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ATV 250 User Manual

ATV 250
228 pages
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Table of Contents

Questions and Answers:

ATV 250 Specifications

General IconGeneral
BrandATV
Model250
CategoryOffroad Vehicle
LanguageEnglish

Summary

Chapter I General Description

Section 1 Description

Describes the main external parts of the ATV and their identification numbers.

Section 2 Special Tools, Instruments & Meters

Lists specialized tools and instruments required for accurate ATV adjustment and assembly.

Section 3 Identification Code, Label of Model and Engine No.

Explains where to find the vehicle's identification code and engine number.

Section 4 Points for Attention in Maintenance

Provides essential advice on preparation, component handling, and safety during maintenance.

Section 5 Specification

Explains unit conversion tables and defines various measurement units used in the manual.

II. Basic Specification

III. ATV Body

Steering System

Specifies dimensions and tolerances for the ATV's steering system components.

Front Wheel

Specifies dimensions and tolerances for the front wheel components.

Front Brake

Specifies dimensions and tolerances for the front brake components.

Rear Wheel

Specifies dimensions and tolerances for the rear wheel components.

Rear Brake

Specifies dimensions and tolerances for the rear brake components.

Brake Lever and Pedal

Specifies dimensions and tolerances for the brake lever and pedal controls.

IV. Electric System

Spark Plug

Details specifications for the ATV's spark plug.

Ignition Coil

Details specifications for the ATV's ignition coil.

Ignition System

Details specifications for the ATV's ignition system.

V. Maintenance Specification of Engine

Section 6 Wiring Diagram of ATV

1. Technical Explanation

Explains wiring diagram components, routing, and technical requirements.

2. Technical Requirement

Outlines general wiring and fixing requirements for the ATV.

3. Details of Relative Component

Lists component codes, names, and quantities for the wiring system.

(II) Wiring Diagram(1)

Illustrates the primary wiring connections and component routing for the ATV.

(III) Wiring Diagram(2)

Provides a second detailed wiring diagram for specific ATV systems.

(IV) Wiring Diagram(3)

Presents a third wiring diagram illustrating further circuit connections.

Section 7 Requirements for Torque of Fastener

(I) ATV Body

Lists torque specifications for ATV body fasteners.

(II) Engine

Details torque requirements for various engine component fasteners.

(III) General Torque Specification

Outlines general torque specifications for standard screws.

Section 8 Lubrication

(I) Lubrication Oil Way

Illustrates the engine's lubrication oil flow path.

(II) Lubrication Diagram

Presents a diagram illustrating the engine's lubrication system.

Section 9 Lubrication Point and Type of Lubricants

(I) Lubrication Point and Type of Lubricants (ATV Body)

Lists lubrication points and recommended lubricant types for the ATV body.

(II) Lubrication Point and Type of Lubricants (Engine)

Details lubrication points and recommended lubricant types for engine components.

Chapter II MAINTENANCE AND ADJUSTMENT OF VEHICLE

Section 1 Periodic Maintenance/Lubrication

Provides a schedule for periodic maintenance and lubrication tasks.

Section 2 Diassembly and Assembly of Cushion, Fender and Fuel Tank

Details disassembly and reassembly steps for the ATV's cushion.

(II) Rear Fender

Outlines the procedure for disassembling the rear fender of the ATV.

(III) Fuel Tank

Provides instructions for removing the ATV's fuel tank.

(IV) Front Fender

Explains the procedure for disassembling the front fender of the ATV.

Section 3 Maintenance and Adjustment of Vehicle Body

Covers inspection and adjustment of front and rear brakes.

(I) Wear Inspection of Front & Rear Brake

Details procedures for inspecting front and rear brake wear.

(II) Adjustment of Front Brake

Guides on adjusting the front brake's free clearance.

(IV) Position Adjustment of Steering Lever

Explains the procedure for adjusting the steering lever's position.

(V) Lubricating Oil Level Inspection of Rear Driving Gear Case

Guides on checking and maintaining the lubricating oil level in the rear driving gear case.

(VI) Replacement of Engine Oil of Rear Driving Gear Case

Provides instructions for draining and refilling the engine oil in the rear driving gear case.

(VII) Rubber Sleeve Inspection of Rear Wheel Fork

Explains how to inspect the rubber sleeve on the rear wheel fork for wear or damage.

(VIII) Inspection of Steering System

Guides on inspecting various parts of the ATV's steering system.

(IX) Adjustment of Toe-in of Front Wheel

Details the procedure for measuring and adjusting the toe-in alignment of the front wheels.

(X) Inspecion of Front/Rear Shock Absorber

Guides on inspecting front and rear shock absorbers for damage or leaks.

(XI) Adjustment of Rear Shock Absorber

Details how to adjust the spring preload on the rear shock absorber.

(XII) Inspection of Tire

Discusses tire types, characteristics, and correct tire pressure for safe operation.

(XIII) Inspection of Rim

Explains how to inspect wheel rims for cracks, bends, or damage.

Section 4 Maintenance and Adjustment of Electrical Appliance

(I) Inspection of Battery

Covers inspection, safety precautions, and maintenance of the battery.

(II) Inspection of Fuse

Details the procedure for inspecting and testing fuses.

(III) Replacement of Headlight Lamp

Provides step-by-step instructions for safely replacing the headlight bulb.

Section Five Maintainace and Adjustment of Engine

(I) Adjustment of Clutch

Covers clutch adjustment procedures for proper engagement.

(II) Clean of Air Filter

Details the procedure for cleaning the engine's air filter.

(III) Inspection of Spark Plug

Guides on inspecting, cleaning, measuring clearance, and installing the spark plug.

(IV) Adjustment of Idle Speed

Details the procedure for setting the correct idle speed for the engine.

(V) Adjusting ment of Free Clearance of Throttle Grip

Guides on adjusting the throttle grip's free play for responsiveness.

(VI) Adjustment of Speed Limitor

Details how to adjust the speed limiter to control maximum throttle opening.

(VII) Adjustment of Valve Clearance.

Provides detailed steps for adjusting the valve clearance when the engine is cold.

(VIII) Adjustment of Timing Chain Tension

Clarifies that timing chain tension is automatic and requires no manual adjustment.

(IX) Inspection of Ignition Timing

Guides on checking the ignition timing for correct engine performance.

(X) Measuring of Compressive Force

Details the steps for measuring engine compression force to assess performance.

(XI) Inspection of Oil Quantity of Engine

Guides on checking the engine oil level and adding oil if insufficient.

(XII) Replacement of Engine Oil and Inspection of Oil Flow.

Provides instructions for replacing engine oil and inspecting the oil flow system.

Chapter III Repair and Maintenance of Vehicle body

Section 1 Rear Driving Gear Case and Driving Shaft

Addresses troubles and troubleshooting for the rear driving gear case and driving shaft.

(I) Trouble

Provides guidance on identifying and diagnosing common troubles in the rear drive system.

(II) Inspection

Outlines inspection steps for rear driving gear case and driving shaft components.

(IV) Disassembly

Outlines the steps for disassembling the rear driving gear case assembly.

(V) Inspection

Guides on inspecting gear teeth, oil seals, and bearings in the rear drive case.

(VI) Pad Choice of Main Driving Gear and Shift Gear

Details the process for calculating and selecting the appropriate washer thickness for gears.

(VII) Installation:

Provides instructions for installing various parts of the rear drive assembly.

Section 2 Front Wheel and Front Brake

(I) Disassembly

Details disassembly steps for the front wheel and brake system.

II. Inspecting Procedures

Details inspection steps for the front wheel, including rim run-out and tire surface.

Section 3 Rear Wheel/Rear Brake/Rear Wheel Axle

(I) Removal Steps

Details the steps for removing the rear wheel and brake components.

(II) Inspection Steps:

Details inspection procedures for rear wheel, brake, and related parts.

(III) Installment Steps:

Provides instructions for installing rear wheel components, emphasizing lubrication.

Section 3 Steering Operation System

(I) Removal Steps of Steering Bar

Details the removal steps for the steering bar assembly.

(II) Removal Steps of Steering Vertical Column Welding

Outlines the removal of the steering vertical column assembly and related parts.

(III) Inspection Content

Guides on inspecting the steering bar, vertical column, and tension rod for damage.

(IV) Installment Steps

Provides instructions for installing the steering vertical column assembly.

(V) Installation Steps of Steering Bar

Guides on installing the steering bar, throttle grip, and related controls.

Section 4 Front Shock Absorber and Front Wheel Fork

(I) Disassembly:

Details the disassembly steps for the front shock absorber and wheel fork.

(II) Inspection Step

Guides on inspecting the front shock absorber and related parts for damage.

(III) Installment Steps

Provides instructions for installing the front shock absorber and wheel fork assemblies.

Section 5 Rear Shock Absorber and Rear Wheel Fork

(I) Disassembling Steps

Details the disassembly steps for the rear shock absorber and wheel fork.

(II) Checking Steps

Guides on checking the rear shock absorber for leaks or damage.

(III) Mounting Steps:

Provides instructions for mounting the rear shock absorber and wheel fork assemblies.

Chapter IV Electric Appliance

Section 1 Inspect Switch

Covers inspection procedures for various electrical switches.

Section 2 Check Lamp (Headlight)

Explains how to test the headlight bulb and socket for proper electrical continuity.

Ignition System Diagram

Section 3 Troubleshooting the Ignition System Failure

Step

Provides a step-by-step guide for troubleshooting ignition system failures.

Electric Starting Diagram

Section 4 Running of Starting Circuit

Section 5 Troubleshooting Electric Starting System

1. Safety

Outlines safety precautions before troubleshooting the electric starting system.

2. Battery

Details checks for the battery condition and voltage.

3. Starting Motor

Details checks for the starting motor's running condition.

Section 6 Check Starting Motor

1. Check

Covers inspection of the reverser's cleanliness and diameter.

2. Ensure

Ensures the reverser diameter is within specifications.

3. Measure

Covers measurement of the mica cut sheet for the reverser.

4. Check

Covers inspection of the armature winding for insulation and power on.

Section 7 No Charging in the Battery

1. Safety

Outlines safety precautions before checking battery charging.

2. Battery

Details checks for the battery condition and voltage.

3. Charging Voltage

Guides on checking the charging voltage of the battery.

Diagram of Lighting System

Section 8 Troubleshooting

Steps

Provides troubleshooting steps for headlight or taillight failures.

Section 9 Inspection of Lighting System

(I) If the Headlight is Out of Work

Details inspection procedures for headlight failures.

(II) If the Taillight is Out of Work

Guides on troubleshooting when the ATV's taillight is not working.

(III) If the HB Indicated Lamp is Out of Work

Guides on troubleshooting when the HB indicator lamp is not working.

Diagram of Signal System

Section 10 Troubleshooting

(I) If Indicated Lamp is Out of Work

Provides troubleshooting steps for indicated lamp failures.

Section 11 Inspection of Signal System

(I) If the Neutral Indicated Lamp is Out of Work

Guides on troubleshooting when the neutral indicator lamp is not working.

(II) If the Reverse Indicated Lamp is Out of Work

Guides on troubleshooting when the reverse indicator lamp is not working.

(III) If the HB Indicated Lamp is Out of Work

Guides on troubleshooting when the HB indicator lamp is not working.

Chapter V Engine

Section 1 Disassembly of Engine

Covers the process of removing the engine from the ATV.

(I) Remove the Engine from Finished ATV

Details the steps for removing the engine from the ATV.

(II) Disassembly of Engine

Provides instructions for dismantling various engine components.

Section 2 Inspection and Maintenance of Engine

Covers inspection and maintenance of engine components like cylinder and valves.

1. Cylinder Cover

Covers inspection and maintenance of the cylinder cover.

2. Intake and Exhaust Valve

Covers inspection and maintenance of intake and exhaust valves.

3. Valve Guide Pipe

Covers inspection and maintenance of the valve guide pipe.

8. Valve Rocker and Rocker Shaft

Covers inspection and measurement of valve rocker and shaft.

9. Timing Chain

Explains how to inspect the timing chain for wear or damage.

10. Timing Sprocket and Crankshaft Sproket

Guides on inspecting timing sprockets and crankshaft sprockets.

11. Guide Plate

Explains how to inspect the guide plates for wear or damage.

12. Chain Tensioner

Details inspection of the chain tensioner's pushing rod and washer.

16. Crankshaft

Covers measurement and inspection of the crankshaft.

17. Driving Gear of Balance Shaft and Gear of Balance Shaft

Covers inspection of balance shaft gears for wear or damage.

18. Primary Gear and Electric Starting Gear

Details inspection of primary and electric starting gears.

Piston Pin

Covers inspection and measurement of the piston pin.

22. Shift Fork and Fork Shaft

Guides on inspecting shift forks and shafts for wear or damage.

23. Shift Cam

Guides on inspecting the shift cam's groove for wear or damage.

24. Main/Vice Shaft and Gtar

Details measurement of shaft runout and side clearance.

Section 3 Assembly and Adjustment of Engine

Covers the assembly and adjustment procedures for the engine.

(I) Closing Assembly of Left & Right Crankcase

Details the closing assembly of the left and right crankcases.

(II) Assembly of Right Crankcase

Guides on the assembly of the right crankcase.

1. Balance Shaft Gear and Driving Gear

Covers installation and inspection of balance shaft gears.

2. Shift Shaft and Oil Pump

Covers installation and tightening of the shift shaft and oil pump.

3. Installment

Details installation steps for the reverse operation system.

(V) Assembly of Cylinder Head

Details the assembly of the cylinder head.

6. Installtion of Adjusting Washer

Explains the installation of adjusting washers for proper gear clearance.

3) Washer C

Details the mounting of Washer C for gear adjustment.

4) Washer D

Details the mounting of Washer D for gear adjustment.

Chapter VI Vehicle Ordinary Trouble and Judgment

Trouble

Provides a guide for identifying and diagnosing common vehicle troubles.

Caution:

General caution for troubleshooting vehicle issues.

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