CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.

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CHAPTER 1 FRAME INSTALLATION PAGE 1- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.1 FRAME INSTALLATION

ENGINE INSTALLATION

1 Installation the engine assembly to the frame by the bolt.

The torque of the nut M10X1.25 is 60Nm.
Apply Loctite™ 242.

2. Installation the engine assembly to the frame with

the engine mounting bracket 1 and 2 and cushion engine mounting .

CHAPTER 1 FRAME INSTALLATION PAGE 1- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

REAR GEAR-BOX INSTALLATION

1. Fix the rear gear-box to the rear holder by the bolt M10X1.25X126①(attention don’t tighten
the nut)
2. Connect the rear holder and the rear gear-box to the frame by the bolt M10X1.25X108②
and the bolt M10X1.25X126③.
3. Tighten the nut④⑤⑥, Torque of the nut is 40-45Nm. Apply Loctite™ 242.
Reverse the installation procedure for removal.

CHAPTER 1 FRAME INSTALLATION PAGE 1- 3

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.2 FRONT A-ARM REPLACEMENT
MANTENANCE-FREE PIVOT DESIGN

1. Elevate and safely support vehicle, removal of front wheel.

2. Remove the cotter pin on the front wheel driving shaft nut, than remove the nut.
3. Remove the front disc brake caliper.
4. Remove the tie-rod ball joint.
5. Remove the mounting bolt of front shock absorber and A-arm. Takedown the A-arm
components.
6. Remove the cotter pin, nut, snap spring of the knuckle, FR and joint A-arm ball.

CHAPTER 2 FRONT A-ARM PAGE 2- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

7. Examine the joint A-arm ball. Replace if ball stud excessive gap. Replace new one as
required.
8. Using hub extractor to disassembly the front hub.

9. Remove seal.
10. Remove the snap spring of the bearing hub.
11. Using bearing extractor to disassembly the hub bearing.

CHAPTER 2 FRONT A-ARM PAGE 2- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

12.
Notice: when reassembling hub bearing that were removed and rear hub, which
are need replaced.
12. Remove rubber cushion, ARM, and collar. Replace if worn. Discard hardware.

13 Install new A-arm assembly onto vehicle frame from step12 to step 1. Install new bolts
and new nuts.
NOTE. Tighten the nuts only finger-tighten at this time. They will be tightened to the
final torque after the front wheels are installed and the vehicle is on the ground.

CHAPTER 2 FRONT A-ARM PAGE 2- 3

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

WARNING
DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during
operation.
14. Install hubs, calipers and wheels, lower the vehicle to the ground. Apply Loctite™ 242 to
screw threads of the A arm bolts and torque bolts to 44 ft. lbs. (60 Nm ).

WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular
service.

CHAPTER 2 FRONT A-ARM PAGE 2- 4

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.3 REAR A-ARM REMOVE/INSTALLATION
MANTENANCE-FREE PIVOT DESIGN

1. Remove rear wheel.

2. Remove the cotter pin on the rear wheel driving shaft nut, than remove the nut.
3. Remove the rear disc brake caliper.
4. Remove the link, RR. Stabilizer.
5. Remove the mounting bolt of rear shock absorber and upper and lower A-arm.
Takedown the A-arm components.
6. Remove the mounting bolt of the rear hub, after that inspect bushes, A-arms and collar.
Replace if worn. Discard hardware.

CHAPTER 3 REAR A-ARM PAGE 3- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

7. Using hub extractor to take down the rear hub.

8. Remove oil seal.
9. Remove the snap spring of the rear hub.
10. Using bearing extractor to take down the hub bearing.
Notice: when reassembling hub bearing that were removed and rear hub, which are
need replaced. (The method is in accordance with removing steering knuckle.)
11. Remove transverse stabilizer bar.

12. Install new A-arm assembly onto vehicle frame，from step11 to step 1 .Install new bolts
and new nuts.

NOTE. Tighten the nuts only finger-tighten at this time. They will be tightened to the final
torque after the front wheels are installed and the vehicle is on the ground.

CHAPTER 3 REAR A-ARM PAGE 3- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

WARNING
DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during
operation.

13. Install hubs, calipers and wheels, lower the vehicle to the ground. Apply Loctite™ 242
to screw threads of the A arm bolts and torque bolts to 44 ft. lbs. (60 Nm ).

WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular
service.

CHAPTER 3 REAR A-ARM PAGE 3- 3

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.4 STEERING SHAFT INSTALLATION

Non- indicated torque above drawing：

1. BOLT M8X30 Torque ：25Nm
2. NUT M8 Torque ：25Nm

NOTE：
1. Use grease M between steering bush and steering shaft.
2. If assembling the nut (M16X1.5) by the torque 80-85Nm and the pin can not be pointed at the
hole, you can tighten the torque until the pin is pointed at it. But the max torque is 108Nm.

CHAPTER 4 STEERING SHAFT PAGE 4- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
THROTTLE CABLE FREEPLAY
ADJUSTMENT
1. Throttle cable free play is adjusted at the
handlebar.
2. Side the bolts off inline cable adjuster,
Loosen adjuster locknut.
3. Turn adjuster until 1/8” to 5/16” (3 to 8
mm) free play is achieved at thumb lever.
NOTE: While adjusting freeplay, it is
important you flip the throttle lever back and
forth.
4. Tighten locknut and slide boots over cable
adjuster.

TOE ALIGNMENT
METHOD: STRAIGHTEDGE OR STRING
Be sure to keep handlebars centered

NOTE: String should just touch side surface

of rear tire on each side of the ATV.
Measure from string to rim at front and rear of
rim.
Rear rim measurement (A) should be 1/10” to
11/40”(5 to 7mm) more than front rim
measurement (B).
NOTE: The steering post arm (frog) can be
used as an indicator of whether the
handlebars are straight. The frog should
always point straight back from the steering
post when handlebars are straight.

WARNING: Always pay attention to tie rods

assembly, Both ends must screw in same and
enough threads length.

CHAPTER 4 STEERING SHAFT PAGE 4- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.5 WHEELS
Inspect all wheels for run out of damage.
Check wheel nuts and ensure they are tight.
Do not over tighten the wheel nuts.

WHEEL REMOVAL
1. Stop the engine, place the transmission in
gear and lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing
a suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the
wheel.

WHEEL INSTALLATION
1. With the transmission in gear and the
parking Brake locked, place the wheel in
the correct Position on the wheel hub. Be
sure the valve stem is toward the outside
and rotation arrows on the tire point
toward rotation.
2. Attach the wheel nuts and finger tighten
them.
Install as shown at left for front or rear
wheels.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the
proper Torque listed in the table. On wheel
nuts, Make sure tapered end of nut goes Wheel Nut Torque Specifications
into taper on wheel. Bolt Size Specification
CAUTION:
If wheels are improperly installed it could Front M12X1.25 69Ft.Lbs 95N.m
affect Vehicle handling and tire wear.
Rear M12X1.25 69Ft.Lbs 95N.m
TIRE PRESSURE
TIRE INSPECTION
CAUTION : Tire Pressure Inspection
 Maintain proper tire pressure. Refer to the
Front Rear
warning tire pressure decal applied to the
vehicle. 700 14PSI 14PSI
Improper tire inflation may affect ATV
maneuverability. (100±0.5KPa) (100±0.5KPa)
When replacing a tire always use original
equipment size and type and replace in WARNING Operating an ATV with worn tires will
pairs, especially in 4X4 model. increase the possibility of the vehicle skidding
 The use of non- standard size or type tires easily with possible loss of control.
may affect ATV handling and cause
machine damage, especially in 4X4 model. Worn tires can cause an accident.
TIRE TREAD DEPTH Always replace tires when the tread depth
Always replace tires when tread depth is measures 1/8" (3 mm ) or less.
worn to 1/8" (3m m ) or less.

CHAPTER 5 WHEELS PAGE 5- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.6.FUEL SYSTEM
CONNECTING GUIDELINES

CHAPTER 6 FUEL SYSTEM 6- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
Fuel strainer screen cleaning:
1. Remove the fuel tank（four bolt）.
2. Drain the gasoline into an approved fuel
container. Remove the two mounting
bolts, collars and the fuel fitting.
3. Remove fuel pumpfender.
4. Remove cable.
5. Remove pipe 1 and 2.
6. Remove fuel pump.
7. The assembly sequence is in turn.
NOTE
After installing the fuel valve and connecting
the fuel line, refill the fuel tank and turn the
fuel valve ON and check that there is no fuel
leaking.
WARNING
Always pay attention to the fittings of the
plastic gas tank during fuel lines service.
Don’t pull the line from the tank directly for
removal. Inspect fittings and tank body for
looseness, nicks, and scratches. Replace
gas tank if necessary.
VENT LINES AND ROLL OVER VALVE*
1. Check fuel tank, oil tank, carburetor,
battery, and transmission vent lines for signs
of wear, deterioration, damage or leakage.
Replace every two years.
2. Be sure vent lines and drain lines are
routed properly toward the ground and
secured with cable ties. CAUTION: Make
sure lines are not kinked or pinched
*NOTE. There is a Roll-Over Valve on the
end of the gas tank vent line. Make sure
the ↑ mark on the R-O Valve is upwards.
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open 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 you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust
fumes are poisonous and can cause loss of consciousness and death in a short time.
Never drain the float bowl when the engine is hot. Severe burns may result.
Item Specification
CLIP 4 N.m
Nut 6 N.m

CHAPTER 6 FUEL SYSTEM 6- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.7 Rear drive shaft

1. Remove the hose clamps.

2. Remove the dust cover of the rear drive shaft.

CHAPTER 7 7- 1
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Remove circlip.

CHAPTER 7 7- 2
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

4. Figure on side of the bearing sleeve bearing sleeve, so that the other side of the fell, then remove
a bearing sleeve;

CHAPTER 7 7- 3
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

5. Remove rear drive shaft spline shaft.

6. Remove rear drive shaft spline shaft.

7. In turn the assembly sequence.

CHAPTER 7 7- 4
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.8 Front drive shaft

1.Remove the hose clamps to connect the engine side, remove the dust cover
(as shown in Figure 1);

2. Clamp front drive shaft by using a special tool and tighten nut at the right end with a wrench to
constrict the drive shaft till it can be removed (as shown in Figure 2).

CHAPTER 8 8- 1
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3.Pull out the front drive shaft(as shown in Figure 3);

4.In turn the assembly sequence.

CHAPTER 8 8- 2
 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.9 SHIFT ROD SYSTEM

CHAPTER 9 SHIFT ROD 9- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

SHIFT LINKAGE ADJUSTMENT

Linkage rod adjustment is necessary when symptoms
include:
 Noise on deceleration
 Inability to engage a gear
 Excessive gear clash(noise)
 Shift moving out of desired range
NOTE: When adjusting shift linkage, always adjust
linkage rods. Remove necessary components to gain
access to shift linkage rod ends.

1. Inspect shift linkage both tie rod ends, and shift collar
and replace if worn or damaged. Lubricate the tie rod Mark for counter
ends with a light aerosol lubricant or grease.

2. Loosen all rod end adjuster jam nuts.

3. Note orientation of tie rod end studs with stud up or

down. Remove rod end studs from transmission
rocker.

4. Be sure idle speed is adjusted properly.

5. Place gear selector in neutral. Make sure the

transmission rocker are engaged in the neutral
position detents.

6. Be sure the shift linkage rod ends are firmly attached

to the gear selector slides. Adjust the linkage rod so
the rod end is centered on the transmission rocker.
Install the lock nut to the rod end and torque to 35
in.lbs ( 4 Nm).

7. Loosen the clamp nut of gear shift. Clockwise

rotation. Lengthening the distance between
handlebar and shift swimming arm, conversely the
distance shorten. Make gear shift handle smooth limit
to L(slot of low gear).then tighten nut of handle.

8. Do not turn shift knob casually after it is assembled

and secured.
9. Be sure to remove shift cable rod before removing
shift knob while disassembling.

CHAPTER 9 SHIFT ROD 9- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10 ELECTRICAL

10.10.1 LIGHTS INSPECTION AND SERVICE

10.10.2 BATTERY

10.10.3 IGNITION SYSTEM

10.10.4 CHARGING SYSTEM

10.10.5 ELECTRICS STARTING SYSTEM

10.10.6 COOLING SYSTEM

10.10.7 LIGHTING SYSTEM

10.10.8 GEAR POSITION INDICATOR SWITCH TEST

10.10.9 SPEEDOMETER SYSTEM

10.10.10 MAIN SWITCH AND HANDLE SWITCH

10.10.11 FUEL GAUGE/ FUEL LEVEL SENSOR

10.10.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT

10.10.13 SINGLE CYLINDER UNWORKING WARNING SYSTEM

CHAPTER 10 ELECTRICAL 10- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

LH700ATV FOR EUROPE MODEL

CHAPTER 10 ELECTRICAL 10- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.10.1 LIGHTS INSPECTION AND SERVICE
A. HEADLIGHT LAMP REPLACEMENT AND ADJUST

1. To lower headlight brightness cut-off line, turn adjusting bolt (1) counterclockwise. And to raise
brightness cut-off line, turn the bolt clockwise.
2. Take rubber cap (2) out from holder. Remove rebound clip to take the worn bulb out from socket.
Align the semicircle on a new bulb with that in the socket before mounting the bulb. Install
rebound clip just removed to fasten the bulb and then plug in wires.
3. Remove position lamp socket out of top cover. Remove the worn bulb by taking a hold of it and
pulling it out. Insert a new bulb into socket before inserting the socket in its mounting hole.

B. TAILLTGHT LAMP REPLACEMENT

4. To remove screws used to fasten lampshade, turn the screws counterclockwise with a Phillips
screwdriver.
5. Remove lampshade.
6. Keeping a firm grasp on holder, hold bulb to remove it by pressing it down and turning it
counterclockwise.
7. To install bulb, align high locating stud on bulb with that in brass socket and low locating stud on
bulb with that in brass socket, and bulb will be locked after being pressed down and turned
clockwise simultaneously.

CHAPTER 10 ELECTRICAL 10- 3

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.10.2 BATTERY

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with
skin, eyes or clothing Antidote:
External: Flush with water.

lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always shield eyes when working near batteries.
KEER OUT OF REACH OF CHILDREN

WARNING: The gases given off by a battery are explosive. Any spark or open flame near a battery
can cause an explosion which will spray battery acid on anyone close to it. If battery acid gets on
anyone, wash the affected area with large quantities of cool water and seek immediate medical
attention.

To ensure maximum service life and performance from a new battery, perform the following steps.
NOTE: Do not service the battery unless it will be put into regular service within 30 days. After initial
service, add only distilled water to the battery. Never add electrolyte after a battery has been in
service.
NOTE: New Battery must be fully charged before use.
1. Remove vent plug from vent fitting.
2. Fill battery with electrolyte to upper level marks on case.
3. Set battery aside and allow it to cool and stabilize for 30 minutes.
4. Add electrolyte to bring level back to upper level mark on case.
NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point,
add only distilled water.
5. Charge battery at 1 /10 of its amp /hour rating. Examples: 1 /10 of 14 amp battery = 1.4 amp;
1/10 of 7 amp battery = 0.7 amp (recommended charging rates).
6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or
higher.

BATTERY INSPECTION / REMOVAL

The battery is located under the left rear fender. Inspect the battery fluid level. When the battery fluid
nears the lower level, the battery should be removed and distilled water should be added to the
upper level line. To remove the battery:
1. Disconnect holder strap and remove cover.
2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.

CHAPTER 10 ELECTRICAL 10- 4

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
CAUTION
Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and
reinstall the negative cable last!
3. Remove the battery. Remove the filler caps and add distilled water only as needed to bring
each cell to the proper level.
Do not overfill the battery.
To refill use only distilled water. Tap water contains minerals which are harmful to a battery.
Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the
battery.
4. Reinstall the battery caps.

BATTERY INSTALLATION
1. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a
solution of one cup water and one tablespoon baking soda. Rinse with clean water and dry
thoroughly.
2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (- ) (black) cable.
3. Install clear battery vent tube from vehicle to battery vent.
WARNING:Vent tube must be free from obstructions and kinks and securely installed. If not, battery
gases could accumulate and cause an explosion. Vent should be routed away from frame and body
to prevent contact with electrolyte. Avoid frame, corrosion will occur.
4. Route cables so they are tucked away in front and behind battery.
5. Reinstall battery cover and holder strap.
Do not start the engine with the battery disconnected. Vehicle lamps will burn out if battery is
disconnected during vehicle operation. Also, the reverse speed limiter can be damaged.

BATTERY TESTING
Whenever a service complaint is related to either the starting or charging systems, the battery
should be checked first.
Following are three tests which can easily be made on a battery to determine its condition: OCV
Test, Specific Gravity Test and Load Test.

MF (Maintenance Free) battery does not require the Specific Gravity Test and Refill

Open Circuit Voltage Test

Battery voltage should be checked with a digital multitester. Readings of 12.6 or less require
further battery testing and charging.
NOTE: Lead acid batteries should be kept at or near a full charge as possible.
Load test
CAUTION: Remove spark plug high tension leads and connect securely to engine ground before
proceeding.
NOTE: This test can only be performed on machines with electric starters. This test cannot be
performed with an engine or starting system that is not working properly.
A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still
may not have the storage capacity necessary to properly function in the electrical system. For this
reason, a battery capacity or load test should be conducted whenever poor battery performance is
encountered. To perform this test, hook a multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts or greater. Engage the electric starter and
view the registered battery voltage while cranking the engine. Continue the test for 15 seconds.
During this cranking period, the observed voltage should not drop below 9.5 volts. If the beginning
voltage is 12.6 or higher and the cranking voltage drops below 9.5 volts during the test, replace the
battery.
10.10.3 IGNITION SYSTEM

CHAPTER 10 ELECTRICAL 10- 5

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

IGNITION SYSTEM TROUBLESHOOTING

No Spark, Weak or Intermittent Spark
 Spark plug gap incorrect
 Fouled spark plug
 Faulty spark plug cap or poor connection to high tension lead
 Related wiring loose, disconnected, shorted, or corroded
Engine stop switch or ignition switch faulty
 Terminal board or connections wet, corroded
 Poor ignition coil ground (e.g. coil mount loose or corroded)
 Faulty stator (measure resistance of all ignition related windings)
Incorrect wiring (inspect color coding in connectors etc. )
 Faulty ignition coil winding (measure resistance of primary and secondary)
 Worn magneto (RH) end crankshaft bearings
 Sheared flywheel key
 Flywheel loose or damaged
 Trigger coil air gap too wide (where applicable) should be 0.030-0 .050" (0. 75-1.25 mm)
 Excessive crankshaft run out on magneto (RH) end should not exceed 0.005"
(0.13mm)
 Faulty ECU

LH700ATV EFI MODEL

CHAPTER 10 ELECTRICAL 10- 6
CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

CHAPTER 10 ELECTRICAL 10- 7

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

IF THE IGNITION SYSTEM FAILS TO OPERATE

Procedure
Check:
1. Fuse (Main) 7.Pickup coil resistance
2. Battery 8.Main switch
3. Spark plug 9.Engine stop switch
4. lgnition spark gap 10.Wiring connection
5. Spark plug cap resistance (entire ignition system)
6. Ignition coil

1.Fuse NO CONTINUITY

Check switches
Replace the fuse.

CONTINUITY
2. Battery INCORRECT
 Check the battery condition.  Clean battery terminals.
Refer to "BATTERY  Recharge or replace the battery.
INSPECTION"
CORRECT
3.Spark plug
OUT OF SPECIFICATION
 Check the spark plug
condition.
 Check the spark plug
type. Repair or replace the spark plug
 Check the spark plug gap. Standard spark plug:FR8DCX/
BOSCH

Spark plug gap: 0.6 ～

0.7mm

CHAPTER 10 ELECTRICAL 10- 8

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
*

4.lgnition spark gap

 Disconnect the spark plug cap from the
spark plug
Connect the ignition tester 1 as shown.
2 Spark plug
Turn the main switch to "ON".
Check the ignition spark gap .
Check the spark by pushing the
MEETS SPECIFICATION
starter switch, and increase the spark
gap until a misfire occurs.
The ignition system is not faulty.
Minimum spark gap:
6mm (0.24 in)
OUT OF
SPECIFICATION
OR Tester (+) lead →
NO SPARK Spark plug side
5.Resistive cable with Spark plug cap Tester (—) lead→
resistance High tension cord side 
Remover the spark plug cap.
Remover the resistive cable from
the ignition coil
Connect the pocket tester (ΩX1 k) to
the spark plug cap and the resistive
cable terminal.
NOTE:
 When removing the spark plug cap.
do not pull the spark plug cap from
the resistive cable.
Remove→Pulling
Connect→Pushing.
Check the resistive cable with
park plug cap
OUT OF SPECIFICATION
Resistive cable
resistance:
Replace the resistive cable
3.68±0.73KΩ (20 ℃)

CORRECT

CHAPTER 10 ELECTRICAL 10- 9

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Tester (+) lead

Right Terminal
Tester (－) lead
6. Ignition coil resistance
Left Terminal
Disconnect the ignition coil
connector from the wire harness.
Connect the pocket tester to the
ignition coil.
 Check if the primary coil has the
specified resistance.

Primary coil resistance:

0.58±0.058Ω(20 ℃)
Tester (+) lead:
Connector side (Right )
Tester (— ) lead
Resistive cable side

Remover the resistive cable from

the ignition coil
Connect the pocket tester
(Ω×1k ) to the ignition coil.
Check the secondary has the
specified resistance
Secondary coil resistance: OUT OF SPECIFICATION
9.6±0.96 KΩ (20℃)
BOTH MEET
SPECIFICATION
Replace the ignition coil.
*

CHAPTER 10 ELECTRICAL 10- 10

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

7. Pickup coil resistance

 Disconnect the pickup coil coupler
from the wire harness.
Connect the pocket tester (Ω 100) to
the pickup coil coupler.

Tester (+) lead →

BI/Y Terminal 
Tester (- ) lead→
B/R Terminal 
OUT OF SPECIFICATION
 Check the pickup coil has the
specified resistance.
Replace the pickup coil.

Primary coil resistance:

168 -252Ω (20℃)
MEETS
SPECIFICATION NO CONTINUITY
8.Main switch
CHECK SWITCHES
Replace the main switch
CONTINIUTY
NO CONTINUITY
9.Engine stop switch ( for USA
model)
Replace the handlebar switch.
CONTINIUTY

10.Wiring connection
Check the connection of the POOR CONNECTIONS
entire ignition system
Refer to “CIRCUIT DIAGRAM”.
Correct
CORRECT

Replace the ECU.

CHAPTER 10 ELECTRICAL 10- 11

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
10.10.4 CHARGING SYSTEM

CHARGING SYSTEM CIRCUIT DIAGRAM

CURRENT DRAW - KEY OFF

CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running.
Damage will occur to light bulbs and speed limiter.
Connect an ammeter in series with the negative battery cable. Check for current draw with the key off,
if the draw is excessive, loads should be disconnected from the system one by one until the draw is
eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate
the draw.

Current draw key off:

Maximum of 0.01DCA(10mA)

CHARGING SYSTEM
Procedure
Check:
1. Fuse (Main) 4.Stator coil resistance
2. Battery 5.Wiring system (entire charging system)
3.Charging voltage

CHAPTER 10 ELECTRICAL 10- 12

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
1. fuse NO CONTINUITY

Replace the fuse

2. Battery

Check the battery condition. INCORRECT

Refer to "BATTERY INSPECTION"

Clean battery terminals

Recharge or replace the battery
3.Charging voltage
Connect the engine tachometer
to the spark plug lead.
Connect the pocket tester
(DC20V) to the battery
Test (+) lead→
Battery (+) terminal 
Tester (-) lead→
Battery (-) terminal 
Measure the battery terminal
voltage.
start the engine and accelerate to
about 5,000rpm
check the terminal voltage
Measured voltage-terminal MEETS SPECIFICATION
Voltage:
0.2-2.5V up
NOTE: Use a fully changed battery.

The charging circuit is not faulty

Replace the battery

OUT OF SPECIFICATION

CHAPTER 10 ELECTRICAL 10- 13

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0
4. Starter coil resistance
Remove the A.C. magneto coupler from
wire harness
Connect the pocket tester (ΩX1) to
the stator coil
Tester (+) lead –yellow terminal
Tester (-) lead –yellow terminal OUT OF SPECITICATION
Measure the stator coil resistance
Stator coil resistance 0.5-0.8Ω（20℃）

Replace the stator coil

MEETS SPECIFICATION

5.Wiring connection
check the entire charging system for
connections
Refer to “CIRCUIT DIAGRAM” POOR CONNECTION

correct

CORRECT

Replace the rectifier/regulator

CHAPTER 10 ELECTRICAL 10- 14

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.5 ELECTRICS STARTING SYSTEM

DI AG R AM

CHAPTER 11 ENGINE PAGE 11- 1

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE

Procedure
Check:
1. Fuse (Main) 7. Engine stop switch

2. Battery 8. front/rear brake switch

3. starter motor 9. starter switch

4. starter relay 10. wiring connection (entire starting system)

5. starting circuit cut-off relay

6. main switch
1. fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section

Replace the fuse

2. Battery
Check the battery condition. INCORRECT
Refer to "BATTERY INSPECTION" section
in CHAPTER 3

Clean battery terminals

Recharge or replace the battery

3. Starter motor DOES NOT MOVE

Connect the battery positive terminal
and starter motor cable using a jumper
lead.
Check the starter motor operation

Repair or replace the starter

motor

CHAPTER 11 ENGINE PAGE 11- 2

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

WARNING
4.Starter relay
A wire used as a jumper lead
Disconnect the relay unit coupler from must have the equivalent
the wire harness. capacity as that of the battery
Connect the pocket tester (Ωx1) and lead or more, otherwise it
battery (12V) to the relay unit coupler may burn.
terminals. This check is likely to
Battery (+) lead→ produce sparks, so be sure
Green/Yellow terminal  that no flammable gas or fluid
Battery (-) lead→ is in the vicinity
Yellow/Red terminal 
Check the starter relay for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal

CONTINUITY
Replace the starter replay

5. .Starting circuit cut-off relay

Disconnect the starting circuit cut-off
relay coupler from the wireharness.
Connect the pocket tester (Ωx1) and
battery (12V) to the starting circuit cut-off
relay coupler terminals.
Battery (+) lead→ terminal 
Battery (-) lead→ terminal 
Check the starting circuit cut-off relay
for continuity.
Test (+) lead →  terminal
Test (-) lead →  terminal

 and  coil resistance 4Ω±10%（20℃）

Replace the starting circuit

cut-off relay

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

6. Main switch
CHECK SWITCHES NO CONTINUITY

Replace the main switch

7. Engine stop switch
NO CONTINUITY

Replace the handlebar switch

8 Front /rear brake switch

NO CONTINUITY
CHECKING SWITCHES

Replace the brake switch

9. Starter switch
NO CONTINUITY
CHECKING SWITCHES

Replace the handlebar switch

10. Wiring connection

POOR CONNECTION
Check the connections of the entire
starting system.
Refer to “CIRCUIT DIAGRAM

Correct

CHAPTER 11 ENGINE PAGE 11- 4

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.6 COOLING SYSTEM

IF THE FAN MOTOR FAILS TO TURN
Procedure
Check:
1. Fuse (Main, Fan) 4. Main switch
2. Battery 5. Fan motor (inspection)
3. Relay 6. Thermo switch
7. Wiring connection (entire cooling
system)

1. fuse
CHECK SWITCHES NO CONTINUITY

Replace the fuse

2. Battery
Check the battery condition.. INCORRECT
Refer to "BATTERY INSPECTION" section

Clean battery terminals

Recharge or replace the battery

3 RELAY
CHECK REALY NO CONTINUITY

Replace the relay

4 Main switch
CHECK SWITCHES NO CONTINUITY

Replace the main switch

CHAPTER 11 ENGINE PAGE 11- 5

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

5. Fan motor(inspection 1)
Connect the battery to the fan motor.
Battery (+) lead→Green/Blue terminal DOES NOT MOVE

Battery (-) lead→Green ground 
Check the fan motor operation

Replace fan motor

Fan motor (inspection 2)

Turn the main switch to off.
Remove the thermo switch lead from DOES NOT MOVE
thermo switch.
Connect jumper lead to thermo switch
leads.
Turn the main switch to on

The wiring circuit from battery to

fan motor is faulty. Repair

6. Thermo switch
Remove the thermo switch from the
radiator.
Connect the pocket tester (ΩX1) to the
thermo switch.
Immerse the thermo switch in the
water 
Check the thermo switch for continuity.
NOTE:
Measure temperatures while heating the
coolant with the temperature gauge

WARNING
Handle the thermo switch with special
care.
Never subject it to strong shocks or
allow it to be dropped. Should it be
dropped, it must be replaced.
Do not touch the thermo switch to the
bottom of the heated vessel.
88±3℃Thermo switch “ON”
OUT OF SPECIFICATION
80 ℃Thermo switch “OFF”

Replace the thermo switch

CHAPTER 11 ENGINE PAGE 11- 6

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

7. Wring connection UPPER CONNECTION

Check the connection of the entire
cooling system.
Refer to “CIRCUIT DIAGRAM”

Correct

CHAPTER 11 ENGINE PAGE 11- 7

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.7 LIGHTING SYSTEM

FOR EUROPE MODEL

CHAPTER 11 ENGINE PAGE 11- 8

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

TROUBLESHOOTING
Procedure

Check:
1. Fuse (Main) 4.Lights switch
2. Battery 5.Dimmer switch
3. Main switch 6. Wiring connection (entire lighting
system)

1.fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section

Replace the fuse

2. Battery
Check the battery condition. INCORRECT
Refer to “BATTERY INSPECTION” section
in CHAPTER 3

Clean battery terminals

Recharge or replace the battery

3. Main switch
NO CONTINUITY
CHECK SWITCHES

Replace the main switch

4. Light switch
NO CONTINUITY
CHECK SWITCHES

Replace the right handlebar

switch

5. Dimmer switch
NO CONTINUITY
CHECK SWITCHES

CHAPTER 11 ENGINE PAGE 11- 9

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Replace the left handlebar

switch

POOR CONNECTIONS
5. Wiring connection
Check the connection of the entire
lighting system

correct

6. check the condition of each of the

lighting system’s circuits
Refer to “LIGHTING SYSTEM CHECK”

LIGHT SYSTEM CHECK

1. If the headlight and the high beam indicator light fail to come on
NO CONTINUITY
1.Blub and bulb socket
CHECK SWITCHES

Replace the bulb and/ or bulb

socket
2. Voltage
Connect the pocket tester (DC20V) to
the headlight and high beam indicator
light couplers.

A When the dimmer switch is on low

beam.
B When dimmer switch is on high
beam

Headlight::
Tester (+) lead →White or Blue lead
Tester negative (-) lead →Green lead

Turn the main switch to on.

Turn the light switch to on position.
Turn the dimmer switch to low beam or
high beam.
Check for voltage (12V) on the lead at
bulb socket connectors OUT OF SPECIFICATION

CHAPTER 11 ENGINE PAGE 11- 10

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

The wiring circuit from the main

switch to
bulb socket connector is faulty.
This circuit is not faulty Repair

2. the taillight fails to come on

1. Bulb and bulb socket NO CONTINUITY

CHECK SWITCHES

Replace the bulb and /or bulb

socket

CONTINUITY

2. Voltage
Connect the pocket tester (DC20V) to
the bulb
socket connector.
Tester (+) lead→
Black terminal 
Tester (-) lead→
Green terminal 
Turn the main switch to on. OUT OF SPECIFICATION
Turn the lights switch to on pilot position.
Check the voltage (12V) on the bulb
socket connector

The wiring circuit from main

switch to
bulb connector of faulty.
Repair

This circuit is not faulty

CHAPTER 11 ENGINE PAGE 11- 11

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.8 GEAR POSITION INDICATOR SWITCH TEST

DI AG R AM

CHAPTER 11 ENGINE PAGE 11- 12

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

CHAPTER 11 ENGINE PAGE 11- 13

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.9 SPEEDMETER SYSTEM

OPERATION OF SPPED SENSOR

Speed Sensor on the Transmission Out Put Shaft.
Operation Instructions of LCD Meter and Speed Sensor

Main Technical Parameter：

Item Code Vol value Unit
Operating voltage Vcc 5-20 V
Operating current Icc ≤15 mA
Operating distance D 1mm≤D≤8mm mm

The following is the graphic illustration for sensor installation。

CHAPTER 11 ENGINE PAGE 11- 14

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

LCD Meter

1. Neutral indicator light 9 . Engine rpm meter

2. High beam indicator light 10. hour / distance selector
3. Turn indicator light 11. km/ mile selector
4. Reverse indicator light 12: Front diff lock
5. SVS light 13. Rear diff lock
6. Speedometer 14. Engine working hour counter
7. Coolant temperature meter 15. Gear position
8. Fuel gauge Indicator 16. 2WD/4WD or DIFF LOCK indicator

CHAPTER 11 ENGINE PAGE 11- 15

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.10 MAIN SWITCH AND HANDLE SWITCH

HANDLE SWITCH SCHEMATIC FOR USA MODEL

USA. model

HANDLE SWITCH SCHEMATIC FOR EUROPE MODEL

CHAPTER 11 ENGINE PAGE 11- 16

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.11 FUEL GAUGE/ FUEL LEVEL SENSOR

Remove seat, and then remove fuel sensor

attached to fuel tank

Hold fuel sensor in an upright position after

removing it. It is normal if indicator shows
“ E ” , otherwise, circuitry connection, fuel
sensor or instrument should be inspected

Turn fuel sensor upside down. It is normal if

indicator shows “ F ” , otherwise, circuitry
connection, fuel sensor or instrument should
be inspected

CHAPTER 11 ENGINE PAGE 11- 17

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

What displays on instrument while fuel

sensor is in its upright position

What displays on instrument while fuel

sensor is in its upside-down position:

Fuel sensor resistance range

RESISTANCE(20℃/
FLOAT POSITION
68°)
TOP(FULL) 4-10Ω
BOTTOM(RESERVE) 100-110Ω

CHAPTER 11 ENGINE PAGE 11- 18

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.10.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD /DIFF LOCK SHIFT

(Fig 1)

1, The rider shifts by the Switch on handlebar.

2. The Switch gives signal to Controller.
3, The controller gives power to the solenoid.
During this time, the 4WD/Diff lock indicator is not on, this requires the rider to back or move (ride)
the ATV a little to allow the Dog change position for engagement. ( See owner’s manual or decal).

CHAPTER 11 ENGINE PAGE 11- 19

 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

TROUBLESHOOTING
Procedure
Check:
4. 1. 1Fuse 5.controler
5. 2. Battery 6. solenoid
3. Main switch 7. Wiring connection
4. 4WD/Diff lock switch

1.fuse
refer to “CHECKING SWITCHES” NO CONTINUITY
section

Replace the fuse

2. Battery
Check the battery condition. INCORRECT
Refer to “BATTERY INSPECTION”
section in CHAPTER 3

Clean battery terminals

Recharge or replace the battery

3. Main switch
NO CONTINUITY
CHECK SWITCHES

Replace the main switch

4. 4WD/Diff lock switch

NO CONTINUITY
CHECK SWITCHES

Replace the switch

5. controller
 Disconnect the controller from the
wire harness.
 Connect the controller input to the
battery.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Battery (+) lead→Brown/Black

terminal
Battery (-) lead→Green ground
Check the controller output::
(+):Dark Brown terminal
(-):Green/Orange terminal

INCORRECT

Replace the controller

6. solenoid
 Disconnect the solenoid from the
wire harness.
 Connect the solenoid to the
battery.
Battery (+) lead→Dark Brown DOES NOT MOVE
terminal
Battery (-) lead→Green ground

Replace the solenoid

POOR CONNECTIONS
7. Wiring connection
Check the connection of the entire
lighting system

correct

CHAPTER 11 ENGINE PAGE 11- 21

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11 ENGINE
10.11.1 MAINTENANCE SPECIFICATIONS
10.11.1.1 SPECIFICATIONS
10.11.1.2 TIGHTENING TORQUES

10.11.2 PARTS INSPECTION AND SERVICE

10.11.2.1 VALVE CLEARANCE ADJUSTMENT
10.11.2.2 IDLING SPEED CHECK
10.11.2.3 SPARK PLUG INSPECTION
10.11.2.4 COMPRESSION PRESSURE
10.11.2.5 ENGINE OIL LEVEL INSPECTION
10.11.2.6 COOLANT LEVEL INSPECTION

10.11.3 CYLINDER HEAD COVER

10.11.4 CYLINDER HEAD

10.11.5 CAMSHAFT AND ROCKER ARMS

10.11.6 VALVES AND VALVE SPRINGS

10.11.7 CYLINDER AND PISTON

10.11.8 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE

10.11.9 A.C. MAGNETO AND STARTER CLUTCH

10.11.10 CRANKCASE

10.11.11 CRANKSHAFT AND BALANCE SHAFT

10.11.12 OIL PUMP

10.11.13 SHIFT SYSTEM

10.11.14 TRANSMISSION SYSTEM

10.11.15 REAR OUTPUT SHAFT ASSY.

10.11.16 FRONT OUTPUT SHAFT ASSY.

10.11.17 COOLING SYSTEM

10.11.17.1 RADIATOR
10.11.17.2 WATER PUMP
10.11.17.3 THERMOSTAT
10.11.17.4 OIL COOLING PARTS

10.11.18 FUEL INJECTION SYSTEM

10.12 FRONT GEAR-BOX

10.13 REAR GEAR-BOX

CHAPTER 11 ENGINE PAGE 11- 22

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.1 MAINTENANCE SPECIFICATIONS

10.11.1.1 SPECIFICATIONS

Item Standard Limit

Cylinder head : 0.05 mm
Warp limit.
Cylinder:
Bore size 102.000- 102.015 mm 102.05 mm
Out of round limit 0.03 mm
Camshaft:
Cam height
Intake: 33.945-34.045 mm 33.745 mm
Exhaust: 33 .547- 33 .647 mm 33 .35 mm
Camshaft runout limit: ….. 0.1m m

Cam chain:
Cam chain type/No. of links 92RH2010-128

Rocker arm /rocker arm shaft:

Rocker arm inside diameter 14.000- 14.018 mm 14 .05 mm
Rocker shaft outside diameter 13.981- 13.991 mm 13.94 mm
Rocker arm - to- rocker arm shaft
clearance 0.009- 0.037 mm 0.08
Valve, Valve seat, Valve guide:
Valve clearance (cold)
IN 0.08-0.1 mm
Valve dimensions EX 0.1-0.12 mm

"A" head diameter IN 36.9-37.1mm

EX 31.9-32.1mm
"B" face width IN 2.121-2.97mm
EX 2.121-2.97mm
"C " seat width IN 0.9-1.1mm
EX 0.9-1.1 mm
"D" margin thickness IN 0.85-1.15 mm
EX 0.85-1.15 mm
Stem outside diameter IN 6.57- 6.585 mm 6.545mm
EX 6.555-6.57 mm 6.53 mm
Guide inside diameter IN 6.6- 6.615 mm 6.63mm
EX 6.6- 6.615 mm 6.63 mm

CHAPTER 11 ENGINE PAGE 11- 23

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

I te m Standard Limit
Stem-to-guide clearance IN 0.015- 0.045 mm 0.08 mm
EX 0.03-0.06mm 0.1 mm
Stem run out limit 0.05 mm
Valve seat width IN 0.9-1.1 mm 1.6 mm
EX 0.9-1.1 mm 1.6 mm

Valve spring :
Free length (Inner) IN/EX 44 mm 43.1 mm
(Outer) IN/EX 45.25 mm 44.15 mm

Piston:
Piston to cylinder 0.03 - 0.062 mm 0.15m m
clearance
Piston size "D" 101.95-101.97 mm 101.87
Measuring point "H" 10mm
Piston pin bore
inside diameter 23.002-23.008 mm 23.03 mm

Piston pin outside diameter 22.99-23.0 mm 22.98 mm

Piston rings :
Top ring :
Type Barrel …
End gap (installed) 0.2- 0.4 mm 0.55 mm
Side clearance (installed ) 0.18mm
2nd ring :
Type Taper
End gap (installed) 0.2- 0.4 mm 0.55 mm
Side clearance 0.02- 0.06 mm 0.15 mm
Oil ring :
End gap (installed) 0.2- 0.7 mm 0.9 mm
Crankshaft:

Crank width "A" 73.95-74.05 mm

Run out limit "C " 0.03 mm
Big end side clearance "D" 0.35- 0.8 mm

CHAPTER 11 ENGINE PAGE 11- 24

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

V-belt:
V-belt width 29.2 mm 27.6 mm

Oil pump:
Type Trochoid type
Tip clearance 0.1- 0.34 mm 0 .4 mm
Side clearance 0.1- 0.14 mm 0.2 mm
Housing and rotor clearance 0 .04- 0.10 mm 0.15 mm

I te m Standard Limit
Radiator:
Type Cooling fin with electric fan
Width/height/thickness 400/434/62 mm
Radiator cap opening pressure 110-140kPa (1.1-1.4kg/cm 2,
1.1-1.4bar)
Radiator capacity 3.8 L
Reservoir tank capacity 0.35 L

Thermostatic valve:
Valve opening temperature 63- 67℃
Valve full open temperature
Valve full open lift 78℃
8mm

CHAPTER 11 ENGINE PAGE 11- 25

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.1.2 TIGHTENING TORQUES

Tightening
Part Thread
Part to be tightened Q’ty Torque Remarks
name size
N.m m.kg
Bolt M6 10 1.0
Crankcase Bolt M8 2 25
Rocker shaft Bolt M8 2 15
Valve adjuster locknut Nut M6 4 14
Sprocket Bolt M10 1 50 Left-hand thread
Decompression Bolt M5 2 5 Loctite 263
camshaft baffle Bolt M6 1 10 Loctite 243
Cylinder head Stud M8 4 13
Spark plug Plug M14 1 28
Crank balancer drive gear Nut M35 1 150 Loctite 243
Crank balancer driven gear Bolt M10 2 55 Loctite 243
Oil passage Bolt M10 2 20
Crankcase Stud M10 4 18
Oil filter block Bolt M20 1 36
Oil filter M18 1 20
Drain bolt Bolt M12 1 25
Cylinder head Nut M10 4 53
Timing check plug Plug M16 1 8
Magnetic motor Nut M16 1 100
One way clutch Bolt M8 6 30 Loctite 243
Trigger coil Bolt M5 2 7 Loctite 243
Mounting bolt, driving wheel Bolt M10 1 55
Mounting bolt, driven wheel Bolt M12 1 75
Parking brake disc Screw M5 4 5 Loctite 243
Gearshift cam stopper plate Bolt M4 2 4
Gearshift cam stopper Bolt M6 1 10 Loctite 243
Drive bevel gear Nut M20 1 100
Bearing plate Screw M6 3 6 Loctite 243
Rear output shaft Nut M22 1 100
Bearing braket Stud M8 4 12
Bearing braket Nut M8 4 30
Cam chain tensioner Bolt M8 1 23 Loctite 243

CHAPTER 11 ENGINE PAGE 11- 26

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.2 PARTS INSPECTION AND SERVICE

10.11.2.1 VALVE CLEARANCE ADJUSTMENT

NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at Top Dead
Center (T.D.C.) on the compression.

1. Remove :
Spark plug
2. Remove :
CVT cover 

3. Remove :
 Water Pump 
 Observed Cover 

4. Remove :
 Valve cover (intake side)○,1
 Valve cover (exhaust side)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

5. Adjust :
Rotate the CVT primary sheave assembly
anti-clockwise to align the slit○,a on the rotor
with the stationary pointer ○,b on the right
crankcase cover when the piston is Top Dead
Center (TDC).
NOTE :
Check the slit○,c (have “EX”) on the cam
chain sprocket and the up plane○,d of the
cylinder head alignment When the piston is
Top Dead Center (TDC).
If not, rotate the CVT primary sheave
assembly anti-clockwise again.

6.Measure:
Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve 0.10- 0.12mm
Exhaust valve 0.14- 0.16mm

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 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

7. Adjust
Valve clearance
Adjustment steps:
Loosen the locknut 
Turn the adjuster○,2 in or out with a flat tip
screwdriver ○,3 until specified clearance is
obtained.
Turning in → Valve clearance is decreased
Turning out → Valve clearance is increased
Hold the adjuster to prevent it from moving
and tighten the locknut.

Measure the valve clearance.

If the clearance is incorrect, repeat above
steps until specified clearance is obtained.

8. Install:
Valve cover (intake side) 

 Valve cover gasket  NEW

9. Install:
Valve cover (exhaust side) ○,4

 Valve cover gasket ○,3 NEW

10. Install:
Water Pump

 Observed Cover

CVT cover

Spark plug

10.11.2.2 IDLING SPEED CHECK

1. Start the engine and let it warm up for
several minutes. The temperature is
lower , the engine warm up time is longer.
2. Attach:
 Inductive tachometer to the spark plug lead.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Check:
Engine idling speed
Engine idling speed:
1,300-1,500 r/min

4. Repair
If the engine idling speed is out of normal
range too much, you need to do the following:
 Check the battery voltage. When the engine
is stopped, the battery voltage should be
greater than 12 volts(≥12V).
 If the battery voltage is normal, you may
turn off the engine. Wait several minutes and
check again. (At the time, please don’t
remove the battery.)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.2.3 SPARK PLUG INSPECTION

1.Remove :
 Spark plug cap
 Spark plug

CAUTION:
Before removing the spark plug, use
compressed air to blow away any dirt
accumulated in the spark plug wells to prevent
it from falling into the cylinder.
1. Check:
Spark plug type
Incorrect Replace.
Standard spark plug:
FR8DCX (BOSCH)

2.Inspect:
Electrode 
Wear/ damage Replace.
Insulator 
Abnormal color Replace.
Normal color is a medium - to- light tan color.

3.Clean:
Spark plug
(with spark plug cleaner or wire brush)
4.Measure:
Spark plug gap ③
(with a wire gauge)
Out of specification Adjust gap.
Spark plug gap :
1.1 mm

5. Install:
Spark plug

NO TE:
Before installing a spark plug, clean the
Gasket surface and plug surface.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.9.2.4 COMPRESSION PRESSURE

MEASUREMENT
NOTE :
Insufficient compression pressure will result in
performance loss.
1. Check:
Valve clearance
Out of specification Adjust.
Refer to “VALVE CLEARANCE ADJUSTMENT”
section.
2. Start the engine and let it warm up for
several minutes.
3. Turn off the engine.
4. Remove:
Spark plug
CAUTION:
Before removing the spark plug, use
compressed air to blow away any dirt
accumulated in the spark plug well to prevent
it from falling into the cylinder.
5. Attach:
 Compression gauge
6. Measure:
 Compression pressure
If it exceeds the maximum pressure allowed
→ Inspect the cylinder head, valve surfaces
and piston crown for carbon deposits.
If it is below the minimum pressure →
Squirt a few drops of oil into the affected
cylinder and measure again. Follow the table
below.
Compression pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Possible defective ring (s),valves,
Same as
cylinder head gasket or Piston
without oil
→Repair.
Compression pressure(at sea level):
Standard: 1100±50 kPa
(11.2±0.5Kg/cm2, 11±0.5 bar)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Measurement steps :
Crank the engine with the throttle wide open
until reading on the compression gauge
stabilizes.

WARNING :
Before cranking the engine, ground all spark
plug leads to prevent sparking.
8. Install:
 Spark plug

10.11.2.5 ENGINE OIL LEVEL INSPECTION

1. Start the engine and let it warm up for a few
minutes.
2. Turn off the engine.
3. Remove:
Oil Plug○,1

4. Inspect: (Do not Oil Plug○,1 in)

Engine oil level
Oil level should be between maximum and
minimum marks②.
If oil level is below the minimum mark, then
add oil up to the proper lever.

RECOMMENDED ENGINE OIL

Refer to the chart for selection of the oils
suited to the atmospheric temperature.

API STANDARD:
API SE or higher grade

CAUTION:
Do not put in any chemical additives or
use oils with a grade of CD or higher.
Be sure not to use oils labeled
"ENERGY CONSERVING I" or higher. En-
gine oil also lubricates the clutch and ad-
ditives could cause clutch slippage.
Be sure no foreign material enters the
crankcase.

5. Start the engine and let it warm up for a few

minutes.
6. Turn off the engine.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for
several minutes.
2. Turn off the engine and place an oil pan
under the engine.
3. Remove :
Bolt plug 

 Gasket 
Drain the crankcase of its oil.
4. Install:
 Gasket
 Bolt plug
5. Fill:
Crankcase
Oil quantity:
3L
6. Check:
Engine oil level
Refer to "ENGINE OIL LEVEL INSPECTION"
section

ENGINE OIL PRESSURE INSPECTION

Inspection steps:
Slightly loosen the Drain Plug 
Start the engine and keep it idling until the
oil begins to seep from the Drain Plug. If no oil
comes out after one minute, turn the engine
off so it will not seize.
Check oil passages and oil pump for
damage or leakage.

Start the engine after solving the problem

(s), and recheck the oil pressure.
Tighten the Drain Plug to specification.

CAUTION:
Start the engine and check the oil pressure
with the Drain Plug loosened.
Do not apply at high speeds more than
specified when checking the pressure.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

NOTE:
Wipe any spilled oil off the engine.

10.11.2.6 COOLANT LEVEL INSPECTION

Inspect:
Coolant level
Coolant level should be between the
maximum○,a and minimum○,b marks.
When coolant level is below the "LOWER”
level line, Add coolant up to the proper level.
CAUTION:
Hard water or salt water is harmful to engine
parts. Use only soft water if coolant is not
available. Use only distilled water if soft water
is not available. If you use tap water, make
sure it is soft water.
1. Start the engine and let it warm up for
several minutes.
2. Turn off the engine and inspect the coolant
level again.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

NOTE:
Wait a few minutes until the coolant settles
before inspecting the coolant level.
COOLANT REPLACEMENT
1. Remove:
Front cover of ATV plastic body work.
2. Loosen:
Clamp 
3. Remove:
Hose○,2 (reservoir tank)
Drain the reservoir tank of its coolant.
4. Remove:
Clamp 
Hose ○,2
Radiator cap
WARNING:
Do not remove the hose ○,2 when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury. When the engine has cooled,
remove the hose.
When you remove the hose, please make
sure the exhaust pipe○,3 is not hot. The
hot exhaust pipe may cause burns.
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury. When the engine has cooled, open
the radiator cap as follows:
Place a thick rag or a towel over the
radiator cap. Slowly rotate the cap
counterclockwise toward the detent. This
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning
counterclockwise and remove it.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

5. Drain:
When you remove the hose, the coolant will
flow out.
WARNING:
When the coolant flows out, place a basin
under the hose.
The coolant may be for environmental
harm, please don’t be arbitrarily discarded.
6. Install:
 Hose 
 Clamp 

7. Connect:
Hose (reservoir tank)
8. Tighten:
Clamp (hose of the reservoir tank)
9. Fill:
Radiator ( to specified level )
Fill the coolant slowly, until the coolant comes
to specified level.
Reservoir tank
( to maximum level○,a )

Recommended coolant:
High quality ethylene glycol
anti-freeze containing corrosion
inhibitors for aluminum engine.

Total amount: 3.8L

Reservoir tank capacity: 0.35L

Handling notes for coolant:

Coolant is potentially harmful and should be
handled with special care.

WARNING:
splashes in your eyes:
Thoroughly wash your eyes with water and
consult a doctor.
If coolant splashes on your clothes:
Quickly wash it away with water and then with
soap and water.
If coolant is swallowed:
Vomit immediately and see a physician.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

CAUTION:
Do not use coolant containing impurities or
oil.
Take care that no coolant splashes onto
painted surfaces. If it does, wash them
immediately with water.
Do not mix different types of ethylene glycol
antifreeze containing corrosion inhibitors for
aluminum engines.

10. Install:
Radiator cap
11. Start the engine and let it warm up for
several minutes.
12. Stop the engine and inspect the level.

NOTE:
Wait a few minutes until the coolant settles
before inspecting the coolant level.

CHAPTER 11 ENGINE PAGE 11- 38

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.3 CYLINDER HEAD COVER

Order Job name / Part name Q ’ty Remarks

Cylinder head cover removal Remove the parts in order.
Water Pump 1
1 Drain Plug B 1
2 Composite gasket 4
3 Drain Plug A 1
4 Tubing Components 2 1
5 Bolt M6×16 4
Apply bond to the mating surface of
the valve cover.
6 Valve cover (intake side) 1
CAUTION: If this is not done, oil
may leak.
Apply bond to the mating surface of
the valve cover.
7 Valve cover (exhaust side) 1
CAUTION: If this is not done, oil
may leak.
8 Valve cover gasket 2
9 Bolt M6×32 2
10 Pin 8×9 2
11 Bolt M6×60 1
12 Bolt M6×25 6
13 Bolt M6×105 2
14 Cylinder Head Cover 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

 Refer to "CYLINDER HEAD COVER REMOVAL AND INSTALLATION" section. Reverse the
removal procedure for installation.
CYLINDER HEAD COVER REMOVAL
1. Remove :
 Water Pump ○,1
2. Remove :
 Drain Plug B ○,2
 Composite gasket
 Drain Plug A
 Tubing Components 2 ○,3
3. Remove :
 Valve cover (intake side)
 Valve cover (exhaust side)
4. Loosen:
 Bolt
NOTE:
Loosen the nuts in their proper loosening
sequence (number order).
Start by loosening each nut 1/2 turn until all
are loose.
5. Remove:
 Bolt
6. Remove:
 Cylinder head Cover

CYLINDER HEAD COVER INSPECTION:

1. Eliminate:
 Sealant (from the surface○,a) use a rounded
scraper.
NOTE:
Do not use a sharp instrument to avoid
scratching the plane○,a.
2. Inspect:
Cylinder head cover
Scratches/damage → Replace

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Measure:
Cylinder head cover warpage
Out of specification → Resurface .

Warpage measurement and resurfacement

steps:
Place a straight edge and a feeler gauge
across the cylinder head cover.
Measure the warpage.
If the warpage is out of specification,
resurface the cylinder head cover.
 Place a 400 ~ 600 grit wet abrasive paper
on the surface plate, and resurface the head
cover using a figure eight sanding paten.

NOTE:
Rotate the cylinder head cover several times
for an even resurfacement.

CYLINDER HEAD COVER INSTALLATION

1. Install:
Dowel pins
Cylinder head cover

NOTE:
Apply the sealant onto the surface○,a.
Tighten the nuts in a crisscross pattern
(number order).

2. Tighten:
Bolts (cylinder head cover)

3. Check
Valve clearance
Out of specification → Adjust.
NOTE:
Refer to “VALVE CLEARANCE ADJUSTMENT”
section.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

4. Install:
 Valve cover gasket NEW
 Valve cover (intake side)
 Bolts (Valve cover)

5. Install:
 Valve cover gasket NEW
 Valve cover (exhaust side)
 Bolts (Valve cover)

6. Install:
 Composite gasket NEW
 Tubing Components 2
 Composite gasket NEW
 Drain Plug B and Drain Plug A

7. Install:
 Water Pump

CHAPTER 11 ENGINE PAGE 11- 42

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.4 CYLINDER HEAD

Order Job name / Part name Q ’ty Remarks

Cylinder Head Cover removal Remove the parts in order.
Pipe A, Exhause 1
Pipe B, Exhause 1
Water Pump 1
Drain the coolant
Air Cleaner 1
Cylinder head cover 1
Spark Plug cap 1
1 TB D46 (Throttle Body Assembly D46) 1
2 Bolt M8×25 2
3 Feed Hose Assy. 1
4 O-Ring 51.5×2 2
5 Joint, TB 1
6 Split Washer d5 1
7 Decompression Centrifugal Shaft 1
8 Tighten Bolt (Cam Chain Sprocket) 1
9 Sprocket Washer 1

10 Bolt M6×30 2

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name / Part name Q ’ty Remarks

11 Cam Chain Tensioner Assy. 1
12 Gasket, Tensioner Case 2
13 Joint, Tensioner Assy. 1
14 Cam Chain Sprocket 1
15 Nut M10×1.25 4
16 Washer 10 4
17 Spark Plug 1
18 Gasket 1, Cylinder Head 1
19 Dowel Pin 14×16 1
 Refer to "CYLINDER HEAD REMOVAL AND INSTALLATION" section. Reverse the removal
procedure for installation.

CYLINDER HEAD REMOVAL

1. Align:
"I" mark ○,a on the rotor with the stationary
pointer○,b on the right crankcase cover.
NOTE:
If any special mark found, contact the ATV
manufacture via the agent for the parts and
special instruction.
NOTE:
Turn the CVT primary sheave assembly
counterclockwise with a wrench and align
the "I" mark○,c (have “EX”) on the cam chain
sprocket with the up plane○,d of the cylinder
head when the piston is Top Dead Center
(TDC).
Refer to “VALVE CLEARANCE ADJUSTMENT”
section, part 5 “Adjust”.

2. Remove:
 Split Washer d5○,1
 Decompression Centrifugal Shaft○,2

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Loosen:
 Tighten Bolt (Cam Chain Sprocket) 
4.Remove:
 Sprocket Washer ○,2
Cam Chain Tensioner Assy.○,3
Gasket, Tensioner Case
Joint, Tensioner Assy.
Cam Chain Sprocket○,4
Timing chain○,5

NOTE:
Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
Remove the Tighten Bolt  while holding
the rotor mounting bolt with a wrench.
5. Remove:
 Cylinder head
NOTE:
Loosen the nuts in their proper loosening
sequence.
Start by loosening each nut 1/2 turn until all
are loose.

CYLINDER HEAD INSPECTION:

1. Eliminate:
Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
Spark plug threads
Valve seats

2. Inspect:
Cylinder head
Scratches/damage → Replace.
3. Measure:
Cylinder head warpage
Out of secification → Resurface .

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Warpage measurement and resurfacement

steps:
Place a straight edge and a feeler gauge
across the cylinder head.
Measure the warpage.
If the warpage is out of specification,
resurface the cylinder head.
 Place a 400 ~ 600 grit wet abrasive paper
on the surface plate, and resurface the head
using a figure eight sanding paten.
NOTE:
Rotate the cylinder head several times for an
even resurfacement.

CYINDER HEAD INSTALLATION

1. Install:
Gasket (cylinder head) NEW
Dowel Pin 14×16
Cylinder head
NOTE:
Apply engine oil onto the nut threads.
Tighten the nuts in a crisscross pattern.
2. Tighten:
Nuts (cylinder head)

3. Install:
Cam Chain Sprocket 
Timing chain 

Installing steps :
Turn the CVT primary sheave assembly （or
the primary sheave）counterclockwise until
the TDC mark ○,a matches the stationary
pointer ○,b.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Align the "I" mark○,c (have “EX”) on the

cam chain sprocket with the up plane○,d of
the cylinder head.
NOTE:
If any special mark found, contact the ATV
manufacture via the agent for the parts and
special instruction.
Refer to “VALVE CLEARANCE ADJUSTMENT”
section, part 5 “Adjust”.
Fit the timing chain onto the cam sprocket
and install the cam chain sprocket on the
camshaft.

NOTE:
When installing the cam sprocket, keep the
timing chain as tense as possible on the
exhaust side.
Align the "I" mark○,c (have “EX”) on the cam
chain sprocket with the up plane ○,d of the
cylinder head.
Align the pin on the cam shaft with the slot in
the cam chain sprocket.

CAUTION:
Do not turn the crankshaft during installation of
the cam shaft. Dam age or improper valve
timing will result.
While holding the camshaft, temporarily
tighten the bolts.
Remove the safety wire from the timing
chain.
4. Install:
 Sprocket Washer
5. Tighten:
 Tighten Bolt (Cam Chain Sprocket)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

6. Install:
 Cam Chain Tensioner Assy.
Installing steps:
Remove the tensioner cap bolt.
Turn a small flat tip screwdriver○,2 clockwise
in the hole○,3 of the Cam Chain Tensioner
Assy until the tensioner rod ○,4all the way in.
7. Install:
 Gasket, Tensioner Case NEW
 Joint, Tensioner Assy.
 Gasket, Tensioner Case NEW
8. Tighten:
 Bolt M6×30

9.Tighten：
 Tighten the tensioner cap bolt. Please in
the thread place daub a little sealant.

10. Install:
 Split Washer d5
 Decompression Centrifugal Shaft
11. Check:
 Valve timing
Out of alignment → Adjust.
Repeat installing sequence 3 ~ 5
12. Check:
 Valve clearance
Out of specification → Adjust.
Refer to “VALVE CLEARANCE ADJUSTMENT”
section,

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 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.5 CAMSHAFT AND ROCKER ARMS

10.11.5.1 ROCKER ARMS

Order Job name / Part name Q ’ty Remarks

Rocker Arms removal Remove the parts in order.
Cylinder Head Cover 1
1 Lock Rocker Arm Bolt 2
2 Washer d8 (aluminum ) 2
3 Rocker Arm Shaft & O-Ring 9.8×2.4 2
4 Rocker Arm (exhaust) 1
5 Rocker Arm (intake) 1
 Refer to "ROCKER ARMS INSTALLATION" section. Reverse the removal procedure for installation.

ROCKER ARMS REMOVAL

1. Remove:
Lock Rocker Arm Bolt
Washer d8 (aluminum )
2. Remove:
Rocker Arm Shaft & O-Ring 9.8×2.4

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 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

ROCKER ARMS AND ROCKER ARM SHAFTS

INSPECTION
1. Inspect:
Cam lobe contact surface 
Adjuster surface 
Wear/Pitting/Scratches/Blue/Non-rotation
discoloration→Replace.

Inspection steps:
Inspect the two contact areas on the rocker
arms for signs of unusual wear.
Rocker arm shaft hole.
Cam-lobe contact surface.
Excessive wear → Replace.
Inspect the surface condition of the rocker arm
shafts.
Pitting/scratches/blue discoloration → Replace or
check lubrication.
Measure the inside diameter A of the rocker arm
holes.
Out of specification → Replace.
Inside diameter (rocker arm ):
14.000- 14.018 mm
< Limit: 14.05 mm >

Measure the outside diameter B of the rocker

arm shafts.
Out of specification → Replace.
Outside diameter(rocker arm shaft):
13.981- 13.991 mm
< Limit: 13.94 mm >

ROCKER ARM INSTALLATION

6. Lubricate:
Molybdenum disulfide oil onto the rocker arm
and rocker arm shaft.
7. Install:
Rocker Arm (exhaust)
Rocker Arm Shaft & O-Ring 9.8×2.4

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 CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

8. Install:
Rocker Arm (intake)
Rocker Arm Shaft & O-Ring 9.8×2.4
NOTE:
Before installing the Rocker Arm Shaft & O-Ring
9.8×2.4, check the O-Ring 9.8×2.4. If the O-Ring
is damaged, replace it.
9. Install:
Washer d8 (aluminum )
Lock Rocker Arm Bolt

NOTE:
When installs the Lock Rocker Arm Bolt, the
groove○,c on the Rocker Arm Shaft should match
with the hole(○,a/○,d) in the Cylinder head cover.
If not, the Lock Rocker Arm Bolt maybe damage.
10.11.5.2 CAMSHAFT

Order Job name / Part name Q ’ty Remarks

Camshaft removal Remove the parts in order.
Cylinder Head 1
1 Bolt 6×12 1
2 Plate, Locate 1
3 Camshaft 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

 Refer to "CAMSHAFT INSTALLATION" section. Reverse the removal procedure for installation.

CAMSHAFT REMOVAL
2. Remove:
 Bolt 6×12
 Plate, Locate

CAMSHAFT INSPECTION
1. Inspect:
Cam lobes○,a
Pitting/Scratches/Blue discoloration →Re-place

2. Measure:
Cam lobes length ○,a
Out of
Cam lobes length:
Intake:
33.945-34.045 mm
<Limit: 33.745 mm>
Exhaust:
33 .547- 33 .647 mm
<Limit: 33.35 mm>

specification → Replace.
3. Inspect:
Cam shaft oil passage
Stuffed → Blow out oil passage with
compressed air.

CAMSHAFT INSTALLATION
1. Lubricate:
Camshaft
Camshaft:
Molybdenum disulfide oil
Camshaft bearing:
Engine oil

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

2. Install:
Camshaft

3. Install:
Plate, Locate
Bolt 6×12

NOTE:
Apply Loctite 243(Blue) to screw threads

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.6VALVES AND VALVE SPRINGS

Order Job name / Part name Q ’ty Remarks

Valves and valve springs removal Remove the parts in order.
Cylinder head 1 Refer to "CYLINDER HEAD " section .
Camshaft 1 Refer to "CAMSHAFT" section.
1 Valve cotters 8
2 Spring retainer 4
3 Valve spring (inner) 4
4 Valve spring (Outer) 4
5 Valve (intake) 2
6 Valve (exhaust) 2
7 Seal Valve Stem 4
8 Spring seat 4
Refer to "VALVES AND VALVE SPRINGS INSTALLATION" section. Reverse the removal
procedure for installation.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

VALVES AND VALVE SPRINGS REMOVAL

1. Remove:
 Valve cotters 
NOTE:
Attach a valve spring compressor and
attachment  between the valve spring
retainer and cylinder head to remove the valve
cotters.

CAUTION:
Do not compress so much as to avoid damage
to the valve spring.

VALVE AND VALVE SPRINGS INSPECTION

1. Measure:
Valve stem diameter
Out of specification → Replace.

Valve stem diameter:

Intake:
6.57-6.585mm
<Limit: 6.545mm>
Exhaust:
6.555-6.57mm
<Limit: 6.53mm>

2. Measure:
Runout (valve stem )
Out of specification → Replace.
Runout limit:
0.05 mm
3. Measure:
Free length (valve spring)
Out of specification → Replace.
Valve spring free length:
Inner spring:
44 mm
<Limit: 43.1mm>
Outer spring:
45.25 mm
<Limit: 44.14mm>

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

4. Measure:
Spring tilt
Out of specification → Replace.

Spring tilt limit:

1.7mm (2.5º)

5. Inspect:
 Spring contact face
Wear/Pitting/Scratches → Replace.

6. Measure:
Valve guide inside diameter
Out of specification → Replace.

Valve guide inside

diameter:
Intake:
6.6-6.615 mm
<Limit: 6.63mm>
Exhaust:
6.6-6.615 mm
<Limit: 6.63 mm>

7. Measure:
Stem-to-guide clearance=
Valve guide inside diameter-
Valve stem diameter

Stem-to-guide clearance:
Intake:
0.015-0.045mm
<Limit:0.08 mm>
Exhaust:
0.03-0.06mm
<Limit:0.10 mm>
Out of specification → Replace the valve
guide.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

VALVE SEATS INSPECTION

1. Eliminate:
Carbon deposits
(from the valve face and valve seat)
2. Inspect:
Valve seats
Pitting/wear → Reface the valve seat.

3. Measure:
Valve seat width ○,a
Out of specification → Reface the valve seat.

Valve seat width:

Intake:
0.9-1.1mm
<Limit:1.6mm>
Exhaust:
0.9-1.1mm
<Limit:1.6mm>

Measurement step:
Apply Mechanic’s blueing dye (Dykem) to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be replaced.

4. Lap:
Valve face
Valve seat
NOTE:
After replacing the valve seat, valve and valve
guide, the valve seat and valve face should be
lapped.

Lapping steps:
Apply a coarse lapping com pound○,a to the
valve face.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

CAUTION:
Do not let compound enter the gap between
the valve stem and the guide.
Apply molybdenum disulfide oil to the valve
stem.
Install the valve into the cylinder head.
Turn the valve until the valve face and valve
seat are evenly polished, then clean off al com
pound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hand.
Apply a fine lapping compound to the valve
face and repeat the above steps.
NOTE:
Make sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
Apply Mechanic’s blueing dye (Dykem) ○,b
to the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
Measure the valve seat with ○,c again.

VALVES AND VALVE SPRINGS

INSTALLATION
1. Deburr:
Valve stem end
Use an oilstone to smooth the stem end.
2. Apply:
Molybdenum disulfide oil
(onto the valve stem and oil seal  )

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Install:
Valve spring seat 
Valve stem sealNEW
Valve (into the cylinder head)
Valve spring (under) 
Valve spring (outer) 
Spring retainer 

NOTE:
Install the valve spring with the larger pitch
○,a facing upwards.
○,bSmaller pitch

4. Instal:
Valve cotters 
NOTE:
Install the valve cotters while com pressing
the valve spring with a valve spring
compressor and attachment .

5. Secure the valve cotters onto the valve

stem by tapping lightly with a piece of wood.

CAUTION:
Do not hit so much as to damage the valve.

CHAPTER 11 ENGINE PAGE 11- 59

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.7CYLINDER AND PISTON

Order Job name / Part name Q ’ty Remarks

Cylinder and piston removal Remove the parts in order.
Cylinder head Refer to " CYLINDER HEAD "
1 Timing chain guide 1 section .
2 Cylinder 1
3 Dowel pin 2
4 Cylinder gasket 1
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Piston ring 1 set (top ring) 1
9 Piston ring 2 set (2nd ring) 1
10 Side rail/Spacer 3
11 Gasket , cylinder 1
12 Inlet pipe, cylinder 1
13 Hose , water pump 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

PISTON AND PISTON RINGS

REMOVAL
1. Remove:
Piston pin clip 
Piston pin 
Piston 

NOTE:
Before removing the piston pin clip, cover
the crankcase opening with a clean towel
or rag to prevent the clip from falling into
the crankcase cavity.

2. Remove:
Top ring
2nd ring
Oil ring

NOTE:
When removing the piston ring, open the
end gap of the ring by fingers, and push up
the other side of the ring.

CYLINDER INSPECTION
1. Measure:
Cylinder bore
Out of specification → Rebore or replace.

NOTE:
Measure the cylinder bore with a cylinder
bore gauge.
Measure the cylinder bore in parallel to
and a right angle to the crankshaft. Then,
find the average of the measurements.

Cylinder bore:
102.000- 102.015 mm
< Limit: 102.05 mm>
< Difference limit between A,B
and C :0.03m m >

2. Measure:
Warpage
Out of specification → Replace.

Cylinder warpage limit:

0.03mm

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

PISTON AND PISTON PIN INSPECTION

1. Measure:
Piston skirt diameter
Out of specification → Replace .
○,a 10.0mm from the piston bottom edge.

Valve skirt diameter:

101.95-101.97 mm
< Limit: 101.87 mm>

2. Calculate:
Piston-to-cylinder clearance
Piston-to-cylinder clearance=
Cylinder bore-Piston skirt diameter
Refer to “CYLINDER” section for cylinder
bore measurement.
Out of specification → Replace the piston
and piston rings as a set.
Piston-to-cylinder clearance:
0.03 - 0.062 mm
<Limit:0.15mm>

3. Measure:
Piston pin bore diameter
Out of specification → Replace.
Piston pin bore diameter:
23.002-23.008mm
<Limit: 23.03mm>

4. Measure:
Piston pin outside diameter
Out of specification → Replace.
Piston pin bore diameter:
22.99-23.0mm
<Limit: 22.98mm>

5. Inspect:
Piston pin
Blue discoloration/groove → Clean or
replace.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

PISTON RINGS INSPECTION

1. Measure:
Side clearance ○,1
Out of specification → Replace the piston
and the piston rings as a set.
NOTE:
Eliminate the carbon deposits from the piston
ring grooves and rings before measuring the
side clearance.
Side clearance (piston ring):
Top ring:

<Limit: 0.18mm>
2nd ring:
0.02 - 0.06mm
<Limit: 0.15mm>

2.Position:
Piston ring into the cylinder

NOTE :
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder
bore.

○,1 5.0mm

3. Measure:
End gap
Out of specification → Replace.
NOTE:
You cannot measure the end gap on the
expander spacer of the oil ring. If the oil ring
rails show excessive gap, replace all three
rings.
End gap:
Top ring:
0.20-0.40mm
<Limit:0.55mm>
2nd ring:
0.20-0.40mm
<Limit:0.55m m>
Oil ring:
0.20-0.70mm
<Limit:0.90m m>

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

PISTON RINGS, PISTON AND

CYLINDER INSTALLATION
1. Install:
Top ring 
2nd ring 
Side rails (oil ring) 
Expander spacer (oil ring) 

NOTE:
1st ring (1) and 2nd ring (2) differ in shape.
Face the side with the edge “C” and
stamped mark ”D” when assembling.
When installing the spacer, be careful so
that the both edges are not overlapped.
Lubricate the pistons and piston rings
liberally with engine oil

2.Install:
Piston 
Piston pin 
Piston pin clip  NEW
NOTE:
Apply engine oil to the piston pins.
make sure to install the piston so that the
intake valve are located above of the exhaust
valve(the intake valve is bigger than the
exhaust valve)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Before installing the piston pin clip, cover

the crankcase opening with a clean rag to
prevent the piston pin clip from falling into the
crankcase.

3. Install:
Gasket (cylinder) NEW
Dowel pins
4. Position:
Piston rings
NOTE:
Position the gaps of three rings and side rails
as shown. Before inserting piston into the
cylinder, check that the gaps are so located.
“D”: 2nd ring and lower side rail
“E” upper side rail
“F” 1ST ring and spacer

5. Lubricate:
Piston outer surface
Piston ring
Cylinder inner surface

Engine oil

6. Install:
Cylinder

NOTE:
Install the cylinder with one hand while com
pressing the piston rings with the other hand.
Pass the timing chain and timing chain
guide (exhaust side) through the timing chain
cavity.

7. Install:
socket head bolt

NOTE:
 Apply Loctite 243(Blue) to screw threads
and torque screws to 10N.m

CHAPTER 11 ENGINE PAGE 11- 65

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.8 V-BELT,CLUTCH AND SECONDARY/PRIMARY SHEAVE

COVER (LEFT)

Order Job name / Part name Q ’ty Remarks

cover (left) Remove the parts in order.

removal
1 socket head cap screws 8 Tightening torque:10N.m
2 m6x20
cvt big cover componets 1
3 out pipe 1
4 washer,cvt big cover 1

Reverse the removal

procedure for installation .

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

V-BELT, DRIVEN ASSY COMPLETE&PRIMARY SHEAVE

Order Job name / Part name Q ’ty Remarks

V-belt, driven assy complete/ Remove the parts in order

primary sheave removal
mounting bolt,driving wheel 1/1
1
2 installation sleeve,driving sheel 1/1
3 mounting bolt,driven wheel 1
4 installation sleeve,driven sheel 4
5 driving wheel sub-assy. 8
6 driven sheel sub-assy. 1 Reverse the removal
7 belt 1 procedure for installation.

CHAPTER 11 ENGINE PAGE 11- 67

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

DRIVING WHEEL REMOVAL

1. Remove:
Bolt (primary sheave)
Plate washer
Use the driving cluch puller
remove the driving wheel

DRIVEN ASSY AND V-BELT

REMOVAL
1. Remove:
 Bolt  (driven assembly)
 Plate washer
 Driven assembly
 V-belt ③

CLUTCH CARRIER INSPECTION

1.Inspect:
Scratches → Glaze using coarse
sandpaper.
Wear /Damage → Replace

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

V-BELT INSPECTION
1.Inspect:
V-belt 
Cracks/Wear /Scaling /Chipping →
Replace.
Oil/Grease → Check primary
sheave and secondary sheave.
2. Measure:
V-belt width 
Out of specification → Replace

V-belt width:
29.2mm
(Limit:27.6 mm)

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.9 A.C. MAGNETO AND STARTER CLUTCH

MAGNETO COVER AND STATOR COIL

Order Job name / Part name Q ’ty Remarks

Magneto cover and stator coil Remove the parts in order.
removal Refer to "ENGINE OIL REPLACEMENT"
Drain the engine oil. section.

1 Couplers (A.C. magneto lead) 1 NOTE:

2 1 Disconnect the couplers
Couplers（Pick up coil lead）
3 Magneto cover 1
4 Gasket (magneto cover) 1
5 Dowel pins 2
6 Pick up coil 1
7 Stator coil 1

Reverse the removal procedure for

installation.

NOTE:
Apply Loctite 243(Blue) to screw threads
and torque screws to 8N.m and 10N.m

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

A. C. MAGNETO AND STARTER CLUTCH

Order Job name / Part name Q ’ty Remarks

A.C. magneto and starter clutch Remove the parts in order.
removal
1 Rotor 1 Refer to "A.C. MAGNETO ROTOR
REMOVAL /INSTALLATION" section

2 Starter torque limiter 1

3 idle gear shaft 1
4 idle gear 1
5 Starter one way clutch assembly 1
6 Woodruff key 1
7 Starter driven gear 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

A.C. MAGNETO ROTOR REMOVAL

1. Remove:
Nut  (rotor)
washer (rotor)

2. Remove:
Rotor
Woodruff key

NOTE:
special tools and equipment
flywheel puller

Remove the rotor with the flywheel puller.

Screw the flywheel puller in the rotor.
Make sure the threaded connections of the
flywheel puller and rotor tightening, then
screwing in the special bolt.

3. Remove:
Starter torque limiter
 idle gear shaft
 idle gear

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

4. Remove:
Starter one way clutch assembly
1) Hold the generator rotor with a 41mm offset
wrench and remove the starter clutch bolts

2) Remove the one way clutch(1) from the

guide(2).

CAUTION:
Cover the crankshaft end with the box wrench
for protection.
STARTER DRIVE GEAR INSPECTION
1. Inspect:
Starter idle gear teeth
Starter drive gear teeth
Starter torque limiter teeth
Burrs /chips /roughness /wear → Replace.

2. Check:
Starter clutch operation
1) Install the starter driven gear onto the
starter clutch.
2) Turn the starter driven gear by hand to
inspect the starter clutch for smooth
movement. The gear turns in one
direction only（A）. If a large resistance is
felt for rotation, inspect the starter clutch
or the starter clutch contacting surface on
the starter driven gear for wear or
damage.
3) If they are found to be damaged, replace
the one way clutch with a new one.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Starter torque limiter.

CAUTION:
Do not attempt to disassemble the starter
torque limiter. The starter torque limiter is
available only as an assembly.
1）Set the starter torque limiter to the special
tools and vise.
2）Turn the starter torque limiter and check
the slip torque.
Special tool
Starter torque limiter holder(A)
Starter torque limiter socket(B)
Starter torque limiter slip torque
Standard : 41.2-62.8N.m(4.2-6.4kgf-m)

Starter driven gear bearing

Inspect the starter driven gear bearing for
wear or damage. If necessary, replace it with
a new one.

A.C. MAGNETO ROTOR INSTALLATION

1. Install:
 Starter clutch
1) When inserting the one way clutch(1)into
the guide(2), fit the flange ”A” in the step of
the guide(2).

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Note:
Be sure to seat the flange “A” of the one
way clutch (1) to the guide (2).

2) Install the guide to the generator rotor.

Note :
The arrow mark “B” must face the generator
rotor side

3) Apply Loctite 243(Blue) to the bolts, and

then tighten them to the specified
toque.(30N.m)

2. Install
Starter driven gear.
Woodruff key 

NOTE:
Install the starter wheel gear, then install
the woodruff key.
Engine oil

3. Install:
Rotor
Plain washer (rotor)
 Nut  (rotor)
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
When installing the magneto rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.

4.Tighten:
Nut(rotor) 100N.m

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

NOTE:
Apply Loctite 243(Blue) to screw threads and
torque screws to 100N.m

5. Install:
 idle gear& idle gear shaft
 Starter torque limiter
Engine oil

CHAPTER 11 ENGINE PAGE 11- 76

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.10CRANKCASE

Order Job name/ Part name Q'ty Remarks

· Wipe the crankcase mating surface
(both surfaces)
· Insert the locating pin(34) onto the
1 Left crankcase 1
crankcase
·Apply bond to the mating surface of the
left crankcase
2 Oil road plug 1
3 Right crankcase 1
4 Engine mount bushing 4
5 Tubing components 1 1
6 Needle roller bearing baffle 4
7 O- ring 8.8X1.9 2 Apply grease
8 Tubing baffle 2
9 Oil passage bolt A 1 Tightening torque:20N.m
10 Oil filter block 1 Tightening torque:36N.m
11 Double end studs 4 Tightening torque:23N.m
12 Oil passage bolt B 1 Tightening torque:20N.m
13 Limit axis 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name/ Part name Q'ty Remarks

14 Oil-cooling connector 1
15 Ring 1
16 O -ring 11.2X1.8 2 Apply grease
17 Tubing components 2 1
18 Combinatorial gasket 4
19 Ventilation mouth components 1
20 Oil seal 45X55X4 1 Apply grease
21 Oil strainer 1
22 Cold oil connector tube assembly 2
23 Oil filter 1 Tightening torque:20N.m
24 Drain bolt 1 Tightening torque:26N.m
25 Washer 1
26 Bearing 6209 1
27 Bearing 6209-2U 1 First installation the seal to bearing
6209-2U, then installation the bearing
28 Seal 1 6209-2U to left crankcase

29 Bearing 6004 2
30 Bearing 5206 1
31 Bearing 6205 3
32 Bearing 6204 1
33 Bearing 61805 1
34 Locating pin 10X16 2
35 Needle roller bearings NK20/16 2
36 Locating pin 8X14 6
37 Nut M10X1.25 4 Tightening torque:45N.m
38 Washer 10 4
Apply Loctite 243(Blue)
39 Socket head cap screws M5X12 1
Tightening torque:7N.m
Apply Loctite 243(Blue)
40 Socket head cap screws M6X12 6
Tightening torque:10N.m
41 Socket head cap screws M8X80 1 Tightening torque:25N.m
42 Socket head cap screws M8X95 1 Tightening torque:25N.m
43 Socket head cap screws M6X55 3
44 Bolt M6X45 1
45 Bolt M6X70 2
46 Bolt M6X80 1 Tightening torque:10N.m
47 Bolt M6X110 2
48 Bolt M6X30 1
49 Bolt M6X12 2

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.11CRANKSHAFT AND BALANCE SHAFT

Order Job name/ Part name Q'ty Remarks

Apply Loctite 243(Blue)
Tightening torque:150N.m
Lock the crank balancer drive gear nut with a
center punch.

1 Locknut M35x1.5 1

CAUTION: the removed nut must be

replaced with a new one.
2 key 1
3 Flat key A4x20 1
4 Flat key A4x30 1
5 Cylindrical pin 5x8 1

CHAPTER 11 ENGINE PAGE 11- 79

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name/ Part name Q'ty Remarks

Apply Loctite 243(Blue)
6 Bolt M10x1.25x25 2
Tightening torque:55N.m
7 Crankshaft assy. 1
8 Initiative sprocket oil pump 1
9 Front balance shaft 1
10 Rear balance shaft 1
Align the punch mark as shown in the figure.

11 Crank balancer drive gear 1

12 Crank balancer driven gear B 1

13 Crank balancer driven gear A 1

CRANKSHAFT INSPECTION
1. Measure:
Crankshaft runout
Out of specification → Replace crankshaft
and/or bearing.

NOTE:
Measure the crankshaft runout with the
crankshaft assembly running slowly.

Runout limit:
0.03 mm

2. Measure:
Big end side clearance
Out of specification → Replace big end
bearing, crank pin and/or connecting rod.

Big end side clearance:

0.35-0.80 mm

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

3. Measure:
Crank width
Out of specification → Replace crankshaft.

Crank width:
73.95-74.05 mm

4. Inspect:
Crankshaft sprocket
Wear/ Damage → Replace crankshaft.

Crankshaft journal
Clogged → Blow out the journal with
compressed air.

CHAPTER 11 ENGINE PAGE 11- 81

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.12OIL PUMP

Order Job name/ Part name Q'ty Remarks

Oil pump removal Remove the parts in the order.
Drain the engine oil. Refer to "ENGINE OIL REPLACEMENT"
section.
V-belt, clutch, secondary/ primary Refer to "V BELT, CLUTCH AND
sheave SECONDARY/ PRIMARY SHEAVE"
section.
1 Cvt small cover componets 1
2 Wash B , small cover 1
3 Wash A , small cover 1
4 Left cover 1
5 Dowel pins 1
6 Gasket , left cover 1
7 Oil pump driven gear 1
8 Oil pump drive gear 1
9 chain 1
10 Cylindrical pin 4 X 16 2
11 Pump housing 1
12 Oil pump shaft 1
13 Inner rotor 1
14 Outer rotor 1
15 Pump housing cover 1
16 Gasket , oil pump 1
17 Drain plug 1
Reverse the removal procedure for
installation.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

OIL PUMP INSPECTION

1. Inspect:
Oil pump driven gear
Pump housing
Pump housing cover
Oil pump drive gear
Wear /cracks/ damage → Replace.

Rotate the oil pump by hand and check that it

moves smoothly. If it does not move smoothly,
Replace the oil pump assembly.

2. Measure:
 Tip clearance
(between the inner rotor  and the outer
rotor)
Side clearance
(between the outer rotor  and the pump
housing  )
Housing and rotor clearance
(between the pump housing  and the rotors
 )
Out of specification → Replace the oil pump
assembly.

Tip clearance □,A:

0.10-0.34 mm <Limit: 0.40mm>
Side clearance □,B:
0.1- 0.14mm <Limit:0.20mm>
Housing and rotor clearance □,C:
0.04-0.10 mm <Limit: 0.15mm>

OIL PUMP INSTALLATION

1. Install:
CHAPTER 11 ENGINE PAGE 11- 83
CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

 Oil pump
Install the oil pump in the reverse of removal.
pay attention to the following points.
1) Apply Loctite 243(Blue) to the oil pump
bolts
2) Install the new snap ring

2. Install
 Oil pump drive gear and chain
NOTE:
1) Install the oil pump drive gear with chain.
2) The flange side of the oil pump drive gear
inside.

3)Apply Loctite 243(Blue) to the oil pump drive

gear bolt.
4) Hold the crank balancer driven gear and Refer to " CRANKCASE AND CRANKSHAFT "
tighten the oil pump drive gear bolts to 60N.m. section

CHAPTER 11 ENGINE PAGE 11- 84

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.13SHIFT SYSTEM

CHAPTER 11 ENGINE PAGE 11- 85

CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name/ Part name Q'ty Remarks

Align the punch mark as shown in
1 Shift drum shaft 1 the figure
Align the punch mark as shown in
2 Low speed-reverse shift drum 1
the figure
3 High Gearshift Fork 1
4 Shift compression spring 3
Align the punch mark as shown in
5 High gearshift drum 1
the figure
6 Washer 28.2 3
Align the punch mark as shown in
7 Parking stalls shift drum 1
the figure
8 Gearshift cam stopper plate 1
9 In the car stalls plectrum 1
10 Gearshift fork shaft 1
11 Low/reverse gearshift fork 1
12 Return spring 1
13 Gearshift cam stopper bolt 1
14 Gearshift cam stopper 1
15 Shift shaft assy. 1
Align the punch mark as shown in
the figure（order 8 and order 16）

16 Shift gear assy. 1

17 Gearshift shaft 1
18 Sleeve 1
19 Gearshift return spring 1
20 Washer 14 1
21 Ring 14 1
22 B-type cylindrical pin 1
23 Ring 28 4
24 Socket head cap screws M4X35 2
25 Open retaining ring 6 1
26 Washer 6 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.14TRANSMISSION SYSTEM

Order Job name/ Part name Q'ty Remarks

1 Drive shaft 1
2 Reverse idle gear shaft 1
3 Reverse sleeve 1
4 Reverse idle gear 1
5 Parking brake disc 1
6 Counter shaft 1
7 Parking switch plate 1
8 Washer 25.2 3
9 Ring 25 3
10 High driven gear 1
11 High gearshift dog 1
12 Vice shaft spline housing 2
13 Reverse driven gear 1

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name/ Part name Q'ty Remarks

CAUTION: the surface of gear bushing
must be applied oil before installing.
When installing the gear bushing onto
the counter shaft（order 6）, align the shaft
oil hole with the bushing oil hole as shown
in the figure.

14 Gear bushing 3

15 Low-reverse gearshift dog 1

16 Low driven gear 1
17 Intermediate gear 1 1
18 Counter shaft plug 1
Apply Loctite 243(Blue) to screw threads
19 Slotted head screws M5x14 4
and torque screws to 5N.m
20 Cylindrical pin 5x12 4

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.15REAR OUTPUT SHAFT ASSY.

Order Job name/ Part name Q'ty Remarks

1 Idler wheel 2 1
2 Drive bevel gear 1
3 Rear output shaft 1
4 Driven bevel gear 1
5 Bearing braket 1
Tightening torque:100N.m
Lock the drive bevel gear nut with a
center punch.

6 locking nut M20x1.5 1

CAUTION: the removed drive bevel

gear nut must be replaced with a
new one.

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

Order Job name/ Part name Q'ty Remarks

7 Bearing 5206 1
8 Bearing plate 1
Apply Loctite 243(Blue) to screw
Phillips head screws M6x14
9 3 threads and torque screws to 5N.m
10 Washer 1 1
11 Shim 2 （optional) 1
Tightening torque:100N.m
Lock the driven bevel gear nut with
a center punch.

12 Locking nut M22x1.5

CAUTION: the removed drive bevel

gear nut must be replaced with a
1 new one.
13 Needle bearing 32NQ5419 1
14 Bearing braket, rear output shaft 1
15 O-ring 59.6x3.5 1 Apply grease
16 Shim （optional) 2
17 Bearing 5205 1
18 Washer 52 1
19 Seal 35x54x8 1 Apply grease
Apply Loctite243(Blue) to screw
Stud bolts M8x38
20 2 threads and torque screws to 13N.m
Apply Loctite243(Blue) to screw
Stud bolts M8x45
21 2 threads and torque screws to 13N.m
22 Socket head screw M6x20 3 Tightening torque:10N.m
23 Socket head screw M6x16 1 Tightening torque:10N.m
24 Washer 22 1
25 O-ring 20x3 1 Apply grease
26 Nut M16x1.5 1 Tightening torque:100N.m
27 Washer 16.5 1
28 Nut M8 4 Tightening torque:32N.m
29 Pin dowel 12x14 2

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CHAPTER 10 MAINTENANCE ATV700 SERVICE MANUAL 12.0

10.11.15.1 Rear output shaft drive bevel gear shim inspection and adjustment

Feel the backlash by turning the drive bevel Rear output shaft bevel gear backlash
gear shaft in each direction, If the backlash is Standard:0.03-0.15mm
not within specification, the shim must be Shim (order 16)
backlash
changed and backlash should be re-checked adjustment
until correct. Increase shim
Under 0.03mm
thickness
0.03-0.15mm correct
Over 0.15mm Decrease thickness
Note: Adjust the backlash by referring to the table at the using the thickness of the
removed shims as a guide.

10.9.15.2 Check the tooth contact

CAUTION: Make sure to check the
backlash after the tooth contact has been
adjusted, since it may have changed.
Adjust the tooth contact and backlash until
they are both within specification. If the
correct tooth contact cannot be maintained
when adjusting the backlash, replace the
rear output shaft drive and driven bevel
gears.
Clean and degrease several teeth of the drive
and driven bevel gears, and then apply a
coating of machinist’s layout dye or paste to
several teeth of the rear output shaft driven
bevel gear.
Rotate the rear output shaft driven bevel gear
several turns in both directions.
Remove the Bearing braket and inspect the
coated teeth of the rear output shaft bevel
gear. The tooth contact pattern should be as
shown in [A],[B] and [C]. if tooth contact is
found to be incorrect (example [A] and [C]),
the shim thickness between the rear output
shaft drive bevel gear and bearing must be
changed and the tooth contact re-checked
until correct (example [B]).
shim (order 11)
tooth contact
adjustment
Increase shim
Contact at tooth top [A]
thickness
Decrease shim
Contact at tooth top [C]
thickness

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10.11.16FRONT OUTPUT SHAFT ASSY.

Order Job name/ Part name Q'ty Remarks

Remove the parts in order.
Socket head screws m6x20(order 11)
Bearing seat, front drive shaft(order 3)
Front drive assembly removal
Wire ring Ф21x1.3(order 6)
Front drive shaft(order 1)
Sleeve, front drive shaft(order 4)
1 Front drive shaft 1
2 Spline sets 1
3 Bearing braket, front drive shaft 1
4 Sleeve, front drive shaft 1
5 Sheath holder 1
6 Wire ringФ21x1.3 1
7 Bearing 6205 1
8 Seal 35x54x8 1 Apply grease
9 O-ring 59.6x3.5 1 Apply grease
10 Ring 52 1
11 Socket head screws m6x20 4 Torque screws to 10N.m

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10.11.17COOLING SYSTEM
10.11.17.1RADIATOR

Order Job name/ Part name Q'ty Remarks

Radiator removal Remove the parts in order.

Drain the coolant. Refer to "COOLANT REPLACEMENT"
section.
1 Fan motor leads 1
2 Cool fan thermo-switch leads 1
3 Inlet hose , radiator 1
4 Outlet hose , radiator 1
5 Pipe , storage tank 1
6 Pipe , water pump 1
7 Radiator 1
8 Safety valve 1
9 Cool fan thermo-switch 1 Apply silica gel and a new O-ring when
installing.
Reverse the removal procedure
for installation.

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INSPECTION
1. Inspect:
Radiator 
Obstruction → Blow out with compressed
air through the rear of the radiator.
Flattened fins → Repair or replace.
If flattened over the 20% of radiator fin,
repair or replace the radiator.
CAUTION:
Use only specified adhesive to repair the
radiator.
Cooling fan
1) Disconnect the cooling fan motor
coupler
2) Test the cooling fan motor for load
current with an ammeter connected as
show in the figure. If the fan motor
does not turn, replace the cooling fan
assembly with a new one.
NOTE:
1) When making this test, it is not
necessary to remove the cooling fan.
2) The voltmeter is for making sure that
the battery applies 12 V to the motor.
With the fan motor with electric motor
fan running at full speed, the ammeter
should be indicating not more than 8
A.
Refer to "COOLING SYSTEM ".

2. Inspect:
 Water tank feed hose
 Water tank outlet hose
Cracks/damage → Replace.

3. Measure:
Safety valve opening pressure
Safety valve opens at a pressure below
the specified pressure → Replace.

Safety valve opening pressure:

110-140kPa
(1.1-1.4kg/cm2 , 1.1-1.4 bar)

Measurement steps:
Attach the safety valve tester and
adapter  to the safety valve .

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Apply the specified pressure for 10

seconds, and make sure there is no
pressure drop.

4. Inspect:
Pipes
Cracks/damage → Replace.

5. Inspect
 Cool fan thermo-switch
1）Remove the cooling fan
thermo-switch.
2） Check the thermo-switch closing or
opening temperatures by testing it at
the bench as shown in the figure.
3） Connect the thermo-switch (1) to a
circuit tester and place it in the water
“A” contained in a pan, which is placed
on the stove.
4） Heat the water to raise its temperature
slowly and read the column
thermometer
(2) when the switch closes or opens. If
any abnormality is found, replace the
cooling fan thermo-switch with a new
one.
CAUTION
1) Take special care when handing the
cooling fan thermo-switch. Do not
subject it to strong blows or allow it to
be dropped.
2) Do not contact the cooling fan thermo-
switch and the column
thermometer(2) with a pan.

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10.11.17.2WATER PUMP

Order Job name/ Part name Q'ty Remarks

Water pump removal Remove the parts in order.

Drain the coolant. Refer to "COOLANT REPLACEMENT"
section.
1 Hose , water pump 1
2 Ventilation tube radiator
3 Water pump 1
4 O-ring 36X3.2 1

Reverse the removal procedure for

installation.

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10.11.17.3THERMOSTAT

Order Job name/ Part name Q'ty Remarks

Thermostat removal Remove the parts in order.

Drain the coolant Refer to "COOLANT REPLACEMENT"
section.
1 Outlet hose , Cylinder head 1
2 Minor cycle conduit 1
3 Inlet hose , radiator 1
4 Thermostatic holder 1
5 Thermostatic cover 1
6 Thermostatic valve 1
7 Thermostatic shell 1
Reverse the removal procedure for
installation.

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INSTALLATION
1. Inspect:
Thermostatic valve
Valve does not open at 63-67℃→Replace.

Inspection steps:
Suspend the thermostatic valve in a vessel.
Place a reliable thermometer in water.
 Observe the thermometer, while continually
stirring the water.

 Thermostatic valve
Vessel
Thermometer
Water
A CLOSE
B OPEN

NOTE:
The thermostatic valve is sealed and its
setting requires specialized work. If its
accuracy is in doubt, replace. A faulty unit
could cause serious over-heating or over
cooling.

2.Inspect:
Thermostatic cover
Cracks /damage → Replace.

3.Inspect
 Outlet hose , Cylinder head
 Minor cycle conduit
 Inlet hose , radiator
Cracks /damage → Replace

INSTALLATION
1. Install:
Thermostatic valve
Thermostatic cover

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10.11.17.4 OIL COOLING PARTS

Order Job name/ Part name Q'ty Remarks

Oil cooling parts removal Remove the parts in order.
Drain the engine oil Refer to " ENGINE OIL LEVEL
INSPECTION " section.
1 Oil cooling hose A 1
2 Oil cooling hose B 1
3 Oil filter 1
4 O-ring 2
5 Oil filter mount 1
6 Oil-cooling connector 1
7 Connecting tube assembly , oil 2
cooling
8 O-ring ,11.2X1.8 2

Reverse the removal procedure for

installation.

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INSPECTION
1. Inspect:
 Oil filter
Cracks/damage/oil spilling → Replace
NOTE:
Replace oil filter and engine oil initially at
200Km (1month) and every 2000Km
(6month) thereafter. Oil filter replacement at
the above intervals, should be done together
with the engine oil change.
Engine oil change refer to " ENGINE OIL
LEVEL INSPECTION " section.

2. Inspect:
 Oil cooling hose A
 Oil cooling hose B
Cracks/damage → Replace.

INSTALLATION
Reverse the removal procedure for
installation.
CAUTION:
The oil cooling hoses and the oil cooling
connector must be keeping away from the
muffler when installing.

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10.11.18 FUEL INJECTION SYSTEM

10.11.18.1 ECU
10.11.18.1 .1 Description & Working Principle
10.11.18.1 .2 Appearance
10.11.18.1 .3 Handling – DOs & DONTs
10.11.18.1 .4 Installation requirements
10.11.18.1 .5 Power Requirements
10.11.18.1 .6 Temperature Requirements
10.11.18.1 .7 Maintenance service and Repair
10.11.18.2 INJECTOR
10.11.18.2.1 Appearance
10.11.18.2.2 Sealrings
10.11.18.2.3 Sealrings replacement
10.11.18.2.4 Lubricant Recommendation
10.11.18.2.5 Over -Voltage
10.11.18.2.6 Temperature Requirements :
10.11.18.2.7Fuel Contamination
10.11.18.2.8Wire Routing
10.11.18.2.9 Handling - DOs & DONTs
10.11.18.2.10 Installation guide lines
10.11.18.2.11 Replacement Techniques
10.11.18.2.12Interchange ability
10.11.18.2.13Plugging
10.11.18.2.14Cleaning Procedure
10.11.18.3 Throttle Body As sembly (with stepper motor )
10.11.18.3.1 Description and Working Principle
10.11.18.3.2Appearance
10.11.18.3.3 Technical Parameters
10.11.18.3.4 Operating Conditions
10.11.18.3.5 Throttle Body Removal
10.11.18.3.6 Cleaning Procedure
10.11.18.3.7Throttle Body Installation
10.11.18.3.8Precautions
10.11.18.3.9 Handling - DOs & DONTs
10.11.18.4 Engine Cool ant Temper ature Sensor
10.11.18.4.1Description and Working Principle
10.11.18.4.2Appearance
10.11.18.4.3 Installation Requirements
10.11.18.4.4 Operating Environment
10.11.18.4.5 Storage Environment
10.11.18.4.6 Sample Cleaning
10.11.18.5 Intake AirPressure and Temperature Sensor(MAP&MAT)
10.11.18.5.1Description and Working Principle
10.11.18.5.2 Appearance
10.11.18.5.3 Operating Environment

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10.11.18.5.4 Storage Environment

10.11.18.5.5 Electrical Environment
10.11.18.5.6 Sample Cleaning
10.11.18.6 Oxygen Sensor
10.11.18.6.1 Description and Working Principle
10.11.18.6.2 Appearance
10.11.18.6.3 Technical Parameters
10.11.18.6.4 Fuel Quality Requirements
10.11.18.7 Ignition Coil
10.11.18.7.1Description and Working Principle
10.11.18.7.2 Appearance
10.11.18.7.3 Technical Parameters
10.11.18.7.4 Installation requirements
10.11.18.7.5 DOs a nd DONTs
10.11.18.8 Fuel Pump Module
10.11.18.8.1 Description and Working Principle
10.11.18.8.2 Appearance & Components of Fuel Module
10.11.18.8.3 Dimensions
10.11.18.8.4 Identification and Markings
10.11.18.8.5 Operating Conditions
10.11.18.8.6 Service Procedure
10.11.18.8.7 Fuel Module Diagnosis:
10.11.18.8.8 Fuel Module Removal:
10.11.18.8.9 Fuel Module Installation:
10.11.18.8.10 Pressure Regulator Assembly Replacement:
10.11.18.8.11 Fuel Pressure Relief Procedure:
10.11.18.8.12 Fuel Leakage Check Procedure:
10.11.18.8.13 Handling – DOs and DONTs :
10.11.18.9 Diagnostic Tools
10.11.18.9.1 Motor Scanner ( for MT05 EMS)
10.11.18.9.1.1 Precautions
10.11.18.9.1.4 . Functions
Below shows the layout of typical EMS for engine. The solid lines in the figure 1 below indicate
the output signals from the Engine Controller and the dotted lines indicate the input signals to
the controller from various sensors and switches.

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10.11.18.1 ECU
10.11.18.1 .1 Description & Working Principle
The ECU continuously monitors the operating conditions of the engine through the system
sensors. It also provides the necessary computation, adaptability, and output control in order to
minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all
operating conditions. The ECU also provides diagnosis when system malfunctions occur.
10.11.18.1 .2 Appearance
The MT05 ECU has a polyester header, with an aluminum base plate. below shows the top
and bottom view of the MT05 ECU.

10.11.18.1 .3 Handling – DOs & DONTs

ACTION REASON
DO NOT: Place the ECU close to the High temperature might reduce the life of
exhaust pipe or Engine when removed the ECU and also can damage the ECU

DO NOT: Place the ECU close to or pour ECU is susceptible to water and liquids
water, oil or any other liquids.

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DO NOT: Allow mud or other debris to Having mud or debris accumulated on the
accumulate on the surface of the ECU ECU casing reduces its heat dissipation
efficiency.
DO NOT: Apply any voltage relative to any Drastically affects the performance of the
point to the ECU ECU and may lead to ECU damage
DO NOT: Clean ECU with any solvent or Can damage the housing of the ECU
any corrosive liquid
DO: Take extreme care that water droplets ECU connectors can get short and may
or excess moisture should not fall on ECU lead to ECU damage
connectors
DO: Clean the ECU with a moist cloth and Prevents ECU damage
keep it dry
10.11.18.1 .4 Installation requirements
The ECU shall be mounted using M5 machined screws with a torque of 3.9Nm ±10%. The
mounting surface should also be flat to avoid subjecting the base plate to unnecessary force
and warping the PCB.

10.11.18.1 .5 Power Requirements

Power Supply: The controller’s power supply module will power up the
microprocessor if the battery voltage is greater than 6.3 Volts. The power on is
controlled by the controller hardware only.
Operating Range: All planned functions are executed in this range. Battery
and/or Ignition voltage: 9.0 to 16V DC
Power Off: The controller will turn its power off when the ignition voltage: < 6.2
V DC. The controller prepares for entry into Power Down mode. The
preparation involves storing important information into EEPROM.
Reset: During reset, all outputs shall be set to a predefined state. The
controller shall monitor itself for proper operation and enter reset should any
internal errors be detected. The controller shall then restart normal operations
after the computer has properly reset
Over Voltage: the controller will survive no permanent damage if the ignition
voltage do not exceed 26V for more than 1 minute
Reverse Voltage: The controller will survive with no permanent damage: Battery
and/or Ignition voltage < -13V DC for 1 minute

10.11.18.1 .6 Temperature Requirements

Storage: The controller shall suffer no damage as a result of being stored at
temperatures of -40 C or +105 C continuously for 168 hours. If the storage temperature is
not as extremely high as +105 C or as extremely low as -40 C, the ECU could be stored for
longer time without damage.
Operating: The controller shall operate in the ambient temperature from -20 C to +85 C.

10.11.18.1 .7 Maintenance service and Repair

ECU is a non-serviceable part. Once there are problems, it’s important to first
determine if the problem is caused by software/calibration. If it is caused by
software/calibration, please refer to software/calibration reflashing procedure. In the event of
ECU hardware failure or malfunction (during warranty period only) the ECU should be sent back
to the vehicle manufacturer giving complete details of the ECU Part No, Serial number, Vehicle
Model & Make, manufacturing Date, Total kms run on the vehicle, Location of use, Vehicle No,
Date of return.

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10.11.18.2 INJECTOR
10.11.18.2.1 Appearance
The figure below shows the standard Multec 3 Fuel Injector appearance

10.11.18.2.2 Sealrings
Seal rings for injectors (refer to Figure 12) are made to withstand temperatures
ranging from -40℃ to 150℃ (-40 to 302℉) without leakage or seeping. They must also be
resistant to varying amounts of fuel additives to fuel (i.e., ethanol, etc.). The following are
currently available seal rings designs. Please contact a Delphi representative if the specific
sealing requirements are not met by these designs:
Injector to fuel rail seal ring
• Dimensions:
• ID. : 6.35 mm
• OD. : 14.85 mm
• Cross-section: 4.25 mm
• Materials
• Viton GLT (blue color). For low temperature applications
• Viton A (black). All other applications.

Injector to manifold
• Dimensions:
• ID: 9.61 mm
• OD: 14.49 mm
• Cross-section: 2.44 mm
• Materials:
• Viton A (black or brown other applications.)

10.11.18.2.3 Sealrings replacement

Lubricate the seal rings with an approved lubricant or equivalent. The lubricant application
process must prevent lubricant from contacting the director plate, which could possibly restrict
the injector flow.
It is preferred to not reuse the seal rings when re-installing an injector. If re-use is necessary,
carefully inspect each seal ring for any signs of damage, as even minor defects can lead to fuel
/ vacuum leakage. Always install injectors and seal rings using the recommended service
procedures to avoid the possibility of a safety hazard.
When installing seal rings to the injector inlet, take extra care not to damage the seal on the
injector top flange.

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10.11.18.2.4 Lubricant Recommendation

Lubrication should be applied to the O-rings only for ease of injector installation.
The table 4 is a list of lubricant oils that were tested and approved for O-ring
lubrication. These lubricants have shown to have no effect on injector performance (plugging,
sticking).

10.11.18.2.5 Over -Voltage

The Multec 3 injectors and the Multec 3.5 injectors can withstand a voltage of 26v for a
maximum of one minute at a duty cycle of 100 ms pulse width and 200 ms period. The injector
will be pressurized with calibration test fluid at normal operating pressure during the test. This
will not result in any permanent physical damage to the injector or coil assembly, or any
degradation in electrical performance.
10.11.18.2.6 Temperature Requirements :
Typical injector temperature environments are defined below. The Multec 3
injectors and the Multec 3.5 injectors will not experience any loss of the ability to comply with
the flow tolerance requirements after exposure to the following
temperature environments. Also, they will not experience unacceptable external
leakage, any type of physical degradation, or loss of service life during or after
being exposed to these ambient conditions.
Normal Operating Temperature Range: - 30 to 125C
Extreme Operating Temperature Range (some performance degradation): - 40
to 150C
Storage Temperature Range: -60 to 60C
10.11.18.2.7Fuel Contamination
The injector fuel inlet filter protects the fuel injector from initial build fuel
contamination as well as from fuel system assembly contamination. Filtration is
extremely important because particle contaminants can cause an injector to stick
open, flow shift or tip leak.
The injector inlet filter is not a serviceable component and is designed only to trap
potential built-in contamination between the chassis fuel filter and injector.
10.11.18.2.8Wire Routing
Electrical wiring to the injector should be routed so that conductors are
protected from excessive heat, damage, and wear.
Avoid unnecessary handling (disconnecting and connecting) of the electrical
connector.

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10.11.18.2.9 Handling - DOs & DONTs

ACTION REASON

DO NOT: Re-use injector seal rings if at all Leakage.

possible. If no other choice exists, take extra
care in inspecting the seal rings for damage.
DO NOT: Dip injector tips into lubricants. Can plug injector spray orifices.
DO NOT: Cycle injector repeatedly without fuel Damage to internal mechanical components.
pressure.
DO NOT: Pulse (actuate) a suspected high leak Can dislodge internal contamination if
rate injector (leak >50 sccm air)
DO NOT: Allow water to enter fuel system from Can damage injectors.
air lines, etc. during leak checks.
DO NOT: Contact or apply load to the injector tip Apply load to 45 deg angle on nylon over mold
for installation. see
DO NOT: Pound injectors into manifold during Can damage injectors or seal rings.
assembly to engine.
DO NOT: Apply excessive side loads to May cause loss of electrical continuity.
electrical connectors.
DO NOT: Use any dropped unit. Internal damage may have occurred.
DO NOT: Store injectors, rails, or External contamination can damage the
subassemblies including engines on which the injector electrically and/or mechanically.
injectors have been installed in an unprotected
environment.
DO NOT: Use the injector as a handle. Do not use the injector to lift assemblies
DO NOT: Rack, stage, or handle parts in a Damage will occur.
manner that allows contact between parts.
DO NOT: Remove packing in a way that allows Damage could occur due ton contact
contact between parts. between parts
DO NOT: Tap on fuel injectors to correct any Can damage injector.
malfunction..
DO NOT: Replace the injector with other part Will severely affect the performance of the
number not recommended for this application injector
DO: Take extra care when installing new fuel Prevent tearing seal ring during installation
seal ring over injector inlet flange.
DO: Use proper lubricants on seal ring surfaces Avoid damage to seal ring during
to install injector in engine. Minimize time installation.
between applying lubricant and inserting injector Avoid contamination at seal.
/rail.
DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure
suspected injector (Actuate consists of one
pulse<5 sec duration at 9 to 15V).
DO: Pulse (actuate) injectors prior to a dry fuel Injector valves may not reseat without fuel
system leak test at engine/vehicle assembly to after shipping and handling resulting in
reseat injector valves. false leakage.
DO: Avoid any liquid contamination in the Coil could short circuit.
injector area.
DO: Use care during connection of harness to Avoid terminal damage.
injector.
DO: Use recommended terminal lubricant on Minimize potential for terminal fretting
mating connector. corrosion.
DO: Return any dropped, damaged, or suspect Ensure fast and correct diagnosis of root
material with a tag that describes the cause.
problem.

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10.11.18.2.10 Installation guide lines

Follow these guidelines to prevent damage to the injector and its electrical
interface during the replacement or re-installation process.
Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO
10 light mineral oil or equivalent is recommended.
The preferred technique is to apply the lubricant to the sockets the injectors are
being installed into, rather than directly to the seal ring itself. This will help
minimize the possibility of injector contamination.
Avoid applying lubricant over the director plate holes – this may restrict injector
flow. Do not dip the injector tip in lubricant.
All Multec 3 and Multec 3.5 injectors come from the factory with the seal rings
attached. The re-use of seal rings is not preferred when replacing an injector. If
an injector is to be re-used, and no new seal rings are available, take care to
inspect each seal ring for signs of damage. Even minor defects in the seal ring
can lead to leakage. Take extra care in installing seal ring over flange of
injector inlet.
Carefully installing the harness connector will prevent terminal damage. Listen
for a positive audible click from the connector retention device — this ensures
that it is fully engaged.
Avoid unnecessarily disconnecting/reconnecting the harness connector.
Wires routed in a manner that can allow them to become pinched between
components can result in a short circuit and a stuck open injector.
For injectors that require orientation for spray pattern, do not rotate the injector
in the fuel rail assembly to install the injector electrical connector. This may
dislodge the retaining clip, and result in improper spray orientation
10.11.18.2.11 Replacement Techniques
The following procedure outlines standard Multec 3 and Multec 3.5 Fuel Injectors
removal and replacement.
Warning: The injector and all associated hardware may be extremely hot.
Shut off ignition.
Disconnect negative battery cable to avoid possible fuel discharge if an
accidental attempt is made to start the engine.
Disconnect the electrical connector from the injector wiring harness.
Relieve fuel pressure
Remove the retaining clip from the fuel injector.
Remove the fuel line connection from the injector
Carefully clean debris from the interface surfaces. Do not damage seal mating
surfaces.
Remove the injector from the manifold
Apply a light coating of a lubricant to both the upper and lower injector seal ring
of the replacement injector.
Install the new injector into the manifold. Check that the injector is installed in
the original orientation to maintain proper spray targeting, and that the retaining
clip is properly seated on the injector and the fuel line
Install the retaining clip after connecting the fuel line
Tighten the injector mounting to the desired torque as mentioned in the
manufacturer manual
Tighten the fuel line
Re-install the injector electrical connector
Check for fuel leaks with the key “on” and the engine “off”

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Start engine and verify proper operation

10.11.18.2.12Interchange ability
The injector should be replaced in service only with an equivalent injector of the
same part number. On occasion, a new part number may supersede part
numbers. Consult the appropriate vehicle service manual and part number guide
for the latest replacement injector part number information.
10.11.18.2.13Plugging
Fuel deposits cause plugging resulting in flow shifts over the life of the injector.
Fuel varnish or gumming, a type of injector deposit, is created when certain types
of fuel are heated by high injector tip temperatures at soak (no fuel flow). Deposit
build up in the director holes causes the flow shifts
Plugging can cause flow restrictions, frictional changes and the collection of
other particles attracted by the tacky surface. The flow restrictions can degrade
emissions and drivability.
Other fuel and environmental conditions may cause crystal or corrosion growth
in the injector and cause a flow shift.
Oxidation stability of the gasoline affects the potential for deposit formation and
must be controlled by the fuel supplier.
Increased levels of detergent additives reduce the rate of injector plugging.
Incase of plugging of injector follow the injector cleaning procedure mentioned
in the section below
10.11.18.2.14Cleaning Procedure
Electrically disable the fuel pump by removing the fuel pump connection.
Relieve the fuel pressure in the system and disconnect the fuel connection at
the injector. Plug the fuel feed line.
Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed in
the Injector cleaning tank.
Connect the injector-cleaning tank to injector in the vehicle.
Pressurize the injector-cleaning tank to system pressure.
Start and idle the engine for 15- 20 minutes.
Disconnect the injector-cleaning tank from the system and install the fuel pump
connections. Connect the fuel feed line to injector.
Start and idle the vehicle for an additional 2 minutes to ensure the residual
injector cleaner is flushed from system.
10.11.18.3 Throttle Body As sembly (with stepper motor )
10.11.18.3.1 Description and Working Principle
The Throttle Body Assembly is an interactive system comprised of the following
subsystems: the main casting body, bearing system, shaft and valve system,
return spring system, cable interface system, throttle position sensing system, and
the bypass air control system. The subsystems interact and support each other to
provide all the functional requirements, which are mentioned below -
Control intake air flow
Control idle air flow
Sense throttle position - Provide position feedback to Engine Controller
Provide reactionary force to the throttle

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10.11.18.3.2Appearance

10.11.18.3.3 Technical Parameters

Throttle Position Sensor:
Reference voltage: 5±0.1VDC
Resistance between T1 and T2: 3k~12kΩ

Idle Air Control Valve:

Operating voltage: 7.5~14.2 VDC
Solenoid resistance: 53Ω±10%
Solenoid inductance: 33mH±20%
10.11.18.3.4 Operating Conditions
Normal Operating Temperature: -30~120°C
10.11.18.3.5 Throttle Body Removal
Disconnect negative terminal of the battery
Disconnect electric lead wire of throttle position sensor coupler, stepper motor
coupler and MAP/MAT sensor coupler ( if this sensor is mounted on the throttle
body)
Disconnect accelerator cable from throttle body
Remove air cleaner outlet hose and throttle body outlet hose

10.11.18.3.6 Cleaning Procedure

If there is cover on the bottom, it may be removed and cleaned using carburetor
cleaner (3M make recommended). Once the throttle body cover is removed, spray
the throttle-body cleaner inside the shipping air passage, and use the brushes to
gently dislodge the dirt, gum and varnish that are present. Do not let the bye pass
holes be blocked by dirt or foreign particles.

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10.11.18.3.7Throttle Body Installation

Reverse the procedure for installation noting the following:
Adjust accelerator cable play
Check to ensure that all removed parts are back in place.
Reinstall any necessary part which have not been reinstalled
10.11.18.3.8 Precautions
Do not submerge TPS in any cleaning fluid.
Always open the throttle valve using the throttle cable or lever.
Do not hold the valve at opening position by inserting tools or any sticks into the
bore. The valve may be warped and the bore may be scratched. This type of
damage may keep the throttle from opening easily or fully closing.
10.11.18.3.9 Handling - DOs & DONTs
ACTION REASON

DO: Use care during assembly of harness to Avoid terminal damage.

throttle body.
DO: Avoid any liquid contamination in the Ensure proper operation.
throttle body area.
DO: Unload and install units one at a time from Damage may be done to critical components.
packing trays.
DO: Return any dropped, damaged, or suspect Ensure fast and correct diagnosis of root cause.
material with a tag that describes the problem.
(Only warranty cases)
DO: Remove and discard protective caps just Protects system from contamination, which can
before assembling mating components. prevent proper operation.
DO: clean the by pass passage after removing To ensure good idle stability
bottom cover
DO NOT: Use any dropped or impacted unit. Internal damage may have occurred or
emissions settings may have been upset.
DO NOT: Store units without protective caps in Contamination may impair correct operation.
place.
DO NOT: Ship or store near saltwater without Corrosion buildup may impact proper
protection. operation.
DO NOT: Exposed to environmental conditions Corrosion buildup may impact proper
(Moisture)prior to complete vehicle installation. operation.
DO NOT: Apply any voltage other than system Damage could occur
voltage for testing.
DO NOT: Apply excessive band clamp loading Damage could occur.
DO NOT: Remove packing in a way that allows Minimum air leakage could be affected and/or
contact between parts. other damage could occur.
DO NOT: Release the throttle cam abruptly from Damage could occur.
any position without the throttle linkage
attached.
DO NOT: Let the by pass holes be blocked by This could effect idle stability
dirt or foreign particles.
DO NOT: Rake, stage, or handle parts in a Damage will occur.
manner that allows contact between parts.
10.11.18.4 Engine Cool ant Temper ature Sensor
10.11.18.4.1 Description and Working Principle
This sensor is used in water cooled engines. It provides a resistance that varies as a function of
temperature within prescribed tolerance limits. The sensor has a
negative temperature coefficient of resistance. This is a non-serviceable part.

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10.11.18.4.2 Appearance

10.11.18.4.3 Installation Requirements

Dynamic Torque Requirement: The sensor shall be hand into the application
and then driven by a driver with a maximum no load speed of 400 rpm or
installed to the desired torque by a hand torque wrench (5/8” hex). The
recommended installation torque is:
Minimum: 20 N·m
Maximum: 25 N·m
Static Torque Requirement: The torque required to remove the sensor from the
mating hole shall be within 200% of the installation torque mentioned above.
10.11.18.4.4 Operating Environment
This device is intended for use in engine coolant and air cooled applications
and shall withstand such an under hood environment.
Normal Operating Temperature: -40°C ~ 135°C (continuously).
Relative Humidity: 0 to 100% RH.
Typical Pressure: When installed at the minimum torque the sensor shall be
capable of sealing engine coolant with a positive pressure of 206.8 kPa (30 psi)
at 135°C applied to the probe tip end of the sensor.
Extreme Operating Environment: Maximum temperature excursion to 150°C for
1 hour.
10.11.18.4.5 Storage Environment
Storage temperature: -40°C to 120°C for an indefinite duration
Transport at altitudes to: 13,700 m for an indefinite duration
E l e c t r i c a l Enviro nmen t
Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ±
0.1 VDC.
Maximum Excitation Current: The sensor calibration shall not be affected by a
current source of less than 1 mA at all temperatures.

10.11.18.4.6 Sample Cleaning

When necessary the samples may be cleaned in isopropyl alcohol for one
minute with mating connectors in place and then air-dried

10.11.18.5 Intake AirPressure and Temperature Sensor(MAP&MAT)

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10.11.18.5.1Description and Working Principle

This sensor has two functions. The first is the intake manifold air temperature, it
provides a resistance that varies as a function of temperature within prescribed
tolerance limits. The second is the intake manifold air pressure; it provides a
voltage varies as the intake air pressure.

10.11.18.5.2 Appearance

The appearance of the MAP&MAT Sensor is shown as above.

10.11.18.5.3 Operating Environment

This device is intended for use in inlet manifold for sensing air temperature and
pressure which shall withstand such an under hood environment.
Pressure Range: 20~102kPa
Temperature Range: -40~105°C
Relative Humidity: 0 to 100% RH.
Extreme Operating Environment: Maximum temperature excursion to 125°C for
2 hours.

10.11.18.5.4 Storage Environment

Storage temperature: -50°C to 150°C for an indefinite duration

10.11.18.5.5 Electrical Environment

Typical Voltage: The sensor circuit operates with a DC voltage reference of 5 ±
0.1 VDC.

10.11.18.5.6 Sample Cleaning

When necessary the samples may be cleaned in isopropyl alcohol or gasoline
for one minute with mating connectors in place and then air-dried

10.11.18.6 Oxygen Sensor

10.11.18.6.1 Description and Working Principle
This sensor is a device for monitoring the residual oxygen in the exhaust of an
internal combustion engine. It consists of the wide range sensor and stoichiometric
sensor. Usually we use stoichiometric sensor on the small engine. It is the
feedback element for engine closed loop control.

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10.11.18.6.2 Appearance
The appearance of the Engine Oxygen Sensor is shown as below

10.11.18.6.3 Technical Parameters

A/F ratio rich threshold: ＞750 mVDC
A/F ratio lean threshold:＜120 mVDC
Heater power: 7.0W
(These parameters as above are measured basing on 450°C (engine dyno),
typically on 70% duty at 10Hz and under 13.5V)
Heater part resistance: 9.6±1.5Ω
(This parameter is measured basing on 21°C)
Operating temperature range: 260-850 °C

10.11.18.6.4 Fuel Quality Requirements

Pb≤0.005g/L
P≤0.0002g/L
S≤0.04% (weight proportion)x
MMT≤0.0085g/L
Si≤4ppm

10.11.18.7 Ignition Coil

10.11.18.7.1Description and Working Principle
This coil provides energy to the spark plug in the combustion chamber. The coil
itself doesn’t have a driver. The high voltage tower of the coil is connected to the
spark plug using a high voltage cable assembly. This is a non-serviceable
component.

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10.11.18.7.2 Appearance
The appearance of the Ignition coil is shown as below.

10.11.18.7.3 Technical Parameters

Input voltage: 9~14VDC
Output voltage: ~25~30KV
Operating temperature: -30 ~110 °C
Storage temperature: -40~155°C
Mounting Torque: 8.8~11.8Nm
10.11.18.7.4 Installation requirements
The vehicle frame provides the mounting surface and mounting holes.
Mount coil close to the spark plug and keep the plug wire length very short (less
than 6 “).
Mount coil away from any pick coil device. Especially, a VR type Crank / Cam
sensor. Keep a Min distance of 150 mm (around 6”) between coil and any VR
sensor device.
Never route the coil C- wire with the same bundle as the Crank sensor wires.
There is around 200 V peak potential between C- wire and engine ground. This
voltage potential could cause a noise on sensor cables.
10.11.18.7.5 DOs a nd DONTs
ACTION REASON
DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing,
the power applied possibly leading to personal injury
DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in such a
secondary boots from the secondary tower. Use manner that creates an electrical path to outside the
tools designed for secondary removal. system permitting improper system operation misfire,
or even possible personal injury if arcing occurs.
DO NOT: Use parts that have been dropped or Damaged components can lead to premature failure.
display physical damage

DO NOT: Scratch or apply any non approved This can jeopardize the seal integrity of the mating
material to the surface of the high voltage tower surfaces which in turn can create a secondary high
which mates with the high voltage secondary voltage leak path.
leads.
DO NOT: Strike any part of the ignition system with This can lead to physical damage which can cause a
a tool or other object. system malfunction or failure.

DO NOT: Permit paint or other sprayed materials Insulating type sprays can create a high resistance or
to open connection. And, a conductive type spray can
be sprayed onto the electrical connectors. create an electrical short condition.

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ACTION REASON
DO NOT: Support the ignition system by the wiring These leads are not designed to support the weight
harness or plug wire. of
the ignition system. It can create a poor electrical
connection Or become disconnected allowing the
system to fall and be subjected to physical damage

DO NOT: Pierce or probe the secondary leads. This creates an electrical path to outside the system
permitting improper system operation, misfire, or
even
possible personal injury if arcing occurs.
DO NOT: Operate without the spark plug attached If a technician or mechanic comes in contact with the
high voltage generated during operation, personal
injury may occur. Or, if the engine is operated under
this condition, unburned fuel may fill the converter
area creating a potential hazard
DO NOT: Share ignition component wiring with This prevents electrical cross talking between
other components, Dedicated wiring is required. components which can lead to component
malfunction.
DO NOT: Apply voltage to the ignition system other This can cause reduced performance or an electrical
than vehicle system voltage for testing purposes. malfunction of the ignition system
DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or mating
plug boot to the ignition secondary towers. connection surfaces might occur.
Installation of the high voltage secondary leads by
hand is preferred.
DO: Install the secondary leads before connecting In the event the low voltage connection has been
the primary leads. made and the power applied, unwanted secondary
output might occur possibly resulting in injury,
damage
the ignition component, and test equipment
DO: Take care when working around the ignition The high voltage produced by the coil secondary
system. circuit can cause personal injury and/or damage test
equipment
DO: Proper handling and shipping methods need Damaged components can lead to premature failure.
to
be in place to reduce the risk of damage due to
impact, moisture, or contamination
DO: Avoid unnecessary disconnecting and The electrical connections are not designed for
connecting of the electrical components. repeated connection and disconnection.
DO: Insure the low voltage connectors are entirely This prevents intermittent electrical connections
seated and the locking mechanism is engaged. leading to an improper ignition system operation.
DO: Use approved connector breakouts when Connector and/or component damage may occur.
testing the ignition system.
DO: Insure the appropriate seals are included in Liquid intrusion into the terminal connection area
the connector system. might occur causing an electrical intermittent or short
condition. In the event of severe terminal corrosion,
an open condition might occur.
DO: Operate with gasoline based internal Other fuels or combustion designs may require
combustion engines. additional design considerations
DO: The power feed line should be fused. This could protect the system in the event of an
electrical short
DO: The module heat sink and back plate must not The high level of voltage and current which the
be used as a connection point when jump starting module could be subjected to, could cause module
the engine performance degradation or failure.
DO: Connection of the module back plate to This greatly reduce potential ground loops and acts
vehicle ground is desirable whenever possible as a heat transfer source from the module.
DO: The ignition system ground wire should be This would greatly reduce the possible of unwanted
kept as short as possible. And, when permissible, electrical ground loops.
should be grounded at the same engine block
position as the engine controller

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ACTION REASON
DO: The electrical wiring to the ignition system Helps prevent electrical intermittent, open or shorted
should be routed so that the conductors are operating conditions.
protected from excessive heat, damage, and wear.
DO: Ignition secondary leads should not be routed Voltage spikes can be transmitted from the
with the ignition primary harness or any other secondary
electrical harness. cables into other leads which are in close. This could
create a component performance degradation or
failure condition
DO: Spark plug wires(secondary leads) & primary - Spark plug wires carry very high voltage (30,000
wiring: volt). If the secondary lead loses its dielectric
- must not contact sharp surface characteristics thru being nicked, cut , chaffed, then
- must not be under tension between fixed points an arc thru to a near by ground could take place. This
- must be clear of moving parts (belts, fan, etc…) kind of condition could lead to misfire, no start, or
- must be protected from or kept at least 125 mm premature failure of ignition system.
away from radiant heat source exceeding 400 F.
- must be protected from environmental damage
(dirt, splash, oils, fluids, etc….)
- must be retained, secured or insulated to prevent
pinching, mis-routing, rattles, and squeaks
DO: Not all fasteners are designed for repeat use. Adequate retention force might not be achieved if the
Beware of fastener specifications. All harnesses fastener is not designed to be reused. Mating
should be supported within 6" of a mating connections are not designed to support the weight
connection. of the harness assembly
DO: For removing spark plugs follow the following To remove spark plugs from Aluminum heads, allow
steps: the engine to cool. The heat of the engine, in
1- Grasp the spark plug boot and gently rotate combination with a spark plug that is still hot, may
90; and then pull the spark plug boot and cause the spark plug threads to strip the cylinder
cable away from the spark plug head
2- Before removing spark plug, brush or air blast upon removal
dirt away from the well areas Use goggles to protect eyes from dirt when applying
3- Use correct size deep socket wrench to loosen compressed air to spark plug wells
each spark plug one or two turns
DO: Cleaning a spark plug could be done as follow: - Cleaning a spark plug will reduce the voltage
1- wipe all spark plug surfaces clean….remove required for an electrical arc(spark) across the
oil, water, dirt and moist residues. electrodes
2- If the firing end of spark plug has oily or wet - Cleaning & re-gapping will not restore a used
deposit, brush the spark plug in an approved, spark plug to a new condition. It may be more
non-flammable and non-toxic solvent. Then economical and efficient to replace used spark
dry the spark plug thoroughly with compressed plugs with new plugs instead of cleaning.
air - Sooted plugs should be replaced
3- Use a propane torch to dry wet-fuel fouled - Do not cool by using water or any liquid
plugs. Allow the torch flame to enter up the center - Clean threads permit easier installation and
electrode insulator. Allow plug to cool down proper seating which will maximize transfer heat
4- If the spark plug threads have carbon & scale away from the plug
deposits, clean with wire brush, taking care not
to injure the electrode or the insulator tip
DO: Regap spark plugs to the exact measurement - Too wide a gap could cause the plug to
specified by the engine manufacturer to keep the misfire(higher required
best fuel economy and proper engine performance ignition voltage).
- Use round wire-type gauge for an accurate - Too narrow of a gap could affect idle stability
measure of gap on all used spark plugs - A flat gauge can’t accurately measure the spark
- when gapping a spark plug only the side plug on used plugs
electrode
is moved. The center electrode must not be moved
DO: When replacing spark plugs with new ones, - Higher heat range plug(hotter plug) could lead to
always use equivalent plugs with same heat range, pre-ignition & possible piston damage
thread, size, etc…. - Lower heat range (colder plug) could lead to cold
fouling & emission problem

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ACTION REASON
DO: For installing spark plugs follow the - If the thread is damage, it prevents a good heat
following transform from the shell to the cylinder head
steps: - Do not use any type of anti-seize compound on
1- make sure the cylinder head threads and spark spark plug threads. Doing this will decrease the
plug threads are clean. Make sure the spark amount of friction between the threads. The result
plug thread is free of dings and burrs. If of the lowered friction is that when the spark plug
necessary, use a thread chaser and seat is torqued to the proper specification, the spark
cleaning tool. plug is turned too far into the cylinder head. This
2- Make sure the spark plug gasket seat is clean, increases the likelihood of pulling or stripping the
then thread the gasket to fit flush against the threads in the cylinder head
gasket seat. Tapered seat plugs do not require - Over-tightening of a spark plug can cause
gaskets stretching of the spark plug shell and could allow
3- Screw the spark plugs finger-tight into the blowby to pass thru the gasket seal between the
cylinder head. Then, use a torque wrench to shell and insulator. Over-tightening also results in
tighten spark plugs following manufacturer’s extremely difficult removal
recommendation).
Torque is different for various plug type & cylinder
head material

10.11.18.8 Fuel Pump Module

10.11.18.8.1 Description and Working Principle
Fuel Pump Module supplies fuel to engine at system pressure. Fuel Pump Module is
mounted to fuel tank at bottom and supplies fuel to engine through hoses.
Fuel Pump module consists of Fuel Pump to generate the fuel flow and pressure
regulator to regulate the fuel pressure.
Fuel Pump
When power is supplied to fuel pump, motor in pump assembly rotates the impeller.
Impeller in turn draws the fuel from strainer and pumps the flow to generate the system pressure.
Pressure Regulator
Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the inlet of
pressure regulator. Pressure regulator regulates the fuel pressure at a set pressure by releasing the
excessive fuel flow to fuel tank.

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10.11.18.8.2 Appearance & Components of Fuel Module

1. Fuel Pump
2. Strainer
3. Gasket, Fuel Module
4. Fuel Tube (in pump)
5. Module Bracket
6. Pressure Regulator
7. Module Harness
8. Fuel Tube (out pump)

10.11.18.8.3 Dimensions
Fuel Module Cover in elliptical shape with outer edge dimensions as 115mm x 70mm.

10.11.18.8.4 Identification and Markings

Fuel Module, Fuel Pump and Regulator are marked with batch code in Julian Date Code.
On Fuel Module, batch code in mentioned on the label available on fuel module cover.
On Fuel Pump Batch code is engraved on pump body (shell).
On Fuel Pressure Regulator, batch code is engraved on regulator dome area.
10.11.18.8.5 Operating Conditions
Fuel Pump Module needs to be mounted on Fuel Tank Bottom according to the
installation instructions.
Fuel Pump Module is intended to use with gasoline. However if the fuel contains
ethanol, please contact vehicle manufacture to check whether the fuel pump module
itself can survive or not.
Make sure there is at least 3 liters of gasoline in the fuel tank before priming for first
time (do not run the pump dry)
Fuel Hose connections needs to be installed according to the fuel flow diagram shown

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Fuel Flow Description in vehicle fuel system

10.11.18.8.6 Service Procedure
Precautions:
Before attempting any service on fuel system, following cautions should be always
followed for personal safety and to avoid system damages.
Disconnect negative cable at battery.
DO NOT smoke, and place ‘No SMOKING” sign near work area
Make sure to have fire extinguisher handy.
Make sure to perform work in well ventilated area and away from any open fire/flames.
Wear Safety glasses
To relieve fuel vapor pressure in fuel tank, remove fuel filler cap fuel filler neck and
then reinstall it.
As fuel lines are at high pressures when the engine is stopped, loosening or
disconnecting fuel line will cause dangerous spout of fuel. Before loosening/
disconnecting fuel lines, please follow the “Fuel Pressure Relief Procedure” described
in this section.
Small amount of fuel may drip after the fuel lines are disconnected. In order to reduce
the risk of personal injury, cover the pipe/ hose ends with suitable blind with no rust or
contamination.
After servicing, make sure that the fuel hoses and clamps are connected according to
the hose fitment instructions given in vehicle instruction manual.
After servicing, please follow the ‘Fuel Leakage Check Procedure’ described in this
section.
After servicing make sure to fill at least 3 liters gasoline before pump is primed
(ignition key should be turned on only after ensuring there is minimum 3 liters of fuel in
the fuel tank)

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10.11.18.8.7 Fuel Module Diagnosis:

Step Action Yes No
1 Switch on Ignition key. Fuel Pump If fuel pump running If fuel pump running
primes for 3 seconds when the ignition noise can be heard, noise can not be
key is ON. go heard, go to step 2.
Check for fuel pump running noise for to step 4.
3 seconds after ignition key is ON.
2 Disconnect fuel module coupler. Go to step 3 Check the electrical
Check voltage at harness coupler. circuit from Ignition to
Is the voltage within 10-14V? fuel module.
3 Connect 12V DC power supply 1. Check electrical 1. Check Fuel Pump
(battery) to fuel module. circuit from fuel Harness integrity
Make sure that enough fuel available module to ECU 2. Check Fuel Pump
in fuel tank to avoid fuel pump running 2. Check ECU
dry.
Is the fuel pump running?
4 Check fuel system pressure at Injector Fuel Module Go to Step 5
inlet (with a T-joint) while engine is Operation
running in idle condition. Normal
Is the pressure between 220 ~
270kPa?
5 Is the Pressure below 220kPa? 1. Check for 1. Clogged Filter
leakages from 2. Kink/ Blockage in
hoses, hose joints Fuel Hoses
2. Check Fuel Pump 3. Check Re
3. Check Pressure
Regulator

10.11.18.8.8 Fuel Module Removal:

Relieve fuel pressure in fuel lines referring to the ‘Fuel Pressure Relief Procedure’
provided in this section.
Disconnect negative cable at battery.
Disconnect fuel module wire coupler.
Drain the fuel in fuel tank thru fuel filler with help of hand pump (siphon). Collect the
fuel in approved container for contamination and safety.
Disconnect the fuel hoses from fuel module by using standard tools
Remove the fuel tank from vehicle.
Place the fuel tank with bottom up condition. Care to be taken not to cause any
scratches/ damages on fuel tank.
Open the fuel module mounting bolts.
Take out fuel module assembly from fuel tank with care
Care to be taken not to damage the strainer while removing fuel module from tank.
10.11.18.8.9 Fuel Module Installation:
Replace the fuel module gasket in fuel module assembly with a new one. Old/ used
gaskets can cause leakages.
Fold strainer towards fuel pump and insert fuel module in tank opening with care. Care
should be taken not to cause any damages on strainer.
Fuel Module Orientation: Fuel module bolts not symmetrical and can be mounted
only in the intended direction. Regulator side should be facing the Fuel Tank rear
side.
Make sure that the fuel tank surface at module mounting area is clean and free of
surface defects.
Place the bolts on module cover and tighten the bolts gradually in star pattern
sequence to apply equal compression on gasket. It is shown as below.

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Bolt Tightening Torque: 3~4 Nm.

Fuel module is installed with special bolts (step bolts). Use designated bolts only.
Follow the tightening torque and tightening sequence instruction. Over torque and
miss-sequence can cause unequal compression of gasket and leakage.
Install the fuel tank to vehicle.
Connect for fuel hoses with suitable hose clamps.
Connect fuel module coupler
Follow “Fuel Leakage Check Procedure’ to check any leakage before the engine is
started.
10.11.18.8.10 Pressure Regulator Assembly Replacement:
Remove the regulator retainer from module.
Apply gradual pull force on retainer to avoid any personal injury due to spring action of
retainer.
Take out the pressure regulator assembly from module.
Do not hit/ damage on the regulator dome and crimping portion.
Lubricate the O-rings in new pressure regulator assembly with recommended
lubrication oils as mentioned in Table no: 3. Lubrication oil is applied only for ease of
regulator assembly.
Make sure that 2 O-rings (one is bigger diameter the other is smaller diameter) are
assembled in pressure regulator.
Place the pressure regulator on module at regulator pod. Push the regulator gently in
the pod.
Do not hit/ damage on the regulator dome and crimping portion. This will disturb the
pressure setting.
Assemble the retainer on the regulator pod
Replace the gasket, module with new gasket provided in the kit.
10.11.18.8.11 Fuel Pressure Relief Procedure:
Caution: This work must not be done when engine is hot. If done so, it may cause
adverse effect to catalyst (if equipped)
After making sure that engine is cold, relieve fuel pressure as follows.
Place vehicle gear in ‘Neutral’.
Disconnect fuel module electrical coupler from vehicle harness.
Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF
for 2 ~ 3 times of about 3 seconds each time to relieve fuel pressure in lines. Fuel
Connections are now safe for servicing.
Upon the completion of servicing, Connect Fuel Module Connector to Vehicle Harness

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10.11.18.8.12 Fuel Leakage Check Procedure:

After performing any service on fuel system, check to make sure that there are no fuel
leakages as below.
Fill about 3 ~ 5 liters of fuel in tank.
Turn Ignition key to ON position for 3 seconds (to operate fuel pump) and then turn to
OFF position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines.
In this state, check to see that there are no fuel leakage from any part of fuel system
(Fuel Tank, Hoses, Hose Joints, etc)
Handling – DOs and DONTs :

ACTION REASON
DO NOT: Drop Fuel Module on Floor Could cause internal damage to Fuel Pump.

DO NOT: Run Fuel Pump Dry (without fuel at Caused internal damage to Fuel Pump
pump inlet/ strainer) ensure atleast 3 litres of
gasoline is present in the fuel tank
DO NOT: Damage the strainer during servicing, Contamination enters fuel pump thru damaged
insertion of fuel module in fuel tank strainer damages the Fuel Pump

DO NOT: Disassemble Fuel Pump and regulator Warranty void.

internal parts out side Delphi premises.
DO NOT: Do any adjustments on pressure
regulator and pump except for replacement.
DO NOT: Use module harness for hold/ carry fuel Wiring Harness Breakage/ Fuel Pump Power
module. disconnection
DO NOT: Pull Wiring Harness in vertical direction
to module cover
DO NOT: Use damaged/ distorted hose clamps Can cause fuel seepage/ leakage.

DO NOT: Use Fuel Module if the strainer with Contamination enters fuel pump thru damaged
excessive damage/ cut. strainer damages the Fuel Pump
DO NOT: Use Fuel Pump for draining duel in fuel Not intended function of fuel module
tank.
DO NOT: Use module mounting bolts for mounting Affects fuel module sealing.
other components.
DO NOT: Damage fuel pump harness while Damaged terminals will cause intermittent/ No
servicing fuel module. contact for power supply.
DO NOT: Force hand pump towards fuel module To avoid any damages on fuel module
while draining fuel from tank.
DO : Ensure that there are no damages to fuel Can cause fuel seepage/ leakage.
pipes while servicing fuel module
DO: Use genuine module gasket only. Spurious gaskets can cause leakages
DO: Use designated hose clamps. To ensure no leakages/ seepages thru hose
joint.
DO: Clamp fuel module harness to vehicle chassis Clamp provides mechanical support for wiring
harness in vibrations.
DO: Use only standard gasoline for operating Fuel Module is intended to run in standard
vehicle/ module gasoline. Adulterated fuel can cause fuel
module premature failures which are not
covered under warranty.
DO: Change the fuel filter at recommended Clogged fuel filter will cause restriction in fuel
intervals. flow and can cause flow reduction.
DO: Use fuel filters supplied/ recommended fuel Spurious fuel filters causes damages to
filters only. injector, regulator and fuel pump performance.
DO: Ensure that the hoses are routed properly Improper routing, kinks and fouling of hoses
and there are no kinks / rubbing with other with other components causes hose damage
components.
DO : Ensure that always sufficient fuel till the Avoids Pump running in dry
strainer height

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ACTION REASON
DO: Replace two O-rings along with replacement/ For proper functioning of regulator
re-installation of pressure regulator.
DO: Use care during connection of harness to Avoid terminal damage.
module coupler.
DO: Return any dropped, damaged, or suspect Ensure fast and correct diagnosis of root
material with a tag that describes the problem. cause.

10.11.18.9 Diagnostic Tools

10.11.18.9.1 Mot or Scanner ( for MT05 EMS)
10.11.18.9.1.1 P re c a u t i o ns
Motor-Scanner is a precision instrument and should be protected from vibration
and impact.
If the unit does not run correctly or the screen is unstable when first turned on,
disconnect it from the main lead and try again.
Make sure the DLC is always firmly inserted into the diagnostic socket.
Never test electrical signals that exceed the limit of specifications.
Test cannot be performed by the person who is driving the car.
This unit should be used and stored in the following conditions:
Ambient temperature: 0~50℃
Relative humidity: <90%
10.11.18.9.1.2 .Co nf ig ur a t io ns
Delphi Motor scanner consists of 2 main part: the main units (with diagnostic main
cable) and diagnostic connector link (one end is 6PIN connector; the other is the
interface for connecting diagnostic main cable). They are shown in figure 34 as
below.

Ou t l i n e o f Ma i n Un i t

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The 6 PIN diagnostic connector link cable and USB type main unit’s software
update cable are in the delivered package.

Screen:
128×64 array high definition screen with back light for displaying all the
information during testing.
Keyboard:
There are 5 keys (one is reserved) on the main unit for selecting and controlling
test steps.
10.11.18.9.1.3 . Preparations Connection
Find the 6PIN diagnostic socket on the motor.
Connect one end of the diagnostic main cable to the main unit, and the other
end to diagnostic socket on the motor, tighten the screws.
Normal Powe r – on Display
When power is on normally, the unit will display:

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Seconds later, the unit will display:

10.11.18.9.1.4 . F u n c t i ons
Delphi Motor-Scanner can be used to diagnose Delphi Engine Management
System with functions: Read DTC, Clear DTC, Data Stream, Status Stream, and
Record Data.
Op e r a t i o n s
When the unit is powered up, the screen will display the interface as below.

Here, we take diagnostic function for demonstration.

Select 1 and press key, it will display an interface for language selection, as
shown below:

Select ‘English’ and press key, it will display information about the diagnostic
software version, press to continue, the interface will display as below:

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Diagnostic Function
Here, we take ‘diagnostic function’ for demonstration.
Select ‘diagnostic function’ and press , the screen will display an interface to indicate
‘Delphi-3’ diagnostic connector should be used.
Press , the screen will display engine information as below:

Press , with ‘accessing system’ fleeting on the screen, then, it will display as below:

Available functions are as follows:

Read DTC
Clear DTC
Data Stream
Status Stream
Record Data
Press or key to select function you needed.
1. Read DTC
Select ‘Read DTC’, and press , it will display fault code as below:

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Press or key to move ‘.’ icon, and select fault code, take ‘P0118’ for
example, it’s selected when there is ‘.’ in front of it, press , the screen will
display detailed information of the code, as below:

2. Clear DTC
Select ‘Clear DTC’ and press , it will display as below:

3. Data Stream
Select ‘Data Stream’ and press , it will display as below:

Press or key for page up/down to view more. Press key to exit.
4. Status Stream
Select ‘Status Stream’ and press , the interface will display as below:

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Press or key for page up/down to view more. Press key to exit.
5. Record Data
Select ‘Record Data’ and press , it will display:

Press or key to enter code, when the first number of the code was set,
press to confirm and continue to input the sequent numbers, till all the 7
numbers were input.
When all the 7 numbers were set, press , the screen will display a message
for confirmation of the Plate Number input. Press to return to the previous
interface to input the code again or press to confirm the code.
Press , another interface will be displayed for you to input date, as below:

It’s the same way to enter month as vehicle code input.

Month was input, then enter date, as below:

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Then, ‘Enter Year’ continues, as below:

After that, ‘Enter Week’ follows, as below:

Till now, the ‘date input’ was completed, and it starts to record data, press to stop recording.

Check malf code meaning by reading the below table.

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Malf code Description

in MT05
P0107 MAP Circuit Low Voltage or Open
P0108 MAP Circuit High Voltage
P0112 IAT Circuit Low Voltage
P0113 IAT Circuit High Voltage or Open
P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage
P0118 Coolant/Oil Temperature Sensor Circuit High Voltage or Open
P0122 TPS Circuit Low Voltage or Open
P0123 TPS Circuit High Voltage
P0131 O2A Circuit Low Voltage
P0132 O2A Circuit High Voltage
P0031 O2A Heater Circuit High Voltage
P0032 O2A Heater Circuit Low Voltage
P0201 Injector 1 Circuit Malfunction
P0202 Injector 2 Circuit Malfunction
P0230 FPR Coil Circuit Low Voltage or Open
P0232 FPR Coil Circuit High Voltage
P0336 CKP Sensor Noisy Signal
P0337 CKP Sensor No Signal
P0351 Cylinder 1 Ignition Coil Malfunction
P0352 Cylinder 2 Ignition Coil Malfunction
P0505 Idle Speed Control Error
P0562 System Voltage Low
P0563 System Voltage High
P0650 MIL Circuit Malfunction
P1693 Tachometer Circuit Low Voltage
P1694 Tachometer Circuit High Voltage

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10.12 FRONT GEARCASE

10.12.1 FRONT GEARCASE COMPONENT IDENTIFICATION
External Components
A Jointor
B Bolt M8X25
C Diff filler plug
D Washer 16
E Oil-seal 27x42x7
F Diff lock cover
G Bolt M6X22
H Bolt M8X25
I Bolt M6X40
J Oil-seal 22X48X11
K Oil drain plug
L Washer 12
M Diff 4WD cover
N Electromagnetic valve
O Bead flange
P Input shaft
Q Oil-seal 35X62X7
R Housing cover
S Housing
10.12.2 FRONT GEARCASE DISASSEMBLY
1 Remove the oil drain plug A and let
the oil drain from the gearcase.

2. Remove the electromagnetic

valves A and the oil-seal B, then
remove the diff lock cover assy. C and
the diff 4WD cover assy. D.

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3. Remove the D62 lock snap ring A

and remove the input shaft with the
bearing 6007 B.

4. Remove the splined dog A, then

remove the housing cover B. Remove
the D52 lock snap ring C, then remove
the pinion with the bearing 6205 D.

5. Remove the differential A.

10.12.2.1 FRONT DIFFERENTIAL DISASSEMBLY

1. Remove the diff carrier cover A.

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2.Remove the roll pin A, remove

center pin B, bevel pinion washers C,
bevel pinions D, center spacer E
bevel gear F and washer G from
differential housing. Remove the
bevel crownwheel H.

Note: Clean all components and inspect for wear. Inspect gears for wear, cracks, chips or
broken teeth. Inspect engagement dogs and detent ball housing, replace if edges are rounded.
Inspect casting for crack. Inspect bearings for smooth operation. Check for excessive play
between inner and outer race. Inspect detent spring and finger spring for wear, cracks,
relaxation. Replace part with any defects.
IMPORTANT: New seals should be installed after the transmission is completely assembled.

10.12.3 FRONT GEARCASE ASSEMBLY

1.Install the bevel crownwheel
A, tighten the screws B with
screw threads glue. and torque
bolts to 24ft.lbs. (32Nm). Install
washer C, bevel gear D into
differential housing. Install
center pin E, bevel pinion
washers F, bevel pinions G,
center spacer H, then install the
roll pins I.

2. Install bevel gear A, washer

B and the diff carrier cover C,
tighten the screws D with screw
threads glue. and torque bolts
to 16ft.lbs. (22Nm).

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3.Install the bearing 6006 A

into the housing B, install the
bearing 6007 C into the
housing cover D.

4.Install the bearing 6205 B to

the pinion A with the D25 lock
snap ring C. Install the bearing
6007 E to the input shaft D with
the D35 lock snap ring F, install
the bead flange G to the input
shaft D.

Components
A Diff lock cover
B D8 lock snap ring
C Diff fork pivot
D Return spring 1
E Diff lock pawl spring
F Return spring 2
G Diff lock fork pawl
H Diff dog selr fork
I Diff 4WD pawl spring
J Diff 4WD fork pawl
K Diff 4WD cover
5. Assemble components as
shown in figure.

6. Install the differential A into

the housing B and install the
pinion assy. C with the D52
lock snap ring D.

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7. Apply Loctite sealant

evenly on the surface A or
B, then assemble the two
semi-housings. Tighten the
screws C and D, torque
bolts to 14ft.lbs. (20Nm)

8.Put the splined dog F into the

housing, install Diff 4WD cover
assy. D with paper washer B,
locating pin C, tighten the
screws E, torque bolts to
8ft.lbs. (12Nm).
.Put the splined dog F into the
housing cover, install diff lock
cover assy. H with paper
washer A, locating pin C,
tighten the screws G, torque
bolts to 8ft.lbs. (12Nm).
NOTE: the splined dog should
glide smooth on the diff dog
selr fork.

9. Install the input shaft assy. A

with the D62 lock snap ring B.

10. Install oil-seal 35X62X7 A, oil-seal

27x42x7 B, oil-seal 22X48X11.

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11. Install the jointor A into the

housing. Install the
electromagnetic valves B, torque
bolts to 40ft.lbs (54Nm).Install oil
drain plug D and washer C, torque
bolt to 21ft.lbs (28Nm).
Add 450 ml gear oil, then install diff
filler plug F and washer E, torque
bolt to 24ft.lbs. (32Nm).

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10.12.4 FRONT GEARCASE EXPLODED VIEW

1. Electromagnetic valve 2. Bolt M6X22 3. Diff lock cover 4. Diff lock pawl spring
5.Locating pin 6. Paper washer A 7.D8 lock snap ring 8. Return spring 2
9. Diff dog selr fork 10. Diff fork pivot 11. Return spring 1 12. Diff lock fork pawl
13. Splined dog 14. Bolt M8X25 15. Bolt M8X25 16. Oil-seal 27x42x7 17. Diff filler
plug 18. Washer 16 19. Housing cover 20. Bearing 6007 21.Bolt M8X15
22. Diff carrier cover 23. Bevel crownwheel 24. Washer 25. Bevel gear
26. Roll pin 27. Center pin 28. Bevel pinion washer 29. bevel pinion 30. Center
spacer 31. Differential housing 32.Bolt M8X18 33. Jointor 34.Housing
35. Oil-seal 22X48X11 36. Paper washer B 37. Diff 4WD cover 38. Bolt M6X40
39. Diff 4WD pawl spring 40. Diff 4WD fork pawl 41. Oil drain plug 42. Washer 12
43. Pinion 44. Bearing 6205 45. D25 lock snap ring 46. D52 lock snap ring
47. Input shaft 48. D62 lock snap ring 49. D35 lock snap ring 50. Oil-seal 35X62X7
51. Bead flange 52 Bearing 6006 53. Differential 54.Front gearcase

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10.13REAR GEAR-BOX
10.13.1 REAR GEAR CASE DISASSEMBLY
1. Drain and properly dispose of used oil.
2. Loosen the cover bolts in a crisscross pattern
in several steps and remove them.
3. Pry the cover at the prying points using a
screw-driver and remove the output cover.
Remove the o-ring.
4. Remove the ring gear and bearing assembly.
5. Remove the oil seals and o-ring.
6. Unstake the pinion bearing lock nut with a drill
or grinder. Remove the lock nut using the
special tool.
7. Remove the pinion bearing assembly.

10.13.2 REAR GEAR CASE ASSEMBLY

1. Drive the pinion gear assembly into the drive
housing.
2. Install a new lock nut and tighten it using the
special tool.
3. Stake the lock into the case groove.
4. Coat a new O-ring with grease and install it
onto the pinion gear shaft.
5. Apply grease to the lips of new oil seals.
Install the inner oil seal into the drive housing
until it is flush with the stepped edge.
6. Install the outer oil seal into the drive housing
until with the drive housing outer surface.

7. Coat a new O-ring with grease and install it

into the cover groove.
8. Install the outer cover onto the drive housing.

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9. Install the cover bolts and tighten them in

several steps until the cover evenly touches
the drive housing. Then while rotating the
pinion gear, tighten the bolts to the specified
torque in a crisscross pattern in several
steps.
TORQUE:
10mm bolt:45N.m
8mm bolt: 25N.m
10. Check that the gear assembly turns
smoothly without binding.

10.13.3 BACKLASH INSPECTION

Remove the oil filler cap.

Install the special tool into the pinion joint, and set
the final drive assembly and tool in a vise.
Install the drive shaft into the final drive assembly
and hold it.
Set a horizontal type dial indicator on the ring gear
through the filler hole.
Turn the ring gear back and forth with the drive
shaft to read backlash.
STANDARD:0.05-0.25mm
SERVICE LIMIT:0.4mm
Remove the dial indicator. Turn the ring gear 120°
and measure backlash.
Repeat this procedure once more.
Compare the difference of the three
measurements.
SERVICE LIMIT:0.2mm
If the difference in measurements exceeds the
service limit, it indicates that the bearing is not
installed squarely, or the case is deformed.
Inspect the bearings and case.

If the backlash is excessive, replace the ring gear

right shim with a thinner one.
If the backlash is small, replace the ring gear right
shim with a thicker one.
Backlash is changed by about 0.06mm when
thickness of the spacer is changed by 0.12mm.

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REAR GEARCASE EXPLODED VIEW

1. REAR GEAR-BOX ASSY 2. DRIVE HOUSING 3. OUTPUT COVER 4. O-RING 160X2.65

5. BOLT M8X28 6. BOLT M10X1.25X28 7. WASHER 35.5 8. O-RING 20X3 9. NUT M16X1.5
10. OUTPUT AXLE, RING REAR GEAR-BOX 11. INPUT AXLE, RING REAR GEAR-BOX 12.
LOCK NUT 13. SEAL 35X55X11 14. SEAL 38X85X8 15. SEAL 38X80X8 16. BEARING
15NQ2815 17. OIL SCREEN CAP 18. O-RING 19. WASHER 20. OIL PLUG 21.tube, REAR
GEAR-BOX BREATHER 22. BEARING 6306 23. BEARING 6007 24. BEARING 6207
25 WASHER 60

CHAPTER 13 REAR GEARCASE PAGE 13- 3