JI-EE ATV BXL 100 User manual

CONTENTS
1.INFORMATION…………………………………………………...2
2.MAINTENANCE………………………………………………….6
3.ENGINE REMOVAL AND INSTALLATION………………….12
4.ENGINE FUEL SYSTEM………………………………………14
5.ENGINE LUBRICATION AND COOLING SYSTEM………..18
6.ENGINE COMBUSTION SYSTEM…………………………...21
7.TRANSMISSION SYSTEM……………………………………25
8.FRONT WHEEL AND STEERING SYSTEM………………..29
9.REAR WHEEL SYSTEM………………………………………42
10.FENDERS AND EXHAUST PIPE…………………………...45
11.HYDRAULIC DISC SYSTEM………………………………..48
12.ELECTRICAL SYSTEM………………………………………53
13.TROUBLE SHOOTING………………………………………57
1

1. INFORMATION
1.1 SAFETY 1.4 SPECIFICATION
1.2 NOTES 1.5 TORQUE VALUES
1.3 SERIAL NUMBER
1.1 SAFETY
Gasoline is extremely flammable and is explosive under certain condition.
Do not smoke or allow sparks or flames in your work area.
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.
 The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing.
If you contact it, flush thoroughly with water and call a doctor if electrolyte
gets in your eyes.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base on the latest
product information available at the time of approval for printing.
JI-EE Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring
any obligation whatever.
No part of this publication may be reproduced without written permission.
2

1.3 SERIAL NUMBER
The frame serial number is stamped on the right side of the frame.
The engine serial number is stamped on the left side of the crankcase.
Frameserialnumber Engineserialnumber
3

1.4 SPECIFICATION
ENGINE
Type Forced Air-Cooling 2-Stroke
Displacement
Bore and Stroke
Compression
Maximum Torque
Carburetor
Ignition
Starting
Lubrication
Oil Capacity
Transmission
49.3cc/95.6cc
40.0*39.2mm/52.0*45.0mm
6.8:1/7.8:1
4.8 N-m@6500rpm/8.0N-m@4500rpm
Mikuni VM16
Capacitor Discharge Ignition
Electric/Kick Starter
Oil Pump Separate Supply
1. 0 liter
Automatic (C.V.T V-belt)
CHASSIS
Overall Length 1600mm(62.9inch)
Overall Width 795mm(31.2inch)
Overall Height 1020mm(40.1inch)
Seat Height 700mm(27.5inch)
Wheel base 1020mm(40.1inch)
Ground Clearance 120mm(4.7inch)
Dry Weight 141kg
Fuel Tank Capacity 6.5±0.2liter
SUSPENSION
Front Dual Absorber& Swing arm
Rear Single Absorber& Swing arm
BRAKES
Front Drum
Rear Hydraulic Disc
TIRIES
Front 19”*7”-8”
Rear 19”*8”-8”
COLORING Red / Blue / Silver
Specifications subject to change without notice.
4

1.5 TORQUE VALUES
ENGINE
Item N•mLbf-ft
Cylinder head nut 28-30 20.7-22.1
park plug 12-19 8.9-14.0
Cylinder head bolt 20-30 14.8-22.1
Alternator bolt 8-12 5.9- 8.9
FRAME
Item N•mLbf-ft
Handlebar upper holder bolt 24-30 17.7-22.1
Steering shaft nut 50-60 36.9-44.3
Steering shaft bushing holder nut 24-30 17.7-22.1
Wheel rim bolt 18-25 13.3-18.4
Tie rod lock nut 35-43 25.8-31.7
King pin nut 30-40 22.1-29.5
Handlebar lower holder nut 40-48 29.5-35.4
Front wheel bolt 24-30 17.7-22.1
Front axle castle nut 40-60 30-45
Front brake arm nut 4-7 3.0- 5.2
Rear brake arm nut 7-12 5.2- 8.9
Rear axle castle nut 40-60 30-45
Rear wheel bolt 24-30 17.7-22.1
Exhaust muffler mounting bolt 30-35 22.1-25.8
Engine hanger bolt 24-30 17.7-22.1
5

2. MAINTENANCE
2.1 MAINTENANCE DATA 2.8 IDLE SPEED
2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN
2.3 FUEL TUBE 2.10 BRAKE SYSTEM
2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES
2.5 THROTTLE CABLE ADJUSTMENT 2.12 STEERING SYSTEM
2.6 AIR CLEANER 2.13 TOE-IN
2.7 SPARK PLUG 2.14 GEAR OIL
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG GAP: 0.6-0.7 mm
RECOMMENDED SPARK PLUGS: NGK BPR7HS
THROTTLE LEVER FREE PLAY: 5-10 mm
IDLE SPEED: 1800±100 rpm
BRAKE LEVER FREE PLAY: 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
FRONT/REAR TIRE SIZE 19X7-8/19X8-8
FRONT/REAR TIRE PRESSURE 12 psi (0.8 kgf/cm
2
)
TOE-IN 5±10 mm
TORQUE VALUES
SPARK PLUG
TIE-ROD LOCK NUT
25-30 N.m
35-43 N.m
ENGINEOIL JASOFCGradeorsamedegreeoil
GEAR LUBRICATION OIL SAE 90
2.2 MAINTENANCE SCHEDULE
The maintenance internals in the follow table is based upon average riding, conditions. Riding in
unusually
dusty areas, require more frequent servicing
INITIAL
SERVICE
(First week)
REGULAR SERVICE
(Every 30
operating days)
EVERY YEAR
FUEL LINE I
THROTTLE OPERATION I I
AIR CLEANER C
SPARK PLUG I
CARBURETOR IDLE SPEED I I
DRIVE CHAIN I, L I, L
BRAKE SHOE WEAR I
BRAKE SYSTEM I I
NUT, BOLT, FASTENER I I
WHEEL I I
STEERING SYSTEM I
SUSPENSION SYSTEM I
C.V.T. AIR FILTER C
GEAR OIL R
Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary
C: Clean L: Lubricate R: Replace
6

2.3 FUEL TUBE
Inspect the fuel lines for deterioration, damage or
leakage and replace any parts if necessary.
2.4 THROTTLE OPERATION
Inspect throttle lever for smooth full opening and
automatic full closing in all steering positions.
Inspect if there is no deterioration, damage or kinking
in the throttle cable, replace it if occur any damage.
Check the throttle lever, free play is 5-10 mm at the tip
of the throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to
prevent from premature wear.
2.5 THROTTLE CABLE ADJUSTMENT
Slide the rubber cap of the adjuster off the throttle
Housing, loosen the lock nut and adjust the free play
of the throttle lever by turning the adjuster on the throttle
housing. Inspect the free play of the throttle lever.
2.6 AIR CLEANER
Unscrew the air cleaner cover screws.
Pull out the air filter element from the air cleaner case.
Wash the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the element into air cleaner carefully.
7

2.7 SPARK PLUG
This spark plug located at the front of the engine.
Disconnect the spark plug cap and unscrew the spark plug.
Inspect the spark plug electrodes for wear.
Change a new spark plug if the electrodes and insulator tip
appear unusually fouled or burned.
Discard the spark plug if there is apparent wear or if the
insulator is cracked or chipped.
The spark plug gap shall keep in 0.6-0.7mm.
With the sealing washer attached, thread the spark plug in
by hand to prevent cross threading.
Tighten the spark plug with 25-30 N.m
2.8 IDLE SPEED
ADJUST SCREW
Connect an engine speedometer.
Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw on the carburetor
to obtain the idle speed. “Turn in” (clockwise) will get higher
speed. “Turn out” (counter clockwise) will get lower speed.
IDLE SPEED: 1800±100 rpm
2.9 DRIVE CHAIN
Inspect the chain slack. The standard is 10-25mm.
Adjust the chain slack.
Loose the lock bolts (4 pcs) then adjust the drive chain
slack by turn the adjusting nut.
Tighten the four lock bolts.
8

When the drive chain becomes very dirty, it should be
removed, cleaned and lubricated by specify lubricator.
Using commercial chain lubricant to lubricate the drive
chain.
Clean the drive chain with kerosene and wipe it dry.
Inspect the drive chain for possible wear or damage.
Replace the chain, if it is worn excessively or damaged.
Inspect the sprocket teeth, if it is excessive wear
or damage, replace it.
2.10 BRAKE SYSTEM
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
brake lever. The standard of free play is 15-25 mm.
Inspect the rear brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the free play of the rear brake lever at the end of
the lever. The standard is 10-20 mm.
2.11 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails or other
sharp objects.
Check the tire surfaces at cold tire condition.
The standard of tire pressure is 12 psi (0.8 kgf/cm
2
).
9

2.12 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.
2.13 TOE-IN
Let the vehicle on level ground and the front wheels
facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Carefully move the vehicle back, let the wheels have
turned 180 °, so the marks on the tires are aligned
with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.
Toe-in: 5±10mm
If the toe-in is out of standard, adjust it by changing
the length of the tie-rods equally by turning the tie-rod
while holding the ball joint. Tighten the lock nuts.
Torque: 35-43 N.m
10

2.14 GEAR OIL
OIL DRAIN
BOLT
Gear oil needs to be changed every year.
There is a gear oil release bolt at the rear of engine.
Unscrew this release bolt and can let the dirty oil flow out.
The re-add oil hole is on the engine case beside gearbox.
FILL OIL
11

3. ENGINE REMOVALS AND INSTALLATION
3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION
3.2 ENGINE REMOVAL
3.1 SERVICE INFORMATION
Engine shall be removed in the conditions of necessary repairment or adjustment in the transmission and
combustion system only.
3.2 ENGINE REMOVAL
Remove the seat and rear fender. (Chapter 10)
Remove the spark plug cap from the spark plug.
Remove the rear tires first, and than disassemble 2.REMOVE
TAILPIPE
1.REMOVE REAR TIRE
the exhaust pipe.
Caution: When remove the tailpipe before, be careful
the temperature. Please wear the gloves to avoid the heat
from tailpipe.
Remove the drive chain cover. This is under the chain.
Remove the drive chain retaining clip and master link,
than remove the drive chain.
12

Remove the three engine hanger nuts and bolts.
ENGINE HANGER NUTS
Two hanger nuts are outside and one is inside.
Remove the engine from the left side of frame.
3.3 ENGINE INSTALLATION
Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm
Route the wires and cable in reverse order properly.
13

4. ENGINE FUEL SYSTEM
4.1 TROUBLESHOOTING 4.3 CARBURETOR
4.2 FUEL TANK 4.4 ASSEMBLY
4.1 TROUBLESHOOTING
ENGINE CAN NOT START ★NO FUEL IN TANK
★NO FUEL TO CARBURETOR
★TOO MUCH FUEL INTO CYLINDER
★NO SPARK AT PLUG
★AIR CLEANER CLOGGED
ENGINE IDLES UNSTEADY, STALLS OR RUNS
POORLY
★
UNPROPER ADJUSTMENT TO THE
IDLE SPEED SCREW
★IGNITION MALFUNCTION
★FUEL/AIR MIXTURE RATIO NOT GOOD
★AIR CLEANER DIRTY
★INSULATOR LEAKAGE
★
FUEL TANK CAP BREATHING HOLE
CLOGGED
LEAN MIXTURE ★FUEL JET OF CARBURETOR CLOGGED
★
FUEL TANK CAP BREATHING HOLE
CLOGGED
★FUEL FILTER CLOGGED
★
FUEL FLOWS IN THE TUBE
UNSMOOTHLY
★
FLOAT LEVEL IN CARBURETOR TOO
LOW
RICH MIXTURE ★
FLOATNEEDLEVALVEIN
CARBURETOR FAULTY
★FLOAT LEVEL TOO HIGH
★
AIR DUCT IN CARBURETOR IS
CLOGGED
★AIR CLEANER DIRTY
14

4.2 FUEL TANK
REMOVAL
Remove the seat and rear fender.
Disconnect the fuel line from the carburetor.
Remove the fuel tank cap and front fender.
Unscrew the fuel tank fixed bolts.
Note: Keep gasoline away from flames or sparks.
Wipe up spilled gasoline at once.
4.3 CARBURETOR
REMOVAL
Remove the air cleaner.
Disconnect the fuel line and auto-choke electric wire.
Unscrew the intake pipe mounting bolts at the carburetor
then remove the carburetor.
Note: Turn off the fuel pipe by turn the fuel cup (below fuel
tank) to “off” position.
DISASSEMBLY
Remove the carburetor cap.
Remove the throttle cable from the throttle valve while
depressing the throttle valve spring.
Remove the needle clip retainer, the jet needle and
needle clip. Inspect the throttle valve and jet needle
surface for wearness, scratches or dirt.
15

Unscrew the float chamber screws and remove the float
chamber.
Disassembly the float arm pin, float and float needle
valve. Inspect the seat of the float needle valve for wear
or damage.
Disassembly the idle jet, main jet, idle speed adjust screw
and idle mixtures adjust screw.
Inspect all the jets and screws for wear or damage.
Clean the passages and jets with compressed air.
16

4.4 ASSEMBLY
Clean all parts in solvent and blow it dry with clean
compressed air. Assembly is essentially the reverse
order of disassembly.
THROTTLE VALVE ASSEMBLY
Install the needle clip on the jet needle.
Install the jet needle into the throttle valve.
Assemble the throttle cable, spring and the throttle valve.
Align the throttle valve groove with the idle speed
adjust screw and install the carburetor cap to the carburetor.
17

5. ENGINE LUBRICATION AND COOLING SYSTEM
5.1 ENGINE LUBRICATION SYSTEM 5.4 COOLING SYSTEM
5.2 CAUTION 5.5 TROUBLESHOOTING
5.3 OIL PUMP
5.1 ENGINE LUBRICATION SYSTEM
The engine crankshaft drives the pump gears of oil pump.
Pump gears rotate the plunger shaft in oil
pump. This shaft sent the lubricating oil into the crankcase
to mix with the mixture of air-fuel flow evenly.
The oil drops and foam cover the cylinder inner wall,
piston surface and piston rings.
5.2 CAUTION
Having enough oil supply to engine is very important.
If the oil quantity is not enough, this engine will be serious scratched, and then this engine will stop, even
cannot work again.
When this engine is serious scratched, you need to change the piston, piston rings and cylinder together.
Also you need to check the combustion system and lubrication system carefully.
5.3 OIL PUMP
The quantity of oil that deliver out from oil pump increased by the engine speed and the carburetor throttle
open width. Oil pump is under the right side of the engine and connected by a control cable of throttle.
5.4 COOLING SYSTEM
The engine-cooling fan sucks the air.
The cooling fan is on the right side of engine.
The air is forced to flow through cylinder fin and
cylinder head. So, the cylinder and piston will not
over heat.
18

5.5 TROUBLESHOOTING
NO ENOUGH OIL SUPPLY TO ENGINE ★THE OIL LEVEL IN OIL TANK IS TOO LOW.
★OIL TUBES WERE NOT FIXED WELL.
★OIL HAS LEAKAGED FROM TUBE ENDS.
★OIL TUBES WERE BROKEN.
★OIL TUBES WERE CLOGGED.
★
OIL PUMP CANNOT WORK.
ALWAYS INSUFFICIENT OIL LEVEL ★EXTERNAL OIL LEAKS
IN LUBRICATE OIL TANK ★WORN CYLINDE HEAD GASKET
★WORN PISTON RINGS
19