Starts the engine, inspects does not have the air By-pass pipe
bubble in the radiator coolant, also the coolant
liquid level is stable.
y Stop the engine. Add coolant to proper level if
necessary.
y Screw and tighten up the radiator filler cap.
Caution
In order to avoid the water tank rusting, please do
not use the unclear trade mark refrigerant.
Coolant recommended: SYM Bramax radiator
agent.
Concentration: 50%
12-5
12. COOLING SYSTEM
Check reserve tank

y Remove the front center cover, and then
remove reserve tank filler cap.
y Check the liquid level in the front fender right
side. Add coolant to proper level if too low.
y Reinstall the reserve tank filler cap. Upper
Caution
The reserve tank liquid level coca too is not high, Lower
after avoids the water temperature elevating, in
the cooling system the refrigerant backflow
floods.
Radiator
Check
Remove the front center cover, side covers and
front fender. (refer chapter 13), check for any
leakage from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure water
jet to clean it.
Care shall be taken when straightening the sink
fan.
Removal
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Drain bolt
Filler pipe clamp

Remove coolant filler pipe.
12-6
12. COOLING SYSTEM
Loosen the radiator 4 bolts.
Coolant inlet pipe
Remove coolant upper side pipes.
4 bolts
Remove coolant outlet pipe. Coolant outlet pipe

Disconnect the couplers for the thermo switch and
fan motor, and then remove radiator and cooling
fan.
Thermo switch coupler
Disassembly
Loosen the 3 bolts from the fan duct, and then Cooling fan
remove the fan duct. duct bolts x3
Loosen 3 screws from the fan motor, and take off
the fan motor.
Cooling fan
Remove nut to remove the fan from fan motor. motor screws x3
Assembly
Install fan motor onto fan duct and insert the fan
into the motor shaft.
Apply a coat of the adhesive to the shaft thread of
the motor, and then install the washer and the lock
nut. Thermo switch
Tighten the fan duct onto the radiator with 3 bolts.
Please refer to chapter 17 for the inspection of the Fan nut
thermo switch.
Caution
Liquid packing must be applied to the thermo
switch before installing to avoid damaging the
radiator.
Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.
12-7
12. COOLING SYSTEM
Water Pump
Check water pump seal / cooling
system divulges inspection
y Disassembles the refrigerant drain bolt,
overflows little buckles the N actually fluid,
confirmed overflows the refrigerant whether has
the greasy dirt.
y Turns on lathe the engine oil gauge rule, the
inspection engine oil whether does have
bleaches situation of the emulsified.
If has the above two kind of interior to divulge the
Drain bolt
phenomenon, possibly for the water pump inner
two seal damages, the engine cooling system
damages or the cylinder and the cylinder head
gasket damages, please first dismantles the right
crank case to say A confirms the replacement
water pump seal, if does not have the question to
take apart for overhaul cooling system of system
again the cylinder head, the cylinder.
Removal of water pump

Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen 4 bolts and remove the pump cover.
Loosen 9 bolts and remove the right cover.
Take off the gasket and dowel pins.
Turn pump impeller clockwise and remove.

Caution
The impeller is provided with left turn thread.
Remove the cir clip from the right crankcase cover.

Remove the water pump shaft and the inner
bearing.
Remove the outside bearing by inner bearing
puller.
Rotate the inner ring of bearing, the bearing shall
move smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it with new one.
Special tool:
12-8
12. COOLING SYSTEM
Check any wear and damage of the mechanical Mechanical seal
seal and inside seal.
Caution
The mechanical seal and inside seal must be
replaced as a unit.
Replacement of Mechanical Seal Water pump bearing

Remove the inside bearing by inner bearing puller. driver
Drive the mechanical seal and inner seal out of the
right crankcase.
Special tools:
Water pump bearing driver
Caution
Replace a new mechanical seal after removing
it.
Mechanical seal
Apply a coat of sealant to the mating surfaces of
the right crankcase before installing the new
mechanical seal.
Install the mechanical seal onto the right

crankcase.
Special tools: Water pump mechanical
Water pump mechanical seal driver seal driver
12-9
12. COOLING SYSTEM
Install the new inner seal onto the right crankcase.
Water pump oil seal
Special tools: driver (inner)
Water pump oil seal driver (inner)
Install a new outside bearing to the right

Water pump bearing
crankcase cover. driver (6901)
Special tools:
Water pump bearing driver (6901)
Caution
Do not reuse old bearing. It must be replaced
with a new one once it has been removed.
Mount the water pump shaft and the inner bearing Inner bearing
to the right crankcase cover.
Water pump shaft
Install the cir clip to hold the inner bearing.
12-10
12. COOLING SYSTEM

Install the seal washer into the impeller.
Caution
Washer must be replaced together with the
mechanical seal.
Install the impeller onto the water pump shaft and Water pump rotor
tighten.
Torque Value: 1.0~1.4kgf-m
Caution
The impeller is left thread.
Install the dowel pin and right cover gasket.

The rotation water pump impeller, causes the
water pump drive shaft scoop channel, aligns the
oil pump drive shaft flange, install the right crank
case. (9 bolts)
Install the dowel pin and new gasket.

Install the water pump cover with 4 bolts.
12-11
12. COOLING SYSTEM
Thermostat Temperature sensor By-pass pipe

Please refer to chapter 17 for inspection of
temperature sensor.
Removal
Drain out the coolant.
Remove the thermostat set. (2 bolts)
2 Bolts
Inspection
Visually inspect thermostat for any damage.
Place the thermostat into heated water to check its

operation.
Caution
Whenever the thermostat and the thermometer
are in contact to the wall of heated water
container, the reading displayed is incorrect. If
the valve of the thermostat remains open at
room temperature or the valve operation is not
corresponding to the temperature change, then
it must be replaced.
Technical Data
Valve begins to open 82~95℃
Valve stroke 0.05 ~ 3mm
Installation
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out the air bubble
(Page 12-5).
12-12
Home page Contents
13. BODY COVER
Mechanism Diagram ························· 13-1 Fuel tank cover ································ 13-5

Maintenance······································· 13-2 Front fender······································ 13-6
Handle front cover / Meter cover······ 13-3 Rear carrier······································· 13-10
Handle protect cover························· 13-4 Rear fender······································· 13-11
Front center cover····························· 13-4 Footrest ············································ 13-14
Mechanism Diagram
Fuel tank cover

Meter cover
Seat
Rear carrier
Right handle protect cover
Tail cover
Handle cover
Left handle protect cover Rear bumper
Rear fender 13
Front center cover

Right footrest
Right side grille

Right side cover
Front fender Left footrest
Front grille
Left side cover
Left side grille

Front emblem Right side lower cover
Front bumper cover

Left side lower cover
Front bumper grille
13-1
13. BODY COVER
Maintenance
Body covers disassemble sequence:
Handle cover R/L Lower side covers Rear carrier
Handle protect cover R/L Side covers R/L Lower side covers
Front center cover Front center cover R/L Side covers
R/L Footrests Front fender Rear fender
R/L Side grilles Rear bumper
Tail cover
y Be careful not to damage various covers in assembly or disassembly operation.

y Never injure hooks molded on the body covers.
y Align the buckles on the guards with slot on the covers.
y Make sure that each hook is properly installed during the assembly.
y Never compact forcefully or hammer the guard and the covers during assembly.
13-2
13. BODY COVER
Handle front cover / Meter cover

Remove
Loosen 4 bolts from handle cover right and left
side.
4 bolts
Meter couplers
Remove couplers of meter.
Remove speedometer cable, and then remove

handle cover, meter cover and meter.
Speedometer cable
Disassembly
Remove 4 screws of meter stay and meters.
4 screws
13-3
13. BODY COVER
Remove meter stay and meters.
Remove 3 screws and disassembly handle cover

and meter.
Installation
3 Screws
Handle protect cover

Loosen 2 bolts from handle protect cover, and
then remove handle protect cover.
Installation
2 bolts
Front center cover

Remove
Loosen 2 screws from the front center cover.
Please disassemble first then push the cap
upward, and then remove front center cover.
Installation
Install in reverse order of removal procedures. 2 screws
13-4
13. BODY COVER
Fuel tank cover

Remove
Remove front center cover.
2 screws
Remove seat. Fuel tank cap
Remove fuel tank cap.
Remove 1 bolt, and then remove fuel tank cover.
Installation
1 Bolt
13-5
13. BODY COVER
Front fender
Remove
Remove seat.
Remove fuel tank cap and fuel tank cover.
Loosen the two bolts of front fender rear side.
2 bolts
Remove 1 screw, and then remove fixed support

catch.
1 screw
Loosen the 6 screws, which connect the front

fender and side lower covers, these 6 screws just
be twin the front fender two side.
6 screws
Remove right and left side lower covers rear side

screws (each side 3 screws), and then remove
side lower covers.
3 screws
13-6
13. BODY COVER
Remove right and left side covers (each side 1

screw).
1 screw
Loosen the front fender two side bolts (each side 1

bolt).
1 Bolt
Remove headlight, front winker light and power Headlight coupler
outlet couplers.
Winker coupler
Remove front fender under side bolts (each side 1

bolt).
1 Bolt
13-7
13. BODY COVER

Remove front fender front side bolts (2 bolts).
2 Bolts
Remove the left crankcase cover duct.
Duct
Remove front fender upper bolt, and then remove

front fender and headlight.
1 Bolt
Disassembly
Remove 3 screws to remove front emblem.
3 screws
13-8
13. BODY COVER

Remove headlights inner side 4 screws.
Each side
2 screws
Remove headlights front side 4 screws, and then

remove headlights.
4 screws
Each side
Remove winker lights 4 screws, and then remove 2 screws
winker lights.
Remove 8 screws, and then remove right and left

grille.
Each side 4 screws
13-9
13. BODY COVER

Remove power outlet setting nut, and then remove
power outlet.
Installation
Setting nut
Rear carrier
Remove
Loosen 4 bolts from the rear carrier. 4 Bolts
Remove the rear carrier.
Installation
13-10
13. BODY COVER
Rear fender
Remove rear carrier.
Pull the “Seat Release Bar” up in order to remove
the seat.
This seat release bar is under the rear side of the
rear fender.
Seat release bar
Loosen the 6 screws, which connect the front

fender and side lower covers, these 6 screws just
be twin the front fender two side.
6 screws
Remove right and left side lower covers rear side

screws (each side 3 screws), and then remove
side lower covers.
3 screws
Remove right and left side covers (each side 1

screw).
1 screw
13-11
13. BODY COVER

Remove rear fender front side bolts and screws Each side 1 bolt
(each side 1 screw and 1 bolt).
Each side 1 screw
Remove battery, CDI unit, start relay and fuse box.

Remove rear fender upper side 5 bolts.
5 bolts
Loosen the 2 bolts, which connect the rear tender

and frame, these 2 bolts just below the rear fender
light coupler side.
Each side 1 bolt
Loosen the 2 bolts, which connect the rear tender

and frame, these 2 bolts just below the rear fender
rear side.
Remove taillight couplers, and then remove rear
fender.
Installation
Each side 1 bolt
13-12
13. BODY COVER
Disassembly 2 screws
Remove rear fender and rear bumper upper side 2

screws.
Remove rear fender and rear bumper inner screws

(each side 2 screws).
Remove rear bumper and taillights.
Each side 2 screws
Remove tail cover and rear bumper 6 screws, and 6 screws

then remove tail cover.
Remove license light 2 screws, and then remove
license light.
2 screws
Loosen the 10 screws, and then remove taillights

(each side 5 screws).
Installation
Each side 5 screws
13-13
13. BODY COVER
Footrest
Remove
Loosen the 6 bolts, which connect the footrest and
frame, these 6 bolts just be twin under the
footrests.
2 bolts
1 bolt
Loosen the 4 bolts, and then remove footrest bars

and footrests.
These 4 bolts just are the right and left footrests.
Installation
2 bolts
13-14
Home page Contents
14. FRONT BRAKE & FRONT WHEEL
Mechanism Diagram···························14-1 Adding Brake Fluid ···························· 14-8

Maintenance Description ···················14-2 Brake fluid replacement / Air-bleed·· 14-9
Trouble Diagnosis ······························14-3 Front Brake Caliper···························· 14-10
Front Wheel·········································14-4 Brake Disk ·········································· 14-11
Front Wheel Hub·································14-4 Front Brake Master Cylinder ············· 14-11
Disk Brake System Inspection ··········14-7
Mechanism Diagram
Front brake master cylinder Front pressure control valve
Brake hose bolts (3.5kgf-m)
Air-bleed valve (0.5kgf-m)
To rear pressure control valve

14
Brake caliper bolts

(3.25kgf-m)
Brake disk bolts (4.25kgf-m)
Bearing (6203LU)
Front wheel nuts

(2.4kgf-m)
Front axle castle nuts

(5.0kgf-m)
14-1
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or
dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
y The brake caliper can be removed without removing the hydraulic system.
y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
y While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
y Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
y Check the operation of the brake system before riding.
y Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and
installation of the tire.
Specifications
Item Standard (mm) Limit (mm)
The thickness of front and rear brake disk 3.500 2.000
Front and rear brake disk eccentricity < 0.100 0.300
Master cylinder inner diameter 14.000~14.043 14.055
Master cylinder piston outer diameter 13.957~13.984 13.945
Diameter of front disk 175.000 -
Thickness of front brake lining 5.500 2.000
Tire pressure as cold: 0.8 kg/cm² (12psi)
Torque values
Brake hose bolts 3.50kgf-m
Bolt for brake caliper 3.25kgf-m
Bolts for the brake disk 4.25kgf-m
Brake lever nut 1.00kgf-m
Air-bleed valve 0.50kgf-m
Front wheel nut 2.40kgf-m
Front axle castle nut 5.00kgf-m
14-2
Trouble Diagnosis
Soft brake lever Hard steering
1. Air inside the hydraulic system 1. Faulty tire
2. Hydraulic system leaking 2. Insufficient tire pressure
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disk Front wheel wobbling
7. Low brake fluid 1. Faulty tire
8. Blocked brake hose 2. Worn front brake drum bearing
9. Warp/bent brake disk 3. Bent rim
10. Bent brake lever 4. Axle nut not tightened properly
Hard operation of brake lever

Steers to one side
1. Blocked brake system
2. Poor brake caliper 1. Bent tie rods
3. Blocked brake pipe 2. Wheel installed incorrectly
4. Seized/worn master cylinder piston 3. Unequal tire pressure
5. Bent brake lever 4. Incorrect wheel alignment
Uneven brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake disk
5. Restricted brake hose and fittings
Tight brake
Brake noise
1. Dirty lining
2. Deformed brake disk
3. Poor brake caliper installation
4. Imbalance brake disk or wheel
14-3
Front Wheel
Removal
Raise the front wheels off the ground by placing a
jack or other support under the frame.
Remove the front wheel axle cover (4 screws).
4 screws
Remove the front wheel nuts, and then remove

front wheels.
Installation
Install the front wheel and tighten the nuts.
Torque: 2.4kgf-m
4 nuts
Front Wheel Hub

Removal
Remove front brake caliper (2 bolts).
2 bolts
Remove cotter pin, wheel hub nut and washer. Wheel hub nut
Remove wheel hub and brake disk.
Cotter pin
14-4
Inspection Wheel hub

Check bearings on wheel hub.
mounted on wheel hub.
if necessary.
Brake disk Collar
Disassembly Inner bearing puller
Caution
Remove out side bearing and seal from wheel hub
using following tools.
Special tool:
Remove front wheel hub bearing inner spacer.
Inner spacer
Remove inner side bearing and oil seal from wheel

hub using following tools.
Special tool:
14-5
Remove 4 socket bolts, and then remove the 4 bolts
brake disk from wheel hub.
Assembly Bearing driver

Install brake disk.
Install new inner side bearing and seal into front
wheel hub.
Install front wheel hub bearing inner spacer.
Install new out side bearing and seal into front
wheel hub.
Special tool:
Oil seal drive (24×35×7)
Installation Wheel hub nut
Install the front brake disk to the wheel hub.

Install wheel hub and brake disk on to knuckle.
Install wheel hub washer and tighten the wheel
hub nut.
Torque: 5.0kgf-m
Install cotter pin.
Cotter pin
Install front brake caliper.

Torque: 3.25kgf-m
2 bolts
14-6
Disk Brake System Inspection

Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube seam
whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.
Check the brake from behind the brake caliper. Brake linings
The brake pad must be replaced with new lining Front brake
wear limit
when the brake pad wear limit reaches the brake groo es
disk.
Brake disk
Caution
y Check the front brake lining must be removed
front wheel first.
Park the ATV on a level ground, and check if fluid

level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 3).
Caution
y The vehicles inclined or just stop, the survey oil
level could not be accurate, had to settle the
3~5 minute.
y In order to prevent has the chemical change,
please do not use counterfeiting or other
unclear trade marks brake fluid.
y Uses by all means must with the trade mark
brake fluid, guarantees the ghost vehicle
efficiency.
14-7
Adding Brake Fluid Master cylinder

Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid please do not surpass the
upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in their damages.
Screw
Remove the master cylinder cap and diaphragm. Master cylinder cap
Upper level
Increases the high quality brake fluid, uses by all
means must with the trade mark brake fluid joins Diaphragm
in the master cylinder.
Clean the dirty brake disk.
Caution
y The dirty brake lining or disk will reduce the
brake performance.
y To mixed non-compatible brake fluid will
reduce brake performance.
y Foreign materials will block the system
causing brake performance to be reduced or
totally lost.
14-8
Brake fluid replacement / Air-bleed Air-bleed valve
Connect drain hose to air-bleed valve.

Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out.
Close the drain valve and add specified brake fluid
into the brake master cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
Pressure control valve
Air-bleed must from pressure control valve fist. Air-bleed valve

Connect one end of transparent hose to the
air-bleed valve, and put the other end into a
container.
Open the drain valve around 1/4 turns, and at the

same time hold the brake lever until the there is no
air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake

system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.
Bubble Air-bleed valve
If brake is still soft, please bleed the system as
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the
valve.
Caution
y Do not release the brake lever before the
drain valve is closed.
y Always check the brake fluid level when
carrying out the air bleeding procedure to Transparent hose
avoid air enters into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
14-9
Front Brake Caliper Brake hose bolt
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper bolts and the caliper.
2 bolts
Inspection
Make sure the brake linings condition. Replace
the linings if the brake linings wear limitation
groove close to the brake disk.
Brake lining replacement

Remove two guide pins.
Compress caliper mounting plate, and then
remove brake linings.
Install new linings, and tighten the guide pins.
Installation Guide pins

Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.25kgf-m
Caution
y Use M8 x 20 mm flange bolt only.
y Long bolt will impair the operation of brake
disk.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.5kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
14-10
Brake Disk Brake disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit: 2.5 mm
Micrometer
Remove the brake disk from wheel hub.

Check the disk for deformation and bend.
Caution
brake performance.
y Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the
operator should dress the mouthpiece and
the glove, use vacuum cleaner clean it.
Front Brake Master Cylinder

Master Cylinder Removal
Caution
Do not let foreign materials enter into the
cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.
Brake light switch

Push the lead of brake light switch, and then
remove brake light switch.
Drain out the brake fluid.
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder socket bolts and the
master cylinder.
2 socket bolts
14-11
Remove the rubber boot.
Remove the cir clip. Cir clip
Remove the piston and the spring. Rubber boot
Clean the master cylinder with recommended
Piston
brake fluid.
Piston cup
Spring
Master cylinder
Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds
allowable limit.
Master Cylinder Assembly

Caution
y It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
y Make sure there is no dust on all components
before assembling.
Apply clean brake fluid to the piston cup, and then
install the cup onto the piston.
Cir clip
Install the larger end of the spring onto the master Rubber boot
cylinder.
The master cup’s cavity should be face inside of Piston
master cylinder when installing the master cup.
Install the cir clip. Piston cup
Caution Spring
y Never install cup lip in the opposite direction.

y Make sure the cir clip is seated securely in
the groove.
Install the rubber boot into groove properly. Master cylinder
14-12
Master Cylinder Install

Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
2 socket bolts
Install the brake lever, and connect leads to brake Brake lever bolt Brake light switch
light switch.
Connect brake hoses with 2 new washers. 2 Washers

Tighten the brake hose bolt to the specified torque
value.
Torque: 3.5kgf-m
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Kink of brake leads, hose or pipe may reduce
brake performance.
Add specified brake fluid and bleed the system.
14-13
Notes:
14-14
Home page Contents
15. STEERING / FRONT SUSPENSION
Mechanism Diagram ··························15-1 Steering Tie-Rod ································ 15-6

Operational Precautions ····················15-2 Knuckle ··············································· 15-7
Trouble Diagnosis ······························15-2 Front Cushion ···································· 15-8
Steering Handle ··································15-3 Suspension Arm ································ 15-9
Steering Shaft ·····································15-5 Toe-In ·················································· 15-10
Mechanism Diagram
2.4kgf-m
4.0kgf-m
3.4kgf-m
3.6kgf-m
15
5.0kgf-m
4. 6kgf-m
5.0kgf-m
5.0kgf-m
5.0kgf-m
5.0kgf-m
15-1
Operational Precautions
Torque Values
Handlebar upper holder bolt 2.4kgf-m
Handlebar under holder nut 4.0kgf-m
Steering shaft holder bolt 3.4kgf-m
Steering shaft nut 5.0kgf-m
Steering tie-rod nut 5.0kgf-m
Knuckle nut 5.0kgf-m
Tie rod lock nut 3.6kgf-m
Suspension arm nut 5.0kgf-m
Front cushion mounting nut 4.6kgf-m
Trouble Diagnosis
Hard to steer Front suspension noise
y Faulty tire. y Loose front suspension fasteners.
y Steering shaft holder too tight. y Binding suspension link.
y Insufficient tire pressure.
y Faulty steering shaft bushing.
y Damaged steering shaft bushing. Hard suspension
y Faulty front swing arm bushings.
y Improperly installed front swing arms.
Front wheel wobbling y Bent front shock absorber swing rod.
y Faulty tire.
y Worn front brake drum bearing.
y Bent rim. Soft suspension
y Axle nut not tightened properly. y Weak front shock absorber springs.
y Worn or damage front swing arm bushings.
Steers to one side

y Bent tie rods.
y Wheel installed incorrectly.
y Unequal tire pressure.
y Bent frame.
y Worn swing arm pivot bushings.
y Incorrect wheel alignment.
15-2
Steering Handle
Removal
Remove the handle cover, meter set, handle
protect cover and front fender. (Refer to chapter
13)

Loosen the socket bolts for the front brake master brocket bolts
cylinder, and remove front brake master cylinder.
Caution
Do not let foreign materials enter into the cylinder.
Master cylinder bolts
Remove 2 screws, and then remove throttle

hosing holder and throttle hosing.
2 Screws
Loosen the socket bolts for the front brake master Master cylinder bolts
cylinder, and remove front brake master cylinder.
Caution
Do not let foreign materials enter into the cylinder.

brocket bolts
15-3
Loosen 2 screws, and then remove handle left
switch and choke hosing.
2 screws
4 socket bolts
Remove switch wire band.
Remove handle mounting bolt, and then remove
the handle upper holder, handle.
Remove 2 nuts to remove handle under holder

and meter bracket.
2 Nuts
Installation
Torque value:
Handlebar under holder nut 4.0kgf-m
Handlebar upper holder bolt 2.4kgf-m
15-4
Steering Shaft Tie-rod nuts
Remove
Remove cotter pins, and loosen right and left
steering tie-rod nuts.
Remove tie-rod.
Cotter pin
Steering shaft nut

Remove the cotter pin below steering shaft, and
remove steering shaft nut and washer.
Cotter pin
Bend out the steering shaft holder nut fixed plate.

Loosen 2 bolts, and then remove steering shaft
holder, nut fixed plate, pressed plate and steering
shaft.
Inspection
Check oil rings for wear or damage, and replace it
if necessary.
Fixed plate
Measure the holder inner diameter.
Maximum limit: Ø39.5 mm
Oil rings
Installation
Apply with grease onto oil liner and holder.
Torque value:
Steering shaft holder bolt 3.4kgf-m
Steering shaft nut 5.0kgf-m
Steering tie-rod nut 5.0kgf-m Oil rings
Oil liners
15-5
Steering Tie-Rod Tie-rod nuts
Remove
Remove cotter pin and tie-rod nut from steering
shaft side.
Cotter pin
Tie-rod nuts
Remove cotter pin and tie-rod nut from wheel side.
Cotter pin
Inspection
Inspect the tie-rod for damage or bending.
Inspect the ball joint rubbers for damage, wear or
deterioration.
Turn the ball joints with fingers. The ball joints
should turn smoothly and quietly.
Ball joint
Installation
Install the ball joint with “adjustment groove” on
the wheel side.
Install tie-rod nuts, and tighten the nuts.
Torque value: 5.0kgf-m
After tightened the tie-rod nut, install the cotter pin.
Adjustment groove
15-6
Knuckle
Remove
Remove front wheel, front brake caliper, front
wheel hub and brake disk.
Tie-rod
Remove cotter pin and tie-rod nut, remove tie rod.
Nut
Cotter pin
Remove cotter pin and ball joint nut. Universal holder
Remove upper and under ball joints by ball joint

driver.
Remove the knuckle.
Special Tool：ball joint driver
Ball joint
Ball joint
Inspection
Inspect the upper and under ball joints and
knuckle for damaging or cracking. Knuckle
Installation
Torque value:
Steering tie-rod nut 5.0kgf-m
Ball joint nut 5.0kgf-m
After tightened the nuts, install the cotter pins. Ball joint
15-7
Front Cushion Nut
Remove
Remove front cushion under bolt nut, and remove
the bolt.
Nut
Remove front cushion upper bolt nut, and remove
the bolt and cushion.
Installation
Torque value:
Front cushion nut 4.6kgf-m
15-8
Suspension Arm
Remove
Remove front wheel, wheel hub, and brake caliper,
brake disk, tie-rod, knuckle and front cushion.
Suspension arm nuts and bolts

Loosen upper suspension arm nuts, remove swing
arm bolts.
Remove upper suspension arm.
Suspension arm nuts and bolts

Loosen under suspension arm nuts, remove swing
arm bolts.
Remove under suspension arm.
Inspection
Inspect the suspension arm, ball joint and bush for
damage or bending.
Installation
Install in reverse order of removal procedures. Bush
Torque value: Bush
Suspension arm nut 5.0kgf-m Ball joint
Lubricate with grease into suspension arm.
15-9
Toe-In
When repair or disassemble steering system parts,
must to adjustment the toe-in.
Keep the vehicle on level ground and the front
wheels facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Carefully to move the vehicle back, let the wheels

turn 180 degree, so the marks on the tires are
aligned with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.
Toe-in: 5±10mm
If the toe-in is out of standard, adjust it by hanging Lock nut

the length of the tie-rods equally by turning the
tie-rod while holding the ball joint.
Loosen two side tie-rod lock nuts; turn the tie-rods
to adjustment toe-in.
Tighten the lock nuts.
Torque value: 3.6kgf-m
Adjustment groove
15-10
Home page Contents
16. REAR BRAKE & REAR WHEEL & REAR CUSHION
Mechanism Diagram···························16-1 Disk Brake System Inspection·········· 16-10

Maintenance Description ···················16-2 Adding Brake Fluid ···························· 16-11
Trouble Diagnosis ······························16-3 Brake fluid replacement / Air-bleed·· 16-12
Rear Wheel ··········································16-4 Rear Brake Caliper ····························· 16-13
Rear Wheel Shaft Connecter ·············16-4 Brake Disk ·········································· 16-14
Rear Wheel Axle ·································16-5 Rear Brake Master Cylinder ·············· 16-14
Disk Brake System Inspection ··········16-10 Rear Cushion······································ 16-18
Mechanism Diagram
Rear brake master cylinder A
Brake hose bolts (3.5kgf-m)
Rear pressure control valve

To front pressure control valve
Air-bleed valve (0.5kgf-m)
Brake disk bolts (4.25kgf-m)
Brake caliper Rear wheel axle

bolts (3.25kgf-m) nuts (9.2kgf-m)
Rear axle holder
bolts (9.2kgf-m) Rear brake
master cylinder B
Driven gear nuts

(4.6kgf-m)
16
Rear wheel nuts

(2.4kgf-m)
Rear axle castle nuts

(5.0kgf-m)
16-1
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or
dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
y The brake caliper can be removed without removing the hydraulic system.
y After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
y While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
y Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
y Check the operation of the brake system before riding.
y Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and
installation of the tire.
Specifications
Item Standard (mm) Limit (mm)
The thickness of front and rear brake disk 4.000 2.500
Front and rear brake disk eccentricity < 0.100 0.300
Master cylinder inner diameter (hand brake) 14.000 ~ 14.043 14.055
Master cylinder piston outer diameter (hand brake) 13.957 ~ 13.984 13.945
Master cylinder inner diameter (foot brake) 15.900 ~ 15.943 15.955
Master cylinder piston outer diameter (foot brake) 15.857 ~ 15.884 15.845
Diameter of rear disk 220.000 -
Thickness of rear brake lining 7.000 2.000
Tire pressure as cold: 0.8 kg/cm² (12psi)
Torque values
Brake hose bolt 3.50kgf-m Rear axle castle nut 5.00kgf-m
Bolt for brake caliper 3.25kgf-m Rear axle holder bolt 9.20kgf-m
Bolts for the brake disk 4.25kgf-m Rear wheel axle nut 9.20kgf-m
Brake lever nut 1.00kgf-m Rear cushion mounting bolt 4.6kgf-m
Air-bleed valve 0.50kgf-m Swing arm pivot bolt 9.2kgf-m
Rear wheel nut 2.40kgf-m
Special tools
Rear axle bearing driver (6007LLU): SYM-9100100 RA1 A3017
16-2
Trouble Diagnosis
Soft brake lever Vibration or Wobble
1. Air inside the hydraulic system 1. Axle is not tightened well
2. Hydraulic system leaking 2. Bent rim
3. Worn master piston 3. Axle bearings are worn
4. Worn brake pad 4. Faulty tires
5. Poor brake caliper 5. Rear axle bearing holder is faulty
6. Worn brake lining/disk
7. Low brake fluid
8. Blocked brake hose
9. Warp/bent brake disk Hard Suspension
10. Bent brake lever 1. Bent damper rod
2. Faulty swing arm pivot bushings
Hard operation of brake lever

1. Blocked brake system Soft Suspension
2. Poor brake caliper
3. Blocked brake pipe 1. Weak shock absorber damper
4. Seized/worn master cylinder piston 2. Weak shock absorber spring
5. Bent brake lever
Uneven brake
3. Clogged brake hose
5. Restricted brake hose and fittings
Tight brake
Brake noise
1. Dirty lining
2. Deformed brake disk
3. Poor brake caliper installation
4. Imbalance brake disk or wheel
16-3
Rear Wheel
Removal
Raise the rear wheels off the ground by placing a
jack or other support under the frame.
Remove rear axle cover (4 screws).
4 screws
Remove the rear wheel nuts, and then remove

rear wheels.
Installation
Install the rear wheel and tighten the nuts.
Torque: 2.4kgf-m
4 nuts
Rear Wheel Axle Connecter Wheel hub nut
Removal
Remove cotter pin, rear wheel axle connecter nut
and washer.
Cotter pin
Remove right and left rear wheel axle connecter.
Installation
Install the rear wheel shaft connecter.
Install wheel shaft connecter washer and tighten
the wheel shaft connecter nut.
Torque: 2.4kgf-m
Install cotter pin.
16-4
Rear Wheel Axle

Remove right and left rear wheel, wheel
connecter.
Remove 2 bolts, and then remove rear brake
caliper.
2 bolts
Remove 2 bolts and 1 nut, and remove drive chain 2 bolts

cover.
1 nut
Remove 4 bolts to remove rear under protect. Front side 2 bolts
Rear side 2 bolts
Remove drive chain lock clip, master link, and Master link
then remove drive chain.
Lock clip
16-5
Remove 4 nuts, and remove driven sprocket.
Bend out the rear axle nut fixed plate.
4 nuts
Bend out the rear wheel axle holder nut fixed

plate.
Fixed plate
Remove rear wheel axle nuts.

Special tool:
Rear axle nut wrench (55mm)
Remove rear brake disk bracket and disk. Brake disk bracket
16-6
Remove rear wheel axle and driven sprocket
holder.
Driven sprocket holder
Inspection
Check bearings on rear wheel axle bearing seat.
mounted on bearing seat.
if necessary.
Disassembly
Caution
Remove bearing and seal from rear wheel axle
bearing seat using following tools.
Special tool:
Inner bearing puller (SYM-6204022)
Remove bearing spacer.
Assembly
Install new left side bearing and seal into rear
wheel axle bearing seat.
Install rear wheel axle bearing inner spacer.
Install new out right bearing and seal into front
wheel hub.
Apply with grease onto the oil seal lip of rear
wheel axle.
Special tool:
Bearing driver (6007LLU)
16-7
Installation
Install rear wheel axle and driven sprocket holder.
Driven sprocket holder
Install rear brake disk bracket and disk. Brake disk bracket
Install rear wheel axle nuts, rear axle nut fixed

plate and tighten the nuts.
Torque: 9.2kgf-m
Special tool:
Rear axle nut wrench (55mm)
Rear axle nut torque wrench
Torque wrench
After tightened the axle nut, bend the rear axle nut Fixed plate
fixed plate.
16-8
Install driven sprocket, drive chain, drive chain Master link
cover and brake caliper. Moving direction
Caution
y Note the chain lock clip direction.
Install rear wheel shaft connecter, rear wheel.
Lock clip
Driven sprocket inspection

Check the condition of the driven sprocket teeth.
Replace the sprocket if it worn.
{ X
Caution
y The drive chain, drive sprocket and driven
sprocket must be also inspected for wear.
Rear swing arm

Removal
Remove rear under protect, drive chain, driven
sprocket, rear brake caliper, brake disk and rear
axle.
Remove 2 nuts and bolt, and remove rear axle
holder.
Remove rear swing arm lock nut. Lock nut
Remove rear swing arm bolt, and then remove

rear swing arm.
16-9
Disk Brake System Inspection

Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube seam
whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.
Check the brake from behind the brake caliper. Brake lining wears
The brake pad must be replaced with new lining limit grooves
when the brake pad wear limit reaches the brake
disk.
Caution
Brake disk
y Check the rear brake lining must be removed
rear wheel first.
Park the ATV on a level ground, and check if fluid

level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 3).
Caution
y The vehicles inclined or just stop, the survey oil
level could not be accurate, had to settle the
3~5 minute.
y In order to prevent has the chemical change,
please do not use counterfeiting or other
unclear trade marks brake fluid.
y Uses by all means must with the trade mark
brake fluid, guarantees the ghost vehicle
efficiency.
16-10
Adding Brake Fluid Fluid cup
Before the brake fluid reservoir is removed, turn

the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid please do not surpass the
upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in their damages.
Fluid cup
Remove the brake fluid cap and diaphragm.

Increases the high quality brake fluid, uses by all
means must with the trade mark brake fluid joins
in the master cylinder.
Clean the dirty brake disk.
Caution
brake performance.
y To mixed non-compatible brake fluid will Master cylinder
reduce brake performance.
y Foreign materials will block the system
causing brake performance to be reduced or Screw
totally lost.
Brake fluid cap
Upper level
Diaphragm
16-11
Brake fluid replacement / Air-bleed Air-bleed valve
Connect drain hose to air-bleed valve.

Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out.
Close the drain valve and add specified brake fluid
into the brake master cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
Connect one end of transparent hose to the drain

valve, and put the other end into a container.
Air-bleed valve
Open the drain valve around 1/4 turns, and at the Bubble
same time hold the brake lever until the there is no
air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.
If brake is still soft, please bleed the system as

described below:
1. Tightly hold the brake lever and open the drain Transparent hose
valve around 1/4 turns, and then close the
valve.
Caution
y Do not release the brake lever before the
drain valve is closed.
y Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air enters into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
16-12
Rear Brake Caliper Brake hose bolt
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper bolts and the caliper. 2 bolts
Inspection
Make sure the brake linings condition. Replace
the linings if the brake linings wear limitation
groove close to the brake disk.
Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.25kgf-m
Caution
y Use M8 x 20 mm flange bolt only.
y Long bolt will impair the operation of brake
disk.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.5kgf-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
Brake lining replacement

Remove two guide pins.
Guide pins
Remove brake caliper cylinder, and then remove

brake linings.
Install new linings and brake caliper cylinder.
Tighten the guide pins.
Torque: 1.8kgf-m
16-13
Brake Disk Brake disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Micrometer
Remove the brake disk from rear wheel axle.

Check the disk for deformation and bend.
Caution
brake performance.
y Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the
operator should dress the mouthpiece and
the glove, use vacuum cleaner clean it.
Rear Brake Master Cylinder

Master Cylinder Removal Brake lever bolt
Caution
Do not let foreign materials enter into the
cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.
Brake light switch coupler Brake lever nut
Handle left side – rear brake master cylinder A

Remove brake light switch coupler.
Drain out the brake fluid.
Remove the brake hose.
Remove the brake lever from the brake master
cylinder.
master cylinder.
2 socket bolts
16-14
Right footrest side – rear brake master cylinder 2 bolts
B
Place a container under the brake master cylinder,
remove fluid hose clamp, and drain out the brake
fluid.
Loosen the brake hose bolt and finally remove the
brake hose.
Hose clamp
Remove the E type clip, and remove brake push

rod pin.
master cylinder.
E type clip
Disassembly
Cir clip
Remove the rubber boot.
Remove the cir clip. Rubber boot
Remove the piston and the spring. Piston
Clean the master cylinder with recommended
brake fluid. Piston cup
Spring
Master cylinder
Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit:
Hand brake 14.050 mm
Foot brake 15.950 mm
16-15
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit:
Hand brake 13.954 mm
Foot brake 15.850 mm
Master Cylinder Assembly

Caution
y It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
y Make sure there is no dust on all components
before assembling.
Cir clip
Apply clean brake fluid to the piston cup, and then
Rubber boot
install the cup onto the piston.
Install the larger end of the spring onto the master Piston
cylinder.
The master cup’s cavity should be face inside of Piston cup
master cylinder when installing the master cup. Spring

Install the cir clip.
Caution
y Never install cup lip in the opposite direction.
Master cylinder
y Make sure the cir clip is seated securely in
the groove.
Install the rubber boot into groove properly.
Master Cylinder Install

Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Kink of brake leads, hose or pipe may reduce
brake performance.
Handle left side – rear brake master cylinder A 2 socket bolts
Install the rubber pad into the groove correctly.

Place the master cylinder onto handlebar, and Brake lever bolt
install the bolts.
Install the brake lever, and connect coupler to
brake light switch.
Connect brake hoses with 2 new washers.
value.
Torque: 3.5kgf-m
Add specified brake fluid and bleed the system.
Brake light switch coupler Brake lever nut
16-16
Right footrest side – rear brake master cylinder 2 bolts
B
Install the master cylinder bolts and the master
cylinder.
Hose clamp
Install brake push rod to the brake pedal, and

Lock nut Adjustment nut
install pin and E type clip.
Caution
To adjustment brake pedal, you must be
removed push rod pin fist.
Loosen lock nut, and turn adjustment nut and
push rod bracket to adjustment brake free play.
E type clip
Install fluid hose and clamp.

Connect brake hoses with 2 new washers.
value.
Torque: 3.5kgf-m
Add specified brake fluid and bleed the system. 2 washers
Hose clamp
16-17
Rear Cushion Nut
Removal
Support the frame.
Loosen rear cushion under bolt nut, and remove
rear cushion under bolt.
Rear cushion under bolt
Remove rear cushion upper bolt, and then remove

rear cushion.
Installation
Install rear cushion, and install rear cushion upper
bolt.
Install rear cushion under bolt, and install nut.
Tighten the rear cushion upper bolt and under nut
to the specified torque value.
Torque: 4.6kgf-m
Rear cushion upper bolt
16-18
Home page Contents
17. ELECTRICAL SYSTEM
Mechanism Diagram ··························17-1 Meters················································· 17-12

Maintenance Data·······························17-2 Light / Bulb········································· 17-13
Technical Specification······················17-2 Switch / Horn······································ 17-16
Trouble Diagnosis ······························17-3 Fuel Unit ············································· 17-19
Battery ·················································17-4 Cooling Fan Thermo Switch ············· 17-20
Charging System ································17-5 Thermo unit········································ 17-21
Ignition System···································17-8 Water Temperature Indicator Light ·· 17-21
Starting System ··································17-10
Mechanism Diagram
Front brake switch
C.D.I. Unit Main switch
Battery Shift gear

control unit
Fuse box Hazard

control unit
Starter relay
Winker relay
Rear brake switch
Regulator rectifier
AC. Generator
Thermo unit
Start & light &

winker & horn & 17
brake switch
DC. Power outlet
Fuel unit
Headlight relay Ignition coil
Spark plug
Horn
Change switch
17-1
Maintenance Data
Operational precaution
y When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
y The model of the spark plug and the tightening torque.
y The ignition timing.
y Adjustment of headlight.
y Removal and installation of AC generator.
y The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water.
y To recharge the battery, remove the battery from rack without removing ventilation caps.
y Unless in emergency, never rapid charge the battery.
y The voltage must be checked with the voltmeter while charging the battery.
y As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check
C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary.
Technical Specification
Charging system
Description Specification
Capacity 12V10Ah
Battery
1A / 5 hours (standard)
Charging rate
4A / 1 hour (fast charging)
Leak current < 1mA
Charging current 1.2 A / 1500rpm
Control voltage in charging 14.5 + 0.5 V / 1500rpm
Ignition system
Description Specification
Model NGK CR8E (Recommended)

Spark plug
Gap 0.8mm
Primary winding 0.17 ± 10%Ω

Ignition coil and
Without cap: 3.1 ± 10KΩ
resistance Secondary winding
With cap:8.1 ± 10KΩ
10° TDC / 1700rpm

Ignition timing “F” mark
27°TDC / 4000rpm
17-2
Trouble Diagnosis
No voltage Charging system does not operate
y Battery discharged properly
y The cable disconnected y Burnt fuse
y The fuse is blown y Poor contact, open or short circuit
y Improper operation of the main switch y Poor regulator
y Poor ACG
Low voltage
y The battery is not fully charged Engine does not crank smoothly
y Poor contact y Primary winding circuit
y Poor charging system - Poor ignition coil
y Poor voltage regulator - Poor connection of cable and connectors
- Poor main switch
y Secondary winding circuit
No spark produced by spark plug - Poor ignition coil
y The spark plug is out of work - Poor spark plug
y The cable is poorly connected, open or - Poor ignition coil cable
short-circuited - Current leakage in the spark plug
- Between AC.G. and C.D.I. y Incorrect ignition timing
y Poor connection between C.D.I. and ignition - Poor AC.G.
coil - Improper installation of the pulse sensor
- Poor connection between C.D.I. and the - Poor C.D.I.
main switch
y Poor main switch
y Poor C.D.I. Weak starter motor
y AC.G. is out of work y Poor charging system
y The battery is not fully charged
y Poor connection in the windings
Starter motor does not work y The motor gear is jammed by foreign material
y The fuse is blown
y The battery is not fully charge
y Poor main switch Starter motor is working, but engine does
y Poor starter switch
not crank
y The front and rear brake switches do not
y Poor starter motor pinion
operate correctly
y The starter motor run in reverse direction
y Starter relay is out of work
y Poor battery
y The ignition coil is poorly connected, open or
short-circuited
y The starter motor is out of work
Intermittent power supply

y The connector of the charging system becomes
loose
y Poor connection of the battery cable
y Poor connection or short-circuit of the
discharging system
y Poor connection or short-circuit of the power
generation system
17-3
Battery
Removal
Remove the seat, and then you can see the
battery.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery clamp, and then remove
battery...
Clamp
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 13.0~13.2 V at 20℃
Undercharged: Below 12.3 V at 20℃
Charging
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard Maximum
Charging current 1A 4.0A
Charging time 5H 1H
Warning
y Keep flames away while recharging.
y Charging is completely controlled by the
ON/OFF switch on the charger, not by
battery cables.
Caution
y Never rapid charge the battery unless in
emergency.
y Verify the battery is recharged with current
and duration prescribed above.
y Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable terminal

with grease.
17-4
Charging System
Charging circuit
Main switch
Green Red
Black Yellow Yellow

Fuse 20A
Yellow
Battery
Regulator rectifier
AC. Generator
Current Leakage Inspection

Turn the main switch to OFF position, and remove
the negative cable terminal (-) from the battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal. Battery negative terminal
Caution
y In the current leakage test, set the current
range at the largest scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.
y Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified value, it
may indicate a short circuit.
Allowable current leakage: Less than 1mA
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.
17-5
Inspection on Charging Voltage Connect a tachometer.

Turn on the headlight to high beam and start the
Voltmeter engine.
Accelerate the engine to the specified revolution
Ammeter per minute and measure the charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 + 0.5 V / 2000 rpm
Caution
To replace the old battery, use a new battery with
the same current and voltage.
Fuse connector
The following problems are related to the charging

Caution system; follow the instructions provided in the
checking list to correct it if any one of the problems
y Before conducting the inspection, be sure that
takes place.
the battery is fully charged. If undercharged,
(1) The charging voltage can not exceed the
the current changes dramatically.
voltage between two battery terminals and
y Use a fully charged battery having a voltage
the charging current is in the discharging
larger than 13.0 V
direction.
y While starting the engine, the starter motor
(2) The charging voltage and current are too
draws large amount of current from the
much higher than the standard values.
battery.
The following problems are not related to the
After the engine is warmed up, replace original charging system; correct it if any by following
battery with a fully charged battery. steps indicate in the checking list.
Connect a digital voltmeter to the battery (1) The standard charging voltage and current
terminals. can only reach when the revolution of the
Connect an ammeter between both ends of the engine exceeds the specified rpm.
main fuse. - Bulbs used exceed their rate and
consume too much power.
Caution - The replacement battery is aged and
When the probe is reversibly connected, use a does not have enough capacity.
voltmeter having an indication that the current (2) The charging voltage is normal, but the
flows from the positive or the negative direction current is not.
and the measurement should be at zero, - The replacement battery is aged and
ammeter at one direction only. does not have enough capacity.
- Battery used does not have enough
Caution electricity or is over charged.
- The fuse of the ammeter is blown.
y Does not use short-circuit cable.
- The ammeter is improperly connected.
y It is possible to measure the current by
(3) The charging current is normal, but the
connecting an ammeter between the battery
voltage is not.
positive terminal and the cable position
- The fuse of the voltmeter is blown.
terminal, however, while the starter motor is
activated, the surge current the motor draws
from the battery may damage the ammeter.
Use the kick starter to start the engine.
y The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the cable
while there is current flowing through. It may
damage the ammeter.
17-6
Inspection on regulator rectifier

Remove the seat, rear carrier and rear fender.
Disconnect two 3 pin couplers of the regulator
rectifier.
Inspection the rectifier coupler to the wire harness
passes the condition.
Item Check Points Standard Value
Main switch Battery voltage
R–B
connection (ON)
Battery
R–G Battery voltage
connection
Charging coil Y–Y 0.17 ~ 0.8Ω
2 couplers
If the readings measured are not normal, check

parts in the circuit.
If the parts are normal, then trouble is in the wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
Regulator rectifier
17-7
Ignition System
Ignition circuit diagram
B Black
R Red
Shift gear control unit CDI. Unit
G Green
W White
Y Yellow
L Blue
G B/W G/W B/Y
G
W/B
Fuse 15A
Ignition
coil
B
Main fuse L/Y
30A
Spark plug
Battery G
Main switch
Pulse generator
C.D.I unit
Disconnect connectors of the C.D.I unit.
Check the following connectors as indicated in the table at the harness side.
Item Points to check Result
Main switch turn to “ON” position Black/white ~ green Battery voltage
Pulse generator Green/White ~ Blue/yellow 50~170Ω
Primary circuit Black/yellow ~ green 0.17±10%Ω
Ignition coil Black/yellow ~ with no cap 3.6±10%Ω

Secondary circuit
Black/yellow ~ with cap 7.3~11KΩ
17-8
Inspection on Ignition Coil

Disengage the connector of the ignition coil and
the spark plug cap.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 0.17Ω ± 10%
Remove the cap from the spark plug and measure
the resistance between the spark plug and the
primary winding.
Standard resistance:
With no cap: 3.6Ω ± 10%
With cap: 7.3~11 KΩ
Ignition Coil Replacement Ignition coil Spark plug

Loosen the lock bolt and replace the ignition coil if
necessary.
Inspection of Pulse Generator Pulse generator coupler
Disconnect the coupler of the pulse generator and

measure the resistance between the terminals of
green/white and blue/yellow.
Standard resistance: 50~170Ω
17-9
Starting System
Starting circuit diagram
Shift gear
control unit
Fuse 15A
W/B B
BR/Y R
Main switch Main fuse
G/W
30A
G G/R
Brake
switch
F Battery
N
R G/Y
Change switch
Y/B
Starter relay
B Black Starter motor
Y/R
R Red G
G Green
W White
Y Yellow Starter switch
BR Brown
G/Y
Brake light
Inspection on starter relay

Open the main switch. Starter relay
Press the brake.
Push down the starter switch.
If a sound of “Looh Looh” is heard, it indicates the
relay function normally.
Remove the seat.

Disconnect the negative cable terminal of the
battery.
Disconnect the cable positive terminal from the
relay.
Disconnect the positive cable of the starter motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal end.
Connect the yellow/red cable to the battery
positive terminal and the yellow/black cable to the
battery negative terminal.
Check the continuity of the large terminal end.
If there is no continuity, replace the relay.
17-10
Removal of Starter motor Negative

Remove the seat.
Disconnect the cable negative terminal (-), then
the cable positive terminal (+).
Remove starter motor cable. 2 Bolts

Loosen the lock bolts and remove the starter
motor.
Installation of Starter motor

Starter motor cable
17-11
Meters
Removal
Loosen 4 bolts of the meter stay.
Each side 2 bolts
Meter set couplers

Remove the front center cover, and then remove
meter couplers and main switch coupler.
Remove speedometer cable.
Main switch coupler
Remove speedometer cable, and then remove

meter set, main switch and handle cover
Speedometer cable
4 nuts
Remove 4 nuts and meter wire, and then remove
speedometer and fuel meter.
17-12
Light / Bulb
Replacing Bulb for Headlight
Remove 4 screws for the headlight cover, and
remove the cover.
Adjustment screw 4 screws
Loosen headlight bulb setting plate screw.
1 screw
Remove bulb setting hook. Hook
Take out the bulb connector and the bulb. 1 screw

Replace with new bulb if necessary.
(H7 12V 55W)
Caution
y Never touch the bulb with finger, which will
create a heat point.
y Clean the fingerprint left on the bulb with
alcohol.
Install the bulb of the headlight in reverse order of
removal.
Upon completion of replacement, turn on the main
switch to ensure the headlight works well.
Adjust the beam and distance of the headlight if
necessary.
17-13
Replacing the Front winker light Bulb Front winker bulb

Pull out the front winker light bulb seat.
Replace with new front winker light bulb.

(12V 21W)
Position light bulb

Replacing Bulb of Position Light
Pull out the position light bulb seat.
Replace with new position light bulb.

(12V 5W)
17-14
Replacing Bulb of Taillight and Rear Taillight bulb

Winker Light
Turn the taillight and rear winker light bulb
connectors by CCW.
Rear winker bulb
Taillight
Replace with new taillight bulb.
(12V 5W/21W)
Replace with new rear winker light bulb. Rear winker light
(12V 21W)
Replacing Bulb of License Light License light

Turn the license light bulb connectors by CCW.
Replace with new license light bulb.
17-15
Switch / Horn
Main Switch
Inspection
Remove the front center cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below:
Pin
BAT1 BAT2
Position
OFF
Main switch coupler
ON
Wire Color Red Black

Replacement of main switch
Disconnect the coupler of the main switch.
Push out the main switch.
Align the main switch stopper with the meter cover
groove, and install main switch.
Install the main switch coupler.
Headlight switch couplers

Handle switches
Disconnect the coupler of handle from front fender
left side.
Check the continuity between two points as
indicated in the table below.
Start switch
Start Switch
Pin
ST SG
Position
FREE
Yellow Yellow
Wire Color
/ Red / Black
17-16
Headlight Switch Headlight switch
Pin
BAT3 LO HI PL
Position
●
White
Wire color White Blue Brown
/ Black
Winker switch
Pin
L WR R
Position
N PUSH OFF
Brown /
Wire color Pink Black Winker switch
White
Horn switch
Pin
BAT3 HO
Position
FREE
Wire Color White/ Black Light green
Horn switch
Hazard switch Hazard switch

Pin
HD E
Position
Wire Color Green / Red Green
17-17
Front Brake Switch Brake light switch

While grasp the brake lever firmly, the terminals of
brown/blue and green/yellow of the brake should
have continuity.
Replace the switch if damaged.
Rear Brake Switch Brake light switch

While grasp the brake lever firmly, the terminals of
white/black and green/yellow of the brake should
have continuity.
Replace the switch if damaged.
Horn
Remove the horn from front fender left side.
1 bolt
Apply 12 V power source to two terminals of the

horn, the horn should sound.
Replace the horn if necessary.
17-18
Fuel Unit 4 bolts

Remove the seat.
Remove the fuel tank cap.
Remove the fuel tank cover and front fender (refer
chapter 13).
Disconnect the coupler of the fuel unit.
Remove the fuel unit (4 bolts).
Caution
y Great care shall be taken not to damage or
bend the float arm of the gauge.
Fuel unit coupler
When the float arm shifts to the F position or the E

position, the resistance measured shall be as
follows:
Position Resistance Full
E (Empty) 97.5~107.5 Ω
F (Full) 4~10 Ω
Connect the wiring to the fuel unit and the
ohmmeter as shown.
Empty
Connect the fuel unit coupler to the wire harness.

Turn on the main switch.
Move the float arm to verify the proper position the
fuel gauge needle indicates.
Arm Position Needle Position

Up (Full) F (Full)
Down (Empty) E (Empty)
Caution
While conducting the test, turn on the direction
indication lamp to make sure that the battery is in
serviceable condition.
17-19
Cooling Fan Thermo Switch

The thermo switch mounted on the radiator
controls the operation of the cooling fan motor.
In case that the fan motor fails to work, disconnect
the green and black/blue leads and connect jump
wires to the terminals, then, turn on the main
switch, the fan motor should operate.
If the fan motor still fails to run, measure battery
voltage between the green and black/blue leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit.
If the fan motor runs, check the thermo switch in Thermo switch
the manner as described below:
Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and closing
temperatures, confirm the switch is open circuited
at room temperature, increase the coolant
temperature gradually. The switch should have
continuity at 98±3℃.
Caution
y Keep the coolant at a constant temperature at
least for three minutes. Sudden increase the
coolant temperature will cause the
thermometer and the tester to indicate wrong Thermometer
readings.
y Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
y The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.
17-20
Thermo unit Thermo unit
Remove the thermo unit.

Hang the thermo unit in an oil heater, heat the oil
and measure the resistance at each temperature.
Temperature 50°C 80°C 100°C 120°C
Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2
Caution
y Wear gloves and goggles when performing
this test.
Caution
y Engine oil should be used as a heating
medium as the test temperature must be
higher than 100℃.
y Contacting the container wall by the
thermometer and the thermo unit may result in
wrong readings.
Thermo unit
Water Temperature Indicator Light

Disconnect the water temperature meter and
connect it to engine ground.
Turn on the main switch.
The indicator light of the fuel meter should be
lighting.
17-21
Notes:
17-22
Home page Contents
18. ELECTRICAL DIAGRAM
QUAD LANDER 250 ELECTRICAL DIAGRAM 18
18-1
Home page Contents
18. ELECTRICAL DIAGRAM
Notes:
18-2

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FORWARD CONTENTS

HOW TO USE THIS MANUAL SERIAL NUMBER

Quad Lander 250

The first chapter covers general information and trouble diagnosis.

Page Content Index

1-1 ~ 1-18 GENERAL INFORMATION 1

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2

3-1 ~ 3-8 LUBRICATION SYSTEM 3

4-1 ~ 4-12 FUEL SYSTEM 4

5-1 ~ 5-6 ENGINE REMOVAL 5

6-1 ~ 6-16 CYLINDER HEAD/VALVE 6

7-1 ~ 7-8 CYLINDER/PISTON 7

8-1 ~ 8-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8

9-1 ~ 9-12 FINAL DRIVING MECHANISM 9

10-1 ~ 10-10 ALTERNATOR 10

11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11

12-1 ~ 12-12 COOLING SYSTEM 12

13-1 ~ 13-14 BODY COVER 13

14-1 ~ 14-14 FRONT BRAKE AND FRONT WHEEL 14

15-1 ~ 15-10 STEERING/FRONT SUSPENSION 15

16-1 ~ 16-18 REAR BRAKE/REAR WHEEL/REAR CUSHION 16

17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17

18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

Symbols and Marks............................. 1-1 Specifications..................................... 1-10 1

Grease King Mate G-3 is recommended.

Oil seal Apply with lubricant.。

Renew Replace with a new part before installation.

Special tools Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

Components assembly directions each other.

y Rubber parts may become deteriorated when

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

y Tighten assemblies with different dimension Clamp

Both of these examples can result in

y Check if positions and operation for installed

y Make sure that the battery post caps are

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

y Before battery removal operation, it has to

y Secure wires and wire harnesses to the frame

y Make sure if the connector pins are bent,

y Wire band and wire harness have to be

y Insert the connector completely.

y Check if the connector is covered by the twin

y Before terminal connection, check if the boot is

Never too tight

y Wire harnesses routed along the handlebar

y Before operating a test instrument, operator

Do you know how to set the

Overall Height 1115 mm Front AT22x7-10 (off road)

Passengers/Weight Two /150 kg Primary

Exhaust Pipe Position and Left side, and

Number/Arrange Forced circulation &