HER CHEE ATV-600 Manual de usuario
SERVICE MANUAL
ATV-600
Aug, 2011
HER CHEE INDUSTRIAL CO., LTD.
Foreword
This service manual contains information on servicing ATV-600
This manual is written for use as a guideline only. It is recommended that any
mechanic, with or without sufficient experience, thoroughly read through the manual
and only attempt to service those areas that are fully understood in accordance with
the guidelines provided by this manual. For fully qualified mechanics, this manual
supplies service data necessary for repairs and maintenance. It is highly
recommended that a qualified mechanic, regardless of technical level, should study
the service manual in full before attempting service on ATV-600
All the data and diagrams provided in this service manual are valid at the time of
publication. Information may be updated without notice due to improvements or
upgrades.
No quotation, reproduction, or reprint of the service manual, as a whole or in part,
will be permitted without the express written consent from ADLY Motor sports.
HOW TO USE THIS MANUAL
This service manual describes basic information of different system parts and
system inspection & service for ADLY ATV-600. In addition, please refer to
the manual contents in detailed for the model you serviced in inspection and
adjustment.
Chapter.1 includes general information and trouble diagnosis.
Chapter 2 includes service maintenance information and special tools manual.
Chapter 3~12 includes engine and driving systems.
Chapter 13 includes cooling system.
Chapter 14~17 includes assembly frame body.
Chapter 18 includes electrical equipment.
Chapter 19 includes wiring diagram.
Please see index of content for quick having the special parts and system
information.
CONTENTS Index
Chapter 1 GENERALINFORMATION 1
Chapter 2 MAINTENANCE INFORMATION 2
Chapter 3 LUBRICATIONSYSTEM 3
Chapter 4 FUELSYSTEM 4
Chapter 5 ENGINEREMOVAL 5
Chapter 6 CYLINDERHEAD/VALVE 6
Chapter 7 CYLINDER/PISTON 7
Chapter 8 V BELT DRIVING SYSTEM 8
Chapter 9 TRANSMISSION 9
Chapter 10 WHEEL, DRIVE SHAFT & PROPELLER SHAFT 10
Chapter 11 A.C GENERATOR/STARTING CLUTCH 11
Chapter 12 CRANKCASE / CRANKSHAFT 12
Chapter 13 COOLINGSYSTEM 13
Chapter 14 BODYCOVER 14
Chapter 15 FRONT BRAKE AND FORNT WHEEL 15
Chapter 16 STEERING/FRONT SUSPENSION 16
Chapter 17 REAR BRAKE / WHEEL / SUSPENSION 17
Chapter 18 ELECTRICAL EQUIPMENT 18
Chapter 19 ELECTRICALDIAGRAM 19
Ch. 1 GENERAL INFORMATION
Vehicle Identification Number
Frame Number:
＊The frame serial number is
engraved on lower front right side of the
frame, which is under the front
differential box.
VIN Plate
＊* The VIN (Vehicle Identification
Number) is attached to the lower
front right side of frame behind the
radiator.
Engine Number
＊The engine serial number is stamped
on the lower right side of the transmission
cover.
Engine No.
Ch. 1 GENERAL INFORMATION
1-1
Symbols and Marks ………………………1-1 Specifications …………………………..1-9
General Safety ……………………………...1-2 Locking Torque ………………………..1-10
Attention on operation ...………………….1-4 Troubles Diagnosis …………………...1-12
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service
is needed. In case supplemental information of procedures is needed for these symbols
and marks, explanations will be added to the text instead of using the symbols or marks.
Warning Means that serious injury or even death may result if procedures are
not followed.
Caution Means that equipment damages may result if procedures are not
followed.
Engine oil Limits to use SAE 10W-40 API SG class oil. Warranty will not cover
the damage that caused by not apply with the limited engine oil.
Grease Chassis grease is recommended.
Gear oil Gear oil serials are recommended. (Gear oil SAE 80/90 is
recommended )
Locking
sealant Apply sealant; medium strength sealant should be used unless
otherwise specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT4.
Special tools Special tools
Ch. 1 GENERAL INFORMATION
1-2
General Safety
Gasoline
Gasoline is a low ignition point and explosive material. Work in a well-ventilated
place, no flame or spark should be allowed in the work place or where gasoline is being
stored.
Caution
Gasoline is highly flammable, and may explode under some conditions, keep it
away from children.
Battery
Caution
-- Battery emits explosive gases; Flame is strictly prohibited. Keeps the place well
ventilated when charging the battery.
-- Battery contains sulfuric acid (electrolyte) which can cause serious burns so be
careful do not spray on your eyes or skin. If you get battery acid on your skin, flush it off
immediately with water. If you get battery acid in your eyes, flush it off immediately with
water and then go to hospital to see an ophthalmologist.
-- If you swallow it by mistake, drink a lot of water or milk, and take some laxative such
as castor oil or vegetable oil and then go to see a doctor.
-- Keep electrolyte beyond reach of children.
Carbon monoxide
If you must run your engine, ensure the place is well ventilated. Never run your
engine in a closed area.
Run your engine in an open area, if you have to run your engine in a closed area,
be sure to use an extractor.
Caution
Exhaust contains toxic gas which may cause one to lose consciousness and even
result in death.
Ch. 1 GENERAL INFORMATION
1-3
Used engine oil
Caution
Prolonged contact with used engine oil (or transmission oil) may cause skin cancer
although it might not be verified. We recommend that you wash your hands with soap
and water right after contacting.
Keep the used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system can become extremely hot after
engine running. They remain very hot even after the engine has been stopped for some
time. When performing service work on these parts, wear insulated gloves and wait
until cooling off.
Brake pad
Do not use an air hose or a dry brush to clean components of the brake system;
use a vacuum cleaner or the equivalent to avoid dust flying.
Caution
Inhaling brake shoe or pad ash may cause disorders and cancer of the breathing system.
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber parts may cause damage to the
parts. Place a clean towel on the above-mentioned parts for protection when servicing
the brake system. Keep the brake fluid beyond reach of children.
Ch. 1 GENERAL INFORMATION
1-4
Attention on Operation
All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new item
when dismounted.
Locking of all screws, nuts, cross screws shall be performed in the order of first the large
screws and then the small ones and from inside to outside in opposite angles by
tightening the torque locks.
All items must use original parts, pure oil and greases.
All service shall use special tools and general tools to repair.
All dismounted items requiring for checks shall be duly cleaned and for assembly, all
items shall be duly lubricated.
Ch. 1 GENERAL INFORMATION
1-5
Attention on Operation
Certified lubricants in cans shall be used on all the elements to be lubricated.
After assembly, performance of all elements shall be duly checked and the locking shall
be duly verified.
In case of an operation is performed by over 2 people, the assignment shall be
conducted in coordination and safety shall be the first priority.
Remove residues of the old gasket or sealant before reinstallation, grind with a
grindstone if the contact surface has any damage.
The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they
can go to their connections so that there is enough room below the enlarged ends for
tightening the clamps.
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