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GAMAX MOTO ATV
AX 600/600LX-BW
Service Manual
This service manual contains the technical data of each component
inspection and repair for the GAMAX AX- 600 ATV. The manual is shown
with illustrations and focused on “Service Procedures”, “Operation Key
Points”, and “Inspection Adjustment” so that provides technician with service
guidelines.
If the style and construction of the ATV, GAMAX AX600 ATV, are different
from that of the photos, pictures shown in this manual, the actual vehicle
shall prevail. Specifications are subject to change without notice.
Service Department
GAMAX MOTO CO., LTD.
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and system
inspection & service for GAMAX AX600 ATV. In addition, please refer to the manual contents
in detailed for the model you serviced in inspection and adjustment.
Chapter.1 includes general information and trouble diagnosis.

Chapter 2 includes service maintenance information and special tools manual.
Chapter 3~12 includes engine and driving systems.
Chapter 13 includes cooling system.
Chapter 14~17 includes assembly frame body.
Chapter 18 includes electrical equipment.
Chapter 19 includes wiring diagram.
Please see index of content for quick having the special parts and system information.
SERIAL NUMBER
Frame number:
Engine number:
Home page Contents

CONTENTS Page Content Index
1-1 ~ 1-23 GENERAL INFORMATION 1
2-1 ~ 2-17 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-9 LUBRICATION SYSTEM 3
4-1 ~ 4-13 FUEL SYSTEM 4
5-1 ~ 5-7 ENGINE REMOVAL 5
6-1 ~ 6-17 CYLINDER HEAD/VALVE 6
7-1 ~ 7-9 CYLINDER/PISTON 7
8-1 ~ 8-17 “V”BELT DRIVING SYSTEM 8
9-1 ~ 9-15 TRANSMISSION 9
10-1 ~ 10-17 WHEEL DRIVE SHAFT & PROPELLER SHAFT 10
11-1 ~ 11-11 A.C GENERATOR/STARTING CLUTCH 11
12-1 ~ 12-9 CRANKCASE / CRANKSHAFT 12
13-1 ~ 13-12 COOLING SYSTEM 13
14-1 ~ 14-14 BODY COVER 14
15-1 ~ 15-14 FRONT BRAKE AND FORNT WHEEL 15
16-1 ~ 16-10 STEERING/FRONT SUSPENSION 16
17-1 ~ 17-18 REAR BRAKE/REAR WHEEL / REAR CUSHION 17
18-1 ~ 18-22 ELECTRICAL EQUIPMENT 18
19-1 ~ 19-2 ELECTRICAL DIAGRAM 19
GENERAL INFORMATION
1. Symbols and Marks 1-1
2. General Safety 1-2
3. Service Precautions 1-4
4. Specifications 1-16
5. Torque Values 1-17
6. Troubles Diagnosis 1-19
1. Symbols and Marks

Symbols and marks are used in this manual to indicate what and where the special service is
needed. In case supplemental information of procedures is needed for these symbols and
marks, explanations will be added to the text instead of using the symbols or marks.
Means that serious injury or even death may result if procedures are not
Warning
followed.
Caution Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-40 API SG class oil. Warranty will not cover the
Engine oil
damage that caused by not apply with the limited engine oil.
Grease Chassis grease is recommended.
Gear oil Gear oil serials are recommended. (Gear oil SAE 80/90 is recommended )
Apply sealant; medium strength sealant should be used unless otherwise
Locking sealant
specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT4.
Special tools Special tools
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions
1-1
GENERAL INFORMATION
2. General Safety
Carbon monoxide
If you must run your engine, ensure the place is well ventilated. Never run your engine in a closed area.
Run your engine in an open area, if you have to run your engine in a closed area, be sure to use an
extractor.
Caution
Exhaust contains toxic gas which may cause one to lose consciousness and even result in death.
Gasoline
Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or
spark should be allowed in the work place or where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode under some conditions, keep it away from children.
Used engine oil

Caution
Prolonged contact with used engine oil (or transmission oil) may cause skin cancer although it might
not be verified. We recommend that you wash your hands with soap and water right after contacting.
Keep the used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system can become extremely hot after engine running. They
remain very hot even after the engine has been stopped for some time. When performing service work
on these parts, wear insulated gloves and wait until cooling off.
Battery
Caution
x Battery emits explosive gases; Flame is strictly prohibited. Keeps the place well ventilated
when charging the battery.
x Battery contains sulfuric acid (electrolyte) which can cause serious burns so be careful do not
be spray on your eyes or skin. If you get battery acid on your skin, flush it off immediately with
water. If you get battery acid in your eyes, flush it off immediately with water and then go to
hospital to see an ophthalmologist.
x If you swallow it by mistake, drink a lot of water or milk, and take some laxative such as castor
oil or vegetable oil and then go to see a doctor.
x Keep electrolyte beyond reach of children.
1-2
GENERAL INFORMATION
Brake pad
Do not use an air hose or a dry brush to clean components of the brake system; use a vacuum cleaner
or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the parts. Place a clean
towel on the above-mentioned parts for protection when servicing the brake system. Keep the brake
fluid beyond reach of children.
1-3
GENERAL INFORMATION
3. Service Precautions
Always use with GAMAX genuine parts and recommended oils. Using non-designed parts for GAMAX
ATV may damage the ATV.
Special tools are designed for remove and install of components without damaging the parts being
worked on. Using wrong tools may result in parts damaged.
When servicing this ATV, use only metric tools. Metric bolts, nuts, and screws are not
interchangeable with the English system, using wrong tools and fasteners may damage this vehicle.
Clean the outside of the parts or the cover before removing it from the ATV. Otherwise, dirt and
deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause
damage.
Wash and clean parts with high ignition point solvent, and blow dry with compressed air. Pay special
attention to O-rings or oil seals because most cleaning agents have an adverse effect on them.
1-4
GENERAL INFORMATION
Never bend or twist a control cable to prevent unsmooth control and premature worn out.
Rubber parts may become deteriorated when old, and prone to be damaged by solvent and oil. Check
these parts before installation to make sure that they are in good condition, replace if necessary.
When loosening a component which has different sized fasteners, operate with a diagonal pattern
and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small
fasteners may receive too much stress.
Store complex components such as transmission parts in the proper assemble order and tie them
together with a wire for ease of installation later.
Note the reassemble position of the important components before disassembling them to ensure they
will be reassembled in correct dimensions (depth, distance or position).
Components not to be reused should be replaced when disassembled including gaskets metal seal
rings, O-rings, oil seals, snap rings, and split pins.
1-5
GENERAL INFORMATION
The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be
sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length
with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for
the same assembly should have the same length.
Tighten assemblies with different dimension fasteners as follows: Tighten all the fasteners with
fingers, then tighten the big ones with special tool first diagonally from inside toward outside,
important components should be tightened 2 to 3 times with appropriate increments to avoid warp
unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the
threads.
When oil seal is installed, fill the groove with grease, install the oil seal with the name of the
manufacturer facing outside, and check the shaft on which the oil seal is to be installed for
smoothness and for burrs that may damage the oil seal.
1-6
GENERAL INFORMATION
Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the
contact surface has any damage.
The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they can go to their
connections so that there is enough room below the enlarged ends for tightening the clamps.
Connector
Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.
The tool should be pressed against two (inner and outer) bearing races when removing a ball bearing.
Damage may result if the tool is pressed against only one race (either inner race or outer race). In this
case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races.
(Both of these examples can result in bearing damage)
1-7
GENERAL INFORMATION
Lubricate the rotation face with specified lubricant on the lubrication points before assembling.
Check if positions and operation for installed parts is in correct and properly.
Make sure service safety for each other when conducting by two persons.
Do not let parts fall down.
Before battery removal operation, it has to remove the battery negative (－) cable firstly. Tools like
open-end wrench do not contact with body to prevent from short-circuit and create spark.
1-8
GENERAL INFORMATION
After service completed, make sure all connection points is secured. Battery positive (+) cable should
be connected firstly.
And the two posts of battery have to be greased after connected the cables.
Make sure that the battery post caps are located in properly after the battery posts had been serviced.
If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse.
1-9
GENERAL INFORMATION
When separating a connector, it locker has to Insert the terminal completely, unlocked it first. Then,
conduct the service Check if the terminal is covered by the boot. Do not let boot open facing up.
Do not pull the wires as removing a connector or wires. Hold the connector body.
Make sure if the connector pins are bent, extruded or loosen.
Insert the connector completely. If there are two lockers on two connector sides, make sure the lockers
are locked in properly. Check if any wire loose.
Check if the connector is covered by the twin connector boot completely and secured properly.
1-10
GENERAL INFORMATION
Before terminal connection, check if the boot is crack or the terminal is loose.
Secure wires and wire harnesses to the frame with respective wire bands at the designated locations.
Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.
Wire band and wire harness have to be clamped secured properly.
Do not squeeze wires against the weld or its clamp.
1-11
GENERAL INFORMATION
Do not let the wire harness contact with rotating, moving or vibrating components as routing the
harness.
Keep wire harnesses far away from the hot parts.
Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and
screws.
Route harnesses so that they neither pull too tight nor have excessive slack.
1-12
GENERAL INFORMATION
Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner.
Thoroughly clean the surface where tape is to be applied.
Secure the rubber boot firmly as applying it on wire harness.
Never use wires or harnesses which insulation has been broken. Wrap electrical tape around the
damaged parts or replace them.
Never clamp or squeeze the wire harness as installing other components.
1-13
GENERAL INFORMATION
Do not let the wire harness been twisted as installation.
Wire harnesses routed along the handlebar should not be pulled too tight or have excessive slack, be
rubbed against or interfere with adjacent or surrounding parts in all steering position.
Before operating a test instrument, operator should read the operation manual of the instrument. And
then, conduct test in accordance with the instruction.
1-14
GENERAL INFORMATION
With sand paper to clean rust on connector pins/terminals if found.And then conduct connection
operation later.
1-15
GENERAL INFORMATION
4.Specifications
MAKER GAMAX MODEL FBE
Overall Length 2160 mm Front Double arm
Suspension System
Overall Width 1200 mm Rear Double arm
Overall Height 1180 mm Front 25×8-12(off road)
Tire Specifications
Wheel Base 1294 mm Rear 25×10-12(off road)
Front 965 mm Rim Steel/Aluminum
Wheel tread
Rear 914 mm Front Disk (Ø220mm)
Weight Brake System
Front 168 kg Rear Disk (Ø190mm)
Dimension
Curb Weight Rear 158 kg Max. Speed Above 92 km/hr
Performance
Total 326 kg Climb Ability Below 25ﾟ
Passengers/ weight Two / 150 kg Primary
Belt
Front 230kg Reduction
Total Weight
Rear 246kg Secondary
Gear / Shaft
Total 476 kg Reduction Reduction
Type 4-Stroke Engine Clutch Centrifugal,dry type

Installation and Vertical, below C.V.T., auto speed
Transmission
arrangement center, incline change
unleaded
Fuel Used Speedometer 0 ~ 140 km/hr
gasoline
4-stroke/Water Expansion &
Cycle/Cooling Muffler
cooled Pulse Type
Exhaust Pipe Position and Right side, and
Bore Ø92 mm
Direction Backward
Forced circulation &
Cylinder Stroke 85 mm Lubrication System
splashing
Engine Number/
Single Cylinder Ignition C.D.I
Arrangement
Displacement 600 cc
Compression Ratio 9.2 : 1
Max. HP 14.9kw/6500rpm
Max. Torque 49Nm/ 5500rpm
Ignition C.D.I.
Starting System Electrical starter
Air filtration Sponge
1-16
GENERAL INFORMATION
5. Torque
The torque values listed in table are for more important tighten torque values. Please see standard
values for not listed in the table.
Engine Torque
Thread Dia. Tor Value
Item Q’ty Remarks
(mm) (N-m)
Cylinder stud bolt 4 10 10~14
Cylinder head nut 4 8 36~40
Cylinder head right bolt 2 8 20~24
Cylinder head side cover bolt 2 6 10~14
Cylinder head cover bolt 4 6 10~14
Cylinder head stud bolt (inlet pipe) 2 6 10~14
Cylinder head stud bolt (EX. pipe) 2 8 24~30
Air inject pipe bolt 4 6 10~14
Air inject reed valve bolt 2 3 0.7~0.9
Tappet adjustment screw nut 4 5 7~11
Spark plug 1 10 10~12
Tensioner lifter bolt 2 6 10~14
Carburetor insulator bolt 2 6 7~11
Oil pump screw 2 3 1~3
Water pump impeller 1 7 10~14
Engine left cover bolt 9 6 11~15
Engine oil draining bolt 1 12 35~45
Engine oil strainer cap 1 30 13~17
Mission draining bolt 1 8 11~15
Mission filling bolt 1 12 35~45
Shift drum fixing bolt 1 14 35~45
Clutch driving plate nut 1 28 50~60
Clutch outer nut 1 14 50~60
Drive face nut 1 14 85~105
ACG. Flywheel nut 1 14 50~60
Crankcase bolts 7 6 8~12
Mission case bolt 7 8 26~30
1-17
GENERAL INFORMATION
Frame Torque
Thread Dia. Tor Value
Item Q’ty Remarks
(mm) (N-m)
Handlebar upper holder bolt 4 6 24
Steering shaft nut 1 14 84
Steering tie-rod nut 4 10 40
Knuckle nut 4 10 40
Steering shaft holder bolt 2 8 23
Front wheel nut 8 10 50
Front axle castle nut 2 18 150
Rear axle castle nut 2 22 180
Rear wheel nut 8 10 50
Engine hanger nut 3 10 40
Drive gear bolt 5 10 55
Driven gear nut 4 10 55
Front/Rear suspension arm bolt 8 10 45
Front / Rear suspension arm nut 8 10 45
Brake lever bolt 2 5 10
Brake hose bolt 13 10 23
Brake caliper bolt 6 8 30
Air-bleed valve 2 8 10
Exhaust muffler mounting bolt 2 8 29
Exhaust muffler connection nut 2 8 25
1-18
GENERAL INFORMATION
6.Troubles Diagnosis
A.Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to

check if there is gasoline inside
the carburetor
● No fuel in fuel tank

● Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
Fuel supplied tom No fuel is supplied to ● Float valve clogged
carburetor sufficient carburetor ● Lines in fuel tank evaporation system
clogged
● Malfunction of fuel pump
● Loosen or damaged fuel pump vacuum
hose
Remove spark plug, install it ● Fuel filter clogged
into spark plug cap, and perform
a spark test against engine
ground.
● Malfunction of spark plug

● Spark plug foul
Check if sparks Weak sparks, no spark at ● Malfunction of CDI set
all ● Malfunction of AC generator
● Ignition coil is in open or short circuit
● Ignition coil leads open or short circuit
Perform cylinder compression ● Malfunction of main switch
pressure test.
Cylinder compression Low compression ● Piston ring seized

pressure normal pressure or no pressure ● Malfunction of cylinder valves
● Worn cylinder and piston ring
● Cylinder gasket leak
● Sand hole in compression parts
Re-start by following the starting

procedures
No ignition There are some signs of ● Malfunction of throttle valve operation

● Air sucked into intakemanifold
ignition; nut engine can ● Incorrect ignition timing
not be started
Remove the spark plug again

and check it.
● Fuel level in carburetor too high

Dry spark plug Wet spark plug ● Malfunction of throttle valve operation
● Throttle valve opening too wide
Remove carburetor after 30

minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air
Blowing in normal Blowing clogged ● Malfunction of automatic by- starter
1-19
GENERAL INFORMATION
B.Engine run sluggish (speed does not pick up,lack of power)
Try gradual acceleration and

check engine speed
● Air cleaner clogged

● Poor fuel supply
Engine speed can be Engine speed can not be ● Lines in fuel tank evaporation
increased increased system clogged
● Exhaust pipe clogged
● Fuel nozzle clogged in carburetor
● Fuel nozzle clogged in carburetor
Check ignition timing (Using
ignition lamp)
● Malfunction of CDI
Ignition timing correct Incorrect ignition timing ● Malfunction of AC alternator
Check cylinder compression

pressure (using compression
pressure gauge)
● Cylinder & piston ring worn out

● Cylinder gasket leaked
Compression pressure No compression pressure ● Sand hole in compression parts
correct ● Valve deterioration
● Seized piston ring
Check if carburetor jet is

clogged
No clogged Clogged ● Remove foreign
Remove spark plug
● Remove dirt
No foul or discoloration Fouled and discoloration ● Incorrect spark plug heat range
Check if engine over heat

● Piston and cylinder worn out
● Lean mixture
● Poor fuel quality
Normal Engine overheat ● Too much carbon deposited
in combustion chamber
● Ignition timing too advanced
● Poor circuit on the cooling system
Continually drive in acceleration
or high speed
● Too much carbon deposited
No knock Knock ● Lean mixture
● Poor fuel quality
● Ignition timing too advanced
1-20
GENERAL INFORMATION
C.Engine runs sluggish (especially in low speed and idling)
Check ignition timing (using

ignition lamp)
Normal Abnormal ● Incorrect ignition timing

(malfunction of CDI or AC alternator)
Adjust the air screw of

carburetor
● Rich mixture (loosen the screw)

Good Poor ● Lean mixture (tighten the screw)
Air sucked through carburetor

gasket
● Poor heat insulation gasket

No air sucked Air sucked ● Carburetor lock loose
● Poor intake gasket
● Poor carburetor O-ring
● Vacuum hose crack
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground
● Spark plug fouled

Good spark Poor ● Malfunction of AC generator
● Malfunction of ignition coil
● Open or short circuit in spark plug leads
● Malfunction of main switch
D.Engine runs sluggish (High speed)

Check ignition timing
Normal Abnormal ● Malfunction of AC alternator
Check for fuel supplying system

in automatic fuel cup
● Insufficient fuel in fuel tank

Good Abnormal ● Fuel filter clogged
● Restricted fuel tank vent
Check if carburetor clogged
No clogged clogged Clogged ● Cleaning
1-21
GENERAL INFORMATION
E.Clutch, driving and driving pulley
FAULT CONDITIONS PROBABLE CAUSES
● Drive belt worn out or deformation

Engine can be started but ● Ramp plate of movable drive face damaged
motorcycle can not be moved. ● Driving pulley spring broken
● Clutch weights broken
● Drive slide-shaft gear groove broken
● Transmission gear damaged
Engine running and misfire as

motorcycle initial forward moving or ● Clutch weights spring broken
jumping suddenly (rear wheel rotating ● Clutch outer stuck with clutch weights
● Connection parts in clutch and shaft worn out or burned
as engine in running)
● Drive belt worn out or deformation

Poor initial driving (Poor climbing ● Weight roller worn out
performance) ● Movable drive face shaft worn out
● Driven pulley spring deformation
● Driven pulley shaft worn out
● Greased in drive belt and driven face.
F.Poor handling
FAULT CONDITIONS PROBABLE CAUSES
Steering is heavy ● Damaged steering bearing

● Damaged steering shaft bushing
● Bent rim
● Improperly installed wheel hub
One wheel is wobbling ● Excessive wheel bearing play
● Bent swing arm
● Bent frame
● Swing arm pivot bushing excessively
● Worn
● Bent tie-rod
Vehicle pulls to one side ● Incorrect tie-rod adjustment
● Rear tie air pressure incorrect
● Improper wheel alignment
● Bent frame
1-22
GENERAL INFORMATION
G.Loss power
Raise wheels off ground and

spin by hand
● Brake dragging
Spin freely Abnormal ● Drive chain too tight
● Damaged wheel bearing
● Wheel bearing needs lubrication
Check tire pressure
● Punctured tire
Normal Abnormal ● Faulty tire valve
Accelerate lightly, engine speed

can be increase
● Fuel / air mixture ratio too rich or lean
● Clogged in air cleaner
Normal Abnormal ● Clogged in muffler
● Restricted fuel flow
● Clogged fuel tank cap breather hole
Check ignition timing
● Faulty pulse generator

Normal Abnormal ● Faulty CDI unit
Test cylinder compression
● Leaking head gasket

Normal Abnormal ● Worn cylinder and piston rings
Check carburetor
Normal Clogged ● Clean
Check spark plug
● Clean the spark plug

Normal Fouled or discolored ● Spark plug is incorrect heat range
Check for engine overheating

● Excessive carbon deposited
● Wrong type of fuel
Normal Overheating ● Fuel / air mixture ratio is lean
● Use of poor quality fuel
Accelerate or run at high speed

● worn piston and cylinder
● Fuel / air mixture ratio is lean
● Wrong type of fuel
Normal Knocks ● Ignition timing too advanced
● Excessive carbon deposited
1-23
MAINTENANCE INFORMATION
1. Technical Date 2-2
2. Periodical Maintenance Schedule 2-3
3. Fuel Hoses 2-4
4. Throttle Cable 2-4
5. Air Cleaner 2-4
6. Spark Plug 2-5
7. Valve Clearance 2-6
8. Carburetor Idle Speed Adjustment 2-7
9. Ignition System 2-8
10. Cylinder Compression Pressure 2-8
11. Drive Belt 2-9
12. Brake System (Disk Brake) 2-10
13. Brake Light Switch/Starting Inhibitor 2-11
14. Headlight Beam Distance 2-12
15. Clutch Wear 2-12
16. Suspension 2-12
17. Steering Handle 2-13
18. Wheel/Tire 2-13
19. Nuts, Bolts Tightness 2-13
20. Special Tools List 2-14
2-1
1. Technical Date
Fuel Tank Capacity 25000 c.c.
Capacity 3000 c.c.
Engine Oil Change 2400 c.c.

Oil and oil filter
change
2700c.c.
Capacity 200c.c
Front differential oil
Change 180c.c
Capacity 130 c.c.

Rear gear box oil
Change 110 c.c.
Engine + radiator 1800 c.c.
Capacity of coolant
Reservoir upper 700 c.c.
Clearance of throttle valve 1~3 mm
Type NGK CR8E
Spark plug
Gap 0.7~0.8 mm
“F”Mark in idling speed BTDC 20º/ 1500 rpm
Full timing advanced BTDC 51º/ 6200 rpm
Idling speed 1600±100 rpm
Cylinder compression pressure 12±2 kgf/cm²
Valve clearance IN:0.10 ±0.02 mm EX:0.15 ±0.02 mm
Front AT25x8-12
Tire dimension
Rear AT25x10-12
Tire pressure (cold) 8(7)±0.2 psi (On road) / 5(3.5) ±0.2 psi (Off road)
Battery 12V18Ah (type : MF battery)
2-2
2. Periodical Maintenance Schedule
Maintenance 1.st 300KM 1 Month or 3 month or 6 month or 1 year or
Item 1,000KM 3,000KM 6000KM 12,000KM
Code
1 Air cleaner I C R
2 Fuel filter I I R
3 Oil filter R C
4 Engine oil change R Replacement for every 1000 km
5 Tire pressure Checking before every riding
6 Battery inspection I I I
7 Brake fluid & free ply check I I R
8 Steering handle check I I
9 Cushion operation check I I
10 Bolts and nuts tighten check I I I
11 Spark plug check or change I I R
Replacement for
12 Final Gear oil change I I
every 5000 km
13 Frame lubrication L
14 Exhaust pipe I I
15 Ignition timing I I
16 Throttle operation I I I
17 Engine bolt tightening I I
18 CVT driving device(belt) I R
19 CVT driving device(roller) C
20 Rear wheel axle nut I Checking every 500 km
Lights/electrical
21 I I
equipment/multi-meters
22 Fuel hoses and connectors I I
23 Valve clearance I I
Lines & connections in
24 I I A
cooling
25 Coolant I I R
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ cleaning (replaced if necessary) L ~ Lubrication
Have your ATV checked, adjusted, and recorded maintenance data periodically by your GAMAX
Authorized Dealer to maintain the ATV at the optimum condition. The above maintenance schedule is
established by taking the monthly 1000 kilometers as a reference which ever comes first.
Remarks:
1. Clean or replace the air cleaner element more often when the ATV is operated on dusty roads or
in the Heavily- polluted environment.
2. Maintenance should be performed more often if the ATV is frequently operated in high speed and
after the ATV has accumulated a higher mileage.
3. Preventive maintenance :
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire,
after-burn, overheating occur
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust
system when power is obvious lower. Than ever
2-3
3.Fuel Hoses
Remove the fuel tank cover. Loosen 5 screws
and 4 bolts, Remove the tank cover
Check all lines, and replace it when they are
deterioration, damage or leaking
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.
4. Throttle Cable
Have a wide open of throttle valve as handle in
any position and release it to let back original(full
Closed) position.
Check handle if its operation is smooth. Check
acceleration cable and replace it if deteriorated,
twisted or damaged.
Lubricate the cable if operation is not smooth.
Measure the throttle lever free play in its flange
part.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment screw.
Tighten the fixing nut, and check acceleration
operation condition.
Free play: 1~3 mm.
5. Air Cleaner
Remove seat, loosen 5 hooks from the air
cleaner cover and then remove the cover.
Loosen the clamp strip and 1 screw of air cleaner
Clamp
element, and then remove the air cleaner
element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Caution Element
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and
then squeeze it out. Install the element onto the
element seat and then install the air cleaner
cover.
2-4
6. Spark Plug
Recommended spark plug : NGK-R-CR7E
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap 0.8 mm
Carefully bend ground electrode of the plug to

adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with
plug socket after installed.
Tighten torque: 10N-m
2-5
7. Valve Clearance
Caution
Checks and adjustment must be performed when
the engine temperature is below 35 .
Remove front fender.
Remove cylinder head cover.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the
“T” mark on the camshaft sprocket aligns with
cylinder head mark so that piston is placed at
TDC position in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.
Valve clearance inspection and adjustment.
Check & adjust valve clearance with feeler
gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.
2-6
8. Carburetor Idle Speed
Adjustment
Caution
Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted. Idle
speed check and adjustment have to be done
after engine is being warm up. (It is enough that
operates engine from stop to running for 10
minutes.) Park the ATV with main stand and
warm up engine. Connect tachometer (the wire
clamp of tachometer is connected to the high
tension cable). Turn the throttle valve stopper
screw to specified idle speed.
Specified idle speed:
1600 ± 100 rpm
Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let
engine runs in 1500±100 rpm.
Ignition cable
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust
pipe. Adjust the air adjustment screw so that
emission value in idle speed is within
standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 0.5~1.5%
HC: below 2000ppm AirStopper
adjustment
screwscrew
2-7
9. Ignition System
Caution
C.D.I ignition system is set by manufacturer so it
can not be adjusted.
Ignition timing check procedure is for checking CDI unit
whether CDI function is in normal or not.
Connect tachometer and ignition light.
Start engine.
As engine in idle speed: 1600 rpm, aim at the
mark “H” with the ignition light. Then, it means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located
within the ignition advance degrees, it is means
that the ignition advance degree is normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if
malfunction of these parts is found.
10. Cylinder Compression

Pressure
Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 10 ± 2.5 Kg/cm2
Check following items if the pressure is too low:

Incorrect valve clearance. Valve leaking.
Cylinder head leaking, piston, piston ring and
cylinder worn out. If the pressure is too high, it
means carbon deposits in combustion chamber
or piston head.
2-8
L case cap
11. Drive Belt
Release 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover cap.
Remove left crankcase cover bolts (17bolts).
Remove 2 dowel pin and gasket.
15 bolts 2 bolts
Inspection
Check the drive belt for crack or wear. Replace it Belt tooth
if necessary. Width
Measure the width of drive belt as diagram
shown.
Service Limit: 29.2 mm
Replace the belt if exceeds the service limit.
Caution
z Using the genuine parts for replacement.
z The surfaces of drive belt or pulley must be free
of grease.
z Clean up all grease or dirt before installation.
2-9
12. Brake System (Disk Brake)
Brake System Hose
Make sure the brake hoses contain no corrosion
or leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found.
Caution
In order to maintain brake fluid in the reservoir in
horizontal position, do not remove the cap until
handle stop.
Do not operate the brake lever after the cap had
been removed. Otherwise, the brake fluid will
spread out if operate the lever. Do not mix
non-compatible brake fluid together.
Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid.
Operate the brake lever so that brake fluid
contents fill inside the brake system hoses.
Air Bleed Operation

Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release
the brake lever.
Added Brake Fluid

Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 brake
fluid.
Caution
Never mix or use dirty brake fluid to prevent from
damaging brake system or reducing brake
performance.
2-10
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Replace the brake lining pad if the wear limit
mark closed to the edge of brake disc.
Caution
To check front brake lining must be remove front
wheel first.
It is not necessary to remove brake hose when
replacing the brake lining.
Brake Pads Replacement (refer

chapter 14)
Make sure the brake lining condition. Replace
the lining pads if the brake lining wear limitation
groove close to the brake disc.
Caution
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining. In
order to maintain brake power balance, the brake
pads must be replaced with one set.
13. Brake Light Switch/Starting

Inhibitor Switch
The brake light switch is to light up brake light as
brake applied.
Make sure that electrical starter can be operated
only under brake applying.
2-11
14. Headlight Beam Distance
Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.
Caution
To adjust the headlight beam follows related
regulations.
Improper headlight beam adjustment will make in
Ad ju s t s c r e w
coming driver dazzled or insufficient lighting.
15. Clutch Wear

Run the ATV and increase throttle valve opening
gradually to check clutch operation.
If the ATV is in forward moving and shaking,
check clutch condition. Replace it
16. Suspension
Warning
Do not ride the ATV with poor suspension.
Looseness, wear or damage suspension will
make poor stability and drive-ability.
Front suspension
Press down the front suspension for several
times to check its operation.
Check if it is damaged
Replace relative parts if damage found.
Tighten all nuts and bolts.
Rear suspension
Press down the rear suspension for several
times to check its operation.
Check if it is damaged
Replace relative parts if damage found.
2-12
17. Steering Handle
Caution
Check all wires and cables if they are interfered
with the rotation of steering handle bar.
Lift the front wheel out of ground.
Turn handle from right to left alternative and
check if turning is smoothly.
18. Wheel/Tire
Caution
Tire pressure check should be done before
riding.
Check if tire surface is ticked with nails, stones or
other materials.
Appointed tire pressure

Tire pressure
5psi (Off-road recommended)
Check if front and rear tires’ pressure is in
normal.
Measure tire thread depth from tire central
surface.
Replace the tire if the depth is smaller than :
Front tire: 1.5 mm
Rear tire: 2.0 mm
19. Nuts, Bolts Tightness

Perform periodical maintenance in accord with
the Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamp,
and wire holders for security.
2-13
NAME Rocker arm pin puller NAME Tappet adjusting wrench NAME Tappet adjusting wrench
NO SYM-1445100 NO SYM-9001200 NO SYM-1472100
Valve cotter remove &

NAME Tappet adjuster NAME assembly tool
NAME AC.G. Flywheel puller
NO SYM-2301000-HMA NO SYM-1471110/20 NO SYM-3110000-HMA
KNUCKLE BODY BRG.

NAME NAME Drive shaft puller NAME Driveshaft BRG. 6228 driver
6006 driver
NO SYM-5024000-REA 6006 NO SYM-2341120-REA NO SYM-2341110-REA 6228
BEVEL GEAR HOUSHING WHEEL DRIVE SHAFT Countershaft OIL SEAL

NAME BRG 6306 driver NAME NAME
BALL SET tool 20*40*5
NO SYM-2343700-REA A6306 NO SYM-4423500-REA NO SYM-9121000-REA
2-14
NAME NEEDLE BRG. 2220C driver NAME MDF. Fixer NAME Final shaft gear stopper
NO SYM-9100400-REA 2220 NO SYM-2211000-REA NO SYM-2343100-REA
OUTPUT SHAFT OIL SEAL OUTPUT SHAFT OIL SEAL

NAME Driveshaft BRG. 6328 driver NAME 42*52*7
NAME 38*52*7
NO SYM-9100500-REA A6328 NO SYM-9120900-REA NO SYM-9120800-REA
(12*28*7) (6901)
NAME Water pump oil seal driver NAME WATER PUMP BRG. 6001 driver NAME Water pump mechanical seal driver
NO SYM-9120200-REA NO SYM-6001300-REA A6001 NO SYM-1721700-H9A
CLUTCH COVER BRG. 6207

NAME driver NAME R COVER OIL SEAL GUIDE NAME Lock nut driver
NO SYM-9610000- REA A6207 NO SYM-1133000-REA NO SYM-9020100
2-15
NAME Inner bearing puller NAME Inner bearing puller NAME Outer bearing puller
NO SYM-6204002 NO SYM-6204022 NO SYM-6204001
NAME Universal holder NAME Clutch nut wrench NAME Crankcase tool
NO SYM-2210100 NO SYM-9020200 NO SYM-1120000-ALL
(55mm) (55mm)
NAME Rear axle nut wrench NAME Torque wrench NAME Rear axle nut torque wrench
NO SYM-HT06007 NO SYM-HT07004-RA1 NO SYM-4230200
WHEEL KNUCKLE BODY WHEEL KNUCKLE BODY

NAME ARM SUSPENSION NAME NAME
SEAL 40*55*8 driver SEAL 40*50*6.5 driver
NO SYM-2300000 NO SYM-9123200-REA NO SYM-9123000-REA
2-16
To this chapter contents
MAIN BRG. UP/LWR 40*44*20 PULLEY DRIVEN FACE

NAME driver
NAME NAME 41*44*4 OIL SEAL GUIDE
NO SYM-9100110-REA NO SYM-9100400 G5A ADA NO SYM-9121100-REA
ENG L COVER RADIAL BALL PULLEY DRIVEN FACE

NAME BRG. 6006 driver
NAME FINAL SHAFT BRG 6307 driver NAME expander
NO SYM-9615010-REA 6006 NO SYM-2343110-REA 6307 NO SYM-2321000-REA
CLUTCH COVER 35*55*8 DRIVEN PULLEY PULLEY DRIVEN FACE

NAME NAME NAME
OIL SEAL Disassemble tool SEAL COLLER tool
NO SYM-9120300-REA NO SYM-2301000-REA NO SYM-2323700-REA
R CASE PARK GEAR CLIP OUTPUT SHAFT BRG 6307

NAME NAME Driveshaft oil seal driver NAME
GUIDE & installer driver
NO SYM-9060200-REA NO SYM-9120600-REA NO SYM-2346000-REA A6307
2-17
2-18
LUBRICATION SYSTEM
1. Mechanism Diagram 3-1
2. Precautions in Operation 3-3
3. Troubleshooting 3-3
4. Engine Oil 3-4
5. Engine Oil Strainer Clean 3-4
6. Oil Filter Unit 3-5
7. Oil pump 3-6
1.Mechanism Diagram
3-1
LUBRICATION SYSTEM
Valve Rocker Arm
Press-In Lubrication
Cam Shaft
Oil Route
Oil Route
Spray Lubrication
Con-Rod
Spray Lubrication
3-2
LUBRICATION SYSTEM
2.Precautions in Operation
General Information
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil capacity Disassembly: 3000 c.c.
Replacement: 2400 c.c.
Replacement with oil filter replaced: 2700 c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Rear axle gear oil replacement: 100c.c.
Front differential gear oil replacement: 200c.c.
Gear oil viscosity SAE 80 or 90
Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20
Oil pump Clearance between outer rotor and body 0.15~0.20 0.25
Clearance between rotor side and body 0.04~0.09 0.12
(Recommended SYM Hypoid gear oil)
Torque value
Torque value oil strainer cap 1.3~1.7kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Gear oil drain bolt 1.1~1.5kgf-m
Gear oil join bolt 3.5~4.5kgf-m
Oil pump connection screw 0.1~0.3kgf-m
3.Troubleshooting
Low engine oil level Dirty oil
z Oil leaking z No oil change in periodical
z Valve guide or seat worn out z Cylinder head gasket damage
z Piston ring worn out z Piston ring worn out
Low oil pressure
z Low engine oil level
z Clogged in strainer, circuits or pipes
z Oil pump damage
3-3
LUBRICATION SYSTEM
4.Engine Oil
Turn off engine, and park the ATV in flat surface.
Check oil level with oil dipstick.
Do not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out recommended
oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that makes Drain bolt

sure oil can be drained smoothly and completely.
Place an oil pan under the ATV, and remove oil

drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value：3.5~4.5kgf-m
5.Engine Oil Strainer Clean

Drain engine oil out.
Remove the oil strainer and spring.
Clean the oil strainer.
Check if the `O-ring can be re-used.
Install oil strainer and spring.
Oil strainer cap
Install oil strainer cap.
Refill oil to crankcase (oil viscosity SAE 10W-30)

Recommended using King serial oil.
Drain bolt
Engine oil capacity: 2400c.c. when replacing
Install dipstick, start the engine for running
Oil strainer
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
3-4
LUBRICATION SYSTEM
6.Oil Filter Unit
Remove the oil filter unit with special tool.
Drain bolt
Special Service Tool:
Tool No: SYM-1445100
Install the oil filter unit by hand.
Lock the oil filter unit with special tool.

Tool No: SYM-1445100
3-5
LUBRICATION SYSTEM
7.Oil Pump
Oil Pump Removal
Remove the recoil starter and the AC Generator.
(Refer to chapter 10) 。
Remove the cir clip and take out the oil pump
sprocket.
Cir Clip
Make sure that pump shaft can be rotated freely.

Remove 3 screws on the oil pump, and then
remove the oil pump.
3 screws
Pin Roller
Oil Pump Disassembly
Remove the screws on oil pump cover and remove
the cover.
Remove oil pump shaft roller and shaft.
1 screw
3-6
LUBRICATION SYSTEM
Oil Pump Inspection
Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer rotors.

Limit: 0.20 mm
Check clearance between rotor side face and

pump body
Limit: 0.12 mm
Oil Pump Re-assembly

Install the inner and outer rotors into the pump body.
Align the indent on driving shaft with that of inner Pins
rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.
3-7
LUBRICATION SYSTEM
Tighten the oil pump screw. 1 screw
Roller
Oil Pump Installation

Install the oil pump, and then tighten screws.
Make sure that oil pump shaft can be rotated

freely.
3 screws
Install the oil pump sprocket, and then install cir

clip onto oil pump shaft.
Cir Clip
3-8
LUBRICATION SYSTEM
Notes:
3-9
FUEL SYSTEM
3. Trouble Shooting 4-3
4. Carburetor Remove / Install 4-4
5. Air Cut-Off Valve 4-5
6. Throttle Valve 4-6
7. Float Chamber 4-7
8. Adjustment of Idle Speed 4-9
9. Fuel Tank 4-10
10. Air Cleaner 4-11
1. Mechanism Diagram
Fuel tank
Fuel Strainer
Carburetor
Fuel pump
UA60A-6 4H
4-1
FUEL SYSTEM
2. Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.
Cautions
z Do not bend off throttle cable. Damaged throttle cable will make unstable drivability.
z When disassembling fuel system parts, pay attention to O-ring position, replace with new one
after re-assembly
z There is a drain screw in the float chamber for draining residual gasoline.
z Do not disassemble air cut valve arbitrarily.
Specification
ITEM UA60A-6
Carburetor diameter Ø35mm
I.D. number AG8
Fuel level 17 mm
Main injector #132
Idle injector #92
Idle speed 1600 ± 100rpm
Throttle handle clearance 1~3 mm
Pilot screw 1 1/2 turns
Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge
4-2
FUEL SYSTEM
3. Trouble Shooting
Mixture too lean
Poor engine start z Clogged fuel injector
z No fuel in fuel tank z Vacuum piston stick and closed
z Clogged fuel tube z Malfunction of float valve
z Too much fuel in cylinder z Fuel level too low in float chamber
z No spark from spark plug(malfunction of z Clogged fuel tank cap vent
ignition system ) z Clogged fuel filter
z Clogged air cleaner z Obstructed fuel pipe
z Malfunction of carburetor chock z Clogged air vent hose
z Malfunction of throttle operation z Air existing in intake system
Stall after started Mixture too rich

z Malfunction of carburetor chock z Clogged air injector
z Incorrect ignition timing z Malfunction of float valve
z Malfunction of carburetor z Fuel level too high in float chamber
z Dirty engine oil z Malfunction of carburetor chock
z Air existing in intake system z Dirty air cleaner
z Incorrect idle speed
Rough idling
z Malfunction of ignition system
z Incorrect idle speed
z Malfunction of carburetor
z Dirty fuel
Intermittently misfire as acceleration

Late ignition timing

z Malfunction of carburetor
Power insufficiency and fuel

consuming
z Fuel system clogged
4-3
FUEL SYSTEM
4. Carburetor Remove / Install
Throttle cable
1 screw
Remove 1 screw from throttle lever cap them
remove throttle lever cap.
Loosen throttle cable adjustment nut and remove
throttle cable
adjustment nut
Remove the sleep adjustment wire.

adjustment wire
Disconnect the fuel hose and by-starter and drain

tube
Release 2 clamps strip of air cleaner and inner
pipe.
Remove the carburetor.
Installation
Install in reverse order of removal procedures.
4-4
FUEL SYSTEM
5. Air Cut-Off Valve
Disassembly
Remove 2 screws.
2 screws
Remove air cut-off valve cover, spring and valve. Air cut-off valve
Inspection Cover Spring O-ring

Check the valve is in normal.
If the valve is in normal, it will restrict air-flow.
If air-flow is no restricting, replace carburetor
assembly.
Check the vacuum pipe o-ring is in normal.
Assembly
4-5
FUEL SYSTEM
6. Throttle Valve
vacuum chamber cover
Disassembly
Removal
Loosen drain screw, and drain out residual fuel in
float chamber.
Remove screws (4 screws) of vacuum chamber
cover and the cover.
4 bolts
Remove compress spring and vacuum piston.
Spring
vacuum piston Needle

Remove fuel needle seat, spring, and injector
needle. Needle seat
Check if the vacuum piston for wear out, crack or
other damage.
Check if the diaphragm for damage or crack.
Cautions
Do not damage vacuum diaphragm. Spring
4-6
FUEL SYSTEM
7. Float chamger
Disassembly
Remove 4 mounting screws and remove float
chamber cover.
4 screws
Remove the float pin, float and float valve. Float valve Pin
Float
Inspection Pin
Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.
Float valve
Caution Float
In case of worn out or dirt, the float valve and

valve seat will not tightly close causing fuel Check for wear or damage
level to increase and as a result, fuel flooding.
A worn out or dirty float valve must be replaced
with a new a new one.
4-7
FUEL SYSTEM
Remove main jet, needle jet holder, needle jet,
slow jet and air adjustment screw. Needle jet
Caution Needle Jet Holder
Take care not to damage jets and adjust screw.
z Before removing adjustment screw, turn it all
the way down and note the number of turns.
z Does not turn adjust screw forcefully to avoid Slow jet
damaging valve seat face.

Main jet
Clean jets with cleaning fluid. Then use compressed

air to blow the dirt off.
Blow carburetor body passages with compressed
air.
Assembly
Install main jet, needle jet holder, needle jet, slow
jet and air adjustment screw.
Caution
Air adjustment screw
Set the air adjustment screw in according to
number of turns noted before it was removed.
Install the float valve, float, and float pin.
Checking fuel level

Caution
z Check again to ensure float valve, float for

roper installation. Float gauge
z To ensure correct measurement, position
the float meter in such a way so that float
chamber
Fuel level: 14.8mm
Installation of carburetor Main jet

Install carburetor in the reverse order of removal.
Following adjustments must be made after Air adjustment
installation.
˙Throttle cable adjustment.
4-8
FUEL SYSTEM
˙Idle adjustment
4-9
FUEL SYSTEM
8. Adjustment of Idle Speed
Caution
z Air screw was set at factory, so no
adjustment is needed. Note the number of
turns it takes to screw it all the way in for
ease of installation.
z The parking brake must be used to stop
the ATV to perform the adjustments.
PARKING LEVER
Use a tachometer when adjusting engine RPM.

Screw in air adjustment screw gently, then back up
to standard turns. Throttle valve stopper wire
Standard turns: 2 turns

Warm up engine; adjust the throttle stopper wire of
throttle valve to standard RPM.
Idle speed rpm: 1700 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust Air adjustment screw
front end. Press test key on the analyzer.
Adjust the pilot screw and read CO reading on the
Analyzer
CO standard value: 0.5~1.0 %
Accelerate in gradual increments; make sure rpm
and CO value are in standard value after engine
running in stable. If rpm and CO value fluctuated,
repeat the procedures described above for
adjusting to standard value.
4-10
FUEL SYSTEM
9. Fuel Tank
Fuel unit removal
Remove fuel unit (4 bolts).
4 bolts
Caution
Do not bend the float arm of fuel unit
Do not fill out too much fuel to fuel tank.
Fuel unit inspection (Refer to electrical equipment
chapter 17).
Fuel unit installation

Install the gauge in the reverse order of removal.
Caution
Do not forget to install the gasket of fuel unit or
damage it. fuel tubes
Fuel tank removal

Remove fuel unit wire from tank.
(Covers remove please refer chapter 13)
remove 2 fuel tubes from
Remove fuel tank front and rear side 4 bolts, and then
remove fuel tank.
Installation
Install the tank in the reverse order of removal.
4-11
FUEL SYSTEM
10. Air Cleaner
Removal
Loosen the clamp strip of air cleaner and
carburetor, and then remove the vapor hose.
Clamp
Loosen the clamp strip of air cleaner, and then

remove the air cleaner vapor hose.
Remove the air cleaner (4 bolts).
Installation
Install the tank in the reverse order of removal.
4 bolts
Cleaning air cleaner element

Remove the air cleaner cover (5 catch hooks).
5 catch hooks
Remove element mounting screw.

Loosen the clamp strip of air cleaner element.
Clamp Clamp
4-12
FUEL SYSTEM
Remove the air cleaner element.
Clean the element with non-flammable or high-flash
point solvent and then squeeze it for dry.
Caution
Never use gasoline or acid organized

solvent to clean the element. Element
Soap the element into cleaning engine oil and then

squeeze it out. Install the element onto the
element seat and then install the air cleaner cover.
4-13
FUEL SYSTEM
Notes:
4-14
ENGINE REMOVAL
2. Removal of Engine 5-2
3. Engine Installation 5-6
General Information
z The engine has to be supported with special service tools that can be lifted or adjustable.
z The following parts can be serviced as engine being mounted on frame:
Carburetor
Drive pulley, drive belt, clutch, and movable drive face assembly.
Start motor.
AC. Generator, oil pump and start one-way clutch.
Specification
Item Capacity
Replacement 2400 c.c.
Engine oil capacity Oil and oil filter change 2700 c.c.
Disassembly 3000 c.c.
Rear axle gear oil capacity Replacement 110 c.c.
Front differential gear oil capacity Replacement 180 c.c.
Engine& radiator 1800 c.c.
Coolant capacity Reservoir 700 c.c.
Total 2400 c.c.
Torque
Engine hanger bolt 7.5~9.5 kgf-m
Exhaust muffler mounting bolt 2.8~3.2 kgf-m
Exhaust muffler connection nut 1.0~1.4 kgf-m
5-1
ENGINE REMOVAL
2. Engine Removal
Remove the seat.
Remove the battery negative terminal (-).
Remove the battery positive (+) terminal.
Remove front fender and the footrest (refer
chapter 13).
Negative(-) Positive(+)
Remove starter motor wire.
starter motor wire
Remove the spark plug cap.
spark plug
Disconnect A.C. Generator wire couplers.
Starter motor wire
5-2
ENGINE REMOVAL
Remove the front left and rear left tires.
Remove the idle speed adjustment nut. idle speed adjustment nut
Remove the throttle cable.
throttle cable
Remove the choke cable and ventilation tube. choke cable
ventilation tube
5-3
ENGINE REMOVAL
Remove 2 manifold clamps.
Remove the carburetor.
Manifold clamps
Remove 4 bolts.
Remove the air cleaner.
4 bolts
Remove 2 bolts.
Remove the muffler.
2 bolts
Remove 2 nuts. 2 nuts

Remove the exhaust pipe.
5-4
ENGINE REMOVAL
Remove the coolant drain bolt and drain out
coolant. PVC pipe
Remove the coolant inlet pipe from the water
pump cover and the outlet pipe from the
thermostat cover.
Remove the PCV pipe.
Coolant pipe
Remove 2 bolts. Starter motor
Remove the starter motor.
2 bolts
Remove 3 bolts on the front propeller shaft

connector. 3 bolts
Remove the front propeller shaft.
Rubber boot
Remove 3 bolts on the rear propeller shaft

3 bolts
connector.
Remove the rear propeller shaft.
Be careful not to do any damage to the rubber

Rubber boot
boot.
5-5
ENGINE REMOVAL
Remove the rear brake pedal.
Remove the coolant reserve tank.
Remove the front and rear side engine hanger

mounting nuts and bolts.
Remove left side engine hanger, and then

remove engine by left side.
3. Engine Installation
Check the bush of engine hanger parts for any 3 bolts
damage.
Install the engine in the reverse procedures of
removal. Engine hanger
Caution
z Be careful when removing and installing the
engine.
z Do not bend or twist the wires and tubes.
z Cables wires have to be routed in
accordance with normal layout.
Engine hanger Bolt:
Torque value: 7.5~9.5kgf-m
5-6
ENGINE REMOVAL
NOTE:
5-7
CYLINDER HEAD/VALVE
3. Troubleshooting 6-3
4. Cylinder Head Removal 6-4
5. Cylinder Head Inspection 6-7
6. Valve Stem Replacement 6-10
7. Valve Seat Inspection and Service 6-11
8. Cylinder Head Reassembly 6-13
9. Cylinder Head Installation 6-14
10. Valve Clearance Adjustment 6-16
1.0~1.4kgf-m
1.0~1.4kgf-m
3.6~4.0kgf-m
2.4~3.0kgf-m
1.0~1.4kgf-m
1.0~1.2kgf-m
1.0~1.4kgf-m
0.7~1.1kgf-m
1.0~1.4kgf-m
1.0~1.2kgf-m
6-1
CYLINDER HEAD/VALVE
General Information
● This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well
as rocker arm.
● Cylinder head service can be carried out when engine is in frame.
Specification
Item Standard Limit
Compression pressure 12±2 kg/cm2 ---
Intake 36.478 36.458
Camshaft Height of cam lobe
Exhaust 36.847 36.832
ID of valve rocker arm 13.000~13.018 13.098
Rocker arm
OD of valve rocker arm shaft 12.991~13.009 11.936
Intake 4.975~4.990 4.900
OD of valve stem
Exhaust 4.955~4.970 4.900
ID of valve guide 5.000~5.012 5.030
Clearance between Intake 0.010~0.037 0.080

valve stem and guide Exhaust 0.025~0.062 0.100
Valve
Free length of valve Inner 33.700 30.100
spring outer 38.800 35.200
Valve seat width 1.600 ---
Intake 0.10 ± 0.02mm ---
Valve clearance
Exhaust 0.15 ± 0.02mm ---
Tilt angle of cylinder head --- 0.050
Torque Value
Cylinder head cover bolt 1.0~1.4kgf-m
Exhaust pipe stud bolt 2.4~3.0kgf-m
Cylinder head bolt 1.0~1.4kgf-m
Cylinder head Nut 3.6~4.0kgf-m
Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cylinder side cover bolt 1.0~1.4kgf-m
Cam sprocket bolt 1.0~1.4kgf-m
Tappet adjustment screw nut 0.7~1.1kgf-m
Spark plug 1.0~1.2kgf-m
Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
6-2
CYLINDER HEAD/VALVE
3.Troubleshooting
Engine performance will be affected by troubles on engine top parts. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise
generated.
Low compression pressure

1. Valve
● Improper valve adjustment
● Burnt or bent valve
● Improper valve timing
● Valve spring damage
● Valve carbon deposit.
2. Cylinder head
● Cylinder head gasket leaking or damage
● Tilt or crack cylinder
3. Piston
● Piston ring worn out.
High compression pressure

● Too much carbon deposit on combustion chamber or piston head
Noise
● Improper valve clearance adjustment
● Burnt valve or damaged valve spring
● Camshaft wear out or damage
● Chain wear out or looseness
● Auto-tensioner wear out or damage
● Camshaft sprocket
● Rocker arm or rocker arm shaft wear out
6-3
CYLINDER HEAD/VALVE
4. Cylinder Head Removal
2 nuts
Remove the engine from the frame. (Refer to
chapter 5)
Remove the inlet pipe (2 nuts).
Remove 2 thermostat bolts and then remove the

Thermostat bolts
thermostat.
Remove the bolt and spring of the cam chain
tensioner.
Loosen 2 bolts, and then remove tensioner.
Remove thermostat (2 bolts).
Tensioner bolts
Remove Air Injection system (AI) pipe mounting

4 bolts
bolts.
Remove the spark plug.
Loosen 4 bolts from the head cover then remove

head cover.
4 bolts
6-4
CYLINDER HEAD/VALVE
Remove the side cover mounting blots of cylinder
head, and then remove the side cover.
3 bolts
Remove left crankcase cover, and turn the drive Timing Mark
face. 2 bolts
Align the timing mark on the cam sprocket with that
of cylinder head to make the piston at TDC
position.
Loosen 2 bolts from the cam sprocket. Remove

Cam sprocket disk
the cam sprocket disk and washer. Remove the
cam sprocket.
Special Service Tool: Cam shafts

Tool no: SYM-1445100
TOOL number: rocker arm and camshaft puller
rocker arm and
camshaft puller
6-5
CYLINDER HEAD/VALVE
Remove the 2 cylinder head mounting bolts
fromcylinder head right side, and then remove 4 nuts
and washers from cylinder head upper side.
Remove the cylinder head.
4 nuts
2 bolts
Remove cylinder head gasket and 2 dowel pins. Gasket
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Caution
Do not damage the matching surfaces of
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide Dowel pins
Use a valve cotter remove & assembly tool to

press the valve spring, and then remove valves.
Caution
In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press lengths
is based on the valve cotter in which
can be removed.
Valve cotter
Special Service Tool: Remove and
Tool no: SYM-1471110/20-4v
TOOL number: valve cotter remove & assembly Inlet valve Innor spring Spring retainer
tool
Exhaust valve Outer spring Cotter
6-6
CYLINDER HEAD/VALVE
Remove valve stem seals.
Valve stem seals
Clean carbon deposits in combustion chamber.

Clean residues and foreign materials on cylinder
head matching surface.
Caution
Do not damage the matching surface of
cylinder head.
5. Cylinder Head Inspection

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.05 mm
Camshaft
Inspect cam lobe height for damaged.
Service Limit:
IN: Replacement when less than 34.860mm
EX: Replacement when less than 34.725mm
Inspect the camshaft bearing for looseness or
wear out. If any damage, replace whole set of
camshaft and bearing.
6-7
CYLINDER HEAD/VALVE
Rocker Arm
Measure the cam rocker arm I.D., and wear or
damage, oil hole clogged?
Service Limit: Replace when it is more than
12.080 mm.
Rocker Arm Shaft

Measure the active O.D. of the cam rocker arm
shaft and cam rocker arm.
Service Limit: Replace when it is more than
11.936 mm.
Calculate the clearance between the rocker arm
shaft and the rocker arm.
Service Limit: Replace when it is less than
0.10mm.
Valve spring free length

Measure the free length of intake and exhaust
valve springs.
Service limit:
Inner spring 35.20 mm
Outer spring 36.90 mm
Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve
stem outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm
6-8
CYLINDER HEAD/VALVE
Valve guide 5.0mm valve guide reamer
Caution
Before measuring the valve guide, clean carbon
deposits with reamer.
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner

diameters.
The difference that the inner diameter of valve

guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN＜0.08 mm
EX＜0.10 mm
Caution
If clearance between valve stem and valve
guide exceeded service limit, check whether
the new clearance that only replaces new
valve guide is within service limit or not. If so,
replace valve guide.
Correct it with reamer after replacement. If

clearance still exceeds service limit after
replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing
valve guide.
6-9
CYLINDER HEAD/VALVE
6. Valve Stem Replacement
Valve guide driver
Heat up cylinder head to 100~150 ℃ with 5.0mm
heated plate or toaster.

Caution
Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
when heating it.
Wear on a pair of glove to protect your hands
when operating.
Hold the cylinder head, and then press out old

Valve guide driver
valve guide from combustion chamber side.
5.0mm
Tool: Valve guide driver: 5.0 mm
Caution
Check if new valve guide is deformed after
pressed it in.
When pressing in the new valve guide, cylinder
head still have to be kept in100~150 .
Adjust the valve guide driver and let valve guide Valve guide reamer 5.0mm
height within 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve
guide with reamer.
Caution
Use cutting oil when correcting valve guide with
a reamer.
Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal

residues from cylinder head.
Tool: Valve guide reamer: 5.0 mm
6-10
CYLINDER HEAD/VALVE
7. Valve Seat Inspection and
Service
Clean up all carbon deposits on intake and
exhaust valves. Apply with emery slightly onto
valve contact face. Grind valve seat with a rubber
hose or other manual grinding tool.
Caution
Do not let emery enter into between valve
stem and valve guide.
Valve seat width
Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and
valve seat. Remove the valve and check its
contact face.
Caution
Replace the valve with a new one if valve seal
is roughness, wear out, or incomplete
contacted with valve seat. Roughness
Valve seat inspection
If the valve seat is too width, narrow or rough,
corrects it.
Valve seat wide
Service limit: 1.6mm 45 ﾟ
Check the contact condition of valve seat.
Valve seat grinding
The worn valve seat has to be ground with valve
seat chamfer cutter.
Refer to operation manual of the valve seat
Old valve seat width
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any
rough or uneven surface from valve seat.
Caution 32 ﾟ
After valve guide had been replaced, it has to
be ground with 45° valve seal chamfer cutter
to correct its seat face.
Use 32° cutter to cut a quarter upper parts out.
6-11
CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower parts out.
Remove the cutter and check new valve seat.
Old valve seat width
60 ﾟ
Use 45° cutter to grind the valve seat to specified

width. 10mm
Caution
Make sure that all roughness and uneven
faces had been ground.
Grind valve seat again if necessary.
45 ﾟ
Coat the valve seat surface with red paint.

Install the valve through valve guide until the
valve contacting with valve seat, slightly press Contact surface too high
down the valve but do not rotate it so that a seal Old valve seat width
track will be created on contact surface.
Caution 32 ﾟ
The contact surfaces of valve and valve seat
are very important to the valve sealing
capacity.
If the contact surface too high, grind the valve Contact surface too low Old valve seat width
seat with 32° cutter. Then, grind the valve seat to
specified width. If the contact surface too low,
grind the valve seat with 60° cutter. Then, grind
the valve seat to specified width.
60 ﾟ
6-12
CYLINDER HEAD/VALVE
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and
valve after ground.
8. Cylinder Head Reassembly

Lubricate valve stem with engine oil, and then
valve stem seal
insert the valve into valve guide.
valve springs retainer
Install new valve stem oil seal.
Install valve springs and retainers. Inlet valve
Valve cotter
Caution
The closed coils of valve spring should face
down to combustion chamber.
Use a valve cotter remove & assembly tool to valve spring

press the valve spring, and then remove valves. Exhaust valve
Caution
To avoid damaging the valve stem and the
cylinder head, in the combustion chamber
place a rag between the valve spring
remover/installer as compressing the
valve spring directly.
Valve cotter remove and

assembly tool
Valve cotter remove & assembly tool
Tap the valve stems gently with a plastic hammer

to make sure valve retainer and valve cotter is
settled.
Caution
Place and hold cylinder head on to working
table so is can prevent from valve damaged.
6-13
CYLINDER HEAD/VALVE
9. Cylinder Head Installation
Gasket
Clean up all residues and foreign materials from
the matching surfaces of both cylinder and
cylinder head.
Install chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.
Caution
Do not damage the matching surfaces of
Chain guide Dowel pins
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Install 4 washers and tighten 4 nuts on the

cylinder head upper side, and then tighten 2
cylinder head mounting bolts of cylinder head
right side.
Torque value:
Nut 3.6~4.0kgf-m 4 nuts
Bolt 1.0~1.4kgf-m
2 bolts
Install camshaft into cylinder head, and install

rocker arm, rocker arm shaft.
Install rocker arm pin mounting plate.

Cam shaft setting plate
6-14
CYLINDER HEAD/VALVE
Install cam chain to sprocket and align the timing
mark on the sprocket with the two sprocket bolt
Timing mark
holes and the lower bolt hole of the cylinder 2 bolts
side cover.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolts
Caution
Make sure timing marks are matched.
Install the cylinder head side cover (3 bolts).

3 bolts
Install the thermostat (2 bolts).
Thermostat bolts
Loosen auto tensioner adjustment bolt and

remove bolt and spring.
Install tensioner and install spring and
adjustment bolt.
Tensioner adjustmet bolt
Tensioner adjustmet bolt

Install cylinder head cover (4 bolts).
4 bolts
6-15
CYLINDER HEAD/VALVE
Install Air Injection system (AI) pipe. (4 bolts)
Install inlet pipe onto cylinder
Install and tighten spark plug 4 bolts
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can not
be exceeded standard value in order to avoid
causing cylinder head deformation, engine
noise and leaking so that vehicle performance
be affected.
Install the engine onto frame (refer chapter 5).
10.Valve Clearance Adjustment

Loosen Air Injection system (AI) pipe upper side
bolt (2 bolts).
Remove the cylinder head cover.
Remove the cylinder head side cover.

Remove left crankcase cover, and turn the drive
face, and align the timing mark on the cam
sprocket with that of cylinder head, piston is at
TDC position.
Loosen valve clearance adjustment nuts and Timing mark
bolts located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Install the cylinder head side cover.
Start the engine and make sure that engine oil
flows onto the cylinder head.
Stop the engine after confirmed, and then install
the cylinder head cover and AI pipe.
Caution
If lubricant does not flow to cylinder head,engine
components will be worn out seriously. Thus, it
must be confirmed.
When checking lubricant flowing condition, run
the engine at idle speed. Do not accelerate
engine speed.
6-16
CYLINDER HEAD/VALVE
NOTE:
6-17
CYLINDER/PISTON
3. Trouble Shooting 7-2
4. Cylinder and Piston Removal 7-3
5. Piston Ring Installation 7-6
6. Piston Installation 7-7
7. Cylinder Installation 7-7
1.0~1.4kgf-m
0.8~1.2kgf-m
7-1
CYLINDER/PISTON
General Information
Both cylinder and piston service cannot be carried out when engine mounted on frame.
Specification Unit：mm
Item Standard Limit

ID 92.00 92.100
Cylinder
Bend - 0.050
Clearance between Top ring 0.015~0.050 0.090
piston rings 2nd ring 0.015~0.050 0.090
Top ring 0.150~0.300 0.500
nd
Piston / Ring-end gap 2 ring 0.300~0.450 0.650
Piston ring Oil ring side rail 0.200~0.700 -
OD of piston (2nd) 74.430~75.480 75.380
Clearance between piston and cylinder 0.010~0.040 0.100
ID of piston pin boss 17.002~17.008 17.020
OD of piston pin 16.994~17.000 16.960
Clearance between piston and pin 0.002~0.014 0.020
ID of connecting rod small-end 17.016~17.034 17.064
3. Trouble Shooting
Low or Unstable Compression Pressure
z Cylinder or piston ring worn out
Smoking in Exhaust Pipe

z Piston or piston ring worn out
z Piston ring installation improperly
z Cylinder or piston damage
Knock or Noise
z Cylinder or piston ring worn out
z Carbon deposits on cylinder head top-side
z Piston pin hole and piston pin worn out
Engine Overheat
z Carbon deposits on cylinder head top-side
z Cooling pipe clogged or not enough in coolant flow
7-2
CYLINDER/PISTON
4. Cylinder and Piston Removal
Remove the cylinder head (refer to chapter 6).
Remove the coolant hose from cylinder.
Remove the cylinder.
Cover the holes of crankcase and cam chain with

a piece of cloth to prevent foreign material falling
into the crankcase.
Remove the piston pin clip, and then remove the
piston pin and piston.
Remove the cylinder gasket and dowel pin. Dowel pins

Clean up all residues or foreign materials from
the two contact surfaces of cylinder and
crankcase.
Caution
Wet the residues by solvent so that the
residues can be removed more easily.
Inspection
Check if the inner diameter of cylinder is worn out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective Top
in the cylinder. Center
Bottom
7-3
CYLINDER/PISTON
Check cylinder if warp.
Measure clearance between piston rings and

grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.
Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
7-4
CYLINDER/PISTON
Measure the outer diameter of piston pin.
Measure the inner diameter of connecting rod

small end.
Service Limit: 17.064mm
Measure the inner diameter of piston pin hole.

Calculate clearance between piston pin and its
hole.
Measure piston outer diameter.

Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：75.380 mm
Compare measured value with service limit to

calculate the clearance between piston and
cylinder.
7-5
CYLINDER/PISTON
7-6
CYLINDER/PISTON
5. Piston Ring Installation
Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
z Do not damage piston and piston rings in installation.
z All marks on the piston rings must be forwarded to up side.
z Make sure that all piston rings can be rotated freely after installed.
Top ring
2nd ring
Oil ring
Top groo ve
2nd groove
Oil groove
7-7
CYLINDER/PISTON
Clean up all residues and foreign materials on
the contact surface of crankcase. Pay attention to
not let these residues and foreign materials fall
into crankcase.
Caution
Wet the residues into solvent so that the residues
can be removed more easily.
6. Piston Installation In mark
Install piston and piston pin, and place the IN

marks on the piston topside forward to inlet
valve.
Dowel pins
Clip end gap

Install new piston pin clip.
Caution
Do not let the opening of piston pin clip align
with the piston cutout.
Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as during servicing.
Cut out
7. Cylinder Installation
Install dowel pins and new gasket.
Dowel pins
7-8
CYLINDER/PISTON
Coat some engine oil to inside of cylinder, piston
and piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because piston and piston rings will be damaged.
Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).
coolant hose
7-9
CYLINDER/PISTON
NOTE:
7-10
V-BELT DRIVING SYSTEM
1. Mechanism 8-1
2. Maintenance Description 8-2
3. Trouble Diagnosis 8-2
4. Left Crankcase Cover 8-3
5. Drive Belt 8-3
6. Drive Plate 8-4
7. Movable Drive Face Disassembly 8-6
8. Driven Pulley Disassembly 8-13
5.0~6.0kgf-m
5.0~6.0kgf-m
5.0~6.0kgf-m
8-1
2. Maintenance Description
Precautions in Operation
General Information
z Drive face, clutch outer, and driven pulley can be serviced on the vehicle.
z Drive belt and drive pulley must be free of any grease.
Specification
Item Standard value Limit
Driving belt width 30.700 mm 29.200 mm
OD of movable drive face boss 35.970~35.990 mm 35.950 mm
ID of movable drive face 36.010~36.035 mm 36.055 mm
OD of weight roller 29.992~30.008 mm 29.950 mm
ID of clutch outer 140.000~140.200 mm 140.500 mm
Thickness of clutch weight 6.000 mm 3.000 mm
Free length of driven pulley spring 124.500 mm 119.500 mm
OD of driven pulley boss 40.965~40.985 mm 40.945 mm
ID of driven face 41.000~41.050 mm 41.070 mm
Weight of weight roller 19.700~20.300 g 19.200 g
Torque value
Drive face nut: 8.5~10.5kgf-m
Clutch outer nut: 5.0~6.0kgf-m
Drive plate nut: 5.0~6.0kgf-m
Special Service Tools
Clutch spring compressor: SYM-2301000
Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
3. Trouble Diagnosis
Engine can be started but motorcycle can not be moved
1. Worn drive Belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight
Insufficient horsepower or poor high speed performance

1. Worn drive belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley operation un-smoothly
8-2
4. Left Crankcase Cover
L case cap
Left crankcase cover removal
Release 2 clamp strips of left crankcase cover
ducts, and then remove the ducts.
Remove left crankcase cover cap.
Remove left crankcase cover bolts (17bolts).
Remove 2 dowel pin and gasket.
15 bolts 2 bolts
Left crankcase cover installation

Install left crankcase cover in the reverse
procedure of removal.
5.Drive Belt SYM-2211000-REA
Loosen 1nut from the drive face with Special tool.

Tool name: Movable Drive Face Holder
Tool NO: SYM-2211000-REA
Remove the movable drive face.
8-3
Loosen 1nut from the driven pulley with Special
tool. SYM-2210100
Tool name: Universal holder
Tool NO: SYM-2210100
Remove the drive pulley and belt.
Inspection
Check the drive belt for crack or wear. Replace it
if necessary.
Measure the width of drive belt as diagram
shown.
Service Limit: 29.2 mm Drive face
Replace the belt if exceeds the service limit.
Caution
z Using the genuine parts for replacement. Belt tooth
z The surfaces of drive belt or pulley must be free Width
of grease.
z Clean up all grease or dirt before installation.
6.Drive Plate
Remove the drive face.
Loosen 5 bolts from the CVT cooling plate then
remove it.
5 bolts
8-4
Loosen 10 bolts from the clutch cover. 10 bolts
Remove the clutch cover.
Remove the clutch outer.
One-way Clutch Inspection

Check each roller for wear or damage.
Hold the clutch outer and turning the one way
clutch for right side.
Loosen the drive plate nut with special tool. SYM-2230000-REA

Remove the drive plate.
Tool name: drive plate holder
Tool NO: SYM-2230000-REA
8-5
Driven face
7.Movable Drive Face Disassembly
Loosen 4 bolts form the drive face.
Remove the drive face plate.
Remove the drive face plate.
Remove the ramp plate and weight roller (8pcs).
Inspection
The weight rollers are to press movable drive
face by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be affected.
Check if rollers are worn out or damaged.
Replace it if necessary.
Measure each roller’s outer diameter. Replace it
if exceed the service limit.
8-6
Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive
face boss, and replace it if it exceed service limit.
Measure the inner diameter of movable drive

face,and replace it if it exceed service limit. Movable drive face
Drive face boss
Reassembly/installation
Install weight rollers.
Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.
Install ramp plate.
8-7
Left crankcase cover inspection
Remove cir clip with inner cir clip pliers Cir clip
Check bearing on left crankcase cover.

Rotate bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on cover tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Remove the bearing 6302 with inner bearing SYM-6204025

puller.
Tools number: SYM-6204025
Tools name: INNER BEARING PULLER.
Remove the bearing 6006 with inner bearing SYM-6204025

puller.
Tools number: SYM-6204025
Tools name: INNER BEARING PULLER.
8-8
Bearing installation SYM-9615000-REA A6302
Install the bearing 6302 with special tool
Tool name: L COVER FR BRG. 6302 bearing IN.
puller with air
Tool NO. : SYM-9615000-REA A6302
Put the caller and nut. SYM-9615000-REA A6302
caller nut
Install the bearing with air or head tool.

Air tool
head tool
8-9
Make sure the bearing code and put the bearing. SYM-9615010-REA 6006
Install the bearing 6006 with special tool
Tool name: L COVER FR BRG. 6006 bearing
driver
Tool NO. : SYM-9615010-REA 6006
SYM-9615010-REA 6006
Knock the bearing to the objected position.
Install the cir clip.

Cir clip
8-10
Drive plate Disassembly
Remove 5 e-ring from drive plate.
Remove the spring plate and centrifugal clutch centrifugal clutch

plate.
E-ring
Remove 5 springs from the drive plate Spring

Check if spring is damaged or insufficient
elasticity.
Remove 5 clutch weights.

Check if spring is damaged or insufficient
elasticity.
8-11
Measure each clutch weight thickness.
Replace it if exceeds service limit.
Apply grease onto setting pins.
Install the spring into groove with pliers.
Install new clutch weight onto setting pin and

then push to the specified location.
Apply with grease onto setting pins.
Caution
Grease or lubricant will damage the clutch weight
and affect the block’s connection capacity.
8-12
Install the spring plate and centrifugal clutch
plate.
Install 5 e-ring in the drive plate.
8.Driven Pulley Disassembly

Disassemble the driven pulley with special tool.
Apply special tool compressor onto the pulley
Special tool compressor
8-13
Remove cir clip with pliers.
Cir clip
Loosen the special tools nut

nut
Remove the driven pulley collar and 4 roller

guides.
4 roller guides Drive pulley collar
Remove the movable driven face.
8-14
Driven pulley spring
Measure the length of driven pulley spring.
Free length
Driven pulley
Check following items:
z If both surfaces are damaged or worn. Driven face
z If guide pin groove is damaged or worn.
Replace damaged or worn components.
Measure the outer diameter of driven face and
the inner diameter of movable driven face.
Service limit: Outer diameter 40.945 mm Movable driven face Guide pin groove
Inner diameter 41.070 mm
Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.
Check if needle bearing is damage or too big
clearance. Replace it if necessary. Needle bearing
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and
silent. Outer ball bearing
Check if the bearing outer parts are closed and
fixed. Replace it if necessary.
8-15
Installation Driven Face Assy.Expander
Use the driven face assy. expander to expand
the driven face assy.
Put the drive belt into the driven face assy. and
hold it tight by hand.
Special Tool
Tool number: SYM-2321000-REA
Tool name: Driven Face Assy. Expander
Driven Face Assy
Put the driven face assy. onto the drive shaft.
Caution
z Use special tool to keep the driven face
assy. open.
z Do not oppress friction plate in order to avoid
distortion or damage.
Drive Shaft
Install the movable drive face assy.
Hold the movable drive face assy. with the MDF
holder, and then tighten nut to specified torque
value.
Hold the driven face with universal holder, and

then tighten nut to specified torque value.
Universal holder
8-16
NOTE:
8-17
TRANSMISSION
1. Mechanism 9-1
2. Precautions in operation 9-2
4. Transmission Disassembly 9-3
5. Transmission Inspection 9-7
6. Bearing Replacement 9-9
7. Transmission Reassembly 9-12
1.Mechanism Diagram
Drive shaft
Radial Ball Bearing 6228

Needle Bearing HK2220C
Shift Drum
Counter Shaft
Radial Ball Bearing 6304 Reverse Shaft
Sliding Claw
Park Gear
Counter Gear
Radial Ball Bearing 6307
Final shaft
Left crank case

Bevel Gear Housing Needle Bearing HK2220C
Drive Bevel Geart
Shift fork
9-1
TRANSMISSION
Specification
Ite Standard value Limit (mm)
OD of shift fork shaft 13.984~14.000 mm 13.966 mm
ID of shift fork 14.000~14.016 mm 14.034 mm
Shift fork claw thickness 5.930~6.000 mm 5.730 mm
Torque value
Gear oil drain bolt 1.1~1.5kgf-m
Gear oil fill bolt 3.5~4.5kgf-m
Tools
Special tools
Bearing driver (6228): SYM-2341110-REA A6228
Bearing driver (6307): SYM-2343110-REA 6307
Bearing driver (2220): SYM-9100400-REA 2220
Bearing driver (6307): SYM-2346000-REA A6307
Final shaft gear stopper: SYM-2343100-REA
Needle bearing driver (HK2016): SYM-9100300-RB1
Drive shaft and oil seal driver: SYM-9120200-HMA
Drive shaft puller: SYM-2341100
Inner bearing puller: SYM-6204002
3.Trouble Diagnosis
Engine can be started but vehicle cannot move.
z Damaged drive gear
z Burnt out drive gear
z Damaged gear shift system
Noise
z Worn or burnt gear
z Worn gear
Gear oil leaks
z Excessive gear oil.
z Worn or damage oil seal
9-2
TRANSMISSION
4.Transmission Disassembly
Remove gear change lever (2 bolts).
Remove the gear change lever.
2 bolts
Remove 2 c clips from brake pedal. Concave marks

Remove brake spring & stop switch spring
Remove brake penal.
Gearshift spindle
Shift drum
Remove the front and rear propeller shaft.

Remove the engine from the frame before
performing the transmission disassembly.
Propeller shaft
Remove the front and rear output shaft Bolt

connectors.
9-3
TRANSMISSION
Remove the front and rear output shaft covers. 4 Bolts
Remove 13 bolts from the right crankcase.
Remove the right crankcase from the left

crankcase.
Remove the counter shaft, shift fork and the shift Shift drum
Shift fork
drum.
Counter shaft
9-4
TRANSMISSION
Remove the reverse shaft and the output shaft. Reverse shaft Output shaft
Remove the bevel gear with the final shaft Final gear stopper
stopper.
Special tool:
Tool number：SYM-2343100-REA
Tool name：Final shaft stopper.
Bevel gear housing

Shim
Remove 4 bolts.
Remove the shims from the bevel gear housing.
Remember the number of the shims and put the
same number of shims when reassembling.
Shim
Remove the shims from the final shaft.

Remember the number of shims and put the
same number o shims when reassembling.
Remove the final shaft.
Final shaft
9-5
TRANSMISSION
Remove the drive shaft bearing setting plate (1
bolt).
Bearing setting
Remove the drive shaft. Drive shaft bearing

Remove the output shaft.
Output shaft
Caution Bearing
z Do not remove the drive shaft from the
crankcase if unnecessary.
z When removing the drive shaft from the
crankcase, then the bearing has to be replaced.
9-6
TRANSMISSION
5.Transmission Inspection
Check the shift spindle for any wear or damage.
Check if the shift drum is worn or damaged.
Check if the shift fork and shaft is worn or

damaged.
Measure the outer diameter of shift fork shaft.
Replace it if it exceed service limit.
Measure the inner diameter of shift fork.
Measure the thickness of shift fork claw.
Check if the counter shaft is worn or damaged.
9-7
TRANSMISSION
Check if the reverse shaft is wear or damage.
Check if the final shaft and gear are burn, wear or

damage.
Check bearings on the left and right crankcase. Balance shaft bearing
Rotate each bearing’s inner ring by fingers. Drive shaft bearing
Check if the bearings can be rotated smoothly
and
silently and also check if the bearing outer ring is
mounted on gear tightly.
If the bearing rotation is uneven, noising, or loose
Check oil seal for wear or damage, and replace it
if necessary.
Drive shaft bearing Final shaft bearing
Caution
z The bearings should be replaced with new
one after they are removed from the
crankcase by the bearing puller.
Balance shaft bearing Counter shaft bearing
9-8
TRANSMISSION
6.Bearing Replacement
Caution
z Never install used bearings. Once bearing
removed, it has to be replaced with new one.
Left crankcase side
Remove the drive shaft and bearing from the left
crankcase.
Remove the drive shaft bearing from the shaft by

outer bearing puller. Outer bearing puller
Replace the drive shaft bearing with new one by

bearing driver.
Special tool:
Tool number：SYM-2341110-REA A6228
Tool name：Bearing driver (6228)
Bearing driver
Park gear
Remove the cir-clip and the park gear.
Remove the counter gear needle bearing.
9-9
TRANSMISSION
Install the park gear cir-clip by using cir-clip Park gear cir-clip installer
installer.
Special tool:
Tool name：Park gear cir-clip installer
cir-clip Park gear
Inner bearing puller
Right crankcase side

Remove the final shaft bearing on the right
crankcase with inner bearing puller.
Special tool:
Tool number：SYM-6204025
Tool name：Inner bearing puller
Remove the counter shaft bearing on the right

Special tool: Inner bearing puller
cir-clip
Remove the drive shaft needle bearing on the

right
Special tool:
9-10
TRANSMISSION
9-11
TRANSMISSION
Install the final shaft bearing with the bearing Bearing driver
driver.
Special tool:
Tool number：SYM-2343110-REA 6307
Tool name：Final shaft bearing driver
Install the counter shaft bearing with the bearing

driver.
Special tool:
Tool number：SYMTool
name：Counter shaft bearing driver Bearing driver
Bearing driver
Install the drive shaft needle bearing with the

bearing driver.
Special tool:
Tool number：SYM-9100400-REA 2220
Tool name：Drive shaft needle bearing driver
9-12
TRANSMISSION
7.Transmission Reassembly Reverse shaft
Install the reverse shaft onto the left crankcase.
Drive shaft
Install the counter shaft and gearshift fork.

Shift drum
Gearshift fork
Install the shift drum.

Rotate the shift drum and make sure it can rotate Counter shaft
smoothly.
Install the final shaft onto the right crankcase.

Put the same numbers of shim, which were
removed during removal, on the final shaft. Shim
Final shaft
9-13
TRANSMISSION
Install the bevel gear housing Bevel gear housing
Put the same numbers of shim, which were Shim
removed during removal, on the bevel gear
housing.
Install the bevel gear. Final gear stopper

Lock the nut by using final shaft stopper.
Special tool:
Tool name：Final shaft stopper.

Bevel gear
Concave marks
Reassemble the right and left crankcase.

Install the gearshift spindle.
Align the concave marks on the shift gear and the
shift drum gear.
Install 2 dowel pins and transmission cover
gasket.
Gearshift spindle Shift drum gear
4 bolts
Install the transmission cover.
Transmission cover
9-14
TRANSMISSION
Install the change lever arm.
Keep the level mark on the change lever arm Change lever arm
horizontal.
Lever mark
9-15
TRANSMISSION
NOTE:
9-16
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
3. Wheel Drive Shaft Removal 10-3
4. Wheel Drive Shaft Disassembly 10-4
5. Wheel Drive Shaft Inspection 10-7
6. Repair Pack 10-8
7. Wheel Drive Shaft Assembly 10-10
8. Front and Rear Propeller Shaft 10-14
10-1
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
2.Trouble Diagnosis
Engine can be started but vehicle cannot move.
z Damaged wheel drive shaft
z Damaged propeller shaft
z Damaged front differential or rear gear box
Noise
z Worn or burnt drive shaft
z Worn or burnt steel ball
z Worn or burnt gear
Gear oil leaks

z Excessive gear oil
z Worn or damaged rubber boot
z Worn or damage oil seal
10-2
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
3. Wheel Drive Shaft Removal
Front wheel drive shaft removal
Remove the front wheel.
Remove the front brake caliper and disk.
Remove the tie-rod.
Remove the knuckle body.
Remove the wheel drive shaft with special tool.
Rear wheel drive shaft removal

Remove the rear wheel.
Remove the rear wheel connecter.
Remove the rear wheel hub.
Remove the rear cushion.
Remove the rear wheel drive shaft with special

tool.
10-3
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
4. Wheel Drive Shaft Disassembly
Universal joint disassembly
Open the boot band clip with scrapper.
Scrapper
Remove the rubber boot bands.

UJ small boot band
UJ large boot band

Remove the UJ rubber boot.
Disassemble the wheel drive shaft UJ assembly SYM-4423000-REA

with rubber hammer & special tool.
Tools name：Wheel driveshaft assembly seat
Tools number：SYM-4423000-REA
Caution
Do not disassemble UJ assembly by using the Rubber hammer
10-4
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
steel hammer.
10-5
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Remove 6 steel balls from UJ assembly outer SYM-4423500-REA
race.
Tools name：Wheel drive shaft assembly seat
Tools number：SYM-4423500-REA
Remove the inner race and cage from the outer

race.
Clean the inner race, outer race, steel balls and

cage.
Cage Inner Race Steel Balls
Double Offset Joint Disassembly

Open DOJ band clip with scrapper.
Remove the wheel drive shaft boot band.
Remove the DOJ rubber boot.
10-6
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Remove the inner cir-clip with screw drive.
Disassemble DOJ assembly.
Clean the DOJ assembly.

Remove the cir-clip from the drive shaft.
Remove the steel balls from cage.
10-7
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
5. Wheel Drive Shaft Inspection
Clean all spare parts. Check the surface of these
parts for wear or scratch.
Replace DOJ or UJ assembly if any stepped
scratch is found.
Check the inside surface of UJ outer race.

Replace UJ assembly if it is damaged.
Check the inside surface of DOJ assembly outer

race.
Replace double offset joint assembly if it is
damaged.
10-8
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
6. Repair Pack
Check if DOJ & UJ boot is damaged
Replace DOJ or UJ assembly if it is damaged.
Remove the DOJ & UJ boot.
Remove the DOJ & UJ cage.
Remove the DOJ & UJ boot.
10-9
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Disassemble and clean all spare parts. Check if
there is any corrosion on the surface of these
parts. Replace DOJ or UJ assembly if any
damaged part is found.
Clean the DOJ & UJ cage.
Unpack DOJ Repair Pack.
Unpack UJ Repair Pack.
10-10
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
7.Wheel Drive Shaft Assembly Drive shaft
DOJ assembly
Assemble the DOJ boot.
DOJ boot
Inner race Drive shaft

Assemble 6 steel balls, inner race and cage then
drive shaft into the assembly.
DOJ cage
6 Steel balls
Assemble exit cir-clip onto drive shaft. Cir-clip
Grease into the DOJ outer race.
Caution
Please use the grease of the repair pack. Using
other oil may cause the part to be damaged.
10-11
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Install the wheel drive shaft and cir-clip into DOJ
outer race.
Small band
Install DOJ boot outside band.
Large band
Install DOJ boot.
Pull and open DOJ boot Pressure balancing that
make it inside and external.
Deduct DOJ band closely with rubber hammer.
10-12
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
UJ assembly
Assemble universal joint and UJ boot and Pour Grease
into the grease.
Pour grease into the UJ boot inside.

Inner band
Caution
Please use the grease of the repair pack. Using
other oil may cause the part to be damaged.
Assemble cir-clip with the tool.
Strike the wheel drive shaft by rubber hammer.
10-13
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Install UJ boot.
Pull and open DOJ boot to balance the inside

and outside pressure.
Install band with rubber hammer.
10-14
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
8. Front and Rear Propeller Shaft
Remove
Loosen 3 bolts from the front propeller connector.
Disassemble the engine and propeller connector. Spring

Remove the front propeller shaft connector
Propeller shaft connector
Propeller shaft
Remove the front propeller shaft connector,
spring, spring pin and shaft.
Spring pin
Propeller shaft disassembly

Remove the front side exit cir-clip. Spur gear
Remove the propeller spur gear.
Cir-clip
10-15
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Remove the rear side exit cir-clip.
Cir-clip
Remove propeller shaft and rubber boots. Rubber boot
Drive shaft inspection

Check if the spur gear has is damaged or not. Spur gear
Please replace new parts if it has split or
damaged.
Check if the propeller shaft is split or damaged.

Please replace new parts if it is split or damaged.
Propeller shaft
10-16
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
Check if the propeller shaft rubber boot is Rubber boot
damaged or not.
Propeller shaft installation

Install in the reverse order of removal
procedures.
10-17
WHEEL DRIVE SHAFT &
PROPELLER SHAFT
NOTE:
10-18
A.C GENERATOR/STARTING CLUTCH
3. Right Crankcase Cover Removal 11-3
4. A.C.Generator Removal 11-3
5. Flywheel Removal 11-4
6. One Way Clutch Removal 11-4
7. Recoil Starter Cover Removal 11-5
8. One Way Clutch Installation 11-7
9. Flywheel Installation 11-8
10. A.C. Generator Installation 11-9
11. Right Crankcase Cover Installation 11-9
Recoil Starter Grip
Recoil Starter Cover
Volute Spring
Starter Drive Pulley
R. Case Cover
Stator Rope
Stator Ratchet
Water Pump Shaft
Recoil Stator Cover Gasket
Stator Driven Pulley
Stator
Flywheel
One Way ClutchGear
Starting Clutch
R. Cover Gasket
11-1
General information
z Refer to chapter 18: The troubleshooting and inspection of alternator
z Refer to chapter 18: The service procedures and precaution items of starter motor
Specification
Item Standard value (mm) Limit (mm)
ID of starting clutch gear 27.026~27.045 27.050
OD of starting clutch gear 45.192~45.283 45.183
Torque value
Flywheel nut 5.0~6.0kgf-m
Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive
8 mm bolts 0.8~1.2kgf-m
12 mm bolts 1.0~1.4kgf-m
Tools
Special tools
A.C.G. flywheel puller: SYM-3110000-HMA
Universal holder: SYM-2210100
11-2
3.Right Crankcase Cover Removal
Water pump cover 5 bolts 5 bolts
Remove the left footrest.
Drain the engine oil and coolant, and then
remove
coolant hoses.
Remove 5 bolts from the recoil starter cover.
Remove the recoil starter cover and gasket.
Remove the water pump cover (5 bolts)
Coolant hoses
12 screws
4. A.C. Generator Removal
Remove the connector bolt and starter pulley.
Remove 12 mounted screws from the right
crankcase cover and then remove it.
Connector bolt and starter pulley
Remove 5 screws from right crankcase cover. 5 screws
Remove the stator.
11-3
5. Flywheel Removal
Flywheel puller
Remove the A.C. Generator flywheel with special
tool.
Tool name：A.C.G. flywheel puller
Tool number：SYM-3110000-HMA
Starting Clutch Gear Inspection ID

Remove the starting clutch driven gear.
Check the gear for wear or damage.
Measure the ID and OD of the starting clutch
driven gear.
Service Limit: ID: 27.050 mm
OD: 45.183 mm
OD
Starting reduction gear Shaft
Check the starting reduction gear and shaft for

wear or damage.
3 bolts
6. One Way Clutch Removal

Remove 3 bolts from the A.C. Generator
flywheel.
11-4
Check each roller for wear or damage.
Install the starting clutch driven gear onto one

way clutch.
Hold the flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
7. Recoil Starter Cover Removal bolt

Loosen bolt on the ratchet cover then remove
ratchet cover.
Remove the starter ratchets from the ratchet Starter ratchet

cover.
11-5
Remove the 2 springs from the ratchet cover.
2 springs
Do not remove the volute spring from the recoil Volute spring
starter cover unless the spring is broken. If the
volute spring is removed from the recoil starter
cover, it should be replaced with a new one.
Remove the starter grip rubber. Starter rope

Disassemble the starter grip and rope.
Starter grip rubber
Installation
Install in reverse order of removal procedures
Caution
First before installing the drive pulley must
establish 2 1/2 of the pressures transferred to
pressure springs.
11-6
8. One Way Clutch Installation
3 bolts
Install the components in the reverse procedures
of removal.
Caution
Tape a tightening tape onto the thread of
hexagon bolt.
Install the starting driven gear. One-way clutch
starting driven gear
11-7
9. Flywheel Installation
Install the reduction gear shaft and reduction
gear.
Assemble the starting driven gear of the flywheel.

Align the key on crankshaft with the flywheel
groove, and then install the flywheel.
Install the flywheel onto crank shaft.
11-8
10. A.C. Generator Installation
Install the A.C. Generator stator set onto right 3 bolts 2 bolts
crankcase cover (3 screws).
Install the pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed under
pulse generator.
11.Right Crankcase Cover Installation

Install the dowel pin and new gasket.
Dowel pin
Remove the water pump cover.

Install the right crankcase cover onto the
crankcase.
Note: Align the water pump shaft indent with the
oil pump shaft.
Assemble the connector bolt and starter pulley

on
the right crankcase cover.
Assembly 12 bolts on the right case cover.
Connector bolt and starter
11-9
Install the water pump cover (5 bolts)
5 bolts
Assemble the gasket. 5 bolts

Assemble the starter cover on the right
crankcase
cover.
11-10
NOTE:
11-11
CRANKCASE / CRANKSHAFT
2. General Information 12-2
4. Crankcase Disassembly 12-3
5. Crankshaft Inspection 12-5
6. Crankcase Assembly 12-6
1.0~1.4kgf-m
Eng. Oil drain bolt

1.0~1.4kgf-m
12-1
2. General Information
Operational precautions
This Section concerns disassembly of the crankcase for repair purpose.
Remove following components before disassembling crankcase.
－Engine remove Section 5
－Cylinder head Section 6
－Cylinder and piston Section 7
－Drive face and driven pulley Section 8
－AC generator/Start one way clutch Section 10
In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing
chain, it is preferably to replace crankshaft as a unit.
Specification Unit: mm
Item Standard Limit
Connecting rod side clearance of the big end 0.100~0.400 0.600
Crankshaft
Vertical clearance of the big end of the connecting rod 0~0.008 0.050
Run-out - 0.100
Torque value
Bolts for crankcase 0.8~1.2kgf-m
Engine oil drain bolt 3.5~4.5kgf-m
Cylinder stud bolt 1.0~1.4kgf-m
Tools
Special tools
Crankcase Main Bearing Install Tool: SYM-9100100-REA
Engine noise
z Loose crankshaft bearing
z Loose crankshaft pin bearing
12-2
z Worn out piston pin and pin hole
12-3
4. Crankcase Disassembly
Cam chain tensioner
Remove the cam chain setting plate, and then
remove cam chain.
Loosen the pivot bolt and remove the cam chain
tensioner.
Cam chain setting plate
2 bolts
Loosen 2 bolts on the left crankcase.
Loosen 13 bolts on the right crankcase. 13 bolts
Place left crankcase downward and right

crankcase up.
Tap the right crankcase with a plastic hammer to
remove it.
Caution
Do not make damage to the contact faces.
12-4
Remove balance shaft from left crankcase. Balance shaft
Remove crankshaft from left crankcase.

Remove gasket and dowel pins.
Scrape gasket residues off the crankcase
contact surface.
Caution
Do not damage the contact face of the gasket.
It is better to moisten the gasket residue for easy
scrapping.
Replace crankcase main bearings if necessary.
12-5
5. Crankshaft Inspection
Use a thickness gauge to measure left and right
clearance of connecting rod big end.
Measure point for the crank

big end of the connecting rod.
Measure the clearance of the big end at the

vertical directions.
Place the crankshaft on a V-block, measure

run-out of the crankshaft.
90mm 60mm
Check crankshaft bearing

Use hand to crank the bearing to see if it moves
freely, smoothly and noiseless.
Check the inner ring to see if it links firmly on the
bearing.
If any roughness, noise and loose linkage are
detected, replace the bearing with new one.
Caution Crank bearing

The bearing shall be replaced in pair
Special tool: outer bearing puller
12-6
Check balance shaft bearing
Check bearings on right and left crankcase. Balance shaft bearings
Rotate each bearings inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
Special tool:
Tool name：Inner bearing puller bearing
driver
6. Crankcase Assembly
Install wave washer into right crank bearing seat.
Wave washer
Install crank shaft on the right crankcase.
Position mark
Align the position mark on the balance shaft

drive
gear with that of balance shaft driven gear, and
then install balance shaft onto right crankcase.
12-7
Install 2 dowel pins and new gasket.
Dowel pins
Install the left crankcase onto the right
crankcase.
Tighten 11 bolts on the left crankcase. 11 bolts

Tighten 2 bolts on the right crankcase.

2 bolts
12-8
Clean the crankshaft.
Apply a layer of grease on the lip of oil seal, Puts
on the left crank shaft.
Install the oil seal in the left crankcase with care
not to damage the lip of the oil seal.
By oil seal driver (27×42×7), oil seal will knock Crank and oil seal installation
into located.
Special tool:
Tool number：SYM-11332100-HMA RB1
Tool name：Crank and oil seal installation.
Tensioner
Install the tensioner and tighten the pivot bolt.

Torque value: 0.8 ~1.2kgf-m
Install the cam chain.
Install the cam chain setting plate.
Cam chain setting plate
12-9
NOTE:
12-10
COOLING SYSTEM
General Information
Warning:
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot
coolant may shoot out and cause serious scalding injury. No maintenance work is allowed to
perform unless the engine is completely cooled down. Refill the radiator with distilled water or
specified additives. Add coolant to the reservoir.
The cooling system can be serviced on the ATV.
Never spill the coolant to the painted surface.
Test the cooling system for any leakage after the repair.
Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.
Technical Specification
Item Specification
Pressure to open filler cap 0.9±0.15 kgf/cm2
Capacity of coolant: Engine + radiator 1800c.c.
Reservoir upper 700c.c.
Thermostat Begins to activate at 65~72
Thermos switch (fan) Begins to activate at 93±3
Not-pressure: 107.7
Boiling point
Pressurized: 125.6
Torque Value
For water pump impeller 1.0~1.4 kgf-m
Special tools
Water pump bearing driver (6901)
Water pump oil seal driver (Inner)
Water pump mechanical seal driver
13-1
COOLING SYSTEM
Trouble Diagnosis
The engine temperature is too high
The water thermometer and the temperature sensor do not work properly.
The thermostat is stuck to close.
Insufficient coolant.
The water hose and jacket are clogged.
Fan motor malfunction.
The radiator filler cap of the radiator malfunction.
The engine temperature is too low

The water thermometer and the temperature sensor malfunction.
The thermostat is stuck to open.
Coolant is leaking
The water pump mechanical seal does not function properly.
The O-ring is deteriorated.
The water hose is broken or aged.
13-2
COOLING SYSTEM
Trouble Diagnosis for Cooling System
The temperature indicated is too high
Y
A. Stop and waiting for the
engine is completely A1.Refill the radiator with
cooled down, open cap N coolant then check for Y Water leaking problem
to check the capacity of any leakage?
coolant in radiator.
N
Y
B. Turn on main switch and

check the water N B-1.Measure thermo unit to N Replace thermo unit
temperature indicator confirm voltage 6V↑?
back to zero?
Y
Y B-2.Inspect the circuits of

water temperature have Y Short or earth handle
short or earth?
N
Meter problem
C-1.Eng. stop and remove

C. Open radiator cap and water pump cover, start
softly throttle, inspect N the motor to inspect N Water pump repair
coolant have circulated? pump its rotation?
Y Y
Water hose clogged
D. Close radiator cap,

measure thermo unit to
confirm voltage reduced N
comply with temperature Replace thermo unit
rise?
Next page
13-3
COOLING SYSTEM
Preceding page
E. Keep eng. 3000~4000 E-1.Measure thermal switch

rpm and inspect cooling N to confirm voltage be N Replace thermal switch
fan was operating after changed (12→0V)?
the temperature gauge
over 3 checks?
Y
Y E-2.Connect cooling fan
F. Confirm the cooling fan terminals with battery N Replace cooling fan
was convulsion? (12V) directly to inspect
its operation?
Y Y
E-3.Keep eng. 3000~4000
Meter unusual rpm and inspect coolant
flow into reserve tank
after the temperature
gauge over 3 checks?
If circuit connects reverse
cooling fan will forward, Y
correct and check again.
E-4.Remove thermostat
from holder then heats it N Replace thermostat
by water directly to
check its operation?
Y Refill with coolant then

check again
For bleed the air bubbles Notice the water hose

completely, open radiator can’t any unsuitable
cap and start engine while bend or twist and
engine is cool then press bleed the air bubbles
water hose softly by hand completely.
to bleeding. Turn the
throttle repeatedly until
the coolant surface
becomes stable.
13-4
COOLING SYSTEM
System Test
Test on the filler cap
Hermetically seal the filler cap, apply water
and pressure to the filler cap. Replace it with
new one if found failing to maintain the
specified pressure within a given time limit, or
the opening pressure is too high or too low.
The specified pressure shall be maintained at Pressure tester Filler cap
least for 6 seconds in the test
Relief pressure for the filler cap:
0.9-1. 05 kgf/cm2
Apply pressure to the radiator, engine and
water hose to check for any leakage
Caution
High pressure may damage the radiator.
Never use pressure which exceeds
1.05 kg/cm2.
If the system fails to maintain the specified
pressure for at least 6 seconds, repair or Radiator filler cap
replace parts.
Change of coolant
Warning
Never attempt to carry out service work on
the cooling system unless the engine is
completely cooled down, otherwise, you may
get scalded. Remove the front center cover,
and then remove filler cap. Place a water pan
under the water pump; loosen the drain bolt to
drain out the coolant. reinstall the drain bolt.
Refilling system with coolant and bleeding the

air bubbles. Run the engine, and remove
by-pass pipe. Check by-pass hole whether
has the air bubble to emit. If emits without the
air bubble, only has the coolant to flow out,
then backflow pipe joint on, engine flameout. Drain bolt
Remove radiator filler cap.
Starts the engine, inspects does not have the
air bubble in the radiator coolant, also the By-pass pipe
coolant liquid level is stable. stop the engine.
Add coolant to proper level if necessary.
Caution
In order to avoid the water tank rusting,
please do not use the unclear trade mark
refrigerant.
13-5
COOLING SYSTEM Upper Lower
Check reserve tank

Remove the front center cover, and then
remove reserve tank filler cap.
Check the liquid level in the front fender right
side. Add coolant to proper level if too low. Upper
Reinstall the reserve tank filler cap.
Caution
The reserve tank liquid level cannot too high,
to avoiding overheats of the water Lower
temperature of the cooling system.
Radiator
Check
Remove the front center cover, side covers
and front fender. (Refer chapter 13), check for
any leakage from weld seam.
Blow radiator clean using compressed air. If
the radiator is blocked by dirt, use low
pressure water jet to clean it.
Care shall be taken when straightening the
sink fan.
Removal
Place a water pan under the water pump;
loosen the drain bolt to drain out the coolant.
Remove coolant filler pipe. Filler pipe clamp
13-6
COOLING SYSTEM
Loosen the radiator 4 bolts.

Remove coolant upper side pipes.
4 bolts
Remove coolant outlet pipe.
Disconnect the couplers for the thermo switch
and fan motor, and then remove radiator and
cooling fan.
Collant outlet pipe

Disassembly
Loosen the 4 bolts from the fan duct, and
then remove the fan duct.
Loosen 4 screws from the fan motor, and
take off the fan motor. Thermo switch
Remove nut to remove the fan from fan
motor.
Assembly
Install fan motor onto fan duct and insert the
fan into the motor shaft.
Apply a coat of the adhesive to the shaft
thread of the motor, and then install the
washer and the lock nut.
Tighten the fan duct onto the radiator with 4
bolts.
Please refer to chapter 17 for the inspection
of the thermo switch.
4 bolts
Caution
Liquid packing must be applied to the thermo
switch before installing to avoid damaging the 4 bolts
radiator.
Installation
Install the removed parts in the reverse order
of removal.
Install radiator in the reverse order of
removal.
Upon completion, check for any leakage.
13-7
COOLING SYSTEM
Water Pump
Check water pump seal / cooling
system divulges inspection
Disassembles the refrigerant drain bolt,
overflows little buckles the actually fluid,
confirmed overflows the refrigerant whether
has the greasy dirt.
Turns on the engine oil gauge rule, the
inspection engine oil whether does have
bleaches situation of the emulsified.
If has the above two kind of interior to divulge
the phenomenon, possibly for the water pump
inner two seal damages, the engine cooling
system damages or the cylinder and the
cylinder head gasket damages, please first
dismantles the right crank case to confirms
the replacement water pump seal, if does not
have the question to take apart for overhaul
cooling system of system again the cylinder
head, the cylinder.
Removal of water pump

Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen 5 bolts and remove the pump cover.
Loosen 9 bolts and remove the right cover.
Take off the gasket and dowel pins.
Turn pump impeller clockwise and remove.
Caution
The impeller is provided with left turn thread.
Remove the cir clip from the right crankcase

cover.
Remove the water pump shaft and the inner
bearing.
Remove the outside bearing by inner bearing
puller.
Rotate the inner ring of bearing, the bearing
shall move smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it with new one.
Special tool:
13-8
COOLING SYSTEM
Thermostat Temperature sensor

Please refer to chapter 17 for inspection of
temperature sensor. By-pass pipe
Removal
Drain out the coolant.
Remove the thermostat set. (2 bolts)
2 bolts
Inspection
Visually inspect thermostat for any damage.
Place the thermostat into heated water to

check its operation.
Caution
Whenever the thermostat and the thermometer
are in contact to the wall of heated water
container, the reading displayed is incorrect. If
the valve of the thermostat remains open at
room temperature or the valve operation is not
corresponding to the temperature change,
then it must be replaced.
Technical Data
Valve begins to open 65~72
Valve stroke 0.05 ~ 5mm
Installation
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out the air bubble
(Page 12-6).
13-9
BODY COVER
2. Maintenance 14-2
3. Front handle cover / Meter cover 14-3
4. Front center cover 14-4
5. Upper center cover 14-4
6. Footrest 14-5
7. R/L side cover 14-5
8. Front fender 14-6
9. Rear fender 14-7
10. Front bumper cover 14-8
14-1
BODY COVER
2. Maintenance
Disassemble sequence:
Seat R/L Footrests
Handle cover R/L side covers
Front center cover Front fender
Upper center cover Rear fender
Front bumper cover
Be careful not to damage various covers in assembly or disassembly operation.

Never injure hooks molded on the body covers.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the guard and the covers during assembly.
14-2
BODY COVER
3. Front handle cover / Meter cover
Remove 4 screws
Remove 4 screws from meter cover ,and then
remove front handle cover.
Loosen 2 bolts from meter stay.
2 bolts
Remove couplers of meter.
Disassembly 4 screws
Remove 4 screws and 2 nuts.
Installation
2 nuts
14-3
BODY COVER
4. Front center cover
Remove
Loosen 3 screws from the front center cover.
Please disassemble first then push the cap
upward, and then remove front center cover.
Installation
Install in reverse order of removal procedures 3 screws
5. Upper center cover

Remove
Remove seat.
Loosen 4 screws , and then remove upper center
cover.
Installation
14-4
BODY COVER
6. Footrest cover
Remove
Loosen the 4 bolts, which connect the footrest,
these 4 bolts just between footrests.
Loosen the 6 bolts connect with front fender both

side, also loosen 5 bolts connect with rear fender
both side, and then remove footrest cover.
These 4 bolts on the right and left footrests.
Installation
7. R/L side cover

Remove
Loosen the 4 bolts, and then remove upper
center cover.
Remove 1 bolt and take off shift lever.
Loosen the 6 bolts, and then remove side cover.
Installation
14-5
BODY COVER
8. Front fender
Remove
Remove the seat.
Remove front center cover, and then loosen 4
screws of fuel tank cover.
Loosen the screws which connect to footrest and

side cover, (each side 9 screws)
Loosen the 4 screws, which connect the front

fender right and left side, then remove front
winker and headlight coupler,
Remove head lamp stay bolts(each side 2 bolts)
Installation
14-6
BODY COVER
9. Rear fender
Remove the seat.
Loose screws which connect to footrest and side
cover.(each side 6 screws)
Remove fuse box, starter relay, battery and C.D.I

on rear fender.
Caution Polar
Loose battery screw from polar side, never
connect polar and negative with any electric
object. 3 bolts
Remove R/L Tail light coupler and R/L position

lamp coupler.
Rear fender stay

Loosen rear fender stay screws. (each side
2screws)
Installation
14-7
BODY COVER
10. Front bumper cover
Remove
Loosen 4 bolts from the rear carrier.
Remove the front bumper cover.
Installation
Caution
Please put the shift lever in the “N” or “p” position
Warning
It will be very dangerous if not follow this process that the engine gear will
jump position from”N”to”F”or”R”
14-8
FRONT BRAKE & FRONT WHEEL
4. Front Wheel 15-4
5. Front Wheel Hub 15-4
6. Disk Brake System Inspection 15-7
7. Adding Brake Fluid 15-8
8. Brake fluid replacement / Air-bleed 15-9
9. Front Brake Caliper 15-10
10. Brake Disk 15-11
11. Front Brake Master Cylinder 15-11
15-1
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose
or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the hydraulic
system.
While refilling brake fluid, care should be taken not to let the foreign material entering into the brake
system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before riding.
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and
installation of the tire.
Specifications
Item Standard (mm) Limit (mm)
The thickness of front brake disk 4.00 3.50
The thickness rear brake disk 6.00 5.50
Front and rear brake disk eccentricity < 0.100 0.300
Master cylinder inner diameter 14.000~14.043 14.055

Master cylinder piston outer diameter 13.957~13.984 13.945
Diameter of front disk 220mm -
Diameter of rear disk 190mm -

Thickness of brake lining 4.800 2.000
Tire pressure as cold: 8(7) psi (on road tire)

5(3.5) psi (off road tire)
Torque
Brake hose bolts 23 N-m
Bolt for brake caliper 28 N-m
Bolts for the brake disk 25 N-m
Brake lever nut 10 N-m
Air-bleed valve 5 N-m
Front wheel nut 24 N-m
Front axle castle nut 50 N-m
15-2
Soft brake lever Hard operation of brake lever

1. Air inside the hydraulic system 1. Blocked brake system
2. Hydraulic system leaking 2. Poor brake caliper
3. Worn master piston 3. Blocked brake pipe
4. Worn brake pad 4. Seized/worn master cylinder piston
5. Poor brake caliper 5. Bent brake lever
6. Worn brake lining/disk
7. Low brake fluid
8. Blocked brake hose Tight brake
9. Warp/bent brake disk 1. Dirty brake lining/disk
10. Bent brake lever 2. Poor wheel alignment
3. Deformed or warped brake disk
Uneven brake
1. Dirty brake lining/disk Hard steering
2. Poor wheel alignment 1. Faulty tire
3. Clogged brake hose 2. Insufficient tire pressure
4. Deformed or warped brake disk
5. Restricted brake hose and fittings
Front wheel wobbling
1. Faulty tire
Brake noise 2. Worn front brake drum bearing
1. Dirty lining 3. Bent rim
2. Deformed brake disk 4. Axle nut not tightened properly
3. Poor brake caliper installation
4. Imbalance brake disk or wheel
Steers to one side

1. Bent tie rods
2. Wheel installed incorrectly
3. Unequal tire pressure
4. Incorrect wheel alignment
15-3
4. Front Wheel
Removal
Raise the front wheels off the ground by placing a
jack or other support under the frame.
Remove the front wheel nuts, and then remove
front wheels.
Installation 4 nuts
Install the front wheel and tighten the nuts.
Torque: 50 N-m
5. Front Wheel Hub

Removal
Remove front brake caliper (2 bolts).
2 bolts
Remove cotter pin, wheel hub nut and washer.

Remove wheel hub and brake disk.
Wheel hub nut
Cotter pin
15-4
Remove 4 socket bolts, and then remove the
brake disk from wheel hub.
4 bolts
Inspection
Install the front brake disk to the wheel hub.
Install wheel hub and brake disk on to knuckle.
Install wheel hub washer and tighten the wheel Wheel hub nut
hub nut.
Torque: 80 N-m
Install cotter pin. Cotter pin
Install front brake caliper.

Torque: 28 N-m
2 bolts
15-5
6.Disk Brake System Inspection
Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube
seam whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.
Check the brake from behind the brake caliper.

The brake pad must be replaced with new lining
when the brake pad wear limit reaches the brake
disk.
Caution
Check the front brake lining must be removed
front wheel first.
Park the ATV on a level ground, and check if fluid

level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 4).
Caution
If the vehicles inclined or just stopped, the survey
oil level could not be accurate, had to settle the
3~5 minute.
In order to prevent chemical change, please do
not use counterfeited or other unclear trade
marks brake fluid.
Uses the trade mark brake fluids, which
guarantee brake vehicle efficiency.
15-6
7. Adding Brake Fluid
Master cylinder
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid. Please do not surpass
the upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in damages.
Remove the master cylinder cap and diaphragm.

Add high quality brake fluid, uses only trade mark
brake fluid joins in master cylinder.
Clean the dirty brake disk.
Caution
The dirty brake lining or disk will reduce the brake
performance.
To mixed non-compatible brake fluid will reduce
brake performance.
Foreign materials will block the system causing
brake performance to be reduced or totally lost.
15-7
8. Brake fluid replacement /
Air-bleed
Connect drain hose to air-bleed valve.
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out.
Close the drain valve and add specified brake
fluid into the brake master cylinder.
Recommended brake fluid:
DOT 4 brake fluid
Air-bleed must from pressure control valve first.

Connect one end of transparent hose to the
air-bleed valve, and put the other end into a
container.
Air-bleed valve
Open the drain valve around 1/4 turns, and at the
same time hold the brake lever until the there is
no air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake

system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
Air bubble Drain valve
brake system or not.
If brake is still soft, please bleed the system as
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the valve.
Caution
Do not release the brake lever before the drain
valve is closed.
Always check the brake fluid level when carrying Transparent hose
out the air bleeding procedure to avoid air enters
into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.
15-8
9. Front Brake Caliper
Removal Brake hose bolt
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.
Remove two caliper bolts and the caliper.
Inspection
Make sure the brake linings condition. Replace
the linings if the brake linings wear limitation
groove close to the brake disk.
2 bolts
Brake lining replacement
Remove two guide pins.
Compress caliper mounting plate, and then Guide pin
remove brake linings.
Install new linings, and tighten the guide pins.

Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 28 N-m
Caution
Use M8 x 25 mm flange bolt only.
Long bolt will impair the operation of brake disk.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 23 N-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
15-9
10. Brake Disk
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Allowable limit: 3.5 mm
Remove the brake disk from wheel hub.

Check the disk for deformation and bend.
Caution
The dirty brake lining or disk will reduce the brake
performance.
Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the operator
should dress the mouthpiece and the glove, use
vacuum cleaner clean it.
11. Front Brake Master Cylinder

Master Cylinder Removal
Caution
Do not let foreign materials enter into the
cylinder.
Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.
Push the lead of brake light switch, and then

remove brake light switch.
Drain out the brake fluid.
2 socket bolts
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder socket bolts and the
master cylinder.
15-10
Remove the rubber boot.
Remove the cir clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds
Master Cylinder Assembly

Caution
It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir clip.
Make sure there is no dust on all components
before assembling.
Apply clean brake fluid to the piston cup, and
then install the cup onto the piston.
Install the larger end of the spring onto the
master cylinder.
The master cup’s cavity should be face inside of
master cylinder when installing the master cup.
Caution
Never install cup lip in the opposite direction.
Make sure the cir clip is seated securely in the
groove.
Install the rubber boot into groove properly.
15-11
Master Cylinder Install
Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
Install the brake lever, and connect leads to

brake light switch, then install the brake stopper 2 washers Brake light switch
at last.
Brake lever bolt
Connect brake hoses with 2 new washers.

Tighten the brake hose bolt to the specified
torque value.
Torque: 23 N-m
Make sure the hose is installed correctly.
Install all wires, hoses, and components and
avoid twisting them together.
Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Wrong brake leads, hose or pipe may reduce
brake performance.
Add specified brake fluid and bleed the system.
15-12
Notes:
15-13
STEERING / FRONT SUSPENSION
2. Operation Precautions 16-2
4. Steering Handle 16-3
5. Steering Shaft 16-5
6. Steering Tie-Rod 16-6
7. Knuckle 16-7
8. Front Cushion 16-8
9. Suspension Arm 16-9
10. Toe-In 16-10
16-1
2. Operational Precautions
Torque
Handlebar upper holder bolt 24 N-m
Steering shaft holder bolt 23 N-m
Steering shaft nut 84 N-m
Steering tie-rod nut 40 N-m
Knuckle nut 50 N-m
Tie rod lock nut 40 N-m
Suspension arm nut 70 N-m
Front cushion mounting nut 45 N-m
Hard to steer
z Faulty tire.
z Steering shaft holder too tight.
z Insufficient tire pressure.
z Faulty steering shaft bushing.
z Damaged steering shaft bushing.
Front wheel wobbling
z Faulty tire.
z Worn front knucle bearing.
z Bent rim.
z Axle nut not tightened properly.
Steers to one side
z Bent tie rods.
z Wheel installed incorrectly.
z Unequal tire pressure.
z Bent frame.
z Worn swing arm pivot bushings.
z Incorrect wheel alignment.
Front suspension noise
z Loose front suspension fasteners.
z Binding suspension link.
Hard suspension
z Faulty front swing arm bushings.
z Improperly installed front swing arms.
z Bent front shock absorber swing rod.
Soft suspension
z Weak front shock absorber springs.
z Worn or damage front swing arm bushings.
16-2
4. Steering Handle
Removal
Remove the handle cover, meter set, handle
protect cover and front fender. (Refer to chapter
13)
Loosen the socket bolts for the front brake

master cylinder, and remove front brake master
cylinder.
Caution
cylinder.
Master cylinder bolts
Remove 2 screws, and then remove throttle

hosing holder and throttle hosing.
2 screws
Loosen the socket bolts for the front brake

master cylinder, and remove front brake master
cylinder.
Caution
cylinder.
Master cylinder bolts
16-3
Loosen 2 screws, and then remove handle left
switch and choke cable.
2 screws
Remove switch wire band.

Remove handle mounting bolt, and then remove
the handle upper holder, handle.
Installation
Torque: 4 socket bolts
Handlebar holder bolt 24 N-m
16-4
5. Steering Shaft
Remove
Remove cotter pins, and loosen right and left
steering tie-rod nuts.
Remove tie-rod.
Steering shaft nut
Remove the cotter pin below steering shaft, and

remove steering shaft nut and washer.
Steering shaft nut Cotter pin
Bend out the steering shaft holder nut fixed plate.

Loosen 2 bolts, and then remove steering shaft
holder, nut fixed plate, pressed plate and steering
shaft.
Inspection
Check wear of damage, and replace it if
necessary.
Measure the holder inner diameter. Fixed plane
Maximum limit: 39.5 mm
Installation
Apply with grease onto oil liner and holder.
Torque:
Steering shaft holder bolt 23 N-m
Steering shaft nut 50 N-m
16-5
6. Steering Tie-Rod
Cotter pin
Remove
Remove cotter pin and tie-rod nut from steering
shaft side.
Tie-rod nuts
Remove cotter pin and tie-rod nut from wheel

side.
Tie-rod nuts Cotter pin
Inspection
Inspect the tie-rod for damage or bending.
Inspect the ball joint rubbers for damage, wear or
deterioration.
Turn the ball joints with fingers. The ball joints
should turn smoothly and quietly. Ball joint
Installation
Install the ball joint with “adjustment groove” on
the wheel side. Adjust boit
Install tie-rod nuts, and tighten the nuts.
Torque: 50 N-m
After tightened the tie-rod nut, install the cotter

pin.
Adjust bolt
16-6
7. Knuckle
Remove
Remove front wheel, front brake caliper, front
wheel hub and brake disk.
Tie-rod
Remove cotter pin and tie-rod nut, remove tie

rod.
Tie-rod
Nut
Tie-rod nuts Cotter pin
Remove cotter pin and ball joint nut.

Remove upper and under ball joints by ball joint
driver.
Remove the knuckle.
Special Tool : Ball joint driver
Inspection
Inspect the upper and under ball joints and
knuckle for damaging or cracking.
Installation
Torque:
Ball joint nut 40 N-m
After tightened the nuts, install the cotter pins.
16-7
8. Front Cushion
Remove
Remove front cushion under bolt nut, and
remove the bolt.
Nut
Remove front cushion upper bolt nut, and Nut

remove the bolt and cushion.
Installation
Torque:
Front cushion nut 45 N-m
16-8
9. Suspension Arm
Remove
Remove front wheel, wheel hub, and brake
caliper, brake disk, tie-rod, knuckle and front
cushion.
Loosen upper suspension arm nuts, remove

swing arm bolts.
Remove upper suspension arm.
Suspension arm nuts and bolts
Loosen under suspension arm nuts, remove

swing arm bolts.
Remove under suspension arm.

Inspection
Inspect the suspension arm, ball joint and bush
for damage or bending.
Installation
Torque value:
Suspension arm nut 70 N-m
Lubricate with grease into suspension arm.
16-9
10. Toe-In
When repair or disassemble steering system
parts, must to adjustment the toe-in.
Keep 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

turn 180 degree, 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: 5~7mm
If the toe-in is out of standard, adjust it by

hanging the length of the tie-rods equally by
turning the tie-rod while holding the ball joint.
Loosen two side tie-rod lock nuts; turn the
tie-rods to adjustment toe-in.
Tighten the lock nuts.
Torque: 40 N-m
16-10
NOTE:
16-11
REAR BRAKE & REAR WHEEL
& REAR CUSHION
4. Rear Wheel 17-4
5. Rear Wheel Axle 17-5
6. Disk Brake System Inspection 17-6
7. Adding Brake Fluid 17-7
8. Brake Fluid Replacement / Air-Bleed 17-8
9. Rear Brake Caliper 17-9
10. Brake disk 17-10
11. Rear Brake Master Cylinder 17-12
12. Rear Cushion 17-16
17-1
& REAR CUSHION
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose
or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead. The brake
caliper can be removed without removing the hydraulic system. After the hydraulic system is removed,
or the brake system is felt to be too soft, bleed the hydraulic system. While refilling brake fluid, care
should be taken not to let the foreign material entering into the brake system. Do not spill brake fluid on
the painted surfaces, plastic or rubber parts to avoid damage. Check the operation of the brake system
before riding. Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair
and installation of the tire.
Specifications
Item Standard (mm) Limit (mm)
The thickness of front brake disk 4.00 3.50
The thickness rear brake disk 6.00 5.50
Front and rear brake disk eccentricity < 0.100 0.300
Master cylinder inner diameter 14.000~14.043 14.055

Master cylinder piston outer diameter 13.957~13.984 13.945
Diameter of front disk 220mm -
Diameter of rear disk 190mm -

Thickness of brake lining 4.800 2.000
Tire pressure as cold : 8(7)psi (On-road)
5(3.5)psi (Off-road)
Torque
Brake hose bolt 23 N-m
Bolt for brake caliper 39 N-m
Bolts for the brake disk 25 N-m
Brake lever nut 10 N-m
Air-bleed valve 5 N-m
Rear wheel nu 50 N-m
Rear axle castle nut 100 N-m
Rear wheel axle nut 50 N-m
Rear cushion mounting bolt 45 N-m
17-2
& REAR CUSHION
Soft brake lever
z Air inside the hydraulic system
z Hydraulic system leaking
z Worn master piston
z Worn brake pad
z Poor brake caliper
z Worn brake lining/disk
z Low brake fluid
z Blocked brake hose
z Warp/bent brake disk
z Bent brake lever
Hard operation of brake lever
z Blocked brake system
z Poor brake caliper
z Blocked brake pipe
z Seized/worn master cylinder piston
z Bent brake lever
Uneven brake
z Dirty brake lining/disk
z Poor wheel alignment
z Clogged brake hose
z Deformed or warped brake disk
z Restricted brake hose and fittings
Tight brake
z Dirty brake lining/disk
z Poor wheel alignment
z Deformed or warped brake disk
Brake noise
z Dirty lining
z Deformed brake disk
z Poor brake caliper installation
z Imbalance brake disk or wheel
17-3
& REAR CUSHION
4. Rear Wheel
Removal
Raise the rear wheels off ground by placing a jack or
other support under the frame.
4 nuts
Remove the rear wheel nuts, and the remove

rear wheel.
Installation
Install the rear wheel and tighten the nuts.
Torque: 50 N-m
17-4
& REAR CUSHION
5. Rear Wheel Axle
Remove cotter pin, rear wheel axle connecter nut
and washer.
Installation Wheel hub nut
Install wheel shaft connecter washer and tighten the
Cotter pin
wheel shaft connecter nut.
Torque:100 N-m
Install cotter pin.
Remove rear wheel knuckle 2 bolts.(R/L)
Installation
Install rear wheel knuckle and tighten the bolts.
Torque:70 N-m
Remove rear wheel knuckle.(R/L)
Remove rear wheel axle.(R/L)
17-5
& REAR CUSHION
6. Disk Brake System Inspection
Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube
seam whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.
Check the brake from behind the brake caliper.

The brake pad must be replaced with new lining
when the brake pad wear limit reaches the brake
disk.
Caution
Check the rear brake lining must be remove rear
wheel first.
Park the ATV on a level ground, and check if fluid

level is under the “LOWER” mark.
Recommended Brake Fluid: BRAKE OIL (DOT
4).
Caution
If the vehicles is inclined or just stopped, the
survey oil level could not be accurate, had to
settle the 3~5 minute.
In order to prevent has the chemical change,
please do not use counterfeiting or other unclear
trade marks brake fluid.
Uses only trade mark brake fluid, guarantees the
vehicle efficiency.
17-6
& REAR CUSHION
7.Adding Brake Fluid
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir Fluid cup
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid please do not surpass
the upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in their damages.
Remove the brake fluid cap and diaphragm.

Add high quality brake fluid, uses only trade mark
brake fluid in the master cylinder.
Clean the dirty brake disk.
Caution
The dirty brake lining or disk will reduce the
brake performance.
To mixed non-compatible brake fluid will reduce
brake performance.
Foreign materials will block the system causing
brake performance to be reduced or totally lost.
17-7
& REAR CUSHION
8. Brake fluid replacement /
Air-bleed
Connect drain hose to air-bleed valve.
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out.
Close the drain valve and add specified brake
fluid into the brake master cylinder. Air-bleed valve
Recommended brake fluid:
DOT 4 brake fluid
Connect one end of transparent hose to the drain

valve, and put the other end into a container. Air bubble Drain valve
Open the drain valve around 1/4 turns, and at the
same time hold the brake lever until the there is
no air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.
If brake is still soft, please bleed the system as Transparent hose
described below:
1. Tightly hold the brake lever and open the drain
valve around 1/4 turns, and then close the
valve.
Caution
Do not release the brake lever before the drain
valve is closed. Always check the brake fluid
level when carrying out the air bleeding
procedure to avoid air enters into the system.
2. Slowly release the brake lever, and wait for a

few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the fluid
if necessary.
6. Cover the cap.
17-8
& REAR CUSHION
9. Rear Brake Caliper
Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces. Brake hose bolt
Remove two caliper bolts and the caliper.
Inspection
Make sure the brake linings condition. Replace
the linings if the brake linings wear limitation
groove close to the brake disk.
2 bolts
Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 39 N-m
Caution
Use M8 x 60 mm flange bolt only.
Long bolt will impair the operation of brake disk.
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 23 N-m
Refill up the brake fluid to the reservoir and make
necessary air bleeding.
17-9
& REAR CUSHION
10. Brake Disk
Removal
Removal the rear wheel.
Removal the rear wheel knuckle.
Removal the rear wheel axle.
Removal the cushion 4 bolts.
4 bolts
Removal the rear arm upper 1 bolts.(R/L)
Installation
Install the rear arm upper and tighten the bolt.
Torque: 70 N-m
Removal the rear arm lower 2 bolts.(R/L)
Installation
Install the rear arm lower and tighten the bolts.
Torque: 70 N-m
2 bolts
Removal the stabilizer joint 2 nuts.(R/L)
Installation
Install the stabilizer joint and tighten the nuts.
Torque: 40 N-m 2 nuts
17-10
& REAR CUSHION
Removal the stabilizer bar 4 bolts.
Installation
Install the stabilizer bar and tighten the bolts.
Torque: 28 N-m
Removal the rear brake disk 4 bolts.
Installation
Install the rear brake disk and tighten the bolts.
Torque: 25 N-m
Removal the rear differential 3 bolts.
Installation
Install the rear differential and tighten the bolts.
Torque: 83 N-m
3 bolts
17-11
& REAR CUSHION
Inspection
Visually check the brake disk for wear or break.
Measure the thickness of the disk at several
places. Replace the disk if it has exceeded the
service limit.
Remove the brake disk from rear differential.

Check the disk for deformation and bend.
Caution
The dirty brake lining or disk will reduce the
brake performance.
Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the operator
should dress the mouthpiece and the glove, use
vacuum cleaner to clean it.
11. Rear Brake Master Cylinder Brake lever bolt

Master Cylinder Removal
Caution
cylinder.
Caution
The whole set of master cylinder, piston, spring, Brake light switch coupler
diaphragm and cir-clip should be replaced as a
set.
2 socket bolts
Handle left side – rear brake master cylinder A
Remove brake light switch coupler.
Drain out the brake fluid.
Remove the brake hose.
Remove the brake lever from the brake master
cylinder.
master cylinder.
17-12
& REAR CUSHION
Right footrest side – rear brake master cylinder
Place a container under the brake master
cylinder, remove fluid hose clamp, and drain out
the brake fluid.
Loosen the brake hose bolt and finally remove
the brake hose.
2 boits
Remove the E type clip, and remove brake push

rod pin.
master cylinder.
Disassembly
Remove the rubber boot.
Remove the cir-clip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit:
Hand brake 11.055 mm
Foot brake 18.955 mm
17-13
& REAR CUSHION
Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.
Allowable limit:
Hand brake 10.945 mm
Foot brake 18.845 mm
Master Cylinder Assembly

Caution
It is necessary to replace the whole set
comprising piston, spring, piston cup, and cir clip.
Make sure there is no dust on all components
before assembling.
Apply clean brake fluid to the piston cup, and
then install the cup onto the piston.
Install the larger end of the spring onto the
master cylinder.
The master cup’s cavity should be face inside of
master cylinder when installing the master cup.
Caution
Never install cup lip in the opposite direction.
Make sure the cir clip is seated securely in the
groove.
Install the rubber boot into groove properly.
Master Cylinder Install

Caution
Improper routing may damage leads, hoses or
pipes.
Caution
Wrong brake leads, hose or pipe may reduce
brake performance.
Handle left side – rear brake master cylinder A
Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts. Install the brake lever, and
connect coupler to brake light switch.
torque value.
Torque: 23 N-m
Install all wires, hoses, and components carefully
so avoid to twisting them together.
17-14
& REAR CUSHION
Right footrest side – rear brake master cylinder
Install the master cylinder bolts and the master
cylinder.
Install brake push rod to the brake pedal, and

install pin and E type clip.
Caution
To adjustment brake pedal, you must be remove
push rod pin first.
Loosen lock nut, and turn adjustment nut and
push rod bracket to adjust brake free play.
Install fluid hose and clamp.

torque.
Torque: 23 N-m
Install all wires, hoses, and components carefully
avoid twisting them together.
17-15
& REAR CUSHION
12. Rear Cushion
Removal
Support the frame.
Loosen rear cushion under bolt nut, and remove
rear cushion under bolt.
Remove rear cushion upper bolt, and then

remove rear cushion.
Installation
Install rear cushion, and install rear cushion
upper bolt.
Install rear cushion under bolt, and install nut.
Tighten the rear cushion upper bolt and under
nut to the specified torque value.
Torque: 45 N-m
17-16
& REAR CUSHION
NOTE:
17-17
ELECTRICAL EQUIPMENT
2. Maintenance Date 18-2
3. Technical Specification 18-2
5. Battery 18-4
6. Charging System 18-5
7. Ignition System 18-8
8. Starting System 18-10
9. Meters 18-12
10. Light / Bulb 18-13
11. Switch / Horn 18-16
12. Fuel Unit 18-19
13. Cooling Fan Thermo Switch 18-20
14. Thermo Unit 18-21
15. Water Temperature Indicator Light 18-21
18-1
2. Maintenance Data
Operational precaution
y When remove the battery, the disconnection sequence of cable terminals shall be strictly
observed. (First disconnect the negative cable terminal, next, the positive cable terminal.)
y The model of the spark plug and the tightening torque.
y The ignition timing.
y Adjustment of headlight.
y Removal and installation of AC generator.
y The maintenance free battery requires no inspection of electrolyte level and refilling of distilled
water.
y To recharge the battery, remove the battery from rack without removing ventilation caps.
y Unless in emergency, never rapid charge the battery.
y The voltage must be checked with the voltmeter while charging the battery.
y As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect,
check C.D.I and AC generator. Verify with an ignition timing light after replacement if
necessary.
3. Technical Specification
Charging system
Description Specification
Capacity 12V18Ah
Battery
1.4A / 5 ~ 10 hours (standard) hour
Charging rate
9A / 0.5(fast charging)
Leak current < 1mA
Charging current 1.2 A / 1500rpm
Control voltage in charging 14.5 + 0.5 V / 1500rpm
Ignition system
Description Specification
Model NGK CR8E(Recommended)

Spark plug
Gap 0.8mm
Primary winding 2.9 ±10%Ω

Ignition coil and
resistnace Without cap: 15.0 ±10%Ω
Secondary winding
With cap: 20.0 ±10%KΩ
15∘TDC/1700rpm
Ignition timing “F”mark
46∘TDC/4200rpm
18-2
No voltage
Battery discharged Charging system does not operate
The cable disconnected properly
The fuse is blown Burnt fuse
Improper operation of the main switch Poor contact, open or short circuit
Poor regulator
Low voltage Poor ACG
The battery is not fully charged
Poor contact Engine does not crank smoothly
Poor charging system Primary winding circuit
Poor voltage regulator y Poor ignition coil
y Poor connection of cable and
No spark produced by spark plug connectors
The spark plug is out of work y Poor main switch
The cable is poorly connected, open or Secondary winding circuit
short-circuited y Poor ignition coil
y Between AC.G. and C.D.I. y Poor spark plug
¾ Poor connection between C.D.I. y Poor ignition coil cable
and ignition coil y Current leakage in the spark plug
¾ Poor connection between C.D.I. Incorrect ignition timing
and the main switch y Poor AC.G.
Poor main switch y Improper installation of the pulse
Poor C.D.I. sensor
AC.G. is out of work y Poor C.D.I.
Starter motor does not work

The fuse is blown Weak starter motor
The battery is not fully charge Poor charging system
Poor main switch The battery is not fully charged
Poor starter switch Poor connection in the windings
The front and rear brake switches do not The motor gear is jammed by foreign material
operate correctly
Starter relay is out of work Starter motor is working, but engine does
The ignition coil is poorly connected, open or not crank
short-circuited Poor starter motor pinion
The starter motor is out of work The starter motor run in reverse direction
Poor battery
Intermittent power supply
The connector of the charging system
becomes loose
Poor connection of the battery cable
Poor connection or short-circuit of the
discharging system
Poor connection or short-circuit of the power
generation system
18-3
5. Battery
Removal
Remove the seat, and then you can see the
battery.
Disconnect the negative cable terminal first,
then the positive cable terminal.
Remove the battery clamp, and then remove
battery. Clamp
Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 13.0~13.2 V at 20℃
Undercharged: Below 12.3 V at 20℃
Charging
Connect the positive terminal (+) of the charger
to the battery positive terminal (+).
Connect the negative terminal (-) of the charger
to the battery negative terminal (-).
Standard Maximum
Charging current 1.4A 9.0A
Charging time 5~10H 1H
Warning
Keep flames away while recharging.
Charging is completely controlled by the
ON/OFF switch on the charger, not by battery
cables.
Caution
Never rapid charge the battery unless in
emergency.
Verify the battery is recharged with current and
duration prescribed above.
Large current and fast time to charge will
render damage to the battery.
When installing the battery, coat the cable

terminal with grease
18-4
6. Charging System
Charging circuit
Current Leakage Inspection

Turn the main switch to OFF position, and
remove the negative cable terminal (-) from the
battery.
Connect an ammeter between the negative
cable terminal and the battery negative
terminal.
Caution
In the current leakage test, set the current
range at the largest scale, then gradually
decrease to the lower scale as the test process
goes to avoid possible damage to the ammeter
and the fuse.
Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified

value, it may indicate a short circuit.
Allowable current leakage: Less than 1mA

Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.
18-5
Inspection on Charging Voltage Connect a tachometer.
Turn on the headlight to high beam and start
the engine.
Accelerate the engine to the specified
revolution per minute and measure the
charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 + 0.5 V / 2000 rpm
Caution
To replace the old battery, use a new battery
with the same current and voltage.
The following problems are related to the
Caution charging system; follow the instructions
Before conducting the inspection, make sure that provided in the checking list to correct it if any
the battery is fully charged. If undercharged, the one of the problems takes place.
current changes dramatically. (1) The charging voltage can not exceed the
Use a fully charged battery having a voltage voltage between two battery terminals and
larger than 13.0 V the charging current is in the discharging
While starting the engine, the starter motor draws direction.
large amount of current from the battery. (2) The charging voltage and current are too
After the engine is warmed up, replace original much higher than the standard values.
battery with a fully charged battery.
Connect a digital voltmeter to the battery
terminals. The following problems are not related to the
Connect an ammeter between both ends of the charging system; correct it if any by following
main fuse. steps indicate in the checking list.
(1) The standard charging voltage and current
Caution can only reach when the revolution of the
When the probe is reversibly connected, use a engine exceeds the specified rpm.
voltmeter having an indication that the current x Bulbs used exceed their rate and
flows from the positive or the negative direction consume too much power.
and the measurement should be at zero, x The replacement battery is aged and
ammeter at one direction only. does not have enough capacity.
Caution (2) The charging voltage is normal, but the
Do not uses short-circuit cable. It is possible to current is not.
measure the current by connecting an ammeter - The replacement battery is aged and
between the battery positive terminal and the does not have enough capacity.
cable position terminal, however, while the starter - Battery used does not have enough
motor is activated, the surge current the motor electricity or is over charged.
draws from the battery may damage the - The fuse of the ammeter is blown.
ammeter. - The ammeter is improperly connected.
Use the kick starter to start the engine. (3) The charging current is normal, but the
The main switch shall be turned to OFF position voltage is not.
during the process of inspection. - The fuse of the voltmeter is blown.
Never tamper with the ammeter and the cable
while there is current flowing through. It may
damage the ammeter.
18-6
Inspection on regulator rectifier

Remove the seat, side cover L.
Disconnect three couplers of the regulator
Rectifier.
Inspection the rectifier coupler to the wire harness
passes the condition.
Item Check Points Standard Value
Main switch
Connection R–B Battery voltage
(ON)
Battery
connection R---G Battery voltage
Charging coil Y---Y 0.17 ~ 0.8Ω
If the readings measured are not normal, check

parts in the circuit.
If the parts are normal, then trouble is in the wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.
regulator
Regulator
18-7
7. Ignition System
Ignition circuit diagram
C.D.I unit
Disconnect connectors of the C.D.I unit.
Check the following connectors as indicated in the table at the harness side.
Item Points to check Result
Main switch turn to “ON”position B ~ W/B Battery voltage
Pulse generator G/W ~ L/Y 50~170Ω
Primary circuit B/Y ~ GND 2.9±10%Ω
Ignition coil B/Y ~ with no cap 15.0±10%Ω

Secondary circuit
B/Y ~ with cap 20.0±10%KΩ
18-8
Inspection on Ignition Coil

Disengage the connector of the ignition coil and
the spark plug cap.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 2.9Ω±10%
Remove the cap from the spark plug and
measure the resistance between the spark plug
and the primary winding.
Standard resistance:
With no cap: 15.0±10%Ω
With cap: 20.0±10% KΩ
Ignition Coil Replacement

Loosen the lock bolt and replace the ignition coil if
necessary.
Ignition coil
Spark plug
Inspection of Pulse Generator

Disconnect the coupler of the pulse generator
and measure the resistance between the
terminals of green/white and blue/yellow.
Standard resistance: 50~170
Pulse generator coupler
18-9
8. Starting System
Starting circuit diagram
Inspection on starter relay

Open the main switch.
Press the brake. Starter relay
Push down the starter switch.
If a sound of .”Looh Looh”. is heard, it indicates
the relay function normally.
Remove the seat.

Disconnect the negative cable terminal of the
battery.
Disconnect the cable positive terminal from the
relay.
Disconnect the positive cable of the starter
motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal
end.
Connect the yellow/red cable to the battery
positive terminal and the yellow/black cable to
the battery negative terminal.
Check the continuity of the large terminal end.
If there is no continuity, replace the relay.
18-10
Removal of Starter motor

Remove the seat. Negative
Disconnect the cable negative terminal (-), then
the cable positive terminal (+).
Remove starter motor cable.

Loosen the lock bolts and remove the starter
motor.
Starter motor cable
Installation of Starter motor

2 bolts
18-11
9. Meter 4 screws
Removal
Remove 4 screws from meter cover ,and then
remove front handle cover.
Loosen 2 bolts from meter stay.
2 bolts
Remove couplers of meter.
Remove 4 screws and 2 nuts, and then remove 4 screws

speedometer.
2 nuts
18-12
10. Light / Bulb

Replacing Bulb for Headlight
Remove waterproof cover for the headlight.
Remove bulb setting hook.
Take out the bulb connector and the bulb.

Replace with new bulb if necessary.
(Hight light H1 12V 55W)
(Low light H7 12V 55W)
Caution
Never touch the bulb with finger, which will
create a heat point.
Clean the fingerprint left on the bulb with
alcohol.
Install the bulb of the headlight in reverse
order of removal.
Upon completion of replacement, turn on
the main switch to ensure the headlight
works well.
Adjust the beam and distance of the
headlight if necessary.
18-13
Replacing the Front winker light

Bulb
Pull out the front winker light bulb seat.
2 screws
Replace with new front winker light bulb.

(12V 10W)
Replacing Bulb of Position Light

Pull out the position light bulb seat.
Replace with new position light bulb.

(12V 5W)
18-14
Replacing Bulb of Taillight and

Rear
Winker Light
Turn the taillight and rear winker light bulb
connectors by CCW.
Replace with new taillight bulb.

(12V 16W)
Replacing Bulb of License Light

Turn the license light bulb connectors by
CCW.
Replace with new license light bulb.
Replace with new license ight bulb.

(12V 5W/)
18-15
11. Switch / Horn

Main Switch
Inspection
Remove the front center cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below:
Replacement of main switch

Disconnect the coupler of the main switch.
Push out the main switch.
Align the main switch stopper with the meter
cover groove, and install main switch.
Head light switch coupler
Install the main switch coupler.
Handle switches
Disconnect the coupler of handle from front
fender left side.
Check the continuity between two points as
indicated in the table below.
Start Switch
Start switch
2W/4W switch
2W/4W switch
18-16
Headlight Switch Head light switch
Winker switch
Winker switch
Horn switch
Horn switch
Hazard switch
Hazard switch
18-17
Front Brake Switch

While grasp the brake lever firmly, the Brake light switch
terminals of brown/blue and green/yellow of
the brake should have continuity.
Replace the switch if damaged.
Rear Brake Switch

While grasp the brake lever firmly, the
terminals of white/black and green/yellow of
the brake should have continuity.
Replace the switch if damaged.
Rear Brake Switch
Horn 1 bolt
Remove the horn under front fender.
Apply 12 V power source to two terminals of

the horn, the horn should sound.
Replace the horn if necessary.
18-18
12. Fuel Unit

Remove the seat.
Remove the fuel tank cap.
Remove the upper center cover and front
fender (refer chapter 13).
Disconnect the coupler of the fuel unit.
Remove the fuel unit (4 bolts).
Caution
Great care shall be taken not to damage or 4 bolts
bend the float arm of the gauge.
When the float arm shifts to the F position or

the E position, the resistance measured shall
be as follows:
Position Resistance
E (Empty) 97.5~107.5
F (Full) 4~10Ω
Connect the wiring to the fuel unit and the
ohmmeter as shown.
Connect the fuel unit coupler to the wire

harness.
Turn on the main switch.
Move the float arm to verify the proper position
the fuel gauge needle indicates.
Arm Position Needle Position
Up (Full) F (Full)
Down (Empty) E (Empty)
Caution
While conducting the test, turn on the direction
indication lamp to make sure that the battery is
in serviceable condition.
18-19
13. Cooling Fan Thermo Switch

The thermo switch mounted on the radiator
controls the operation of the cooling fan
motor.
In case that the fan motor fails to work,
disconnect the green and black/blue leads
and connect jump wires to the terminals, then,
turn on the main switch, the fan motor should
operate.
If the fan motor still fails to run, measure switch
Thermo switch
battery voltage between the green and
black/blue leads.
If there is no voltage, check for blown fuse,
loose connection or short-circuit.
If the fan motor runs, check the thermo switch
in the manner as described below:
Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and
closing temperatures, confirm the switch is
open circuited at room temperature, and
increase the coolant temperature gradually.
The switch should have continuity at 93±3 .
Caution
Keep the coolant at a constant temperature at
least for three minutes. Sudden increase the
coolant temperature will cause the
thermometer and the tester to indicate wrong
readings.
Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.
18-20
14. Thermo unit

Remove the thermo unit.
Hang the thermo unit in an oil heater, heat the oil
and measure the resistance at each temperature.
Thermo unit
Thermo unit
Caution
Wear gloves and goggles when performing this
test.
Caution
Engine oil should be used as a heating medium
as the test temperature must be higher than
100 .
Contacting the container wall by the thermometer
and the thermo unit may result in wrong readings.
15. Water Temp Indicator Light

Disconnect the water temperature meter and
connect it to engine ground.
Turn on the main switch.
The indicator light of the fuel meter should be
lighting.
18-21
Notes:
18-22
ELECTRICAL DIAGRAM
1. Electrical Diagram 19-1
switch
19-1
ELECTRICAL DIAGRAM
Notes:
19-2

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GAMAX MOTO ATV

Chapter.1 includes general information and trouble diagnosis.

Home page Contents

1. Symbols and Marks

Used engine oil

Do not let parts fall down.

Make sure if the connector pins are bent, extruded or loosen.

Wire band and wire harness have to be clamped secured properly.

Do not squeeze wires against the weld or its clamp.

Keep wire harnesses far away from the hot parts.

Secure the rubber boot firmly as applying it on wire harness.

Never clamp or squeeze the wire harness as installing other components.

Type 4-Stroke Engine Clutch Centrifugal,dry type

Air filtration Sponge

Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to

● No fuel in fuel tank

● Malfunction of spark plug

Cylinder compression Low compression ● Piston ring seized

Re-start by following the starting

No ignition There are some signs of ● Malfunction of throttle valve operation

Remove the spark plug again

● Fuel level in carburetor too high

Remove carburetor after 30

Blowing in normal Blowing clogged ● Malfunction of automatic by- starter

Check and adjustment Fault condition Probable causes

Try gradual acceleration and

● Air cleaner clogged

Check cylinder compression

● Cylinder & piston ring worn out

Check if carburetor jet is

No clogged Clogged ● Remove foreign

Remove spark plug

Check if engine over heat

Check ignition timing (using

Normal Abnormal ● Incorrect ignition timing

Adjust the air screw of

● Rich mixture (loosen the screw)

Air sucked through carburetor

● Poor heat insulation gasket

● Spark plug fouled

D.Engine runs sluggish (High speed)

Check ignition timing

Check for fuel supplying system

● Insufficient fuel in fuel tank

Check if carburetor clogged

No clogged clogged Clogged ● Cleaning

FAULT CONDITIONS PROBABLE CAUSES

● Drive belt worn out or deformation

Engine running and misfire as

● Drive belt worn out or deformation

FAULT CONDITIONS PROBABLE CAUSES

Steering is heavy ● Damaged steering bearing

Raise wheels off ground and

Check tire pressure

Accelerate lightly, engine speed

Check ignition timing

● Faulty pulse generator

Test cylinder compression

● Leaking head gasket

MAIN BRG. UP/LWR 404420 PULLEY DRIVEN FACE

CLUTCH COVER 35558 DRIVEN PULLEY PULLEY DRIVEN FACE