Pelemao@yahoo.com 400 Carte Atv 250cc Text

ATV250-11B pkârnce GP? e and welcome to our world-wide family of udly produce an exciting line of utility and recreational BASHAN sets a standard of excellence for all utility and les manufactured in the world today. Many years of experience have the engineering, design, and development of our ATV, making it the finest je we’ve ever produced. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, ATV specifications, and drive safety. Due to this manual you can know necessary skill of ATV driving. Otherwise owners may find out parts you need out of part’s shape, name, coding or composed relationships through this manual, but for our products are in continue developing, can this make some difference between real object Thank you for pure BASHAN owners. products. We recreations and image, please according to real object. IMPORTANT SAFETY INFORMATION Tal THREE. Potential hazard and how to avoid. FOUR control sysiem location of vehicle parts 2power switch 3uleft operation bar A,accelerator controller Saauiliary brake lever G-main brake parking break B,uel cock filter 9.gearshit settings 10instrumeni cluster ‘ontents Index 11. carburetor 12.battery 13. engine cooling system 14. air filter FIVE.OPERATION 1 fuel 2. Engine break-in and lubrication 3 pre-riding inspection 4 starting engine Sire installation SIX. driving safety 1. loaded riding making turns 3.driving on slippery surface 4.Climbing a hill 5. lateral riding 6. down hill riding 7. Turing on slope 8. wade riding S.obstacle riding 10. reverse driving {parking on the slope SEVEN.maintenance and lubrication |. lubrication oil type 2oil check 3.oil changing way and steps 24 24 25 25 27 28 29 29 30 30 31 31 31 32 32 33 33 34 36 36 36 36 4. transitions hai lubrication 3 S.engine cooling system maintenance 6. parts catalogue coding check list 7. brake system maintenance 38 SUR. tre maintenance 38 9.Spark plug maintenance 39 10.Air cleaner maintenance 40 1 Lights 40 12.Battery n Aransportation 42 42 42 43 fault inspection and maintenance a TEN. parameter 45 ELEVEN. electric principle diagram 15 TWELVE. parts eatalogue a7 2. front whee! 48 3. 49 4 a s 51 6 52 7. tsar bridge dismantle 53 sine exploded View a 73 9 paris catalogue coding check list |. a IMPORTANT SAFETY INFORMATION WARNING Improperly riding vehicle may cause sever ‘Always use an approved helmet and prote Never operate an ATV on a publi Never carrying a passeng Never operating the A] ining alcohol or drugs, it may cause hallucination, distraction nd tired situation, disability and result in an accident this product contains chemicals known to cause cancer or other reproducti gine or let it run in an enclosed area. ing to avoid vehicle overtuins on hill and rough terrain, and in turns. wed surfaces, which may adversely affect handling and control, ROHIBITED PROHIBITED: Operate without proper tr PROHIBITED: Operate on public highway. A collision can oecur with another vehicle PROHIBITED: Operate at speed beyond your skills or the conditions. PROHIBIVED: Take ALCOHOL or DRUGS before or while operating this vehicle. PROHIBITED: Carry Passengers PROHIBITED: Drive in tired cont PROHIBITED: Stat the PROHIBITED: Never allow anyone under 16 years of age to operate this ATV. WARNING STICKER Waring tickers shal be placed on left and right side ofthe ATV for your protection Read and follow the instructions ofthe decals onthe ATV carefully. If any ofthe decals depicted inthis manual differs from the decals on ‘Your ATY, always read and follow the instructions ofthe decals on the ATV. The safety alert warning indicates a potential hazard that may eause serious injury or death, The safety alert caution indicates a potential hazard that may cause minor injury or damage tothe vehicle, Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your n or bad spirit or let it run in an enclosed area, owners manual Never operate an ATV without proper instruction. Please tak Never permit a guest to operate the ATV unless the guy training course. Never operate an ATV without wearing an ‘boots, a fong-sleeved shit or jack Never cor Course about ATY. safety alcohol or drugs, ays avoid riding an AT ile operating an ATV. rfaces, including pavillion, driveway’, parking lots, and express way. vel at speed appropriate for the terrain, visibility and operating conditio and your exper Nevera Always che, normal operating condition before operating. Always follow the inspection and mainten: proc: :dules outlined in your owner’s manual oth hands on the handlebars and both feet on the Footrests ofthe ATV during operation. avel slowly with extra caution while operating on unfamiliar terra er operate on excessively rough, slippery or loose terrain, ‘Safe riding gear helmet Your helmet is the most important satey unit of protective gear for riding. A helmet can prevent a severe head injury. Select an approved helmet that meets safety standards in your state. Clothing Always wear clothing suited for riding. Riding ATV requires special protective clothing for comfort and to reduce the chance of inju Always wear long sleeves and long trousers to protect arms and k the best protection, Be alert to changing terrain conditions. Riding trousers with kneepads and a jersey with shoulder pads provide Eye protection Do not depend on sunglasses for proper eye protection. A par of goggle ora helmet ace shield offers the best protection for your eyes. They should be kept clean and be of shatterproof desi Gloves Offroad style gloves with knuckle pads are the best for comfort and protection. ith heels, like motor-cross boots. Boots ‘The best footwear isa pair of stro @know your vehicle As the operator of the vehic Read and understand bbe responsible for your personal safety, the safety of others, and the protection of our environment. anual, which includes valuable information about all aspects of your vehicle, including safe operating n other vehicles, such as motorcycles and cars, A collision or rollover can occur on hills or over obstacles, if you fail to take proper precautions HS much more difficult to operate t e routine maneuvers like tuming, or di ele is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years ol. course that covers all aspects of vehicle safety. You were Safe tain When you purchase your new ATV. your dealer will offer a hands-on safety tai ating procedures. You should review this information on a regular basis. also provided with printed materials that explain safe o ‘This isan off-road vehicle. Be familiar with all the laws and regulations concerning the operation of the ATV in your area. We strongly advise you to strictly follow the recommended maintenance procedure outlined in your owner’s manual. This preventive le are thoroughly inspected at specific intervals. Maintenance program is designed to ensure that all tical components on your veh Operator safety eTRE Loading capacity: INCLUDE DRIVER, LOAD TIRE PRESSURE: FRONT 100KPa REAR, TATALLY 270KG WARNING Improper tire pressure oF ov ease loss of control resulting in se injury or death. @loading Reduce spe loading or carrying tall, off-center, or unsecured loads will increase, losing control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, ght, Be care best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block Lif fids over the side ofthe rack sds (IF HAVE RACK) : FRONT 10KG, REAR 20KG ot tow from rack or bumper „Vehicle damage or tip over may <: Do se severe injury oF death. Tow only from tow hooks or bitch @Air cleaning filter WARNING Operation of this vehiel: without the air filter elem Clean pre-filter element often, more frequently cleaning required in dusty conditions. Do not operate vehicle before cleaning. Operation ofthis vehicle without engine breather filter(s) can cause engine damage. Consult owner's manual or dealer for details. nt will severely damage the engine. DRIVING ATTENTION: Never operate on hills oo steep for the ATV or for your abilities Practice on smaller hills before larger hill ills, Check the terrain carefully before ascending a hill. Never climb hills with excessively s. Never go over the top 13 follow proper procedures for limbi slippery of lose surfaces. Keep your weight forward. Never open the throttle suddenly or make sudden gear chang fa hill at high speed. ways follow proper procedures for se e downhill and for braking on hills. Check the terrain carefully before you ride down a hill. Keep ever go down ah speed. ‘down a hill at an angle, which would cause the vehicle to lean sharply “weight backward. Never zo di igh sp al P side, Travel straight down the hill when possible. follow proper proce Avoid hills with excessively slippery or loose surfaces. Keep your weight to Hill until you've mastered (on level ground) the turning skill outlined Gil or roll backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing the special procedure for braking described in this manual. Always dismount on the uph aight uphill. Turn the ATV around and remount following the procedure described in this manual. large obstacles, such as rocks or fallen trees. Always follow proper procedures when skidding or sliding. On slippery surfaces like ice, travel slowly with extra caution to reduce the chance of skidding or ting the ATV through deep or fast-flowing water. IT's unavoidable, travel slowly, balance your weight carefully, avoid sudden ents, and maintain a slow and steady forward motion, Don not make sudden turns of stops. and do not make sudden throttle changes. cheek for obstacles or people behind the ATV before operating in reverse. When its safe to proceed in reverse, move slowly and avoid at sharp angles. Instruction to using brake rakes may have reduced stopping ability: Always check the brakes after leaving water. I necessary apply them several times to et on dry out the pads. speed when carrying cargo or pulling a trailer. Based on manual allow a greater distance for braking. ton Attention concerned forthe safety of our customers and for the general public, Therefore, we strongly recommend that consumers do not install ATV any equipment that may inerease the speed or power of the vehicle, or make any other modifications to the vehicle for these Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury. warranty on your ATV is terminated if any equipment has been added to the vehicle. or if any modifications have been made to the : The addition of certain accessories, including (but not limited to) mowers, blades, tres, sprayers, or large racks, may change the handling characteristics of the vehicle. Adopt only approved access Effect on the vehicle. ‘company, and familiarize yourself with their function and POTENTIAL HAZARD and HO! WARNING POTENTIAL HAZARD: Oj THE HAZARD without following instruction realy increased ifthe operator does not know how to operate the ATV properly in different situations and on THE HAZARD f and inexperienced operators should complete the certified training course offered by dealer. Operators should regularly practice Teamed in the course and the operating skill described in the owner's manual. WARNING POTENTIAL HAZARD: Carrying a passenger on an ATV, WHAT CAN HAPPEN Carrying a passenger greatly reduces the operators ability to balance operator and/or passenger. HOW TO AVOID THE HAZAR Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is mot în For carrying passengers. control the ATV, which could cause an accident and injury to the: WARNING POTENTIAL HAZARD: Failure to follow the age recommendations for this ATV. RISK 6. injury and/or death could occur if a child under thy ge recommendation operates an ATV. Even though a child may be recommended age group for operating so sue may not have the skills abilities, or judgment needed to operate an ATV Id collide with another vehicle. TO AVOID THE HAZARD ‘operate the ATV on any public tect, road or highway, including dir and gravel roads, In many areas and countries îts illegal to ‘ATVs on public street, roads and highways. ING HAZARD: Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. AT CAN HAPPEN ire are designed fr off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could în loss of control, accident, nd /or injury. 'TO AVOID THE HAZARD operating the ATV on pavement. If is unavoidable, travel slowly and avoid sudden turns or stops. is ATV without wearing an approved helmet, eye protection and protective clothing, WHAT CAN HAPPEN Operating an ATV without an approved helmetincreases the severe head injury or death i without eye protection could result i the event ofan accident, Operating nce of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet erly. Always wear eye protection (goggles or face shield). gloves, boots, long-sleeved jacket, and long pants. WARNING POTENTIAL erating the ATV after consuming alcohol or drugs. jgment, Reaction fon could be affected. IT could result in an accident severe injury or death, may be slower and operator balance and HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while opera WARNING POTENTIAL HAZARD: Operating the ATV at excessive speeds, WHAT CAN HAPPEN Excessive speed increases the operators chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that's proper forthe terrain, visibility ‘operating conditions, and your experi WARNING POTENTIAL HAZARD: Attempting wheelies, jumps and other stunts CAN HAPPEN ‘stunts increases the chance of an accident, in în overturn. AVOID THE HAZARD he ATV before operating eases the possibility of an accident or equipment damage |AVOID THE HAZARD inspect your ATV especially ensure fastener nuts tightness ol mportant parts before sure it's in safe operating ING IAL HAZARD: Removing hands from the handlebars or Feet from the footrests during operation. CAN HAPPEN even one hand or fot can reduce ability to contra the vehicle or eoul cause loss of balance and ejection from the ATY. the foot isnot firmly planted on te footrest, it could come into contact withthe rear wheels and lad to accident or injury AVOID THE HAZARD keep both hands on the handiebars and both feet on the footrests of the ATV duri peration. L HAZARD: Failure to use extra e CAN HAPPEN tion when operating the ATV on unfamiliar terrain, nilar terrain may contain hidden rocks, bumps, or hol ‘cause loss of control or overturn and lead to accident or injury, HOW TO AVOID THE HAZARD Travel slowly and use extra caution when op În familiar terrain, always be ert to changing terrain cond WARNING POTENTIAL HAZARD: Failure to use extra ca erating on excessively ro slippery or loose terrain. vely rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an aceident TO AVOID THE HAZARD o not operate on excessively rough, slippery or loose terrain until you're learned and practiced the skills necessary to control the ATV such terrain, WARNING POTENTIAL HAZARD: Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting 10 Faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD: Operating on excessively steep hills -10- \ le WHAT CAN HAPPEN ‘The vehicle may overtum. HOWTO AVOID THE HAZARD Never operate on hills too steep for the AJ our abilities Never operate the ATV on hills jan 20° + Practice on smaller hills before attempting large hills. imbing hills improperly. II climbing could cause loss of control or overturn, TO AVOID THE HAZARD ‘Always follow proper procedures for climbing hills as described in the owner's manual. ‘Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 20° Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill, WARNING POTENTIAL HAZARD: ‘Traveling downhill improperly WHAT CAN HAPPEN Improperiy descending a il could cause loss of contol or overturn and lad to injury or death HOW TO AVOID THE HAZARD A special technique is required when braking while traveling downhill 1 Always check the terrain carefully before descending a hill. Shit it backward. Never travel down a hill at high speed, Avoid traveling down a hill at an angle, which woul hiele to lean sharply to one side. Travel straight down the hill when possible. WARNING POTENTIAL HAZARD: Improper! pills and turning on WHAT CAN HAPPEN Improperly crossing ills could cause loss of control or overtum and lead to injury or death HAZARD im the ATV around on any hill until you've ‘uring on any hill. Avoid crossing the side of a ills with excessively slippery or loose surfaces. astered the turning technique as described in the owner's manual. Use extra WARNING POTENTIAL HAZARD: Stalling, rolling backwards of improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could cause loss of control or overtum and k jury or death HOW TO AVOID THE HAZARD Keep steady speed when climbing a hill. Ifa forward speed is lost, keep your wei IFATY begins rolling backwards, apply the brakes, Lock the parking brake when fully stopped. ' rolling backwards, keep weight uphill: never apply eng -lever brake gradually. 2155 Dismount on uphill side, or to either side iC ATV is point hil “Turn the ATV around and remount. WARNING POTENTIAL HAZARD: Improperly 0 + obstacles. WHAT CAN HAPPEN Operating over obs se loss of control or overtum and lead to injury or death. în a unfamiliar area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees if possible, If caution and always follow proper procedures as outlined in the owner's manual. POTENTIAL HAZARD: Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control. Ifthe tires regain traction unexpectedly, the ATV could overturn, ing e HOW TO AVOID THE HAZARD ‘Avoid skidding or sliding, on slippery of control, faces such as ice, travel slowly and take extra caution to reduce the chance of skidding or sliding out WARNING POTENTIAL HAZARD: Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury. .43- HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for E behind the ATV. When it's safe to proceed, back slowly. WARNING POTENTIAL HAZARD: Operating thy ‘deep or fast-flowing water. WHAT CAN HAPPEN: Tires may float, eausing Fon and loss of control, which could lead to an accident or overturn. HOWTO. RD (CATV through deep or fast-flowing water. If its unavoidable to enter M valance your weight carefully, avoid sudden movements, and maintain a slow and steady forward Hops, and do not make sudden throtle changes. Wet brakes may have reduced stopping ability. Always test the brakes after leav Fr. If necessary, apply them several times to let friction dry out the pads. + water that exceeds the recommended maximum depth jon, Do not make sudden Avoid WARNING POTENTIAL HAZARD: Operating this ATV with improper tres, oF with improper or uneven tie pressure WHAT CAN HAPPEN It could cause loss of control or accident and result ion of the ATV with pressure. HOW TO AVOID THE HAZARD ‘Always adopt size and type ofthe tires specified for the ATV. Always maintain proper tire pressure as spe WARNING POTENTIAL HAZARD: Operating the ATV with improper modific WHAT CAN HAPPEN -14- lation of accessories or modification ofthe, Improper ins injury or death. HOW TO AVOID THE HAZARD: Never modify the ATV through imprope ‘company or equivalent compones loading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Never carry passengers. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking, Always follow the instructions in the owners manual for carrying cargo or pulling a trailer. WARNING POTENTIAL HAZARD: Operating on frozen bodies of water, Severe injury or death can happen if the ATV and/or the operator fall through the ice for loss of control HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water, -15- CONTROLS @ Location Shifing Lever Seat 13 | brate ped Front Light E IEI mi Cop © | Parking A | Front Shock Absorbs 7 [Re 19 | Seat Pe 20 [Front Wheel Shook Absorber [20 [ Mumer Rear Fender 32 | Front Taming Lig 11 | Rear Wheel [23 [ear ru wine ‘Clutch Lever | Ș @Main Switch Main switch is located on the right side of the vel There are ON * “and OFF) on the sy ‘Turn the key 10 3 , main switch is turned Tur the key to... the engine can be st ine can not be started, The key can be removed. switch is tumed on, and the key ean not be removed. WARNING a Leaving the keys i Can lead to unauthorized use ofthe vehicle , resulting in se death. Always remove the ignition key when the emove the spare key and store it in a safe place. both keys Jn must be replaced. & s/ 2 Press the emergency switch to start the engine: press again to stop the engine. The purpose is to provide operator with a quick means of engine shutdown in case of an emergency. Parking Brake Lever Stop e parking brake. i sete Pll the park brake lever left to engage the brake = Push the brake lever forward to release the rear Pe 8 wheel. Fi E Main Switch — To stat the engine, turn the stop switch and m [ee Switch on the position. Squeeze the clutch lever = by fet hand, and step the brake pedal by right foot DESI Release the key when the engine stars. - A7- WARN The parking brake may relax if left on \A ited again in 10 seconds when releasing the key. result in an accident and serious injury or death. Always check to be sure the e. Always block the wheels to prevent rolling. @ Accelerator controller Throttle controls is ly Throttle Lever right side of handlebar. e movement are co fs spring loaded. En olled by pressing the throttle lever ne speed returns to idle wh the lever is released, tightening nut, twist the adjust screw 2) to control the maximum speed. Twist the nut anticlockwise to increase the speed, and ickwise to decrease the speed. Tighten the tightening nut when adjust the speed, WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle, Always contact your dealer for service if throttle problems Failure to check or maintain proper operation ofthe throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and retum before starting the engine. Also check ‘occasionally during operation. @ auxiliary Brake Lever ixiliary brake is applied by squeezing the brake lever toward the handlebar It only acts on -18- te font wheels Your ATV has an auxiliary brake for ad safety. Woe brake serves asa backup tothe main brake syste "brake, reduce brake lever pressure to brake e right side of handlebar and is operated by the right hand. The auxiliar in system becomes inoperative. Ifthe rear wheels slide while using the auxiliary els without skidding, CAUTION: rating the ATV with a spongy brake lever or low brake fluid level can result in loss of braking, which could cause an accident. “Take caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The front wheels may skid and slide sideways, causing loss of control and serious injury or death, ‘Agaressively applying the auxiliary brake when driving down a hill may cause rear tip over, wl serious injury or death. After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, ‘meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to h could resul carly brake fade andthe possiblity of accident or severe injury Main Brake [i “The front and rear brakes are applied by pressing the brake pedal by right foot. The front and rear brakes are hydraulically activated dise type mp Î Miâmtamoniva nb enepea, The math tek minele land asin bee ame Brake Fluid Level ‘Check the brake fluid level frequently for the brake system. The reservoir is located under the se he auniliary brake. Maintain the fluid level between the maximum and minimum marks. -19- CAUTION: ‘Always inspect the brake pedal, Lubricate the Funct e vehicle only can be driven when the broken or deformed brake pedal is maintained or replaced. Always test brake pedal travel and mas level before riding When pressed, the pedal should f Any sponginess would indicat uid leak or low master cylinder Muid level, which must be corrected before riding. Contact your dealer for proper diagnos) A Always check dise and dise brake pump replace the bro aks or broken before riding, Contact your dealer or authorized maintenance to loss of braking, which could cause an accident ng the ATV with a spongy brake pedal can result in loss of braking, which could cause an accident perating the ATV with leak dise brake tube or disc brake pump can result in no braking, which could cause an accident @ parking brake The parking brake is applied by pulling the parking brake lever. The parking brake lever Is located on the right handlebar. = To set the parking brake, place the transmission in park, and stop the engine. Parking braid Pull the parking brake lever backward to the handlebar. now its in parking term. TE the parking brake, push the lever back to it unlocked position. To relea CAUTION: The parking brake may relax ile on for a long period of time. Always block the wheets to prevent rolling. Always block the wheel onthe downhill sie ofthe ATV if eaving if parked on a hill Another option sto park the ATV în a side hill position Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling. WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death -20- ‘@F ue! Valve, Fuel Filter ed by your dealer after every y. Do ot attempt to cl he fuel filter. o shif into reverse gear, you must first apply the gear to N., then tum reverse control switch clockwisely, meanwhile press forward the gear shifting pedal. To shift out reverse gear, tick backward only. CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. Whenever the ATV is left unattended, always place the transmission in N and lock the parking brake and steering lock, To extend power, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time. E instrument cluster Instrument cluster (if there is) is the rider's information center. ‘The instrument cluster works while getting through the power of the instrument cluster. The information and function of the instrument cluster isa bellows: indicator. tumin lamp high-Light indicator © indicator light, neutral gear -21- ‘indicator light, reverse gear Sifuel-reminding lamp (indicator light.right tuning lamp speed indicator WWrev indicator mode switeh (12) emergeney la SEL A won) (13) Metric/Mj Caution: Carburetor is a precision instrument; please do not dismantle it without professional knowled; Please check the i Wthere is n in carburetor, please ask for clearance in the professional maintenanceshop or dealer. Please check if there is oil leaking before riding, if there is, please repair before riding. Didle adjusting serew Daraining oil screw idle adjustment | the engine and warm the eylinder up to 95 Put the en hometer to the engine, or with a remoter. Turing the idle adjusting serew with timing w: With the betraying the timing way could redus when the tachometer fh can enla the idle, en 1400r/min and 16007 min, please stops. idle, Turning the serew ales beta Caution The best proper way oi zine idle adjustment must be taken under ceai Do not attempt to adjust the idle in oth -22- mperature system: you can adjust it in professional maintenance shop or d der shop, e battery Caution Blectrolyte is poisonous, please do not dispose, Please take off the battery ifthe vehicle w {if you want to keep the battery in the ve the battery, do not have cathode Ifthe electrolytes touch yo fand treat it according to the or local environment regulations. r a long time, after full of charging, put it in dry circumstance. should disconnect the wires with the anode of the battery, and then disconnect the anode of E contacted the metal in order to avoid short circuit ol can wash it with water. please wash it at once no less than 15 minutes and then ask for the doctorhelp. Nou drink careless, you can drink much of water or milk and ask the doctorhelp at once h. Before putting the battery into box, please cut the cathode firstly and then the anode. ir away of the spark, Mame and cigarette , because battery can disperse poisonous gas. Please make sure there is ventilation if use the Mery in a closed environme e a explosion to dead, i “The electrolyte isin battery, it could cause serious di touch the skin or eyes. Danode 2 cathode al @ Engine cooling system This engine is air and Water coolin Is related to the normal work and useful life ofthe engine, you should chose the re ne. If the Water cooler works smoothly sdcoolant in certain areas and environment, cooler is on the front of Caution Keep regularly check the water cooler if there is dust in, if yes, pl Please check if the Water cooler fan works smoothly before riding, ifthe 2 e wash it at once, n breaks, please replace if ater cooler) fan @Air filter Clean the air filter every 30 days at least, if it works under the damp or dusty environment, please wash it more frequently Cleaning process. -23- DD 33 Remove air filter from frame of vehicle Drain the dust or sediment out of the intake valve by hi Fit the air filter by the way of negative direction of w re ir current Caution Do not wash the filter element with e filter clement is made of paper, mpregnant is explosive, o er impregnant because th ind of petrol or the e an explosion or fire the ar fite, oF i could accelerate the abrasion Out a breather iter can cause engine damage ther filter afer removing for service. ie ne eck the intact of the air filter and maintenance or replact broken Caution: Please use unleaded gasoline no less than 924. Gasoline is highly flammable and explosive under certain conditions. Always with extreme caution whenever handling gasoline, Always refuel with the engine stopped, and outdoors or in a well ventilated area, Do not smoke or allow flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck, If gasoline spills on your skin or clothing wash it immediately with soap and water and change clothing, Turn the fuel valve off whenever the ATV is stored or parked. Warning Never refuel în a close environment. It may cause injury to body by the steam volailized by gasoline -24- break-in period for your new ATV is deff aline. No single action on your p ent brands or non-recommended oil may cause seriou’ engine damage. We recommend the use fnium synthetic Oil or another SAEISW/40-SE, or SE, SF, SC certified SH oil. Never substitute or mix oil brands. X the oil reservoir level on the dipstick Add oil if necessary to maintain the level between the safe n open area that allows room to familiarize yourself with vehicle operation Perform regular checks on fluid levels, during the break-in period; change both the oil and the filter at 20 “hours, 200 miles, or one month, whichever comes first? jury or accident of death if there is lack of proper inspeciton, Make sure the vehicle is under the good condition for riding. Inspecting Items for pre-riding -25- WARNING în proper operating condition. {fa proper inspection is not done before each use, severe i ‘could result. Always inspect the vehicle before each use to ensure its nem Remark Item Remark [Ensure proper operation Frame nuts, bolts, fasteners Inspect, ensure each nuts and ols tightness: [Ensure proper level applicable) Fuel and oii Ensure proper levels ‘ular brake Ensure proper operation( applicable) | Coolant evel if applicable) | Ensure proper level applicable) Front suspension inspect, ubicate if necessary Coolant hoses (if applicable)| Ensure operation Rear suspension inspec, ubricate itnecessary Indicator ights/sitch Ensure operation Steering Ensure tee operation Engine stop switch Ensure operation Tres inspect condition and pressure Ai fier, pre-fiter Inspect, lean Wheels rim fasteners Inspect, ensure fastener tightness Air box sediment tube Drain deposits whenever visibi} Headlight [Check normal or not Brake lighttail ight Check normal or not Riding gear | Wear helmet, goggles, protective clothing] -26- the Engine the Cold Engine the ignit pull the choke knob out until engin stats. ‘engine slows or stops, place the cl If way in to allow proper engine warm-up. ‘warm-up. When the engine idles smoothly. push the choke completely is fully on when the knob is pulled completely out. The choke is off when the knob is pushed complete ‘gradually, depending on how much choke is needed for starting, Be sure the choke is off during operation, as excess e engine oil will speed up wearing on engine components. the starter for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, release the starter ‘wait five seconds. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine stars. ING “Run the vehicle immediately after stating could cause engine damage. Allow the engi „es before operating the to warm up for several WARNING “Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe jury or death. ‘Starting a Warm Engine engine do not normally require the use ofthe choke. Using the choke can cause the spark plug fo become wet fouled the vehicle on a level surface with the transmission in PARK. 2.Lock the parking brake, turn the fuel tank valve on, sit on the vehicle, turn the engine stop switch to RUN. the engine has cooled toa point where it does not readily start, pull the choke continously (knob pulled half way out) may be necessary. the engine is over-choked when heating, depress the throttle lever fully while cranking to aid in stating. the throtl lever immediatly after the engine starts. Ifthe engine does not start and all conditions are favorable, change the spark and try again, -27- If the ATV is used year-round, check the oil level frequently. A risi or excess fuel on the bottom of the oil tank, Water on the bot e Wheel installation cate the accumulation of cont :cumulation increases as outside temperature decreases. nts such as water comfortable and prolong, and adjust it when Proper tre pressure can make the pressure (Kpa) Front wheel 100 | Rear wheel 100 the using time. Often check mays tire size 21X7-10 20 10-9 Caution Check gh re before riding, and make sure if there is no cut, nail or other stiff things on the tie. c îs sunken, transformed or needing replaced. sure that all nuts are tighten before dri Jays replace tires when tread depth is worn to 1/8" (3 com) or less, Warning Do not repair the broken tire, or the balance and stability would be influenced and it may lea overturn Less of tire stability and cause the hidden trouble, e.g. ifthe tire e ‘out of tire, even itis possible to loss control and cause death, Overcharging of air also can cause danger, because it affects the friction and operation. -28- not hold the ground tightly and cause the rim Driving Safely ‘Hauling Cargo "ATV has been designed to cary or tow g int of load. Always read and understand the load distribution warning labels on the 4 în the specifications section of the owner's manual and on the safety decals. the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating ions. Do not obstruct the headlight beam with sured loads can create unstable operating conditions, which could result in loss of control of the vehicle. ERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling ff-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load othe hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. ‘Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill E EXTREME CAUTION ‘operating with loads that extend over the rack sides. Stability and maneuverability may be adversely causing the vehicle to overturn. not block the front headlight beam when earrying load on the front rack. ot travel faster than the recommended speeds. e should never exceed 10 mph (16kph) while towing a load on a level grass surface. Vehicle speed should never exceed $ mph (8kph) en towing lads in rough terrain. while comering, or while ascending or descending a hill. Warning! -29- Improper loading on your ATV can make you lose the control of Never carry cargo when no rear carrier or box are equipped jg d e steady of break, and lead to injury or death wise accident will happen even cause injury or death to rider. Making Turns Not Your ATV is equipped with a solid n ich drives both rear wheels equally at all times. The wheel on the outside of the turn travels a ‘greater distance than the inside wl turning, and the inside tire slips traction slightly, To turn, steer in the direction of the tum, leaning. le supporting your weight on the outer footpad. This technique alters the balance of traction turn to be made smoothly. The same leaning technique should be used for tuning in reverse ng on slippery surfaces such as wet trails or loose gravel, or during freez 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting you weight forward. 4. Ifyou use AWD (if there is) when rear wheels still work, it may destroy the drive axle, Do not use AWD until rear wheels stopped or lose, of traction, ‘weather, follow these precautions: Warning: e Failure to exercise care when operation on slippery surfaces can result în loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on exces especially when downshifting ly slippery surfaces. Always reduce speed and use additional caution, -30- uphill steep hills(20 maximum) in hilly tera. Improper procedure could cause loss of control or overturn and fous injury or de se loss of control or overturn when operating on hill more than 20° n when operating on hills, and follow all procedures outlined în the owner's manual oid erossing the side ofa hill when possible. Follow proper procedures as outlined in the owners manual. enter into a situation where side hilling is unavoidable: the hill, transferring your upper body weight toward the hill while keeping your feet on the footplates. 3, Steer slightly into the hill o maintain vehicle direction, Ifthe vehicle begins to tip, quickly tum the front wheels downhill, if possible, or dismount on the uphill side immediately! ring! perly crossing hills or tuming on hills can result in loss of control or Vehicle overturn, resulting in severe injury or death ing downhill descending a hill follow these precautions: 1. Proceed directly downhill -31- 2. Transfer your weight tothe rear ofthe vehicle. 3. Slow down 4. Shift to the lowest gear possible while maintaining. 5. Apply the foot brake slightly to aid in slowing. Wamir Excessive speed can cause loss of lead to serious injury or death. Always operate slowly when traveling down e Tuming around on a Avoid climbing maximum) ‘operating on hills, and follow proper operation procedures outlined in the owner's manual. bile climbing a bill, never back it down the hill! lock the parking brake, and keep your body weight uphill. he transmission in gear. Dismount on the uphill sie ofthe vehicle or on the lft si Keep ATV uphill, and tum the handlebar to ful eft. With the front brakes applied, pull n the clutch lever. Use the brakes to slowly allow the ve across the hill o slightly downward Lock the parking brake, and restart from the direction of uphill; keep your body weight uphill. Restart the engine with the working transmission system. Release the parking brake and control the speed with hand brake until ATV reach smooth place. WARNING: Improper hill limbing procedures could cause loss of control or overturn and result in serious injury or death eDrving through water Note: Your ATV ean operate through water with a maximum recommended depth equal to he level of the footag. Follow these procedures when operating through water: 1. Check water depths and current before crossing. ifthe vehicle is point strait uphill, +10 roll around to your right until its pointing -32- Choose a crossing road where both banks have gradual Proceed slowly, avoiding rocks and obstacles “After crossing. dry i 1o the lever until braking action is normal "Avoid operating the vehicle through dee ig water. IF you cannot avoid water that exceeds the recommended maximum depth, en movements, and maintain a slow and steady forward motion. Do not make sudden Ahead and learn to read the terrain you're traveli on. Be constantly alert for hazards such as logs, rocks and low hanging branches ing! injury or death can result i caution in unfamiliar terrain. comes in contact with a hidden obstacle, Not all obstacles are immediately visible. Travel riving in Reverse low these precautions when operating in reverse: Avoid move downhill in reverse yer. Move back slowly. Apply the brakes lightly for stopping. void turning at sharp angles; never open the throttle suddenly while backing -33- injury or death, Before shifting into reverse, always check for Failure to use caution when operating in reverse can ‘or people behind the vehicle. (parking on slope Avoid parking onan slope if possi avoidable, follow these precautions: “Turn the engine off place s¥ion in first gear, lock the parking brake, always block the rear wheels on the down hill si illustration, Turn the fuel val possible, IF it's unavoidable, follow these precautions: place the transmission in first gear, lock the parking brake, always block the rear wheels on the down hill side. @ CHAIN ADJUSTING STEPS 1-To have the engine been at neutral; 2.To fetch a bolt with M10 X 1.25%50 ats 3.Pushing the ATV back and for to make one of the & 12 hole into the serew thread hole of M10% 1.25 (The middle serew thread hole should be beer) the rear bridge shelf she the sketch map of rear bridge Shell and boz sprocket); 4.10 loosen the two bolts OF MBX 100 and bolts of MB inthe fork cli 510 get through the & 12 hole and set it tightly inthe serew tread hole (M10 1.25)with bolt of MIO 1.25 50; ‘6.pushing the ATV back and fro to adjust the ct 7.To fetch out the bolt of MIO, 1.25% 50; 8.To tighten the two bolts of MB_ 100 and bolts of M8 în the fork clip. a ROGET sea -34- riodic Maintenance Chart Inspect, clear, lubricate, adjust and replace parts as acement parts, use our genuine parts available from your dealer Inspect leaking [in| 3 | coo pt te | ‘spark pus 1 200 | _nwpsxt, clean ot | 200 mea | = | caectrestae | cil — | cask rede | -35- e Maintenance and Lubrication e Lubrication Recommendations 4 AII Season synthetic engine oil of our company has Its a fully synthetic, high performance, mul i also can use the lubrication oil with the SH cer ly formulated for use in 4-eyele engines the SW-1SW/40, though itis recommended only forthe use in engine. CAUTION! Mixing brands or using a non ‘il may cause serious engine damage. @Engine oil Level ‘The dipstick( Dg Start the the right side of the e le for 20 to 30 seconds ind remove the dipstick. Wipe it dry with a clean cloth ‘dipstick completely. The dipstick must be screwed completely to keep the angle and depth of the stick consistent. e the dipstick and check the oil level Maintain the oil level between the full and add marks. Do not overfill ine If the ATV is used year-round, check the oil level frequently. A rising oil level could indic: or excess fuel in the bottom ofthe oil tank. Please replace immediatel :the accumulation of contaminates such as water the oil level is under the limits, @oil change Position the vehicle on a level surfaces Clean the area around the oil tank and crankease Run the engine fortwo to three minutes until warm, then stop the engine. Place a drain pan beneath the oll tank and remove the drain plug, allow the oi to drain completely Reinstall dhe drain plug and infuse 1 Lot kerosene from dipstick. Run the engine for 20 to 30 seconds, then tum off and drain = ‘Ada fresh standard lubrication il about 1.0L, -36- Chain and sprocket wheel atthe same time when they have been worn deeply. ‘of lubrication oil may accelerate the abrasion between chain and sprocket and then separated, it may cause loss of control and result în injury or death. “The chain ack ofthe lubrication will accelerate the abrasion between chain and chain wheels, cause severe injury and death “ ooling System Maintenance. he engine cooling system plays an important roe inthe cooling system. model of vehicle is liquid-cooling.and air cooling. ION: quently inspect the surface ofthe oil-cooler, please clean with water if there îs dust, but not with too high-pressure water. Because it may the radiator out of shape the fans of the oil-cooled before operating, please replace if needed . insufficiency of the machine oil will cause the adverse performance of the radiator, thus frequently inspect and complement when need. RNING. broken radiator and connecting hose may cause a great damage on the engine, please inspect pre-ride. -37- ©The maintenance of braking system. nance is very important Ve foot brake pedal. Both brakes are self-adjusting. the following. CAUTION: Never store or boiling and dripping, cause the Chu copie and will immediately absorb the aquosity in the air, the moisture will make the brake brake system. Desert a part of the useless after opening a bottle of brake flu jure and death. Please keep. Severe injury or death can result from riding ATV under the condition of without brake, or inferior brake performance (@THE MAINTENANCE OF F&R WHEELS. CAUTION. eep proper tre pressure as described on the ATV decal and în the owner's manual, Make sure the wheels are installed properly Always replace tires when tread depth is worn to<<3mm, The F&R wheel nuts is the Key parts in the vehicle, please do not dismantle or install yourself ‘Tre pressure should be check before you ride while the tres are cold, ch Check the rims for dents or deformation, Do not attempt to patch a damaged tire or Improper ti veck the tires for cuts, embedded nails, or other sharp objects. balance and tyre reliability may be impaired inflation will cause abnormal tread wear and create a safety hazard -38- tices or improperly installed tires will affect vehicle operating and A vehicle handling, which can result in serious injury or death, Never install the us are torqued to specification. ing în the toolkit. ‘and center for deposits, erosion or carbon fouling, ifthe erosion or deposit is heavy, replace the plug. Clean a carbon or wet- with a plug cleaner, or use a wire brush. plug in the reverse order of removal, please use recommended plug, max torque îs 24N.m insulator tip is grey, tan oF light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates type and heat range for the engine and the service. A white insulator tip indicates overheating, caused by use of an improper spark plug carburetion adjustments fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the are not worn, General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect adjustment. ommended spark plugs may result in serious engine damage protective gloves when removing a spark plug for inspection to avoid the serious burns caused from the hot exhaust system and engine -39- @Air cleaner maintenance ‘The air cleaner should be cleaned at least once every 30-day's dri e more frequently when riding in unusually wet or dusty areas, Ur and remove the seat, release the two airbox cover clip. Wash the filter element in clean, nonflammable o hi it solvent and let it dry Reinstall the air cleaner in the reverse order of rer Caution Never use gasoline or low. ‘solvents for cleaning the filter element, otherwise. a fire or explosion could result. is forbidden to start without the air cleaner core. or premature wear of the piston and cylinder may produce, _ Make sure the air e is intact. please replace if needed. Please replac aner when it cannot be cleaned with high-pressured current. @Lights a halogen lamp, don't touch the lamp with bare fingers. Oil residue of your handwill cause a hot spot that Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during ni operation. Wash the Headlights frequently to maintain lighting quality Hot components can cause serious burns to skin. Do not service the headlamps until they ve cooled sufficiently. -40- ling a new battery, make sure its Fully cl to its initial use. Using a new battery that has not been fully charged can battery and result in a shorter life tt er vehicle performance. vehicle is placed in storage fo mths or more, the battery should be removed and stored in dark . cool, dry place. Test and battery will register 12.8 V or higher. sitery, it can ruin a battery because of the minerals in it. Only fil distilled water as plain water. vification below when use DC charging battery condition before and 1-2 hours after charging. Sate of Charge | Voge Action ‘Charge time battery could explode, causing or death. Always watch charging lly. 100% 123130% ing if the battery becomes very warm None, check No require from date of n iad May need slight charge, 125128 if no charge given, check| 3.6 hours în 3 months ‘Allow i to coo! before resuming ‘connecting or disconnecting battery result in an explosion and cause 5% 75% 12012; Needs charge 5-1 hours jury oF death, When removing a disconnect the negative (black) 5 isi20v Needs charge eee When reinstalling the battery, always veri state of charge negative cable last. US woltsorles Needs charge Atleast 20 hours -41- Cleaning, Storage and Transportation of the vg Cleaning Keep your vehicle clean will not only improve its ap so it can also extend the life of various components. The best and safest way to clean the vehicle caning the upper body fen hose and a pail of mild soap and water. Use a professional -type washing cloth, 1, Rinse with clean water frequently. Dry surfaces with a chamois to prevent water spots. Ifa high pressure water sy following items: Tr for cleaning (not recommended), exercise extreme caution. Avoid directing the water stream at the ‘Cab and body panels, Brakes and Labels and Decals. 0 run for a w fitting immediately after washing. Allow the er to evaporate any water that may have entered the engine Avoid the use of automotive products, some of which can scratch the finish of your vehicle. WARNING: Certain products, including insect repellents and chemicals, will damage plastic surface. Do not allow these types of products to contact the vehi STORAGE When the vehicle will be in long period of storage, do the procedure as following, e with clean water, towel surfaces to prevent water spot and recline it for several hours. Drain cut all gasoline in the fuel tank, and daub antirust on the interior of fuel tank. Unserew the oil nail and drain out of gasoline in the carburetor, and then serew 4 Tal oil nail tightly. - 18 of the spark plug, infusing about 10ml engine oil inthe cylinder, electrically start the engine, the engine oil will come into the piston linder. ring and form a protective membrane inthe ci Inspect and clean of replace the pre-cleaner and air filter, Clean the air box and drain the sediment tube. Inspect the following fluid level and change if necessary: front and rear gear cases: transmission and brake fluid (change every two years oF as -42- ted. al cables and lubricate. Follow bri ly support the ATV with the tires 30-40mm off the ground. Be sure the storage area is well ventilated, and cover ine ATV cov Fase plastic or coated material, They do not allow enough ventilation to prevent condensat ion, sure clean the fuel tank with gasoline and refill the fresh gasoline while restoring the vehicle. ‘make sure recharge the battery before installing the battery lubrication of all movement parts when restoring the vehicle. Lubricate if necessary. you start to use vehicle after a long period of storage, eliminate any lubri ing engine with kerosene. 1 and may promote corrosion and remaining in the engine, then to lubricate again after hice. ing the ATV these procedures when transporting the vehicle fff the engine and remove the key to prevent loss during transporting. the transmission in PARK and lock the park brake. the fuel valve off and be sure the fuel cap, oil eap and seat are installed securely. tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie strap to the front swing-arms -43- @ TROUBLE SHOOTING Sec your dealer, or go to a professional repair shop wisengot leis out of work. Also you may solve some simple problems yourself. according to the solution below. Weorrect spark Set gap to specs or Liei Less ret AL _sepince plugs ‘Outi Refit li Sica Ts Ser oma pee 2 signees io Water prevent ta fuel [Weoiace with-new tot] § $l ctacueenitcivoaine Tepe len an eps ie er es 12.5 VDC -enganeer malfunction See your dealer or go ta repair shop Tated oF pTWRECE TVET | aspect ana rep vent Line. a worm of electric apparatus Replace Seer Tepiace oF rccomended fuel coerce lire See our deo pon pa sep Trspect and STEI OP -44- ing! hot exhaust system and engine can cause serious “sait for engineer and exhaust system cooling to room temperature for îdintor fins and reduce cooling efficiency. Specifications Electronical parameters mm Batery 12V dA mm Breakiailor light 12V 14W05W mm Neutral indicator Rv mm Fuse 15A mm Structure Engine type model Single cylinders, ke water-cooling, four stroke. kg Cylinder capacity Domi ‘Cylinder diameter» Joumey 67mm*65mm m 921 să col WoL 11.2Kw(7000r/min) 27-10 17:67Nm(5500)rmin 20-10-9 Lubrication pressure splash 100 kpa Starting mode electric 100 kpa ‘Clutch mode centifugal-wvet multiple piece chain drive Engine oil SE 15 W/4Olubrication oil spring hydraulic absorber engine transmission rate 3.333 transmission rate 3 gearshift transmission rate frst gear 2.909 second gear 1.867 reverse gear. 1.389 third gear 1.000 fourth gear 2.807 3 scification 9areas front; dise brake rear dise brake -45- Electrical principle diagram romeo ses amen a ma i === fd eke == i ata Severs want more FETE = etanse AI Ete moraconconn amas FE _ SITA EMR PART CATELAG | Pitt Part No. ription SAAB Part name 1 BOT _IEXI6 EX 2 7300-123 LEFT-UP_ SWING ARM LGW 3 GB6187- M10 SE EM0 4 „507, LEFT-DOWN SWING ARM ZE FSE 5 9 BOLT__M6X 20, SME X 20 6 2000 BOLI MOX58 TR IEMLOX 60 E 501300-033_ ‘FRONT SHOCK ABSORBER ies 2000 BOLT M1040 yew 0x 40 804009 001 CONNECTING SUPPORT FRONT BODY fi 4 IEE IR 0 (85787-2000, BOLT_M6X10 SRYENG X10 TI 100001 00.3 PROTECT PLATE, ENGINE Bess 2 311000427 FRAME_ASSY FREER (a3 336100-017 FUOTREST ea EI EST? 2000 or Mox35 ETNICE 15. 536400-013) LEFT PEDAL ETE ac) 16 536003 006_ LEFT FOOTREST SUPPORT Pease a TB/193- 1987 SPRING WASHER 3 3A es 1s (GRSTST 2000 HOLT _WxT6 ET TERTI 19 332000-021 REAR LANP_ASSY rae [306100002 REFLECIOR REAR Ba a SI1100-175 FRAME REAR EI 523100-141 REAR ARM_ASSEMBLY een 301801-001 TIGHT SUPPORT REAR FEN Firat Za GB5787-2000_ BOLT_MS X40, SE AEMS X40 524700 OOL ARM, REAR SHOCK ABSORBER ia RE îi 5230020053 UBER DOOT, REAR ARW Bye ETER CONNECTING. PT 7] i 540300-118 REAR Sie im seit _ | 801803 001 LEFT Supa RAR FENDER TPs E 1 a 130005- 010. TOSI TORSIONAL SPRING 1 CBBIȘT 2000 NT wa | ‘| 230010-001, TENSION PULLEY 1 | | 22006 002 ARM AXLE BUSHING n | 902001 HENANGULAR AXLE i | 130 REAR BRAKE RESET SPRING. n 4 WEAR BRAKE SWITCH SPRING 3 1 a 1.006 RIGHT FUOTREST SUPPORT Pears n — 536500 013 RIGHT_PEDAL n + $30100-035 REAR BRAKE PEDAL 1 + TESTE? 2000 DT wx 12 2 — 6000-008 PROTEC PEDAL 1 5070600117 RIGHT Des STING ARI i B07500-119 RIGHT-UP SWING ARW 1 =| 2100-205 BOWER 1 — ESD Etaz bracket, r/1 turn Tight aes AT OR 1 333701-002 Bracket, r/r turn light CEI HAT SOR 1 805004-009 bracket, rear license plate Bai MA HR d Gb16774 BOLT MR¥16 RHE use 2 333102-007 bracket, £/1 turn light eens 1 333302-007 bracket, 2/1 turn Light ft pi e, |] Gb 16774 BOLT MO=16 si MOwI6 4 LLL itt itt -49- BRAC Part ve. Donsrigs fo ir eee Ra mantia TOTO oo ra) Taleo cat Ty Tare i esa Sa aaa i noo 01 (wom Fe EI 2 200 Ea at i ini 00015 INLET IU mea i sa ae Bat ai it = i fae TARO TOR AS Te i ERIE TEC AS BE Ei Ra —— — iz 23 Storr ae ete x 25 x îi ro = SERE t a Fae i ata i i iza = o a nai n aa ce TATE a + mere Toe ana abies fe ‘6100-001 RATTERY ASS a i Ea Va ini a iti cai RD. FE a souol du aNd — TRL : foi caz ue Fa Ei 104z01-005 TEIN. PIPE DEI ru sot aa ICE Ani TAN mre i iiaaa ae — IAR The t întoco mat SETI PRA iei Ia i aps AUT i sta ae Bat aor Prairies = ET a TR EREI OF WOT SuSE : eee TA aos bee 7 ‘he oa ai sati a isca sei ENE ELIE ala + Aste ae i ra rr ic. ia pure a ear o TEORIE NL Oe asta Loris 7 airs ot = nai = = oot ir ASS ee i II UI TITEI Aici CORTERIIEE EEE! i Tez001 O18 LG TEAPEATIRE DUBE dar i Teg002-024 MAE TORE wae z Te2100-001 Seat air tule tee i CENTRE Toitineă TPE VALVE aan i Ter ERIE TTI iw z Toxo TEEN Pps, ISTE E zii T îsâno ap: Seri ae CoMeC FISE COREE era i Boe Lo {OORT SSC OCICS ERTS wore i IEI Dac STRGLE HOR Cos i [azn aa MIMS PPE Bik i “51. nes Se all E aK cae TRIP Part Noy Description SMB Part name SU Quantity Puen FRAT FALE maz, i EIOEET TAD box20 He oon i a BOLT wx 16 TRG AF Late a 21 HEAD LIGHT ASSY EET 1 TEZĂ FRIRI FENDER ARH 1 corsa ToNITIOR SIC ZI IA 1 ESEITEETEI front turn Tight ne wT 1 ‘906181002 CLIP NT EFA A 701000-990 Sear SHON Bx 1 ‘GB5787_ 2000 ‘BOLT MEX 20 SB HEM6 x 20 2 805100-659. REAR FENDER CEI 1 333700-014 Tear turn light Jae ast 1 0200-001 TOOLS HATA n “905606002 BATTERY ALVEOLI iii 2 500600-006 MIDDLE PLATE EXT 1 0621-001 PLASTIC BOLT Pied 2 801000-03 1 FUEL_TANK_ASSY_ TER we 1 1700-001 TAP LOCK, FUEL TAN Tat n 5797-2000 TRATATI Tein x16 2 IES? 3000 BOLT BIG iii 2 -53- WER. ASSAY Hk PART CATELAG SMR Part No. ri pei a Part name SU Quantity Era ra ie, 2 105000 055 Eo tte 2 GB6187-2000 NI_MOX1. 25 SKHEMIOX 1. 25, 8 243000- 219 REAR BRIDGE ASSY CATEII 1 > SHEIN ER aa E PROTECTING FRAME OF REAR BRIDGE pă 1 z BOLI _WX16 EIISEITI 8 372000 NUI __MIOX 1. 25, SAMO x1, 25, EI 442001 006 REAR BRAKE DISC Js tk SR 1 GB5787-2000 BOLT MX 20, SE PPM X20 5 “000-041 TE bist ME IS aaa i ETEN SIReRET nisa i 309200-02 SPEED SENSOR eT — -55- WEE ASSEMBLY EH PART CATELAG FIER Part n ” EI Description aw Part name en FRONT TH [EI 2 SE (ED 2 STEERING PARTS ‘ety HALE 2 FRONT DISK-BRAF TIE z ROD _ASSY FETEI 2 DUSTEROOF RUBBER BOOT BRI 2 PIN COTTER 2×20 TI Lți2x20 1 44101-0083, FRONT BRAKE DISK E Bat 2 GB/197. 122000 WASHERIO sa 10 4 (GB/T93-1987 SPRING WASHERIO isa) 10 4 GB6187-86 NUT_MI0 SE Egulo 8 GB/191-2000 PIN OTTER 2. 5X30 JEL 5×30 2 ‘GB5181-2000 NUL Sed 2 GB/T97. 1-2000 WASHERIA ZICE 2 ‘GP5181-2000 NUT_MI0 SEENO 4 400300-001 ‘AIR CHAIN MOUTH ai 2 -57- 7 TREE AEM _ SA | i EEE DT HELA Ba. 7 812000 UT ro, sasiuio n a FIAT WASHER EET i n STEERING STEW Fiat 1 + TOLT_ Axo ilps xe EI a STEERING ROD CLIP EI i + STEERING STEM CLIP WASTER IA: 1 3 i SIRE CLIP CE STEERING STE TBR 1 00-032 LEFT HINDLEBAR SWITCH Parone i a AITIEIEEI TARILE BAR. ERE 1 0430-007 LEFT_LEVER. BA = 5001-002 IT, STEERING ERE Fie E 2 BOLT 5% 60 (70) x 1.25. Wiha coco SIE i a LEFT WANOCE COM A eae n a THROTTLE ASSY mia i IT 113000-041 TAND PROTECTOR PAR i a ais -2000 EDIT BAO. i aa | e1o00-0s1 WIND RESISTED CALE CTE 1 | iv soTH0G=030 CABLE, THROTTLE: BF (emma 20 e000 CTC CABLE Baan 1 | 21 351000-028 INSTRUMENT ASSY CHE i 31020005 METER COVER te a i 23 3106170005 BOLT use16 FEAR i J ATO E ETI 350800-008 ‘SUPPORT SPEED METER LIE i 061 70-008 BOLT M6#16 TERA Jl RETO EI a 0100-064 REARVIEN MIRROR [ITI 2 3 CITITI CLIP, WIRROR SEAT WHET 2 E 360208 001 STEERING LOCK EET 1 a 0202-001 SUPPORT STEERING LOCK TINT i ca/T819.1 BOLT asez PPB HAAGIINGEI a 31 0068 TIGHT HANDL LEVER ror -59- arian 2rg012-00 fa wr 20 [PIN COTTER 3. [so Nit wan. asta [eanectan PoE Se ir 10 [ates (IEEE 1 [aa CTE semana a iza pa DIS BRACKET. REAR RI SAT REAR DISC DRAKE Ta fa ia TEARING REAR AXLE ASSY -60- ză R 8 HEXANGULAR NUT | 906163002 | KEM STUDS 40 Prot ieH_(DSTC) ErEETZE Gree] Bit Moos BOLT MB [ET at M62 BOLI MG [usicezore | FII SE os WASHER 65-12 CYLINDER HEAD SSEMBLY ORE 3353 ‘ORING INTAKE PIPE 335%3 | 118113-011 | [2 [aaa INTAKE PIPEASSY | 100008-008 | [in osama TEXANOULAR NUTS. | 66 14 | HE Mezzo BOLT a | [is [Weamezezs0 BEAȚIE3E)_| CARBURETORASSY | 161000-056 | 16_| BLOBS RARE M883 BOLT MS:83 ~_| 102217.912 | (an tiem sens WASHER 3522-1007 | | 18 | HBAS CYLINDER CAP SANI UNIT] 10223 | ALINGMENTPIN | | CYLINDER UNIT | (CYLINDER SHIM -62- er ne AIR INTAKE VALVE _108301-481 ‘AIR EXHAUST VALVE Ia AARE VALVE SPRING SEAT Tiosns16 Gano SEAT INSIDE SPRING 10430507, TIR VALVE OUTER SPRING 1030409 Eu VALVE INNER SPRING IBist-019 ATARE VALVE SPRINGCOVER | 10307009 EI [aww TIRE LOCKING NUT 10336010 z ADIUSTING DaNIS-010 [aa 35-2218 vaste 85-2208 1219-007 12 | Een ss BOLTM 3 |nosaos-ons Eni ARAL ROCKER ASSY TOMIO-19 a PUSH LEVE.. STAND, [1oms-007 | PUSH LEVER COMP 10412012 ELASTIC AHERIZ3<02209 | 104404005 LOWER ROCKER ARM TOHOL-008 SHAFILOWER ROCKER ARM | 1042-005 ONG 025| To3.0 | SPRING —_[rowos.os | RING 2025 TOM OT-08 2 | atei ‘AIR MLET CAM SHAFT [tostos.ons 23 [ite n WASHER 1451-2 | meroaa3 ERENIITA ~ [CAMSHAFT UNIT 104130082 | RHE M616 [mist Messa ‘IRIE M628 BOLTMIG-20 BOLT M616 [pour M6-s0 BOLT M625. Tisio0.001 5100-019 “[iistooaws [eRe WATER PUMPCOVER | 101411-008 |1 OREHE 814K) [ORING 85:19 mons [1 _ Rat EIE M0 pour Me-10 101433.002 [1 [meee 9-12-63, [ALINGMENTPIN | Hielo8.o18 RH OWENS 626968 |ORING 65-265 | 10141209 [1 a [RaiowsHmors [oRnoos roes2s.o08 [2 Rennanae crmenocaa ate] 10620018 [1 | n Ree COMPRESSION SPRING | 106301-014 | 1 | 13_| GB879.1 Mf 3-12 COTTER PIN 3*12 106312-006 | 1 | n See acanacu cor ee 1011-301 [1 15 | ERE „OIL DIPSTICK. 100016-009 | 1 16 [OEI 183 O-RING 183 10044208 | 1 17 [Om sea ALINOMENTPING14 | 116108012 [2 | 18 | sae marawsciseconmousst | 101403-029 |1 | 19 | BE MD BOLT M6»20_ 115100-008 | 3 | 20 | patit Mea BOLTM6-23 tisioo-o48 [2 | 21 | RARI Mort? BOLT M6«12 115100-010 | 4 EXE II tar cansene ea ser] 01301240 |1 25 | wR cAKIONSTO) ‘NEEDLE ROLLER BEARING | 16220005 [1 24 | SAREE urawcrcomoser | 101904024 |! -63- 3, BEI (CCB AD -64- E 3 132265 |ORNGIB2265__ MUARSE OVER © = 3 10131404, WARES | COVER GEAR [tii 10-4 ___ ȚALINGMENTPIN a [awit ves [Bourme25 | fal cc a Coo hI KAU OFTEN sorsizaur [1 | FITE TEI mons | 1 1 1900017005 za a] i ne [e] a sat CLUTCH COMP [osoon.066 | | CLUICHPOSTROD | 1osni4013 |! | RawLAReH 625 [BOLT neo e | AER _(16003) BEARING ‘6210-038 |1 | pă RESEED ‘PRESSURE PLATE rosso [i MI AAA [CLUTCH SPRING 106247-015 | 6 | a CITE) [ereu 106104005 [1 RanhOR CENTER CLUTCH 106281-003 [1 ia EET EET 10623019 [7 RABHANIE os. [6 | PE [Ramat 106246-001 [1 Tt [Reman ‘WASHER wooo fi) | [sansa 106260-013 [1 | C7] -66- GINE OIL FINE FILTER 105200-01€, CTUBEOIL. [osa0z-006 [+ KART MS 12 | SCREWMSX 12 115200.007 ABA ATMN | SPRINGEXTUBE COVERENGINE OIL FILTER | 105201-011 | voszos-ooe, ‘TRANSMISSION PIN | 105205-008 ts ____|GASKETFILTER HEADCOVER | 10s20%-005 [on FILTER BODY 105221-06 | + | DRIVE GEAR 106001-028 |! o #817 MEX 30 | SCREW MEX30 11s200-028 |2 [n ieste | DRIVE SHAFT, GEAR [Tostis.o16 | ERAI e „Oli. PUMP GEAR UNIT |_10$120-008 | 1 | mist OIL PUMPCASING rosti6on [+ | [OUTER ROTOR OIL PUN [ostis012 [1 | INNER ROTOR On PUMP frosuz-o12 n | [ou PUM covER [iosi7.o12 | | | FIRUL ASI NAX:12 | SCREW 115200.036 [2 i [oRING [host21-oo2 [2 | ENGINE OT PUMP Hrosnio-o4 [1 BOLTMEX6S_ LOCATING PLATE UNIT te 9 Tstoo.086 | 106304. GLEE ME CAP NUT M8 102218-0 FRE 8.618 WASHER 8.6«18%2 | 102219-011 | LTR B BOUBLE-HEASSCREWB | 1on1osos [2 | C | FSB Mox28 BOLTM6X28 [nstoroos [2 [|_| ERIE TIEN, PIPE [norao1-oo7 | | “Cati FROM) | HOORAIRDRAIN [aora0s-on1 | Sita BREATHER TUBE 1 | WUE FROM) [HOORAIRDRAIN [0120-001] | [pete tots ALINOMENT PIN 116108-008 Ti | i0t$ăiă (0NK1S2712)__ | NEEDLE ROLLER BEARING | 116220.006 | LR (6006) BEARING 116210-039 EI RIGHTCRANKCASE ASSY | 1o1230-116 aH 20:97 OIL SEAL 20-347 10114a-002 SER (6204) BEARING 16210-0480 SOIR A ‘BOUBLE-HEAD SCREWA 101103-028 EI (CONNECTING CASE GASKET 101101-028 ate LEFT CRANKCASE ASSY 101140-289 NEEDLE ROLLER BEARING 116220.007 BEARING | me210-036 [oak e awEH 450 RETAINER [pour OL SEALS E a fi 1 FI 1 1 101210002 1 1 4 1 1 1 1 1 1 1 7 1 1 | 109201-004 10n160-ă -68- PIER 12x220 RE WASHER DRAINBOLT M216 ft 4 10121-00311 101119-008 [coasa tite | PRESSING PIN ASSY TOIS0.005 EREI kun) THRUST WASHER 6 7-1-144 1ONss.002 BOLTNG OIL SEAL 0-10 ENGINE OIL FILTER ASSY | 101130-010 SPRING. OLFIETER | 101116013, ORING 353 [tomie-006 [IEI EI OIL DRAN PLUG SCREW | 1017-012 REE CHKIOIHO) NEEDLE ROLLER BEARING | 116220.005 on PLATE . CABLE 113-007 ASHE MO BOLT 115100-010 EREI POSITION PLATE» CAMSHAFT | 101146-003 To [ae meso BOLTAMG:S0 115160-001 0 | atat Mociu BOLTMG-100 |usicaos [st | pasate Merz BOLT M6:70 Tisioooss 2 | ASiRHE M660 BOLT M660 113100.047 SEPARATOR OIL AND AIR 162200.002 n FAR E SEH opta ee Seon [BLOT MIO-36 ROCKET EAI 28-144 | WOODRUFF KEY MESH ______ | CONNECTINGROD COMP | scenes) 103233 Theioon oszos-on 10323008 | tnezioosa EEE | DISHWASHER [unitate | NUTOLL ISTONRING ISTONRING ILRING ASSY 103213.006 103237-002 10310303 103108037 3110014 ASSEMBLY PIN STON ASTON 103120039 T | [ese] | = | 10700-056 |î | | | 107114-008 | 1 | | | SHIFT2 DRIVING GEAR | 1onoKois [1 | | SHIFT 4 DRIVING GEAR 107106-012 |1 | ) | SPLINE WASHER [romi2-009 [3 | TemcuP Tomar [3 | Că [ REVERSE GEAROOUNTERSHAT | 07-a [1 e [SHITSDRIVING GEAR 0n0s-015 1 | & | MARV SHAFT onorată |n ER TET 20X0SX27_ | THRUST WASHER 20527 107114-013 | 1 FS ASSENBLY, STARTING GEAR [071.0051 bs ‘ASSEMBLY, COUNTERSHAFT | 107200-073 1S oe | mere eg | PRING PLATE, DRIVE SPROCKET | lis T 13 EREI DRIVE SPROCKET | $ & 16 | ENEA 20X1X27__ THRUSTWASHER 20% 1027 1 pisi & {7 | wie Lit SHIFT2DRIVEN GEAK UNIT pna [1 oa @: 1 | wea SHIFTS DRIVENGEAR | 1omn-os|t | | iy CC | COUNTER AXLEUNIT | 107201.058 [1 | & [A [> | amet | REVERSEGEAR | omzisoos | | | – 21 WERE SHIFT3DRIVENGEAR | 107209-015 [1 | | ba 2 |IEPASE 165X05X235__| THRUSTWASHERIESxOSx235 | 107202-010 [1 | | 2 [astuia coum THSPED CER | 107207005 1 | | 24 ÎMI SPACERNASHER | 1om06015 72 -70- Le losxosxaas cr 27 | HOHIBIE 1SK1XD 2 | RAE – EDEN [REVERSE AXLE KEE ‘THRUST WASHER [THRUST WASHER ‘COUNTER SHAFT BUSH — BtiAET BUS | Înezzoaos [2 a fe 10721704 107341-006 lormo10 | 107202023 Rs ma 0 rae TGEARREOULTION | 07.006 [ Tanecas | AiR a 107M0-012 [1 iBo1ssxi2Xo221 10737002 ata 6731-09 Ei (MIDDLE DRIVE SHAFT [10752007 Tama ‘OUNTERSIATISTSPEED | 10733005 37 EE PRESSURE PLATE 10735004 58 | Mn 8 20 SREI | Mast wseR vas —[rOTINAOIS ‘y | Se 18 SHAFTREDUTION O-FNG 107344-003 – [a | stein TASSEWBLY DUE Geancon? | orar „72. jena [Reinke vos SHORT SHIFT FORK AXLE EN 08126-0148 SHIFTFORKS (R) 108123-014 P SHIFT FORK? 1081220103 ied SHIFTFORKI (L) 10512104 tt ve: Bo 6101-001 _TNEIICA SRR LOCRNASIER | 115300-001 SHIFTCANSEGMENT___| osie fig ax | STARGEARDOWEL PIN | 10811608 SHIFTCAM Tosti 19 | aR CONTACTING RING 108113-008 > [RORRaTE carenta more | 13200069 2 | +P REIT AGIs SCREW 115200-057 2 |stare A BOLT ora $9)M6x20 [EI E: | 1OSIO01-016 | 1 seu se ICTETEI n. th [DOUBLE GEAR SIIAFTASSY AURUCHMEET IX6_| LOCATINGPIN 3-6 “BE 109X05X18__| WASHER 105<05x18 6109-004 ‘keukwitiag | BIGDOUBLE GEARASSY 109231-011 | a STARTER IDLE GEAR? 109003-009 7_| 8H Meas SCREW, 115200-054 HSRENER __[eurevormscnc sea st 10910015 aratat Em Tor asc stra 10921001 2752 9 CLAP (3520-185 AHH) | WATER TUBE _(13-20- 7 Woe WEL arene MECHANISM SEA Tinaras.on2 ‘OL TAPER SEO BOLT 6:16 114800-058, 1StoD-O1S