ATV 200 - Page 154

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13.Remove

.Gasket of left crankcase cover

.Location pin

.Intermediate gear shaft

.Washer

.Duplex intermediate gear(starting motor)

14.Remove

.Magneto

Caution:

Disassemble the magneto rotator with special

tool

15.Remove

.Semicircle key

.Electric starting gear assy

.Washer

16.Remove

.Upper guide plate(air intake side)

.Timing chain

- 148 -

Main Page

Table of Contents3
Chapter I General Description7
Section 1Description7
Section 2 Special Tools, Instruments & Meters8
(I) Special Tools8
(II) Instruments & Meters9
Section 3 Identification Code, and Engine no10
Section 4 Points for Attention in Maintenance10
Section 5 Specification14
How to Use Conversion Table of Unit14
How to Use Conversion Table14
Definition of Unit14
II.basic Specification15
III.ATV Body16
IV.electric System17
Maintenance Specification of Engine19
Section 6 Wiring Diagram of ATV22
(I)Technical Explanation and Requirement, Details of Relative Component22
(II) Wiring Diagram(1)24
(III) Wiring Diagram(2)25
(IV) Wiring Diagram(3)26
Section 7 Requirements for Torque of Fastener27
ATV Body27
Engine29
General Torque Specification31
Section 8 Lubrication32
Lubrication Oil Way32
Lubrication Diagram33
Section 9 Lubrication Point and Type of Lubricants35
Lubrication Point and Type of Lubricants(ATV Body)35
Lubrication Point and Type of Lubricants(Engine)36
Chapter II Maintenance and Adjustment of Vehicle37
Section 1 Periodic Maintenance/Lubrication37
Section 2 Disassembly and Assembly of Cushion, Fender and Fuel Tank38
(I) Cushion38
(II) Rear Fender39
(III)Fuel Tank41
(IV)Front Fender43
Section 3 Maintenance and Adjustment of Vehicle Body45
(I) Wear Inspection of Front and Rear Brake45
(II)Adjustment of Front Brake45
(III)Adjustment of Free Clearance of Left Lever and Rear Brake Pedal46
(IV)Position Adjustment of Steering Lever48
(V) Lubricating Oil Level Inspection of Rear Driving Gearcase48
(VI)Replacement of Engine Oil of Rear Driving Gear Case49
(VII) Rubber Sleeve Inspection of Rear Wheel Fork50
(VIII)Inspection of Steering System50
(IX)Adjustment of Toe-In of Front Wheel51
(X) Inspection of Front/Rear Shock Absorber52
(XI)Adjustment of Rear Shock Absorber52
(XII) Inspection of Tire53
(XIII)Inspection of Rim54
Section 4 Maintenance and Adjustment of Electrical Appliance55
(I)Inspection of Battery55
(II)Inspection of Fuse56
(III)Replacement of Headlight Lamp57
Section 5 Maintenance and Adjustment of Engine59
(I)Adjustment of Clutch59
(II)Clean of Air Filter59
(III)Inspection of Spark Plug61
(IV)Adjustment of Idle Speed62
(V)Adjustment of Free Clearance of Throttle Grip62
(VI)Adjustment of Speed Limitator63
(VII)Adjustment of Valve Clearance64
(VIII)Adjustment of Timing Chain Tension66
(IX)Inspection of Ignition Timing67
(X)Measuring of Compressive Force68
(XI) Inspection Oil Quantity of Engine69
(XII)Replacement of Engine Oil and Inspection of Oil Flow70
Chapter III Repair and Maintenance of Vehicle Body73
Section 1 Rear Driving Gearcase and Driving Shaft73
(I)Trouble73
(II)Inspection73
(III)Trouble-Shooting Table74
(IV)Disassembly75
(V)Inspection78
(VI)Pad Choice of Main Driving Gear and Shift Gear79
(VII)Installation81
Section 2 Front Wheel and Front Brake82
(I)Disassembly82
II.inspecting Procedures84
(III)Installation Procedures87
Section 3 Rear Wheel/Rear Brake/Rear Wheel Axle90
(I)Removal Steps91
(II)Inspection Steps93
(III)Installment Steps96
Section 4 Steering Operation System100
(I)Removal Steps of Steering Bar100
(II)Removal Steps of Steering Vertical Column Welding101
(III)Inspection Content102
(IV)Installment Steps103
(V)Installation Steps of Steering Bar106
Section 5 Front Shock Absorber and Front Wheel Fork107
(I)Disassembly107
(II)Inspection Steps109
(III)Installment Steps110
Section 6 Rear Shock Absorber and Rear Wheel Fork113
(I)Disassembling Steps113
(II)Checking Steps115
(III)Mounting Steps117
Chapter IV Electrical Appliance120
Section 1 Inspect Switch120
(I)Inspect Switch120
Section 2 Check Lamp(Headlight)121
Section 3 Troubleshooting the Ignition System Failure123
Section 4 Running of Starting Circuit128
Section 5 Troublshooting Electric Starting System129
Section 6 Check Starting Motor132
Section 7 no Charging in the Battery135
Section 8 Troubleshooting138
Section 9 Inspection of Lighting System140
(I)If the Headlight Is out of Work140
(II)If the Taillight Is out of Work141
Section 10 Troubleshooting143
(I)If Indicated Lamp Is out of Work143
Section 11 Inspection of Signal System145
(I)If the Neutral Indicated Lamp Is out of Work145
(II)If the Reverse Indicated Lamp Is out of Work146
(III)If the HB Indicated Lamp Is out of Work147
Chapter V Engine148
Section 1 Disassembly of Engine148
(I)Remove the Engine from Finished ATV148
(II) Disassembly of Engine151
Section 2 Inspection and Maintenance of Engine161
Section 3 Assembly and Adjustment of Engine185
(I) Closing Assembly of Left & Right Crankcase185
(II) Assembly of Right Crankcase186
(III) Assembly of Left Crankcase186
(IV) Assembly of Cylinder Head205
(V) Manual Starting Mechanism and Others212
(VI) Mount the Engine on the Finished Vehicle214
Chapter VI Vecicle Ordinary Trouble and Its Judgement219
( I )Starting Trouble/Difficulty219
(II)Poor Idle Speed Performance220
(III) Poor Middle and High Speed Performance220
(IV)Shifting Trouble220
(V) Clutch Slips221
(VI) Clutch Is Locked221
(VII) Engine Is Overheat221
(VIII) Brake Trouble221
(IX) Shock Absorber Failure/Improper Operation221
(X) Lighting System222

ATV 200 - Page 154

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