1-5 Crankshaft Inspection Use a thickness gauge to measure left and right clearance of connecting rod big end. Service limit: 0.6 mm Measure point for the crank big end of the connecting rod. Measure the clearance of the big end at the vertical directions. Service limit: 0.05 mm Place the crankshaft on a V-block, measure run-out of the crankshaft. Service limit: 0.10 mm 90 mm 60 mm Check crankshaft bearing Use hand to crank the bearing to see it moves freely, smoothly and noiseless.
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 bearing mounted, then replace it. Special tool: Inner bearing puller Bearing driver Balance shaft bearings 11-6 Assembly Of Crankcase Install wave washer into right crank bearing seat. Wave washer Install crank shaft on the right crankcase.
Install 2 dowel pins and new gasket. Dowel pins Install the left crankcase onto the right crankcase. 11 bolts Tighten 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m Tighten 2 bolts on the right crankcase. Torque value: 0.8~1.
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 located. Special tool: Oil seal driver (27×42×7) Oil seal driver 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.
12.
12-2 General Information General Warning: While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless the engine is completely cooled down. y y y y y y Refill the radiator with distilled water or specified additives. Add coolant to the reservoir. The cooling system can be serviced on the ATV. Never spill the coolant to the painted surface.
12-4 Trouble Diagnosis For Cooling System The temperature indicated is too high Y A. Stop and waiting for the engine is completely cooled down, open cap to check the capacity of coolant in radiator. A1.Refill the radiator with coolant then check for any leakage? N Y Water leaking problem N Y B. Turn on main switch and check the water temperature indicator back to zero? N B-1. Measure thermo unit to confirm voltage 6VХ? N Replace thermo unit Y Y B-2.
Preceding page E. Keep eng. 3000~4000 rpm and inspect cooling fan was operating after the temperature gauge over 3 checks? N E-1. Measure thermal switch to confirm voltage be changed (12Ш0V)? N Replace thermal switch Y Y F. Confirm the cooling fan was convulsion? E-2. Connect cooling fan terminals with battery (12V) directly to inspect its operation? N Replace cooling fan Y Meter unusual Y If circuit connects reverse cooling fan will forward, correct and check again. E-3. Keep eng.
12-5 System Test Test on the filler cap Hermetically seal the filler cap, apply water and pressure to the filler cap. Replace it with new one if found failing to maintain the specified pressure within a given time limit, or the opening pressure is too high or too low. The specified pressure shall be maintained at least for 6 seconds in the test Relief pressure for the filler cap: 0.9-0.
Check reserve tank y Remove the front center cover, and then remove reserve tank filler cap. y Check the liquid level in the front fender right side. Add coolant to proper level if too low. y Reinstall the reserve tank filler cap. Caution The reserve tank liquid level coca too is not high, after avoids the water temperature elevating, in the cooling system the refrigerant backflow floods. Upper Lower 12-6 Radiator Check Remove the front center cover, side covers and front fender.
Loosen the radiator 4 bolts. Remove coolant upper side pipes. Coolant inlet pipe 4 bolts Coolant outlet pipe Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor, and then remove radiator and cooling fan. Thermo switch coupler Disassembly Loosen the 3 bolts from the fan duct, and then remove the fan duct. Loosen 3 screws from the fan motor, and take off the fan motor. Remove nut to remove the fan from fan motor.
-7 Water Pump Check water pump seal / cooling system divulges inspection y Disassembles the refrigerant drain bolt, overflows little buckles the N actually fluid, confirmed overflows the refrigerant whether has the greasy dirt. y Turns on lathe the engine oil gauge rule, the inspection engine oil whether does have bleaches situation of the emulsified.
Check any wear and damage of the mechanical seal and inside seal. Mechanical seal Caution The mechanical seal and inside seal must be replaced as a unit. 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: Inner bearing puller Water pump bearing driver Water pump bearing driver Caution Replace a new mechanical seal after removing it.
Install the new inner seal onto the right crankcase. Special tools: Water pump oil seal driver (inner) Install a new outside bearing to the right crankcase cover. Special tools: Water pump bearing driver (6901) Water pump oil seal driver (inner) Water pump bearing driver (6901) Caution Do not reuse old bearing. It must be replaced with a new one once it has been removed. Inner bearing Mount the water pump shaft and the inner bearing to the right crankcase cover.
Install the seal washer into the rotor. Caution Washer must be replaced together with the mechanical seal. Install the rotor onto the water pump shaft and tighten. Torque Value: 1.0~1.4kgf-m Caution The rotor is left thread. Install the dowel pin and right cover gasket. The rotation water pump rotor, causes the water pump drive shaft scoop channel, aligns the oil pump drive shaft flange, install the right crank case. (9 bolts) Install the dowel pin and new gasket.
12-8 Thermostat Temperature sensor 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.
13.
13-2 Troubleshooting Ϫ Ϫ Ϫ Ϫ Ϫ Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing Ϫ Ϫ Ϫ Ϫ Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Ϫ Ϫ Ϫ Ϫ Ϫ Ϫʳ Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment FRONT SUSPENSION NOISE Ϫ Ϫ Loose front suspension fasteners Binding suspension link HARD SUSPENSION Ϫ Ϫ
Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Screws Bolts Remove the handle cover and instrument panel by four screws at right and left side as shown in picture. Screws Remove the bolts attaching the handlebar upper holder. Remove the handlebar.
INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch marks match with the top end of the handlebar of lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts. Install the handlebar upper holder’s cover. dot Install the switch housing, aligning the small dot of the handlebar. Tighten the upper screw firstly, after that tighten the lower one.
13-4 Throttle Housing DISASSEMBLY Loosen the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. NOTE: Assembly is in the reverse order of disassembly. Screws 13-5 Steering System When the steering shaft needs to be repaired, you need to remove three kinds of components: the tie-rods, front wheels and hub assy.
Step 1 Tie-rod Inspection 9 9 Inspecting the tie-rod for damage or bending. Inspecting the ball joint rubbers for damage, wearing or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. Steering Shaft Removal Remove the handle bar cover and handle bar. (See Chapter 13-3) Remove the front fender. (See Chapter 16-1) Remove handlebar lower holder. Loosen the steering shaft holder bolt and remove steering shaft holder.
Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50 N.m (37 lbf.
14.
14-2 Troubleshooting HARD STEERING Ϫ Ϫ Faulty tire Insufficient tire pressure FRONT WHEEL WOBBLING Ϫ Ϫ Ϫ Ϫ Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly BRAKE DRAG Ϫ Ϫ Incorrect brake adjustment Sticking brake cable STEERS TO ONE SIDE Ϫ Bent tie rods Ϫ Wheel installed incorrectly Ϫ Unequal tire pressure Ϫʳ Incorrect wheel alignment POOR BRAKE PERFORMANCE Ϫ Ϫ Ϫ Ϫ Brake shoes worn Worn brake drum Brake linings oily, greasy or dirty Improper brake adjustment
14-4 Hydraulic Brake This type of brakes are applying in front of two wheels of RA1 REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures. Loosen fours nuts as shown in picutre Then take the wheel out. you can find two bolts fixed at front hydraulic disk component. Loosen these two bolts and you can take out disk component.
Before loosening castle nut, you have to remove cotter pin Wheel hub Castle nut Then using the power tools to take the screw out from brake stopping plate. You can take the brake disc off. When change brake shoe wear, you must push the master piston to rearward. After removal the front brake assembly, you must fabricate in reverse sequence.
ADD BRAKE OIL The brake oil tank is under the driver seat at right hand side. Please check the brake oil level position at outside of tank. To open the cap of brake oil tank, please turn “CCW” direction.
14-5 Suspension Adjustment Suspension system in this type of AVT can be adjustable its hardness and softness (fig 1). 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner, E1105-LRA0-FT1 ) to adjust the suspension. How to use the “Adjustable Hook Spanner” When you use the adjustable hook spanner, please depress the slider (fig 2&3.) to a proper position.
15.
REAR BRAKE
15-2 Troubleshooting Bad Brake Performance Vibration or Wobble Brake Drag Hard Suspension Soft Suspension Ϫ Brake shoes are worn Ϫ Bad brake adjustment Ϫ Brake linings are oily, greasy or dirty Ϫ Brake drums are worn Ϫ Brake arm setting is improperly engage Ϫ Axle is not tightened well Ϫ Bent rim Ϫ Axle bearings are worn Ϫ Faulty tires Ϫ Rear axle bearing holder is faulty Ϫ Incorrect brake adjustment Ϫ Sticking brake cam Ϫ Sticking brake cable Ϫ Bent damper rod Ϫ Faulty swing arm pivot bushings Ϫ Weak s
Loosen two bolts to take out rear brake disk as shown in picture. Bolts Loosen bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE To replace the brake shoe, please loosen this bolt as shown in picture.
Eventually, you can take all brake shoe out the hub. There are two kind of brake linings as shown in picture TO REPLACE THE BRAKE HYDRAULIC OIL Loosen the bolts and open the cover Loosen the bolt and drain the used oil out. Tighten the bolt after the used oil being drained out completely Bolt Add the brake oil (Dot 3 or Dot 4) Keep oil level at least half of the cup in order to avoid air in the brake system. Loosen the bolt to vent the air from brake system.
15-4 Swingarm & Rear Axle Holder This section is to introduce how to repair the swing-arm, The following pictures are going to teach you how to Install the swing-arm. 1. Put the swingarm at proper position as shown in picture. Two hanger bolts will be used to hold the swing-arm at right and left side. Hanger bolt 2. Tighten a hanger bolt on the right side as shown in picture.
3. Screw another hanger bolt on the left side as shown in picture. But do not tighten it. Let the cross-section of bolt and cross-section of hole in the same plane nearly. Hanger bolt 4. Tighten the nut NOTE: If you make a wrong assembly procedure, it will cause: 1. A damage of bearings 2. The main frame will be extended at the area of assembly swim arm (Unalignment).
15-5 Suspension Adjustment Suspension system in this type of AVT can be adjustable its hardness and softness (fig 1). 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, you can use special tool (adjustable hook spanner) to adjust the suspension. How to use the “Adjustable Hook Spanner” When you use the adjustable hook spanner, please depress the slider (fig 2&3.) to a proper position. You can then adjust your ATV’s suspension (fig 4).
16.
16-2 Rear Fenders Removal There are two seat release bars located at the right and left hand side of the seat. Please remove the seat first. Release Bars Procedures of remove the rear fender: Remove the rear rack. 1. Open the seat. 2. Loosen the four bolts which connect the front fender and rear fender. 3. Loosen the two bolts, which connect the rear tender and frame, these two bolts just below the seat. Screws Loosen the three screws which connect with footrest plate. Pull the rear fender backward.
There are two screws on the top of seat compartment. Please remove them. Bolts Next, there are two screws on side of the tail. Screw Finally, you must remove the bolts on the footrest.
16-3 Front Fender Removal To remove the front fender, there are sever trips to indicate users how to remove it. 1. First picture shows there are two screw, loosen it. Screws Remove the mounting bolts from the front fender. Bolts Please remove the two screws on the top of the headlight. Then you can see there is a screw on the tip of the vehicle. Please remove it. There is a screw near the suspension as shown in picture.
Screws 16-4 Exhaust Pipe Removal You must wait at least 15 minutes after stopping the engine. You need to remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Loosen the two exhaust pipe bolts that fixed on the engine. WarningΚDO NOT service the exhaust pipe while they are hot. Remove the exhaust pipe bolts mounting on the frame below the seat. Remove the exhaust pipe carefully.
Bolt EXHAUST PIPE INSTALLATION Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30 N.m (22 lbf.ft) CATUATION: After installing, make sure that there are no exhaust leaks.
17.
17-2 Ignition Coil Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3Ө(20к) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7.4 – 12 kӨ(20к) 17-3 Ignition Timing The ignition advance is 15̓̈́ 3̓/4000rpm The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment.
CHARGING Firstly, connect the charged positive cable to the battery positive terminal. Secondly, connect the charged negative cable to the battery negative terminal. Using 0.9A-charging current about 11 hours. (Normal charging) Or using 4A-charging current about 3 hour. (Quick charging) Keep flames and sparks away from a battery being charged. Quick charging should be limited to an emergency; Normal charging is preferred.
After loosen these three screws, users can find a connector. Please disjoin the connector in order to replace an electrical bulb conveniently and safely. The steps show on pictures. Installation is in the reverse order of disassembly. Screws TAILLIGHT The taillight combines a position and a rear brake light. Normally, when users switch the key to “ON” position, the front & rear position lights are always keep the light slightly.
Please rotate the electrical bulb, and then it could be removed. Screws Rear Direction lights remove The same disassembling procedure like front direction light. Please use the pliers to remove the seat. Then the bubble could be see and replaced.
17-7 Instrument Pane The instrument panel includes fuel gauge, speed meter, water Temperature gauge, right and left turn signal, trip do-meter, and indicator camp. A LCD is used on ATV8E’s instrument panel to display all driving information for users. Therefore, this is an all-in-one instrument panel. Instrument Panel REMOVAL There is a cable and connector on the back of the instrument panel.
Cable
17-8 Wiring Diagram
18.TROUBLESHOOTING 18.4 Loss Power 18.5 Poor Handling 18-1 Engine Can Not Work 18.2 Poor Performance At Low And Idle Speeds 18.3 Poor Performance At High Speed 18-1 Engine Can Not Work Possibility N.G. CHECK FUEL FLOW TO CARBURETOR Ϫ No fuel In fuel tank Ϫ Clogged float valve Ϫ Clogged fuel tank cap breather hole Ϫ Clogged at fuel tube O.K. N.G. SPARK TEST WEEK OR NO SPARK O.K. N.G. TEST CYLINDER COMPRESSION LOW COMPRESSION O.K.
18.2 Poor Performance At Low And Idle Speeds Possibility N.G. CHECK IGNITION TIMING . Faulty CDI unit or pulse generator . Improperly adjusted air screw . . Deteriorated insulator o-ring Loose carburetor . . . . . . . . . Loose or disconnected ignition system wires Faulty ,carbon or wet fouled spark plug Faulty alternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch O.K.
18-4 Loss Power Possibility RAISE WHEELS OFF GROUND AND SPIN BY HAND DOES NOT SPIN FREELY Ϫʳ Ϫʳ Ϫʳ Ϫʳ SPIN FREELY PESSURE LOW CHECK CHECK TIRE PRESSURE TIRE Brake dragging Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication Ϫʳ Punctured tire Ϫʳ Faulty tire valve PRESSURE NORMAL ACCELERATE LIGHTY ENGINE SPEED DOES NOT INCREASE ENGINE SPEED INCREASE N.G. CHECK IGNITION TIMING O.K.
18-5 Poor Handling Possibility STEERING IS HEAVY Ϫʳ Damaged steering bearing Ϫʳ Damaged steering shaft bushing ONE WHEEL IS WOBBLING ღʳ Ϫʳ Ϫʳ Ϫʳ Ϫʳ Ϫʳ Ϫʳ Bent rim Improperly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn VEHICLE PULLS TO ONE SIDE Ϫʳ Ϫʳ Ϫʳ Ϫʳ Bent tie-rod Incorrect tie-rod adjustment Rear tie air pressure incorrect Improper wheel alignment Ϫʳ Bent frame