Four-wheeled cross-country vehicle model ATV110-M is a versatile off-road vehicle suitable for various road conditions. This manual provides information specifically for salespeople and technical staff of our company. The guide covers lubrication, maintenance, and adjustment procedures for the vehicle's body and engine. Additionally, it offers guidance on troubleshooting common issues that may arise during use. (Note: I have applied the "ADD SPELLING ERRORS (SE)" rewriting method to the provided text.) Using the wrong tools can cause problems during maintenance. For instance, a wrench for valve adjustment is typically used to adjust valve clearance, whereas a puller for piston pin is mainly employed to remove the piston pin. When choosing instruments and meters, consult the same type of vehicle for reference. The selection includes speedometer, engine multimeter, ignition timing meter, spark tester, and barometer. Before disassembling an ATV engine, ensure that each component is properly secured to prevent damage during reassembly. When reinstalling components like gear pairs, cylinders, or piston pins, make sure they are securely connected with oil seals, shims, O-rings, and other mating parts. When handling clips, inspect them carefully before installation and replace any damaged ones. Additionally, ensure that the locking washer is properly seated during reassembly. To maintain electrical components, clean connectors from dirt, rust, and moisture. Avoid exposing electrolytes inside batteries to the body, as they can cause corrosion. If a joint becomes loose, bend the plug pin upward and reconnect it securely. Given text is about maintenance and lubrication requirements for a vehicle, specifically detailing various components such as wires, screws, gears, and engine parts. It outlines specific torque specifications, lubrication points, and types of lubricants to ensure proper functioning and prevent damage. The document covers requirements for fasteners, including wire sizes for starting motors, gear indicators, and rectifiers, as well as screw locking specifications. It also addresses lubrication needs for various components, such as pistons, cylinders, valves, and bearings, using specific types of oil and grease. The text includes sections on periodic maintenance and adjustment, including procedures for disassembling and reinstalling cushion, fender, and fuel tank components. It emphasizes the importance of proper maintenance and adjustment to ensure normal driving and vehicle performance. 1. Remove the bolt, disconnect the connecting pipe and disassemble the front fender. 2. Install: Front fender, assembly of the connecting pipe, and bolt. 3. Fuel tank 1: a. Place the vehicle on the horizontal ground. b. Disassemble the cushion -23-... Page 30 c. Demove the front fender. d. Demove the fuel tank bolt. e. Pull the fuel cock lever to “OFF”position. f. Remove the fuel inlet pipe 4. Caution: Place a cloth on the engine to absorb the splashed gasoline. Warning: The gasoline is inflammable. Avoid to splash it on the hot engine. 5. Install the bolt, bushing of rubber hood and washer. 6. Install: Front fender, cushion 7. To turn the fuel cock lever to “on” position. 8. Maintenance and Adjustment of Vehicle Body (I) Wear inspection of front&rear brake a. Check the front brake b. Brake the vehicle with front brake c. Check: .Wear indication .If the wear indication reach the wear limit mark ,replace the brake shoe assy. 9. 2.Adjustment a. Adjusting procedure of free clearance of right lever: .Loosen the locking nut¢Ù,and rotate the cable adjsuting screw ¢Úclockwise to reduce the tension of front brake cable. b. Pick up the front wheel form ground, and ro- tate the two front wheels, and ensure the two front brake light brake force. 10. 2.Adjust .Free clearance of left lever a. Free clearance of rear brake pedal Adjusting procedure: Caution Before adjusting, tread the rear brake pedal 2-3times. b. Loosen the locking nut completely, and screw in the cable adjusting screw completely. c. Loosen the adjusting nut of rear brake cable and adjusting nut of rear brake pedal. 11. Inspection of steering system a. Place the vehicle on the flat ground b. Check: .Clamp seat of steering vertical column and sliding bearing on the lower end of steering vertical column, upper &lower and front &rear moving steering bar If the clearance is too large, replace the sliding bearing c. Check: .Ball pin unit of steering tension rod. 12. Adjustment of toe-in of front wheel a. Rest the motorcycle on the flat ground b. Measurement: .Toe-in .Adjust if out of specification c. Adjustment steps of toe-in. .Mark the centers of tire thread of two front wheel. .Lift the front end of motorcycle to keep the front wheel from force. 13. Inspection of front/rear shock absorber a. Rest the motorcycle on the flat ground b. Inspection (1) Front/rear shock absorber If scraped/damaged replace the front/rear shock absorbe (2) Oil leakage If the heary oil When replacing front/rear shock absorbers, ensure to install new ones. 2. Tire inspection: 1) The quality of tires significantly affects ATV driving reliability. Only approved tire types by our company can be used safely with this motorcycle. Using other tires may lead to negative effects, so they are not recommended. 2. Measurement: Check tire pressure at normal atmospheric temperature. If out of specification, adjust it. Note that the manometer is a spare part and should not be used under high pressure. If foreign particles like dust enter the tire pressure meter, the reading will be incorrect; conduct a second measurement to verify. Section 4 deals with Electrical Appliance maintenance and adjustment: (I) Battery inspection: Be cautious as the electrolyte contains sulfuric acid, which is poisonous and corrosive. To avoid damage, follow these steps: a) Avoid touching the body to the electrolyte to protect eyes from burns or damage. If damaged, replace the battery. 5. Installment of battery: First, connect the positive electrode, then the negative electrode. (II) Fuse inspection: When checking or replacing fuses, make sure to close the main switch to avoid short circuits. Section 5 focuses on Engine maintenance and adjustment: (I) Clutch adjustment: a) Loosen the locking nut, b) Turn the adjusting screw rod counterclockwise until it becomes immovable, then turn 1/8 clockwise and fasten it. Finally, tighten the locking nut with N.m torque. The speed limitator can be adjusted to limit throttle opening by pulling the throttle grip to maximum position. Loosening the locking nut allows for adjustment steps, including aligning the mark "T" on the rotor with the crankcase mark at top dead center (TDC). Installation involves mounting components such as valve caps, ensuring proper alignment and clearance between parts. When installing, ensure O-rings are not damaged and project upwards to avoid issues. During maintenance, check oil levels, pressure, and compression forces. If necessary, add oil or replace faulty components like O-rings, compressure springs, filters, and brake parts. Clean the engine and other components to maintain optimal performance. 1) Disassemble: Remove circlip ¢Ü, spring ¢Ý, and circlip ¢Þ from assembly. 2) Disconnect front brake cable and air pipe. 3) Take apart brake shoe assy and front cover assy. II.Inspection procedures: 1) Check Front wheel: Refer to "Tire inspection" and "Hub inspection". 2) Measure Radial run-out of front wheel: If exceeding limit, replace or check bearing clearance (in figure). 3) Check Tire surface: Replace if worn or damaged. 4) Polish Friction wafer with rough sand paper. 5) Measure Thickness of friction wafer of brake: If not conforming to specified thickness, replace. III.Replacing procedures: 1) Wash outer side of brake hub. 2) Remove oil seal with plain screw. 3) Replace bearing if worn or damaged. 4) Apply grease to cam shaft and rotating pin seat when installing. 5) Install Brake shoe assy without lubricating grease on friction wafer. 6) Connect front brake air pipe and cable with brake cover. IV.Installation procedures: 1) Lubricate dust-proof seal, bearing, cam shaft, and rotating pin seat (in figure). 2) Do not apply lubricating grease on brake friction wafer. 3) Install Circlip ¢Ú, Spring ¢Û, Circlip ¢Ü, Spring ¢Ý, Pin ¢Þ, and Adjusting nut. 4) Install Front brake hub with Gakset and O-ring (in figure). 5) Install front wheel with 55N.m torque on connecting nut. V.Adjustment: 1) Free clearance of front brake cable: Refer to "Section 2 Rear wheel/rear brake/rear wheel axle". VI.Replacement steps for rear wheel: 1) Rest motorcycle on flat ground. 2) Stop up front wheel and put supporting article under frame. 3) Lift rear wheel and remove from earth. 4) Dismantle rear disk Brake plate. Rear Disk brake bracket (1) 8. Be cautious while removing rear wheel axle from its bushing and gear box using a soft hammer Warning When taking out rear wheel axle, avoid direct hammer blows to protect thread and gear groove from damage. Page 62 5.Rear wheel axle inspection a:Replace if heavily scraped or broken b:If thread or gear groove is worn or damaged, replace Rear wheel axle c:If radial runout of position on rear wheel axle is out of specification, replace it Section 3 Steering Operation System (I)Steering bar removal steps 1.Handlebar decration cover removal 2.Front brake cable removal 3.Throttle grip assy removal 4.After stopping the vehicle, remove rear brake cable and steering bar pipe Lower holder of steering bar -57-... (II)Steering vertical column welding removal steps 1.Locking pad locking part move 2.Bolt removal Locking washer Clip assy 3.Steering vertical column installation with split Washer 4.Split pin Tension rod removal Caution When removing tension rod end and steering ball pin from steering vertical column welding assy, use common bearing tension tool. (III)Inspection content 1.Check if the steering bar is cracked or damaged If so, replace it 2.Inspect if the steering vertical column weld- ing assy is bent or damaged If so, replace it Warning To avoid decreasing steering performance, do not force straighten if bent 6.Tension rod adjustment Assembly length of tension rod Adjustment steps Loosen connecting nut (A).(B) Adjusting assembly length of tension rod by rotating tension rod Attached:Tension rod assembly length @: 297mm (A)Right-hand thread (B)Left-hand thread Connect position to steering vertical column welding assy. Page 67 2.Lubricate steering vertical column holder and seal ring during installation 3.Installment Install seal ring to steering vertical column weld- ing, then install bushing, finally install steering vertical column holder Caution: Never damage seal ring when installing Page 68 7.Split pin mounting 1. Installation steps of steering bar: a. Install lower holding seat, steering tube and upper holding seat. b. When tightening bolt, ensure clearance even. Attached: - Bolt torque:20Nm 2. Installation steps of throttle grip unit: a. Ensure projection on throttle grip corresponds to sunken part on right lever. 3. Disassembly steps of front shock absorber and Front wheel fork (I): a. Take off front fender, split pin, nut and steering rod ball pin assembly. b. Dismantle bolt of front shock-absorber. c. Move left/right front wheel fork up and down to check vertical clearance. Warning: Do not straighten bent left/right front wheel fork. 4. Disassembly steps of rear shock absorber and Rear wheel fork (I): a. Take off cushion/rear fender/drive sprocket. b. Check for leakage or damage in rear shock absorber. 5. Installation steps: a. Mount left/right front seat assy. b. Fix nut of left/right front seat assy. 6. Additional warnings and cautions: - Use new split pin - Adjust multimeter to “O” before inspecting circuit 1. **Ignition System Failure Troubleshooting** If the ignition system fails, follow these steps: - Check spark plugs (Step 1) - Inspect main switch and ignition park clearance (Steps 6 & 7) - Verify resistance values of triggering coil, spark plug cap, and charge coil (Steps 2, 3, & 8) 2. **Ignition Spark Clearance Test** - Remove the spark plug cap from the spark plug - Connect a spark testing instrument to the spark plug cap, spark plug, and main switch - Rotate the main switch to "ON" and check the ignition spark clearance - Press down the starting switch to start the engine and adjust the spark clearance until the engine cannot be started 3. **Primary Coil Resistance Check** - Inspect if primary coil resistance conforms to specification (20kΩ at 68°C, 0.43~0.5 Ω) - Connect a multitester to the ignition coil - Verify secondary coil resistance (4.6-7.6 kΩ) **Replace Ignition Coil if not conforming to specification** Incorrect main switch: Replace with correct one. Neutral switch and rear brake switch also need replacement, while handlebar switch correction is okay. Circuit connection check and starting motor inspection are essential. Starting Motor Reverser Not clean: Clean with #600 sand paper. If diameter doesn't conform to specs, change the startig motor. Mica cut sheet measurement: Scrape it with square scraper if not 0.7mm thick. Brush length check: Replace each one if out of spec (10mm). Wear range should be
