Kolpin Powersports 180cc Service Manual
CONTENTS FIG.-01 FIG.-02 FIG.-03 FIG.-04 FIG.-05 FIG.-06 FIG.-07 FIG.-08 FIG.-09 FIG.-10 FIG.-11 FIG.-12 FIG.-13 FIG.-14 FIG.-15 FIG.-16 FIG.-17 FIG.-18 FIG.-19 FIG.-20 FIG.-21 INFORMATION.……………………….……………. VEHICLE INSPECTION…………………………....... OVERVIEW…………………………………….…….. FENDER..……………………………………...……... FUEL &OIL TANK……………..…………………….. MUFFLER……………………………………………. HANDLEBAR………………………………………... ENGINE REMOVAL…….…………………………… TIRE AND RIM……………….……………………… FRONT BRAKE……………………………………… REAR BRAKE………………………………………...
FIG-01 INFORMATION SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing.
FIG-01 INFORMATION SPECIFICATIONS TYPE OVERLAND – 180CC ENGINE TYPE Air-Cooled 4-stroke, with Oil Cooler, Horizontal Stroke CYLINDER NUMBER 1 DISPLACEMENT 169 cc BORE STROKE ∮ 61×57.8mm COMPRESSION RATIO 9.1:1 MAX. TORQUE 6.37 Nm@4403 rpm CARBURETOR MIKUNI 180 STARTING Electric/ Kick back-up LUBRICATE Forced pressure and wet sump LUBR. CAPABILITY 1 Liter TRANSMISSION Automatic (C.V.
FIG-01 INFORMATION SERIAL NUMBER The frame serial number is stamped on the front frame. The engine number is stamped under the crankcase.
FIG-01 INFORMATION TORQUE VALUES STANDARD 5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 5 N.m (3.5 lbs.ft) 10 N.m (7.2 lbs.ft) 22 N.m (16 lbs.ft) 35 N.m (25 lbs.ft) 55 N.m (40 lbs.ft) ENGINE Cylinder head nut Spark plug Cylinder head bolt 28 N.m (20.7 lbs.ft) 12 N.m (8.9 lbs.ft) 20 N.m (14.8 lbs.ft) Alternator bolt 8 N.m (5.9 lbs.
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FIG-02. Vehicle Inspection MAINTENANCE DATA SPARK PLUG Spark plug cap Recommended spark plugs Throttle lever free play: Idle speed Brake lever free play: Drive chain slack Front/rear tire size Front/rear tire pressure Toe-in 0.6-0.7mm NGK C7HSA or CR7HSA 5-10mm 1800rpm 10~20mm 15-25mm 21x7-10” / 21x10-8” 3±0.3psi (0.15 kgf/cm2) 5±10mm TORQUE VALUES Spark plug Tie-rod lock nut 12-19 N.m 35-43 N.
FIG-02. Vehicle Inspection MAINTENANCE SCHEDULE The maintenance intervals in the follow table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent servicing.
FIG-02. Vehicle Inspection FUEL TUBE Inspect the fuel lines for deterioration, (a-1) damage or leakage and replace if necessary. (Photo 1) THROTTLE OPERATION 1. Inspect for smooth lever operation, full opening and automatic full closing in steering positions. 2. Inspect for deterioration, damage, cuts and nicks, or kink in the throttle cable, replace it if necessary. 3. Check the throttle lever, free play should be not more than 5-10 mm at the tip of the throttle lever. (a-1) 4.
FIG-02. Vehicle Inspection SPARK PLUG The spark plug is located at the front of the engine. 1. Disconnect the spark plug cap and remove the spark plug (a-1) 2. Visually inspect the spark plug electrode for wear or cranks in insulator. Replace if needed 3. The center electrode should have square edges and the side electrode should have a constant thickness. 4. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. 5.
FIG-02. Vehicle Inspection DRIVE CHAIN ADJUSTMENT Stop ATV and shift transmission into neutral. Inspect the chain slack midway between the sprockets. The standard is 10-25 mm (5/8-1 inch). If needed remove the chain protectives cover and adjust the chain slack. (a-1) (Photo 8) Loosen the axle holder lock nut then adjust the drive chain slack by turning the adjusting nut. Tighten the axle holder lock nut. (a-1) Torque = 90N.m (65 Ft.
FIG-02. Vehicle Inspection FRONT BRAKE ADJUSTMANT The front brake has two cables to control right and left side brake simultaneously. You could adjust the gap of the front brake (a-1). (Photo 11) Loosen the fix nut (a-1) and adjust the position of cable to proper situation. (Photo 12) Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the lever. The standard is 10~20 mm.
FIG-02. Vehicle Inspection REAR BRAKE ADJUSTMENT Remove the rear brake locking nut set and the brake cylinder mounting bolts (a-1) (Photo 17) The setup of the adjusting nut of the brake pump(a-1): 1. The brake pedal should be in the highest location with the returning spring functioning correctly. 2. The adjusting nut changes the distance between the brake master cylinder and the hydraulic cylinder-driving rod. Make sure the nut touches the surface of the rod and revolve back 1 turn (360˚).
FIG-02. Vehicle Inspection REAR BRAKE FLUID REFILLING METHOD 1. Remove the oil tank cover (a-1). 2. Refill with the recommended DOT-3 brake fluid until the level reaches the upper limit.
FIG-02. Vehicle Inspection FRONT SUSPENSION 1. Check the R. and L. side suspension, the front suspension should be adjusted to the same preload (a-1). 2. Inspect the shocks for oil leakage; if any is present, replace shocks. 3. Check the welding of frame bracket, which is connected to front suspension. 4. Also, check the swing arm for cracks or dents (a-2). (Photo 23) REAR SUSPENSION 1. Check the rear suspension for proper spring preload (a-1).
FIG-02. Vehicle Inspection STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. (a-1). (Photo 27) STEERING SHAFT HOLDER BUSHING Remove the front fender. Remove the steering shaft holder and check the steering shaft bushing for wear or damage. If the bushing is worn or damaged, replace the bushing.
FIG-02. Vehicle Inspection GEAR OIL MAINTENANCE Gear oil needs to be changed every 200 hours. There is a gear oil drain hole bolt at the rear of the engine. 1. Unscrew this drain hole bolt and let the dirty oil flow out, catching the oil in a proper container for later disposal. 2. Reinstall the drain hole bolt and tighten. 3. Fill with new gear oil through the oil fill hole located on the engine case beside the gearbox. (Photo 32) LUBRICATE There is a grease valve on the R. and L.
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FIG-03. Overview Parts Description 01. HANDLE BAR COVER 02. FRONT FENDER CARRIERS 03. HEAD LIGHT ASS’Y 04. POSITION LIGHT ASS’Y 05. MASTER CYLINDER SUB(L) 06. FRONT METAL RACK 07. BUMPER 08. FRONT SUSPENSION 09. RIGHT LEVER ASS'Y (Including parking brake) 10. L. SWITCH ASS'Y 11. MAIN SWITCH ASS'Y 12. NEUTRAL INDICATOR 13. REVERSE INDICATOR 14. FUEL GAUGE ASS'Y 15. TRANSMISSION LEVER 16. REAR SUSPENSION 17. SEAT 18. TAIL LIGHT ASS’Y 19. REVERSE LIGHTS 20. REFLECTOR 21. REAR METAL RACK 22.
FIG-04. Fender BUMPER Loosen the bolts (a-1) and Remove the bumper (a-2) from the frame body (Photo 1) FRONT METAL RACK Loosen the bolts (a-1) and Remove the front metal rack (a-2) from the frame body (Photo 2) REAR METAL RACK Loosen the screws (a-1) Loosen the bolts (a-3) Remove the rear rack bracket (a-2) Loosen the bolts (a-3) Remove the rear metal rack (a-4) (Photo 3) Note: Refer to the preceding disassembly instructions for re-assembly.
FIG-04. Fender FRONT FENDER COVER Loosen the screws (a-1) Remove the front fender cover (a-2) (Photo 4) BUMPER COVER Loosen the screws (a-1) Loosen the screws (a-2) Take off the main wire connect with the lights wire (a-3) Remove the front fender cover (a-4) (Photo 5) LICENSE PLATE Loosen the screws (a-1) Loosen the screws (a-2) Take off the main wire connect with the lights wire (a-3) Remove the license plate (a-4) (Photo 6) SEAT ASS'Y Pull the “Seat Release Bar” to take off the seat.
FIG-04. Fender FOOTREST Loosen the bolts (a-1) Remove the footrest ass’y (a-2) (Photo 10) Note: Refer to the preceding disassembly instructions for re-assembly.
FIG-05. Fuel & Oil Tank FUEL TANK Loosen the bolts (a-1) Take off the main wire connect with the fuel gauge wire (a-2) Loosen the bolts (a-3) Remove the petcock ass’y, vacuum shut-off (a-4) Remove the fuel tube (a-5) with the fuel filter ass’y(a-6) Remove the air tube (a-7) Remove the fuel tank (a-8) leave the frame body (Photo 11,12) CAUTION 1. There are rubbers on the frame body to reduce the vibration and to protect the fuel tank. 2. There is a breather tube in the fuel cap.
FIG-06. Muffler MUFFLER Loosen the bolts (a-1) and make it connected to the cylinder (a-2). (Photo 13) CAUTION 1. The muffler is hot during operation. 2. Do not touch the muffler or the heat shields. 3. Please check the gasket of muffler before mounting the muffler. Loosen the bolts (a-1) of the muffler (a-2) on the frame body (a-3). (Photo 14) Note: Refer to the preceding disassembly instructions for re-assembly.
FIG-07.
FIG-07. HANDLEBAR REAR BRAKE CABLE Remove the rear brake cable (a-1) (Photo 18) FRONT BRAKE CABLE Remove the R. and L. front brake cable (a-1) (Photo 19) THROTTLE CABLE Right lever ass’y loosen the screws (a-1) open the cover and mount the throttle cable (a-2) in the box (Photo 20) CAUTION 1. Smear grease on the throttle wire before mounting it in the throttle box. 2. There is a park brake on the R. level. 3. It is design for safety assurance.
FIG-08. Engine Disassembly DRIVE CHAIN ASS'Y Take off the chain master link set (a-1) Remove the drive chain (a-2) (Photo 23) TRANSMISSION ASS'Y Loosen the bolts (a-1) Remove the shifter plate (a-2) with the reverse cut-out switch and reverse indicator switch Remove the transmission lever (a-3) Remove the transmission fork link (a-4) (Photo 24) RADIATOR Loosen the bolts (a-1) on the frame body. Loosen the bolts (a-2) on the oil hose outlet.
FIG-09. Tire and Rim FRONT WHEEL ASS’Y Take off the rubber cap (a-1) and cotter pin (a-2) Loosen the insert lock nut (a-3) Remove the washer (a-4) and plain washer (a-5) (Photo 28,29) FRONT WHEEL ASS’Y Loosen the bolts (a-1) Remove the wheel tire (a-2) and rim (a-3) Remove the front brake drum (a-4) (Photo 30) FRONT TIRE SPECIFICATIONS Front tire -- 21*7.
FIG-10. Front Brake BRAKE SYSTEM Brake Parts & Location .
FIG-10. Front Brake FRONT BRAKE PLATE ASS'Y Remove the front brake cable (a-1) with the front brake arm put in the up side hole (a-2). Remove the front brake plate ass’y (a-3) Remove the front brake shoe comp (a-4). (Photo 34,35) CAUTION 1. Brake pads must be changed when the friction material is worn out (see indicator on brake face). 2. Assemble the front brake plate ass’y on the knuckle with the fixed position.
FIG-11. Rear Brake MASTER CYLINDER SUB Brake fluid level must be below the maximum level Fill with fluid when the level is below the “min” line (a-1) (Photo 37) CALIPER ASS'Y Check the brake pad kit, when the friction material is worn away, pads must be changed to a new set (a-1) (Photo 38) Loosen the bolts (a-1) Remove the caliper ass’y (a-2) Loosen the bolts (a-3) on the caliper Remove the brake pad kit (a-4) (Photo 39) CAUTION 1.
FIG-11.
FIG-12. Suspension FRONT SUSPENSION The front suspension is mounted on the frame (a-1) and suspension arm (a-2). Loosen the bolts (a-3) and nuts (a-4) Remove the front suspension (a-5) (Photo 47) CAUTION 1.The front suspension of the 50cc/100cc can be adjusted to the proper damper according driver’s preference. REAR SUSPENSION The rear suspension is mounted on the frame (a-1) and swing arm sub ass’y (a-2).
FIG-13. Suspension Arm KNUCKLE Take off the cotter pin (a-1) Loosen the nut (a-2) Remove the steering tie-rod ass’y (a-3) (Photo 49) Take off the cotter pin (a-1) Loosen the insert lock nut (a-2) Remove the washer (a-3) Remove the knuckle (a-4) (Photo 50) SUSPENSION ARM Loosen the bolts (a-1) with the suspension (a-2) Loosen the bolts (a-3) and nuts (a-4) with the frame body (a-5) (Photo 51) CAUTION 1. The suspension arm marked “R” is for the right side. 2.
FIG-14.
FIG-15. Steering Shaft STEERING SHAFT Turn on the spring washer (a-1) Loosen the bolts (a-2) Remove the spring washer (a-3) and cable fix seat (a-4) Remove the steering shaft hold (a-5) Remove the space ring steering shaft oil seal (a-6) (Photo 56) CAUTION 1. Before mounting steering shaft, please smear grease on the steering shaft oil seal.
FIG-16. Frame Comp FRAME COMP Take off the o-ring (a-1) Remove the steering bearing seat (a-2) (Photo 58) Note: Refer to the preceding disassembly instructions for re-assembly.
FIG-17. Light HEAD LIGHT ASS’Y Loosen the screws (a-1) Remove the head light ass’y (a-2) (Photo 59) Turn off the light cover (a-1) Remove the position light bulb ass’y (a-2) (Photo 60) CAUTION 1. The position light bulb specifications is 12V 10W 2. The head light bulb specifications is 12V 20W TAIL LIGHT ASS’Y Loosen the screws (a-1) Remove the tail light cover (a-2) (Photo 61) CAUTION 1. When change the bulb only loosen the screws and then open the cover. 2.
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FIG-18. Engine Disassembly ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY! ENGINE REMOVAL Remove the front, rear rack, and handle bar. Remove the footrest. Remove the spark plug cap from the spark plug. Remove the exhaust muffler. Disconnect the carburetor cable by unscrewing two screws on top of the carburetor. Disconnect the wire connectors.
FIG-18. Engine Disassembly LUBRICATION SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump. Fill the oil pump with clean oil when reassembling the pump. SPECIFICATIONS Engine Oil Capacity Engine Oil Recommendations 0.8-1.0 Liters Viscosity: (SAE 15W-40) API Service classification: SF-SG OIL PUMP STANDARD Cover-to-rotor clearance Rotor tip clearance End clearance SERVIC ----------------0.01-0.
FIG-18. Engine Disassembly LUBRICATION ENGINE OIL LEVEL Place the engine on the level plane. Check the oil level with the oil level gauge, but do not screw it in when making this check.(a-1) (Photo 1) OIL LEVEL GAUGE Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge.
FIG-18. Engine Disassembly LUBRICATION ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. (a-1) (Photo 3) NOTE: drain the oil while the engine is warm to ensure complete draining. Remove the oil filter cap (a-1), spring (a-2) and oil filter screen. (a-3) Check the O-ring for damage or fatigue. (a-4) Install a new oil filter screen and spring then install the cap. (Photo 4) Install a new oil filter screen and spring then install the cap.
FIG-18. Engine Disassembly OIL PUMP REMOVAL FAN COVER ASS’Y Loosen the screw (a-1), Remove the fan cover ass’y (a-2), (Photo 6) FAN Loosen the screw (a-1), Remove the cooling fan composition (a-2), (Photo 7) GENERATOR ASS'Y Loosen the nut (a-1) Use the special tool Remove the generator face flywheel. (a-2) Loosen the bolts Remove the stator comp. (Photo 8) RIGHT CRANKCASE COVER Loosen the bolts (a-1) Remove the right crankcase cover.
FIG-18. Engine Disassembly OIL PUMP REMOVAL OIL PUMP Loosen the bolts (a-1) Remove the oil separator. (a-2) (Photo 11) Remove the oil pump chain (a-1) Remove the oil pump drive (a-2) (Photo 12) Loosen the bolts (a-1) Remove the oil pump ass’y (a-2) (Photo 13) Note: Refer the foregoing disassembly procedures to re-assemble.
FIG-18. Engine Disassembly OIL PUMP REMOVAL DISASSEMBLE THE OIL PUMP INSPECTION Measure the oil pump rotor-to-body clearance. (Photo 14,15) SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump clearance. (Photo 16) SERVICE LIMMIT: 0.12 mm. Remove the oil pump shaft and measure the pump and clearance. (Photo 17) SERVICE LIMMIT: 0.2 mm. Install the outer rotor, inner rotor and oil pump shaft onto the body.
FIG-18. Engine Disassembly CYLINDER HEAD / VALVES SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head, valves, camshaft and associated parts The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.
FIG-18. Engine Disassembly CYLINDER HEAD / VALVES TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope. Low compression valve Incorrect valve adjustment. Worn or damaged valve seats. Burned or bent valve. Incorrect valve timing. Weak valve spring. Cylinder head Leaking or damaged head gasket. Warped or cracked cylinder head.
FIG-18. Engine Disassembly CYLINDER HEAD / VALVES CYLINDER HEAD ASS’Y REMOVAL SHROUD ASS’Y Loosen the bolts (a-1) Remove the carburetor overflow tube Remove the intake manifold Loosen the bolts Remove the shroud (Photo 19) LIFTER TENSIONER LIFTER Relax the cam chain adjuster screw. (a-1) Remove the screw and O-ring and tighten the cam chain adjusting bolt with clockwise direction.
FIG-18. Engine Disassembly CAMSHAFT COMP INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. (a-1) (Photo 24) SERVICE LIMIT: IN：25.57/26.18 mm EX：25.41/26.02 mm Inspect the camshaft and bearings for wear or damage and replace them if necessary. (Photo 25) Screw a 5 mm bolt into the rocker arm shaft threaded end and pull on the bolt to remove the shafts and rocker arms. (Photo 26) Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage.
FIG-18.
FIG-18. Engine Disassembly CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor. (Photo 32) INSPECTION Clean off all carbon deposits from the combustion dome and check the spark plug hole and valve area for cracks (Photo 33) Measure the cylinder head diagonally for warp with a straight edge and feeler gauge. (Photo 34) Measure the free length of the inner and outer valve springs. (Photo 35) SERVICE LIMITS: Inner 31.2 mm Outer 34.
FIG-18. Engine Disassembly CYLINDER HEAD ASS’Y Lubricate each valve stem with oil. Insert the valves into the guides. Install the valve springs, retainers and the cotters. (Photo 37) NOTE: To prevent loss of tension, don’t compress the valve springs more than necessary. INSTALLATION Install the new gasket and dowel pins. (Photo 38) Install the cam chain guide. (Photo 39) Install the cylinder head. (Photo 40) CAMSHAFT ASS’Y INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.
FIG-18. Engine Disassembly CYLINDER HEAD ASS’Y CAMSHAFT ASS’Y INSTALLATION Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole towards the front. (Photo 43) Install the dowel pins and camshaft holder. Tighten the washers and nuts (Photo 44) Torque: 20 n-m (2.0 kg-m) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge. (Photo 45) STANDARD VALVE: 0.
FIG-18. Engine Disassembly CYLINDER AND PISTON SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place. SPECIFICATION ITEM Cylinder STANDARD 52,400-52,410/ 61,730-61,740 SERVICE LIMIT 52.50/ 61.830 Taper ---------- 0.10 Out of round ---------- 0.10 Warp across top ---------- 0.10 I.D.
FIG-18. Engine Disassembly CYLINDER AND PISTON TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings. Overheating Excessive carbon build-up on piston or combustion chamber wall Knocking or abnormal noise Worn piston and cylinder. Excessive carbon build-up. Excessive smoke Worn cylinder, piston, or piston rings. Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal.
FIG-18. Engine Disassembly CYLINDER AND PISTON CYLINDER REMOVAL Remove the cylinder head. (Photo 47) Remove the cylinder. (Photo 48) Remove the cylinder gasket and dowel pins (Photo 49) Clean off any gasket materials from the cylinder surface. (Photo 50) NOTE: Be carefully not to damage the gasket surface.
FIG-18. Engine Disassembly CYLINDER AND PISTON PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. (Photo 51) NOTE: Do not allow the clip to fall into the crankcase. Remove the piston pin from the piston Remove the piston. (Photo 52) Spread each piston ring and remove it by lifting up at a point opposite the gap (Photo 53,54) INSPECTION Inspect the cylinder walls for scratches or wear (Photo 55,56) Measure and record the cylinder I.D.
FIG-18. Engine Disassembly CYLINDER AND PISTON INSPECTION Inspect the top of the cylinder for warp (Photo 57) SERVICE LIMITS: 0.10 mm PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance. (Photo 58) SERVICE LIMITS: TOP 0.12 mm SECOND 0.12 mm Inspect the piston for wear or damage. Insert each piston ring into the cylinder and measure the ring end gap.
FIG-18. Engine Disassembly CYLINDER AND PISTON PISTON / PISTON RING INSPECTION Calculate the piston-to-piston pin clearance. (Photo 63) SERVICE LIMITS: 0.02 mm Measure the connecting rod small end I.D. (Photo 64) SERVICE LIMITS: 15.06 mm PISTON &PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston ring with the marks facing up. NOTE: Don’t interchange the top and second rings to avoid piston and piston ring damage during installation.
FIG-18. Engine Disassembly CYLINDER AND PISTON CYLINDER INSTALLATION Clean any gasket material from the crankcase surface. (Photo 68) NOTE: Be carefully not to damage the gasket surface. Install the dowel pins a new gasket. Coat the cylinder bore and piston rings with engine oil and install the cylinder. (Photo 69,70) NOTE: Avoid piston rings damage cylinder bore during installation. Do not allow the cam chain fall into the crankcase. Install the cylinder head.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER SERVICE INFORMATION If the drain tube ass’y fills with water, the tube should be drained. SPECIFICATIONS ITEM Driven the width Weight roller O.D. Movable drive face I.D. Drive face collar I.D. Drive face boss O.D. Clutch outer I.D. Clutch weight lining thickness Driven face spring length TORQUE VALUES Clutch outer nut Drive face nut STANDARD (mm) 19.8-20.2 15.0-15.02/17.0-17.02 27.98-28.0 24.06-24.09 23.96-23.98 124.8-125.2 -------------168.4-169.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER DISASSEMBLE LH CRANKCASE COVER Relax the band screw (a-1) and remove the C.V.T inlet duct. (Photo 72) Loosen the screws (a-1) Remove the air cleaner case. (a-2) (Photo 73) Loosen the bolts (a-1) Remove the bolts and LH crankcase cover. (a-2) (Photo 74) Remove the gasket and dowel pins (Photo 75) Clean off any gasket material from L crankcase surface.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER C.V.T REMOVAL Relax the flange nut (a-1), and remove the drive face. (a-2) (Photo 77) Relax the flange nut. (a-1) Remove the drive pulley ass’y and driven belt. (a-2) (Photo 78) Remove the drive face boss (a-1) and movable driven face ass’y.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER INSPECTION Inspect the drive belt for wear, tears or damage. Measure the width of drive belt. (Photo 82) SERVICE LIMIT: 19.0 mm Inspect the weight roller for wear or damage and replace them if necessary Measure the O.D. of weight rollers. (Photo 83) SERVICE LIMIT: 14.6/16.6 mm Inspect the drive face collar for wear or damage. Measure the I.D. of drive face collar. (Photo 84) SERVICE LIMIT: 24.098 mm Inspect the drive face boss for wear or damage.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER Measure the length of driven face spring (Photo 88) SERVICE LIMIT: 164.0 mm Inspect the driven face ass’y and replace them if necessary. (Photo 89) KICK STARTER DISASSEMBLY Remove the kick-starter. (a-1) Remove the LH crankcase cover. (a-2) (Photo 90) Remove the ex. Circle-clip and washer from kick starter spindle composition. (a-1) (Photo 91) Remove the kick-starter spindle ass’y. Remove the kick-starter idle gear ass’y Remove the kick spindle bush.
FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER INSPECTION Inspect the kick-starter spindle composition for wear or damage. (Photo 93) Inspect the kick-starter return spring for fatigue or damage Inspect the kick-starter spindle bush for wear of damage. (Photo 94) Inspect the kick–starter gear and spring for wear or damage. (Photo 95) KICK-STARTER ASSEMBLY C.V.T ASSEMBLY Annotate: Refer the foregoing disassembly procedures to re-assemble.
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FIG-19.
FIG-19. Electric System Battery Electrolyte is poisonous. Drink large quantities of water or milk and call a physician if swallowed.
(Photo 2) FIG-19. Electric System BATTERY CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. Electrolyte is poisonous.
FIG-19. Electric System ELECTRIC STARTER Information A weak battery may be unable run the starter motor quickly enough. If the battery voltage is enough while the engine is not cranking, the starter motor may be damaged. Troubleshooting Starter motor turns slowly Weak battery. Poorly connected starter motor cable. Faulty starter motor. Poorly connected battery ground cable. Starter motor will not turn Engine stop switch at left or right position. Gearshift bar is not at neutral position.
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FIG-20. Trouble shooting STARTING DIFFICULT Check 、Adjust Trouble Cause Trouble Condition Loosen the carb fuel drain screw; check the carburetor for fuel flow Fuel available No fuel flow Remove the spark plug and install the spark plug cap to contact with engine. Check for spark Spark plug with spark Spark plug without spark 1. Fuel tank empty 2. Throttle valve jammed 3. Fuel filter jammed 1. Spark plug electrode worn out 2. Spark plug fouled 3. C.D.I no good 4. Generator no good 5.
FIG-20. Trouble shooting STARTS BUT IMMEDIATELY STOPS Check 、Adjust Trouble Condition Trouble Cause Loosen the carb fuel drain screw; check the carburetor for fuel flow Fuel available No fuel flow 1. Fuel tank empty 2.Throttle valve jammed 3.Fuel filter jammed Remove the spark plug 1. Clean the soot off the spark plug Spark plug clean, insulator not discolored ` Spark plug carboned up 2.Spark plug temperature not standard Remove the spark plug and install the spark plug cap to contact with engine.
FIG-20. Trouble shooting STARTS BUT IMMEDIATELY STOPS Check 、Adjust Trouble Cause Trouble Condition Check carburetor air adjust screw 1. Too rich (turn screw out) Adjusted correctly Adjusted incorrectly 2. Too lean (turn screw in) Check carburetor gasket seal 1. Carburetor not tight Tight seal Air leaks 2. Intake manifold gasket no good 3.
FIG-20. Trouble shooting SPEED TOO SLOW、NO POWER Check 、Adjust Trouble Cause Trouble Condition Start engine and check the throttle valve response Engine revs freely Engine doesn’t rev Adjust the ignition timing (use the timing light) 1. Air cleaner dirty 2. Fuel filter plugged 3. Exhaust pipe plugged 1.C.D.I no good Ignition timing normal Ignition timing not normal 2. Generator no good Test compression pressure Pressure normal Pressure not enough or without pressure 1.
FIG-20. Trouble shooting ENGINE RUNS ROUGH (ESPECIALLY AT LOW SPEED AND IDLING) Check 、Adjust Trouble Cause Trouble Condition Check the ignition timing 1. C.D.I no good Normal Not normal 2. Generator no good Check carburetor air Adjust screw 1.C.D.I no good Adjust well Adjust no good 2. Generator Test compression pressure Pressure normal Pressure not enough or without pressure 1. Too rich (turn screw out) 2.
FIG-20. Trouble shooting ENGINE RUNS ROUGH (ESPECIALLY AT HIGH SPEED) Check 、Adjust Trouble Cause Trouble Condition Check the ignition timing 1. C.D.I no good Normal Not normal 2. Generator no good Check the amount of fuel 1. Fuel level low Good No good 2. Oil tube and fuel filter clogged Check for jammed carburetor No Yes 78 1. Clean each jammed throttle cable.
FIG-20. Trouble shooting ABOUT THE CLUTCH AND DRIVE Trouble Cause Trouble Condition 1.V-BELT worn 2. Brake stuck Engine starts, but vehicle doesn’t move Engine will not rev beyond idle speed to engage the clutch 3. Clutch weight spring broken 4. Clutch carrier worn 5. Final gear broken 6. Gear final to worn out 1. Rear brake shoe return spring broken 2. Primary clutch rollers and ramp not activating or broken 3. Axle spline worn/stripped out 1.
FIG-20. Trouble shooting FRONT SUSPENSION AND REAR SUSPENSION NOT BALANCED Trouble Cause Trouble Condition (Front and rear tire pressure normal) 1. Suspension spring too soft Suspension system too soft Suspension system too stiff Suspension abnormally noisy 2. Load weight too high 3. Suspension leaked oil 1. Suspension too stiff 1. Suspension and spring rubbing 2. Suspension and Suspension cover damaged BRAKE NO GOOD Trouble Cause Trouble Condition (Brake adjust follow standard) 1.
FIG-20. Trouble shooting OIL LEVEL LOW BUT LAMP NOT BRIGHT (WHEN MAIN SWITCH “ON”) Check 、Adjust Trouble Cause Trouble Condition Remove the oil level lamp, link battery, check the bulb Bulb good Bulb no good 1. Bulb blown Check each joint 1. Line joint loose ` Good No good 2. Main switch wire broken 3. Wiring incorrect Remove the oil level gauge, test the piston and warning lamp Piston up=to put out light Piston down=light bright 1. Oil level gauge Good No good 2.
FIG-20. Trouble shooting STARTING MOTOR DOES NOT SPIN Check 、Adjust Trouble Cause Trouble Condition Check brake power and brake switch Brake light bright Brake light not bright 1. Fuse blown 2. Battery voltage low .3. Brake light switch no good 4. Wires loose 5. Main switch wire broken Open signal light check battery return Circuit Good No good 1. Battery voltage too low or dead Push start switch, check the starting relay action Normal Not normal 1. Start switch contact no good 2.
FIG-20. Trouble shooting STARTING MOTOR SPINS SLOWLY OR TURNS WITHOUT ENGAGING MOTOR Check 、Adjust Trouble Cause Trouble Condition No signal light check battery ground circuit Good No good 1. Battery voltage low or no good Starting motor connection to battery Starting motor rotates Starting motor does not rotate 1. Starting motor no good 2. Wiring not connected Crankshaft rotation Rotate fast Rotate slowly 1. Cylinder siezed 2. Starting motor broken 3.
0.6~0.
FIG-21.
