User manual SYM TRACK RUNNER 200 SERVICE MANUAL
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Manual abstract: user guide SYM TRACK RUNNER 200SERVICE MANUAL
Detailed instructions for use are in the User's Guide.
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HOW TO USE THIS MANUAL
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Track Runner 200 SERVICE MANUAL
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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.
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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
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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.
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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.
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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
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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
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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
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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
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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
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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. [. . . ]
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