3 LUBRICATION SYSTEM cr service se

3 Lubrication System Cr Service Se-PDF Download

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3 LUBRICATION SYSTEM,Precautions in Operation,General Information. This chapter contains maintenance operation,for the engine oil pump and gear oil replacement. Specifications,Engine oil quantity Disassembly 3500 c c. Filter change 3200 c c,Change 3000 c c,Oil viscosity SAE 10W 40. Items Standard mm Limit mm,Inner rotor clearance 0 15 0 20.
Oil pump Clearance between outer rotor and body 0 15 0 20 0 25. Clearance between rotor side and body 0 04 0 09 0 12. Torque value,Torque value oil filter 1 2 kgf m,Engine oil drain bolt 2 4 kgf m. Troubleshooting,Low engine oil level Dirty oil,Oil leaking No oil change in periodical. Valve guide or seat worn out Cylinder head gasket damage. Piston ring worn out Piston ring worn out,Low oil pressure. Low engine oil level,Clogged in oil strainer circuits or pipes. Oil pump damage, PDF created with pdfFactory Pro trial version www pdffactory com.
3 LUBRICATION SYSTEM,Engine Oil,Turn off engine and park the ATV in flat surface. Check oil level with oil dipstick,So not screw the dipstick into engine as checking. If oil level is nearly low level fill out recommended oil. to upper level,Oil Change 4 screws,Drain oil as engine warmed up so that makes sure. oil can be drained smoothly and completely, Place an oil pan under the ATV and remove oil drain bolt. After drained make sure washer can be re used Install Drain bolt. oil drain bolt,Torque value 2 4 kgf m,Engine Oil Strainer Clean.
Drain engine oil out,Remove oil strainer cap,Clean oil strainer. Check if O ring can be re used,Install oil strainer cap. Torque value 1 0 1 2 kgf m,Engine oil capacity 3000c c when replacing. Replace The Oil Filte r,Same as oil change drain the oil out. Remove the oil filter by special tool, Apply engine oil lightly to the gasket of the new oil filter.
when installation,Torque value 1 2 kgf m,Oil and filter change 3300c c when replacing. Install dipstick start the engine for running several minutes. Turn off engine and check oil level again,Check if engine oil leaks. PDF created with pdfFactory Pro trial version www pdffactory com. 3 LUBRICATION SYSTEM,Oil Pump Removal One way clutch. Remove the one way clutch,Remove the clutch shoe,Remove the snap ring. Remove the washer,Remove the oil pump driver gear,The clutch shoe nut has left hand threads.
Remove the snap ring,Remove the washer,Remove the oil pump driver gear Snap ring. Remove the pin,Remove the washer, Make sure that pump shaft can be rotated freely 3 screws. Remove 3 screws on the oil pump and then,remove oil pump. Oil Pump Disassembly, Remove the screws on oil pump cover and remove 1 screw. Remove oil pump shaft roller and shaft, PDF created with pdfFactory Pro trial version www pdffactory com.
3 LUBRICATION SYSTEM,Oil Pump Inspection,Check the clearance between oil pump body and. outer rotor,Limit 0 25 mm,Check clearance between inner and outer rotors. Limit 0 20 mm,Check clearance between rotor side face and. Limit 0 12 mm,Oil Pump Re assembly,Install inner and outer rotors into the pump body. Align the indent on driving shaft with that of inner. Install the oil pump shaft and roller, Install the oil pump cover and fixing pins properly.
PDF created with pdfFactory Pro trial version www pdffactory com. 3 LUBRICATION SYSTEM,Tighten the oil pump screw,Oil Pump Installation. Install the oil pump and then tighten 3 screws,Torque value 1 0kgf m. Make sure that oil pump shaft can be rotated freely. Install the washer,Install the pin,Install the oil driven gear. Install the washer,Install the snap ring, PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Mechanism Diagram 4 1 Throttle Valve 4 6.
Precautions in Operation 4 2 Float Chamber 4 7, Trouble Diagnosis 4 3 Adjustment of Idle Speed 4 9. Carburetor Remove Install 4 4 Fuel Tank 4 10,Air Cut Off Valve 4 5 Air Cleaner 4 11. Mechanism Diagram, PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Precautions in Operation,General Information. Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and. strictly prohibit flame when working with gasoline. Do not bend off throttle cable Damaged throttle cable will make unstable drive ability. When disassembling fuel system parts pay attention to O ring position replace with new one as. re assembly, There is a drain screw in the float chamber for draining residual gasoline.
Do not disassemble air cut valve arbitrarily,Specification. ITEM BSR33,Carburetor diameter 33mm,I D number 33 77. Fuel level 31 5 0 5mm,Main injector 122 5,Idle injector 35. Idle speed 1700 100rpm,Throttle handle clearance 1 3 mm. Pilot screw 3 turns,Special service tools,Vacuum air pressure pump.
Fuel level gauge, PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Trouble Diagnosis,Poor engine start Mixture too lean. No fuel in fuel tank Clogged fuel injector,Vacuum piston stick and closed. Clogged fuel tube,Malfunction of float valve, Too much fuel in cylinder Fuel level too low in float chamber. No spark from spark plug malfunction of ignition Clogged fuel tank cap vent. system Clogged fuel filter,Clogged air cleaner Obstructed fuel pipe.
Malfunction of carburetor chock Clogged air vent hose. Malfunction of throttle operation Air existing in intake system. Stall after started,Malfunction of carburetor chock. Mixture too rich,Incorrect ignition timing,Malfunction of carburetor Clogged air injector. Dirty engine oil Malfunction of float valve, Air existing in intake system Fuel level too high in float chamber. Incorrect idle speed Malfunction of carburetor chock. Dirty air cleaner,Rough idle,Malfunction of ignition system. Incorrect idle speed,Malfunction of carburetor,Dirty fuel.
Intermittently misfire as acceleration,Malfunction of ignition system. Late ignition timing,Malfunction of ignition system. Malfunction of carburetor,Power insufficiency and fuel consuming. Fuel system clogged,Malfunction of ignition system. PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Carburetor Remove Install,Remove the fuel tank.
Loose the carburetor clamp screws,Clamp Clamp,Loosen the carburetor side cap 3 screws. Remove cap,Disconnect the throttle cable,Disconnect the starter cable. Remove the carburetor,Installation,Install in reverse order of removal procedures. Start cable, PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Air Cut Off Valve,Disassembly,Remove air vent hoses.
Remove fuel hose,Remove vacuum hose,Remove air cut off valve cover 2 screws spring. Inspection,Check the valve is in normal, If the valve is in normal it will restrict air flow. If air flow is no restricting replace carburetor,Check the vacuum pipe o ring is in normal. Air cut off valve,Install in reverse order of removal procedures. PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Throttle Valve,Disassembly,Remove carburetor top comp.
Remove the spring holder needle set jet and,piston valve. Remove the cable adjuster assy,Cable adjuster assy. PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Float Chamber,Disassembly,Remove 4 mounting screws and remove float. chamber cover,Remove the screw float pin float and. float valve Float,Float valve,Inspection Pin Float.
Check float valve and valve seat for damage,Check float valve for wearing and check valve. seat face for wear dirt,Float valve,Check for wear or dam age. In case of worn out or dirt the float valve and valve. seat will not tightly close causing fuel level to increase. and as a result fuel flooding A worn out or dirty float. valve must be replaced with a new a new one, PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM, Remove main jet needle jet holder needle jet Main jet. slow jet and air adjustment screw,Slow jet Starter jet.
T ake care not to damage jets and adjust screw,Before removing adjustment screw turn it all the. way down and note the number of turns,Does not turn adjust screw forcefully to avoid. damaging valve seat face,Air adjustment jet,Assembly Air adjustment screw Main jet. Install main jet needle jet holder needle jet slow jet. and air adjustment screw,Cautions Starter jet, Set the air adjustment screw in according to number Slow jet. of turns noted before it was removed, Install the float valve float and float pin Air adjustment screw.
Checking fuel level, Check again to ensure float valve float for proper. installation,To ensure correct measurement position the float. meter in such a way so that float chamber face is,vertical to the main jet. Float gauge,Fuel level 31 5 0 5mm,Installation of carburetor. Install carburetor in the reverse order of removal. Following adjustments must be made after installation. Throttle cable adjustment,Idle adjustment,Throttle adjustment screw.
PDF created with pdfFactory Pro trial version www pdffactory com. 4 FUEL SYSTEM,Parking brake,Adjustment of Idle Speed. Air screw was set at factory so no adjustment is,needed Note the number of turns it takes to. screw it all the way in for ease of installation,The parking brake must be used to stop the. ATV to perform the adjustments,Use a tachometer when adjusting engine RPM Screw. in air adjustment screw gently then back up to standard. turns Throttle stopper screw,Standard turns 3 turns.
Warm up engine adjust the throttle stopper screw of. throttle valve to standard RPM,Idle speed rpm 1700 100 rpm. Connect the hose of exhaust analyzer to exhaust front. end Press test key on the analyzer,Adjust the pilot screw and read CO reading on the. CO standard value 1 0 1 5, Accelerate in gradual increments make sure rpm and. CO value are in standard value after engine running in. stable If rpm and CO value fluctuated repeat the, procedures described above for adjusting to standard. PDF created with pdfFactory Pro trial version www pdffactory com. 3 LUBRICATION SYSTEM 3 2 Precautions in Operation General Information This chapter contains maintenance operation for the engine oil pump and gear oil replacement Specifications Engine oil quantity Disassembly 3500 c c Filter change 3200 c c Change 3000 c c Oil viscosity SAE 10W 40 Torque value Torque value oil filter 1 2 kgf m

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