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. [. . . ] Remove gear box cover bolts (10 bolts) and then remove the cover and final shaft. 10 bolts Shift spindle bracket Remove shift spindle, shift drum, shift fork shaft and fork. Shift spindle Shift fork Shift drum Remove gear shift shaft, gear and washer. Remove gasket and dowel pin. Dowel pin Counter shaft Gear shift shaft Dowel pin 9-4 To this chapter contents 9. In order to avoid damaging the crankcase, in the cover place a rag between the case and table. Special tool: Shaft protector Oil seal Bearing Caution If non- essential do not remove the drive shaft from the case upper side. If remove the drive shaft from the gear box, then its bearing and oil seal has to be replaced. Remove the final shaft cir clip and washer. Washer Cir clip Remove the final shaft. 9-5 To this chapter contents 9. FINAL DRIVING MECHANISM Inspection of Mission Mechanism Check if the shift spindle is wear or damage. Check if the shift drum is wear or damage. Check if the shift fork and shaft is wear or damage. Check if the gear shift shaft is wear or damage. 9-6 To this chapter contents 9. FINAL DRIVING MECHANISM Check if the counter shaft is wear or damage. Check if the final shaft and gear are burn, wear or damage. Check bearings on gear box and gear box cover. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it. Check oil seal for wear or damage, and replace it if necessary. Gear box Drive shaft bearing Counter shaft bearing Caution If remove the drive shaft from the crankcase upper side, then its bearing has to be replaced. Gear shift shaft bearing Drive shaft bearing lock bolt Gear box cover Final shaft needle bearing Gear shift shaft bearing Counter shaft bearing 9-7 To this chapter contents 9. FINAL DRIVING MECHANISM Bearing Replacement Caution Never install used bearings. 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. [. . . ] Install the main switch coupler. Handle switches Disconnect the coupler of handle from front fender left side. Check the continuity between two points as indicated in the table below. Headlight switch couplers Start Switch Pin Position ST BAT2 Start switch FREE Wire Color Yellow / Red Green 17-16 To this chapter contents 17. ELECTRICAL SYSTEM Headlight Switch Pin Position Headlight switch BAT3 LO HI PL Wire color White White / Black Blue Brown Winker switch Pin Position R WR L N PUSH OFF Wire color Pink Black Brown / White Winker switch Horn switch Pin Position FREE BAT3 HO Wire Color White/ Black Light green Horn switch Hazard switch Pin Position HD E Hazard switch Wire Color Green / Red Green 17-17 To this chapter contents 17. 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. [. . . ]