Chinese 110cc ATV Service & Repair Manual 2nd Edition
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CHINESE
110cc ATV
(4-STROKE)
SERVICE & REPAIR
MANUAL
digitalrepairmanuals@gmail.com
for parts www.streetpartz.com
BRIEF INTRODUCTION TO FOUR-WHEELED
CROSS-COUNTRY VEHICLE MODEL ATV110-M
Four-wheeled cross -country vehicle, model ATV110-M is a full road condition vehicle
which can be driven on every kinds of road conditions such as sand beach, grassland, forest,
village,construction site country road , This maintenance manual of four-wheeled vehicle model
ATV110-M (Hereafter called cross -country vehicle for short) compiled by Chongqing Indus-
tries Co., Ltd is specially provided for saler and technical staff of our Group. This manual
mainly introduce the maintenance, removing and repairing method of cross-country vehicle and
provide some relative technology and performance data. Because this manual can’t collect the
whole content of cross-country vehicle, it can only help maintainer of our group and it’s saler
have a basic understanding on working principle, maintenance procedure and repairing tech-
nology of cross-country vehicle. If you don’t have this knowledge, when repairing cross-coun-
try vehicle, the condition of improper assembling and danger occurs after assembling are easily
happened. Proper operation and maintenance are the advance of your safely driving cross-
country vehicle, it also can reduce the troubles of cross-country vehicle and keep the best
performance of it. The specification, performance and explanation stated in the manual are
determined according to newly design of the vehicle, which are subject to changes without
notce.
In this manual, for specially important requirement, the words of “Warning ” “Caution ” are
labelled to prompt relative maintainer to abide it.
In the manual
Caution
Show that if the content of “Warning ”isn’t obeyed, the driver, maintainer,
checker will be heavily injuried, even dead.
Show that you must be careful to prevent the vehicle from being damaged.
Warning
Maintenance manual of four-wheeled cross-country vehicle model ATV110-M
First edition Aujust 2005
This manual is published by publishing factory. maintain the copyright of
publishing. Without permitted, publishing is prohibited.
Content
Content ............................................................................................................................................... I
Chapter I General description .............................................................................................................. 1
Section 1 Description .......................................................................................................................... 1
Section 2 Special tools, instruments & meters .................................................................................... 2
(I) Special tools ........................................................................................................................ 2
(II) Instruments & tools ........................................................................................................... 3
Section 3 Identification code, label of model and engine No. ............................................................. 4
Section 4 Points for attention in maintenance ..................................................................................... 4
Section 5 Specification ........................................................................................................................ 8
I. How to use conversion table of unit .................................................................................... 8
(1)How to use conversion table ............................................................................................... 8
(2)Definition of unit ................................................................................................................. 8
II. Basic specification............................................................................................................... 9
III. ATV body ........................................................................................................................... 10
V. Maintenance specification of engine .................................................................................. 11
Section 6 Wiring diagram of ATV ........................................................................................................ 14
Section 7 Requirements for torque of fastener .................................................................................... 15
Section 8 Lubrication .......................................................................................................................... 16
Section 9 Lubrication point and type of lubricants ............................................................................. 17
(1) Lubrication point and type of lubricants(ATV body) ......................................................... 17
(2) Lubrication point and type of lubricants(Engine) ............................................................... 18
Chapter II Maintenance and adjustment of vehicle ............................................................................ 19
Section 1 Periodic maintenance/ lubrication ....................................................................................... 19
Section 2 Disassembly and assembly of cushion, fender and fuel tank .............................................. 20
(I) Cushion ............................................................................................................................... 20
(II) Rear fender ......................................................................................................................... 20
(III) Front fender ..................................................................................................................... 22
(IV)Fuel tank ............................................................................................................................ 23
Section 3 Maintenance and adjustment of vehicle body .................................................................... 26
(I) Wear inspection of front and rear brake .............................................................................. 26
(II) Adjustment of front brake.................................................................................................. 26
(III)Adjustment of free clearance of left lever and rear brakepedal ......................................... 27
(IV) Inspection of steering system .......................................................................................... 29
(V) Adjustment of toe-in of front wheel .................................................................................. 30
(VI) Adjustment of rear shock absorber .................................................................................. 31
(VII)Inspection of tire .............................................................................................................. 32
(VIII) Inspection of rim ............................................................................................................ 33
Section 4 Maintenance and adjustment of electrical appliance........................................................... 34
(I) Inspection of battery ........................................................................................................... 34
(II) Inspection of fuse .............................................................................................................. 35
Section 5 Maintenance and adjustment of engine .............................................................................. 36
(I) Adjustment of clutch .......................................................................................................... 36
(II) Clean of air filter ................................................................................................................. 36
(III) Inspection of spark plug ................................................................................................... 37
(IV) Adjustment of idle speed.................................................................................................. 38
(V) Adjustment of free clearance of throttle grip ..................................................................... 38
(VI) Adjustment of speed limitator .......................................................................................... 39
(VII) Adjustment of valve clearance ........................................................................................ 39
(VII) Inspection of ignition timing ........................................................................................... 41
(IX) Measuring of compressive force ...................................................................................... 42
(X) Inspection oil quantity of engine ....................................................................................... 43
(XI) Replacement of engine oil and inspection of oil flow....................................................... 44
Chapter III Repair and maintenance of vehicle body .......................................................................... 46
Section 1 Rear driving gearcase and driving shaft .............................................................................. 46
(I) Disassembly ........................................................................................................................ 46
(II) Inspecting procedures ....................................................................................................... 48
(III) Installation procedure ....................................................................................................... 51
Section 2 Rear wheel/Rear brake/Rear wheel axle............................................................................... 54
(I) Removal steps .................................................................................................................... 54
(II) Inspection steps ............................................................................................................... 55
Section 3 Steering operation system .................................................................................................. 57
(I) Removal steps of steering bar ............................................................................................ 57
(II) Removal steps of steering vertical column welding.......................................................... 58
(III) Inspection content ........................................................................................................... 59
(IV) Installment steps .............................................................................................................. 60
(V) Installation steps of steering bar ...................................................................................... 63
Section 4 Front shock absorber and front wheel fork ........................................................................ 64
(I) Disassembly ....................................................................................................................... 64
(II) Inspection steps ............................................................................................................... 65
(III) Installment steps .............................................................................................................. 66
Section 5 Rear shock absorber and rear wheel fork............................................................................ 69
Chapter IV Electric appliance ............................................................................................................. 70
Section 1 Inspect switch .................................................................................................................... 70
(I) Inspect switch .................................................................................................................... 70
Section 2 check lamp(headlight) ........................................................................................................ 71
Section 3 Troubleshooting the ignition system failure ...................................................................... 75
Section 4 Troublshooting electric starting system ............................................................................ 76
Section 5 Check starting motor .......................................................................................................... 79
Section 6 No charging in the battery ................................................................................................. 81
Section 7 Troubleshooting ................................................................................................................ 83
Section 8 Inspection of lighting system ............................................................................................. 85
Chapter V Engine ............................................................................................................................... 86
Section 1 Disassembly of engine ....................................................................................................... 86
(I) Remove the engine from finished ATV .............................................................................. 86
(II) Disassembly of engine ...................................................................................................... 88
section 2 Inspection and maintenance of engine ............................................................................... 96
Chapter VI Vecicle ordinary trouble and its judgement ...................................................................... 116
(I) Starting trouble/difficulty ................................................................................................... 116
(II) Poor idle speed performance ............................................................................................. 117
(III) Poor middle and high speed performance........................................................................ 117
(IV) Shifting troubler ............................................................................................................... 117
(V) Clutch slips ....................................................................................................................... 118
(VI) Clutch is locked ............................................................................................................... 118
(VII) Engine is overheat .......................................................................................................... 118
(VIII) Brake trouble ................................................................................................................. 118
(IX) Shock absorber failure/improper operation ..................................................................... 118
(X) Lighting system ................................................................................................................ 119
Chapter I General description
Section 1Description
1. Front wheel
2. Shift pedal
3. Fuel cock
4. Cushion
5. Rear wheel
6. Exhaust silencer
7. Rear fender
8. Rear brake pedal
9. Front fender
10. Bumper
11. Left lever of rear brake
12. Left switch unit
13. Fuel tank cover
14. Throttle grip
15. Right lever of front brake
Caution:
The ATV you purchased maybe slightly differ from the pictures in the manual due to im-
provement or other changement.
1 2 3 4 5
6 7 8 10 9
11 12 13 14 15
-1-
Section 2 Special tools, instruments and meters
(I) Special tools
Special tools is the necessary tools used for accurately adjustment and assembly, it is
helpful to prevent the maintenance defects and components damage caused by using improper
tools.
1.Wrench for valve adjustment mainly used for adjusting valve clearance. Specification:
3mm 90890-01311
2.Puller for piston pin, mainly used of removing pistion pin.
3.Remover for rotator, mainly used for pulling magneto rotator form crank.
4. Clamp for rotator, mainly used for clamping magneto rotator when removing it to pre-
vent it’s rotation due to torque force.
5.Stop rotating meter for rotator, mainly used for removing and assembling rotator of kick
starter.
6.Puller for crank, mainly used for disassembling crank from crankcase.
7.Puller for rocker shaft, mainly used for removing rocker shaft.
8.Compressing tools for spring of valve, mainly used for fixing and compressing spring
when assembling valve lock clamp.
9. Assembling and disassembling tool for valve guide, mainly used for assembling and
disassembling valve guide.
10.Assembling buffer, mainly used for assembling crank and balancing gear.
11.Hollow sleeve, mainly used for assembling crank and balancing gear.
12.Assembling toal for crank, mainly used for assembling crank and balancing gear.
13.Assembling and disassembling joint for universal coupling, mainly used for assembling
and dismsembling universal coupling.
14.Assembling and disassembling disc, mainly used for assembling and disassembling re-
verse gear.
15.Fixed puller for gear, mainly used for assembling and disassembling gear.
For the above tools, you can select with reference to special tools of the same type
of vehicle.
-2-
(II) Instruments and meters
The following instruments and meters can be selected with reference to the same type of
vehicle.
speedometer of engine
(90890-03113)
multimeter
Ignition timing meter
(90890-03141)
spark tester of spark plug
barometer ignition checker
measuring tool of gasoling
(90890-01312)
dial indicator
-3-
Section 3 Identification code, label of model and engine N0.
Section 4 Points for attention in maintenance
der of disassembly, this in assembling, can
not only increase the assembling speed, but also
ensure the rightness of assembling.
2.Replace the components
When replacing the components, be sure to
use qualified products provided by use lubricants
and grease which brank is assigned by lubricate.
3.Oil seal, shim, o-ring clip split pin,
elastic washer.
3.1 When disassembling to maintain the
engine, in order to ensure that the reassembled
engine have good sealing and connecting part is
fixed and reliable, all the oil seal, shim, o-ring,
clip, split pin and elastic washer should be
replaced, be sure to keep lip of oil seal surface
of shim and o-ring in cleaning condition.
3.2 When reassembling, apply lubricants to
lubricate all the mated components and bearing,
apply grease for oil seal.
-4-
1.Preparation when disassembling
1.1 First clean the dirt, mud and attachment
on the vehicle befor removing or disassembling.
1.2 Use proper special too cleaning device
and means.
1.3 Keep all the components away from fire
source. Pay attention to the safety, Don’t be
burned by the high temperation portion of engine,
exhuaster and silencer etc. Be sure to take care
of each other when operation with other people.
1.4 When disassembling the ATV, put the
mated components, such as gear pairs, cylinder,
piston and other “mated” components by nor-
mal running in together, When assembling or
replacing these components, they should be in
pairs.
1.5 When disassembling the engine, clean
all the components and put in the tray in the or
Identification code
It is engraved in the left or right side of front
supporting main take of engine of frame.
Engine N0.
The engine No. engrave onthe narrow point
position.
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$28.99
This service and repair manual provides comprehensive information for maintaining and repairing your ATV. It covers a wide range of topics including:
- Description
- Special tools
- Identification code, model, and engine number
- Maintenance specifications
- ATV body
- Maintenance specifications of the engine
- Wiring diagram
- Requirements for torque of fasteners
- Lubrication
- Maintenance and adjustment of the vehicle
This manual contains over 100 pages of detailed information to help you effectively fix, service, maintain, and ensure the safe operation of your ATV.
