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