BLADE 500/525

SERVICE MANUAL

TAIWAN GOLDEN BEE CO.,LTD.

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FORWARD

This service manual contains the technical data of each component inspection and
repair for the BLADE 525/500 ATV.The manual is shown with illustrations
and focused on “Service Procedures”, “Operation Key Points”, and “Inspection
Adjustment” so that provides technician with service guidelines.

If the style and construction of the ATV, BLADE 525/500, are different from that
of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.

Service Department
TAIWAN GOLDEN BEE CO., LTD.

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HOW TO USE THIS MANUAL

This service manual describes basic information of different system parts and
system inspection & service for BLADE 525/500 ATV. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.

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CONTENTS

Page Content Index

1-1 ~ 1-18 GENERAL INFORMATION 1

2-1 ~ 2-14 SERVICE MAINTENANCE INFORMATION 2

3-1 ~ 3-7 LUBRICATION SYSTEM 3

4-1 ~ 4-12 FUEL SYSTEM 4

5-1 ~ 5-14 ENGINE REMOVAL 5

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

7-1 ~ 7-8 CYLINDER/PISTON 7

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

9-1 ~ 9-11 FINAL DRIVING MECHANISM 9

10-1 ~ 10-10 ALTERNATOR/ STARTING CLUTCH 10

11-1 ~ 11-20 CRANKSHAFT/ CRANKCASE 11

12-1 ~ 12-11 COOLING SYSTEM 12

13-1 ~ 13-9 BODY COVER 13

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

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

16-1 ~ 16-15 REAR BRAKE/REAR WHEEL/REAR CUSHION 16

17-1 ~ 17-22 ELECTRICAL EQUIPMENT 17

18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

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SERIAL NUMBER

Frame number

Engine number

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1. GENERAL INFORMATION

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

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-40 API SG class oil. Warranty will not cover the
Engine oil damage that caused by not apply with the limited engine oil.

Grease King Mate G-3 is recommended.

Locking sealant Apply sealant; medium strength sealant should be used unless otherwise
specified.

Oil seal Apply with lubricant.。

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT4 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)

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1. GENERAL INFORMATION

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 water
Gasoline is a low ignition point and explosive 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 it Inhaling brake shoe or pad ash may cause
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.

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1. GENERAL INFORMATION

Service Precautions
● Always use with TGB 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.
TGB ATV may damage the ATV.

● Rubber parts may become deteriorated when old,

● Special tools are designed for remove and and prone to be damaged by solvent and oil.
install of components without damaging the Check these parts before installation to make sure
parts being worked on. Using wrong tools may that they are in good condition, replace if
result in parts 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
● When servicing this ATV, use only metric tools. installation later.
Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
● 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
● Wash and clean parts with high ignition point components before disassembling them to
solvent, and blow dry with compressed air. Pay ensure they will be reassembled in correct
special attention to O-rings or oil seals because dimensions (depth, distance or position).
most cleaning agents have an adverse effect on
● 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.

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1. GENERAL INFORMATION
● The length of bolts and screws for assemblies, ● Remove residues of the old gasket or sealant
cover plates or boxes is different from one another, before reinstallation, grind with a grindstone if
be sure they are correctly installed. In case of the contact surface has any damage.
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.

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1. GENERAL INFORMATION
● 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.

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1. GENERAL INFORMATION
● When separating a connector, it locker has to be ● Insert the terminal completely.
unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot.
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.

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1. GENERAL INFORMATION
● 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

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1. GENERAL INFORMATION
● 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?

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1. GENERAL INFORMATION
Specifications
MAKER TGB MODEL FBG
Overall Length 2155 mm Suspension Front Double arm
Overall Width 1170 mm System Rear Unit Swing
Dimension

Overall Height 1205 mm Tire Front 25X8-12

Wheel Base 1300 mm Specifications Rear 25X10-12
Front 930 mm Rim Aluminum / Steel
Wheel tread
Rear 940 mm Front Disk (Ø 200mm)
Brake System
Front 170 kg Rear Disk (Ø 220mm)
Curb
Rear 145 kg Max. Speed Above 92 km/hr
Weight Performance
Total 315 kg Climb Ability Below 25ﾟ
Weight

Passengers/ weight Two / 150 kg Primary

Belt
Front 205 kg Reduction
Total
Rear 280 kg Secondary
Weight Gear / Shaft
Total 485 kg Reduction Reduction

Type 4-Stroke Engine Clutch Centrifugal, wet type

Installation and Vertical, below C.V.T., auto speed
Transmission
arrangement center, incline change
Fuel Used Above 92 unleaded Speedometer 0 ~ 300 km/hr
Cycle/Cooling 4-stroke/Water cooled Horn 93 ~ 112dB/A
Expansion & Pulse
Bore Ø92 mm Muffler
Type
Cylinder

Exhaust Pipe Position Left side, and

Stroke 75.6 mm
and Direction Backward
Number/ Forced circulation &
Engine

Single Cylinder Lubrication System

Arrangement splashing
Concentration

Displacement 502.56 cc Solid Particulate

Exhaust

Compression Ratio 9.6±0.3 CO Below 7.0 g/ km

Max. HP 15.0kw / 6500rpm HC Below 1.5g/ km
Max. Torque 26.6Nm / 5000rpm Nox Below 0.4g/ km
Front Lamps 12V 55W×2
Ignition C.D.I.
(HI/LO) 55W×2
Lamps

Starting System Electrical starter Rear Lamps 12V 5W×1

Brake Lamps 12V 21W×1
Air filtration Sponge
Turn Lamps 12V 10W×4

1-9
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 1. GENERAL INFORMATION
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 18 16~18
Drive face nut 1 16 11.5~12
ACG. Flywheel nut 1 18 16~18
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0

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1. GENERAL INFORMATION
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

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1. GENERAL INFORMATION

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
carburetor sufficient carburetor
system clogged
● Malfunction of fuel pump
● Loosen or damaged fuel pump
Remove spark plug, install it vacuum hose
into spark plug cap, and perform a
spark test against engine ground. ● Fuel filter clogged

● 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

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1. GENERAL INFORMATION

B. Engine run sluggish (Speed does not pick up, lack of power)

Check and adjustment Fault condition Probable causes

.

Try gradual acceleration and

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

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
● Poor circuit on the cooling system
Continually drive in acceleration
or high speed
● Too much carbon deposited
in combustion chamber
No knock Knock ● Lean mixture
● Poor fuel quality
● Ignition timing too advanced

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 1. GENERAL INFORMATION
.

C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing (using

ignition lamp)

Normal Abnormal ● Incorrect ignition timing (malfunction of

CDI or AC alternator)

Adjust the air screw 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 and adjustment Fault condition Probable causes

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

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contents
1. GENERAL INFORMATION
.

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 rotating
● Connection parts in clutch and shaft worn out or burned
as engine in running)

● Drive belt worn out or deformation

● Weight roller worn out
Poor initial driving (Poor climbing
performance) ● Movable drive face shaft worn out
● 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

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 1. GENERAL INFORMATION
.

G. Loss power

Check and adjustment Fault condition Probable causes

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
● Ignition timing too advanced
● Excessive carbon deposited
in combustion chamber

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1. GENERAL INFORMATION
.

Lubrication Points

Acceleration cable/ Front & rear brake

lever pivot

Speedometer gear Wheel bearing

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1. GENERAL INFORMATION

Note:

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 Home page Contents
2. MAINTENANCE INFORMATION

Precautions in Operation ···················· 2-1 Brake System (Disk Brake) ················· 2-8
2
Periodical Maintenance Schedule ······ 2-2 Brake Light Switch/Starting Inhibitor
Fuel Lines ············································· 2-3 Switch ··················································· 2-9
Acceleration Operation ······················· 2-3 Headlight Beam Distance ···················· 2-10
Air Cleaner············································ 2-3 Clutch Disc Wear ································· 2-10
Spark Plug ············································ 2-3 Cushion················································· 2-10
Valve Clearance ··································· 2-4 Steering Handle···································· 2-11
Carburetor Idle Speed Adjustment····· 2-5 Wheel/Tire············································· 2-11
Ignition System ···································· 2-6 Nuts, Bolts Tightness ·························· 2-11
Cylinder Compression Pressure ········ 2-6 Special Tools List ································ 2-12
Drive Belt ·············································· 2-7

Precautions in Operation
Specification
Fuel Tank Capacity 18000±300 c.c.
Capacity 3700 c.c.
Engine Oil
Change 3200 c.c.
Capacity 350 c.c.
Transmission Gear oil
Change 350 c.c.
Engine + radiator 2200 c.c.
Capacity of coolant
Reservoir upper 1200 c.c.
Clearance of throttle valve 1~3 mm
Type NGK CR7E
Spark plug
Gap 0.7~0.8 mm
“F” Mark in idling speed BTDC 20º / 1500 rpm
Full timing advanced BTDC 51º / 6200 rpm
Idling speed 1500±100 rpm
Cylinder compression pressure 9.2 kgf/cm²
Valve clearance IN:0.10 ± 0.02 mm EX:0.15 ± 0.02 mm
Front AT25x8-12
Tire dimension
Rear AT25x10-12
Tire pressure (cold) 5 ±1 psi(Off road) / 10 ±1 psi (On road)

Battery 12V18Ah (type : MF battery)

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2. MAINTENANCE INFORMATION

Periodical Maintenance Schedule

INTERVAL MONTHS 1 3 6 12

Kms INITIAL 200 EVERY 1000 EVERY 2000 EVERY 4000

MILES INITIAL 120 EVERY 600 EVERY 1200 EVERY 2400

ITEM
Muffler Bolts and Exhaust Pipe
T T T T
Nuts
Valve Clearance I - I I
Air Cleaner - C C R
Engine Idle RPM I I I I
- - I I
Spark Plus
Replace Every 6000KM (4000 MILES)
Engine Oil R - R R
Oil Filter R - R R
- - I I
Front Differential Set Oil
Replace Every 2 Years
- - I I
Final Gear Oil
Replace Every 2 Years
C.V.T Belt - - I I
- I I I
Fuel Tube
Replace Every 4 Years
Throttle Cable Play I I I I
Brakes I I I I
- - I I
Brake Hose
Replace Every 4 Years
- I I I
Brake Fluid
Replace Every 2 Years
Tires - I I I
Suspensions - - I I
Steering System I I I I
Chassis Bolts and Nuts T T T T
General Lubrications - L L L

Code: C ~ Cleaning (replaced if necessary) I ~ Inspection, cleaning, and adjustment

L ~ Lubrication R ~ Replacement T ~ Tighten
Have your ATV checked, adjusted, and recorded maintenance data periodically by your TGB 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 obviously lower than normal.

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2. MAINTENANCE INFORMATION

Fuel Lines
Fuel tank
Remove the seat .Loosen 2 screws and 2 bolts
Remove the tank cover Carbureto
Check all lines, and replace it when they are r
deterioration, damage or leaking
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.
Vacuum hose
Fuel filter
Fuel hose
Acceleration Operation Cook Assy ;Fuel

Have a wide open of throttle valve as handle in any

position and release it to let back original (full Lock nut
closed) position.
Check handle if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth.
Measure the throttle lever free play in its flange
part.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment screw. Tighten
the fixing nut, and check acceleration operation
condition.
Free play: 1~3 mm.
Air Cleaner Throttle adjustment screw

Remove seat.
loosen 4 hooks from the air cleaner cover and Clamp Element
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.

Spark Plug Ground electrode

Recommended spark plug: CR7E
Remove spark plug cap. Central electrode
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap：0.7 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug 0.7~0.8mm
socket after installed.
Tighten torque: 1.0~1.2kgf-m

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2. MAINTENANCE INFORMATION

Valve Clearance
Caution
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove front fender, fuel tank cover and fuel tank.
Remove cylinder head cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position in
compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.

Valve clearance inspection and adjustment. Check

& adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.

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2. MAINTENANCE INFORMATION

Carburetor Idle Speed Adjustment Ignition cable

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 is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the ATV with onto neutral and 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: 1500 ± 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 1500±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe. Air adjustment screw Stopper screw
Adjust the air adjustment screw so that emission
value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm

Carburetor undersurface

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2. MAINTENANCE INFORMATION

Ignition System
Caution
● C.D.I ignition system is set by manufacturer so it
can not be adjusted.
● Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Connect tachometer and ignition light.
Start engine.
As engine in idle speed: 1600 rpm, aim at the mark
“F” with the ignition light. Then, it is means that
ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it is means that the
ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if
malfunction of these parts is found.

Cylinder Compression Pressure

Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 9.2 ± 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.

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2. MAINTENANCE INFORMATION

Drive Belt
Clamp strips
Loosen the 2 clamp strips of clutch cover, and then
remove the clutch cover vapor hose.
Remove 14 bolts of the clutch cover.

14bolts

Check if the belt is crack or worn out.

Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it. Teeth Width
Width limit: 26.8 mm or above

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2. MAINTENANCE INFORMATION

Brake System (Disk Brake)

Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.

Brake Fluid
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found
Caution
● 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

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2. MAINTENANCE INFORMATION

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/Starting Inhibitor

Brake switch
Switch
The brake light switch is to light up brake light as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.

Brake switch

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2. MAINTENANCE INFORMATION

Headlight Beam Distance

Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.
Caution
● To adjust the headlight beam follows related
regulations.
● Improper headlight beam adjustment will make
in coming driver dazzled or insufficient lighting.

Adjust screw

Clutch Shoe Wear

Clutch weight
Run the ATV and increase throttle valve opening
gradually to check clutch operation.
If the ATV is in forward moving and shaking, check
clutch disc condition. Replace it

Drive plate

Cushion
Warning
● Do not ride the ATV with poor cushion.
● Looseness, wear or damage cushion will make
poor stability and drive-ability.

Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Tighten all nuts and bolts.

Rear Cushion
Press down the rear cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.

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2. MAINTENANCE INFORMATION

Steering Handle
Caution
Check all wires and cables if they are interfered with
the rotation of steering handle bar.

Lift the front wheel out of ground.

Turn handle from right to left alternative and check if
turning is smoothly.
If handle turning is uneven and bending, or the handle
can be operated in vertical direction, then check the
handle top bearing.

Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.

Check if tire surface is ticked with nails, stones or other

materials.
Appointed tire pressure
Tire size Front tire Rear tire

Tire pressure as cold 5±1psi

Check if front and rear tires’ pressure is in normal.

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

Nuts, Bolts Tightness

Perform periodical maintenance in accord with the
Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamp, and wire
holders for security.

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 2. MAINTENANCE INFORMATION
Special Tools List

PARTS NO. : 440649 PARTS NO. : 440650

PARTS NAME : EXTENSION PULLER / PARTS NAME : BUSHING(924739)
REMOVER REMOVER

PARTS NO. : 440651 PARTS NO. : 440652

PARTS NAME : BEARING(924384) PARTS NAME : BEARING(924384)
REMOVER φ15 REMOVER φ20

PARTS NO. : 440653 PARTS NO. : 440654

PARTS NAME : BEARING(924384) PARTS NAME : BUSHING(924739)
REMOVER φ45 REMOVER

PARTS NO. : 440655 PARTS NO. : 440656

PARTS NAME : R CRANK CASE OIL SEAL PARTS NAME : L CRANK CASE OIL
(924168) INSTALLER SEAL REMOVER

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 2. MAINTENANCE INFORMATION

PARTS NO. : 440657 PARTS NO. : 440658

PARTS NAME : CRANK SHAFT HOLDER PARTS NAME : STARTER (924136)
HOLDER

PARTS NO. : 440659 PARTS NO. : 440660

PARTS NAME : FLYWHEEL REMOVER PARTS NAME : CHAIN WHEEL(924360)
& WASHER(924718)INSTALLER

PARTS NO. : 440661 PARTS NO. : 440662

PARTS NAME : PISTON & ROD PARTS NAME : CYLINDER HEAD
CONNECTING HOLDER VALVE GAP ADJUSTER

PARTS NO. : 440663 PARTS NO. : 440664

PARTS NAME : GEAR SHAFT (924253) PARTS NAME : FLYWHEEL PULLER
INSTALLER

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 2. MAINTENANCE INFORMATION

PARTS NO. : 440665 PARTS NO. : 440666

PARTS NAME : IDLER GEAR (924187) PARTS NAME : GEAR DRIVEN
PULLER (924146) HOLDER

PARTS NO. : 440667 PARTS NO. : 440668

PARTS NAME : CYLINDER HEAD VALVE PARTS NAME : UNIVERSAL JOINT
AND SPRING INSTALLER/REMOVER HEAD (924646)
INSTALLER

PARTS NO. : 440669 PARTS NO. : 440670

PARTS NAME : CHAIN WHEEL (924360) & PARTS NAME : ENGINE OIL FILTER
WASHER (924718) REMOVER (924153) INSTALLER / REMOVER

PARTS NO. : 440671 PARTS NO. : 924941

PARTS NAME : WET CLUTCH SCREW NUT PARTS NAME : MAINTENANCE TOOL
FIXER PACKAGE

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 3. LUBRICATION SYSTEM

Mechanism Diagram ······························ 3-1 Engine Oil ··············································· 3-3

Precautions in Operation ······················ 3-2 Engine Oil Strainer Clean ······················ 3-3

Troubleshooting ···································· 3-2 Oil Pump ················································· 3-4

Mechanism Diagram

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 3. LUBRICATION SYSTEM
Precautions in Operation
General Information
This chapter contains maintenance operation
for the engine oil pump and gear oil replacement.
Specifications
Engine oil quantity Disassembly: 3500 c.c.
Filter change:3200 c.c.
Change: 3000 c.c.
Oil viscosity SAE 10W-40

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 filter 1.2 kgf-m
Engine oil drain bolt 2.4 kgf-m

Troubleshooting

Low engine oil level Dirty oil

● Oil leaking ● No oil change in periodical
● 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

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 3. LUBRICATION SYSTEM

Engine Oil
Turn off engine, and park the ATV in flat surface
Check oil level with oil dipstick.
So not screw the dipstick into engine as checking.

If oil level is nearly low level, fill out recommended oil

to upper level.

Oil Change
4 screws

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：2.4 kgf-m Drain bolt

Engine Oil Strainer Clean O-ring

Drain engine oil out.

Remove oil strainer cap.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer cap.
Torque value：1.0~1.2 kgf-m
Engine oil capacity: 3000c.c. when replacing

Replace The Oil Filte r

Same as oil change, drain the oil out.
Remove the oil filter by special tool.
Apply engine oil lightly to the gasket of the new oil filter
when installation.
Torque value：1.2 kgf-m
Oil and filter change:3300c.c. when replacing

Install dipstick, start the engine for running several minutes. Gasket

Turn off engine, and check oil level again.

Check if engine oil leaks.

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 3. LUBRICATION SYSTEM
Oil Pump
Oil Pump Removal One way clutch

Remove the one way clutch.

Remove the clutch shoe.
Remove the snap ring.
Remove the washer.
Remove the oil pump driver gear.

Caution

The clutch shoe nut has left-hand threads.

Remove the snap ring.

Remove the washer.
Remove the oil pump driver gear. Snap ring
Remove the pin.
Remove the washer.

Make sure that pump shaft can be rotated freely. 3 screws

Remove 3 screws on the oil pump, and then
remove oil pump.

Pin

Oil Pump Disassembly

Remove the screws on oil pump cover and remove 1 screw
the cover.
Remove oil pump shaft roller and shaft.

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 3. LUBRICATION SYSTEM
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

Oil Pump Re-assembly

Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner
rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.

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 3. LUBRICATION SYSTEM
Tighten the oil pump screw.

Oil Pump Installation

Install the oil pump, and then tighten 3 screws.
Torque value：1.0kgf-m
Make sure that oil pump shaft can be rotated freely.

Install the washer.

Install the pin.
Install the oil driven gear.
Install the washer.
Install the snap ring.

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 4. FUEL SYSTEM

Mechanism Diagram ............................ 4-1 Throttle Valve .......................................4-6

Precautions in Operation..................... 4-2 Float Chamber......................................4-7
Trouble Diagnosis ................................ 4-3 Adjustment of Idle Speed ....................4-9
Carburetor Remove / Install ................ 4-4 Fuel Tank ..............................................4-10
Air Cut-Off Valve .................................. 4-5 Air Cleaner............................................4-11

Mechanism Diagram

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 4. FUEL SYSTEM

Precautions in Operation
General Information

Warning

Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.

Cautions

● 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 BSR33
Carburetor diameter Ø33mm
I.D. number 33_77
Fuel level 31.5±0.5mm
Main injector # 122.5
Idle injector # 35
Idle speed 1500 ± 100rpm
Throttle handle clearance 1~3 mm
Pilot screw 3 turns

Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge

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 4. FUEL SYSTEM

Trouble Diagnosis

Poor engine start Mixture too lean

No fuel in fuel tank ● Clogged fuel injector
● Vacuum piston stick and closed
Clogged fuel tube
● Malfunction of float valve
● Too much fuel in cylinder ● Fuel level too low in float chamber
● No spark from spark plug(malfunction of ignition ● Clogged fuel tank cap vent
system ) ● Clogged fuel filter
● Clogged air cleaner ● Obstructed fuel pipe
● Malfunction of carburetor chock ● Clogged air vent hose
● Malfunction of throttle operation ● Air existing in intake system

Stall after started

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

Rough idle
● Malfunction of ignition system
● Incorrect idle speed
● Malfunction of carburetor
● Dirty fuel

Intermittently misfire as acceleration

● Malfunction of ignition system

Late ignition timing

● Malfunction of ignition system
● Malfunction of carburetor

Power insufficiency and fuel consuming

● Fuel system clogged
● Malfunction of ignition system

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 4. FUEL SYSTEM
Carburetor Remove / Install
Removal
Remove the fuel tank.
Loose the carburetor clamp screws.

Clamp Clamp

Loosen the carburetor side cap 3 screws.

Remove cap.

Disconnect the throttle cable.

Disconnect the starter cable.

Remove the carburetor.

Installation
Install in reverse order of removal procedures.

Start cable

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 4. FUEL SYSTEM
Air Cut-Off Valve
Disassembly
Remove air vent hoses.
Remove fuel hose.
Remove vacuum hose.

Remove air cut-off valve cover 2 screws，spring

and valve.

2 screws

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.
Air cut-off valve

Assembly
Install in reverse order of removal procedures.

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 4. FUEL SYSTEM
Throttle Valve
Disassembly
2 screws
Remove carburetor top comp.

Remove the spring，holder，needle set.jet and

piston valve.

Remove the cable adjuster assy.

Cable adjuster assy

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 4. FUEL SYSTEM
Float Chamber
Disassembly
Remove 4 mounting screws and remove float
chamber cover.

4 screws

Remove the screw, float pin, float and

float valve. Float

Screw

Float valve

Pin

Inspection Pin Float

Check float valve and valve seat for damage,

blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.

Float valve

Check for wear or damage

Cautions

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.

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 4. FUEL SYSTEM
Remove main jet, needle jet holder, needle jet, Main jet
slow jet and air adjustment screw.
Slow jet Starter jet
Cautions

T ake 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.
Air adjustment jet

Assembly Air adjustment screw Main jet

Install main jet, needle jet holder, needle jet, slow jet
and air adjustment screw.

Cautions Starter jet

Set the air adjustment screw in according to number Slow jet

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.
Float gauge
Fuel level: 31.5±0.5mm

Installation of carburetor
Install carburetor in the reverse order of removal.
Following adjustments must be made after installation.
˙Throttle cable adjustment.
˙Idle adjustment
Lock nut

Throttle adjustment screw

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 4. FUEL SYSTEM
Parking brake
Adjustment of Idle Speed

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.
Throttle stopper screw
Standard turns: 3 turns
Warm up engine; adjust the throttle stopper screw of
throttle valve to standard RPM.
Idle speed rpm: 1500 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust front
end. Press test key on the analyzer.
Adjust the pilot screw and read CO reading on the
analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments; make sure rpm and
CO value are in standard value after engine running in
stable. If rpm and CO value fluctuated, repeat the
procedures described above for adjusting to standard
value.

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 4. FUEL SYSTEM

Fuel Tank
Fuel unit removal
Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13) Disconnect fuel
unit coupler. 4 bolts
Remove fuel unit (4 bolts).

Caution

● Do not bend the float arm of fuel unit.

● Do not fill out too much fuel to fuel tank.

Fuel unit inspection (Refer to electrical equipment

chapter 17).

Fuel unit installation

Install the gauge in the reverse order of removal.

Caution

Do not forget to install the gasket of fuel unit or damage

it.

Fuel tank removal

Open the seat.
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender.
(Covers remove please refer chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts). Fuel tube Vacuum tube
Remove the fuel tube.
Remove fuel tank front and rear side 4 bolts, and then
Front
remove fuel tank.
Installation
Install the tank in the reverse order of removal.

Rear 4 bolts

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 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 regulator.
Remove the air cleaner (5 bolts).

Installation
Install the tank in the reverse order of removal.

Cleaning air cleaner element

Remove the air cleaner cover (4 catch hooks).

4 hooks
Remove element mounting screw.
Loosen the clamp strip 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
1 screw

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.
Clamp

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 4. FUEL SYSTEM

Notes:

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 5. ENGINE REMOVAL

Precautions in Operation ..................... 5-1 Engine Disassembly........................... 5-10

Removal of Engine ............................... 5-2 Front differential set oil...................... 5-12
Engine Installation ................................ 5-7 Final gear set oil ................................. 5-13

Precautions in Operation
General Information
● The engine has to be supported with special service tools that can be lifted or adjustable.
● Engine shall be removal in the conditions of necessary repair or adjustment to the only. 5
● The following parts can be serviced as engine mounted on
frame: Carburetor.
Drive pulley, drive belt, clutch, and movable drive face
assembly. Start motor.
AC. Generator, oil pump and start one way clutch.
Crankcase RH cover.
Clutch housing assy.
Unidirectional clutch.
Clutch assy.

Specification
Item Capacity

Replacement 3100 c.c.

Engine oil capacity Oil and oil filter change 3300 c.c.

Disassembly 3700 c.c.

Engine& radiator 2200 c.c.

Coolant capacity Reservoir 1200 c.c.

Total 3400 c.c.

Torque Value
Engine hanger bolt 55N-m(5.5kgf-m or 40lb-ft)
Exhaust muffler mounting bolt 2.8~3.2kgf-m
Exhaust muffler connection nut 1.0~1.4kgf-m

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 5. ENGINE REMOVAL

Engine Removal
Before taking the engine out of the frame.
Clean and wash the engine using A steam cleaner.
Engine removal is explained in the following.
Steps.
Reinstall the engine by reversing the removal procedure.
‧Before removal the engine. Drain engine oil
‧Remove the seat.
‧Remove the seat lock plate.
‧Remove battery negative post (－).
‧Remove battery positive post (＋).

Remove the starter motor wire.

○
+

Caution

Before remove battery positive post, Be sure remove ○

-
negative post (－) first.

Remove the front fender side cover. (L and R)

Remove the footrest nut guard. (L and R)

Remove the Fuel tank cover

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 5. ENGINE REMOVAL

Remove the gearshift lever.

Remove the fuel hose and vacuum hose.

Fuel pipe

Vacuum pipe

Remove the air cleaner.

Air cleaner

Remove the carburetor.

Carburetor

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 5. ENGINE REMOVAL
Remove the speedometer cable.

Remove the gearshift mud.

Remove the connector of lead wire.

Remove the signal generator lead wire connector and
generator lead wire connector.

Remove the spark plug cap.

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 5. ENGINE REMOVAL
Remove the right footrest.
Remove the brake pedal.

Remove the L and R muffler.

Remove the exhaust pipe.

Remove the front and rear tube.

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 5. ENGINE REMOVAL

Remove the front and rear shaft bolts.

Remove the engine mounting bolts and nuts.

Remove the engine mounting bracket.
Remove the engine bolsters.

Remove the flange bolts and take down engine bolster.

Remove the engine from the right side.

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 5. ENGINE REMOVAL

Engine installation
Remove the engine in the reverse order of engine
removal.

Caution
The engine mounting nuts are self-locking
once the nut was been removed it is no
longer of any use.
Be sure to use new nuts. For every time
engine installation and tighten them

Torque value： 55 N-m (5.5kgf-m or 40lb-ft)

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 5. ENGINE REMOVAL

Torque valve:
Engine mounting bracket bolt 26 N-m
(2.6kgf-m,or 19lb-ft)
Apply sealant to the screw.
Apply sealant to the propeller shaft flange coupling bolts.
Tighten them to the standard torque.
Apply sealant to the front propeller shaft flange coupling bolts.
Tighten them to the standard torque.

Torque value:
Front and rear propeller shaft flange coupling bolt:
45N-m(4.5kgf-m, 32.5lb-ft)

Install the new gasket.

.

Apply sealant to the muffler mounting bolt

Install muffler. Pay attention don’t damage the
connector.
Tighten the exhaust pipe nuts and muffler bolts with
specified torque.

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 5. ENGINE REMOVAL

Exhaust pipe nut:

Connector bolt:
Muffler mounting bolt: 25N-m (2.5kgf-m, 16.5lb-ft)

Apply sealant to the muffler mounting bolt to the muffler

fixed bolts and tighten them.

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 5. ENGINE REMOVAL
Engine Disassembly
Remove starter motor wire.

Remove the spark plug cap.

Remove the thermostat.

Remove the spring bolt and remove the cam chain

pensioner adjuster assy.

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 5. ENGINE REMOVAL

Remove the engine oil pipe bolts.

Remove the recoil starter.

Remove the valve timing check plug.

Turn the crankshaft and let the “T.D.C line” on the rotor
with index mark.

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 5. ENGINE REMOVAL

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 5. ENGINE REMOVAL

Front differential set oil

Caution

Be sure the differential set temperature below 35

SAE#90 hypoid gear oil

Oil standard:
Oil capacity: 300c.c.

Remove the under cover.

Place an oil pan below the differential set case.

Drain nut

Remove drain bolt, filler nut and drain oil out.

Tighten the drain bolt to specified torque.
Pour the oil through the filler hole.
Tighten the filler cap to the specified torque,

Drain bolt: 33N-m

Oil filler nut: 3.6N-m

Oil filler nut

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 5. ENGINE REMOVAL

Final gear set oil

Remove the final gear set under cover.

Place an oil pan below the case of final gear set.

Remove the drain blot.
Remove the filler cap
Drain oil nut.

Tighten the drain blot.

Remove the oil check bolt.
Pour the specified oil through the filler hole. until the oil
lever reach the hole lower lever.
Tighten the oil level bolt.
Tighten the filler cap.
Final gear oil drain boil:
34 N-m (3.4 kgf-m, 24 lb-ft)
Final gear oil filler cap:
34 N-m (3.4 kgf-m, 24 lb-ft)

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 5. ENGINE REMOVAL

Note：

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 Home page Contents

6. CYLINDER HEAD/VALVE

Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-10

Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-11
Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-13
Cylinder Head Removal ······················ 6-4 Cylinder Head Installation ················· 6-14
Cylinder Head Inspection ··················· 6-7 Valve Clearance Adjustment ············· 6-16

Mechanism Diagram

6
1.0~1.4 kgf-m

1.0~1.4kgf-m

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6. CYLINDER HEAD/VALVE

Precautions in Operation
General Information
● This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
● Cylinder head service can be carried out when engine is in frame.

Specification
Item Standard Limit
Compression pressure 10±2.5 kg/cm2 ---
Intake 33.442 33.392
Camshaft Height of cam lobe
Exhaust 33.327 33.277
ID of valve rocker arm 12~12.018 12.080
Rocker arm
OD of valve rocker arm shaft 11.966~11.984 11.936
Intake 4.975~4.990 4.900
OD of valve stem
Exhaust 4.950~4.975 4.900
ID of valve guide 5.000~5.012 5.030

Clearance between Intake 0.010~0.037 0.080

valve stem and guide Exhaust 0.025~0.062 0.100
Valve
Free length of valve Inner 36 32.5
spring outer 39.5 36.0
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 2.0~2.2kgf-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

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6. CYLINDER HEAD/VALVE

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

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6. CYLINDER HEAD/VALVE

Cylinder Head Removal

Remove engine. (Refer to chapter 5) 2 Nuts
Remove the inlet pipe (2 nuts).

Remove 1 bolt of thermostat and then remove the

thermostat. Thermostat bolts
Remove hole bolt and spring for the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).

Tensioner bolts

Spark plug
Remove spark plug.

Remove the nuts of cylinder head.(2 nuts)

Remove the screws of cylinder head.(2 screws)

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6. CYLINDER HEAD/VAL

T
Remove cylinder head cover, and hole bolts(3 bolts)

3 bolts

6 bolts
Remove fix stand for spindle .cam (6 bolts).

Remove cam sprocket bolts and then remove Chain tensioner

thesprocket by prying chain out.

1 1bolt
bolts
Remove cam chain tensioner and hole bolt.

2 bolts

Cam shafts
Remove cam shafts.
Remove Rocker arm and cam shaft
puller

Rocker arm
shaft and cam
shaft puller

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6. CYLINDER HEAD/VALVE
Remove the 4 cylinder head mounting bolts from 4 Nuts
cylinder head right side, and then remove 4 bolts
and washers from cylinder head upper side.
Remove the cylinder head.

4 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.
Special Service Tool:
Valve cotter remove & assembly tool
Valve cotterremove
and assembly tool

Inlet valve Inner spring Spring retainer

Cotter
Exhaust valve Outer spring

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6. CYLINDER HEAD/VALVE
Remove valve stem seals.
Valve stem seals

Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder
head matching surface.

Caution
Do not damage the matching surface of cylinder
head.

Cylinder Head Inspection

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.05 mm

Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 33.392mm
EX: Replacement when less than 33.277mm
Inspect the camshaft bearing for looseness or
wear out. If any damage, replace whole set of
camshaft and bearing.

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6. CYLINDER HEAD/VALVE

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 32.5 mm
Outer spring 36.0 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

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6. CYLINDER HEAD/VALVE

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.
Service limit: 5.03 mm
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.10 mm
EX→0.15 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.

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6. CYLINDER HEAD/VALVE

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
● Using cutting oil when correcting valve guide Valve guide reamer 5.0 mm
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

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6. CYLINDER HEAD/VALVE

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
seat chamfer cutter. Roughness

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.
Caution 45°

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°

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6. CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower parts out.
Remove the cutter and check new valve seat.
Old valve seat width

60°

Use 45° cutter to grind the valve seat to specified

width.
1.0mm
Caution
Make sure that all roughness and uneven faces
had been ground.

Grind valve seat again if necessary.

45°

Coat the valve seat surface with red paint.

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

If the contact surface too high, grind the valve seat

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

If the contact surface too low, grind the valve seat

with 60° cutter.
Then, grind the valve seat to specified width.

60°

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6. CYLINDER HEAD/VALVE
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and valve
after ground.

Cylinder Head Reassembly Lubricate

valve stem with engine oil, and then insert the
valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Caution
The closed coils of valve spring should face down
to combustion chamber.

Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.

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

Special Service Tool:

Valve cotter remove & assembly tool Valve cotter remove
anassembly tool

Tap the valve stems gently with a plastic hammer

to make sure valve retainer and valve cotter is
settled.
Caution
Place and hold cylinder head on to working table
so that can prevent from valve damaged.

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6. CYLINDER HEAD/VALVE

Cylinder Head Installation Gasket

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

Install 4 washers and tighten 4 bolts on the cylinder 4 bolts

head upper side, and then tighten 4 cylinder head
nuts to the specified torque.(2 M6,2 M8).
Cylinder head bolt
Bolt: 3.6~4.0kgf-m

Screw: M6:1.0~1.4kgf-m
M6 screws M8 nut
Nut: M8: 2.0~2.5kgf-m

Install camshaft into cylinder head.

Install rocker arm, rocker arm shaft.

6 bolts
Install cam chain tensioner into cylinder head

Install 6 bolts on the stand for spindle,cam.

Bolt: 1.0~1.4 kgf-m.

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6. CYLINDER HEAD/VALVE
Install cam chain on to sprocket and align the
Timing mark
timing mark on the sprocket with that of cylinder
head. 2 bolts
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts.
Caution
Make sure timing marks are matched.
Install the lock washer so that it is covering the
locating pin.
Bend up the washer tongue positively to
lock bolts.

B
A

Align the line Ⓐ on the generator rotor

with the index mark Ⓑ on the crankcase.

Loosen auto tensioner adjustment bolt and

remove bolt and spring.
Install tensioner and install spring and adjustment
bolt.

Install thermostat(2 bolts)

Thermostat bolts Tensioner adjustmet bolt

Install cylinder cover (3 bolts).

3 bolts

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6. CYLINDER HEAD/VALVE

Spark plug
Install and tighten spark plug
Torque value: 1.0~2.0kgf-m
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can not
be exceeded standard value in order to avoid
causing cylinder head deformation, engine noise
and leaking so that motorcycle’s performance be
effected.
Install the engine onto frame (refer chapter 5).

Valve Clearance Adjustment

Remove cylinder head cover.(3 bolts)

Align the line Ⓐ on the generator rotor B
with the index mark Ⓑ on the A
crankcase.

Timing mark

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
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 .
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 in idle speed. Do not accelerate
engine speed.

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 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

7-1
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 T
7. CYLINDER/PISTON

Precautions in Operation
General Information

Specification Unit：mm
Item Standard Limit
ID 93.022~93.052 93.100
Cylinder
Bend - 0.050
Clearance between piston Top ring 0.04~0.075 0.011
rings nd
2 ring 0.02~0.055 0.090
Top ring 0.150~0.300 0.500
Piston/ nd
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 ) 92.30~92.50 92.25
Clearance between piston and cylinder 0.04~0.058 0.120
ID of piston pin boss 22.001~22.006 22.020
OD of piston pin 21.996~22.000 21.960
Clearance between piston and piston pin 0.001~0.010 0.020
ID of connecting rod small-end 22.002~22.01 22.040

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

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7. CYLINDER/PISTON

Cylinder and Piston Removal

Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.

Coolant hose

Cover the holes of crankcase and cam chain with a

piece of cloth.
Remove piston pin clip, and then remove piston
pin and piston.

Remove cylinder gasket and dowel pin.

Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.
Caution
● Soap the residues into solvent so that the Dowel pins
residues can be removed more easily.

Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective in
Top
the cylinder.
Center
Service limit: 92.100 mm Bottom

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7. CYLINDER/PISTON

Check cylinder if warp.

Service limit: 0.05 mm

Measure clearance between piston rings and

grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm

Remove piston rings

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

Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm

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7. CYLINDER/PISTON

Measure the outer diameter of piston pin.

Service Limit: 21.960 mm

Measure the inner diameter of connecting rod

small end.
Service Limit: 22.065 mm

Measure the inner diameter of piston pin hole.

Service Limit: 22.020 mm
Calculate clearance between piston pin and its
hole.
Service Limit: 0. 2 mm

Measure piston outer diameter.

Caution
The measurement position is 8 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：92.250 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.

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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.

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7. CYLINDER/PISTON
Clean up all residues and foreign materials on
the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.

Piston Installation mark

Install piston and piston pin, and place the

marks on the piston top side forward to
exhaust valve.

Install new piston pin clip.

Caution
Cutout
● 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 as operation.

Cylinder Installation
Install dowel pins and new gasket.

Dowel pins

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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

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 Home page Contents
8. V-BELT DRIVING SYSTEM

Mechanism Diagram ··························· 8-1 Drive Belt ··············································8-5

Maintenance Description ···················· 8-2 Drive Face·············································8-7
Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley·················· 8-10
Clutch Cover ························· 8-3

Mechanism Diagram

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8. V-BELT DRIVING SYSTEM

Maintenance Description
Precautions in Operation
General Information
● Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
● Drive belt and drive pulley must be free of grease.

Specification
Item Standard value Limit
Driving belt width 28.500 mm 27.000 mm
OD of movable drive face boss 26.946~26.980 mm 26.926 mm
ID of movable drive face 27.000~27.040 mm 27.060 mm
OD of weight roller 25.800~26.000 mm 25.000 mm
ID of clutch outer 140.000~140.200 mm 140.500 mm
Free length of driven pulley spring 230.000 mm 225.000 mm
OD of driven pulley boss 44.965~44.985 mm 40.935 mm
ID of driven face 45.000~45.035 mm 45.600 mm
Weight of weight roller 18.300~18.500 g 18.800 g

Torque value Special Service Tools

● Drive face nut: 10~12kgf-m Clutch spring compressor:
● Clutch outer nut: 10~12.0kgf-m Inner bearing puller: TGB-
● Drive plate nut: 10~12kgf-m Clutch nut wrench 27 x 15 mm: TGB-
Universal holder: TGB-
Bearing driver: TGB-

Trouble Diagnosis
Engine can be started but motorcycle can Insufficient horsepower or poor high
not be moved speed performance
1. Worn drive Belt 1. Worn drive belt
2. Worn drive face 2. Insufficient spring force of driven pulley
3. Worn or damaged clutch weight 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly

Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight

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8. V-BELT DRIVING SYSTEM

Clutch Cover
Clutch cover removal
Release the 2 clamp strips of clutch cover ducts,
and then remove the ducts.
Remove clutch cover. (14 bolts)
Remove 2 dowel pin and gasket.

14 bolts

Clutch cover install

Install left clutch cover in the reverse
procedures of removal.

Dowel pins

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8. V-BELT DRIVING SYSTEM

Clutch over inspection

Check bearing on clutch 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.

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8. V-BELT DRIVING SYSTEM

Drive Belt Universal holder

Removal
Remove left crankcase cover.
Hold drive face with universal holder, and remove
nut and drive face.
Special Tool：universal holder

Hold clutch outer with universal holder, and

Universal holder
remove nut, and clutch outer.

Caution

● Using special service tools for tightening or

loosening the nut.
● Fixed rear wheel or rear brake will damage
reduction gear system.

Push the drive belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove drive belt.
Remove the drive belt from the groove of driven
pulley.

Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram shown.
Service Limit: 27.0 mm
Replace the belt if exceeds the service limit.

Caution

● Using the genuine parts for replacement.

● The surfaces of drive belt or pulley must be
free of grease.
● Clean up all grease or dirt before installation.

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8. V-BELT DRIVING SYSTEM

Installation Driven face

Caution
● Pull out driven face to avoid it closing.
● Cannot oppress friction plate comp in order
to avoid creates the distortion or the damage.
Install drive belt onto driven pulley.

Install the driven pulley that has installed the belt

onto drive shaft.
On the drive belt another end to the movable drive
face.

Install the clutch outer . Hold the clutch outer whit

Universal holder
universal holder, and then tighten nut to specified
torque value. Torque value: 10~12kgf-m

Install the drive face, washer and drive face nut.

Hold drive face with universal holder, and then
Universal holder
tighten nut to specified torque value.
Torque value: 10~12kgf-m

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8. V-BELT DRIVING SYSTEM

Drive Face Universal holder

Removal
Remove left crankcase cover.
Hold drive face with universal holder, and then
remove drive face nut.
Remove drive face and drive belt.

Remove movable drive face comp and drive face

Movable drive face
boss from crankshaft.

Drive face boss

Remove ramp plate.

Ramp plate

Remove weight rollers from movable drive face. Movable drive face

Weight roller

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8. V-BELT DRIVING SYSTEM

Inspection
Weight roller
The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 25.0 mm
Weight: 18.5g

Check if drive face boss is worn or damaged and Movable drive face

replace it if necessary.
Measure the outer diameter of movable drive face
Drive face boss
boss, and replace it if it exceed service limit.
Service limit: 26.962 mm
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit:27.060 mm
Reassembly/installation
Install weight rollers.
Weight roller
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.

Closure surface

Install ramp plate. Ramp plate

Guide collar

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8. V-BELT DRIVING SYSTEM

With 4~5g grease spreads wipes drives in the

movable drive face axis hole.
Install drive face boss.

Caution
The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.

Drive face boss

Driven pulley installation(By 2 screw)

Press drive belt into pulley groove, and then pull
the belt onto drive shaft. Press down

Drive belt

Install Movable drive face, and nut.

Loosen the 2 screw.

Caution
Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.
Hold drives face with universal holder.
Tighten nut to specified torque.
Torque value: 10~12kgf-m
Install left crankcase cover.

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8. V-BELT DRIVING SYSTEM

Clutch Outer/Driven Pulley

Clutch nut wrench
Disassembly
Remove drive belt, and driven pulley. Install clutch
spring compressor onto the pulley assembly, and
operate the compressor to let the wrench be
installed more easily.

Caution
Do not press the compressor too much.
Clutch spring compressor
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
movable driven sheave and spring from driven
pulley.

Remove seal collar from driven pulley.

Collar

Remove guide pin, guide pin roller, and movable Movable driven face Guide pin
Seal
driven face, and then remove O-ring & oil seal
seat from movable driven face.

O-ring Guide pin Guide pin roller

Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 140.50 mm

Clutch outer

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8. V-BELT DRIVING SYSTEM

Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 225 mm

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 44.93 mm
Inner diameter 45.60 mm Guide pin groove
Movable driven face

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 8. V-BELT DRIVING SYSTEM

Installation of Clutch OUTER/Driven Pulley

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

O-ring Specified grease

Install the movable driven face onto driven face.

Movable driven face Guide pin
Install the guide pin and guide pin roller. Oil seal

O-ring Guide pin

Guide pin roller

Install the collar.

Collar

Install friction plate, spring and into clutch spring

compressor, and press down the assembly by
Clutch nut wrench
turning manual lever until mounting nut that can be
installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m
Install driven pulley and drive belt onto drive shaft.
Clutch spring compressor

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 9. FINAL DRIVING MECHANISM

Transmission system
Remove
Remove the driven output rear shaft and front shaft.
Separate the driven output rear shaft and front shaft.

Remove the c-ring from the universal joint assy.

Remove the driven output front shaft with a chisel.

Remove the joint parts.

Using a vise let the driven output rear shaft held in

movable.

Replace the removed nut and use a new one

when reassemble.

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 9. FINAL DRIVING MECHANISM

Unlock the nut with a chisel

Remove the nut.

Remove the bearing by tapping with the hammer and

tool.
Remove the universal joint assy.
Remove the parts.

Rear universal joint disassembly.

Remove the c-rings from the universal joint assy.

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 9. FINAL DRIVING MECHANISM

Remove the parts.

Using a vise held the driven output rear shaft and

remove the nut.

When reassemble with a new nut.

Unlock the nut with a chisel.

Must be replaced the new bearing and oil seal
when reassembly

Remove the NTT from Driven output front shaft

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 9. FINAL DRIVING MECHANISM

Disassembly the bevel gear

Unlock the nut with a chisel.

Using a vise held the driven output front shaft and

remove the nut.
Remove the washer driven bevel gear and bearing.

Remove the parts.

Replace the new nut fro reassemble.

Must be replaced the new bearing and oil seal for

reassemble.

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 9. FINAL DRIVING MECHANISM

Inspection:
Check the bearings and joint surface. If any defects
(damage, wear or scuffing) replace the bearings and
joint assy.
Install the parts as show.

Insert the bearing to the joint and turning the joint. If

excessive play is noted, must be replace the new
bearing.

Reassemble the driven output rear shaft and front shaft.

In the reverse order of disassembly. Pay attention to the
following items.

Stake the nut with a punch. After The tooth contact and
backlash have been adjusted and checked.

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 9. FINAL DRIVING MECHANISM

Reassembly driven output rear shaft

Before reassembly thoroughly clean all parts with
solvent.

Using a vise hold the bevel gear.

Tighten the new nut to the specified torque.

Torque: 100N-m (10kgf-m, 73lb-ft)

Stake the nut with a punch.

Apply grease to the bearing and seal lip.

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 9. FINAL DRIVING MECHANISM

Apply grease to the oil seal lip.

Install the oil seal to the joint yoke.
(The oil seal lip should be positioned joint yoke side.)
Using a vise hold the driven output rear shaft. Tighten
the new nut to the specified torque.

Torque: 100N-m (10kgf-m, 73lb-ft)

Stake the nut with a punch. After The tooth contact and
backlash have been adjusted and checked.

Put the bearing rings and shaft in the crankcase.

Position the bearing pin to the pin grooves in the
crankcase.
Check the gear backlash and tooth contact correctly.
(Tooth face contact 80% up)
Remove the driven output Rear/Front shaft.
Remove the bevel gear.
Clean tooth face.
Tighten the bevel gear nut and output rear shaft to the
specified torque.
Torque: 100N-m(10kgf-m, 73lb-ft)

Stake the nut with a punch

The bearing knock-pin○

※ should be outside.

○
※

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 9. FINAL DRIVING MECHANISM

Tooth contact: face contact 80% up ○

※

Using the tool to install the bearings and joint.

Reassemble the universal joint. When the tooth contact
and backlash have been adjusted or checked.

Tool: 440668

Install the new c-ring by tapping and hammer. ( copper )

Using the new c-ring for reassembly.

After reassembling the universal joint assy. Check the

joint assy. Movement smoothly. If movement have a
large resistance. Tapping the bearing with the plastic
mallet lightly.

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 9. FINAL DRIVING MECHANISM

FINAL ASSEMBLY
l After adjusting tooth contact correctly, remove the
Front and rear output shafts and drive bevel gear.

l Clean off any dye or paste from the gear teeth, and
lubricate the teeth with engine oil.

l Tighten the drive bevel gear nut and rear out put
Shaft nut to the specified torque.

Rear output shaft nut:100 N．M(10.0 kgf- m, 73 lb-ft)

Drive bevel gear nut:100 N．M(10.0 kgf- m, 73 lb-ft) Ⓐ

l Stake the collar of the nut Ⓐ into the notch in the

shaft.
Ⓐ

NOTE:
After the tooth contact have been checked and adjusted
reassemble the joint.

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 9. FINAL DRIVING MECHANISM

ENGINE REASSEMBLY

NOTE:
When reassembly the engine pay attention, apply engine
oil to sliding parts and running parts before
re-assembling.
CAUTION

Be sure keep the drive belt, drive face and driven

face away from any greasy matter.

l Install the output shaft assembly with a plastic mallet.

l Install the shim drive bevel gear and washer.

l Tighten the bevel gear nut to the specified torque.

Bevel gear nut torque:100 N．M(10.0 kgf- m, 73 lb-ft)

l Use a center punch stake the nut.

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 9. FINAL DRIVING MECHANISM

DRIVE TRAIN
l Install the rear and front out put shaft.
l Install the C-ring.

NOTE:
Must fit the pins on the bearing into the groove of the
crankcase.

TRANSFER/GEARSHIFT
l Install the transfer related parts.

l Install the spacer spring, shaft and reverse idle gear.

l Install the washer.

CRANKCASE
l Clean R and L crankcase surfaces with cleaning
solvent.
l Fit the dowel pins on the hole.
l Apply engine oil to the gears and conrod.

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 9. FINAL DRIVING MECHANISM

Note:

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 10. ALTERNATOR/STARTING CLUTCH

Mechanism Diagram ··························· 10-1 Flywheel Removal ································ 10-4

Precautions in Operation···················· 10-2 Starting Clutch ····································· 10-5
Right Crankcase Cover Removal ······· 10-3 Flywheel Installation ···························· 10-7
A.C.G. Set Removal ····························· 10-3 A.C.G. Set Installation·························· 10-8
Lift Cover Bearing································ 10-3 Right Crankcase Cover Installation···· 10-8

Mechanism Diagram
5

10

4.0~5.0kgf-m
1.0~1.5kgf-m

1.0~1.5kgf-m

0.8~1.2kgf-m 3.0~3.5kgf-m

16~18kgf-m

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 10. ALTERNATOR/STARTING CLUTCH

Precautions in Operation
General information
● Refer to chapter 17: The troubleshooting and inspection of alternator
● Refer to chapter 17: The service procedures and precaution items of starter motor

Specification
Item Standard value (mm) Limit (mm)
ID of starting clutch gear 29

OD of starting clutch gear 52.548~52.445

Torque value

Flywheel nut 16~18kgf-m

Not to be reused should be replaced when disassembled
Starting clutch hexagon bolt 1.2~1.5kgf-m with adhesive
8 mm bolts 2.8~3.0kgf-m
12 mm bolts 1.0~1.4kgf-m

Tools
Special tools
A.C.G. flywheel puller: 440659

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 10. ALTERNATOR/STARTING CLUTCH

Left Crankcase Cover Removal

Remove left footrest. 15 bolts
Drain out the engine oil and coolant, and then remove
coolant hoses.
Remove water pump (2 bolts).
Remove 15 bolts from the left crankcase cover.
Remove the left crankcase cover.
Remove dowel pin and gasket.

Water pump bolts

A.C.G. Set Removal Wire

Remove 3 mounted screws from pulse generator and 3 bolts
then remove it.
Remove 3 screws from left crankcase cover and then
remove generator coil set.

3 screws

Left Cover Bearing

Inspection
Rotate the bearing with finger to check if the bearing
rotation is in smooth and silent.
Check if the bearing outer parts are closed and fixed.
Replace it if necessary.

Remove the bearing.

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 10. ALTERNATOR/STARTING CLUTCH

Check the oil seal for wear or damage.

Oil seal
Replace it if necessary.

Install a new one bearing (16005) by bearing driver.

Bearing

Flywheel Removal
Remove left crankcase cover. Flywheel nut

Remove starter reduction gear and shaft. Pull out

flywheel with A.C.G. flywheel puller.
Special tool:
A.C.G. Flywheel puller
Remove flywheel and starting driven gear.

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 10. ALTERNATOR/STARTING CLUTCH

Starting Clutch
Starting Clutch Inspection
ID
Remove starting clutch driven gear. Check the
gear for wear or damage.
Measure the ID and OD of the starting clutch driven gear.
Service Limit: ID: 29 mm
OD: 52.54mm

OD

Check the starting reduction gear and shaft for wear or

damage.

Check each roller for wear or damage.

Install starting clutch driven gear onto one way clutch.

Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in C.C.W
direction freely, but not C.W direction.
(View as shown in this figure.)

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 10. ALTERNATOR/STARTING CLUTCH

One way clutch removal

Remove starting driven gear.

Starting driven gear

Remove 6 socket bolts, and then remove one way clutch.

6 socket bolts

.
One way clutch

Starting driven gear

One way clutch Installation

Install the components in the reverse procedures of 6 socket bolts
removal.

Caution
Tape a tightening tape onto the thread of
hexagon bolt.

Torque value: 3.0~3.5kgf-m

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 10. ALTERNATOR/STARTING CLUTCH

Install starting driven gear.

Starting driven gear

Flywheel Installation
Align the key on crankshaft with the flywheel groove, and Groove
then install the flywheel.

Hold the flywheel by drive face with universal holder,

and tighten flywheel nut.

Flywheel nut not to be reused should

be replaced when disassembled
Torque value:16~18kgf-m
Special tool:
Universal Holder

Install reduction gear shaft and reduction gear.

Reduction gear

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 10. ALTERNATOR/STARTING CLUTCH

A.C.G. Set Installation Wire

3 bolts
Install the A.C.G. coil set onto right crankcase cover (3
screws).
Install pulse generator (3 screws).
Tie the wire harness securely onto the indent of
crankcase.

Make sure that the wire harness is placed under

pulse generator.

3 screws

Left Crankcase Cover Installation

Install dowel pin and new gasket.

Dowel pin

Remove water pump cover.

Install left crankcase cover onto the crankcase.

Note: Align the water pump shaft indent with the water
pump gear shaft.

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 10. ALTERNATOR/STARTING CLUTCH
Install left crankcase cover (15 screws).
Install the dowel pin, new gasket and water pump cover 15 bolts
onto left crankcase cover.

Water pump bolts

Install the water pipe.

Install the recoil starter assy.(4 bolts).

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 10. ALTERNATOR/STARTING CLUTCH

Note:

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 11. CRANKSHAFT / CRANKCASE

L CASE

R CASE

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 11. CRANKSHAFT / CRANKCASE

Oil SEAL
l Remove the oil seal with the special tool.

Oil seal remover 440656

l Install the oil seal with the special tool.

Bearing installer set 440655
CAUTION
Change the new oil seal to prevent oil leakage.

NOTE:
Be sure the stamped mark on the oil seal faces outside.

OIL SEPARATOR
l When installing the oil guide plate, apply a small
quantity of Loctite 262 TM (Thread locker) to the screw.

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 11. CRANKSHAFT / CRANKCASE

BEARING REASEMBLY
l Install the bearing.

NOTE:
Be sure The sealed cover of the bearing must face
outside.

l Install the chuck,Bearing.

NOTE:
When installing the Bearing chuck,apply a small quantity
of Loctite 262TM (Thread locker) to the screws.

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 11. CRANKSHAFT / CRANKCASE

DRIVE BELT COVER

l Remove the snap ring with the snap ring pliers.

NOTE:
If any damage the bearing,replace the new one.

l Remove the bearing.

REASSEMBLY
l Install the bearing.

l Install the snap ring with snap ring pliers.

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 11. CRANKSHAFT / CRANKCASE

L CRANK CASE COVER

l Remove the oil pressure valve
When installing the oil valve ,tighten it to the specified
Torque.

Oil pressure value:25N．M(2.5kgf-m,17lb-ft)

Using an shaped tool to check the oil pressure valve

Operation. If the piston does not operate, replace the new
one.

ASSEMBLY
Remove the generator stator.

Remove the oil seal retainer of crank case cover.

NOTE:
If the bearing is not abnormal noise, these is not
necessary to replace the new one.

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 11. CRANKSHAFT / CRANKCASE
l Remove the oil seal.

REASSEMBLY
l Install the bearing.

l Apply Grease to the bearing,O-ring and Oil seal lip.

l Install the oil seal.

NOTE:
When installing the oil seals, be sure the stamped mark
on the oil seal faces outside.

l Apply a small quantity of Loctite 262TM (Thread locker)

to the screws and install the bearing retainer.

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 11. CRANKSHAFT / CRANKCASE

Recoil starter

③
⑤
④
①

②
① Nut
② Ratchet set
③ Reel
④ Spiral spring
⑤ Rope

DISASSEMBLY
After removing the nut, take out the recoil starter related
parts from the housing. Ratchet

Nut

Ratchet guide
Friction plate

WARNING

When removing the plastics disc. Spacer

Spring cover
Wear eye and hand protection, because the spring may
Quickly unwind and cause an injury
Spring
Pin

Reel

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 11. CRANKSHAFT / CRANKCASE

REASSEMBLY
l Hook the spiral spring end ① with the recoil starter
case. ①
WARNING

Wear eye and hand protector when reassembly the

reel, because the spring may quickly unwind and
cause an injury.

l Apply Grease to the spiral spring.

②
l Turn the starter rope on the reel properly.
l Engage the part ② of the reel with the spiral spring
End ③.
③

l Hook the rope onto the hook part ④ of the reel,turn

thereel clockwise 5 times with the rope.

l Install the ratchet related parts.

NOTE:
l Apply the shaft and ratchet with Grease.

l Pull the rope and check that the ratchet is pushed out.

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 11. CRANKSHAFT / CRANKCASE

CRANKSHAFT
l Mounting the crankshaft in the crankcase.

NOTE:
Use the front fork oil seal installer as an attachment.

Front fork oil seal installer 440655

l Apply a small quantity of Loctite 262TM (Thread

locker) to the thread and install and the gearshift cam
stopper.

BALANCER
l Install the balancershaft.
l Install the key.

l Install the balancershaft driven gear.

l Install the driven gear balancershaft by aligning the
punched marks.

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 11. CRANKSHAFT / CRANKCASE

l Apply Loctite 510 (Flange sealant) to the mating

surface of the left crankcase.

L CASE

R CASE

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 11. CRANKSHAFT / CRANKCASE

l Assemble the crankcase within few minutes.

NOTE:
l After crankcase screws have been tightened, check if
crankshaft rotate smoothly.
l Fit the clamp to the bolt.

l Check the each shaft rotates smoothly after the

crankcase bolts have been tightend.

OIL PUMP
l Install the oil pump.
l Install the washer and pin.
l Install the oil pump driven gear.
l Install the snap ring with snap ring pliers.

NOTE:
l Assemble the oil pump gear as show.

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 11. CRANKSHAFT / CRANKCASE

OIL PUMP DRIVE GEAR

l Install the pin.
l Install the oil pump drive gear and washer.
l Apply lock tail to the oil pump drive gear bolt.

NOTE:
Flange side of the gear is positioned inside.

l Tighten the oil pump drive gear bolt to the specified

torque.

Oil pump drive gear bolt: 50 N．M( 5.0 kgf- m,37 lb-ft)

Rotor holder 440665

CAM CHAIN
l Install the cam chain.

CLUTCH SHOE
l Install the clutch shoe assembly.
l Apply Loctite 262TM (Thread locker) to the clutch shoe
nut.
l Tighten nut to the torque with the special tool.
Shoe nut torque: 160 N．M( 16 kgf- m, 116 lb-ft)
Rotor holder 440666
CAUTION
The nut of clutch shoe has left-hand threads.

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 11. CRANKSHAFT / CRANKCASE

l Install the one way clutch outside.

l Install the clutch housing.

“OUTSIDE”
The one way clutch outside facing must on the shaft
outside.

NEUTRAL SWITCH
l Install the springs and switch contacts.
l Install the neutral switch.

CLUTCH CASE
l Install the dowel pins and put the new gasket.

l Tighten the clutch case bolts.

l Install the collar.

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 11. CRANKSHAFT / CRANKCASE

AIR DEFECTOR&FIXED DRIVE FACE

l Install the air defector.
l Install the fixed drive face.

MOVABLE DRIVE/DRIVEN FACE AND

DRIVE BELT
l Install the drive belt,between the movable driven face
and fixed driven face by tapping with a plastic mallet.

CAUTION

The drive belt contact surface of the driven face

should be thoroughly cleaned.

l Install the movable driven face assembly.

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 11. CRANKSHAFT / CRANKCASE

l Tighten the movable drive face nut to the specified

torque with the special tool.

Movable drive face nut: 115 N．M( 11.5 kgf- m,85 lb-ft)

Rotor holder 440666

NOTE:
Turn the fixed drive face until the belt is seated in and
both the drive and driven faces check the belt without
slip.

CLUTCH COVER
l Install the dowel pins and new gasket.

l Install the clutch cover.

OIL FILTER
l Apply engine oil lightly to the O-ring.
l Install the oil filter turning it by hand until feeling that
the filter gasket contacts the surface of case. Then
Tighten it 2 turns using the oil filter wrench.

Oil filter wrench 440670

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 11. CRANKSHAFT / CRANKCASE

WATER PUMP GEAR

l Install the pin.
l Install the water pump chain to the two water pump
gears as shon

l Install the water pump gears with special tool.

l Install the wash.

Bearing installer set 440660

l Install the water pump gears and tighe the nut

NOTE:
Make sure the crankshaft can turning smoothly.
If any resistance remove the screw, re-associate the
screw again.

l Install the wash.

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 11. CRANKSHAFT / CRANKCASE

GENERATOR
l Install the key.

l Install the one way clutch and generator rotor sets.

CAUTION

Be sure the one way clutch on the crankshaft is

fitted into the generator rotor properly.

l Tighten the generator rotor nut to the specified torque

with the special tool.
Generator rotor nut: 160 N．M( 16.0 kgf- m, 125 lb-ft)

Rotor holder 440664

l Install the output drive gear by installing the snap ring.

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 11. CRANKSHAFT / CRANKCASE

GEARSHIFT
l Install the cam driven gear.

l Reassemble the gearshift shaft.

l Install the gearshift shaft by aligning the punched

mark with the center of the cam driven gear.

STARTER DRIVEN GEAR/IDLE GEAR

l Install the starter idle gear and driver gear.

LEFT CRANKCASE COVER

l Install the dowel pins and put the new gasket.

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 11. CRANKSHAFT / CRANKCASE

l Tighten the left crankcase cover bolt.

NOTE:
Fit the clamp to the bolt.

SPEEDOMETER GEARBOX
l Fit a new gasket and install the speedometer
gearbox.

WATER PUMP
l Check the water pump shaft position with water pump
gear shat.
l Apply engine oil on the O-ring of water pump.
l Install water pump.

l Tighten the screw.

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 11. CRANKSHAFT / CRANKCASE

STARTER CUP
l Apply engine oil to the O-ring and lip of the oil seal.
l Install the starter cup.

l Tighten the starter cup nut by using a suitable bar.

Starter cup nut: 35 N．M( 3.5 kgf- m, 25 lb-ft)

Cup, Starter installer 440658

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 12. COOLING SYSTEM To this chapter contents

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.

● 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.
● Test the cooling system for any leakage after the repair.
● Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.

Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 2200c.c.
Reservoir upper 1200c.c.
Begins to activate at 65~72℃
Thermostat
Stroke: 0.05~5mm
Thermos switch (fan) Begins to activate at 85±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): TGB-440640
Water pump oil seal driver (Inner): TGB-440641
Water pump mechanical seal driver: TGB-440642
Inner bearing puller: TGB-440645

Trouble Diagnosis
The engine temperature is too high The engine temperature is too low
● The water thermometer and the temperature ● The water thermometer and the temperature
sensor do not work properly. sensor 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 filler cap of the radiator malfunction. function properly.
Ÿ
● Between cylinder head and cylinder do not be ● The O ring is deteriorated.
tighten ● The water hose is broken or aged.

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 To this chapter contents
12. COOLING SYSTEM

Trouble Diagnosis for Cooling System

The temperature indicated is too high

A. Stop and waiting for the

A1.Refill the radiator with
engine is completely N coolant then check for any Y
cooled down, open cap to Water leaking problem
leakage?
check the capacity of
coolant in radiator.
N
Y

B. Turn on main switch and N B-1. Measure thermo unit to N

check the water confirm voltage 6V↑? Replace thermo unit
temperature indicator
back to zero?
Y

Y
B-2. Inspect the circuits of Y
water temperature have Short or earth handle
short or earth?

N
Meter problem

C-1. Eng. stop and remove water N

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

Y Y
Water hose clogged

D. Close radiator cap,

measure thermo unit to N Replace thermo unit
confirm voltage reduced
comply with temperature
rise?

Y
Next page

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 To this chapter contents
12. COOLING SYSTEM

Preceding page

E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to

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

E-3. Keep eng. 3000~4000

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

E-4. Remove thermostat from N

holder then heats it by Replace thermostat
water directly to check its
operation?

Y Refill with coolant then

check again

For bleed the air bubbles

completely, open radiator cap Notice the water hose
and start engine while engine is
can’t any unsuitable
cool then press water hose bend or twist and
softly by hand to bleeding. Turn bleed the air bubbles
the throttle repeatedly until the completely.
coolant surface becomes
stable.

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12. COOLING SYSTEM

System Test
Test on the filler cap
Hermetically seal the filler cap, apply water and
pressure to the filler cap. Replace it with new one if
found failing to maintain the specified pressure
within a given time limit, or the opening pressure is
too high or too low. The specified pressure shall
be maintained at least for 6 seconds in the test
Relief pressure for the filler cap: 0.9-0.15
kgf/cm2 Pressure tester
Apply pressure to the radiator, engine and water Filler cap
hose to check for any leakage
Caution
Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
If the system fails to maintain the specified
pressure for at least 6 seconds, repair or replace
parts.
Change of coolant
Warning
Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down, otherwise, you may get scalded.
Remove the front center cover, and then remove
filler cap.
Place a water pan under the water pump; loosen
the drain bolt to drain out the coolant.
Reinstall the drain bolt.

Refilling system with coolant and bleeding the air

bubbles.
● 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.
● Remove radiator filler cap.
● Starts the engine, inspects does not have the air
bubble in the radiator coolant, also the coolant
liquid level is stable. By-pass pipe
● Stop the engine. Add coolant to proper level if
necessary. Drain bolt
● Screw and tighten up the radiator filler cap.

Caution
In order to avoid the water tank rusting, please do
not use the unclear trade mark refrigerant.
Coolant recommended: TGB Bramax radiator
agent.
Concentration: 50%

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12. 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
side. Add coolant to proper level if too low.
● Reinstall the reserve tank filler cap. Upper
Caution
The reserve tank liquid level coca too is not high, Lower
after avoids the water temperature elevating, in the
cooling system the refrigerant backflow floods.

Radiator
Check
Remove the front center cover, side covers and
front fender. (refer chapter 13), check for any
leakage from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure water
jet to clean it.
Care shall be taken when straightening the sink
fan.

Removal
Place a water pan under the water pump.

Remove coolant filler pipe. Filler pipe clamp

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

4 bolts

Remove coolant outlet pipe.

coolant outlet pipe
Disconnect the couplers for the thermo switch and
fan motor, and then remove radiator and cooling fan.

r thermo switch

Disassembly
Loosen the 4 bolts from the fan duct, and then
remove the fan duct.
Loosen 4 screws from the fan motor, and take off
the fan motor.
Remove nut to remove the fan from fan motor.

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 4 bolts.
Please refer to chapter 17 for the inspection of the
thermo switch.

Caution
Liquid packing must be applied to the thermo
switch before installing to avoid damaging the
radiator.

Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.

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 12. COOLING SYSTEM
Water Pump
Check water pump seal / cooling
system divulges inspection
● Disassembles the refrigerant drain bolt,
overflows little buckles the N actually fluid,
confirmed overflows the refrigerant whether has
the greasy dirt.
● Turns on lathe the engine oil gauge rule, the
inspection engine oil whether does have
bleaches situation of the emulsified.

If has the above two kind of interior to divulge the

phenomenon, possibly for the water pump inner two
seal damages, the engine cooling system damages
or the cylinder and the cylinder head gasket
damages, please first dismantles the right crank
case to say A confirms the replacement water pump
seal, if does not have the question to take apart for
overhaul cooling system of system again the
cylinder head, the cylinder.

Removal of water pump

Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen 2 bolts and remove the water pump.

Caution
Check the water pump shaft position with water
pump gear shat.

Install water pump and tighten the screw.

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12. COOLING SYSTEM

Thermostat Temperature sensor

Please refer to chapter 17 for inspection of
temperature sensor.
By-pass pipe
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 65~72℃
Valve stroke 0.05 ~ 5mm

Installation
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out the air bubble
(Page 12-5).

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 13. BODY COVER

Mechanism Diagram

13

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Maintenance

Body covers dissemble sequence

Fuel tank cover

Right and left foot board

Right and left foot board

Right and left front internal fender

Right and left front shock mount, front bumper

Front air inlet plate

Right and left head lamp support, body cover

Rear body cover

Front protector

rear protector

Upper bracket assembly

l Be careful not to damage various covers in assembly or disassembly operation.

l Never injure hooks molded on the body covers.
l Align the buckles on the guards with slot on the covers.
l Make sure that each hook is properly installed during the assembly.
l Never compact forcefully or hammer the quard and the covers during assembly.

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 13. BODY COVER
Remove seat

Remove 2 bolts from battery fixed

Remove cable and battery fixed

Remove 1 screw and take off shift lever

Remove fuel cap

Remove 4 screws，and then remove fuel tank

cover

Installation

Install in reverse order of removal procedures.

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Remove screws from right or left foot board (each
side 4 screws)

Remove screws from right or left foot board (each

side 8 screws)

Remove M6 bolts from right or left foot board

remove right or left foot board (each side 3 bolts)

Remove bolts from right or left front internal fender

(each side 5 bolts)，and then remove right or left
front internal fender

Remove 4 bolts from front bumper

Remove 2 screws from front bumper

Installation

Install in reverse order of removal procedures.

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Remove screws from front bumper (each side 3
screws)

Remove head lamp couplers，and then remove

front bumper

Remove bolts from right and left head lamp support

(each side 2 bolts)

Remove bolts from front air inlet plate (each side 2

bolts) ，and then remove front air inlet plate

Remove bolts from front body cover (each side 1

bolts)

Installation

Install in reverse order of removal procedures.

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Remove lock cap

Remove power source couplers，and then remove

front body cover

Remove bolts (each side 1 bolts)

Remove 2 couplers

Installation

Install in reverse order of removal procedures.

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Remove 1 couplers and 1 nut from starting motor
relay，and then remove starting motor relay

Remove 1 bolts from rear body covert

Remove 1 nut from bear reflector assembly (each

side 1 bolts)

Remove number-plate lamp couplers 、rear lamp

assembly couplers (L/R) and turn signal lamp
couplers (L/R)

Installation

Install in reverse order of removal procedures.

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Remove screws from rear body covert (each side 2
screws) ，and then remove rear body covert

Remove 2 bolts from front protector

Remove 2 bolts from front protector，and then

remove front protector

Remove bolts from bear protector (each side 1

bolts)

Installation

Install in reverse order of removal procedures.

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Remove bolts from bear protector (each side 1
bolts)，and then remove bear protector

Remove bolts from upper bracket assembly (each

side 2 bolts)

Remove speedometer assembly couplers，and

then remove upper bracket assembly

Installation

Install in reverse order of removal procedures.

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 Home page Contents
14. FRONT BRAKE & FRONT WHEEL

Mechanism Diagram···························14-1 Adding Brake Fluid ···························· 14-8

Maintenance Description ···················14-2 Brake fluid replacement / Air-bleed ·· 14-9
Trouble Diagnosis ······························14-3 Front Brake Caliper···························· 14-10
Front Wheel·········································14-4 Brake Disk ·········································· 14-11
Front Wheel Hub·································14-4 Front Brake Master Cylinder ············· 14-11
Disk Brake System Inspection ··········14-7

Mechanism Diagram

Front brake master cylinder

Front pressure control valve

Brake hose bolts (3.5kgf-m)

Air-bleed valve (0.5kgf-m)

To rear pressure control valve

Brake caliper bolt (3.25kgf-m)

Brake disc

Bearing

Brake caliper Brake pad

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14. FRONT BRAKE & FRONT WHEEL

Maintenance Description
Operational precautions
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 3.500 2.000

Front and rear brake disk eccentricity < 0.100 0.300

Master cylinder inner diameter 14.000~14.043 14.055

Master cylinder piston outer diameter 13.957~13.984 13.945

Diameter of front disk 200.000 -

Thickness of front brake lining 5.500 2.000

Tire pressure as cold: 0.8 kg/cm² (12psi)

Torque values
Brake hose bolts 3.50kgf-m
Bolt for brake caliper 3.25kgf-m
Bolts for the brake disk 4.25kgf-m
Brake lever nut 1.00kgf-m
Air-bleed valve 0.50kgf-m
Front wheel nut 2.40kgf-m
Front axle castle nut 5.00kgf-m

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14. FRONT BRAKE & FRONT WHEEL

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
1. Bent tie rods
2. Poor brake caliper
3. Blocked brake pipe 2. Wheel installed incorrectly
4. Seized/worn master cylinder piston 3. Unequal tire pressure
5. Bent brake lever 4. Incorrect wheel alignment

Uneven brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped brake disk
5. Restricted brake hose and fittings

Tight brake
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or warped brake disk

Brake noise
1. Dirty lining
2. Deformed brake disk
3. Poor brake caliper installation
4. Imbalance brake disk or wheel

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14. FRONT BRAKE & FRONT WHEEL

Front Wheel
Removal
Raise the front wheels off the ground by placing a
jack or other support under the frame.

4 screws

Remove the front wheel nuts, and then remove

front wheels.

Installation
Install the front wheel and tighten the nuts.
Torque: 5.0kgf-m

4 nuts

Front Wheel Hub

Removal
Remove front brake caliper (2 bolts).

2 bolts

Remove cotter pin, wheel hub nut and washer. Wheel hub nut
Remove wheel hub and brake disk.

Cotter pin

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14. FRONT BRAKE & FRONT WHEEL

Remove 4 socket bolts, and then remove the 4 bolts

brake disk from wheel hub.

Installation
Install the front brake disk to the wheel hub.
Install wheel hub and brake disk on to knuckle.
Install wheel hub washer and tighten the wheel
hub nut.
.

Torque: 9.0kgf-m Wheel hub nut

Install cotter pin

Cotter pin

Install front brake caliper.

Torque: 3.5kgf-m

2 bolts

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14. FRONT BRAKE & FRONT WHEEL

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.

Caution
● Check the front brake lining must be removed
front wheel first.

Park the ATV on a level ground, and check if

fluid level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN
BRAKE OIL (DOT 4).
Caution
● The vehicles inclined or just stop, the
survey oil level could not be accurate, had
to settle the
3~5 minute.
● In order to prevent has the chemical
change, please do not use counterfeiting
or other unclear trade marks brake fluid.
● Uses by all means must with the trade
mark brake fluid, guarantees the ghost
vehicle efficiency.

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14. FRONT BRAKE & FRONT WHEEL

Adding Brake Fluid

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

Screw
Remove the master cylinder cap and diaphragm. Upper level
Master cylinder cap
Increases the high quality brake fluid, uses by all
means must with the trade mark brake fluid joins in
Diaphragm
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.

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14. FRONT BRAKE & FRONT WHEEL

Brake fluid replacement / Air-bleed r

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 4
brake fluid

Air-bleed must from pressure control valve fist.

Connect one end of transparent hose to the
air-bleed valve, and put the other end into a
container.

Open the drain valve around 1/4 turns, and at the

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

Close the drain valve when finishing the brake

system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.
Bubble Air-bleed valve
If brake is still soft, please bleed the system as
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the valve.

Caution
● 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. Transparent hose

2. Slowly release the brake lever, and wait for a

few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.

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14. FRONT BRAKE & FRONT WHEEL

Front Brake Caliper

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.

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 18 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.

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14. FRONT BRAKE & FRONT WHEEL

Brake Disk Brake disk

Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit: 2.5 mm

Micrometer
Caution
● Replace the disk should be replace new fix bolt,
. or smear over fixative.

Remove the brake disk from wheel hub.

Check the disk for deformation and bend.
Allowable limit: 0.30 mm
Caution
● The dirty brake lining or disk will reduce the
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, use vacuum cleaner clean it.

Front Brake Master Cylinder

Master Cylinder Removal
Caution
Do not let foreign materials enter into the
cylinder.

Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.

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.

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14. FRONT BRAKE & FRONT WHEEL
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.
Replace it if necessary.
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: 14.055 mm

Measure the outer diameter of the piston. Replace

the piston if its measured value exceeds allowable
limit.
Allowable limit: 13.945 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.
Apply clean brake fluid to the piston cup, and then
install the cup onto the piston.
Cir clip
Install the larger end of the spring onto the master Rubber boot
cylinder.
The master cup’s cavity should be face inside of Piston
master cylinder when installing the master cup.
Install the cir clip. Piston cup
Caution Spring

● 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

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14. FRONT BRAKE & FRONT WHEEL

Master Cylinder Install

Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.

Install the brake lever, and connect leads to brake Brake light switch Brake lever bolt
light switch.

Connect brake hoses with 2 new washers.

Tighten the brake hose bolt to the specified torque
value.
Torque: 3.2kgf-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.

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15. STEERING / FRONT SUSPENSION

Mechanism Diagram ··························15-1 Steering Tie-Rod ································ 15-6

Operational Precautions ····················15-2 Knuckle ··············································· 15-7
Trouble Diagnosis ······························15-2 Front Cushion ···································· 15-8
Steering Handle ··································15-3 Suspension Arm ································ 15-9
Steering Shaft ·····································15-5 Toe-In ·················································· 15-10

Mechanism Diagram

300~350 kgf-cm

300~350 kgf-cm

250~350 kgf-cm

700~900 kgf-cm
15

450~550 kgf-cm
250~350 kgf-cm

400~430 kgf-cm

400~430 kgf-cm
450~550 kgf-cm

450~550 kgf-cm

450~550 kgf-cm

600 kgf-cm

450~550 kgf-cm

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15. STEERING / FRONT SUSPENSION

Operational Precautions
Torque Values
Handlebar upper holder bolt 300~350 kgf-cm
Steering shaft holder bolt 300~350 kgf-cm
Steering shaft nut 250~350 kgf-cm
Steering tie-rod nut 250~350 kgf-cm
Knuckle nut 600 kgf-cm
Tie rod lock nut 450~550 kgf-cm
Suspension arm nut 450~550 kgf-cm
Front cushion mounting nut 450~550 kgf-cm

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 damage 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.

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15. STEERING / FRONT SUSPENSION

Steering Handle
Removal
Remove the handle cover, meter set, handle
protect cover and front fender. (Refer to chapter
13)

Handle protect cover

Loosen the socket bolts for the front brake master brocket bolts
cylinder, and remove front brake master cylinder.
Caution
Do not let foreign materials enter into the cylinder.

Master cylinder bolts

Remove 2 screws, and then remove throttle

hosing holder and throttle hosing.

2 Screws

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

Handle protect cover

brocket bolts

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15. STEERING / FRONT SUSPENSION
Loosen 2 screws, and then remove handle left
switch and choke hosing.

2 screws

4 socket bolts
Remove switch wire band.
Remove handle mounting bolt, and then remove
the handle upper holder, handle.

Remove 2 nuts to remove handle under holder

and meter bracket.

2 Nuts

Installation
Install in reverse order of removal procedures.

Torque value:
Handlebar under holder nut 4.0kgf-m
Handlebar upper holder bolt 2.4kgf-m

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15. STEERING / FRONT SUSPENSION

Steering Shaft
Remove
Remove cotter pins, and loosen right and left
steering tie-rod nuts.
Remove tie-rod.

Steering shaft nut

Remove the cotter pin below steering shaft, and
remove steering shaft nut and washer.

Cotter pin

Bend out the steering shaft holder nut fixed plate.

Loosen 2 bolts, and then remove steering shaft
holder, nut fixed plate, pressed plate and steering
shaft.

Inspection
Check oil rings for wear or damage, and replace it if
necessary.
Fixed plate
Measure the holder inner diameter.
Maximum limit: Ø39.5 mm
Oil rings

Installation
Install in reverse order of removal procedures.
Apply with grease onto oil liner and holder.

Torque value:
Steering shaft holder bolt 3.4kgf-m
Steering shaft nut 5.0kgf-m
Steering tie-rod nut 5.0kgf-m Oil rings
Oil liners

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15. STEERING / FRONT SUSPENSION

Steering Tie-Rod
Remove
Remove cotter pin and tie-rod nut from steering
shaft side.

Remove cotter pin and tie-rod nut from 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.

Ball joint

Installation
Install the ball joint with “adjustment groove” on
the wheel side.
Install tie-rod nuts, and tighten the nuts.
Torque value: 5.0kgf-m

After tightened the tie-rod nut, install the cotter pin.

Adjustment groove

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15. STEERING / FRONT SUSPENSION

Knuckle
Remove
Remove front wheel, front brake caliper, front
wheel hub and brake disk.

Tie-rod
Remove cotter pin and tie-rod nut, remove tie rod.

Nut

Cotter pin

Remove cotter pin and ball joint nut. Universal holder

Remove upper and under ball joints by ball joint
driver.
Remove the knuckle.
Special Tool：ball joint driver

Ball joint

Ball joint
Inspection
Inspect the upper and under ball joints and
knuckle for damaging or cracking. Knuckle

Installation
Install in reverse order of removal procedures.
Torque value:
Steering tie-rod nut 5.0kgf-m
Ball joint nut 5.0kgf-m
After tightened the nuts, install the cotter pins. Ball joint

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15. STEERING / FRONT SUSPENSION

Front Cushion Nut

Remove
Remove front cushion under bolt nut, and remove
the bolt.

Nut
Remove front cushion upper bolt nut, and remove
the bolt and cushion.

Installation
Install in reverse order of removal procedures.
Torque value:
Front cushion nut 4.6kgf-m

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15. STEERING / FRONT SUSPENSION

Suspension Arm
Remove
Remove front wheel, wheel hub, and brake caliper,
brake disk, tie-rod, knuckle and front cushion.

Suspension arm nuts and bolts

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

Suspension arm nuts and bolts

Loosen under suspension arm nuts, remove swing
arm bolts.
Remove under suspension arm.

Inspection
Inspect the suspension arm, ball joint and bush for
damage or bending.

Installation
Install in reverse order of removal procedures.
Torque value:
Suspension arm nut 5.0kgf-m

Lubricate with grease into suspension arm.

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15. STEERING / FRONT SUSPENSION

Toe-In
When repair or disassemble steering system parts,
must to adjustment the toe-in.
Keep the vehicle on level ground and the front
wheels facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.

Carefully to move the vehicle back, let the wheels

turn 180 degree, so the marks on the tires are
aligned with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.

Toe-in: 10± 3mm

If the toe-in is out of standard, adjust it by hanging Lock nut

the length of the tie-rods equally by turning the
tie-rod while holding the ball joint.
Loosen two side tie-rod lock nuts; turn the tie-rods
to adjustment toe-in.
Tighten the lock nuts.
Torque value: 3.6kgf-m

Adjustment groove

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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Mechanism Diagram···························16-1 Brake fluid replacement / Air-bleed ·· 16-9

Maintenance Description ···················16-2 Rear Brake Caliper ····························· 16-10
Trouble Diagnosis ······························16-3 Brake Disk ·········································· 16-11
Rear Wheel ··········································16-4 Rear Brake Master Cylinder ·············· 16-11
Disk Brake System Inspection ··········16-5 Rear Cushion······································ 16-14
Rear Wheel Axle ·································16-6
Adding Brake Fluid ···························· 16-8
Mechanism Diagram

Rear brake master cylinder A

Rear pressure control valve

Rear brake master cylinderB

16
To Brake calipers

Brake caliper

Brake caliper bolts (3.26kgf-m)

Brake pad

Brake disc bolts (4.26kgf-m)

Brake disc

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Maintenance Description
Operational precautions
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
Air-bleed valve 0.50kgf-m 4.6kgf-m Swing arm pivot bolt 9.2kgf-m
Rear wheel nut 2.40kgf-m

Special tools
Inner bearing puller: TGB-440645
Rear axle bearing driver (6007LLU): TGB-440640

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

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
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
1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or warped brake disk

Brake noise
1. Dirty lining
2. Deformed brake disk
3. Poor brake caliper installation
4. Imbalance brake disk or wheel

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

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.

Installation
Install the rear wheel and tighten the nuts.
Torque: 2.4kgf-m

Removal
Remove the brake caliper 2 nuts. and then
remove the brake caliper.

Installation
Install the rear wheel shaft connecter.
Install wheel shaft connecter washer and
tighten the wheel shaft connecter nut.
Torque: 2.4kgf-m
Install cotter pin.

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

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.

Brake lining wears

limit grooves
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. Brake disk

Caution
● Check the rear brake lining must be removed
rear wheel first.

Park the ATV on a level ground, and check if fluid

level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL
(DOT 4)

Caution

● The vehicles inclined or just stop, the

survey oil level could not be accurate, had
to settle the 3~5 minute
● In order to prevent has the chemical
change, please do not use counterfeiting
or other unclear trade marks brake fluid.
● Uses by all means must with the trade
mark brake fluid, guarantees the ghost
vehicle efficiency.

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 s
16. REAR BRAKE & REAR HEEL & REAR CUSHION

Rear Wheel Axle

Remove rear wheel housing 4 bolts.

Escape rear wheel housing from rear fork assy.

Remove tow ball mount 4 bolts (2 bolts each side)

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION
Remove rear axle housing 4 bolts.

Remove rear axle housing

Inspection
Check bearings on rear wheel axle bearing seat.
Rotate each 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 bearing seat.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it if
necessary.

Caution
● Never install used bearings. Once bearing
removed, it has to be replaced with new one.

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 16. REAR BRAKE & REAR WHEEL & REAR CUSHION

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

Remove the brake fluid cap and diaphragm.

Increases the high quality brake fluid, uses by all
means must with the trade mark brake fluid joins in
the master cylinder.
Clean the dirty brake disk.
Caution
● The dirty brake lining or disk will reduce the
brake performance. Master cylinder
● To mixed non-compatible brake fluid will
reduce brake performance.
● Foreign materials will block the system
causing brake performance to be reduced or
Screw
totally lost. Upper level
Brake fluid cap

Diaphragm

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Air-bleed valve
Brake fluid replacement / Air-bleed
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
Air-bleed valve
the drain valve around 1/4 turns, and at the Bubble
same time hold the brake lever until the there is no
air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.

If brake is still soft, please bleed the system as

described below:
1. Tightly hold the brake lever and open the drain Transparent hose
valve around 1/4 turns, and then close the valve.

Caution
● 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.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Rear Brake Caliper Brake hose bolt

Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.

Remove two caliper bolts and the caliper. 2 bolts

Inspection
Make sure the brake linings condition. Replace
the linings if the brake linings wear limitation
groove close to the brake disk.
Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.25kgf-m
Caution
● 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.

Brake lining replacement

Remove two guide pins.
Guide pins

Remove brake caliper cylinder, and then remove

brake linings.
Install new linings and brake caliper cylinder.
Tighten the guide pins.
Torque: 1.8kgf-m

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Brake Disk Brake disk

Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit: 2.5 mm

Micrometer

Remove the brake disk from rear wheel axle.

Check the disk for deformation and bend.
Allowable limit: 0.30 mm
Caution
● The dirty brake lining or disk will reduce the
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, 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.
Remove the master cylinder socket bolts and the
master cylinder.

2 socket bolts

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION
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
Install the cir clip.
Caution
● Never install cup lip in the opposite direction.
● Make sure the cir clip is seated securely in Master cylinder

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.
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.
Add specified brake fluid and bleed the system.
Brake light switch coupler Brake lever nut

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION
Right footrest side – rear brake master cylinder
B
Install the master cylinder bolts and the master
cylinder.

Install brake push rod to the brake pedal, and

install pin and 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.

Install fluid hose and clamp.

Connect brake hoses with 2 new 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.
Add specified brake fluid and bleed the system.

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16. REAR BRAKE & REAR WHEEL & REAR CUSHION

Rear Cushion Nut

Removal
Support the frame.
Loosen rear cushion under bolt nut, and remove
rear cushion under bolt.

Rear cushion under bolt

Remove rear cushion upper bolt, and then remove

rear cushion.

Installation
Install rear cushion, and install rear cushion upper
bolt.
Install rear cushion under bolt, and install nut. Tighten
the rear cushion upper bolt and under nut to the
specified torque value.
Torque: 4.6kgf-m

Rear cushion upper bolt

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17. ELECTRICAL SYSTEM

Mechanism Diagram ··························17-1 Meters ················································· 17-12

Maintenance Data ·······························17-2 Light / Bulb········································· 17-13
Technical Specification······················17-2 Switch / Horn······································ 17-16
Trouble Diagnosis ······························17-3 Fuel Unit ············································· 17-19
Battery ·················································17-4 Cooling Fan Thermo Switch ············· 17-20
Charging System ································17-5 Thermo unit········································ 17-21
Ignition System···································17-8 Water Temperature Indicator Light ·· 17-21
Starting System ··································17-10

Mechanism Diagram
Starter relay

Fuse box Front brake switch

Hazard
Battery control unit

Winker rela
C.D.I. Unitx

Main switch
Shift gear
control unity

Rear brake switch

Thermo unit

17

DC. Power outlet

Start & light &

winker & horn &
brake switch

Headlight relay

Horn

Regulator rectifier

AC.Generator
Spark plug
Ignition coil
Change switch

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17. ELECTRICAL SYSTEM

Maintenance Data
Operational precaution
● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed.
(First disconnect the negative cable terminal, next, the positive cable terminal.)
● 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 rapid charge the battery.
● The voltage must be checked with the voltmeter while charging the battery.
● As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check
C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary.

Technical Specification
Charging system
Description Specification

Capacity 12V18Ah
Battery Charging rate 1.4A / 5 ~ 10 hours (standard)
14A / 0.5 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 CR7E (Recommended)

Spark plug
Gap 0.8mm

Primary winding 2.9 ± 10%Ω

Ignition coil and
Without cap: 15. ± 10KΩ
resistance Secondary winding With cap:20 ± 10KΩ

15° TDC / 1700rpm

Ignition timing “F” mark 31°TDC / 4200rpm

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17. ELECTRICAL SYSTEM

Trouble Diagnosis
No voltage Charging system does not operate
● Battery discharged properly
● The cable disconnected ● Burnt 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 C.D.I. ● Incorrect ignition timing
● Poor connection between C.D.I. and ignition - Poor AC.G.
coil - Improper installation of the pulse sensor
- Poor connection between C.D.I. and the - Poor C.D.I.
main switch
● Poor main switch
● Poor C.D.I. 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 Starter motor is working, but engine does
● The battery is not fully charge not crank
● Poor main switch
● Poor starter motor pinion
● Poor starter switch
● The starter motor run in reverse direction
● The front and rear brake switches do not
● Poor battery
operate correctly
● Starter relay is out of work
● 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

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