User manual SYM TRACK RUNNER 200 SERVICE MANUAL

[. . . ] FORWARD CONTENTS HOW TO USE THIS MANUAL SERIAL NUMBER Track Runner 200 SERVICE MANUAL Homepage Contents FORWARD This service manual contains the technical data of each component inspection and repair for the SANYANG Track Runner 180 ATV. The manual is shown with illustrations and focused on "Service Procedures", "Operation Key Points", and "Inspection Adjustment" so that provides technician with service guidelines. If the style and construction of the ATV, Track Runner 180, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. Service Department SANYANG INDUSTRY CO. , LTD. Homepage Contents HOW TO USE THIS MANUAL This service manual describes basic information of different system parts and system inspection & service for SANYANG Track Runner 180 ATV. [. . . ] Once bearing removed, it has to be replaced with new one. Inner bearing puller Crankcase side Remove driving shaft bearing lock bolt, and then remove driving shaft bearing from left crankcase using following tools. Remove gear shift shaft bearing and counter shaft bearing from left crankcase using following tools. Special tool: Inner bearing puller Install new bearings into left crankcase. Special tool: Bearing driver (6204) Bearing driver (6202) Bearing driver (6203) Bearing driver Install drive shaft. Special tool: Drive shaft puller Drive shaft install bush Extension bush (long) Extension bush (short) Drive shaft puller Drive shaft install bush Extension bush Apply with grease onto new drive shaft oil seal lip, and then install the oil seal. Special tool: Oil seal driver (20x32x6) Oil seal driver 9-8 To this chapter contents 9. FINAL DRIVING MECHANISM Gear box side Use inner bearing puller to remove the final shaft needle bearing, gear shift shaft bearing and counter shaft bearing from the cover inner side. Special tool: Inner bearing puller Inner bearing puller Remove cir clip of final shat out side bearing. Cir clip Remove final shat out side bearing. Special tool: Inner bearing puller Remove oil seal from gear box cover and discard the seal. Inner bearing puller Install new bearings into gear box cover inner side. Special tool: Needle bearing driver (4905) Bearing driver (6302) Bearing driver (6204) Install new final shaft oil seal into gear box cover, and then install new out side bearing. Special tool: Oil seal driver (30x40x5) Bearing driver (6205LU) Bearing driver 9-9 To this chapter contents 9. FINAL DRIVING MECHANISM Re-assembly of Final Driving Mechanism Apply with grease onto the oil seal lip of final driving shaft. Oil seal Install final shaft, and then install the washer and cir clip. Final shaft Cir clip Final shaft washer Install counter shaft and gear shift shaft onto gear box. Counter shaft Gear shift shaft Install shift drum, shift fork and fork shaft onto gear box. Shift drum Shift fork 9-10 To this chapter contents 9. FINAL DRIVING MECHANISM Align the position mark on the shift spindle sprocket with that of shift drum, and then install shift spindle. Position mark Install dowel pin and new gasket. Install gear box cover and bolts, and tighten. Torque value: 1. 0~1. 4kgf-m Apply with grease onto new oil seal lip, and then install the shift spindle oil seal. Special tool: Oil seal driver (14x28x7) Install the shift spindle bracket. Gear oil quantity: 750c. c. 10 bolts Shift spindle bracket 9-11 To this chapter contents 9. FINAL DRIVING MECHANISM Notes: 9-12 Home page Contents 10. ALTERNATOR/STARTING CLUTCH Mechanism Diagram 10-1 Precautions in Operation10-2 Right Crankcase Cover Removal 10-3 A. C. G. Set Removal10-3 Flywheel Removal 10-3 Starting Clutch 10-4 Flywheel Installation 10-7 A. C. G. Set Installation 10-7 Right Crankcase Cover Installation 10-7 Mechanism Diagram 10 1. 0~1. 4kgf-m 5. 0~6. 0kgf-m 0. 8~1. 2kgf-m 10-1 To this chapter contents 10. ALTERNATOR/STARTING CLUTCH Precautions in Operation General information Refer to chapter 17: The troubleshooting and inspection of alternator Refer to chapter 17: The service procedures and precaution items of starter motor Specification Item ID of starting clutch gear OD of starting clutch gear Standard value (mm) 20. 026~20. 045 42. 175~42. 200 Limit (mm) 20. 100 42. 100 Torque value Flywheel nut Starting clutch hexagon bolt 8 mm bolts 12 mm bolts 5. 0~6. 0kgf-m 1. 0~1. 4kgf-m with adhesive 0. 8~1. 2kgf-m 1. 0~1. 4kgf-m Tools Special tools A. C. G. [. . . ] ELECTRICAL SYSTEM Front Brake Switch While grasp the brake lever firmly, the terminals of brown/blue and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake light switch Rear Brake Switch While grasp the brake lever firmly, the terminals of white/black and green/yellow of the brake should have continuity. Replace the switch if damaged. Brake light switch Horn Remove the horn from front fender left side. 1 bolt Apply 12 V power source to two terminals of the horn, the horn should sound. Replace the horn if necessary. 17-18 To this chapter contents 17. [. . . ]