ATV 200 User manual

BRIEF INTRODUCTION TO FOUR-WHEELED
CROSS-COUNTRY VEHICLE MODEL 200ATV
Four-wheeled cross -country vehicle, model 200ATV is a full road condition vehicle
whichcanbedrivenonevery kindsofroadconditionssuchassandbeach,grassland,forest,
village,construction site country road , This maintenance manual of four-wheeled vehicle
model200ATV(Hereafter calledcross-country vehicle for short) compiledbyChongqing
Industries Co., Ltd is specially provided for saler and technical staff of our Group. This
manualmainlyintroducethemaintenance,removingandrepairingmethodofcross-country
vehicle and provide some relative technology and performance data. Because this manual
can’t collect the whole content of cross-country vehicle, it can only help maintainer of our
groupandit’ssalerhaveabasicunderstandingonworkingprinciple,maintenanceprocedure
andrepairingtechnologyofcross-countryvehicle. If you don’t have this knowledge, when
repairingcross-countryvehicle,theconditionofimproperassemblinganddangeroccursafter
assemblingareeasily happened. Properoperationand maintenance aretheadvance of your
safelydriving cross-countryvehicle, italsocan reducethe troublesofcross-countryvehicle
andkeepthebestperformanceofit.Thespecification,performanceandexplanationstatedin
the manual are determined according to newly design of the vehicle, which are subject to
changeswithoutnotice.
Inthismanual,forspeciallyimportant requirement,thewordsof“Warning”“Caution”
arelabelled toprompt relativemaintainertoabideit.
Inthemanual
Caution
Showthatifthecontentof“Warning”isn’t obeyed,thedriver,maintainer,
checkerwillbeheavilyinjuried,evendead.
Showthat you mustbecareful topreventthe vehicle frombeingdamaged.
Warning
Maintenancemanualoffour-wheeledcross-countryvehiclemodel200ATV
Firstedition 2004
This manual is published by publishing factory. maintain the copyright of
publishing. Without permitted, publishing is prohibited.

Content
Content ...............................................................................................................................................I
Chapter I General description..............................................................................................................1
Section 1 Description ..........................................................................................................................1
Section 2 Special tools, instruments & meters ....................................................................................2
(I) Special tools ........................................................................................................................2
(II) Instruments & meters.........................................................................................................3
Section 3 Identification code, and engine No. ...................................................................................4
Section 4 Points for attention in maintenance.....................................................................................4
Section 5 Specification........................................................................................................................8
I. How to use conversion table of unit ....................................................................................8
(1)How to use conversion table...............................................................................................8
(2)Definition of unit .................................................................................................................8
II. Basic specification...............................................................................................................9
III.ATV body...........................................................................................................................10
IV. Electric system ...................................................................................................................11
V. Maintenance specification of engine ..................................................................................13
Section 6 Wiring diagram ofATV........................................................................................................16
(I) Technical explanation and requirement, details of relative component. ..............................16
(II)Wiringdiagram(1)...............................................................................................................18
(III)Wiringdiagram(2) .............................................................................................................19
(IV)Wiringdiagram(3) .............................................................................................................20
Section 7 Requirements for torque of fastener....................................................................................21
(1)ATV body ............................................................................................................................21
(2)Engine.................................................................................................................................23
(3) General torque specification ...............................................................................................25
Section 8 Lubrication ..........................................................................................................................26
(1)Lubrication oil way ..............................................................................................................26
(2) Lubrication diagram ............................................................................................................27
Section 9 Lubrication point and type of lubricants .............................................................................29
(1) Lubrication point and type of lubricants(ATV body).........................................................29
(2) Lubrication point and type of lubricants(Engine)...............................................................30
Chapter II Maintenance and adjustment of vehicle ............................................................................31
Section 1 Periodic maintenance/ lubrication .......................................................................................31
Section 2 Disassembly and assembly of cushion, fender and fuel tank..............................................32
(I) Cushion...............................................................................................................................32
(II) Rear fender .........................................................................................................................33
(III) Fuel tank ...........................................................................................................................35
I

(IV) Front fender ......................................................................................................................37
Section 3 Maintenance and adjustment of vehicle body ....................................................................39
(I) Wear inspection of front and rear brake ..............................................................................39
(II) Adjustment of front brake..................................................................................................39
(III)Adjustment of free clearance of left lever and rear brake pedal .........................................40
(IV) Position adjustment of steering lever ...............................................................................42
(V) Lubricating oil level inspection of rear driving gearcase ...................................................42
(VI) Replacement of engine oil of rear driving gear case .........................................................43
(VII) Rubber sleeve inspection of rear wheel fork....................................................................44
(VIII) Inspection of steering system ........................................................................................44
(IX) Adjustment of toe-in of front wheel ................................................................................ 45
(X) Inspection of front/rear shock absorber ............................................................................46
(XI) Adjustment of rear shock absorber ..................................................................................46
(XII) Inspection of tire .............................................................................................................47
(XIII) Inspection of rim ............................................................................................................48
Section 4 Maintenance and adjustment of electrical appliance...........................................................49
(I) Inspection of battery...........................................................................................................49
(II) Inspection of fuse ..............................................................................................................50
(III) Replacement of headlight lamp .........................................................................................51
Section 5 Maintenance and adjustment of engine .............................................................................. 53
(I) Adjustment of clutch ..........................................................................................................53
(II) Clean of air filter .................................................................................................................53
(III) Inspection of spark plug ................................................................................................... 55
(IV) Adjustment of idle speed..................................................................................................56
(V) Adjustment of free clearance of throttle grip .....................................................................56
(VI) Adjustment of speed limitator .......................................................................................... 57
(VII) Adjustment of valve clearance ........................................................................................58
(VIII) Adjustment of timing chain tension ...............................................................................60
(IX) Inspection of ignition timing ............................................................................................ 61
(X) Measuring of compressive force .......................................................................................62
(XI) Inspection oil quantity of engine ..................................................................................... 63
(XII) Replacement of engine oil and inspection of oil flow ......................................................64
Chapter III Repair and maintenance of vehicle body ..........................................................................67
Section 1 Rear driving gearcase and driving shaft.............................................................................. 67
(I) Trouble................................................................................................................................67
(II) Inspection ..........................................................................................................................67
(III) Trouble-shooting table .....................................................................................................68
(IV)Disassembly .....................................................................................................................69
(V) Inspection ..........................................................................................................................72
(VI) Pad choice of main driving gear and shift gear ................................................................. 73
II

(VII)Installation......................................................................................................................75
Section 2 Front wheel and front brake ...............................................................................................76
(I) Disassembly .......................................................................................................................76
(II) Inspecting procedures ......................................................................................................78
(III) Installation procedures ....................................................................................................81
Section 3 Rear wheel/Rear brake/Rear wheel axle...............................................................................84
(I) Removal steps ....................................................................................................................85
(II) Inspection steps ...............................................................................................................87
(III) Installment steps..............................................................................................................90
Section 4 Steering operation system..................................................................................................94
(I) Removal steps of steering bar ............................................................................................94
(II) Removal steps of steering vertical column welding ..........................................................95
(III) Inspection content...........................................................................................................96
(IV) Installment steps..............................................................................................................97
(V) Installation steps of steering bar ......................................................................................100
Section 5 Front shock absorber and front wheel fork ........................................................................101
(I) Disassembly .......................................................................................................................101
(II) Inspection steps ...............................................................................................................103
(III) Installment steps..............................................................................................................104
Section 6 Rear shock absorber and rear wheel fork............................................................................107
(I) Disassembling steps .......................................................................................................... 107
(II) Checking steps .................................................................................................................109
(III) mounting steps ................................................................................................................111
Chapter IV Electrical appliance ..........................................................................................................114
Section 1 Inspect switch ....................................................................................................................114
(I) Inspect switch ....................................................................................................................114
Section 2 check lamp(headlight) ........................................................................................................115
Section 3 Troubleshooting the ignition system failure ......................................................................117
Section 4 Running of starting circuit .................................................................................................122
Section 5 Troublshooting electric starting system ............................................................................123
Section 6 Check starting motor ..........................................................................................................126
Section 7 No charging in the battery .................................................................................................129
Section 8 Troubleshooting ................................................................................................................132
Section 9 Inspection of lighting system.............................................................................................134
(I) If the headlight is out of work ............................................................................................134
(II) If the taillight is out of work ..............................................................................................135
Section 10 Troubleshooting...............................................................................................................137
(I) If indicated lamp is out of work .......................................................................................... 137
Section 11 Inspection of signal system.............................................................................................. 139
(I) If the neutral indicated lamp is out of work ........................................................................ 139
III

(II) If the reverse indicated lamp is out of work ...................................................................... 140
(III) If the HB indicated lamp is out of work............................................................................ 141
Chapter V Engine ............................................................................................................................... 142
Section 1 Disassembly of engine ....................................................................................................... 142
(I) Remove the engine from finishedATV .............................................................................. 142
(II) Disassembly of engine ...................................................................................................... 145
section 2 Inspection and maintenance of engine ............................................................................... 155
Section 3 Assembly and adjustment of engine .................................................................................. 179
(I) Closing assembly of left & right crankcase........................................................................ 179
(II) Assembly of right crankcase ............................................................................................ 180
(III) Assembly of left crankcase.............................................................................................. 180
(IV) Assembly of cylinder head .............................................................................................. 199
(V) Manual starting mechanism and others ............................................................................ 206
(VI) Mount the engine on the finished vehicle ....................................................................... 208
Chapter VI Vecicle ordinary trouble and its judgement ...................................................................... 213
(I) Starting trouble/difficulty................................................................................................... 213
(II) Poor idle speed performance............................................................................................. 214
(III) Poor middle and high speed performance........................................................................ 214
(IV) Shifting trouble ................................................................................................................ 214
(V) Clutch slips ....................................................................................................................... 215
(VI) Clutch is locked ............................................................................................................... 215
(VII) Engine is overheat .......................................................................................................... 215
(VIII)Brake trouble ................................................................................................................. 215
(IX) Shock absorber failure/improper operation ..................................................................... 215
(X) Lighting system ................................................................................................................ 216
IV

Chapter IGeneral description
Section 1Description
1.Front wheel
2.Headlight
3.Drive select lever
4.Shift pedal
5.Fuel cock
6.Hand-operated lever
7.Air chock
8.Taillight
9.Rear wheel
10.Rear luggage carrier
11.Exhaust silencer
12.Cushion
13.Fuel tank cover
14.Rear brake pedal
15.Front luggage carrier
16.Clutch handle
17.Main switch lock
18.Throttle grip
19.Right lever of front brake
20. Left switch unit
Caution:
The ATV you purchased maybe slightly differ from the pictures in the manual due to
improvement or other changement.
123456789
10 11 12 13 14 15
- 1 -
16 17 18 19
20

Section 2 Special tools, instruments and meters
(I) Special tools
Special tools is the necessary tools used for accurately adjustment and assembly, it is
helpful to prevent the maintenance defects and components damage caused by using im-
proper tools.
1.Wrenchforvalveadjustmentmainlyusedforadjustingvalveclearance.Specification:
3mm 90890-01311
2.Pullerforpistonpin,mainlyusedofremovingpistonpin.
3.Removerforrotator,mainlyusedforpullingmagneto rotatorfromcrank.
4. Clamp for rotator, mainly used for clamping magneto rotator when removing it to
prevent its rotation due to torque force.
5.Stop rotating meter for rotator, mainly used for removing and assembling rotator of
kickstarter.
6.Pullerforcrank,mainlyusedfordisassemblingcrankfromcrankcase.
7.Pullerforrockershaft,mainlyusedfor removingrockershaft.
8.Compressingtoolsforspringofvalve,mainlyusedforfixingandcompressingspring
whenassemblingvalvelockclamp.
9.Assemblinganddisassemblingtoolsforvalveguide,mainlyusedforassemblingand
disassembling valveguide.
10.Assemblingbuffer,mainlyusedforassemblingcrankandbalancinggear.
11.Hollowsleeve,mainlyusedforassemblingcrankandbalancinggear.
12.Assemblingtoolsforcrank,mainlyusedforassemblingcrankandbalancinggear.
13.Assemblingand disassemblingjointfor universalcoupling, mainlyusedfor assem-
blinganddismsemblinguniversalcoupling.
14.Assemblinganddisassemblingdisc,mainlyusedforassemblinganddisassembling
reversegear.
15.Fixedpullerforgear,mainlyusedforassemblinganddisassemblinggear.
For the above tools, you can select with reference to special tools of the same
type of vehicle.
- 2 -

(II) Instruments and meters
The following instruments and meters can be selected with reference to the same type of
vehicle.
speedometer of engine
(90890-03113) multimeter
Ignition timing meter
(90890-03141) spark tester of spark plug
barometer ignition checker
measuring tool of gasolining
(90890-01312) dialindicator
- 3 -

Section 3 Identification code, and engine N0.
Identification code
It is engraved in the left or right side of front
supporting main tube of engine of frame.
Engine N0.
It is engraved on the lug of top middle part of
right crankcases of engine.
Section 4 Points for attention in maintenance
- 4 -
1.Preparation when disassembling
1.1 First clean the dirt, mud and attach-
ment on the vehicle before removing or
disassembling.
1.2 Use proper special tools cleaning de-
vice and means.
1.3 Keep all the components away from
fire source. Pay attention to the safety, Don’t
be burned by the high temperature portion of
engine, exhauster and silencer etc. Be sure to
take care of each other when operation with
other people.
1.4 When disassembling the ATV, put the
mated components, such as gear pairs,
cylinder, piston and other “mated” components
by normal running in together, When assem-
bling or replacing these components, they should
be in pairs.
1.5 When disassembling the engine, clean
all the components and put in the tray in the
order of disassembly, this in assembling, can
not only increase the assembling speed, but also
ensure the rightness of assembling.
2.Replace the components
When replacing the components, be sure
to use qualified products provided by use lubri-
cants and grease which brand is assigned by
lubricate.
3.Oil seal, shim, o-ring, clip, split pin,
elastic washer.
3.1 When disassembling to maintain the
engine, in order to ensure that the reassembled
engine have good sealing and connecting part
is fixed and reliable, all the oil seal, shim, o-
ring, clip, split pin and elastic washer should be
replaced, be sure to keep lip of oil seal surface
of shim and o-ring in cleaning condition.
3.2 When reassembling, apply lubricants
to lubricate all the mated components and
bearing, apply grease for oil seal.
¢Ù

4. Clip
4.1Before assembling, be sure to check
all the clips carefully.Use a new one after re-
moving the clip of piston pin. When mounting
clip ring ¢Ùmake the sharp face ¢Úon the op-
posite position of impacted face ¢Ûof clip.
(see left fig)
5.Locking washer /shim and location pin
5.1When reassembling after
disassembling. be sure to replace all the lock-
ing washer /shim and location pin @ After
bolt or nut is fixed on the locking position. be
sure to bend and fix both ends of locking shim
along head of bolt or direction of nut.
6.Bearing and oil seal
6.1 When assembling bearing and oil seal
put the mark or specification of manufacturer
outside, When assembling oil seal apply a thin
film of lithium-base grease on the lip of oil
seal.
Caution:
Don’t blow to dry the inside of bearing
with compressed air, this would damage the
surface of bearing.
- 5 -

7.Check of electric parts
7.1 Check the rust, dirt and moisture etc.
of connector, if there is moisture, please blow
it dry and clear the rust and dirt.
7.2 The electrolyte inside the battery is a
kind of corrosive, when operating exercise shall
be taken not to let the electrolyte splash on the
body.
7.3 When repairing wire on electric parts,
first remove the wire on the terminal of nega-
tive pole of battery(see fig.7.1).When tighten-
ing or loosening bolt of terminal of big capac-
ity battery, don’t let the wrench contact with
engine or other metal parts of vehicle body to
avoid the electric shock.
7.4 When connecting the wire of battery,
first connect the opositive pole wire of battery,
then connect the negative pole wire. After con-
necting the wire, apply clean grease on the ter-
minal to avoid the increasing of resistance due
to rust.
7.5 Check the terminal of connector
a Grip two terminals of connector together,
check with the multimeter.(see fig.7.3,fig.7.4)
Fig.7.1Removal of negative pole wire of battery
Fig.7.2 Connection of positive pole wire of battery
Fig.7.3
Fig.7.4
- 6 -

b. If joint is slack, bend the plug pin
upward, then connect with connector plug(see
fig7.5)
7.6 Before mounting new fuse, check if
the load of fuse of components is right, espe-
cially for the portion being burned broken
regularly, then mount the fuse having proper
current value.
7.7Wire connector have two kinds, one
is single-head connector, another is multi -head
one.Before connecting single-head connector
,check if there is broken on the housing of
joints, the joint is fixed and if there is a broken
phenomenon on it. When inserting the joint, it
should be fixed, then put in plastic coating af-
ter inserting.
In general, multi-head connector is plas-
tic one, and locking catch is designed. When
disassembling the connector, first open lock-
ing catch when connecting again, first check
if all the joint is in good condition, if there is
bent or twist on them. After connecting, align
the locking catch and lock them.
8. Use torque spanner to tighten screw
and nut, and as per specified torque to tighten
them. It should be tightened in steps from big
ones to small ones, from inside to outside and
along the direction of diagonal line to intersect.
A s shown in fig.8.1.
Fig.7.5
Fig.8.1Tightening method of screw and nut.
- 7 -

Section 5 Specification
(I) How to use conversion table of unit
(1)How to use conversion table
All the specified documents in this manual are taken SI and Metric as unit. With the
followingconversiontable,metricunitcouldbeconversedintoimperialunit.
METRIC MULTIPLY IMPERIAL
mm 0.03937 in
2mm ¡À 0.03937 = 0.08in
Conversiontable
(2)Definitionofunit
Torque
Weight
Length
Volume/capacity
Others
Conversion between metric and imperial
Known unit Multiply product
m.kg
m.kg
cm.kg
cm.kg
kg
g
km/hr
km
m
m
cm
mm
cc(cm3)
cc(cm3)
lit(liter)
lit(liter)
kg/mm
kg/cm2
Centigrade
7.233
86.794
0.0723
0.8679
2.205
0.03527
0.6214
0.6214
3.281
1.094
0.3937
0.3937
0.03527
0.06102
0.8799
0.2199
55.997
14.2234
9/5(¡æ)+32
ft.lb
in.lb
ft.lb
in.lb
lb
oz
mph
mi
ft
yd
in
in
oz(IMP liq)
cu.in
qt(IMP liq)
gal(IMP liq)
1b/in
psi(1b/in2)
Fahrenheit(0 F)
Unit
mm
cm
kg
N
Nm
m.kg
Pa
N/mm
L
cm3
r/min
Read
Millimetre
Centimetre
Kilogram
Newton
Newton meter
Meterkilogram
Pascal
Newtonper millimeter
Liter
Cubic centimeter
Revolutions per minute
Definition
10-3Meter
10-3Meter
103Gram
1 lilo ¡Ámeter /second
Newton ¡Ámeter
Meter ¡Ákilo
Newton/meter2
Newton/centimeter
Measurement
Length
Length
Weight
Force
Torque
Torque
Pressure
Rigid of spring
Volume or capacity
Rotational speed
- 8 -

II.Basic specification
- 9 -
Item Item
Specification Specification
Dimension:
Overall length 1940mm
Overall width 1050mm
Overall height 1160mm
Height of cushion 810mm
Axle base 1160mm
Front wheel distance 785mm
Rear wheel distance 770mm
Min.ground clearance 155mm
Min.turning radius 2900mm
Basic weight:
Engine oil(with full tank) 220kg
Engine Single-cylinder,air-cooled four stroke
Displacement 193.2ML
Cylinder borestroke 63 ¡Á62mm
Compression ratio 9.0:1
Starting system Electric starter or handoperated starter
Lubrication system Pressure splash
Engine oil SAE20W/40,SAE15W/40
Classfication of recommendedengine oil Model SE,SF,SG or above model
Periodic oil replacement 1.0L
Replace filter 1.1L
Overall capacity 1.1L
Oil capacity of gearbox 0.27L
Model: SAE80API¡°GL-4”Gear oil of
standard double curved face
Capacity of main fuel tank 12L.Non-lead gasolining No.90#
Capacity of reserved fuel tank 1.6L
Carburetor:
Type PZ30(INJECT PZ30)
Type of spark plug D8EA
Clearance of spark plug 0.6-0.7mm
Type of clutch Wet hand centrifugal type
Output
Primary reduction system Gear driving
Reduction ratio 3.333
Secondary reduction system Axle driving
Reduction ratio 3.742
Output type Non-cycle,five gear forward,gear back
Operation Left-foot operation
Shifting type
1st speed 2.769
2nd speed 1.882
3rd speed 1.400
4th speed 1.130
5th speed 0.960
Reverse gear 34.427
Frame
Bracket Steel tube
Caster angle 13¡ã
Toe-in of tire 0-5mm
Tire
Type Vacuum
Specification of front wheel AT23 ¡Á7-10
Specification of rear wheel AT22 ¡Á10-10
Pressure of front wheel 20Kpa
Pressure of rear wheel 25Kpa
Brake:
Type of front brake Drum brake(full-closed type)
Operation type Right-hand operation to brake
Type of rear brake Drum brake(full-closed type)
Operation type Right-foot to brake
Front suspension Independent suspension device
Rear suspension Rear centering shock absorbing type
Specification of shock absorber
Front shock absorber spring
Rear shock absorber spring
Electric system:
Ignition system C.D.I
Magneto system A.C magneto
Battery/capacity Free of maintenance,
12V,14AH
Headlight 12V,30W/30W ¡Á2
Taillight 12V,10W¡Á1
Neutral indicator 12V,3W ¡Á1
Reverse indicator 12V,3W ¡Á1
High-beam indicator 12V,3W ¡Á1

III.ATV body
Item Standard Limit
Steering system
Type of steering bearing
Front
wheel
Front
brake
Rear
wheel
Rear
brake
Brake
lever and
brake
pedal
Free play of throttle grip
Type
Materialofrim
Size of tire
Sizeofrim
Radial runout of rim
Lateral swing of rim
Type
Inside diameter of brake drum
Thickness of friction piece
Free length of back spring of brake shoe
Type
Materialofrim
Size of tire
Sizeofrim
Radial runout of rim
Lateral swing of rim
Type
Outside diameter of brake drum
Thickness of friction piece
Free length of back spring of brake shoe
Free play of brake lever (right)
Free play of rear brake pedal
Powder metallurgic sliding bearing
Spoke rim, tubeless tire
Steel plate
AT 23¡Á7-10
AT 10 ¡Á5.5
Drum type
160mn
4.0mm
71.0mm
Spoke rim, tubeless tire
Steel plate
AT 24¡Á10-10
AT 10 ¡Á8.0
Drum type
160mm
4.0mm
71.0mm
5-7mm
20-30mm
3-5mm
2.0mm
2.0mm
161mm
2.0mm
2.0mm
2.0mm
161mm
2.0mm
-10-

Item Standard Limit
Front
suspen-
sion
system
Rear
suspen-
sion
system
Rear
wheel
fork
Elastic coefficient of spring K1
Free length of suspending spring
Stoke of shock absorber
Pre-tension force of spring is
adjsutable or not
Elastic coefficient K2
Free length of suspending spring
Assembling length
Stroke of shock absorber
Pre-tension force of spring is adjust-
able of not
Assembling free play(left-end)
Assembling free play (right-end)_
10N/mm/0-117mm
293mm
117mm
Can’t adjustable
49N/mm/0-85mm
263mm
244mm
85mm
Adjustable
1.0mm
1.0mm
Item Standard Limit
IV.Electric system
Voltage of electric system
Spark
plug
Ignition
coil
Ignition
system
Type
Resistance
Clearance of spark plug
Resistance of primary coil
Resistance of secondary coil
Clearance of min. spark
Ignition timing (Before upper stop point)
Advancing angle of ignition (Before upper stop point)
Type of ignition advance
12V
D8EA
10¦¸
0.6-0.7mm
At 20¡æ(680F),0.5-1.5¦¸
At 20¡æ(680F),4.6-7.6¦¸
6mm(0.24in)
10/2300r/min
5500¡À200r/min
Electric type
-11-

Magneto
Item Standard Limit
Resistance of induction coil/colour
Resistance of source coil /colour
Type of C.D.I
No-loading adjusting voltage
Voltage-resisting value
Type
Rated ouput voltage
Coil resistance/colour
Specific gravity
Capacity
Type
Main fuse
Reserved fuse
Coil resistance
Diode
Type
Rectifier
Charging
system
Battery
Broken
circuit of
circuit
system
Relay of
cut-off
current
Electric
starting
system
Electric
starting
system
Starting
motor
Starting
relay
Output power
Resistance of armature coils
Ampere
Coils resistance
At 20¡æ(680F),189-231¦¸ Blue black
At 20¡æ(680F),470-530¦¸ Yellow/green-red
Electric capacity contactless type
14.1-14.9V
200V
A.C magneto
At2000r/min 14-15V
At 20¡æ(680F),1.0-1.2¦¸ White -white
1.28
12V.14Ah
Fuse
20A
20A
At 20¡æ(680F),72-88¦¸
Yes
Constant mesh type
0.35KW
At20¡æ(680F),0.004-0.005¦¸
100A
At 20¡æ(680F),4.8-5.3¦¸
-12-

V.Maintenance specification of engine
-13-
Item Standard Limit
Axle drive
Meshing clearance of last end gear
Meshing clearance of middle gear(forward)
Meshing clearance of middle gear(backword)
Lubrication system:
Type of filtering oil
Type of oil pump
Clearance of side
Endface clearance”A”or “B”
Releasing pressure of safety valve
Cylinder
Bore size
Cylinder head
Flatenss of lower endface
Timing chain
Type of timing chain
Tension type of timing chain
Camshaft:
Driving method
Roundness tolerance of camshaft
Outside diameter of camshaft
Cam size Exhaust:¡°A”
¡°B”
“C”
Intake:“A”
“B”
“C”
Rocker arm/Rocker arm shaft
Outside diameter of shaft
Inside diameter of rocker arm
Clearance between arm and shaft
Valve spring
Inside spring
Free length:intake/exhaust
Setting length when valve is closed:intake/exhaust
Compressing pressure when assembling:intake/exhaust
Limit value of squareness:intake/exhaust
Twisting direction of spring(top view):intake/exhaust
0.1-0.2mm
0.1-0.2mm
0.10-0.25mm
Wire filtering net
Rotor type,pressure splash type lubrication
0.05mm
0.20mm
80-120Kpa
§¶63.025mm
(Distance between measuring point and upper endface
of cylinder is 40mm)
Measure the surface warp of every portion on the
lower endface of cylinder head with rule.
Roller chain
Free adjustment
Shaft driving(left)
§¶25mm
31.365mm
25mm
6.365mm
31.532mm
25mm
6.532mm
35.5mm
30.5mm
82.4-100.0N
Counterclockwise
0.10mm
0.50mm
§¶63.03
§¶63.02mm
0.10mm
0.02mm
¡À0.04
¡À0.01
¡À0.06
¡À0.04mm
¡À0.01mm
¡À0.06mm
2.5¡ã/1.6mm
§¶12-0.006
-0.024
§¶12+0.018
-0
0.006~0.042

-14-
StandardItem Limitvalue
Valve spring
Outside spring:
Free length:intake/exhaust
Setting length when valve is closed:
Compressing pressure when asembling:intake/exhause
Limit value of squareness:intake/exhaust
Twisting direction of spring(top view):intake/exhaust
Valve,Valve seat,valve guide
Valve clearance(it s cold):intake
exhaust
Size of valve
“A”diameter of valve head
“B” width of valve face
“C” width of valve seat
“D”limit thickness
Outside diameter of valve stem
Inside diameter of valve guide
Clearance between valve stem and guide:exhaust
intake
Roundness of valve seen
exhaust
intake
intake/exhaust
intake/exhaust
intake/exhaust
exhaust
intake
intake/exhaust
Piston ring
First ring
Type
Size(B ¡ÁT)
Clearance of endface(in assembling)
Clearance of side(in assembling)
Second ring
Size(B¡ÁT)
Clearance of endface(in assembling)
Oil ring
Type
Size(B ¡ÁT)
Clearance of endface(in assembling)
Clearance of side(in assembling)
37.2mm
32.0mm
162.8-200.1N
Clockwise
0.05-0.09mm
0.11-0.15mm
28.4-28.6mm
33.9-34.1mm
1.7-2.8mm
0.9-1.1mm
0.8-1.2mm
5.960-5.975mm
5.975-5.990mm
6.000-6.012mm
0.025-0.052mm
0.10-0.037mm
Bucket-shaped back round
1¡Á2.5mm
0.25mm
0.035mm
Flat type
1¡Á2.6mm
0.25mm
0.035mm
2¡Á1.78mm
0.4mm
2.5¡ã/1.6mm
1.6mm
0.10mm
0.08mm
0.03mm
0.35mm
0.05mm
0.35mm
0.05mm
0.7mm