SMC Networks ATV50 User manual

SERVICE MANUAL
CF5/UR5/UR0
ATV 50/100 ATV with F/N/R
3 in 1 engine
Standard Motor Corporation

1-
0
1-
0
1-
0
1-
0
1-
0
1-
0
1.
Thi
s
not
i
ac
k
ch
a
1-
0
Sy
m
is
n
an
d
0
1. Sym
b
0
2. Gene
r
0
3. Servi
c
0
4. Spec
i
0
5. Torq
u
0
6. Trou
b
General
s
chapter
o
i
ce, cautio
n
k
nowledge
a
pte
r
s.
0
1. Sym
b
m
bols an
d
n
eeded. In
d
marks,
e
Warni
n
Cauti
o
Engine
Greas
Gear
o
Oil se
a
Rene
w
Brake fl
Special t
o
b
ols and
r
al Safe
t
c
e Prec
a
i
fication
s
u
e Value
s
b
les Dia
g
Informa
o
ffer you t
h
n
and the
t
and skills
b
ols and
d
marks a
r
case su
p
e
xplanatio
n
g
M
f
o
o
n
M
oil Li oi
li
m
e C
o
il G
r
e
a
l
Ap
w
R
uid U
o
ols S
p
S
MC
Marks
t
y
a
utions
s
s
g
nosis
tion
h
e general
t
ools tong
u
before sta
Marks
r
e used in
p
plement
a
ns will b
e
M
eans that
o
llowed.
M
eans that
mits to us
l. Warrant
m
ited engi
n
hassis gr
e
ear oil s
e
e
commend
p
ply with li
eplace wit
se recom
m
p
ecial tool
s
MC
AT
V
5
0
informati
o
u
e setting,
rt to do an
this man
l informa
t
added to
serious i
n
equipmen
t
e
SAE #
2
y
will not
c
n
e oil.
ase is rec
o
e
rials are
ed )
thium-soa
h
a new p
a
m
ended br
a
s
0
/10
0
Se
o
n of SMC
please re
a
y repair/in
s
ual to ind
t
ion of pr
o
the text i
n
jury or e
v
t
damage
s
2
0 or JAS
O
c
over the
o
mmende
d
recomm
e
p base lu
b
a
rt before
i
a
ke fluid
D
Se
rvice
M
1
2
3
10
12
14
ATV 50/1
0
a
d carefull
y
s
pection j
o
i
cate wha
t
o
cedures
i
n
stead of
v
en death
s
may resu
O
FC clas
s
damage t
h
d
.
e
nded. (
G
b
ricant.
i
nstallatio
n
D
OT4.
M
anua
l
Chapt
e
0
0 with 2
s
y
and mak
o
bs as me
n
t
and wh
e
i
s needed
using th
e
may resul
t
lt if proce
d
s
or simila
h
at cause
d
G
ear oil
S
n
.
er 1 Gen
s
troke eng
i
k
e sure yo
u
n
tioned at
e
re the sp
e
for thes
e
e
symbols
t if proce
d
d
ures are
n
r class 2
s
d
by not a
S
AE #40
-
e
ral Infor
m
ne, safety
u
have wel
furthering
e
cial serv
i
e
symbols
or marks
d
ures are
n
n
ot followe
d
s
troke eng
pply with
t
or above
-
1 -
m
ation
l
i
ce
.
n
ot
d
.
ine
t
he
is

1-
0
Bel
o
Ca
r
If y
o
are
a
us
e
Ex
h
Ga
Ga
s
sp
a
Ga
s
chil
Us
e
Pro
ver
i
Ke
e
Ho
Co
m
Th
e
ser
v
Ba
t
02
Gene
r
o
w is som
e
r
bon mo
n
o
u must ru
a
. Run yo
u
e
an extrac
Cautio
n
h
aust cont
a
s
oline
s
oline is a
a
rk should
Cautio
n
s
oline is hi
d
ren.
e
d trans
m
Cautio
n
longed co
n
i
fied. We r
e
e
p the use
d
t
compo
n
Cautio
n
m
ponents
o
e
y remain
v
v
ice work
o
t
tery
Cautio
n
Batte
r
when
Batte
r
not b
e
imme
d
water
If you
veget
a
Keep
r
al infor
m
e
of the g
e
n
oxide
n your en
g
u
r engine i
n
tor.
n
a
ins toxic
g
low ignitio
n
be allowe
d
n
ghly flam
m
mission
n
n
tact with
u
e
commen
d
d
oil beyo
n
nents
n
o
f the eng
i
v
ery hot e
v
o
n these p
n
r
y emits e
x
charging
t
r
y contain
s
e
spray on
d
iately wit
h
and then
g
swallow it
a
ble oil an
electrolyt
e
S
MC
m
ation r
e
e
neral info
r
g
ine, ensu
r
n
an open
g
as which
n
point an
d
d
in the w
o
m
able, and
oil
u
sed tran
s
d
that you
w
n
d reach o
f
i
ne and e
x
v
en after t
h
arts, wear
x
plosive g
a
t
he battery
s
sulfuric a
c
your eyes
h
water. If
y
g
o to hos
p
by mistak
d then im
m
e
beyond r
e
MC
AT
V
5
0
e
fer to y
r
mation to
r
e the pla
c
area, if yo
may caus
e
d
explosiv
e
rk place o
r
may expl
o
s
mission oi
w
ash you
r
f
children.
x
haust sys
t
h
e engine
h
insulated
a
ses; Flam
.
c
id (electr
o
or skin. If
y
ou get b
a
ital to see
e, drink a
l
m
ediately
g
e
ach of ch
0
/10
0
Se
our ow
n
your own
s
c
e is well v
e
o
u have to
e
one to lo
e
material.
r
where g
a
o
de under
i
l may cau
s
r
hands wi
t
t
em can b
e
h
as been
s
gloves an
d
e is strictl
y
o
lyte) whi
c
you get b
a
a
ttery acid
an ophth
a
l
ot of wate
g
o to see
a
ildren.
Se
rvice
M
n
safety
s
afety duri
e
ntilated.
N
run your e
se consci
o
Work in a
a
soline is
b
some con
d
s
e skin ca
n
t
h soap an
e
come ext
r
s
topped fo
d
wait until
y
prohibite
d
c
h can cau
s
a
ttery acid
in your ey
e
a
lmologist.
r or milk,
a
a
doctor.
M
anua
l
Chapt
e
ng the rep
N
ever run
y
n
gine in a
o
usness a
n
well-ventil
b
eing store
d
itions, ke
e
n
cer altho
u
d water ri
g
r
emely hot
r some ti
m
cooling o
f
d
. Keeps t
h
s
e serious
on your s
k
e
s, flush it
a
nd take s
o
er 1 Gen
p
air/servic
e
your engi
n
closed ar
e
n
d even re
l
ated plac
e
e
d.
ep it awa
y
u
gh it mig
h
g
ht after c
o
t
after engi
m
e. When
p
f
f.
h
e place
w
burns so
b
k
in, flush i
t
off immed
o
me laxati
v
-
e
ral Infor
m
e
time.
n
e in a clo
s
e
a, be sur
e
sult in de
a
e
, no flam
e
from
h
t not be
o
ntacting.
ne runnin
g
p
erforming
w
ell ventila
t
b
e careful
t
off
iately with
v
e such a
s
-
2 -
m
ation
s
ed
e
to
a
th.
e
or
g
.
t
ed
do
s

Br
a
Do
cle
a
Inh
a
Br
a
Spi
l
cle
a
the
1-
0
1.
A

2.
3.
W
v
4.
5.
W
a
ke pad/
s
not use a
n
a
ner or th
e
Cautio
n
a
ling brake
a
ke fluid
Cautio
n
l
ling brake
a
n towel o
n
brake flui
d
0
3. Servi
c
A
lways us

Using n
o
ATV an
d
Special to
o
compone
n
Using wro
W
hen ser
v
interchan
g
v
ehicle.
Clean the
deposit a
c
cause da
m
W
ash and
dry with c
o
seals bec
a
on them.
s
hoe
n
air hose
o
e
equivale
n
n
shoe or pa
d
n
fluid on p
a
n
the abo
v
d
beyond r
c
e Preca
e with SM
C
o
n-genuin
e
d
out of S
M
o
ls are de
s
n
ts without
ng tools
m
v
icing this
A
g
eable wit
h
outside of
c
cumulate
d
m
age.
clean par
t
o
mpresse
d
a
use most
S
MC
o
r a dry br
n
t to avoid
d
ash may
c
a
inted, pla
v
e-mention
each of c
h
utions
C
genuine
e
parts for
S
M
C warran
t
s
igned for
damagin
g
m
ay result i
n
A
TV, use
o
h
the Engli
s
the parts
o
d
on the p
a
t
s with hig
h
d
air. Pay
s
cleaning
a
MC
AT
V
5
0
u
sh to cle
a
dust flying
c
ause diso
r
stic, or ru
b
ed parts f
o
h
ildren.
parts and
S
MC
A
TV
t
y service.
remove a
n
g
the parts
n
parts da
m
o
nly metri
c
s
h system
,
o
r the cov
e
a
rt's surfac
e
h
ignition
p
s
pecial att
e
a
gents ha
v
0
/10
0
Se
a
n compo
n
g
.
r
ders and c
a
b
ber parts
o
r protecti
o
recomme
may dam
a
n
d install o
being wor
m
aged.
c
tools. M
e
, using wr
o
e
r before r
e
e may fall
p
oint solve
n
e
ntion to
O
v
e an adve
Se
rvice
M
n
ents of th
e
a
ncer of th
e
m
ay caus
e
o
n when s
e
nded oils.
a
ge the
f
ked on.
e
tric bolts,
n
o
ng tools
a
e
moving it
into the e
n
n
t, and blo
O
-rings or
o
rse effect
M
anua
l
Chapt
e
e
brake sy
s
e
breathing
e
damage
t
e
rvicing th
e
n
uts, and
s
a
nd fasten
e
f
rom the
A
n
gine, cha
s
w
o
il
SMC
G
er 1 Gen
stem; use
system
to the par
t
e
brake sy
s
s
crews ar
e
e
rs may d
a
A
TV. Other
w
s
sis, or br
a
G
enuine Par
t
-
e
ral Infor
m
a vacuum
s. Place a
s
tem. Kee
e
not
a
mage thi
s
w
ise, dirt
a
a
ke syste
m
t
s
-
3 -
m
ation
p
s
a
nd
m
to

6.
7.
8.
W
9.
10.
11.
12.
13.
w
Never be
n
and prem
a
Rubber p
a
Check the
necessar
y
W
hen loo
s
pattern an
loosen fir
s
Store com
proper as
s
of installat
number ta
Note the r
e
ensure th
e
Compone
n
disassem
b
snap ring
s
T
he lengt
h
boxes is d
installed. I
compare i
t
t
he same
w
assembly
T
ighten a
s
T
ighten al
l
w
ith speci
a
important
c
appropriat
Bolts and
f
t
o the thre
n
d or twist
a
a
ture worn
a
rts may b
e
se parts b
e
y
.
s
ening a c
o
d work fro
m
s
t, small fa
s
plex com
p
s
emble or
d
ion late
r
o
r
b for the s
e
assembl
e
e
y will be r
e
n
ts not to
b
b
led includ
s
, and split
h
of bolts
a
ifferent fro
n case of
c
t
s length
w
w
ith other
should ha
v
s
semblies
w
l
the faste
n
a
l tool first
c
ompone
n
e increme
n
f
asteners
s
ads.
S
MC
a
control
c
out.
e
come det
e
e
fore inst
a
o
mponent
m
inside o
s
teners m
a
p
onents su
d
er and tie
r
you can l
equence t
o
e
position
o
e
assembl
e
b
e reused
ing gaske
t
pins.
a
nd screw
s
m one an
o
c
onfusion,
w
ith other
b
bolts, it is
v
e the sa
m
w
ith differ
e
n
ers with fi
diagonall
y
n
ts should
n
ts to avoi
s
hould be
MC
AT
V
5
0
c
able to pr
e
e
riorated
w
a
llation to
m
which has
ut. Loose
n
a
y receive
ch as tran
s
them tog
e
abel the a
s
o
avoid th
e
o
f the imp
o
e
d in corre
c
should be
t
s, metal s
e
s
for asse
m
o
ther, be s
Insert the
b
olts, if its l
a correct
b
m
e length.
e
nt dimen
s
ngers, the
y
from insi
d
b
e tighten
e
d warp un
l
kept clean
0
/10
0
Se
e
vent uns
m
w
hen old,
a
m
ake sure
different
s
n
the small
too much
s
mission
p
e
ther with
a
ssembly p
e
mistake.
o
rtant com
ct dimensi
replaced
w
e
al rings,
O
m
blies, cov
ure they a
bolt into t
h
l
ength out
s
b
olt. Bolts
f
s
ion fasten
n tighten t
d
e toward
e
d 2 to 3 ti
l
ess other
w
n
and dry.
D
Se
rvice
M
m
ooth con
t
a
nd prone
t
that they
a
s
ized faste
fasteners
stress.
p
arts in th
e
a
wire for
e
arts by
A
r
a
ponents b
e
ons (dept
h
w
hen
O
-rings, oil
er plates
o
r
e correctl
y
h
e hole to
s
ide the h
o
f
or the sa
m
ers as foll
o
he big on
e
outside,
mes with
w
ise indic
a
D
o not ap
p
M
anua
l
Chapt
e
t
rol
t
o be dam
a
a
re in goo
d
ners, ope
r
first. If th
e
e
ase
a
bic
e
fore disa
s
h
, distance
seals,
o
r
y
o
le is
m
e
o
ws:
e
s
a
ted.
p
ly oil
er 1 Gen
a
ged by s
o
d
conditio
n
r
ate with a
e
bigger o
n
s
sembling
e
or positio
n
-
e
ral Infor
m
o
lvent and
, replace i
f
diagonal
es are
them to
n
).
-
4 -
m
ation
oil.
f

14.
15.
16.
17.
18.
When oil
t
he oil se
a
outside, a
n
installed f
o
oil seal.
Remove r
e
reinstallati
has any d
a
T
he ends
o
should be
so that th
e
t
ightening
Rubber a
n
t
he origin
a
T
he beari
n
removing
a
inner race
bearing, u
s
seal is in
s
a
l with the
n
n
d check t
h
o
r smooth
n
e
sidues of
on, grind
w
a
mage.
o
f rubber
h
pushed a
s
e
re is eno
u
the clamp
n
d plastic
b
a
l correct
p
n
g tool sh
o
a
ball bea
r
or outer r
a
s
e equal f
o
(B
o
S
MC
s
talled, fill t
n
ame of th
h
e shaft o
n
n
ess and f
o
the old g
a
w
ith a grin
d
h
oses (for
s
far as th
e
u
gh room
b
s.
b
oots shou
p
ositions a
s
o
uld be pr
e
r
ing. Dam
a
a
ce). In thi
o
rce on b
o
o
th of the
s
MC
AT
V
5
0
he groove
e manufa
c
n
which th
e
o
r burrs th
a
a
sket or se
a
d
stone if t
h
f
uel, vacu
u
e
y can go
t
b
elow the
e
ld be prop
s
designe
d
e
ssed agai
n
a
ge may r
e
s case, th
e
th races.
s
e exampl
e
0
/10
0
Se
with grea
s
c
turer faci
n
e
oil seal i
s
a
t may da
m
alant befo
r
h
e contact
u
m, or co
o
t
o their co
n
e
nlarged e
n
erly reinst
a
d
.
n
st two (in
e
sult if the
t
e
bearing
s
e
s can re
s
Se
rvice
M
s
e, install
n
g
s
to be
m
age the
r
e
surface
o
lant)
n
nections
n
ds for
a
lled to
ner and o
u
t
ool is pre
s
s
hould be
r
s
ult in bea
r
M
anua
l
Chapt
e
u
ter) beari
n
s
sed again
r
eplaced.
T
r
ing dama
g
er 1 Gen
n
g races
w
n
st only on
e
T
o avoid d
ge)
-
e
ral Infor
m
w
hen
e
race (eit
h
amaging t
h
-
5 -
m
ation
h
er
h
e

t
he rotatio
n
points be
f
o
sitions a
n
e
service s
a
parts fall
d
m
oval/inst
a
b
attery re
m
e
(－) cabl
e
w
ith body
t
r
vice com
p
. Battery p
-
install the
two pole
s
u
re that th
e
d
.
y
Voltage
e
rate expl
o
u
stic sulfu
r
o
tective ey
e
b
atteries in
teries aw
a
s
).
SMOKE
w
S
MC
n
ball face
f
ore asse
m
n
d operati
o
a
fety for e
a
d
own.
a
llation.
m
oval oper
a
e
firstly. T
o
t
o prevent
p
leted, ma
k
ositive (+)
battery c
o
s
ide of bat
t
e
battery p
o
and cond
o
sive hydr
o
r
ic acid. T
h
e
gear wh
e
a well-ve
n
a
y from fir
e
w
hen char
g
MC
AT
V
5
0
with spec
i
m
bling.
o
n for inst
a
a
ch other
w
a
tion, it ha
s
o
ols like o
p
from shor
t
k
e sure all
cable sho
o
rd. .
t
ery have t
o
o
st caps a
r
i
tion of c
h
o
gen gas
a
h
erefore,
a
e
n handlin
g
n
tilated a
r
e
, sparks o
r
g
ing or ha
n
0
/10
0
Se
i
fied lubric
a
a
lled parts
w
hen con
d
s
to remo
v
p
en-end w
r
t
-circuit an
connectio
uld be co
n
o
be grea
s
re located
h
arge in b
a
a
nd contai
a
lways foll
o
g
or worki
n
e
a.
r
open fla
m
n
dling batt
e
Se
rvice
M
a
nt on the
is in corre
c
d
ucting by
v
e the batt
e
r
ench do n
o
d
create s
p
n points is
n
nected fir
s
s
ed after c
o
in properl
y
a
ttery
n electrol
y
o
w these p
n
g near b
a
m
es (e.g.,
w
e
ries.
M
anua
l
Chapt
e
c
t and
t
wo perso
n
e
ry
o
t
p
ark.
s
tly
o
nnected
t
y
after the
t
e which i
s
reventive
m
tteries.
w
elding e
q
er 1 Gen
n
s.
t
he cables
.
battery p
o
s
made of
p
m
easures:
q
uipment, l
-
e
ral Infor
m
.
sts had b
e
p
oisonous
ighted
-
6 -
m
ation
e
en



FI
R
EX
T


IN
T

24.
25.
A
KEEP B
A
A
void bo
d
R
ST AID I
N
T
ERNAL
Skin —
W
Eyes —
F
T
ERNAL
Drink lar
g
vegetabl
e
If fuse bur
capacity f
u
Connecto
r
A
. When
s
compl
e
B. Do not
wires.
H
C. Make
s
D. Insert
t
locker
s
locker
s
loose.
E. Check
conne
c
A
TTERIES
d
ily conta
c
N
CASE O
F
W
ash with
w
F
lush with
g
e quantiti
e
e
oil. Get i
m
ned, it ha
s
u
se.
r
unlock/in
s
s
eparatin
g
e
tely, unlo
c
pull the w
H
old the c
o
s
ure if the
c
t
he conne
c
s
on two c
o
s
are locke
if the con
n
c
tor boot c
o
S
MC
AND EL
E
c
t with ele
c
F
BODILY
w
ater.
water for
1
e
s of wate
m
mediate
s
to find ou
s
ert
g
a connec
t
c
ked it firs
t
ires as re
m
o
nnector
b
c
onnector
c
tor compl
e
o
nnector s
i
d in prope
n
ector is c
o
o
mpletely
MC
AT
V
5
0
E
CTROLY
T
c
trolyte as
CONTAC
1
5 minute
s
r
or milk f
o
medical a
t
t
the caus
e
t
or, it lock
e
t
.
m
oving a c
o
b
ody.
pins are b
e
e
tely. If th
e
i
des, mak
e
rly. Check
o
vered by
t
and secur
e
0
/10
0
Se
T
E OUT O
it can cau
s
C
T:
s
and get i
m
o
llowed wit
t
tention.
e
and solv
e
e
r has to I
n
onnector
o
e
nt, extru
d
e
re are tw
o
e
sure the
if any wir
e
t
he twin
e
d properl
y
Se
rvice
M
F REACH
s
e severe
b
m
mediate
h milk of
m
e
d it. And
t
n
sert the t
e
o
r
d
ed or loo
s
o
e
y
.
M
anua
l
Chapt
e
OF CHIL
D
b
urns or p
e
medical a
t
m
agnesia,
b
t
hen repla
c
e
rminal
en.
er 1 Gen
D
REN.
e
rmanent
e
t
tention.
beaten eg
g
c
e with sp
e
-
e
ral Infor
m
e
ye injury.
g
or
e
cified
-
7 -
m
ation

26.
27.
W
28.
29.
30.
31.
F. Before
termin
a
Secure wi
r
locations.
harnesse
s
W
ire ban
d
properly.
Do not sq
u
Do not let
compone
n
Keep wire
Route wir
e
corners a
n
and scre
w
terminal
c
a
l is loose.
r
es and wi
Tighten th
s
.
d
and wire
u
eeze wir
e
the wire h
a
n
ts as routi
harnesse
s
e
harness
e
n
d also av
o
w
s.
S
MC
c
onnection
re harnes
s
e bands s
o
harness
h
e
s against
t
a
rness co
n
ng the ha
r
s
far away
e
s to avoid
o
id the pro
j
MC
AT
V
5
0
,
check if t
s
es to the
f
o
that only
h
ave to b
e
t
he weld o
n
tact with
r
r
ness.
from the
h
sharp ed
g
j
ected en
d
0
/10
0
Se
he boot is
f
rame with
the insul
a
e
clamped
r its clam
p
r
otating, m
h
ot parts.
g
es or
d
s of bolts
Se
rvice
M
crack or t
h
respectiv
e
a
ted surfac
secured
p
.
oving or v
i
M
anua
l
Chapt
e
h
e
e
wire ban
d
e
s contact
i
brating
er 1 Gen
d
s at the
d
t
the wi
r
es
-
e
ral Infor
m
d
esignated
or wire
-
8 -
m
ation

32.
33.
34.
35.
36.
37.
38.
W
39.
40.
W
f
Route har
n
slack.
Protect w
contact a
tape is to
Secure th
e
Never us
e
broken.
W
replace th
e
Never cla
m
compone
n
Do not let
W
ire harn
e
slack, be
r
Before op
e
instrumen
t
W
ith sand
f
ound.
A
n
d
n
esses so
ires or wir
e
sharp ed
g
be applie
d
e
rubber b
o
e
wires or
h
W
rap electri
e
m.
m
p or squ
e
n
ts.
the wire h
a
e
sses rout
r
ubbed ag
a
e
rating a t
e
t
. And the
n
paper to
c
d
then con
S
MC
that they
n
e
harness
e
g
e or corn
e
d
.
o
ot firmly
a
h
arnesses
cal tape a
r
e
eze the
w
a
rness be
e
ed along t
h
a
inst o
r
int
e
e
st instru
m
n
, conduct
c
lean rust
o
duct conn
e
MC
AT
V
5
0
n
either pul
e
s with ele
c
e
r. Thorou
g
a
s applyin
g
which ins
u
r
ound the
d
w
ire harnes
e
n twisted
h
e handle
b
e
rfere with
m
ent, oper
a
test in ac
c
o
n connec
t
e
ction ope
0
/10
0
Se
l too tight
n
c
trical tap
e
g
hly clean
g
it on wir
e
u
lation ha
s
d
amaged
p
s as instal
as install
a
b
ar should
h
adjacent
o
a
tor shoul
d
c
ordance
w
t
or pins/te
r
ration late
r
Se
rvice
M
n
or have
e
e
or tube i
f
t
he surfac
e
e
harness.
s
been
p
arts or
ling other
a
tion.
not be pu
o
r surroun
d
read the
o
w
ith the in
s
r
minals if
r
.
M
anua
l
Chapt
e
e
xcessive
they
e
where
l
led too tig
ding parts
o
peration
m
truction.
er 1 Gen
ht or have
in all stee
m
anual of
-
e
ral Infor
m
excessiv
e
ring positi
o
the
-
9 -
m
ation
e
o
n.

1-
0
1.
Di
m
Se
a
Wh
e
Gro
Wei
En
g
Cyli
Bor
e
Dis
p
Co
m
Lub
Car
Sp
a
Sta
r
Igni
t
Ge
n
Bat
t
En
g
En
g
Air-
F
Tra
n
Ge
a
Fin
a
Fin
a
Ge
a
Ge
a
Fu
e
Fu
e
Ch
a
Fro
n
Re
a
Bra
k
Bra
k
F.
B
R.
B
Tir
e
Fro
n
He
a
Re
a
Fla
s
0
4 Speci
f
SMC CF5
m
ension (Lx
W
a
t height
e
el base
und Cleara
ght
g
ine
nde
r
e
* Stroke
p
lacement:
m
pression
R
ricant :
bureto
r
a
rk
r
ting
t
ion
n
erato
r
t
ery :
g
ine Oil
g
ine Oil
F
ilte
r
n
smission (
a
r Shifting :
a
l ratio
:
a
l Drive :
a
r box oil
:
a
r Ratio :
e
l : Unl
e
e
l tank: 8.1
L
a
ssis : Ste
e
n
t Suspens
a
r Suspensi
k
e (F/R)
k
e (F/R)
B
rake oper
a
B
rake oper
a
e
: Tubeles
s
n
t/Rear: (F
)
(
R
a
d Light (ty
p
a
r Light: 12
V
s
her Light :
f
ication
s
series A
T
W
xH): 165
5
: 845mm
: 1080mm
nce : 23
5
: Un-laden
: 2 Stroke,
A
: Single, H
o
: 40 x 39.2
m
49.3 cc
R
atio : 7.8:1
mixed with
: Mikuni V
M
: NGK BP
R
: Electrical
: C.D.I.
:
A
CG Fly
W
MF type,
F
: 2Stroke
E
: 1.1L
: Wet type
e
F-R): C.V.
T
F- R (shift
s
:
1.59(35/2
2
Chain Dri
v
:
SAE #40,
Forward:
4
e
aded gas
o
L
e
l tube fra
m
ion: Doubl
e
on: Single
s
: Front dua
: Front dua
a
tion: Front
a
tion: Front
pedal for
i
s
)
AT 21x7-1
R
) AT 21x1
0
p
e 1): 12V
3
V
5W* 1 (L
E
12V 10W*
4
S
MC
s
TV
50, CV
T
5
mm/1028
m
5
mm
Mass = 14
2
A
i
r
Cooled
o
rizontal
m
m
fuel by oil
p
M
16 (18m
m
R
7HS x 1
starte
r
/Kic
k
W
heel Mag
n
F
actory def
a
E
ngine Oil,
S
e
lement
T
Automati
c
s
elector fu
n
2
T)
v
e, 428*88
0.12L
4
1.15~17.3
7
o
line
m
e
e
A
-arm; sh
o
s
wing Arm;
l hydraulic
d
l drum bra
k
RH side ha
LH side h
a
i
ntegrate fr
o
0 or others
0
-8 or othe
r
3
5W
/
35W*1
E
D)
4
MC
AT
V
5
0
with rev
e
m
m/1025m
m
2
kg; with fu
e
p
ump
m
), MJ:#65,
k
Starte
r
n
eto 90W
a
ult: YUAS
A
S
AE #20 or
c
with centri
f
n
ction in re
v
7
; Reverse:
o
ck absorb
e
shock abs
o
d
isc / Rear
k
e / Rear si
n
ndle brake
ndle brake
o
nt and rea
r
s
(Hi/Low-B
e
0
/10
0
Se
e
rse gear,
m
e
l Mass =
1
PJ:#17.5,
N
A
/GS Batte
r
JASO FC
c
f
ugal clutc
h
v
erse with
p
34.86- 14.
er
: 72 mm
t
o
rber: 63m
m
single hydr
n
gle drum
b
lever for fr
o
lever for r
e
r wheeler
a
e
am)
Se
rvice
M
Chain dri
1
48 kg
N
J:E-1(#42
6
r
y YTX4L-B
c
lass or ab
o
h
.
p
edal brake
)
71
t
ravel, 5-Se
m
travel, 5-
S
a
ulic disc (
O
b
rake (optio
o
nt wheele
r
e
ar wheeler
/
a
t the same
M
anua
l
Chapt
e
v
e.
6
)
S
/GTX4L-
B
o
ve.
)
c
tion adjus
t
S
ection adj
u
O
ption 1)
n
2)
/
parking br
a
time
er 1 Gen
B
S
t
able pre-lo
ustable pre
a
ke; R side
-
e
ral Infor
m
aded
-loaded
footrest br
a
10 -
m
ation
a
ke

2.
Di
m
Se
a
Wh
e
Gro
Wei
En
g
Cyli
Bor
e
Dis
p
Co
m
Lub
Car
Sp
a
Sta
r
Igni
t
Ge
n
Bat
t
En
g
En
g
Air-
F
Tra
n
Ge
a
Fin
a
Fin
a
Ge
a
Ge
a
Fu
e
Fu
e
Ch
a
Fro
n
Re
a
Bra
k
Bra
k
F.
B
R.
B
Tir
e
Fro
n
He
a
Re
a
Fla
s
SMC CF0
m
ension (Lx
W
a
t height
e
el base
und Cleara
ght
g
ine
nde
r
e
* Stroke
p
lacement:
m
pression
R
ricant :
bureto
r
a
rk
r
ting
t
ion
n
erato
r
t
ery :
g
ine Oil
g
ine Oil
F
ilte
r
n
smission
a
r Shifting :
a
l ratio
:
a
l Drive :
a
r box oil
:
a
r Ratio :
e
l : Unl
e
e
l tank: 8.1
L
a
ssis : Ste
e
n
t Suspens
a
r Suspensi
k
e (F/R)
k
e (F/R)
B
rake oper
a
B
rake oper
a
e
: Tubeles
s
n
t/Rear: (F
)
(
R
a
d Light (ty
p
a
r Light: 12
V
s
her Light:
1
series A
T
W
xH): 165
5
: 845mm
: 1080mm
nce : 23
5
: Un-laden
: 2 Stroke,
A
: Single, H
o
: 52 x 45m
m
95.2 cm3
R
atio : 5.8:1
mixed with
: Mikuni V
M
: NGK BP
R
: Electrical
: C.D.I.
:
A
CG Fly
W
MF type,
F
: 2 Stroke
E
: 1.1L
: Wet type
e
: C.V.T A
u
F-N- R (sh
i
:
1.59(35/2
2
Chain Dri
v
:
SAE #40,
Forward:
4
e
aded gas
o
L
e
l tube fra
m
ion: Doubl
e
on: Single
s
: Front dua
: Front dua
a
tion: Front
a
tion: Front
pedal for
i
s
)
AT 21x7-1
R
) AT 21x1
0
p
e 1): 12V
3
V
5W* 1 (L
E
1
2V 10W*
4
S
MC
TV
100, CV
5
mm/1028
m
5
mm
Mass = 14
4
A
i
r
Cooled
o
rizontal
m
fuel by oil
p
M
16 (18m
m
R
7HS x 1
starte
r
/Kic
k
W
heel Mag
n
F
actory def
a
E
ngine Oil,
e
lement
u
tomatic wit
i
ft selector
f
2
T)
v
e, 428*88
0.12L
4
1.15~17.3
7
o
line
m
e
e
A
-arm; sh
o
s
wing Arm;
l hydraulic
d
l drum bra
k
RH side ha
LH side h
a
i
ntegrate fr
o
0 or others
0
-8 or othe
r
3
5W
/
35W*1
E
D)
4
MC
AT
V
5
0
T
with re
v
m
m/1025m
m
4
kg; with fu
e
p
ump
m
), MJ:#77.
5
k
Starter(op
t
n
eto 90W
a
ult: YUAS
A
S
AE #20 o
r
h centrifug
a
f
unction in
r
7
; Reverse:
o
ck absorb
e
shock abs
o
d
isc / Rear
k
e / Rear si
n
ndle brake
ndle brake
o
nt and rea
r
s
(Hi/Low-B
e
0
/10
0
Se
v
erse gea
r
m
e
l Mass =
1
5
, PJ:#17.5
t
ional)
A
/GS Batte
r
r
JASO FC
a
l clutch.
r
everse wit
h
34.86- 14.
er
: 72 mm
t
o
rber: 63m
m
single hydr
n
gle drum
b
lever for fr
o
lever for r
e
r wheeler
a
e
am)
Se
rvice
M
r
, Chain d
r
1
50 kg
, NJ:E-1(#
4
r
y YTX5L-B
class or ab
h
pedal bra
k
71
t
ravel, 5-Se
m
travel, 5-
S
a
ulic disc (
O
b
rake (optio
o
nt wheele
r
e
ar wheeler
/
a
t the same
M
anua
l
Chapt
e
r
ive.
4
26)
S
/GTX5L-
B
ove.
k
e)
c
tion adjus
t
S
ection adj
u
O
ption 1)
n
2)
/
parking br
a
time
er 1 Gen
B
S
t
able pre-lo
ustable pre
a
ke; R side
-
e
ral Infor
m
aded
-loaded
footrest br
a
11 -
m
ation
a
ke

1-
0
Th
e
val
u
A.
5m
6m
8m
10
m
12
m
B.
Sp
a
Cyl
Cyl
A
ir
A
ir
Fa
n
Oil
Ca
r
Ca
r
A
ir
Int
a
Oil
Oil
Ge
a
Cr
a
ca
s
L.
R
Kic
Idl
e
On
e
Cl
u
Cl
u
Ex
h
Mu
f
Pr
o
A
.
C
Ma
Ge
a
0
5. Tool
T
e
torque v
a
u
es for not
Standard
Ite
m
m Bolt, N
u
m Bolt, N
u
m Bolt, N
u
m
m Bolt,
N
m
m Bolt,
N
Engine T
o
a
rk Plug
inder hea
d
inder hea
d
Shroud
Shroud c
o
n
Bolt
pump bolt
r
buretor u
p
r
buretor fl
o
cleaner fi
x
a
ke bolt (r
e
plug cap
drop bolt
(
a
r box bol
t
a
nkcase c
o
s
e)
R
Crankca
s
k Nut
e
gear plat
e
e
way clut
c
u
tch
u
tch carrie
r
h
aust Pipe
f
fler bolt
o
tector, m
u
C
. Generat
o
gnet (A.C.
a
r shifting
T
orque
v
a
lues listed
listed in t
h
Toque V
a
m
u
t
u
t
u
t
N
ut
N
ut
o
rque
Item
d
/cylinder
s
d
nut
o
ver
p
per bolt
o
at bolt
x
ing bolt
e
ed valve)
(
drain bolt
)
t
o
ver bolt (t
r
s
e bolt
e
bolt
c
h bolt
r
(cylinder
s
u
ffler
o
r nut (fly
w
G. coil) sc
lever nut
S
MC
v
alue se
t
in table a
r
h
e table.
a
lueTorqu
0
0
1
3
5
s
tud bolt
)
r
ansmissi
o
s
ide)
w
heel/roto
r
rew
MC
AT
V
5
0
t
ting
r
e for mor
e
e Value (
k
0
.45~0.60
0
.80~1.20
1
.80~2.00
3
.00~4.00
5
.00~6.00
Q
’
o
n
r
)
1
4
4
3
1
4
2
2
4
2
4
1
1
6
1
6
1
2
1
1
1
2
2
2
1
2
1
0
/10
0
Se
e
importan
t
k
g-m) 5m
6m
6m
8m
10
m
’
ty Thr
e
(
m
1
4
4
3
1
4
2
2
4
2
4
1
1
6
1
6
1
2
1
1
1
2
2
2
1
2
1
1
4
0
7
0
7
0
6
0
6
0
5
0
4
0
4
0
6
0
6
1
4
0
8
0
6
1
1
0
6
0
6
0
6
1
0
1
0
2
8
0
6
0
8
0
6
1
0
0
6
0
6
Se
rvice
M
t
tighten to
Item
m Screw
m Screw
m Screw
m Screw
m
m Screw
e
ad Dia.
m
m)
4
*1.22
7
*1.00
7
*1.00
6
*1.00
6.0
6
*1.00
5
*0.8
4
*0.7
4
*0.7
6
*1.00
6
*1.00
4
*1.50
8
*1.25
6
*1.00
*1.00
6
*1.00
6
*1.00
6
*1.00
0
*1.25
0
*1.00
8
*1.00
6
*1.00
8
*1.25
6
*1.00
0
*1.25
6
*1.00
6
*1.00
M
anua
l
Chapt
e
rque valu
e
T
o
Torqu
e
(kg
1.5
~
1.4
~
1.3
~
0.5
~
0.1
~
0.5
~
0.3
~
0.15
~
0
0.7
~
0.7
~
0.2
~
1.5
~
0.7
~
0.7
~
0.7
~
0.7
~
0.6
~
2.5
~
3.5
~
5
0.7
~
2.2
~
0.7
~
3.8
~
1.0
~
1
er 1 Gen
e
s. Please
o
rque
V
al
u
0.45~
0
1.00~
1
0.70~
1
2.00~
3
3.50~
4
e
Value
g
-m)
~
2.0
~
2.0
~
1.5
~
0.8
~
0.2
~
0.8
~
0.5
~
0.25
.2
~
1.0
~
1.0
~
0.4
~
2.0
~
1.0
~
1.0
~
1.0
~
1.0
~
1.0
~
3.5
~
4.5
.0
~
1.0
~
3.0
~
1.0
~
4.2
~
1.6
.0
-
e
ral Infor
m
see stand
a
u
e (kg-m)
0
.60
1
.40
1
.10
3
.00
4
.50
sugges
2.0
1.0
1.4
0.7
0.2
0.7
0.4
0.2
0.2
0.9
1.1
0.3
1.8
1.2
1.2
1.2
0.9
0.8
4.0
3.0
0.9
2.6
0.9
3.8
0.8
12 -
m
ation
a
rd
t

C.
Ste
Ste
Fro
Fro
Ste
Tie
-
Tie
-
Fro
Fro
Re
a
Re
a
Fro
Re
a
En
g
F.e
n
Sw
i
Un
d
Ch
a
Fo
o
Re
a
Re
a
Re
a
Re
a
Fo
o
Fo
o
Ex
h
Ha
n
Chassis
P
ering colu
m
ering colu
m
nt Shock
a
nt Arm (U
p
ering Knu
c
-
rod (lock
n
-
rod end a
nt hub
nt Wheel
a
r collar w
h
a
r Wheel
nt shield
b
a
r shield b
o
g
ine Moun
t
n
gine and
i
ng-Arm
d
er guard
a
in suppor
t
o
trest L&R
a
r Shock
A
a
r axles h
e
a
r axles h
e
a
r Brake H
o
t brake b
o
o
t brake b
o
h
aust Pipe
n
dlebar H
o
P
arts Tor
q
Item
m
n holder
m
n holder
a
bsorber (
u
p
pe
r
-Fram
c
kle and u
p
n
ut)
nd steerin
g
h
eel
b
olt
o
lt
t
ing
frame
t
e
r
A
bsorber (
u
e
xagon nu
t
e
xagon nu
t
ub Bolt
o
lt
o
lt
holder (fr
a
o
lde
r
S
MC
q
ue Value
and fram
e
and handl
u
pper & lo
w
e)
p
per arm
g
column
u
pper) bolt
t
(IN)
t
(EX)
a
me)
MC
AT
V
5
0
Q
e
e ba
r
w
er)
2
1
4
2
2
4
4
2
8
2
8
4
1
1
1
4
4
4
1
1
1
4
1
2
2
2
0
/10
0
Se
’ty Thr
e
(
2
1
4
2
2
4
4
2
8
2
8
4
1
1
1
4
4
4
1
1
1
4
1
2
2
2
0
8
1
0
1
0
1
0
1
0
1
0
1
0
1
4
1
0
1
4
1
0
0
8
0
8
1
0
1
4
0
8
1
0
0
8
1
0
2
8
2
8
1
0
1
0
0
8
0
8
0
8
Se
rvice
M
e
ad Dia.
(
mm)
8
*1.25
0
*1.25
0
*1.25
0
*1.25
0
*1.25
0
*1.25
0
*1.25
4
*1.50
0
*1.25
4
*1.50
0
*1.25
8
*1.25
8
*1.25
0
*1.25
4
*1.50
8
*1.25
0
*1.25
8
*1.25
0
*1.25
8
*1.50
8
*1.50
0
*1.25
0
*1.25
8
*1.25
8
*1.25
8
*1.25
M
anua
l
Chapt
e
Torqu
(k
g
1.
8
2.
2
4.
0
3
4.
0
2
3
7
4
1
4
2
2
4
8
2
1.
8
2
2.
0
1
0
1
0
5
4.
0
1.
0
1.
8
1.
0
er 1 Gen
u
e Value
g
-m)
8
/2.3
2
/3.5
0
/3.0
3
.0
0
/6.0
2
.5
3
.0
7
.0
4
.5
2.0
4
.5
2
.6
2
.6
4
.5
8
.5
2
.3
8
/2.8
2
.6
0
/3.0
0
/16
0
/16
5
.0
0
/6.0
0
/1.6
8
/2.8
0
/1.5
-
e
ral Infor
m
Rema
r
13 -
m
ation
r
ks

1-
0
A.
E
0
6.Trou
b
E
ngine d
o
b
les Diag
o
es not st
a
S
MC
nosis
a
rt
MC
AT
V
5
0
0
/10
0
Se
Se
rvice
M
M
anua
l
Chapt
e
er 1 Gen
-
e
ral Infor
m
14 -
m
ation

B.
E
C.
E
E
ngine p
o
E
ngine p
o
o
or perfor
m
o
or perfor
m
S
MC
m
ance at
m
ance at
MC
AT
V
5
0
l
ow and i
d
h
igh spe
e
0
/10
0
Se
d
le speed
e
d
Se
rvice
M
M
anua
l
Chapt
e
er 1 Gen
-
e
ral Infor
m
15 -
m
ation

D.
P
P
oor Perf
o
o
rmance
S
MC
MC
AT
V
5
0
0
/10
0
Se
Se
rvice
M
M
anua
l
Chapt
e
er 1 Gen
-
e
ral Infor
m
16 -
m
ation

A.
P
P
oor Stee
r
r
ing
S
MC
MC
AT
V
5
0
0
/10
0
Se
Se
rvice
M
M
anua
l
Chapt
e
er 1 Gen
-
e
ral Infor
m
17 -
m
ation

2-
0
2-
0
2-
0
2-
0
2-
0
2-
0
2-
0
2-
0
2-
0
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-
0
0
1. Tech
n
0
2. Perio
d
0
3. Fuel
H
0
4. Throt
t
0
5. Air C
l
0
6. Spar
k
0
7. Idle
S
0
8. Drivi
n
0
9. Brak
e
0. Brak
e
1. Brak
e
2. Clutc
h
3. Susp
e
4. Steer
i
5. Whe
e
6. Nuts,
7. Toe-I
n
8. Gear
0
1 Tech
n
Cl
e
Spar
k
“
F
Tire
d
n
ical Da
t
d
ical Ma
H
oses
t
le Cabl
e
l
eaner
k
Plug
S
peed A
d
n
g Chai
n
e
Syste
m
e
Syste
m
e
Light S
h
Wear
e
nsion
i
ng Han
d
e
l/Tire
Bolts Ti
n
Oil
n
ical Dat
a
Fuel Tank
2T Eng
i
Gea
r
e
arance of
t
k
plug
Brake leve
r
F
” Mark in
s
Idling
s
d
imension
Tire pr
e
Batt
e
S
M
C
t
a
intenan
c
e
d
justme
n
n
m
(drum
b
m
(Disk
B
witch/St
d
le
ghtness
a
of Oil
&
Capacity
i
ne Oil
r
Oil
t
hrottle val
v
T
y
G
a
r
free play
s
tatic timing
s
peed
F
R
e
ssure
e
ry
C
ATV 5
0
c
e Sche
d
n
t
b
rake)
B
rake)
arting I
n
&
Pressu
r
v
e
y
pe
a
p
F
ront
R
ear
0
/10
0
S
d
ule
n
hibitor
S
r
e Capa
c
50 CC: 1
2
YT
100CC: 1
2
Y
T
S
ervice
M
C
S
witch
c
ity
1.
1
0.
1
N
G
0
B
18
AT21
x
AT21
x
12 p
s
2
V3
A
h (typ
e
X
4L-BS or
2
V4Ah (typ
e
T
X5L-BS or
M
anua
l
C
hapter 2
8.1L.
1
L, SAE 2
0
1
2L, SAE 4
0
4~6 mm
G
K BPR7H
S
.6~0.7 mm
3~5 mm
B
TDC 18º
0
0±100 rp
m
x
7-10
/
or o
t
x
10-8
/
or o
t
i (0.81 kgf/c
m
e
: MF batt
e
GS Battery
e
: MF batt
e
GS Batter
y
Maintena
n
15
16
18
18
18
19
19
20
21
22
24
24
24
25
25
25
26
26
0
0
S
m
t
he
r
s
t
he
r
s
m
2)
e
ry, default:
y
GTX4L-B
S
e
ry, default:
y
GTX5L-B
S
-
1
n
ce Inform
a
YUASA
S
)
YUASA
S
)
1
5-
a
tion

2-
0
Ha
v
A
ut
sch
It
1
2
3
4
5
6
7
8
9
1
1
1
1
1
4
1
1
1
1
1
2
2
2
2
2
4
2
0
2 Perio
d
v
e your A
T
horized D
e
edule is e
s
em
Ch
e
Ite
m
*
*
*
A
*
A
*
*
0 *
1 *
2
*
3 *
4
*
5 *
6 *
7 *
W
8 *
W
9 *
0 *
1 *
2
*
3 *
4
*
5
d
ical Ma
T
V checke
d
e
aler to m
a
s
tablished
e
ck
m
s
Ma
Kil
o
Ma
Engine oil (
2
Gear Oil
Engine idle
s
Fuel Filter(f
u
Spark plug
A
ir cleaner
e
A
ir Cleaner
t
Carburetor
Throttle ope
limiter
Fuel lines (c
cracks/dam
a
Upper and l
o
Steering Sh
a
in check)
Front and R
e
absorber ch
e
Front /Rear
check
Front / Rear
shoe/pad w
e
Front and R
e
Level/Leaka
Wheel rim c
h
Wheel Hub
B
looseness/d
a
Tire (Wear/
P
Nuts, Bolt,
B
check and l
u
Fr. & Rr. St
e
pivot
CVT driving
CVT driving
Driving Cha
i
Battery Volt
a
S
M
C
intenan
c
d
, adjuste
d
a
intain the
by taking
t
intenance
o
meter
intenance In
2
stroke)
s
peed
u
el cup)
e
lement (Re
m
t
ube
ration /Spee
heck or
a
ge) Fram
e
o
w
A
-Arm
a
ft (lubricant
e
ar shock
e
ck
brake free p
l
brake or
e
ar
e
ar Brake Fl
ge Check
h
eck for da
m
B
earing
a
mage
P
ressure)
B
ush, fasten
e
u
bricant.
e
ering Knuc
k
belt/weight
r
Clutch
i
n
a
ge
C
ATV 5
0
c
e Sche
d
d
, and rec
o
ATV at th
e
t
he hours
o
30
0
terval 20
h
En
g
Fu
e
m
ark)
C
d
e
/Steering/S
u
, Toe
l
ay
uid
m
age
e
r
k
le
T
r
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0
/10
0
S
d
ule
o
rded mai
n
e
optimum
o
r kilomet
e
0
KM
h
r
g
ine mainten
a
A
dd 2 strok
R
I
e
l and air sy
s
C
lean or repl
a
(more of
t
I
u
spension/B
r
I
Replac
e
I
I
T
ransmissio
S
ervice
M
C
n
tenance d
condition
.
e
rs as a re
Every 3
M
1000 KM
60 hr
a
nce
e oil into oil
t
I
s
tem
a
ce if neces
s
t
en when in
w
I
I
I
I
r
ake/ Wheel
L
I/
L
I
I
e
whenever
w
I
I
I
I
I
L
n
I/
L
I
M
anua
l
C
hapter 2
ata period
The abo
v
f
erence w
h
M
on. Ev
20
0
12
0
t
ank, when
o
s
ary for Eve
r
w
et or dusty
& Tires
L
w
orn to the li
L
Maintena
n
ically by y
o
v
e mainten
h
icheve
r
c
o
v
ery 6 Mon.
00 KM
0 hr
o
il warning l
a
R
I
I
I
r
y 1000 KM
areas)
I
I
I
I
L
I/L
I
I
i
mited
I
I
I
I
I
L
I
I
I/L
I
-
1
n
ce Inform
a
o
ur SMC
ance
o
mes first.
Remark
s
a
mp is “on”
1
6-
a
tion
s