ATV 250 - (II) Disassembly of Engine

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(II) Disassembly of engine

1.Remove

.Hand starting unit¢Ù

2.Remove

.Screw ¢Ù¢Ú¢Û

.Reverse controlling bar unit¢Ü

.Wahser

Pay attention not to lose washer

3.Remove

.Sproket cabinet cover ¢Ù

4.Remove

.Spark plug¢Ù

.Upper valve cap(intake)¢Ú

.Lower valve cap(exhaust)¢Û

¢Ù

¢Ú

¢Û

-145-

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Table of Contents3
Chapter I General Description7
Section 1Description7
Section 2 Special Tools, Instruments & Meters8
- (I) Special Tools8
- (II) Instruments & Tools9
Section 3 Identification Code, Label of Model 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 Adjustmen of Steering Lever48
- (V) Lubricating Oil Level Inspection of Rear Driving Gearcase48
- (VI)Replacement of Engine Oil of Rear Driving Gear Case49
- (VII) 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 3 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 4 Front Shock Absorber and Front Wheel Fork107
- (I)Disassembly107
- (II) Inspection Steps109
- (III)Installment Steps110
Section 5 Rear Shock Absorber and Rear Wheel Fork113
- (I)Disassembling Steps113
- (II)Checking Steps115
- (III) Mounting117
Chapter IV Electric 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 Engine165
Section 3 Assembly and Adjustment of Engine189
- (I) Closing Assembly of Left & Right Crankcase189
- (II) Assembly of Right Crankcase190
- (III) Assembly of Left Crankcase198
- (IV) Selection and Installation of Adjusting Washer203
- (V) Assembly of Cylinder Head210
- (VI) Manual Starting Mechanism and Others217
- (VII) Mount the Engine on the Finished Vehicle219
Chapter VI Vecicle Ordinary Trouble and Its Judgement224
- ( I )Starting Trouble/Difficulty224
- (II)Poor Idle Speed Performance225
- (III) Poor Middle and High Speed Performance225
- (IV) Shifting Troubler225
- (V) Clutch Slips226
- (VI) Clutch Is Locked226
- (VII) Engine Is Overheat226
- (VIII) Brake Trouble226
- (IX) Shock Absorber Failure/Improper Operation226
- (X) Lighting System227

ATV 250 - (II) Disassembly of Engine

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