Power Max ROUGH-RIDER 700 UTV User manual

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ROUGH-RIDER 700 UTV
Maintenance Manual

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Catalog
General Information……………………………...5
1 Description…………………………………………………..5
1.1 Identification code…...6
1.1.1. Frame No. …………………………………………………6
1.1.2. Engine No.…………………………………………………7
1.2 Special tools, instruments and meters…………………7
1.3 Periodic maintenance chart……………………………….10
Engine………………………………………………………….11
2. Inspection and adjustment of engine…………….11
2.1 Inspection of cylinder head, intake
And exhaust valve………………………………………….11
2.2 Inspection of spark Plug………………………………….14
2.3 Inspection of cylinder, piston and piston ring…….15
2.4 Inspection of crankshaft………………………………….18
2.5 Inspection of clutch……………………………………….19
2.6 Inspection of carburetor………………………………….19
2.7 Inspection of air filter………………………………….20
2.8 Inspection of oil filter………………………………….21
2.9 Inspection of lubrication system……………………….21
2.10 Lubrication of engine…………………………………….22
2.11 Inspection of cylinder head…………………………….22

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3. Disassembly of engine……………………………………27
3.1 Cylinder head and block………………………………….27
3.2 Piston and connecting rod……………………………….32
3.3 starting mechanism………………………………………..33
3.4 Sensor………………………………………………….…….33
3.5 Left crankcase cover……………………………….…….33
3.6 Magneto…………………………………………………..….34
3.7 Oil pump………………………………………….……..….34
3.8 Clutch…………………………………………………...….36
3.9 Carburetor……………………………………………...….36
3.9.1 Structure of carburetor…...36
3.9.2 Inspection and adjustment of carburetor…....….37
4. Chassis
4.1 Direction system…...42
4.2 Brake system…………………………………………...….57
4.3 Wheels and tires……………………………………...….77
4.4 Transmission system…………………………….…...….81
4.5．Reverse mechanism parts………………………………89
4.6 Suspension……....91
4.7 Cooling System of Engine………………..97

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4.8 Lubrication points……….102
5. Electrical system…....105
5.1 Ignition system…....108
5.2 Magneto and charging system…....109
5.3 Battery…....110
5.4 Lighting system…....111
5.5 Meter and signal system…………………………..……112
5.6 Electrical starting system…………….……..…….113
6. Appendix…...115
6.1 Specification…....115
6.2 Requirements for torque of fastener……………….121
6.3 Electrical circuits……………………………....….122

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General Information
1. Description

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1.1 Identification code
1.1.1. Frame No.
Frame No. is carved in the lower right side of Figure 1-1

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Figure 1-1
1.1.2. Engine NO.
Engine NO. Is carved on the right side of the engine,
Figure 1-2
Figure 1-2
1.2 Special tools, instruments and meters
1.2.1 Oil filter detacher
To fasten and detach the oil filter
1.2.2 Height gauge

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To gauge the height of various components
1.2.3 Venire
To measure the length of various components
1.2.4 Outside micrometer
To accurately measure external
Diameter of a column
1.2.5 inside micrometer
To accurately measure internal
Diameter of a hole
1.2.6 Dial indicator
To accurately measure a small distance
1.2.7 Torque Spanner
To measure torque force
1.2.8 Feeler gauge
To measure gap-width

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1.2.9 Multimeter
To check electrical circuits and parts
1.2.10 Barometer
To measure pressure of the tire
1.2.11 Magneto drawing device
To detach the magneto
1.2.12 Snap ring clamp
To install and detach snap rings
1．2．13 Steering wheel pull tool

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1.3 Maintenance schedule
Maintenance schedule
ITEM
ROUTINE
Whichever
comes first
EVERY
INITAL
month
1
3
6
6
12
km
320
1,200
2,400
2,400
4,800
(mi)
(200)
(750)
(1,500)
(1,500)
(3,000)
hours
20
75
150
150
300
Valves
●Check valve clearance.
●Adjust if necessary.
○
○
○
○
Sparkplug
●Check condition.
●Adjust gap and clean.
●Replace if necessary.
○
○
○
○
○
Air filter
element
●Clean.
●Replace if necessary.
Every20-40hours
（More often in wet of dusty areas.）
Carburetor*
●Check and adjust idle speed/starter
operation.
●Adjust if necessary.
○
○
○
○
Crankcase
breather system*
●Check breather hose for cracks of
damage.
●Replace if necessary.
○
○
○
Exhaust system*
●Check for leakage.
●Tighten if necessary.
●Replace gasket(s) if necessary.
○
○
○
Spark arrester
●Clean.
○
○
○
Fuel line*
●Check fuel hose for cracks or damage.
●Replace if necessary.
○
○
○
Engine oil
●Replace.(Warm engine before draining.)
○
○
○
○
Engine oil filter
cartridge
●Replace.
○
○
○
○
Engine oil strainer*
●Clean.
○
○
○
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Final gear oil
●Check for oil leakage.
●Replace every 12 months.
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Differential gear oil
Front brake*
●Check operation/fluid leakage. (See
NOTE page 8).
●Correct if necessary.
○
○
○
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○
Rear brake*
●Check operation.
●Adjust if necessary.
○
○
○
○
○

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Select lever safety
system cable
●Check operation.
●Adjust if necessary.
○
○
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V-belt*
●Check operation.
●Check for cracks or damage.
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○
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Wheel
●Check balance/damage/
●Repair if necessary.
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○
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Wheel bearing*
●Check bearing assemblies for loose/
Damage.
●Replace if necessary.
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○
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Front and rear
suspension*
●Check operation.
●Correct if necessary.
○
○
Steering system*
●Check operation./Replace if damaged
●Check toe-in. /Adjust if necessary.
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○
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Drive shaft universal
joint*
●Lubricate with lithium–soap–based
grease.
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Axle boots*
●Check operation.
●Replace if damaged.
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○
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Fittings and
fasteners*
●Check all chassis fittings and fasteners.
●Correct if necessary.
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○
○
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Lights and
switches*
●Check operation.
●Adjust headlight beams.
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Engine
2. Inspection and adjustment of engine
2.1 Inspection of cylinder head, intake
And exhaust valve
Preheat the engine, then misfire and unplug the spark plug.
Fix pressure gauge into the hole, open the choke and throttle
handle, and start for 4-6 times.
Note: Giving a leakage check to the pressure gauge.
Rotate the engine until the pressure gauge stop rising.
The maximum reading would be greater than 0.7-0.9Mpa

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after starting for 4-6 times.
See figure 2-1.
Figure 2-1
Check the valve lash
Note: when adjust valve lash, the engine must be cooled.
(The temperature should be less than 35℃)
Remove the seat cushion and fuel tank, unplug the vision hole
cover, round the flywheel of magneto anti-clockwise to aim “T”
At the signal of fore cover on the left.
Note: The piston must be fixed to the dead enter. (Figure
2-2)

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Figure 2-2
Remove cylinder valve cover, check the lash between the valve
stem by feeler gauge.
Valve clearance: inlet and exhaust valve: 0.05～0.08mm.
See figure 2-3.
Figure 2-3
Loose the lock nut, rotate the adjusting screw until it
appears that the feeler gauge be pulled .Then fasten the
adjusting screw by valve adjuster, tighten the lock nut and
check the valve lash .Afterword install the cylinder valve
cover , vision hole cover, the fuel tank and cushion. See figure
2-4.

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Figure 2-4
2.2 Inspection of spark Plug
1. Unplug the Spark-Plug cap: remove
The spark plug by box key, look over
To see if spark-plug insulator and
Electrode is damaged or sooting.
If so, see figure 2-5. Figure 2-5
2．Check the spark clearance
By feeler gauge whether it
Is between 0.6～0.7mm.Or adjust
The gap, clean incrustation
With spark-plug cleaner and steel
Wire brush and check if
The spark plug sealing
Washer (Figure 2-6). Figure 2-6
.

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3.Swirl the when spark plug and tighten to 18～20N.m by box
key ,then fix the spark plug cap when assembling.
2.3 Inspection of cylinder, piston and piston ring
Camshaft lube is injected by a hole of engine body into
cylinder, so the hole must not jam. It is necessary to fix
the cushion and adjust without dust permeated into the crank
case before assembly.
item
standard value:mm
limit value:mm
cylinder
bore diameter of cylinder
φ102～φ102.03
φ102.1
taper
0.0040
0.005
out of roundness
0.0035
0.005
degree of touristy
0.04
0.06
Piston,
piston ring
and piston
pin
external diameter of piston
φ101.95～φ101.97
φ101.92
bore diameter of piston pin
hole
φ22.002～φ22.010
φ22.010
gap between piston pin and
piston pin hole
0.007～0.020
0.02
Piston ring
end
clearance
Top ring/the
second ring
0.25～0.40
0.5
gap between
piston ring
and piston
groove
oil ring
0.3～0.9
1.2
top ring
0.3～0.07
0.10
the second
ring
0.02～0.06
0.09
gap between cylinder and
piston
0.03～0.08
0.09
external diameter of piston
pin
φ21.995～φ21.990
φ21.96
connecting
rod
bore diameter
φ22.016～φ22.027
φ22.03
Gap between small end of
connecting rod and piston
pin
0.016～0.033
0.035

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Diagnosing and eliminating of malfunction:
●Emission of black smoke for abrasion of cylinder
or piston,
1. Cylinder, piston of piston ring is worn out.
2. The piston ring is not properly assembled.
3. The piston or cylinder wall is scraped.
●overheated
1、Excessive incrustation of piston.
2、Blast and abnormal noise.
3、Abrasion of cylinder or piston.
Inspection of cylinder.
1. Check whether the cylinder is damaged.
2. Measure the bore diameter of cylinder at three spots.
3. At the top, the middle and the bottom of the piston
stroke .And measure the bore diameter at directions of
right-angle intersection.
Repairing limit value:
Out of roundness: 0.005 mm
Taper ：0.005mm
Inspection of piston and piston ring
Measure the gap between piston ring and piston groove.
1. Unplug the piston ring;

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Note: It is forbidden to damaging the piston ring when
assembling. Check whether the piston and the piston groove
is cracked and abraded. See figure 2-7
Figure 2-7
2. Insert piston ring into
Cylinder, and measure the
End gap. Repairing limit
Value: the first ring/the
Second ring: 0.5mm
See figure 2-8. Figure 2-8
Measure the bore diameter of piston pin hole.
Repairing limit value: see figure 2-9

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Figure 2-9
3. Measure the external diameter 10mm
Above the bottom of the piston skirt.
Extreme position: The gap between
Cylinder and piston repairing
Limit value: 0.1mm See figure 2-10
Figure 2-10
7 Measure the external diameter of piston pin:
The gap between piston and piston pin:
Repairing limit value: 0.02mm .See figure 2-11
Figure 2-11
2.4 Inspection of crankshaft
Check that whether crank and connecting rod can rotate without
stuck and whether the clearance between crank and connecting
rod is 0.5～0.6mm.The hop of crank shaft should be 0.05mm.If
not so, replace it. See figure 2-12-1, figure 2-12-2.

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Figure 2-12-1 Figure 2-12-2
2.5 Inspection of clutch
The wear condition of shoe block and friction plate: See
Figure 2-13
Figure 2-13
2.6 Inspection of carburetor
1、Inspect the idle of carburetor
The engine speed should be 1500±150r/min 10 minutes after
starting at normal idle and will not misfire when briskly
accelerate. If not so, rotate the carburetor idle adjusting
screw clockwise to raise the idle, anti- clockwise to lower.
When adjusting is unavailable, check

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That if there is a jam in
Carburetor idle nozzle or a
Air leakage of intake pipe.
See figure 2-14
Figure 2-14
2.7 Inspection of air filter
1、Disassemble the air cleaner, remove cartridge, clean the
cartridge with non-flammable cleaning solvent, and then
make it dry.
Note: Petrol is forbidden.
2. Dip the air filter cartridge into 20# oil, then take it
out and squeeze the excessive oil, assemble it orderly.
Impermeability is necessary. See figure 2-15, figure
2-16.
Figure 2-15 Figures 2-16