Rato RT150ST-A User manual

RT150ST-A SERVICE MANUAL
Chongqing Rato Power Co., Ltd.
RT150ST-A 维修手册
重 庆 润 通 动 力 有 限 公 司

BRIEF INTRODUCTION TO FOUR-WHEELED
CROSS-COUNTRY VEHICLE MODEL RT150ST-A
Four-wheeled cross -country vehicle, model RT150ST-A is a full road condition vehicle
which can be driven on every kinds of road conditions such as sand beach, grassland,
forest,village, construction site country road , This maintenance manual of four-wheeled
vehicle model RT150ST-A (Hereafter called all terrain vehicle-ATV for short) compiled by
Chongqing Rato power Co., Ltd is specially provided for saler and technical staff of our
Group. This manual mainly introduce the maintenance, removing and repairing method of
cross-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 group and it’s saler have a basic understanding on working principle,
maintenance procedure and repairing technology of cross-country vehicle. If you don’t have
this knowledge, when repairing cross-country vehicle, the condition of improper assembling
and danger occurs after assembling are easily happened. Proper operation and maintenance are
the advance of your safely driving crosscountry vehicle, it also can reduce the troubles of
cross-country vehicle and keep the best performance of it. The specification, performance and
explanation stated in the manual are determined according to newly design of the vehicle,
which are subject to changes without notice.
In this manual, for specially important requirement, the words of “Warning ” “Caution ”
are labelled to prompt relative maintainer to abide it.
In the manual
Warning Show that if the content of “Warning” isn’t obeyed, the driver,
maintainer,checker will be heavily njuried, even dead.
Caution Show that you must be careful to prevent the vehicle from being damaged.
Maintenance manual of four-wheeled cross-country vehicle model RT150ST-A
First edition October 2010
This manual is published by publishing factory. maintain the copyright of
publishing. Without permitted, publishing is prohibited.

Content
Chapter I General description 1
Section 1 Description ..........................................................................................................................................1
Section 2 Special tools, instruments and meters .....................................................................................................2
(I) Special tools ............................................................................................................................................2
(II) Instruments and meters............................................................................................................................3
Section 3 Identification code, label of model 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
(II)Basic specification ..................................................................................................................................9
(III) ATV body ........................................................................................................................................... 10
Section 6 Wiring diagram of ATV........................................................................................................................ 11
Section 7 Requirements for torque of fastener ..................................................................................................... 12
Section 8 Lubrication ........................................................................................................................................ 13
(I) General torque specification ................................................................................................................... 13
Section 9 Lubrication point and type of lubricants ............................................................................................... 14
(I) Lubrication point and type of lubricants(ATV body) ................................................................................. 14
(II)Lubrication point and type of lubricants(Engine) ..................................................................................... 15
Chapter II MAINTENANCE AND ADJUSTMENT OF VEHICLE ........................................................... 16
Section 1 Periodic maintenance/ lubrication ....................................................................................................... 16
Section 2 Disassembly and assembly of cushion, fender and fuel tank ................................................................... 17
(I) Cushion ................................................................................................................................................ 17
(II) Rear fender .......................................................................................................................................... 17
(III) Fuel tank ............................................................................................................................................ 19
(IV)Fuel tank ............................................................................................................................................. 20
...........................................................................................................................

Section 3 Maintenance and Adjustment of Vechicle Body ............................ .......................................... 21
(I)Wear inspection of front&rear brake ........................................................................................................ 21
(II)Adjustment of front brake ...................................................................................................................... 21
(III)Inspection of steering system ................................................................................................................ 23
(IV)Adjustment of toe-in of front wheel ....................................................................................................... 24
(V)Adjustment of rear shock absorber .......................................................................................................... 25
(VI) Inspection of tire ................................................................................................................................. 26
(VII)Inspection of rim ................................................................................................................................ 27
Section 4 Maintenance and Adjustment of Electrical Appliance ........................................................................... 28
(I)Inspection of battery ............................................................................................................................... 28
(II)Inspection of fuse .................................................................................................................................. 29
(III)Replacement of taillight lamp ............................................................................................................... 30
(IV)Replacement of headlight lamp ............................................................................................................. 31
Section 5 Maintainace and Adjustment of Engine ................................................................................................ 33
(I)Clean of air filter .................................................................................................................................... 33
(II)Inspection of spark plug ......................................................................................................................... 34
(III)Adjustment of idle speed ...................................................................................................................... 35
(IV)Adjusting ment of free clearance of throttle grip ..................................................................................... 35
(V)Adjustment of speed limitator ................................................................................................................ 36
(VI)Adjustment of valve, clearance ............................................................................................................. 36
(VII)Inspection of ignition timing ............................................................................................................... 37
(VIII)Measuring of compressive force ......................................................................................................... 38
(IX).Inspection of oil quantity of engine ...................................................................................................... 39
(X)Replacement of engine oil and inspection of oil flow ................................................................................ 40
Chapter III Repair and Maintenance of Vehicle body ...................................................................................... 42
Section 1 Front wheel and Front Brake ............................................................................................................... 42
(I)Disassembly .......................................................................................................................................... 42
(II)Inspecting procedures ........................................................................................................................... 44
(III)Installation procedure .......................................................................................................................... 47
Section 2 Rear wheel/rear brake/rear wheel axle .................................................................................................. 50
..............

(I) Removal steps................................................................. ....................................................... 50
(II) Inspection steps .................................................................................................................................... 51
Section 3 Steering Operation System .................................................................................................................. 53
(I)Removal steps of steering bar .................................................................................................................. 53
(II)Removal steps of steering vertical column welding ..................................................................................54
(III)Inspection content ................................................................................................................................ 55
(IV)Installment steps .................................................................................................................................. 56
(V)Installation steps of steering bar ............................................................................................................. 59
Section 4 Front shock absorber and Front wheel fork ........................................................................................... 60
(I)Disassembly .......................................................................................................................................... 60
(II)Inspection step ...................................................................................................................................... 61
(III)Installment steps .................................................................................................................................. 62
Section 5 Rear shock absorber and Rear wheel fork ............................................................................................. 65
Chapter IV Electric Appliance ........................................................................................................................66
Section 1 Inspect switch .................................................................................................................................... 66
Section 2 Troubleshooting the ignition system failure .......................................................................................... 67
Section 3 Running of starting circuit .................................................................................................................. 71
Section 4 Troubleshooting electric starting system .............................................................................................. 72
Section 5 Check starting Motor .......................................................................................................................... 75
Section 6 No charging in the Battery ................................................................................................................... 77
Section 7 Troubleshooting ................................................................................................................................. 79
Section 8 Inspection of Lighting system ............................................................................................................. 81
Chapter V Engine ...........................................................................................................................................82
Section 1 Disassembly of engine ........................................................................................................................ 82
(I) Remove the engine from finished ATV ..................................................................................................... 82
(II) Disassembly of engine .......................................................................................................................... 84
Section2 Inspection and Maintenance of Engine .................................................................................................. 92
Chapter VI Vehicle Ordinary Trouble and Judgment .................................................................................... 109
................

Chapter I General description
Section 1 Description
1. Front wheel
2. Fuel cock
3. Cushion
4. Rear wheel
5. Exhaust silencer
6. Rear fender
7. Front fender
8. Bumper
9. Left lever of rear brake
10. Left switch unit
11. Fuel tank cover
12. Throttle grip
13. Right lever of front brake
Caution:
The ATV you purchased maybe slightly differ from the pictures in the manual due to
improvement or other changement.
1 2 3 4
5 6 87
9 10 11 12 13
-1-

Section 2 Special tools, instruments and meters
For the above tools, you can select with reference to special tools of the same type
of vehicle.
-2-
(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 improper tools.
1.Wrench for valve adjustment mainly used for adjusting valve clearance.
Specification:3mm
2.Puller for piston pin, mainly used of removing pistion pin.
3.Remover for rotator, mainly used for pulling magneto rotator form crank.
4. Clamp for rotator, mainly used for clamping magneto rotator when removing it
to prevent it’s rotation due to torque force.
5.Stop rotating meter for rotator, mainly used for removing and assembling
rotator of kick starter.
6.Puller for crank, mainly used for disassembling crank from crankcase.
7.Puller for rocker shaft, mainly used for removing rocker shaft.
8.Compressing tools for spring of valve, mainly used for fixing and compressing
spring when assembling valve lock clamp.
9. Assembling and disassembling tool for valve guide, mainly used for assembling
and disassembling valve guide.
10.Assembling buffer, mainly used for assembling crank and balancing gear.
11.Hollow sleeve, mainly used for assembling crank and balancing gear.
12.Assembling toal for crank, mainly used for assembling crank and balancing
gear.
13.Assembling and disassembling joint for universal coupling, mainly used for
assembling and dismsembling universal coupling.
14.Assembling and disassembling disc, mainly used for assembling and
disassembling reverse gear.
15.Fixed puller for gear, mainly used for assembling and disassembling gear.

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

Section 3 Identification code, label of model and engine N0.
Section 4 Points for attention in maintenance
Identification code
It is engraved in the left or right side of front
supporting main take of engine of frame.
Engine N0.
The engine No. engrave on the Narrow Point
Position
-4-
Identification code
Engine N0.
1.Preparation when disassembling
1.1 First clean the dirt, mud and attachment on
the vehicle befor removing or disassembling.
1.2 Use proper special too cleaning device and
means.
1.3 Keep all the components away from fire
source. Pay attention to the safety, Don’t be burned
by the high temperation portion of engine,exhuaster
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 assembling 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 disass-
embly, 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 lubricants and
grease which brank 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
l u b r i c a t e a l l t h e m a t e d c o m p o n e n t s a n d
bearing,apply grease for oil seal.

4. Clip
4.1Before assembling, be sure to check all
the clips carefully.Use a new one after remov-
ing the clip of piston pin. When mounting clip
ring ① make the sharp face ② on the opposite
position of impacted face ③ of clip.(see left
fig)
5.Locking washer /shim and location pin
5.1When reassembling after disassembling.
be sure to replace all the locking 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 di-
rection 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 electirc 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 eclectolyte inside the battery is a
kind of corrosive, when operation 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 termianl of nega-
tive pole of battery(see fig.7.1).When tighten-
ing or loosening bolt of terminal of big capacity
battery, don’t let the wrench contact with en-
gine 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, especially
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 phe-
nomenon on it. When inserting the joint, it should
be fixed, then put in plastic coating after
inserting.
In general, multi-head connector is plastic
one, and locking catch is designed. When disas-
sembling the connector, first open locking catch
when connecting again, first check if all the joint
is in good condition, if there is bent or twisted
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-
Plug pin
According to
intersecting

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 follow-
ing conversion table, metric unit could be conversed into imperial unit.
METRIC MULTIPLY IMPERIAL
mm 0.03937 in
2mm ×0.03937 =0.08in
Conversion table
(2)Definition of unit
Torque
Weight
Length
Volume/capacity
Others
Conversio between metric and imperial
Known unit Multiply produst
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(℃)+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
Meter kilogram
Pascal
Newton per millimeter
Liter
Cubic centimeter
Revolutions per minute
Definition
10-
3Meter
10-
3Meter
103Gram
1 lilo ×meter /second
Newton ×meter
Meter ×kilo
Newton/meter
2
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
1730mm
Overall width
1060mm
Overall height
1160mm
Height of cushion 830mm
Axle base
1100mm
Min.ground clearance
100mm
Min.turning radius
2500±100mm
Basic weight:
Engine oil(with full tank)
160±5 KG
Engine type
4 Stroke, Forced Air Cooling, Automatic
Displacement
149.6cc
Bore ×stroke
57.4×57.8mm
Compression ratio
9.2 :1
Starting system
Electric starter
Lubrication system pressure splash
Engine oil SE 15W/40
classfication of recommendedengine oil Model SE,SF,SG or above model
Overall capacity
0.8~1.2L
Capacity of main fuel tank 7.8L.Non-lead gasolining
No.90#
Carburetor:
Type
PD24J
Type of spark plug
C7HSA NGK
Clearance of spark plug
0.6-0.7mm
Type of clutch automatic
Output
Primary reduction system
CVT
Secondary reduction system
Chain
drive
Output type
Frame:
Bracket steel tube
Caster angle 25°
Tire:
Type
Tubeless
Specification
of front wheel AT21 ×7-10
Specification
of rear wheel AT20 ×10 -10
Pressure
of front wheel 20 3± kPa
Pressure
of rear wheel 25±3 kPa
Brake:
Type
of front brake
Disc
brake
Operation
type
Type
of rear brake
Drum brake
Operation
type Left
hand tobrake
Front
suspension Double wishbone
Rear
suspension Single wishbone
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
12V,
7AH
Headlight 12V,18W×2
Taillight
12V,21/5W
Cylinder arrangement Forward-inclined single cylinder
Rear-wheel drive
Right hand
to brake
YTX7L-BS

III.ATV body
-10-
Item Standard Limit
Front
wheel
Front
brake
Rear
wheel
Rear
brake
Brake
lever and
brake
pedal
Free play of throttle grip
Type
Material of rim
Size of tire
Radial runout of rim
Lateral swing of rim
Type
Type
Material of rim
Size of tire
Radial runout of rim
Lateral swing of rim
Type
Free play of brake lever (left)
Free play of brake lever (right)
Spock rim, tubeless tire
Steel plate
AT 21×7-10
Drum type
Spoke rim, tubeless tire
Steel plate
AT 20×
10-10
Disc
5-7mm
10-25mm
3-5mm
2.0mm
2.0mm
2.0mm
2.0mm

-11-
Section 6 Electrical diagram of ATV

-12-
Section 7 Requirements for torque of fastener
(I) General torque specification
General torque specification (standard screw)
This table is screw locking specification drawn
up by International Standard Association.
In order to avoid the twist or unbalancing phe-
nomenon when locking screw. please cross lock or
londuit as per appointed orders.
*When measuring torque force, standard torque
force testing spanner must be used.
A
(Nut)
B
(Screw)
Specification of general
torque
m.kg
10mm
12mm
14mm
17mm
19mm
22mm
6mm
8mm
10mm
12mm
14mm
16mm
0.6
1.5
3.0
5.5
8.5
13.0
B
A
A.Size of nut
B. Size of thread

-13-
Section 8 Lubrication
(I) General torque specification
:Pressure
:Splashing oil
Standard Item
Piston/cylinder
Piston pin
Connecting rod
Valve
Automatic centrifugal clutch
Crank Camshaft Rocker
Bearing
Sprocket chamber
Branch valve Fine filter
Spindle
Driving shaft
Middle gearbox Oil pump
Rough filter

Section 9 Lubrication point and type of lubricants
(I)Lubrication point and type of lubricants(ATV body)
Lubrication point
Lip of oil seal (full)
O-ring (full)
Steering shaft(upper end,lower end)
Ball connection of steering pushing rod
Front wheel fork (ball-shaped joint)
Front wheel bearing
Dust-proof ring of brake
Joint of front brake cable
Front brake lever axle and rear brake lever axle
Adjusting nut and pin of front brake cable
Adjusting nut and pin of rear brake cable
Rear brake pedal pivot and brake pedal axle hole
Throttle rotating frame shaft and end section of throttle cable
Connection bolt of rear wheel fork and frame,rear wheel fork bearing
Rubber sleeve and rear wheel fork
Rear shock absorber bushing
Front & rear
brake
Braking camshaft
Rotating pin seat
Lip of oil seal
Type of lubricants
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Grease used for bearing
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Light lithium-base grease
Seal gum
Light lithium-base grease
-14-

(II)Lubrication point and type of lubricants(Engine)
-15-
Lip of oil seal
All bearing
O-ring
Stem end of intake and exhaust valve
Fastener of cylinder head
Outside surface of piston pin
Outside surface of piston.piston ring
Clutch
Upper cam plate guide rod
Inner hole of upper cam plate unit
Steel ball bracket unit
Spindle and inside hole jointing face of right crankcase
Outside surface of short fork shaft
Outside surface of long fork shaft
Shift gear camshaft portion,slot portion,contactor
Outside surface of shift gear shaft
Outside surface of over-wheel shaft
Bushing inner hole of big gear of electric stater
Electric starting clutch
Lubrication point(name of component)Type of lubricant
Light lithium-base grease
Lubricating-oil
Light lithium-base grease
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
Lubricating-oil
(Crank,shift gear shaft,spindle,shift gear operation shaft)
(Crank spindle, driving shaft, shift gear camshaft,
pneumatic canshaft)
(Contact position of o-ring)
(Intake and exhaust valve, vale adjsuting screw )
(Bolt flange face,thread portion,washer endface)
(Piston piston pin,small connecting rod)
(Cylinder block ,piston, piston ring)
(Crank main drivinggear)
(Upper cam plate unit guide rod)
(Shift gear shaft, upper cam plate unit)
(Steel ball brakcket unit, upper&lowr cam plate)
(Spindle ,right crankcase)
(Fork shaft ,fork crankcase)
(Fork shaft ,fork ,crankcase )
(Fork, shift gear cam ,crankcase)
(Shift gear shaft and it抯 contacting portion)
(Over-wheel shaft ,crankcase)
(Bushing,left crankcase)
(Rolling post and it抯 contacting portion)