Quad Lander 600: Service Manual

FOREWORD CONTENTS
HOW TO USE THIS MANUAL SERIAL NUMBER
Quad Lander 600

SERVICE MANUAL
Homepage Contents
FOREWORD
This service manual contains the technical data of each component inspection and
repair for the SANYANG Quad Lander 600 ATV. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment”, providing technician with service guidelines.
If the style and construction of the ATV, Quad Lander 600, are different from 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 600ATV. 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 and special tools information.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter contain the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content to acquire the special parts and system information
quickly.
There are 4 buttons, “Foreword”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the PDF version, and can be access to these items by
clicking on them.
If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can link 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 to
the homepage or contents. The content of each chapter can be selected too.
Therefore, when the user needs to check the content 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 on the top of the following
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Homepage
CONTENTS
Page Content Index
1-1 ~ 1-17 GENERAL INFORMATION 1
2-1 ~ 2-17 MAINTENANCE INFORMATION 2
3-1 ~ 3-8 LUBRICATION SYSTEM 3
4-1 ~ 4-13 FUEL SYSTEM 4
5-1 ~ 5-6 ENGINE REMOVAL 5
6-1 ~ 6-17 CYLINDER HEAD/ VALVE 6
7-1 ~ 7-8 CYLINDER/ PISTON 7
8-1 ~ 8-17 “V” BELT DRIVING SYSTEM 8
9-1 ~ 9-14 TRANSMISSION 9
10-1 ~ 10-16 WHEEL DRIVE SHAFT/ PROPELLER SHAFT 10
11-1 ~ 11-11 A.C. GENERATOR/ STARTING CLUTCH 11
12-1 ~ 12-8 CRANKCASE/ CRANKSHAFT 12
13-1 ~ 13-14 COOLING SYSTEM 13
14-1 ~ 14-8 BODY COVER 14
15-1 ~ 15-12 FRONT BRAKE AND FRONT WHEEL 15
16-1 ~ 16-13 STEERING/ FRONT SUSPENSION 16
17-1 ~ 17-18 REAR BRAKE/ REAR WHEEL/ REAR CUSHION 17
18-1 ~ 18-21 ELECTRICAL SYSTEM 18
19-1 ~ 19-2 ELECTRICAL DIAGRAM 19

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

General Safety ..................................... 1-2 Troubles Diagnosis............................ 1-12
Service Precautions ............................ 1-3 Lubrication Points ............................. 1-17
Specifications ...................................... 1-9
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. 1
(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 have • Battery emits explosive gases; flame is strictly
to run your engine in a closed area, be sure to use prohibited. Keeps the place well ventilated
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
Always use with SANYANG genuine parts and Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts for unsmooth control and premature worn out.
SANYANG ATV may damage the ATV.
Rubber parts may become deteriorated when old,

Special tools are designed for remove and install and prone to be damaged by solvent and oil.
of components without damaging the parts being Check these parts before installation to make
worked on. Using wrong tools may result in parts sure that they are in good condition, replace if
damaged. necessary.
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.
Store complex components such as transmission
parts in the proper assemble order and tie them
together with a wire for ease of installation later.
When servicing this ATV, use only metric tools.
Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
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. Note the reassemble position of the important
components before disassembling them to
Wash and clean parts with high ignition point
ensure they will be reassembled in correct
solvent, and blow dry with compressed air. Pay
dimensions (depth, distance or position).
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on Components not to be reused should be
them. replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
The length of bolts and screws for assemblies, Remove residues of the old gasket or sealant
cover plates or boxes is different from one before reinstallation, grind with a grindstone if the
another, be sure they are correctly installed. In 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.
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
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 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
When oil seal is installed, fill the groove with 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 shaft bearing. Damage may result if the tool is pressed
on which the oil seal is to be installed for against only one race (either inner race or outer
smoothness and for burrs that may damage the race). In this case, the bearing should be
oil seal. 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
Lubricate the rotation face with specified After service completed, make sure all
lubricant on the lubrication points before connection points is secured.
assembling. Battery positive (+) cable should be connected
firstly.
And the two posts of battery have to be greased
after connected the cables.
Check if positions and operation for installed

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

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

solved it. And then replace with specified
capacity fuse.
Note that do not let parts fall down.
Capacity
verification
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
When separating a connector, it locker has to Insert the terminal completely.
be unlocked firstly. Then, conduct the service Check if the boot covers the terminal.
operation. Do not let boot open facing up.
Secure wires and wire harnesses to the frame

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.
Make sure if the connector pins are bent,

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

secured properly.
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.
Do not squeeze wires against the weld or its
clamp.
Check if the connector is covered by the twin

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

crack or the terminal is loose.
1-6
Do not let the wire harness contact with rotating, 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.
Keep wire harnesses far away from the hot Secure the rubber boot firmly as applying it on
parts. wire harness.
Never Touch
Route wire harnesses to avoid sharp edges or 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.
Route harnesses so that they neither pull too 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
Do not let the wire harness been twisted as With sand paper to clean rust on connector
installation. pins/terminals if found. And then conduct
connection operation later.
Clean rust
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.
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 UA60A-6
Overall Length 2110 mm Suspension Front Double arm
Overall Width 1150 mm System Rear Unit Swing
Dimension
Overall Height 1220 mm Front AT25x8-12 (off road)

Tire Specifications
Wheel Base 1300 mm Rear AT25x8-12 (off road)
Front 900 mm Rim Aluminum
Wheel tread
Rear 895 mm Front Disk (ψ220mm)
Brake System
Front 180 kg Rear Disk (ψ180mm)
Curb Weight Rear 165 kg Max. Speed Above 80 km/hr
Performance
Total 345 kg Climb Ability Below 25°
Weight
Passengers/Weight Two /150 kg Primary

Belt
Front 215 kg Reduction
Total Weight Rear 280 kg Secondary
Gear / Sprocket
Total 495 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 Ø92 mm Muffler
Type
Cylinder
Exhaust Pipe Position and Left side, and

Stroke 85 mm
Direction Backward
Engine
Number/Arrange Forced circulation &

Single Cylinder Lubrication System
ment splashing
Concentration
Displacement 565cc Solid Particulate

Exhaust
Compression Ratio 10.2 CO Below 7.0 g/ km

Max. HP 20.4ps / 6000rpm HC Below 1.5g/ km
Max. Torque 3.6 Kg m / 2750rpm Nox Below 0.4g/ km
Ignition Full Transistor Ignition E.E.C. ―
Starting System Electrical Starter P.C.V. ―
Catalytic reaction control
Air filtration Sponge ―
system
1-9
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
1-10
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
1-11
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 No fuel in fuel tank
Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
Float valve clogged
Fuel supplied tom No fuel is supplied to
Lines in fuel tank evaporation system
carburetor sufficient carburetor
clogged
Malfunction of fuel pump
Loosen or damaged fuel pump vacuum
Remove spark plug, install it
hose
into spark plug cap, and perform
Fuel filter clogged
a spark test against engine
ground.
Malfunction of spark plug
Spark plug foul
Check if sparks Weak sparks, no spark at
Malfunction of CDI set
all
Malfunction of AC generator
Ignition coil is in open or short circuit
Perform cylinder compression Ignition coil leads open or short circuit
pressure test. Malfunction of main switch
Cylinder compression Low compression Piston ring seized

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

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

and check it.
Fuel level in carburetor too high

Dry spark plug Wet spark plug Malfunction of throttle valve operation
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 Malfunction of automatic by- starter
1-12
B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration and

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

Malfunction of AC alternator
Check cylinder compression

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

Incorrect spark plug heat range
Check if engine over heat Piston and cylinder worn out

Lean mixture
Poor fuel quality
Normal Engine overheat Too much carbon deposited in
combustion chamber
Ignition timing too advanced
Continually drive in acceleration Poor circuit on the cooling system
or high speed
Too much carbon deposited in
combustion chamber
No knock Knock Lean mixture
Poor fuel quality
1-13
C. Engine runs sluggish (especially in low speed and idling)

Check ignition timing (using

ignition lamp)
Normal Abnormal Incorrect ignition timing (malfunction of

CDI or AC alternator)
Adjust the airscrew of

carburetor
Good Poor Rich mixture (loosen the screw)

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

Malfunction of AC alternator
Check for fuel supplying system

in automatic fuel cup
Insufficient fuel in fuel tank

Good Abnormal Fuel filter clogged
Restricted fuel tank vent
Check if carburetor clogged
No clogged Clogged Cleaning
1-14
E. Clutch, driving and driving pulley
FAULT CONDITIONS PROBABLE CAUSES
Drive belt worn out or deformation

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

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

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

Damaged steering shaft bushing
Bent rim
Improperly installed wheel hub
One wheel is wobbling Excessive wheel bearing play
Bent swing arm
Bent frame
Swing arm pivot bushing excessively
Worn
Bent tie-rod
Incorrect tie-rod adjustment
Vehicle pulls to one side Rear tie air pressure incorrect
Improper wheel alignment
Bent frame
1-15
G. Loss power
Raise wheels off ground and

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

Faulty tire valve
Accelerate lightly, engine speed

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

Faulty CDI unit
Test cylinder compression
Normal Abnormal Leaking head gasket

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

Spark plug is incorrect heat range
Check for engine overheating

Excessive carbon deposited in
combustion chamber
Normal Overheating Wrong type of fuel
Fuel / air mixture ratio is lean
Use of poor quality fuel
Accelerate or run at high speed
Worn piston and cylinder
Fuel / air mixture ratio is lean
Normal Knocks Wrong type of fuel
Excessive carbon deposited in
combustion chamber
1-16
Lubrication Points
Acceleration cable/ Front & rear brake/ Lever Pivot
Wheel bearing
1-17
Home page Contents
2. MAINTENANCE INFORMATION
Precautions in Operation ···················· 2-1 Front Differential ·································· 2-8

Periodical Maintenance Schedule ······ 2-2 Rear Axle Gearbox······························· 2-8
Fuel Lines ············································· 2-3 Brake System ······································· 2-9
Acceleration Operation ······················· 2-3 Brake Light Switch······························· 2-10
Air Cleaner············································ 2-3 Headlight Beam Distance ···················· 2-11
Spark Plug ············································ 2-4 Clutch Disc Wear ································· 2-11
Valve Clearance ··································· 2-4 Cushion················································· 2-11
Carburetor Idle Speed Adjustment····· 2-5 Steering Handle···································· 2-12
Ignition System ···································· 2-6 Wheel/Tire············································· 2-12
Cylinder Compression Pressure ········ 2-6 Nuts, Bolts Tightness ·························· 2-12
Drive Belt ·············································· 2-7 Special Tools List ································ 2-13
Propeller Shaft ····································· 2-7
Precautions in Operation 2
Specification
Fuel Tank Capacity 12000 c.c.
Capacity 1400 c.c.
Engine Oil
Change 1200 c.c.
Capacity 1300 c.c.
Transmission Gear oil
Change 1200 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: GTX12-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 12000 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
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.
2-2
Fuel Lines Fuel tank

Remove the seat.
Loosen 2 screws and 2 bolts
Remove the tank cover.
Fuel hose
Check all lines, and replace the lines when they
are deteriorated, damaged or leaking. Carburetor Fuel filter
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.
Acceleration Operation Fuel valve
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 adjusting screw.
Tighten the fixing nut, and check acceleration
operation condition. Throttle adjustment screw
Free play: 1~3 mm.
Clamp Element Screw
Air Cleaner
Remove the seat.
Loosen 5 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.
2-3
Spark Plug Ground electrode

Recommended spark plug: CR8E
Remove the spark plug cap. Central electrode
Clean the dirt around the spark plug hole.
Remove the spark plug.
Measure the spark plug gap.
Spark plug gap：0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold the spark plug washer and install the spark 0.8~0.9mm
plug by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0~1.2kgf-m
Timing mark
Valve Clearance
Caution
Checks and adjustment must be performed when
2 bolts
the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank.
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
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 coil
Caution
Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
Idle speed check and adjustment have to be
done after engine being warmed up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV warm up engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 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.
Adjust the air adjustment screw so that
Idle speed adjust screw
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 0,8~1.5%
HC: below 900ppm
Air/fuel adjusting screw
2-5
Ignition System Full transistor igniter
Caution
Full transistor ignition system is setup by the
manufacturer so it cannot be adjusted.
Ignition timing check procedure is for checking
whether ignition 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 which 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 means that the
ignition advance degree is normal.
If ignition timing is incorrect, check the full
transistor ignition set, 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:
Incorrect valve clearance.
Valve leaking.
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
Loosen the 2 clamp strips of left crankcase cover,
and then remove the left crankcase cover
ventilation pipe.
Remove 17 bolts.
Remove the left crankcase cover.
9 bolts
Check if the belt is cracked or worn out.

Replace the belt if necessary or in accordance
with the periodical maintenance schedule to
replace it. Teeth
Width limit: 32.7 mm or above Width
Propeller Shaft Rubber boot

Remove 3 bolts from the propeller shaft connector.
Check the propeller shaft for any wear.
Check the rubber boots for any damage.
3 bolts Front propeller shaft
Caution Propeller shaft connector

Don’t lose the propeller shaft spring.
Coat the propeller shaft gear with grease before
assembling the propeller shaft.
Propeller shaft spring
2-7
Front Differential
Front differential
Check the front differential for abnormal noise or
unsmooth rotation.
Caution
Do not attempt to disassemble the Front
Differential. Please exchange the whole
assembly if necessary. Differential control unit 2 bolts
Rear axle gearbox

Rear Axle Gearbox
Check the rear axle gearbox for abnormal noise or
unsmooth rotation.
Caution
Do not attempt to disassemble the Rear
Gear Box. Please exchange the whole
assembly if necessary.
3 bolts
2-8
Brake System
Brake System Hose
Check 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
In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
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
2-9
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
To check front brake lining must be remove Brake lining wear
front wheel first. limitation groove
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
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
In order to maintain brake power balance, the
brake lining must be replaced with one set.
Brake Light Switch

Brake 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
2-10
Headlight Beam Distance

Turn on main switch.
Turn the headlight adjusting screw to adjust
headlight beam height.
Caution
To adjust the headlight beam follows related
regulations.
Improper headlight beam adjustment will
make in coming driver dazzled or insufficient
lighting.
Adjusting screw
Clutch Weight
Run the ATV and increase throttle valve opening
gradually to check the clutch operation.
If the ATV is in forward moving and shaking, check
clutch disc condition. Replace it
Clutch weight
Cushion
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.
Warning
Do not ride the ATV with poor cushion.
Looseness, wear or damage cushion will make
poor stability and drive-ability.
2-11
Steering Handle
Caution
Check all wires and cables if they are interfered
with the rotation of steering handle bar.
Lift the front wheel off 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 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 accordance
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.
2-12
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-2301000-HMA NO SYM-1471110/20 NO SYM-3110000-HMA
KNUCKLE BODY BRG.

NAME NAME Drive shaft puller NAME Driveshaft BRG. 6228 driver
6006 driver
NO SYM-5024000-REA 6006 NO SYM-2341120-REA NO SYM-2341110-REA 6228
BEVEL GEAR HOUSHING WHEEL DRIVE SHAFT Countershaft OIL SEAL

NAME NAME NAME
BRG 6306 driver BALL SET tool 20*40*5
NO SYM-2343700-REA A6306 NO SYM-4423500-REA NO SYM-9121000-REA
2-13
NAME NEEDLE BRG. 2220C driver NAME MDF. Fixer NAME Final shaft gear stopper
NO SYM-9100400-REA 2220 NO SYM-2211000-REA NO SYM-2343100-REA
OUTPUT SHAFT OIL SEAL OUTPUT SHAFT OIL SEAL

NAME Driveshaft BRG. 6328 driver NAME 42*52*7
NAME 38*52*7
NO SYM-9100500-REA A6328 NO SYM-9120900-REA NO SYM-9120800-REA
(12*28*7) (6901)
WATER PUMP BRG. 6001 Water pump mechanical seal
NAME Water pump oil seal driver NAME driver
NAME driver
NO SYM-9120200-REA NO SYM-6001300-REA A6001 NO SYM-1721700-H9A
CLUTCH COVER BRG. 6207

NAME driver
NAME R COVER OIL SEAL GUIDE NAME Lock nut driver
NO SYM-9610000- REA A6207 NO SYM-1133000-REA NO SYM-9020100
2-14
NAME Inner bearing puller NAME Inner bearing puller NAME Outer bearing puller
NO SYM-6204002 NO SYM-6204022 NO SYM-6204001
NAME Universal holder NAME Clutch nut wrench NAME Crankcase tool
NO SYM-2210100 NO SYM-9020200 NO SYM-1120000-ALL
(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
WHEEL KNUCKLE BODY WHEEL KNUCKLE BODY

NAME ARM SUSPENSION NAME NAME
SEAL 40*55*8 driver SEAL 40*50*6.5 driver
NO SYM-2300000 NO SYM-9123200-REA NO SYM-9123000-REA
2-15
MAIN BRG. UP/LWR PULLEY DRIVEN FACE

NAME 40*44*20 driver
NAME NAME 41*44*4 OIL SEAL GUIDE
NO SYM-9100110-REA NO SYM-9100400 G5A ADA NO SYM-9121100-REA
ENG L COVER RADIAL BALL FINAL SHAFT BRG 6307 PULLEY DRIVEN FACE
NAME BRG. 6006 driver
NAME driver
NAME expander
NO SYM-9615010-REA 6006 NO SYM-2343110-REA 6307 NO SYM-2321000-REA
CLUTCH COVER 35*55*8 DRIVEN PULLEY PULLEY DRIVEN FACE

NAME NAME NAME
OIL SEAL Disassemble tool SEAL COLLER tool
NO SYM-9120300-REA NO SYM-2301000-REA NO SYM-2323700-REA
R CASE PARK GEAR OUTPUT SHAFT BRG

NAME NAME Driveshaft oil seal driver NAME
CLIP GUIDE & installer 6307 driver
NO SYM-9060200-REA NO SYM-9120600-REA NO SYM-2346000-REA A6307
2-16
MAIN BRG. UP/LWR L COVER FR. BRG. 6302

NAME NAME NAME Drive plate fixer
40*44*20 assemble tool driver
NO SYM-9100100-REA NO SYM-9615000-REA 6302 NO SYM-2230000-REA
NAME NAME NAME

NO NO NO
NAME NAME NAME

NO NO NO
NAME NAME NAME

NO NO NO
2-17
Home page Contents
3. LUBRICATION SYSTEM
Mechanism Diagram ·································3-1 Engine Oil Strainer Clean·························3-4

Precautions in Operation ·························3-3 Oil Filter Unit ·············································3-5
Troubleshooting ·······································3-3 Oil Pump ····················································3-6
Engine Oil ··················································3-4
Mechanism Diagram
3-1
Valve Rocker Arm
Press-In Lubrication
Cam Shaft
Oil Route
Oil Route
Spray Lubrication
Con-Rod
Spray Lubrication
3-2
Precautions in Operation
General Information:
This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil capacity Disassembly: 3000 c.c.
Replacement: 2400 c.c.
Replacement with oil filter replaced: 2700 c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Rear axle gear oil replacement: 100c.c.
Front differential gear oil replacement: 200c.c.
Gear oil viscosity SAE 80 or 90
(Recommended SYM Hypoid gear oil)
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
Oil leaking No oil change periodically
Valve guide or seat worn out Cylinder head gasket damage
Piston ring worn out Piston ring worn out
Low oil pressure

Low engine oil level
Clogged in oil strainer, circuits or pipes
Oil pump damage
3-3
Engine Oil
Turn off engine, and park the ATV in flat surface.
Check oil level with oil dipstick.
Do 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 the oil strainer and spring.
Clean the oil strainer.
Check if the `O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Oil strainer cap
Refill oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.
Engine oil capacity: 2400c.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
3-4
Oil Filter Unit Drain bolt

Remove the oil filter unit with special tool.
Special Service Tool:
Tool No: SYM-1445100
Install the oil filter unit by hand.
Lock the oil filter unit with special tool.

Tool No: SYM-1445100
3-5
Oil Pump
Oil Pump Removal
Remove the recoil starter and the AC Generator.
(Refer to chapter 10) 。
Remove the cir clip and take out the oil pump
sprocket.
Cir Clip
Make sure that pump shaft can be rotated freely.

Remove 3 screws on the oil pump, and then
remove the oil pump.
3 screws
Pin Roller
Oil Pump Disassembly

Remove the screws on oil pump cover and
remove the cover.
Remove the oil pump shaft roller and shaft.
1 screw
3-6
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 the 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.
3-7
1 screw
Tighten the oil pump screw.
Roller
Oil Pump Installation

Install the oil pump, and then tighten screws.
Make sure that oil pump shaft can be rotated

freely.
3 screws
Install the oil pump sprocket, and then install cir

clip onto oil pump shaft.
Cir Clip
3-8
Notes:
3-9
Home page Contents
4. FUEL SYSTEM
`
Mechanism Diagram ......................... 4-1 Vacuum Chamber ............................. 4-6
Precautions in Operation ................. 4-2 Float Chamber................................... 4-7
Trouble Diagnosis............................. 4-3 Adjustment of Idle Speed................. 4-9
Carburetor Removal / Installation.... 4-4 Fuel Tank ........................................... 4-10
Air Cut-off Valve ................................ 4-5 Air Cleaner ........................................ 4-11
Mechanism Diagram
Fuel tank cap
Fuel tank
Carburetor Fuel Strainer
UA60A-6
Fuel valve
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
Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
There is a drain screw in the float chamber for draining residual gasoline.
Do not disassemble air cut valve arbitrarily.
Specification
ITEM UA60A-6
Carburetor diameter 35 mm
I.D. number AG8
Fuel level 17 mm
Main injector #132
Idle injector #92
Idle speed 1700±100 rpm
Throttle handle clearance 1~3
Pilot screw 1 1/2
Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge
4-2
4. FUEL SYSTEM
Trouble Diagnosis
Poor engine start Mixture too lean
No fuel in fuel tank Clogged fuel injector
Clogged fuel tube Vacuum piston stick and closed
Too much fuel in cylinder Malfunction of float valve
No spark from spark plug(malfunction of ignition Fuel level too low in float chamber
system ) Clogged fuel tank cap vent
Clogged air cleaner Clogged fuel filter
Malfunction of carburetor chock Obstructed fuel pipe
Malfunction of throttle operation Clogged air vent hose
Air existing in intake system
Stall after started

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

Late ignition timing

Malfunction of carburetor
Power insufficiency and fuel consuming

Fuel system clogged
4-3
4. FUEL SYSTEM
Carburetor Removal / Installation

Removal
Remove the fuel tank.
Turn the fuel valve lever on off.
fuel valve lever
Remove 1 screw from throttle lever cap them 1 screw throttle cable
remove throttle lever cap.
Loosen throttle cable adjustment nut and remove
throttle cable
adjustment nut
Remove the sleep adjustment wire. adjustment wire
Disconnect the fuel hose and by-starter and drain By-starter Drain tube
tube
Release 2 clamps strip of air cleaner and inner
pipe.
Remove the carburetor.
Installation
Install in reverse order of removal procedures.
2 clamps Fuel hose
4-4
4. FUEL SYSTEM
Air Cut-Off Valve

Disassembly
Remove 2 screws.
2 screws
Remove air cut-off valve cover, spring and valve. Air cut-off valve
Cover Spring O-ring
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
Vacuum Chamber vacuum chamber cover
Disassembly
Removal
Loosen drain screw, and drain out residual fuel in
float chamber.
Remove screws (4 screws) of vacuum chamber
cover and the cover.
4 bolts
Remove compress spring and vacuum piston.

.
Spring
Remove fuel needle seat, spring, and injector needle needle

vacuum Spring
needle. piston
seat
Check if the vacuum piston for wear out, crack or
other damage.
Check if the diaphragm for damage or crack.
Cautions
Do not damage vacuum diaphragm.
4-6
4. FUEL SYSTEM
Float Chamber
Disassembly
Remove 4 mounting screws and remove float
chamber cover.
4 Screws
Remove the float pin, float and float valve. Float valve Pin
Float
Inspection
Check float valve and valve seat for damage, Pin
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
new a new one.
Float Float valve
Check for wear or damage
4-7
4. FUEL SYSTEM
Remove main jet, needle jet holder, needle jet, Needle jet holder Needle jet
slow jet and air adjustment screw.
Caution
Take care not to damage jets and adjust screw.
Before removing adjustment screw, turn it all
the way down and note the number of turns.
Does not turn adjust screw forcefully to avoid
damaging valve seat face. Slow jet
Clean jets with cleaning fluid. Then use Main 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
Check again to ensure float valve, float for
proper installation.
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

Rubbe
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
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.
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 wire of
throttle valve to standard RPM. Throttle valve stopper wire
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: 0.5~1.0 %
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 Fuel unit
Fuel tank removal

Open the seat.
Remove the front cover and front top center cover.
Remove the side covers and lower side covers.
Remove the front fender.
Remove fuel unit wire from tank.
(Covers remove please refer chapter 13)
remove 2 fuel tubes from fuel valve.
Fuel tube
Remove 4 bolts from tank rear side & front side

and then remove fuel tank. FRONT REAR
.
Installation
Install the tank in the reverse order of removal.
4 bolts
4-10
4. FUEL SYSTEM
Air Cleaner
Removal
Loosen the clamp strip of air cleaner and
carburetor, and then remove the vapor hose.
Clamp
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.
4 bolts
Cleaning air cleaner element

Remove the air cleaner cover (5 catch hooks). 5 Catch hooks
Remove element mounting screw. Clamp

Loosen the clamp strip of air cleaner element.
Clamp
4-11
4. FUEL SYSTEM
Remove the air cleaner element. 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.
4-12
4. FUEL SYSTEM
Notes:
4-13
Home page Contents
5. ENGINE REMOVAL
Precautions in Operation...................... 5-1 Engine Installation ................................ 5-6

Engine Removal .................................... 5-2
General Information
The engine has to be supported with special service tools that can be lifted or adjustable.
The following parts can be serviced as engine being 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.
Specification
Item Capacity
Replacement 2400 c.c.

5
Engine oil capacity Replacement with oil filter changed 2700 c.c.
Disassembly 3000 c.c.
Rear axle gear oil capacity Replacement 100 c.c.
Front differential gear oil capacity Replacement 200 c.c.
Engine & radiator 1980 c.c.
Coolant capacity Reservoir 420 c.c.
Total 2400 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
Engine Removal Negative
Remove the seat.

Remove the battery negative terminal (-).
Remove the battery positive (+) terminal.
Remove front fender and the footrest (refer
chapter 13).
Positive
Remove the 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 the front left and rear left tires.
Remove the idle speed adjustment nut. Idle speed adjustment nut
Remove 2 bolt on the muffler.
Remove the muffler.
Remove the throttle cable.

Remove 2 nuts and 1 bolt.
Remove the exhaust pipe.
Throttle cable
Remove the choke cable and ventilation tube.

Choke cable
Remove 2 nuts, and then remove exhaust pipe.
Ventilation tube
5-3
5. ENGINE REMOVAL
Remove 2 manifold clamps.

Remove the carburetor.
Manifold clamps
Remove 4 bolts.
Remove the air cleaner.
4 bolts
Remove 2 bolts.
Remove the muffler.
2 bolts
Remove 2 nuts and 1 bolt.

Remove the exhaust pipe. 2 nuts
Bolt
5-4
5. ENGINE REMOVAL
Remove the coolant drain bolt and drain out PCV pipe
coolant.
Remove the coolant inlet pipe from the water
pump cover and the outlet pipe from the
thermostat cover.
Remove the PCV pipe.
Coolant pipe
Remove 2 bolts. Starter motor

Remove the starter motor.
2 bolts
Remove 3 bolts on the front propeller shaft

3 bolts
connector.
Remove the front propeller shaft.
Rubber boot
Remove 3 bolts on the rear propeller shaft 3 bolts
connector.
Remove the rear propeller shaft.
Be careful not to do any damage to the rubber

boot. Rubber boot
5-5
5. ENGINE REMOVAL
Remove the rear brake pedal.
Remove the coolant reserve tank.
2 bolts
Remove the front and rear side engine hanger

mounting nuts and bolts.
Remove left side engine hanger, and then remove

engine by left side.
Engine Installation
Check the bush of engine hanger parts for any
damage. 3 bolts
Install the engine in the reverse procedures of
removal.
Engine hanger
Caution
Be careful when removing and installing the
engine.
Do not bend or twist the wires and tubes.
Cables wires have to be routed in accordance
with normal layout.
Engine hanger Bolt:
Torque value: 7.5~9.5kgf-m
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
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
1.0~1.2kgf-m
1.0~1.4kgf-m
0.7~1.1kgf-m
1.0~1.4kgf-m
1.0~1.2kgf-m
6-1
General Information
This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
Cylinder head service can be carried out when engine is in frame.
Specification
Item Standard Limit
Compression pressure 12±2 kg/cm2 ---
Intake 36.478 36.458
Camshaft Height of cam lobe
Exhaust 36.847 36.832
ID of valve rocker arm 13.000~13.018 13.098
Rocker arm
OD of valve rocker arm shaft 12.991~13.009 11.936
Intake 4.975~4.990 4.900
OD of valve stem
Exhaust 4.955~4.970 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 33.700 30.100
spring outer 38.800 35.200
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
Improper valve adjustment
Burnt or bent valve
Improper valve timing
Valve spring damage
Valve carbon deposit.
2. Cylinder head
Cylinder head gasket leaking or damage
Tilt or crack cylinder
3. Piston
Piston ring worn out.
High compression pressure

Too much carbon deposit on combustion chamber or piston head
Noise
Improper valve clearance adjustment
Burnt valve or damaged valve spring
Camshaft wear out or damage
Chain wear out or looseness
Auto-tensioner wear out or damage
Camshaft sprocket
Rocker arm or rocker arm shaft wear out
6-3
Cylinder Head Removal 2 nuts

Remove the engine from the frame. (Refer to
chapter 5)
Remove the inlet pipe (2 nuts).
Thermostat bolts
Remove 2 thermostat bolts and then remove the
thermostat.
Remove the bolt and spring of the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Tensioner bolts
4 bolts
Remove Air Injection system (AI) pipe mounting
bolts.
Remove the spark plug.
Loosen 4 bolts from the head cover then remove

head cover.
4 bolts
6-4
Remove the side cover mounting blots of cylinder 3 bolts
head, and then remove the side cover.
Remove left crankcase cover, and turn the drive 2 bolts Timing Mark
face.
Align the timing mark on the cam sprocket with
that of cylinder head to make the piston at TDC
position.
Cam sprocket disk

Loosen 2 bolts from the cam sprocket.
Remove the cam sprocket disk and washer.
Remove the cam sprocket.

Cam shafts
Tool no: SYM-1445100
TOOL number: rocker arm and camshaft puller
Rocker arm shaft

and camshaft 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
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
Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.
Caution
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.
Tool no: SYM-1471110/20-4v Valve cotter remove
TOOL number: valve cotter remove & and assembly tool
assembly tool
Inlet valve Inner spring Spring retainer
Exhaust valve Outer spring Cotter
6-6
Remove the valve stem seals.
Valve stem seals
Clean carbon deposits in the 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
Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
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
Check if new valve guide is deformation after Valve guide driver
pressed it in. 5.0 mm
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
Using cutting oil when correcting valve guide
with a reamer.
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
Do not let emery enter into between valve stem
and valve guide.
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 is 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 is too low, grind the valve

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

Valve spring retainer
Lubricate the valve stem with engine oil, and then Valve stem seal
insert the valve into valve guide.
Install the new valve stem oil seal. Valve cotter
Install the 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 the
valves.
Caution
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 the cylinder head on working table
so that can prevent valve from being 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.
Prevent the 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
2 bolts Timing mark
timing mark on the sprocket with the two sprocket
bolt holes and the lower bolt hole of the cylinder
side cover.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.
Caution
Make sure timing marks are matched.
Install the cylinder head side cover (3 bolts). 3 bolts

Install the 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 head cover (4 bolts).
4 bolts
6-15
Install Air Injection system (AI) pipe. (4 bolts)

Install inlet pipe onto cylinder 4 bolts
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 vehicle performance be
affected.
Install the engine onto frame (refer chapter 5).
Valve Clearance Adjustment

Loosen Air Injection system (AI) pipe upper side
bolt (2 bolts).
Remove the 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
If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
When checking lubricant flowing condition, run
the engine at idle speed. Do not accelerate
engine speed.
6-16
Notes:
6-17
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
0.8~1.2kgf-m
7-1
7. CYLINDER/PISTON
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
UA25A
Specification Unit：mm
Item Standard Limit
ID 92.00 92.100
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 ) 74.430~75.480 75.380
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
Cylinder or piston ring worn out Piston or piston ring worn out
Piston ring installation improperly
Cylinder or piston damage
Knock or Noise Engine Overheat

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

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

a piece of cloth to prevent foreign material falling
into the crankcase.
Remove the piston pin clip, and then remove the
piston pin and piston.
Remove the cylinder gasket and dowel pin. Dowel pins
Clean up all residues or foreign materials from

the two contact surfaces of cylinder and
crankcase.
Caution
Wet the residues by solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is worn 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: 75.100 mm Bottom
7-3
7. CYLINDER/PISTON
Check cylinder if warp.

Measure the 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 the piston outer diameter.

Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：75.380 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
Do not damage piston and piston rings as installation.
All marks on the piston rings must be forwarded to up side.
Make sure that all piston rings can be rotated freely after installed.
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 contact surface of crankcase. Pay attention to
not let these residues and foreign materials fall
into crankcase.
Caution
Wet the residues into solvent so that the residues
can be removed more easily.
Piston Installation IN mark
Install the piston and piston pin, and place the IN

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

Caution
Do not let the opening of piston pin clip align
Clip end gap
with the piston cutout.
Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase during servicing.
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 ··············································8-3

Maintenance Description ···················· 8-2 Drive Plate ············································8-4
Trouble Diagnosis ······························· 8-2 Movable Drive Face Disassembly·······8-6
Left Crankcase Cover ························· 8-3 Driven Pulley Disassembly ·················8-13
Mechanism Diagram
5.0~6.0kgf-m 8
5.0~6.0kgf-m
5.0~6.0kgf-m
8-1
Maintenance Description
General Information
Drive face, clutch outer, and driven pulley can be serviced on the vehicle.
Drive belt and drive pulley must be free of any grease.
Specification
Item Standard value Limit
Driving belt width 30.700 mm 29.200 mm
OD of movable drive face boss 35.970~35.990 mm 35.950 mm
ID of movable drive face 36.010~36.035 mm 36.055 mm
OD of weight roller 29.992~30.008 mm 29.950 mm
ID of clutch outer 140.000~140.200 mm 140.500 mm
Thickness of clutch weight 6.000 mm 3.000 mm
Free length of driven pulley spring 124.5 mm 119.500 mm
OD of driven pulley boss 40.965~40.985 mm 40.945 mm
ID of driven face 41.000~41.050 mm 41.070 mm
Weight of weight roller 19.700~20.300 g 19.200 g
Torque value Special Service Tools

Drive face nut: 8.5~10.5kgf-m Clutch spring compressor: SYM-2301000
Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002
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 vehicle can not Insufficient horsepower or poor high
move 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 L case cap
Left crankcase cover removal

Release 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover cap.
Remove left crankcase cover bolts (17bolts).
Remove 2 dowel pin and gasket.
15 bolts 2 bolts
Left crankcase cover installation

Install left crankcase cover in the reverse
procedure of removal.
SYM-2211000-REA
Drive Belt
Loosen 1nut from the drive face with Special tool.
Tool name: Movable Drive Face Holder
Tool NO: SYM-2211000-REA
Remove the movable drive face.
8-3
Loosen 1nut from the driven pulley with Special SYM-2210100
tool.
Tool name: Universal holder
Tool NO: SYM-2210100
Remove the drive pulley and belt.
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.
Belt tooth
Caution Width
Using the genuine parts for replacement.

The surfaces of drive belt or pulley must be
free of grease. Drive face
Clean up all grease or dirt before installation.
Drive Plate
Remove the drive face.
Loosen 5 bolts from the CVT cooling plate then
remove it.
8-4
Loosen 10 bolts from the clutch cover. 10 Belts
Remove the clutch cover.
Remove the clutch outer.
One-way Clutch Inspection

Check each roller for wear or damage.
Hold the clutch outer and turning the one way
clutch for right side. .
Loosen the drive plate nut with special tool.

SYM-2230000-REA
Remove the drive plate.
Tool name: drive plate holder
Tool NO: SYM-2230000-REA
8-5
Movable Drive Face Disassembly

Loosen 4 bolts form the drive face.
Remove the drive face plate
Remove the drive face plate
Remove the ramp plate and weight roller (8pcs).
Inspection
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn out or damaged.
Replace it if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
8-6
Check if drive face boss is worn or damaged and

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

Movable drive face
and replace it if it exceed service limit.
Drive face boss
Reassembly/installation
Install weight rollers.
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Install ramp plate.
8-7
Left crankcase cover inspection Cir clip

Remove cir clip with inner cir clip pliers
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.
Remove the bearing 6302 with inner bearing

SYM-6204025
puller.
Tools number: SYM-6204025
Tools name: INNER BEARING PULLER.
Remove the bearing 6006 with inner bearing

SYM-6204025
puller.
Tools name: INNER BEARING PULLER.
8-8

Bearing installation SYM-9615000-REA A6302
Install the bearing 6302 with special tool
Tool name: L COVER FR BRG. 6302 bearing IN.
puller with air
Tool NO. : SYM-9615000-REA A6302
Put the caller and nut.

SYM-9615000-REA A6302
caller nut
Air tool
Install the bearing with air or head tool.
head tool
8-9
Make sure the bearing code and put the bearing. SYM-9615010-REA 6006
Install the bearing 6006 with special tool

Tool name: L COVER FR BRG. 6006 bearing
driver
Tool NO. : SYM-9615010-REA 6006
Knock the bearing to the objected position. SYM-9615010-REA 6006
Install the cir clip.

Cir clip
8-10
Drive plate Disassembly

Remove 5 e-ring from drive plate.
Remove the spring plate and centrifugal clutch

plate. centrifugal clutch
l t
e-ring
Spring
Remove 5 springs from the drive plate
Check if spring is damaged or insufficient
elasticity.
Remove 5 clutch weights.

Check if spring is damaged or insufficient
elasticity.
8-11
Measure each clutch weight thickness. Replace

it if exceeds service limit.
Apply grease onto setting pins.
Install the spring into groove with pliers.
Install new clutch weight onto setting pin and then

push to the specified location.
Apply with grease onto setting pins.
Caution
Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity.
8-12

Install the spring plate and centrifugal clutch plate.
Install 5 e-ring in the drive plate.
Driven Pulley Disassembly

Disassemble the driven pulley with special tool.
Apply special tool compressor onto the pulley
Special tool compressor
8-13
Remove cir clip with pliers.

Cir clip
Loosen the special tools nut nut
Remove the driven pulley collar and 4 roller

guides.
4 roller guides Drive pulley collar
Remove the movable driven face.
8-14

Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Free length
Driven pulley
Check following items:
If both surfaces are damaged or worn.
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 40.945 mm
Inner diameter 41.070 mm
Movable driven face Guide pin groove
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
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
8-15
Installation
Use the driven face assy. expander to expand the Driven Face Assy. Expander
driven face assy.
Put the drive belt into the driven face assy. and
hold it tight by hand.
Special Tool
Tool number: SYM-2321000-REA
Tool name: Driven Face Assy. Expander
Driven Face Assy.
Put the driven face assy. onto the drive shaft.
Caution
Use special tool to keep the driven face
assy. open.
Do not oppress friction plate in order to
avoid distortion or damage.
Drive Shaft
Install the movable drive face assy.

Hold the movable drive face assy. with the MDF
holder, and then tighten nut to specified torque
value.
Hold the driven face with universal holder, and

then tighten nut to specified torque value.
Universal holder
8-16

Notes:
8-17
Home page Contents
9. Transmission
Mechanism Diagram ··························· 9-1 Transmission Inspection··················· 9-7

Precautions in operation ···················· 9-2 Bearing Replacement ························ 9-9
Trouble Diagnosis ······························· 9-2 Transmission Reassembly················ 9-12
Transmission Disassembly ················ 9-3
Mechanism Diagram
Needle Bearing HK2220C Drive shaft
Radial Ball Bearing 6228
Shift Drum
Counter Shaft
9
Reverse Shaft
Sliding Claw
Park Gear
Counter Gear

Final shaft
Bevel Gear Housing Needle Bearing HK2220C

Left crank case
Drive Bevel Gear
Shift fork
9-1
9. TRANSMISSION
Specification
Item Standard value Limit (mm)
OD of shift fork shaft 13.984~14.000 mm 13.966 mm
ID of shift fork 14.000~14.016 mm 14.034 mm
Shift fork claw thickness 5.930~6.000 mm 5.730 mm
Torque value
Gear oil drain bolt 1.1~1.5kgf-m
Gear oil fill bolt 3.5~4.5kgf-m
Tools
Special tools
Bearing driver (6228): SYM-2341110-REA A6228
Bearing driver (6307): SYM-2343110-REA 6307
Bearing driver (2220): SYM-9100400-REA 2220
Bearing driver (6307): SYM-2346000-REA A6307
Final shaft gear stopper: SYM-2343100-REA
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 vehicle cannot move.
Damaged drive gear
Burnt out drive gear
Damaged gear shift system
Noise
Worn or burnt gear
Worn gear
Gear oil leaks

Excessive gear oil.
Worn or damage oil seal
9-2
9. Transmission
Transmission Disassembly
Remove gear change lever (2 bolts).
Remove the gear change lever.
2 bolts
Remove 2 c clips from brake pedal. Concave marks

Remove brake spring & stop switch spring
Remove brake penal.
Gearshift spindle Shift drum
Remove the front and rear propeller shaft.

Remove the engine from the frame before
performing the transmission disassembly.
Propeller shaft
Remove the front and rear output shaft Bolt

connectors.
9-3
9. TRANSMISSION
Remove the front and rear output shaft covers.
4 bolts
Remove 13 bolts from the right crankcase.
Remove the right crankcase from the left

crankcase.
Shift drum Shift fork

Remove the counter shaft, shift fork and the shift
drum.
Counter shaft
9-4
9. Transmission
Remove the reverse shaft and the output shaft. Reverse shaft Output shaft
Final gear stopper

Remove the bevel gear with the final shaft stopper.
Special tool:
Tool number：SYM-2343100-REA
Tool name：Final shaft stopper.
Remove 4 bolts. Bevel gear housing Shim

Remove the shims from the bevel gear housing.
Remember the number of the shims and put the
same number of shims when reassembling.
Shim
Remove the shims from the final shaft.
Remember the number of shims and put the same
number o shims when reassembling.
Remove the final shaft.
Final shaft
9-5
9. TRANSMISSION
Remove the drive shaft bearing setting plate (1 bolt).
Bearing setting plate
Remove the drive shaft. Drive shaft bearing

Remove the output shaft.
Output shaft
Caution Bearing
Do not remove the drive shaft from the
crankcase if unnecessary.
When removing the drive shaft from the
crankcase, then the bearing has to be
replaced.
9-6
9. Transmission
Transmission Inspection
Check the shift spindle for any wear or damage.
Check if the shift drum is worn or damaged.
Check if the shift fork and shaft is worn or

damaged.
Measure the outer diameter of shift fork shaft.
Replace it if it exceed service limit.
Measure the inner diameter of shift fork.
Measure the thickness of shift fork claw.
Check if the counter shaft is worn or damaged.
9-7
9. TRANSMISSION
Check if the reverse shaft is wear or damage.
Check if the final shaft and gear are burn, wear or

damage.
Check bearings on the left and right crankcase. Drive shaft bearing Balance shaft bearing
Rotate each bearing’s inner ring by fingers.
Check if the bearings can be rotated smoothly and
silently and also check if the bearing outer ring is
mounted on gear tightly.
If the bearing rotation is uneven, noising, or loose
Check oil seal for wear or damage, and replace it
if necessary.
Counter shaft needle bearing
Caution Drive shaft needle bearing Final shaft bearing
The bearings should be replaced with new

one after they are removed from the
crankcase by the bearing puller.
Balance shaft bearing Counter shaft bearing
9-8
9. Transmission
Bearing Replacement
Caution
Never install used bearings. Once bearing
removed, it has to be replaced with new one.
Left crankcase side
Remove the drive shaft and bearing from the left
crankcase.
Outer bearing puller

Remove the drive shaft bearing from the shaft by
outer bearing puller.
Replace the drive shaft bearing with new one by

bearing driver.
Special tool:
Tool number：SYM-2341110-REA A6228
Tool name：Bearing driver (6228)
Bearing driver
Remove the cir-clip and the park gear. Park gear

Remove the counter gear needle bearing.
9-9
9. TRANSMISSION
Install the park gear cir-clip by using cir-clip Park gear cir-clip installer
installer.
Special tool:
Tool name：Park gear cir-clip installer
Cir-clip Park gear
Inner bearing puller
Right crankcase side

Remove the final shaft bearing on the right
crankcase with inner bearing puller.
Special tool:
Tool number：SYM-6204025
Tool name：Inner bearing puller
Remove the counter shaft bearing on the right

Special tool:
Inner bearing puller
Remove the drive shaft needle bearing on the right Cir clip
Special tool:
9-10
9. Transmission
Bearing driver
Install the final shaft bearing with the bearing
driver.
Special tool:
Tool number：SYM-2343110-REA 6307
Tool name：Final shaft bearing driver
Install the counter shaft bearing with the bearing

driver.
Special tool:
Tool number：SYM-
Tool name：Counter shaft bearing driver
Bearing driver
Install the drive shaft needle bearing with the Bearing driver
bearing driver.
Special tool:
Tool number：SYM-9100400-REA 2220
Tool name：Drive shaft needle bearing driver
9-11
9. TRANSMISSION
Reverse shaft
Transmission Reassembly
Install the reverse shaft onto the left crankcase.
Drive shaft
Install the counter shaft and gearshift fork. Shift drum Gearshift fork
Counter shaft
Install the shift drum.

Rotate the shift drum and make sure it can rotate
smoothly.
Final shaft
Install the final shaft onto the right crankcase.
Put the same numbers of shim, which were
removed during removal, on the final shaft.
Shim
9-12
9. Transmission
Install the bevel gear housing
Bevel gear housing
Put the same numbers of shim, which were
removed during removal, on the bevel gear
housing.
Shim
Final gear stopper

Install the bevel gear.
Lock the nut by using final shaft stopper.
Special tool:
Tool name：Final shaft stopper.
Bevel gear
Reassemble the right and left crankcase. Concave marks

Install the gearshift spindle.
Align the concave marks on the shift gear and the
shift drum gear.
Install 2 dowel pins and transmission cover
gasket.
Gearshift spindle Shift drum gear
Install the transmission cover. 4 bolts
Transmission cover
9-13
9. TRANSMISSION
Install the change lever arm. Change lever arm
Keep the level mark on the change lever arm
horizontal.
Level mark
9-14
Home page Contents
10. WHEEL DRIVE SHAFT/PROPELLER SHAFT
Mechanism Diagram ······················10-1 Wheel Drive Shaft Inspection ·······10-7

Trouble Diagnosis ·························10-2 Repair Pack ····································10-8
Wheel Drive Shaft Removal ··········10-3 Wheel Drive Shaft Assembly ········10-10
Wheel Drive Shaft Disassembly ···10-4 Front and Rear Propeller Shaft·····10-14
Mechanism Diagram
Rear Propeller Shaft
Front Differential Rear Axle Gearbox
10
Front Propeller Shaft
10-1
Trouble Diagnosis
Engine can be started but vehicle cannot move.
Damaged wheel drive shaft
Damaged propeller shaft
Damaged front differential or rear axle gear box
Noise
Worn or burnt drive shaft
Worn or burnt steel ball
Worn or burnt gear
Gear oil leaks

Excessive gear oil
Worn or damaged rubber boot
Worn or damage oil seal
10-2
Wheel Drive Shaft Removal

Front wheel drive shaft removal
Remove the front wheel.
Remove the front brake caliper and disk.
Remove the tie-rod.
Remove the knuckle body.
Remove the wheel drive shaft with special tool.
Rear wheel drive shaft removal

Remove the rear wheel.
Remove the rear wheel connecter.
Remove the rear wheel hub.
Remove the rear cushion.
Remove the rear wheel drive shaft with special

tool.
10-3
Wheel Drive Shaft Disassembly

Universal joint disassembly
Open the boot band clip with scrapper.
Scrapper
Remove the rubber boot bands. UJ small boot band
UJ large boot band
Remove the UJ rubber boot.
Disassemble the wheel drive shaft UJ assembly

SYM-4423000-REA
with rubber hammer & special tool.
Tools name：Wheel driveshaft assembly seat
Tools number：SYM-4423000-REA
Caution
Do not disassemble UJ assembly by using the
steel hammer.
Rubber hammer
10-4
Remove 6 steel balls from UJ assembly outer

SYM-4423500-REA
race.
Tools name：Wheel drive shaft assembly seat
Tools number：SYM-4423500-REA
Remove the inner race and cage from the outer

race.
Clean the inner race, outer race, steel balls and

cage.
Cage Inner Race Steel Balls
Double Offset Joint Disassembly

Open DOJ band clip with scrapper.
Remove the wheel drive shaft boot band.
Remove the DOJ rubber boot.
10-5
Remove the inner cir-clip with screw drive.
Disassemble DOJ assembly.
Clean the DOJ assembly.

Remove the cir-clip from the drive shaft.
Remove the steel balls from cage.
10-6
Wheel Drive Shaft Inspection

Clean all spare parts. Check the surface of these
parts for wear or scratch.
Replace DOJ or UJ assembly if any stepped
scratch is found.
Check the inside surface of UJ outer race.

Replace UJ assembly if it is damaged.
Check the inside surface of DOJ assembly outer

race.
Replace double offset joint assembly if it is
damaged.
10-7
Repair Pack
Check if DOJ & UJ boot is damaged
Replace DOJ or UJ assembly if it is damaged.
Remove the DOJ & UJ boot.
Remove the DOJ & UJ cage.
Remove the DOJ & UJ boot.
10-8
Disassemble and clean all spare parts. Check if

there is any corrosion on the surface of these
parts. Replace DOJ or UJ assembly if any
damaged part is found.
Clean the DOJ & UJ cage.
Unpack DOJ Repair Pack.
Unpack UJ Repair Pack.
10-9
Wheel Drive Shaft Assembly

DOJ assembly
Drive shaft
Assemble the DOJ boot.
DOJ boot
Assemble 6 steel balls, inner race and cage then

drive shaft into the assembly. Inner race Drive shaft
DOJ cage
6 Steel balls
Assemble exit cir-clip onto drive shaft. Cir-clip
Grease into the DOJ outer race.
Caution
Please use the grease of the repair pack. Using
other oil may cause the part to be damaged.
10-10
Install the wheel drive shaft and cir-clip into DOJ

outer race.
Install DOJ boot outside band. Small band
Install DOJ boot. Large band

Pull and open DOJ boot Pressure balancing that
make it inside and external.
Deduct DOJ band closely with rubber hammer.
10-11

Grease
UJ assembly
Assemble universal joint and UJ boot and Pour
into the grease.
Pour grease into the UJ boot inside.

Inside band
Caution
Please use the grease of the repair pack. Using
other oil may cause the part to be damaged.
Assemble cir-clip with the tool.
Strike the wheel drive shaft by rubber hammer.
10-12
Install UJ boot.
Pull and open DOJ boot to balance the inside

and outside pressure.
Install band with rubber hammer.
10-13
Front and Rear Propeller Shaft

Remove
Loosen 3 bolts from the front propeller connector.
Disassemble the engine and propeller connector. Spring

Remove the front propeller shaft connector
Propeller shaft connector
Propeller shaft
Remove the front propeller shaft connector,
spring, spring pin and shaft.
Spring pin
Propeller shaft disassembly Spur gear

Remove the front side exit cir-clip.
Remove the propeller spur gear.
Cir-clip
10-14
Remove the rear side exit cir-clip.
Cir-clip
Remove propeller shaft and rubber boots. Rubber boot
Drive shaft inspection Spur gear

Check if the spur gear has is damaged or not.
Please replace new parts if it has split or
damaged.
Check if the propeller shaft is split or damaged.

Please replace new parts if it is split or damaged.
Propeller shaft
10-15

Check if the propeller shaft rubber boot is
Rubber boot
damaged or not.
Propeller shaft installation

Install in the reverse order of removal
procedures.
10-16
Home page Contents
11. A.C. GENERATOR/STARTING CLUTCH
Mechanism Diagram ··························· 11-1 Recoil Starter Cover Removal ··········· 11-5
Precautions in Operation ··················· 11-2 One Way Clutch Installation ·············· 11-7
Right Crankcase Cover Removal ······ 11-3 Flywheel Installation··························· 11-8
A.C. Generator Removal····················· 11-3 A.C. Generator Installation················· 11-9
Flywheel Removal······························· 11-4 Right Crankcase Cover Installation··· 11-9
One Way Clutch Removal ·················· 11-4
Mechanism Diagram
Recoil Starter Grip
Recoil Starter Cover
Volute Spring
Starter Drive Pulley 11
R. Case Cover
Stator Rope
Stator Ratchet Water Pump Shaft
Recoil Stator Cover Gasket
Stator Driven Pulley
Stator
Flywheel
One Way Clutch
Starting Clutch Gear
R. Cover Gasket
11-1
General information
Refer to chapter 18: The troubleshooting and inspection of alternator
Refer to chapter 18: The service procedures and precaution items of starter motor
Specification
Item Standard value (mm) Limit (mm)
ID of starting clutch gear 27.026~27.045 27.050
OD of starting clutch gear 45.192~45.283 45.183
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-3110000-HMA
Universal holder: SYM-2210100
11-2
Right Crankcase Cover Removal Water pump cover 5 bolts 5 bolts

Remove the left footrest.
Drain the engine oil and coolant, and then remove
coolant hoses.
Remove 5 bolts from the recoil starter cover.
Remove the recoil starter cover and gasket.
Remove the water pump cover (5 bolts)
Coolant hoses.
A.C. Generator Removal 12 screws

Remove the connector bolt and starter pulley.
Remove 12 mounted screws from the right
crankcase cover and then remove it.
Connector bolt and starter pulley
Remove 5 screws from right crankcase cover.

5 screws
Remove the stator.
11-3

Flywheel Removal Flywheel puller
Remove the A.C. Generator flywheel with special
tool.
Tool name：A.C.G. flywheel puller
Tool number：SYM-3110000-HMA
Starting Clutch Gear Inspection

ID
Remove the 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: 27.050 mm
OD: 45.183 mm
OD
Check the starting reduction gear and shaft for

Starting reduction gear Shaft
wear or damage.
One Way Clutch Removal 3 bolts
Remove 3 bolts from the A.C. Generator flywheel.
11-4

Check each roller for wear or damage.
Install the starting clutch driven gear onto one way

clutch.
Hold the flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
Recoil Starter Cover Removal 3 bolts

Loosen bolt on the ratchet cover then remove
ratchet cover.
Remove the starter ratchets from the ratchet

cover. Starter ratchet
11-5

Remove the 2 springs from the ratchet cover. 2 springs
Do not remove the volute spring from the recoil Volute spring
starter cover unless the spring is broken. If the
volute spring is removed from the recoil starter
cover, it should be replaced with a new one.
Remove the starter grip rubber. Starter rope

Disassemble the starter grip and rope.
Starter grip rubber
Installation
Install in reverse order of removal procedures
Caution
First before installing the drive pulley must
establish 2 1/2 of the pressures transferred to
pressure springs.
11-6
One Way Clutch Installation 3 bolts
Install the components in the reverse procedures

of removal.
Caution
Tape a tightening tape onto the thread of hexagon
bolt.
One-way clutch
Install the starting driven gear.
Starting driven gear
11-7
Flywheel Installation
Install the reduction gear shaft and reduction gear.
Assemble the starting driven gear of the flywheel.

Align the key on crankshaft with the flywheel
groove, and then install the flywheel.
Install the flywheel onto crank shaft.
11-8
A.C. Generator Installation 3 bolts

2 bolts
Install the A.C. Generator stator set onto right

crankcase cover (3 screws).
Install the 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.
Right Crankcase Cover Installation

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

Install the right crankcase cover onto the
crankcase.
Note: Align the water pump shaft indent with the oil
pump shaft.
Assemble the connector bolt and starter pulley on

the right crankcase cover.
Assembly 12 bolts on the right case cover.
Connector bolt and starter pulley
11-9

Install the water pump cover (5 bolts) 5 bolts
Assemble the gasket.

Assemble the starter cover on the right crankcase 5 bolts
cover.
11-10
Note:
11-11
Home page Contents
12. CRANKCASE / CRANKSHAFT
Mechanism Diagram ··························12-1 Crankcase Disassembly ···················· 12-3

General Information ···························12-2 Crankshaft Inspection ······················· 12-5
Trouble Diagnosis ······························12-2 Crankcase Assembly························· 12-6
Mechanism Diagram
1.0~1.4kgf-m
12
Eng. Oil drain bolt

3.5~4.5kgf-m
12-1
General Information
Operational precautions
This Section concerns disassembly of the crankcase for repair purpose.
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
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
Crankcase Main Bearing Install Tool: SYM-9100100-REA
Trouble Diagnosis
Engine noise
Loose crankshaft bearing
Loose crankshaft pin bearing
Worn out piston pin and pin hole
12-2
Crankcase Disassembly Cam Chain Tensioner
Remove the cam chain setting plate, and then

remove cam chain.
Loosen the pivot bolt and remove the cam chain
tensioner.
Cam chain setting plate
2 bolts
Loosen 2 bolts on the left crankcase.
13 bolts
Loosen 13 bolts on the right crankcase.
Place left crankcase downward and right

crankcase up.
Tap the right crankcase with a plastic hammer to
remove it.
Caution
Do not make damage to the contact faces.
12-3
Remove balance shaft from left crankcase. Balance shaft
Remove crankshaft from left crankcase.

Remove gasket and dowel pins.
Scrape gasket residues off the crankcase contact
surface.
Caution
Do not damage the contact face of the gasket.
It is better to moisten the gasket residue for
easy scrapping.
Replace crankcase main bearings if necessary.
12-4
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 if it moves
freely, smoothly and noiseless.
Check the inner ring to see if 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
12-5
Check balance shaft bearing Balance shaft bearings

Check bearings on right and left crankcase.
Rotate each bearings inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
Special tool:
Tool name：Inner bearing puller bearing driver
Crankcase Assembly
Install wave washer into right crank bearing seat.
Wave washer
Install crank shaft on the right crankcase.
Position mark
Align the position mark on the balance shaft drive
gear with that of balance shaft driven gear, and
then install balance shaft onto right crankcase.
12-6
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
12-7
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 crank and oil seal
located. installation
Special tool:
Tool number：SYM-11332100-HMA RB1
Tool name：Crank and oil seal installation.
Tensioner
Install the tensioner and tighten the pivot bolt.

Torque value: 0.8 ~1.2kgf-m
Install the cam chain.
Install the cam chain setting plate.
Cam chain setting plate
12-8
Home page Contents
13. COOLING SYSTEM
Mechanism Diagram ··························13-1 System Test········································ 13-5

General Information ···························13-2 Radiator ·············································· 13-6
Trouble Diagnosis ······························13-2 Water Pump ········································ 13-8
Cooling System Troubleshooting ·····13-3 Thermostat ········································· 13-13
Mechanism Diagram
Radiator filler cap
Reserve tank
By-pass pipe
To cylinder head 13
Coolant outlet pipe
Radiator
Cooling fan
Coolant inlet pipe
Thermostat
Thermo switch (fan)
Water pump
13-1
13. COOLING SYSTEM
General Information
General
Warning:
While the engine is running, do not attempt to open the radiator cap, the pressurized hot coolant may
shoot out and cause serious injury. No maintenance work is allowed to perform until the engine is
completely cooled down.
Refill the radiator with distilled water or specified additives.

Add coolant to the reserve tank.
The cooling system maintenance can be serviced on the ATV.
Never spill the coolant to the painted surface.
Test the cooling system for any leakage after the servicing.
Please refer to Section 17 for inspection of the thermo switch for the fan motor and the coolant
temperature sensor.
Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 850c.c.
Reserve tank 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
The water temperature sensor or the thermo The water temperature sensor or the thermo
switch (fan) does not work properly. switch malfunction.
The thermostat is stuck to close. The thermostat is stuck to open.
Insufficient coolant.
The water hose and jacket are clogged. Coolant is leaking
Fan motor malfunction. The water pump mechanical seal does not
The radiator filler cap malfunction. function properly.
The O ring is deteriorated.
The water hose is broken or aged.
13-2
13. COOLING SYSTEM
Cooling System Troubleshooting
The temperature indication is too high
A. Stop and wait for the

A1.Fill the radiator with coolant
engine completely cool N and inspect for any leakage. Y
down, open filler cap and Coolant leaking problem
check the capacity of
coolant in the radiator is
enough or not. N
Y
B. Turn on main switch and N B-1. Measure thermo unit to N Replace thermo unit
check the water confirm voltage 6V↑?
temperature indicator
back to zero or not.
Y
Y
B-2. Inspect the circuits of the Y
cooling system have short Short or earth handle
or earth?
N
Meter problem
C-1. Eng. stop and remove

C. Open radiator cap and N water pump cover, start
softly throttle, inspect if Water pump repair
the motor to inspect if
the coolant circulate or pump rotate or not? N
not?
Y Y
Water hose clogged
D. Close radiator cap,

measure thermo unit to N
confirm if voltage reduce Replace thermo unit
when temperature rise?
Y
Next page
13-3
13. 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 if it
work or not?
Y Refill coolant then

check again
To bleed the air bubbles

completely, open radiator cap Notice the water hose
and start engine while engine can’t be unsuitably
is cool then press water hose bend or twisted.
softly by hand. Turn the throttle
repeatedly until the coolant
surface becomes stable.
13-4
13. 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
Radiator filler cap
Too high pressure may damage the radiator.
Never make 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 until the engine is completely Reserve tank 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.
Refill system with coolant and bleed the air from

the cooling system.
Run the engine, and remove by-pass pipe.
Check by-pass hole whether has the air bubble
to emit.
If emits without the air bubble, only has the
coolant to flow out, then backflow pipe joint on,
engine flameout. Drain bolt
Remove radiator filler cap.
Starts the engine, inspects does not have the air
By-pass pipe
bubble in the radiator coolant, also the coolant
liquid level is stable.
Stop the engine. Add coolant to proper level if
necessary.
Screw and tighten up the radiator filler cap.
Caution
In order to avoid the water tank rusting, please do
not use the unidentified coolant.
Coolant recommended: SYM Bramax radiator
agent.
Concentration: 50%
13-5
13. COOLING SYSTEM
Check reserve tank

Remove the front center cover, and then
remove reserve tank filler cap.
Check the liquid level in the front fender right Upper
side. Add coolant to proper level if too low.
Reinstall the reserve tank filler cap.
Caution
Do not add too much coolant to prevent the
coolant backflow flooding when the temperature
rises.
Lower
Radiator
Check
Remove the front center cover, side covers and
front fender. (Refer to chapter 13), check for any
leakage from weld seam.
Blow the radiator fins with compressed air. If the
radiator is blocked by dirt, use low-pressured
water jet to clean it.
Be careful straightening the radiator fins.
Removal
Remove the radiator outlet hose to drain out the
coolant.
Radiator outlet hose Clamp
Remove the radiator hose clamp and hose. Radiator hose Clamp
13-6
13. COOLING SYSTEM
Disconnect the couplers for the thermo switch.
Coolant inlet pipe
Remove the radiator inner hose clamp, water hose,
fan motor, and then remove radiator and cooling
fan.
Thermo switch
Loosen the radiator 4 bolts and remove the 4 bolts

radiator tank.
Disassembly
Loosen the 4 bolts from the fan duct, and then
remove the fan duct.
Remove nut to remove the fan from fan motor.
Loosen 4 screws from the fan motor, and take off
the fan motor. Cooling fan
duct bolts x4
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.
Tighten the fan duct onto the radiator with 3 bolts.
Please refer to chapter 17 for the inspection of the
thermo switch.
Thermo switch
Caution
Liquid packing must be applied to the thermo
4 bolts Fan nut
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.
Fan nut
13-7
13. COOLING SYSTEM
Water Pump
Check water pump seal / cooling
system divulges inspection
Disassembles the coolant drain bolt, overflow
some coolant, check if the coolant has the oil
pollution or not.
Turn off the oil filler plug, check if the engine oil
becomes milky white or not.
If the above two kinds of interior leaking situation
occur, possibly caused by the water pump inner
Drain bolt
seals damage, the engine cooling system damage
or the cylinder head gasket damage. Check the
water pump seals first. If the water pump seals are
ok, inspect the cooling system of the cylinder and
the cylinder head.
Water pump removal

Remove the recoil starter cover assy. and the
starter driven pulley.
Loosen the drain bolt to drain the coolant.
Remove the water hose.
Loosen 5 bolts and remove the pump cover.
Loosen 12 bolts and remove the right cover.
Take off the gasket and dowel pins.
Starter driven pulley
Unscrew the pump impeller clockwise and remove
it.
Caution
The impeller is provided with left turn thread.
Remove the water pump shaft
13-8
13. COOLING SYSTEM

Remove the outside bearing by inner bearing
puller. SYM-6204024
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:
Check any wear and damage of the mechanical
seal and inside seal.
Caution
The mechanical seal and inside seal must be
replaced as a unit. Mechanical seal
Replacement of Mechanical Seal

Remove the inside bearing by inner bearing puller.
Drive the mechanical seal and inner seal out of the
right crankcase.
Special tools:
Tool name：Inner bearing puller.
Caution
Replace a new mechanical seal after removing
SYM-1721700-H9A
it.
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:
Tool number：SYM-1721700-H9A
Tool name：Water pump mechanical seal driver
Install the water pump oil seal onto the right

crankcase.
Special tools: SYM-9120200-REA
Tool name：Water pump oil seal driver
13-9
13. COOLING SYSTEM
Water pump bearing installation

SYM-6001300-REA
Take the bearing on the special tool. A6001
Put the special tool cap on the right crankcase.
Special tools:
Tool number：SYM-6001300-REA A6001
Tool name：Water pump bearing 6001 inner
puller.
Assemble the bearing for the crankcase with SYM-6001300-REA

special tool. A6001
Bearing 6001
Install the bearing with head or air tool.

Caution
Do not reuse old bearing. It must be replaced
with a new one once it has been removed.
13-10
13. COOLING SYSTEM

Mount the water pump shaft to the right crankcase
cover.
Install the seal washer into the impeller.

Caution
Washer must be replaced together with the
mechanical seal.
Water pump shaft
Install the impeller onto the water pump shaft and

tighten.
Torque Value: 1.0~1.4kgf-m
Caution
The impeller is left thread.
13-11
13. COOLING SYSTEM
Install the impeller onto the water pump shaft and

tighten.
Torque Value: 1.0~1.4kgf-m
Caution
The impeller is left thread.
Install the dowel pin and right cover gasket. Water pump rotor
The rotation water pump impeller, causes the
water pump drive shaft scoop channel, aligns the
oil pump drive shaft flange, install the right
crankcase. (9 bolts)
Install the dowel pin and new gasket.

Install the water pump cover with 5 bolts.
13-12
13. COOLING SYSTEM
Thermostat
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 the air from the
cooling system (Page 12-5).
13-13
13. COOLING SYSTEM

NOTES:
13-14
Home page Contents
14. BODY COVER
Mechanism Diagram ·····························14-1 Front Fender········································· 14-4

Maintenance ··········································14-2 Footrest ················································ 14-5
Front Carrier··········································14-3 Rear Carrier ·········································· 14-6
Fuel Tank Cover····································14-3 Rear Fender·········································· 14-6
Mechanism Diagram Front carrier
Front fender
Meter cover
Front top cover

14
Headlight
Right side cover
Front grille
Footrest
Suspension arm cover
Left side cover
Rear fender
Front under protector
Center under protector
Rear center
up cover
Rear under protector
Rear carrier
14-1
14. BODY COVER
Maintenance
Body covers disassemble sequence:
Maintenance Cover Front Bumper Cover Rear Carrier
Front Top Cover Front Low Bumper Rear Center Up Cover
Fuel Tank Cover R/L Inner Protector Tail Light Low Cover
Front Carrier Front Grille Rear fender
R/L Side Covers Front Fender
Be careful not to damage various covers in assembly or disassembly operation.

Never injure hooks molded on the body covers.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the guard and the covers during assembly.
14-2
14. BODY COVER
Front Carrier
Removal
Loosen 6 bolts from the front carrier.
Remove the front carrier.
Installation
Install in the reverse order of removal procedures.
6 bolts
Fuel Tank Cover

Removal
Remove the maintenance cover.
Remove the front top cover.
Remove the seat.
Front top cover
Remove the fuel tank cap
Fuel tank cap
Remove the fuel tank cover.
Installation
Fuel tank cover
14-3
14. BODY COVER
Front Fender
4 bolts
Removal
Remove the seat.
Remove the maintenance cover and front top
cover.
Remove the fuel tank cap and fuel tank cover.
Remove the right and left side covers.
Remove 4 screws from footrest.
4 screws
Remove 4 screws from the right and left inner

protectors.
Remove the inner protectors.
4 screws
Disconnect the hazard control unit, shift gear

control unit, electricity relay and winker relay on
the front fender.
Installation
3 screws
14-4
14. BODY COVER
Footrest
Removal
Remove right and left foot peg bolts (each side 2
bolts).
Remove the foot pegs.
2 bolts
Remove 2 bolts from the right and left footrests.
2 bolts
Remove 4 screws from the rear part of the

footrest.
Remove the right and left footrests.
Installation
Install in reverse order of removal procedures 4 screws
14-5
14. BODY COVER
Rear Carrier 2 Bolts
Removal
Loosen 4 bolts from the rear carrier.
Remove the rear carrier.
Installation 2 Bolts
Rear Fender Rear center up cover
Remove the rear carrier.

Remove the seat.
Remove the rear center up cover.
Remove 4 screws on the rear side of the footrest.
4 screws
14-6
14. BODY COVER

Disconnect the full transistor igniter, 2WD/ 4WD Full transistor igniter
control unit and battery open control unit.
2WD/ 4WD control unit Battery open control unit
Remove the rear fender.
Installation
14-7
14. BODY COVER

NOTES:
14-8
Home page Contents
15. FRONT BRAKE & FRONT WHEEL
Mechanism Diagram ·····························15-1 Adding Brake Fluid ······························ 15-6

Maintenance Description ·····················15-2 Brake Fluid Replacement / Air-bleed·· 15-6
Trouble Diagnosis ································15-3 Front Brake Caliper······························ 15-8
Front Wheel ···········································15-4 Brake Disk ············································ 15-9
Front Wheel Hub ···································15-4 Front Brake Master Cylinder··············· 15-9
Disk Brake System Inspection·············15-5
Mechanism Diagram
Front brake master cylinder Front pressure control valve
Brake hose bolts (3.5kgf-m)

15
Air-bleed valve (0.5kgf-m)
To rear pressure control valve
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)
15-1
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.
Do not remove brake caliper before removing the hydraulic system.

After the hydraulic system is removed, or the brake system is felt to be too weak, bleed out the air from
the hydraulic system.
While refilling brake fluid, do not let the foreign material enter into the brake system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before riding.
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 /rear disk 175.000/220.000 -
Thickness of front brake lining 5.500 2.000
Tire pressure as cold: 0.8 kg/cm² (12 psi)
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
15-2
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 braking force

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
15-3
Front Wheel
Removal
Raise the front wheels off the ground by placing a
jack or other support under the frame.
Remove 4 nuts from the front wheel.
Remove the front wheel.
4 nuts
Installation
Install the front wheel and tighten the nuts.
Torque: 2.4kgf-m
Front Wheel Hub

Removal
Remove front brake caliper (2 bolts).
2 bolts
Remove cotter pin, wheel hub nut and washer.

Remove wheel hub and brake disk. Wheel hub nut
Cotter pin
15-4
Wheel hub
Inspection
Check disk & hub for wear or damage, and
replace it if necessary.
Installation
Install the front wheel disk and hub.
Brake disk
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.

The brake pad must be replaced with new lining
when the brake pad wear limit reaches the brake
disk.
Front brake
Caution
Before checking the front brake lining, front
wheel must be removed first. Brake disk
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).
Brake linings wear limit
Caution grooves
When the vehicle is inclined or just stopped, the

brake fluid level could not be accurate, settle it
for 3~5 minutes.
In order to prevent the chemical change, please
do not use counterfeiting or other unidentified
trade marks brake fluid.
Use the same brake fluid to guarantee the
braking efficiency.
15-5
Adding Brake Fluid
Before removing the brake fluid reservoir, turn the
handle to make the brake fluid reservoir become
horizontal, and then remove the brake fluid
reservoir.
Before serving the brake system, cover the
surface of the painted or the rubber parts 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.
Master cylinder
Remove the master cylinder cap and diaphragm.
Add the high quality brake fluid; use by all means
must with the trademark brake fluid joins in the
master cylinder.
Clean the dirty brake disk.
Caution
The dirty brake lining or disk will reduce the
brake performance.
To mixed non-compatible brake fluid will
reduce brake performance.
Foreign materials will block the system
causing brake performance to be reduced or
totally lost.
Screw
Brake Fluid Replacement / Air-bleed
Master cylinder cap
Connect drain hose to air-bleed valve. Upper level
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely Diaphragm
drained out.
Close the drain valve and add specified brake fluid
into the brake master cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
Air-bleed must from pressure control valve fist.

Connect one end of transparent hose to the Air-bleed valve
air-bleed valve, and put the other end into a
container.
Pressure control valve
15-6
Open the drain valve around 1/4 turns, and at the Air-bleed valve
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 in brake
system or not.
If brake is still soft, please bleed the system as

described below:
1. Hold the brake lever tightly and open the drain
valve around 1/4 turns, and then close the
valve.
Bubble Air-bleed valve
Caution
Do not release the brake lever before the
drain valve is closed.
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. Transparent hose
4. Tightly close the drain valve.
5. Make sure the brake fluid is at the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
15-7
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 the brake fluid on painted surfaces.
Remove two caliper bolts and the caliper.
2 bolts
Inspection
Make sure the brake linings condition. Replace the Guide pins
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
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.25kgf-m
Caution
Use M8 x 20 mm flange bolt only.
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.
15-8
Brake Disk Brake disk

Inspection
Visually check the brake disk for wear or spoilage.
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
braking performance.
Brake lining includes the asbestos ingredient;
do not use the air-gun clean the caliper, the
operator should dress the mouthpiece and
the glove, use vacuum cleaner to clean it.
Front Brake Master Cylinder

Master Cylinder Removal
Caution
Do not let foreign materials enter the cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and circlip 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
15-9
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
It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
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.
Install the larger end of the spring onto the master
Cir clip
cylinder. Rubber boot
The master cup’s cavity should be face inside of
master cylinder when installing the master cup. Piston
Caution Piston cup
Spring
Never install cup lip in the opposite direction.
Make sure the cir clip is seated securely in
the groove.
Install the rubber boot into groove properly.
Master cylinder
15-10
Master Cylinder Installation

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
light switch.
Brake 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.
15-11
Notes:
15-12
Home page Contents
16. STEERING / FRONT SUSPENSION
Mechanism Diagram ······················16-1 Knuckle·············································· 16-7

Precautions in Operation ··············16-2 Knuckle Disassembly ······················· 16-8
Trouble Diagnosis ·························16-2 Knuckle Assembly ···························· 16-9
Steering Handle ·····························16-3 Front Cushion ··································· 16-11
Steering Shaft ································16-4 Suspension Arm ······························· 16-12
Steering Tie-Rod ····························16-6 Toe-In ················································· 16-13
Mechanism Diagram
2.4kgf
4.0kgf-
3.4kgf- 16
3.6kgf-
5.0kgf-
4.
5.0kgf-
5.0kgf
5.0kgf-
5.0kgf-m
16-1
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
Faulty tire. Loose front suspension fasteners.
Steering shaft holder too tight. Binding suspension link.
Insufficient tire pressure.
Faulty steering shaft bushing.
Damaged steering shaft bushing. Hard suspension
Faulty front swing arm bushings.
Improperly installed front swing arms.
Front wheel wobbling Bent front shock absorber swing rod.
Faulty tire.
Worn front brake drum bearing.
Bent rim. Soft suspension
Axle nut not tightened properly. Weak front shock absorber springs.
Worn or damaged front swing arm bushings.
Steers to one side

Bent tie rods.
Wheel installed incorrectly.
Unequal tire pressure.
Bent frame.
Worn swing arm pivot bushings.
Incorrect wheel alignment.
16-2
Steering Handle Handle wire

Removal
Remove the handle cover, meter set, handle
protect cover and front fender. (Refer to chapter
13)
Remove the handle wire band.
Loosen the socket bolts from the rear brake 2 brocket bolts
master cylinder, and remove front brake master
cylinder.
Caution
Do not let foreign materials enter the brake
master cylinder.
Remove 2 screws, and then remove throttle
hosing holder and throttle hosing.
Loosen 2 screws, and then remove handle left
switch and choke hosing.
Handle lift
Loosen 2 screws, and then remove 2&4 wheel 2 brocket bolts

drive change switch.
Loosen the 2 socket bolts for the front brake

master cylinder, and remove front brake master
cylinder.
Caution
Do not let foreign materials enter the brake
master cylinder.
2
Loosen the 2 screws for throttle hosing holder and 2 screws

remove throttle hosing.
16-3
Remove the handle mounting bolt, and then 4
remove the handle upper holder, handle.
Remove 2 nuts to remove handle under holder

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

shaft nut
Steering shaft
16-4
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.
Measure the holder inner diameter.
Maximum limit: Ø39.5 mm
2 bolts
Installation Oil rings

Apply with grease onto oil liner and holder.
Torque value:
Steering shaft holder bolt 3.4kgf-m
Steering shaft nut 5.0kgf-m
16-5
Steering Tie-Rod Tie-rod nuts

Removal
Remove the cotter pin and the tie-rod nut from the
steering shaft side.
Cotter pin
Remove the cotter pin and the tie-rod nut from the Tie-rod
wheel side.
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.
Cotter
Installation
Install the ball joint with “adjustment groove” on
the wheel side.
Install the tie-rod nuts, and tighten the nuts.
Torque value: 5.0kgf-m
After tightening the tie-rod nut, install the cotter

pin.
Ball
Adjustment
16-6
Knuckle
Remove
Remove front wheel, front brake caliper, front
wheel hub and brake disk.
Remove 2 bolts from front brake caliper them

remove front brake caliper
2 bolts
Remove cotter pin and nut, remove front brake

disk. Nut
After tightened the nuts, install the cotter pins.
Cotter pin
Remove cotter pin and castle nut from front upper
and lower arm suspension. Bolt
UP
Remove 1 bolt front brake caliper clamp then
remove clamp.
LOW
Cotter pin & Bolt
16-7

Remove cotter pin and tie-rod nut, remove tie rod SYM-5325800-REA
with special tool.
Tools number: SYM-5325800-REA
Tools name: ball joint driver
Remove the knuckle body.

Inspection
Inspect the upper and under ball joints and
knuckle for damaging or cracking.
Installation
Torque value:
Ball joint nut 5.0kgf-m
Cotter pin Nut
CIRCLIP IN 55 Oil seal

Knuckle Disassembly
Remove oil seal 40*50*6.5 & 40*55*8 from
knuckle body.
Remove cir-clip in 55 from knuckle body.
Knuckle body Oil seal
SYM-6204025
Remove bearing 6007uu with special tool.

Tools number:SYM-6204025
Tools name: INNER BEARING OUTER PULLER.
16-8
Knuckle Assembly SYM-5024000- REA A6006

Assemble bearing 6006uu by special tool.
Assemble bearing 6006uu by special tool in the

knuckle then lock the nut. SYM-5024000- REA A6006 Nut
Install the bearing with special tool & air tool.

Tools number: SYM-5024000- REA A6006 SYM-5024000- REA A6006
Tools name: wheel knuckle body bearing 6006
in puller with air.
Air tool
Install the cir clip in 55 into knuckle body. SYM-5024000- REA A6006
16-9

Assemble oil seal 40*55*8 by special tool.
SYM-9123200- REA
Oil seal
Install oil seal into the knuckle body with hammer. SYM-9123200- REA Hamme
Tools number: SYM-9123200- REA
Tools name: wheel knuckle body seal 40*55*8
in driver.
Assemble oil seal 40*50*6.5 by special tool. SYM-9123000- REA
Oil seal
Install oil seal into the knuckle body with hammer.

Tools number: SYM-9123000- REA Hamme
Tools name: wheel knuckle body seal 40*50*6.5
in driver.
SYM-9123000- REA
16-10
Front Cushion Nut

Removal
Remove the front cushion under bolt nut, and
remove the bolt.
Remove the front cushion upper bolt nut, and
remove the bolt and the cushion.
Bolt
Installation
Torque value:
Front cushion nut 4.6kgf-m
16-11
Suspension Arm Suspension arm nuts

Removal
Remove the front wheel, wheel hub, and brake
caliper, brake disk, tie-rod, knuckle and front
cushion.
Loosen upper suspension arm nuts.
Remove swing arm bolts.
Loosen 1 bolt from under suspension arm cover

and then remove the cover.
Loosen under suspension arm nuts. Suspension arm nuts and bolts
Remove the swing arm bolts.
Remove under suspension arm.
Inspection
Inspect the suspension arm, ball joint and bush for Ball joint Bush
damage or bending.
Installation
Torque value: Bush
Lubricate with grease into suspension arm.
16-12
Toe-In
After repair or disassembly of the steering system
parts, adjustment of toe-in is required.
Keep the vehicle on level ground and the front
wheels facing forward.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Move the vehicle back carefully and 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 Adjustment

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
Lock
16-13
Home page Contents
17. REAR BRAKE & REAR WHEEL & REAR CUSHION
Mechanism Diagram ··························· 17-1 Suspension Arm ································· 17-10

Maintenance Description···················· 17-2 Disk Brake System Inspection··········· 17-11
Trouble Diagnosis······························· 17-3 Adding Brake Fluid ····························· 17-12
Rear Wheel··········································· 17-4 Brake Fluid Replacement / Air-bleed· 17-13
Rear Wheel Connecter ························ 17-4 Rear Brake Caliper ······························ 17-14
Rear Wheel Hub··································· 17-5 Brake Disk ··········································· 17-15
Rear Cushion······································· 17-9 Rear Brake Master Cylinder ··············· 17-15
Brake hose bolts (3.5kgf-m)

Mechanism Diagram Air-bleed valve (0.5kgf-m)
Rear brake master cylinder A
17
Brake caliper
bolts (3.25kgf-m)
Brake disk bolts (4.25kgf-m)
Rear wheel nuts

(2.4kgf-m)
17-1
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.
The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before riding.
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
17-2
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
17-3
Rear Wheel
Removal
Raise the rear wheels off the ground by placing a
jack or other support under the frame.
Remove the rear wheel nuts, and then remove
rear wheels.
4 nut
Installation
Install the rear wheel and tighten the nuts.
Torque: 2.4kgf-m
Rear Wheel Connecter

Removal Wheel connecter nut
Remove cotter pin, rear wheel connecter nut and

washer.
Cotter pin
Remove right and left rear wheel connecter.
Installation
Install the rear wheel connecter.
Install wheel connecter wheel connecter nut.
Torque: 2.4kgf-m
Install cotter pin.
17-4
Rear Wheel Hub 2 nuts
Remove
Loosen 2 nuts then 2 flange bolts
2 bolts
Remove the rear wheel hub.
Wheel Hub Disassembly

4 washer seals
Remove 4 washer seals & 2 callers from rear
wheel hub.
2 callers
Remove the oil seal 40*55*8 from rear wheel hub. Oil seal 40*55*8
17-5

Remove the cir clip in 55 with Inner cir clip pliers Inner cir clip pliers
Cir clip in 55
Remove the 2 bearing from rear wheel hub with

special tool.
Tools name: inner bearing outer puller.
SYM-6204025
Remove the 4 oiled from rear wheel hub with
special tool. Circlip in 55
Tools name: inner bearing outer puller.
SYM-6204025
17-6
Wheel Hub Assembly SYM-4011600-REA

Assembly oiled & special tool.
Tools name: RR. wheel hub oiled install tool.
.
Cir clip in 55
Assembly oiled & special tool into the rear wheel SYM-4011600-REA
hub with special tool.

Tools name: RR. wheel hub oiled install tool.
oiled
Install 2 bearing 6006uu into the rear wheel hub SYM-5024000- REA A6006
with special tool.

Tools number: SYM-5024000- REA A6006
Tools name: wheel knuckle body bearing 6006
in puller with air or head tool.
Bearing 6006uu
Assembly oil seal 40*50*6.5 by special tool

SYM-9123000-REA
Tools name: wheel knuckle body seal
40*50*6.5 in driver.
Oil SEAL 40*50*6.5
17-7
SYM-9123000-REA
Install the oil seal with special tool & hammer.
Oil SEAL 40*50*6.5
Install the cir clip in 55 into the rear wheel hub. Inner cir clip pliers
Cir clip in 55
Assembly oil seal 40*55*8 by special tool SYM-9123200-REA

Tools name: wheel knuckle body seal 40*55*8
in driver.
Oil SEAL 40*50*6.5
Install the oil seal with special tool & hammer SYM-9123000-REA
Oil SEAL 40*50*6.5
17-8
Rear Cushion
Removal
Remove the rear wheels.
Remove the rear wheel connecter.
Loosen 2 bolts from the rear cushion.
Remove the 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
17-9
Suspension Arm 2 bolts
Removal
Remove the rear wheel, wheel hub and rear
cushion.
Loosen upper suspension arm nuts.
Remove swing arm bolts.
Bolt
Loosen 2 bolts from under suspension arm cover

and then remove the cover.
Loosen under suspension arm nuts.
Remove the swing arm bolts.
Remove under suspension arm.
2 bolts
Bush
Inspection
Inspect the suspension arm for damage or
bending.
Installation Bush

Torque value:
Lubricate with grease into suspension arm.
17-10
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.
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
! Before checking the rear brake lining, remove

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
! When the vehicle is inclined or just stopped, the
oil level could not be accurate, settle it for the
3~5 minutes.
! In order to prevent the chemical change, please
do not use counterfeiting or other unclear
trademarks brake fluid.
! Use the same trademark brake fluid to
guarantee the braking efficiency.
17-11
Fluid cup
Adding Brake Fluid
Before removing the brake fluid reservoir, turn the
handle to make the brake fluid reservoir become
horizontal, and then remove the brake fluid
reservoir.
Before serving the brake system, cover the
surface of the painted or the rubber parts 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.
Master cylinder
Mixed non-compatible brake fluid will reduce
braking performance.
Foreign materials will block the system,
causing braking performance to be reduced Screw
or totally lost. Brake fluid cap
Upper level
Diaphragm
17-12
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.
Open the drain valve around 1/4 turns, and at the Bubble Air-bleed valve
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. Hold the brake lever tightly and open the drain Transparent hose
valve around 1/4 turn, and then close the valve.
Caution
Do not release the brake lever before the
drain valve is closed.
Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air entering 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. Close the drain valve tightly.
5. Make sure the brake fluid is at the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
17-13
Rear Brake Caliper Brake hose bolt 2 bolts
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.
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
Use M8 x 20 mm flange bolt only.
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 Guide pins
necessary air bleeding.
Brake lining replacement

Remove two 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
linings
17-14
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.
Brake lining includes the asbestos ingredient,
cannot use the air gun to be clean, the
operator should dress the mouthpiece and
the glove, and 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
17-15
Right footrest side – rear brake master cylinder Hose clamp
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.
2 bolts
Remove the E type clip, and remove brake push

rod pin.
master cylinder.
E type clip
Disassembly
Remove the rubber boot. Cir clip
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
17-16
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
It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir
clip.
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

Caution
Never install cup lip in the opposite direction.
Master cylinder
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
Brake light switch coupler Brake lever nut
17-17
Right footrest side – rear brake master cylinder Hose clamp
B
Install the master cylinder bolts and the master
cylinder.
2 bolts
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. 2 washers Hose clamp

Connect brake hoses with 2 new washers.
value.
Torque: 3.5kgf-m
17-18
Notes:
17-19
Home page Contents
18. ELECTRICAL SYSTEM
Mechanism Diagram ·····························18-1 Starting System ······································ 18-10

Maintenance Data··································18-2 Meters ······················································ 18-12
Technical Specification ························18-2 Light / Bulb ·············································· 18-13
Trouble Diagnosis·································18-3 Switch / Horn··········································· 18-16
Battery····················································18-4 Cooling Fan Thermo Switch ·················· 18-19
Charging System···································18-5 Thermo Unit············································· 18-20
Ignition System ·····································18-8 Water Temperature Indicator Lamp ······ 18-20
Front brake switch

Mechanism Diagram
Main switch
Full Transistor
Ignition Unit
Battery Shift gear

control unit
Fuse box Hazard

control unit
18
Starter relay
Winker relay
Rear brake switch
AC. Generator Regulator rectifier
Thermo unit
Start & light &

winker & horn &
DC. Power outlet brake switch
Ignition coil
Shaft gear control unit
Spark plug
Headlight relay
Horn
Hazard control
18-1
Maintenance Data
Operational precaution
When removing the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal then the positive cable terminal.)
The model of the spark plug and the tightening torque.
The ignition timing.
Adjustment of headlight.
Removal and installation of AC generator.
The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled water.
To recharge the battery, remove the battery from rack without removing ventilation caps.
Unless in emergency, never recharge the battery rapidly.
The voltage must be checked with the voltmeter while charging the battery.
As Full-Transistor Igniter assembly does not require an ignition timing check. In case ignition timing is
incorrect, check Full-Transistor Igniter and AC generator. Verify with an ignition timing light after
replacement if necessary.
Technical Specification
Charging system
Description Specification
Capacity 12V12Ah
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 2.8 ± 15%Ω

Ignition coil and
Without cap: 9.0 ± 20KΩ
resistance Secondary winding
With cap: 14.0 ± 20KΩ
10° BTDC / 1500 rpm
26° BTDC / 3500~5500 rpm

Ignition timing “F” mark
30° BTDC / 6000~7000 rpm
10° BTDC / 7300 rpm
18-2
Trouble Diagnosis
No voltage Charging system does not operate
Battery discharged properly
The cable disconnected Burned fuse
The fuse is blown Poor contact, open or short circuit
Improper operation of the main switch Poor regulator
Poor ACG
Low voltage
The battery is not fully charged Engine does not crank smoothly
Poor contact Primary winding circuit
Poor charging system - Poor ignition coil
Poor voltage regulator - Poor connection of cable and connectors
- Poor main switch
Secondary winding circuit
No spark produced by spark plug - Poor ignition coil
The spark plug is out of work - Poor spark plug
The cable is poorly connected, open or - Poor ignition coil cable
short-circuited - Current leakage in the spark plug
- Between AC.G. and Full-Transistor Igniter Incorrect ignition timing
Poor connection between Full-Transistor Igniter - Poor AC.G.
and ignition coil - Improper installation of the pulse sensor
- Poor connection between Full-Transistor - Poor Full-Transistor Igniter
Igniter and the main switch
Poor main switch
Poor Full-Transistor Igniter Weak starter motor
AC.G. is out of work Poor charging system
The battery is not fully charged
Poor connection in the windings
Starter motor does not work The motor gear is jammed by foreign material
The fuse is blown
The battery is not fully charge
Poor main switch Starter motor is working, but engine does
Poor starter switch
not crank
The front and rear brake switches do not
Poor starter motor pinion
operate correctly
The starter motor run in reverse direction
Starter relay is out of work
Poor battery
The ignition coil is poorly connected, open or
short-circuited
The starter motor is out of work
Intermittent power supply

The connector of the charging system becomes
loose
Poor connection of the battery cable
Poor connection or short-circuit of the
discharging system
Poor connection or short-circuit of the power
generation system
18-3
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 the
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
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by
battery cables.
Caution
Never rapid charge the battery unless in
emergency.
Verify the battery is recharged with correct
current and duration prescribed above.
Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable terminal

with grease.
18-4
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
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.
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.
18-5
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
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
Use a fully charged battery having a voltage
the charging current is in the discharging
larger than 13.0 V
direction.
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.
Does not use short-circuit cable.
- The ammeter is improperly connected.
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.
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.
18-6
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
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 2 couplers
18-7
Ignition System
Ignition circuit diagram
B Black
R Red
Shift Gear Control Unit Full Transistor Ignition Unit
G Green
W White
Y Yellow
L Blue
W/R W/L
G G/W L/Y B/Y G
R/Y
W/B
L/Y
Fuse 15A
Ignition
Coil
B
Main fuse
30A
Spark Plug
Battery G
Main switch
Pulse Generator
Full Transistor Ignition Unit

Disconnect connectors of the full transistor ignition 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 Red/Yellow ~ Green Battery voltage
Pulse generator Green/White ~ Blue/Yellow 50~170Ω
Primary circuit Black/Yellow ~ Green 2.8±15%Ω
Ignition coil Black/Yellow ~ with no cap 9.0K±20%Ω

Secondary circuit
Black/Yellow ~ with cap 14.0K±20%Ω
18-8
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: 2.8 ± 10% Ω
Remove the cap from the spark plug and measure
the resistance between the spark plug and the
primary winding.
Standard resistance:
With no cap: 9.0 ± 20% KΩ
With cap: 14.0 ± 20% KΩ
Ignition Coil Replacement Ignition coil

Loosen the lock bolt and replace the ignition coil if
necessary.
Spark plug cap
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
18-9
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.
Press the brake.
Push down the starter switch.
If a sound of “Looh Looh” is heard, it indicates the
relay function normally.
Starter relay
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.
18-10
Removal of Starter motor Negative

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

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

2 Bolts
18-11
Meters Meter set couplers

Removal
Remove couplers of meter and main switch
couplers.
Main switch coupler
Remove 4 bolts from meter stay.
4 bolts
Remove 3 screws and speedometer cable.

Disassemble speedometer cover and
speedometer.
3 screws Speedometer cable
18-12
Light / Bulb 2 screws

Headlight bulb replacement
Remove 2 screws for the headlight cover, and
remove the cover.
Adjusting screw
Remove the rubber boot.
Rubber boot
Press the bulb setting hook.

Hook
Remove the bulb connector and the bulb.
Replace with new bulb if necessary.
(H7 12V 35W)
2 screws
Caution
Never touch the bulb with finger, which will
create a heat point and reduce the lifetime of
the bulb.
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.
18-13
Front winker light bulb replacement
Remove 2 screws from the winker light cover. 2 screws
Remove the winker light cover.
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)
Position light bulb
18-14
Replacing Bulb of Taillight and Rear Taillight bulb

Winker Light
Remove 2 screws.
Remove the taillight cover.
2 screws
Replace with new taillight bulb.

(12V 5W/21W)
Remove 2 screws.
Remove the rear winker light cover.
2 screws
Pull out the rear winker bulb.

Replace the rear winker bulb with new one.
(12V 10W)
Caution
Never touch the bulb with finger, which will
create a heat point and reduce the lifetime of
the bulb.
Clean any grease left on the bulb with alcohol.
18-15
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.
Handle switches
Disconnect the coupler of handle from front fender
left side.
Check the continuity between two points as
indicated in the table below.
Headlight switch couplers
Start Switch
Pin
ST SG
Position
FREE
Yellow Yellow
Wire Color
/ Red / Black
Start switch
18-16
Headlight Switch Headlight switch
Pin
BAT3 LO HI PL
Position
●
White
Wire color White Blue Brown
/ Black
Winker switch
Winker switch
Hazard switch
Pin
L WR R
Position
N PUSH OFF
Brown /
Wire color Pink Black
White Horn switch
Horn switch
Pin
BAT3 HO
Position
FREE
Wire Color White/ Black Light green
Hazard switch
Pin
HD E
Position
Wire Color Green / Red Green
18-17
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 right side.
1 bolt
Apply 12 V power source to two terminals of the

horn, the horn should sound.
Replace the horn if necessary.
18-18
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 the
battery voltage between the green and black/blue
leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit. Thermo switch
If the fan motor runs, check the thermo switch in
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
Keep the coolant at a constant temperature at
least for three minutes. Sudden increase the
coolant temperature will cause the Thermometer
thermometer and the tester to indicate wrong
readings.
Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.
18-19
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
Wear gloves and goggles when performing
this test.
Caution
Engine oil should be used as a heating
medium as the test temperature must be
higher than 100℃.
Contacting the container wall by the
thermometer and the thermo unit may result in
wrong readings.
Thermo unit
Coolant Temperature Indicator Lamp Indicator lamp

Disconnect the coolant temperature meter and
connect it to engine ground.
Turn on the main switch.
The indicator lamp of the fuel meter should be
lighting.
18-20
Notes:
18-21
Home page Contents
19. ELECTRICAL DIAGRAM
19
19-1
19. ELECTRICAL DIAGRAM
Notes:
19-2

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FOREWORD CONTENTS

HOW TO USE THIS MANUAL SERIAL NUMBER

Quad Lander 600

HOW TO USE THIS MANUAL

The first chapter covers general information and trouble diagnosis.

Page Content Index

1-1 ~ 1-17 GENERAL INFORMATION 1

2-1 ~ 2-17 MAINTENANCE INFORMATION 2

3-1 ~ 3-8 LUBRICATION SYSTEM 3

4-1 ~ 4-13 FUEL SYSTEM 4

5-1 ~ 5-6 ENGINE REMOVAL 5

6-1 ~ 6-17 CYLINDER HEAD/ VALVE 6

7-1 ~ 7-8 CYLINDER/ PISTON 7

8-1 ~ 8-17 “V” BELT DRIVING SYSTEM 8

9-1 ~ 9-14 TRANSMISSION 9

10-1 ~ 10-16 WHEEL DRIVE SHAFT/ PROPELLER SHAFT 10

11-1 ~ 11-11 A.C. GENERATOR/ STARTING CLUTCH 11

12-1 ~ 12-8 CRANKCASE/ CRANKSHAFT 12

13-1 ~ 13-14 COOLING SYSTEM 13

14-1 ~ 14-8 BODY COVER 14

15-1 ~ 15-12 FRONT BRAKE AND FRONT WHEEL 15

16-1 ~ 16-13 STEERING/ FRONT SUSPENSION 16

17-1 ~ 17-18 REAR BRAKE/ REAR WHEEL/ REAR CUSHION 17

18-1 ~ 18-21 ELECTRICAL SYSTEM 18

19-1 ~ 19-2 ELECTRICAL DIAGRAM 19

Symbols and Marks............................. 1-1 Torque Values .................................... 1-10

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.

Rubber parts may become deteriorated when old,

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

Tighten assemblies with different dimension Clamp

Both of these examples can result in

Check if positions and operation for installed

Make sure that the battery post caps are located

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

Before battery removal operation, it has to

Secure wires and wire harnesses to the frame

Make sure if the connector pins are bent,

Wire band and wire harness have to be clamped

Insert the connector completely.

Check if the connector is covered by the twin

Before terminal connection, check if the boot is

Never too tight

Wire harnesses routed along the handlebar

Before operating a test instrument, operator

Do you know how to set the

Overall Height 1220 mm Front AT25x8-12 (off road)

Passengers/Weight Two /150 kg Primary

Exhaust Pipe Position and Left side, and

Number/Arrange Forced circulation &

Displacement 565cc Solid Particulate