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Maxxam 150 2R
Ace Sports Maxxam 150 2R Service Manual
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150 2R
ACE-Maxxam-002-02-2007
239 County Road 4435
Brundidge,
A
L
36081
www
.acesportsonline.com
P:
1-888-562-9ACE
F:
1-888-562-8A
CE
Bug
g
y Ser
vice Manual
2
Table of Contents
Table of Contents
4
Break-In Procedure
5
General Information
5
Fuel and Oil Recommendations
5
Model Identification
5
Specifications
6
Dimensions
6
Engine
6
Capacities
6
Weight
7
Tire Pressure
7
Location of Parts
8
Periodic Check and Services
9
Spark Plug
9
Periodic Maintenance and Tune-Up Procedures
9
Tire Pressure/Wear
10
Brake Performance
10
Air Cleaner
10
Paper Filter Maintenance
10
Fuel Switch (Petcock)
11
“ON” Position
11
Torque Tightening Chart
11
Chassis Nuts and Bolts
11
Final Gear Oil
12
Engine Oil
12
Chassis
12
Engine Components: Cylinder
13
Cylinder Removal
13
Cylinder Inner Wall Wear Inspection
13
Connecting Rod End Inspection
14
Piston Rings Inspection and Servicing
14
Piston Pin Inspection and Servicing
14
Crank Connecting Rod Mechanism
14
Piston Rings Set up
15
Piston Set Installation
15
Crank Connecting Rod Set
15
Crankcase and Crankshaft Removal
15
Crankshaft and Crankcase Inspection
17
Crankshaft and Crankcase Installation
17
Valve Mechanism Inspection and Servicing
18
General Introduction
18
Valve Clearance Adjustment
19
Camshaft Inspection
20
Camshaft Removal
20
Rocker Arm and Rockshaft
21
Camshaft Installation
21
Rocker Arm and Rockshaft Removal
21
Rocker Arm and Rockshaft Inspection
21
Rocker Arm and Rockshaft Installation
22
Cam Chain Tensioner
22
Valve and Valve Spring Removal
23
Valve and Valve Spring Inspection
23
Valve and Valve Spring Installation
23
Valve Guide Replacement
24
To Clean Carbon Accumulation off the Valve Guide
24
Valve Guide Inner Diameter Measurement
24
Valve Guide
24
Valve Seat
25
Valve Seat Width Measurement
25
Valve Seat Finishing
25
Valve Seat Touching Position Inspection
26
Valve and Valve Seat Lapping
27
Valve and Valve Seat Air Impermeability Inspection
27
Lubrication System Inspection and Servicing
28
Oil Pump Removal
29
Oil Replacement
29
Rotary Oil Pump
29
Oil System Inspection and Replacement
29
Oil Pump Inspection
30
Oil Pump Assembling
31
CV Carburetor
32
Fuel Supply System Inspection and Servicing
32
Carburetor Idling Adjustment
33
Air Adjusting Screw Adjustment
33
Vacuum Chamber
33
Float Chamber Removal
34
Automatic Side Starter
34
Automatic Side Starter Inspection
34
Vacuum Chamber Installation
34
Float Chamber Installation
35
Fuel Level Inspection
35
Carburetor Installation
35
Air Cut Valve (Acv)
36
Air Cut Valve Removal
36
Air Cut Valve Installation
36
Air Check Valve
36
Spiral Spline Transferring Style Starting Mechanism Removal
37
Transmission Components
37
Spiral Spline Transferring Style Starting Mechanism
37
Starting Mechanism Inspection and Servicing
37
Starter Motor
38
Starter Motor Removal
38
Electrical Starting System
38
Armature Inspection
39
Carbon Brush Inspection
39
Starter Motor Installation
40
Reduction Gear Inspection
41
Reduction Mechanism
41
Starting Clutch Inspection
42
Starting Clutch Removal
42
Engaging Mechanism
42
Controlling Mechanism
43
Starting Clutch Installation
43
Starter Relay Inspection
43
Belt Driven Cvt Mechanism Inspection and Servicing
44
Drive Belt Pulley Removal
46
Drive Belt Pulley Inspection
46
Drive Belt Pulley Installation
47
Clutch Disassembling
48
Clutch Inspection
48
Clutch Removal
48
Clutch Installation
49
Driven Belt Pulley
50
Driven Belt Pulley Removal
50
Driven Belt Pulley Inspection
50
Driven Plate Bearing Replacement
51
Driven Belt Pulley Installation
52
Transmission Belt Inspection
52
Transmission Case Oil Inspection
53
Transmission Case Oil Replacement
53
Rear Transmission Mechanism Inspection and Servicing
53
Transmission Case Removal
54
Transmission Case Gear Inspection
54
Driven Belt Pulley
54
Bearing on the Transmission Case Cover Replacement
55
Bearing on the Left Crankcase Body Replacement
56
Charging System Inspection and Servicing
58
Electric Leakage Testing
58
Charging Status Inspection
58
Electrical System
58
Battery Open-Circuit Voltage Inspection
59
Battery
59
Battery Installation
59
Battery Removal
59
Battery Charging
60
Primary Coil
60
Primary Coil Inspection
61
Generator Removal
61
Generator Installation
62
Regulate Rectifier
62
Main Wiring
62
Resistor Resistance Value Measurement
63
Regulate Rectifier Inspection
63
Ignition Time Inspection
64
Ignition System Inspection and Servicing
64
Ignition Charging Coil
65
Trigger Winding
66
CDI Component
66
Remove the CDI Component
66
Ignition Coil Removal
67
Ignition Coil Installation
67
Secondary Ignition Coil Inspection
67
Rear Axle Removal
68
Rear Swingarm
68
Chassis
68
Front & Rear Shocks
69
Adjustment of Front & Rear Shock
69
Front Wheel Replacement
69
Front Hubs
70
Seat
70
Steering Shaft
70
Steering Gear Box and Ball
70
Tie Rod
71
A-Arms
71
Steering Knuckle Support
71
Throttle & Brake Pedal
71
Service Air Cleaner
72
To Service Pre-Cleaner
72
Front Wheel Alignment
72
Chain Tensioner Adjustment
73
Reverse Gear Check
73
Wiring Diagram
74
Index
75
Other manuals for Ace Sports Maxxam 150 2R
Owner's Manual
78 pages
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Ace Sports Maxxam 150 2R Specifications
General
Brand
Ace Sports
Model
Maxxam 150 2R
Category
Utility Vehicle
Language
English
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