Apache ATV100 Service Manual

§CONTENTS § 一、TECHNICAL INFORMATION…………………………………………………………………1~4 二、TROUBLE SHOOTING…………………………………………………………………………..5~9 三、MAINTENANCE……………………………………………………………………………….10~15 3-1 MAINTENANCE SCHEDULE……………………………………………... ……………...10 3-2 MAINTENANCE DATA……………………………………………………………………...10 3-3 FUEL TUBE…………………………………………………………………………………...11 3-4 THROTTLE OPERATION…………………………………………………………………..11 3-5 THROTTLE CABLE ADJUSTMENT……………………………………………………...11 3-6 AIR CLEANER……………………………………………………………………………….11 3-7 SPARKK PLUG………………………………………………………………………………12 3-8 IDLE SPEED………………………………………………………………………………….12 3-9 DRIVE CHAIN……………………………………………………………………………12~13 3-10 BRAKE SYSTEM……………………………………………………………………….13~14 3-11 WHEELS AND TIRES……………………………………………………………………...14 3-12 STEERING SYSTEM……………………………………………………………………….14 3-13 TOE-IN……………………………………………………………………………………….15 3-14 GEAR OIL…………………………………………………………………………………...15 四、ENGINE SYSTEM……………………………………………………………………………..16~36 4-1 ENGINE REMOVAL AND INSTALLATION……………………………………………...16 4-2 ENGINE FUEL SYSTEM………………………………………………………………..17~18 4-3 ENGINE LUBRICATION AND COOLING SYSTEM………………………………..18~20 4-4 ENGINE COMBUSTION SYSTEM…………………………………………………….20~25 4-5 TANSMISSION SYSTEM………………………………………………………………..25~31 4-6 CRANKSHAFT / CRANKCASE……………………...………………………………...31~35 4-7 A.C.G ENERATOR……………………………………………………………………….35~36 五、CARBURETOR SYSTEM……………………………………………………………………..37~40 5-1 CARBURETOR REMOVAL………………………………………………………………...37 5-2 STARTER PLUNGER INSPECTION………………………………………………………38 5-3 FLOAT CHAMBER DISASSEMBLY…………………………………………………..38~39 5-4 FUEL HEIGHT INSPECTION……………………………………………………………...39 5-5 CARBURETOR INSTALLATION……………………………………………………...39~40 5-6 REED VALVE…………………………………………………………………………………40 六、FRAME SYSTEM………………………………………………………………………………41~57 6-1 FRONT WHEEL AND STEERING SYSTEM…………………………………………41~50 6-2 REAR WHEELS………………………………………………………………………….50~54 6-3 FENDERS AND EXHAUST PIPE………………………………………………………55~57 七、ELECTRICAL SYSTEM………………………………………………………………………58~62 7-1 TROUBLESHOOTING………………………………………………………………………58 7-2 BATTERY REMOVAL / INSTALLATION ………………………………………...……...59 7-3 A.C.G. INSPECTION………………………………………………………………….....59~60 7-4 RESISTER INSPECTION…………………………………………………………………...60 7-5 C.D.I. INSPECTION………………………………………………………………………….60 7-6 IGNITION COIL INSPECTION………………………………………………………..60~61 7-7 START MOROTR…………………………………………………………………………….61 7-8 START RELLEY INSPECTION…………………………………………………………….61

7-9 OIL LEVEL GAUGE INSPECTION……………………………………………………….62

一、 TECHNICAL INFORMATION JW50/90/100 《1》 SAFETY z GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITION. DO NOT SMOKE OR ALLOW SPARKS OR FLAMES IN YOUR WORK AREA. z NEVERRUN THE ENGINE IN A CLOSED AREA. THE EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. z THE BATTERY ELECTROLYTE CONTAINS SULFURIC ACID. PROTECT YOUR EYES, SKIN AND CLOTHING. IF YOU CONTACT IT, RINSE THOROUGHLY WITH WATER AND CALL A DOCTOR IF ELECTROLYTE GEST IN YOUR EYES. PREFACE THE CONTENTS OF THIS MANUAL PROVIDE THE SREVICE INFORMATION FOR C.P.I JW50/90/100 MOST CHAPTERS START WITH A SYSTEM OR ASSEMBLY ILLUSTRATION AND SPECIFICATIONS THE FOLLOWED PAGES GIVE DETAIL PROCEDURES. IF YOU DO NOT KNOW WHAT THE SOURCE OF THE TROUBLE IS, PLEASE GO THE TROUBLESHOOTING FOR ADDITIONAL HELP. ALL THE CONTENTS OF THIS MANUAL ARE BASED ON THE LATEST MODEL INFORMATION C.P.I RESERVE THE RIGHT TO MAKE CHANGE AT ANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR ENGAGEMENT ON OUR PART.

一、 TECHNICAL INFORMATION JW50/90/100 《2》 SPECIFICATION ATV TYPE JW50 JW90 JW100 ENGINE Type CPI50S CPI90S CPIOAS Displacement 49.8c.c 82c.c 91.3c.c Bore and stroke φ40.0×39.6 ㎜ φ50.0×42 ㎜ φ52.0×43.0 ㎜ Compression 6.9:1 6:1 6.6:1 Carburetion Mikuni Mikuni Mikuni Lgnition Capacitor Discharge Capacitor Discharge Capacitor Discharge Starting Electric Electric Electric Lubrication Oil Pump Separate Supply Oil Pump Separate Supply Oil Pump Separate Supply Oil tank capacity 1 liter 1 liter 1 liter Transmission Automatic Automatic Automatic CHASSIS Overall Length 1370 ㎜ 1395 ㎜ 1395 ㎜ Overall Width 865 ㎜ 890 ㎜ 890 ㎜ Overall High 875 ㎜ 950 ㎜ 950 ㎜ Wheelbase 865 ㎜ 900 ㎜ 900 ㎜ Dry weight 103 ㎏ 110.5 ㎏ 110.5 ㎏ Fuel Tank Capacity 5 liter 5 liter 5 liter SUSPENSION Front Dual Arm Dual Arm Dual Arm Rear Swung Ann Swung Ann Swung Ann BRAKES Front Drum Drum Drum Rear Drum Drum Drum TIRE Front 16×8－7 19×7－8 19×7－8 Rear 16×8－7 19×8－8 19×8－8 COLORING Red/Yellow/Blue/Silver/Brack Red/Yellow/Blue/Silver/Brack Red/Yellow/Blue/Silver/Brack

一、 TECHNICAL INFORMATION JW50/90/100 《3》 SERIAL NUMBER Please record the frame and engine serial numbers for future reference. The frame serial number (1) is stamped on the front of the frame. FRAME NO. The engine serial number (2) is stamped on the left side of the engine crankcase. ENGINE NO.

一、 TECHNICAL INFORMATION JW50/90/100 《4》 TORQUE VALUES ENGINE JW50/JW90/JW100 Cylinder head nut 1.3~1.5kg-m Spark plug 1.5~2.0kg-m Cylinder head bolt 1.4~2.0kg-m Alternator bolt 3.5~4.0kg-m FRAME JW50/JW90/JW100 Handlebar upper holder bolt 2.0~2.2kgf-m Steering shaft nut 4.5~5.0kgf-m Steering shaft bushing holder nut 2.0~2.2kgf-m Wheel rim bolt 3.5~4.0kgf-m Tie rod lock nut 3.0~3.5kgf-m Knuckle nut 3.5~4.0kgf-m Handlebar lower holder nut 4.5~5.0kgf-m Front wheel bolt 3.5~4.0kgf-m Front axle nut 4.0~4.5kgf-m Rear axle nut 4.5~5.0kgf-m Rear wheel bolt 3.5~4.0kgf-m Exhaust muffler mounting bolt 0.7~1.0kgf-m Engine hanger bolt 2.0~2.3kgf-m Drive sprocket 19T 4.5~5.0kgf-m

二、TROUBLESHOOTING JW50/90/100 《5》 ENGINE DOES NOT START POSSSIBLE REASON CHECK FUEL FLOW TO CARBURETOR NOT OK NO FUEL IN FUEL TANK CLOGGED FLOAT VALVE CLOGGED FUEL TANK CAP BREATHER HOLE CLOGGED FUEL TUBE OK SPARK TEST FAULTY SPARK PLUG WEAK OR NO SPARK NOT OK FOULED SPARK PLUG FAULTY C.D.I. UNIT FAULTY ALTERNATOR FAULTY ENGINE STOP SWITCH POORLY CONNECTED, BROKEN OR SHORTED WIRES BROKEN OR SHORTED IGNITION COIL BROKEN OR SHORTED SPARK PLUG WIRE FAULTY PULSE GENERATOR FAULTY IGNITION SWITCH FAULTY SAFETY SWITCH OK TEST CYLINDER COMPRESSION NOT OK WORN CYLINDER AND PISTON RINGS DAMAGED CYLINDER HEAD GASKET START THE ENGINE AUTO CHOKE OFF OR DAMAGED AUTO CHOKE POWER WIRE DISCONNECTED IMPROPERLY ADJUSTED AIR SCREW IMPROPER IGNITION TIMING FUEL / AIR MIXTURE RATIO IS TOO LEAN LOW COMPRESSION ENGINE FIRES, BUT DOES NOT START ENGINE DOES NOT FIRE OK REMOVE AND INSPECT SPARK PLUG CARBURETOR FLOODED WET PLUG IMPROPERLY ADJUSTED AIR SCREW FUEL / AIR MIXTURE RATIO TOO RICH AUTO CHOKE STUCK OR DAMAGED AIR CLEANER DIRTY

二、TROUBLESHOOTING JW50/90/100 《6》 POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE REASON CHECK IGNITION TIMING FAULTY C.D.I NOT OK OK CHECK CARBURETOR MIXTVRE TOO LEAN AIR SCREW ADJUSTMENT MIXTURE TOO RICH NOT OK OK CHECK FOR LEAKING DETERIORATED INSULATOR O-RING INTAKE PIPE LOOSE CARBURETOR PERFORM SPARK TEST LOOSE OR DISCONNECTED IGNITION SYSTEM WIRES WEAK OR INTERMITTENT SPARK FAULTY, CARBON OR WET FOULED SPARK PLUG FAULTY ALTERNATOR OK NOT OK FAULTY C.D.I. UNIT FAULTY IGNITION SWITCH FAULTY IGNITION COIL FAULTY PULSE GENERATOR BROKEN OR SHORTED SPARK PLUG WIRE FAULTY ENGINE STOP SWITCH

二、TROUBLESHOOTING JW50/90/100 《7》 POOR PERFORMANCE AT HIGH SPEED POSSIBLE REASON CHECK IGNITION TIMING FAULTY C.D.I. UNIT FAULTY PULSE GENERATOR CHECK FUEL TUBE AT LACK OF FUEL IN TANK CARBURETOR CLOGGED FUEL LINE CLOGGED FUEL VALVE LOGGED FUEL TANK BREATHER HOLE REMOVE CARBURETOR CLEAN WITH HIGH PRESSURE AIR GUN CHECK FOR CLOGGED CHECK AIR CLEANER CLEAN THE FILTER FILTER ELEMENT OK NOT OK NOT CLOGGED FUEL FLOWS FREELY DIRTY JETS CLOGGED FUEL FLOW RESTRICTED

二、TROUBLESHOOTING JW50/90/100 《8》 LOSS POWER POSSIBLE REASON RAISE WHEELS OFF GROUND BRAKE DRAGGING AND SPIN BY HEND DRIVE CHAIN TOO TIGHT DAMAGED WHEEL BEARING WHEEL BEARING NEEDS LUBRICATION CHECK TIRE PRESSURE PUNCTURED TIRE FAULTY TIRE VALVE ACCELERATE SLOWLY FUEL/AIR MIXTURE RATIO TOO RICH OR LEAN CLOGGED IN AIR CLEANER CLOGGED IN MUFFLER RESTRICTED FUEL FLOW CLOGGED FUEL TANK CAP BREATHER HOLE CHECK IGNITION TIMING FAULTY PULSE GENERATOR FAULTY C.D.I. UNIT TEST CYLINDER COMPRESSION LEAKING HEAD GASKET WORN CYLINDER AND PISTON RINGS CHECK CARBURETOR CLEAN CHECK SPARK PLUG CLEAN THE SPARK PLUG SPARK PLUG IS INCORRECT HEAT RANGE CHECK FOR ENGINE EXCESSIVE CARBON DEPOSITED IN OVERHEATING COMBUSTION CHAMBER WRONG TYPE OF FUEL FUEL/AIR MISTURE RATIO IS LEAN USE OF POOR QUALITY FUEL ACCELERATE OR RUN WORN PISTON AND CYLINDER AT HIGH SPEED FUEL/AIR MIXTURE RATIO IS LEAN WRONG TYPE OF FUEL OK OK OK OK ENGINE SPEED DOES NOT INCREASE PRESSURE LOW DOESNOTSPINFREELY OK PRESSURE NORMAL ENGINE SPEED INCREASES SPIN FREELY KNOCKS OVERHEATING FOULED OR DISCOLORED CLOGGED TOO LOW NOT OK IGNITION TIMING TOO ADVANCED EXCESSIVE CARBON DEPOSITED IN

Apache ATV100 Service Manual

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