Page 1 FOREWORD Brief introduction to maintenance handbook of HS700UTV-4 The handbook is edited by Technical Center of Chongqing Huansong Science And Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain vehicles （UTV）, and supplies some relevant technique and performance data.
Page 2: Table Of Contents
CONTENT CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION……………………………………………………………………1 WATNINGS CAUTIONS AND NOTES……………………………………………………1 DESCRIPTION……………………………………………………………………………………2 IDENTIFICATION CODE……………………………………………………………………… 3 Frame No. ………………………………………………………………………………… 3 Engine No. ………………………………………………………………………………… 3 SAFETY ………………………………………………………………………………………… 4 Handing gasoline safely…………………………………………………………………… 5 Cleaning parts……………………………………………………………………………… 5 Warning labels……………………………………………………………………………… 6 SERIAL NUMBERS…………………………………………………………………………… 6 FASTENERS…………………………………………………………………………………… 6 Torque specifications ………………………………………………………………………...
Page 3 Wrenches ………………………………………………………………………………… 12 Adjustable wrenches …………………………………………………………………… 12 Socket wrenches, ratchets and handles ……………………………………………… 13 Impact drivers …………………………………………………………………………… 14 Allen wrenches…………………………………………………………………………… 14 Torque wrenches………………………………………………………………………… 14 Torque adapters ………………………………………………………………………… 15 Pliers……………………………………………………………………………………… 16 Snap ring pliers…………………………………………………………………………… 16 Hammers ………………………………………………………………………………… 17 Ignition grounding tool…………………………………………………………………… 17 PRECISION MEASURING TOOLS …………………………………………………………...
Page 4 Removing hoses ………………………………………………………………………… 28 Bearings…………………………………………………………………………………… 28 Removal…………………………………………………………………………………… 29 Installation………………………………………………………………………………… 29 Interference fit …………………………………………………………………………… 30 Seal replacement………………………………………………………………………… 32 STORAGE……………………………………………………………………………………… 32 Storage area selection…………………………………………………………………… 32 Preparing the motorcycle for storage …………………………………………………… 32 Returning the UTV to service…………………………………………………… 33 TROVBLESHOOTING……………………………………………………………………… 33 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 34 STARTING THE ENGINE …………………………………………………………………...
Page 5 Engine smoke……………………………………………………………………………… 43 Black smoke ……………………………………………………………………………… 43 Blue smoke………………………………………………………………………………… 43 White smoke or steam…………………………………………………………………… 43 Low engine compression ………………………………………………………………… 43 High engine compression ……………………………………………………………… 44 Engine overheating (cooling system) ………………………………………………… 44 Engine overheating (engine)…………………………………………………………… 44 The ignition advance angle is too large……………………………………………… 45 Detonation…………………………………………………………………………………...
Page 6 Continuity test……………………………………………………………………………… 55 Testing for a short with a self-powered test light or ohmmeter……………………… 55 Testing for a short with a test light or voltmeter………………………………………… 56 BRAKE SYSTEM……………………………………………………………………………… 56 Soft or spongy brake lever or pedal…………………………………………………… 56 Brake drag………………………………………………………………………………… 57 Hard brake lever or pedal operation……………………………………………………...
Page 7 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE……………………………………………………………… 84 ENGINE Adjusting the valve clearance…………………………………………………………… 86 Checking the spark plug ………………………………………………………………… 89 Checking the ignition timing……………………………………………………………… 89 Measuring the compression pressure………………………………………………… 91 Checking the engine oil level …………………………………………………………… 92 Changing the engine oil …………………………………………………………………...
Page 8 Adjusting the front shock absorbers………………………………………………… 115 Adjusting the front and rear shock absorbers(Option 1) ………………………………115 Adjusting the front and rear shock absorbers(Option 2) …………………………… 116 Spring preload……………………………………………………………………………117 Rebound damping force…………………………………………………………………117 Compression damping force……………………………………………………………118 Checking the tires ……………………………………………………………………… 118 Checking the wheels…………………………………………………………………… 120 Checking and lubricating the cables …………………………………………………...
Page 9 CRANKCASE Crankcase………………………………………………………………………………………176 Crankcase bearings…………………………………………………………………… 177 CRANKSHAFT AND OIL PUMP Crankshaft and oil pump ……………………………………………………………181 Oil pump…………………………………………………………………………………182 TRANSMISSION Transmission…………………………………………………………………………… 185 Drive axle assembly…………………………………………………………………… 186 MIDDLE GEAR Middle gear………………………………………………………………………………190 Middle drive shaft………………………………………………………………………… 191 CHAPTER 5 CHASSIS MALFUNCTION INSPECTION…………………………………………………………… 197 DIRECTION SYSTEM The steering wheel parts(EPA type)…………………………………………………… 200 The steering wheel parts(E-mark type)…………………………………………………203 BRAKE SYSTEM……………………………………………………………………………...
Page 10 Front bridge……………………………………………………………………………246 Rear axle ……………………………………………………………………………… 256 Rear bridge…………………………………………………………………………………257 Speed reducer component with differential……………………………………………261 REVERSE MECHANISM PARTS ……………………………………………………… 267 SUSPENSION……………………………………………………………………………… 271 Front Suspension and arm …………………………………………………………… 271 Rear suspension ……………………………………………………………………… 277 Rear arm shaft…………………………………………………………………………… 279 Rear suspension and arm………………………………………………………………281 COOLING SYSTEM………………………………………………………………………… 283 Radiator 1………………………………………………………………………………...
Page 11 STARTER MOTOR ……………………………………………………………………… 314 Checking the starter motor …………………………………………………………… 315 Assembling the starter motor ………………………………………………………… 316 CHARGING SYSTEM …………………………………………………………………… 316 Circuit diagram………………………………………………………………………… 316 Troubleshooting …………………………………………………………………… 317 LIGHTING SYSTEM ……………………………………………………………………… 318 Circuit diagram………………………………………………………………………… 318 Troubleshooting …………………………………………………………………… 319 Checking the lighting system …………………………………………………...
Page 12 Fuel pump module…………………………………………………………………………353 EMS FAULT DIAGNOSIS EME fault diagnosis ………………………………………………………………………359 Fault code list………………………………………………………………………………359 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD STARTING………………………………………………… 361 Fuel system ……………………………………………………………………………… 361 Electrical system ………………………………………………………………………… 361 Compression system …………………………………………………………………… 362 POOR IDLE SPEED PERFORMANCE ………………………………………………… 362 Poor idle speed performance…………………………………………………………… 362 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ………………………………...
Page 13 CHAPTER 9 HS700UTV-4 WIRING DIAGRAM HS700UTV-4 WIRING DIAGRAM………………………………………………………… 367 HS700UTV-4 WIRING EFI DIAGRAM…………………………………………………… 368 IGNITION SYSTEM CIRCUIT DIAGRAM…………………………………………………369 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM…………………………………370 CHARGING SYSTEM CIRCUIT DIAGRAM…………………………………………… 371 LIGHTING SYSTEM CIRCUIT DIAGRAM………………………………………………372 SIGNALING SYSTEM CIRCUIT DIAGRAM………………………………………………373 COOLING SYSTEM CIRCUIT DIAGRAM………………………………………………374 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM………………………………...
Page 14: General Information
GENERAL INFORMATION GENERAL INFORMATION The text provides complete information on maintenance， tune-up repair and overhaul， Hundreds of photographs and illustrations created during the complete disassembly of four wheel utility terrain venires (UTV) guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time.
Page 15: Description
GENERAL INFORMATION DESCRIPTION 1. Headlights 2. Front shock absorber assembly Adjusting ring 3. Brake fluid reservoir 4. Air filter element (Engine and air intake duct) 5. V-belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9. Cargo bed 10.
Page 16: Identification Code
GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved in the lower right side of Figure. Engine No. Engine No. is carved on the right side of the Engine, Figure. - 3 -...
Page 17: Safety
GENERAL INFORMATION SAFETY Professional mechanics can work for years and never sustain a serous injury or mishap. Follow these guidelines and practice common sense to safely service the utility terrain venires Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide.
Page 18: Handing Gasoline Safely
GENERAL INFORMATION Handling Gasoline Safely Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is always present in the fuel tank, fuel line and throttle.
Page 19: Warning Labels
GENERAL INFORMATION Warning Labels Most manufacturers attach information and warning labels to the UTV. These labels contain instructions that are important to personal safety when operating, servicing, transporting and storing the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement labels from the dealers or manufacturer if they are missing or damaged.
Page 20: Washers
GENERAL INFORMATION Washers The two basic types of washers are flat washers and lock washers. Flat washers are simple discs with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose. Washers can be used as spacers and seals.
Page 21: Shop Supplies
GENERAL INFORMATION Remove and install snap rings with snap rings pliers. Refer to Basic Tools in this chapter In some applications. it may be necessary to replace snap rings after removing them Compress or expand snap rings only enough to install them.
Page 22: Greases
GENERAL INFORMATION Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide range of operating conditions. Multi-grade oils are identified by a W after the first number, which indicates the low-temperature viscosity. Engine oils are most commonly mineral (petroleum) based, but synthetic and semi-synthetic types are used more frequently.
Page 23: Gasket Sealant
GENERAL INFORMATION water-soluble. Local ordinances may types of cleaning chemicals. Refer to Safer in this chapter. Use brake parts cleaner to brake system components. Brake parts cleaner leaves no residue. Use electrical contact cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel system components.
Page 24: Basic Tools
GENERAL INFORMATION BASIC TOOLS Most of the procedures in this manual can be carried out with basic hand tools and test equipment familiar to the home mechanic. Always use the correct tools for the job. Keep tools organized and clean. Store them in a tool chest with related tools organized together. Quality tools are essential.
Page 25: Wrenches
GENERAL INFORMATION NOTE Another way to prevent cam out and to increase the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw ＆ socket Gripper onto screwdriver tip. After loosening/tightening the screw, clean the screw recess to prevent engine oil contamination.
Page 26: Socket Wrenches, Ratchets And Handles
GENERAL INFORMATION off the fastener. Because one jaw is adjustable and may become loose, this shortcoming is aggravated. Make certain the solid jaw is the one transmitting the force. Socket Wrenches, Ratchets and Handles Sockets that attach to a ratchet handle (Figure 7) are available with 6-point or 12-point openings (Figure 8) and different drive sizes.
Page 27: Impact Drivers
GENERAL INFORMATION Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers.
Page 28: Torque Adapters
GENERAL INFORMATION A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Please refer to the followed manufacturer’s instructions for their care and calibration. Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench.
Page 29: Pliers
GENERAL INFORMATION The effective length is the sum of L and A. Example: TA=20 ft.-lb. A=3in. L=14in. × =16.5 ft. - lb. In this example, the torque wrench would be set to the recalculated torque value (TW = 16.5 ft. –lb.).
Page 30: Hammers
GENERAL INFORMATION WARNING Snap rings can slip and fly off when removing and installing them. Also, the snap ring pliers tips may break. Always wear eye protection when using snap ring pliers. Hammers Various types of hammers are available to fit a number of applications. Use a ball-peen hammer to strike another tool, such as a punch or chisel.
Page 31: Feeler Gauge
GENERAL INFORMATION Precision measurements can vary according to the experience of the person performing the procedure. Accurate results are only possible if the mechanic possesses a feel for using the tool. Heavy-handed use of measuring tools produces less accurate results. Hold the tool gently by the fingertips to easily feel the point at which the tool contacts the object.
Page 32: Micrometers
GENERAL INFORMATION increments. To obtain a reading, establish the first number by the location of the 0 line on the movable scale in relation to the first line to the left on the fixed scale. In this example, the number is 10 mm. To determine the next number, note which of the lines on the movable scale align with a mark on the fixed scale.
Page 33: Adjustment
GENERAL INFORMATION around an object. Close the micrometer around the highest point so it can be removed with a slight drag. Adjustment Before using a micrometer, check its adjustment as follows: Clean the anvil and spindle faces. 2A. To check a 0-1 in. or 0-25 mm micrometer: Turn the thimble until the spindle contacts the anvil.
Page 34: Standard Inch Micrometer
GENERAL INFORMATION mm increments. This numbering sequence continues with larger micrometers. On all metric micrometers, each mark on the lower half of the sleeve equals 0.50 mm. The tapered end of the thimble has 50 lines marked around it. Each mark equals 0.01 mm. One completer turn of the thimble aligns its 0 mark with the first line lower half of the sleeve line or 0.50mm.
Page 35: Telescoping And Small Bore Gauges
GENERAL INFORMATION 2. Count the number of lines between the numbered sleeve mark and the edge of the thimble. Each sleeve mark equals 0.025 in. 3. Read the thimble mark that aligns with the sleeve line. Each thimble mark equals 0.01 in. NOTE If a thimble mark does not align exactly with the sleeve line, estimate the amount between the...
Page 36: Compression Gauge
GENERAL INFORMATION Dial indicators are available in various ranges and graduations and with three basic types of mounting bases: magnetic (B. Figure 31). Clamp, or screw-in stud. When purchasing a dial indicator, select on with a continuous dial (A, Figure 31). Cylinder Bore Gauge A cylinder bore gauge is similar to a dial indicator.
Page 37: Cliop-On Ammeter
GENERAL INFORMATION needle location on the ohms scale. The needle must Align with the 0 mark to obtain accurate measurements. 4. If necessary, rotate the meter ohms adjust knob until the needle and 0 mark align. Clip-on ammeter Clip-on ammeter (Figure 35) is the basic tool for electrical system diagnosis which is used to measure the current of charging system and other electrical components work current.
Page 38: Amperage
GENERAL INFORMATION Resistance is measured in an inactive circuit with an ohmmeter. The ohmmeter sends a small amount of current into the circuit and measures how difficult it is to push the current through the circuit. An ohmmeter, although useful, is not always a good indicator of a circuit’s actual ability under operating conditions.
Page 39: Removing Frozen Fasteners
GENERAL INFORMATION before proceeding. 8. To prevent objects or debris from falling into the engine, cover all openings. 9. Read each procedure thoroughly and compare the illustrations to the actual components before starting the procedure. Perform the procedure in 10. Recommendations are occasionally made to refer service to a dealership or specialist. In these cases, the work can be performed more economically by the specialist than by the home mechanic.
Page 40: Removing Broken Fasteners
GENERAL INFORMATION For frozen screws, apply penetrating fluid as described, the insert a screwdriver in the slot and rap the top of the screwdriver with a hammer. This loosens the rust so the screw can be removed in the normal way. If the screw head is too damaged to use this method, grip the head with locking pliers and twist the screw out.
Page 41: Removing Hoses
GENERAL INFORMATION against each other. Remove the stud by turning the lower nut (Figure41). Measure the height of the stud above the surface. Thread the stud removal tool onto the stud and tighten it, or thread two nuts onto the stud. Remove the stud by turning the stud remover or the lower nut.
Page 42: Removal
GENERAL INFORMATION NOTE Unless otherwise specified, install bearings with the manufacturer’s mark or number facing outward. Removal While bearing are normally removed only when damaged, there may be times when it is necessary to remove a bearing that is in good condition. However, improper bearing removal will damage the bearing and possibly the shaft or case.
Page 43: Interference Fit
GENERAL INFORMATION When installing a bearing as described in Step 1, some type of driver is required. Never strike the bearing directly with a hammer or it will damage the bearing. When installing a bearing, use a piece of pipe or a driver with a diameter that matches the bearing inner race.
Page 44 GENERAL INFORMATION bearing chills, it will tighten on the shaft, so install it quickly. Make sure the bearing is installed completely. 2. Follow this step when installing a bearing in a housing. Bearings are general installed in a housing with a slight interference fit Driving the bearing into the housing using normal methods may damage the housing or cause bearing damage.
Page 45: Seal Replacement
GENERAL INFORMATION inner-bearing race. Install the bearing(s) until it seats completely. Seal Replacement Seals (Figure 49) contain oil, water, grease or combustion gasses in a housing or shaft. Improperly removing a seal can damage the housing or shaft. Improperly installing the seal can damage the seat. Note the following: Prying is generally the easiest and most effective method of removing a seal from the...
Page 46: Returning The Utv To Service
GENERAL INFORMATION 5. Remove the spark plug and ground the ignition system with a grounding tool as described in this chapter. Then pour a teaspoon (15-20ml) of engine oil into the cylinder. Place a rag over the opening and Start the engine over to distribute the oil. Remove the grounding tool and reinstall the spark plug.
Page 47: Engine Principles And Operating Requirements
GENERAL INFORMATION By following a systematic approach, the possibility of unnecessary parts replacement can be avoid, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting.
Page 48: Engine Is Cold
GENERAL INFORMATION 2.Special fault： Idle instability, CH and CO of off-gas out of limits Reason：Oxygen sensor loosing cause slight leakage or pipe slight leakage and makes the oxygen sensor collect too much oxygen ion signal. The wrong signal transmits to the ECU which result the increasing of oil supply.
Page 49: Flooded Engine
GENERAL INFORMATION the engine speed has reduced to idle speed (1450RPM). Flooded engine If the engine fails to start after several attempts, it is probably flooded. This occurs when too much fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident when the engine is flooded.
Page 50: Spark Test
GENERAL INFORMATION insulating material, causing an engine misfire. NOTE Engine misfire can also be caused by water that enters through connectors. Check the connectors for loose wire ends. On waterproof connectors, check for damage where the wires enter the connector. Perform the Spark Test in this section.
Page 51: The Starter Cannot Work Repeatedly Or Can Only Work Slowly
GENERAL INFORMATION can ignite fuel ejected through the spark plug hole. Shift the transmission into neutral. WARNING Do not hold the spark tester, spark plug or connector or a serious electrical shock may result. Turn the engine over using the starter and push the starter button. A fat blue spark must be evident between the spark tester or spark plug terminals.
Page 52: Engine Backfires, Cuts Out Or Misfires During Acceleration
GENERAL INFORMATION Contaminated or stale fuel. Clogged air filter. 10. Intake pipe air leak. 11. Plugged exhaust system. Check the silencer or muffler, especially if the utility terrain vehicle was just returned from storage. 12. Faulty ignition system component. Engine Backfires, Cuts Out or Misfires During Acceleration A backfire occurs when fuel is burned or ignited in the exhaust system.
Page 53: Poor Fuel Mileage
GENERAL INFORMATION Poor Fuel Mileage 1. Clogged fuel system. 2. Dirty or clogged air filter. 3. Incorrect ignition timing. Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4.
Page 54: Poor Idle Or Low Speed Performance
GENERAL INFORMATION A clogged exhaust system will prevent some of the burned exhaust gasses from exiting the exhaust port at the end of the exhaust stroke. This condition effects the incoming air/fuel mixture on the intake stroke and reduces engine power Check for retarded ignition timing.
Page 55: Poor High Speed Performance
GENERAL INFORMATION Poor High Speed Performance Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. Perform the Peak Voltage Check the fuel system as described in this chapter Check the valve clearance as described. Note the following: If the valve clearance as correct.
Page 56: Lean Mixture
GENERAL INFORMATION ECU program error or damage Lean Mixture The following conditions can cause a lean air/fuel mixture: 1. The injector is clogged 2. The pump pressure is not enough 3. ECU program chaos 4. ECU damage 5. The pressure sensor, oxygen sensor, solar term door position sensor fault ENGINE Engine Smoke The color of engine smoke can help diagnose engine problems or operating conditions...
Page 57: High Engine Compression
GENERAL INFORMATION 1. Valves: The gap between the valve is not suitable. b. Incorrect valve timing. Worn or damaged valve seat surfaces. d. Bent valves. e. Weak or broken valve springs. 2. Cylinder head: Loose spark plug or damaged spark plug hole. Damaged cylinder head gasket.
Page 58: The Ignition Advance Angle Is Too Large
GENERAL INFORMATION 3. Oil not circulating properly. 4. Valves leaking. 5. Heavy carbon deposits in the combustion chamber. 6. Dragging brake(s). 7. Slipping clutch. The Ignition Advance Angle Is Too Large Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber. Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all cause preignition.
Page 59: Englne Lubrication
GENERAL INFORMATION the engine has warmed up, piston expansion reduces piston-to-cylinder clearance. 3. Knocking or rapping while decelerating—Usually caused by excessive rod bearing clearance. 4. Persistent knocking and vibration occurring every crankshaft rotation—Usually caused by worn rod or main bearing(s). Can also be caused by broken piston rings or a damaged piston pin.
Page 60: No Oil Pressure
GENERAL INFORMATION Clogged oil gallery or metering orifices. No Oil Pressure Low oil level. The lubrication oil pressure valve is stuck and closed. Damaged oil pump. Incorrect oil pump installation. Internal oil leak. Oil Level Too Low The lubrication oil does not keep at the normal level. Worn piston rings.
Page 61 GENERAL INFORMATION Remove the air filter assembly Open and secure the throttle so it is at its wide-open position. Remove the spark plug. Install the threaded hose adapter from the leak down kit. Then install the leak down gauge onto the hose. Remove the ignition timing hole cap from the left crankcase cover.
Page 62 GENERAL INFORMATION a. Turn the drive sprocket by hand and shift the transmission into top gear with the shift pedal. b. Mount a holding tool or equivalent onto the drive sprocket. Use a wooden block and clamp to hold the holding tool so it cannot move when the combustion chamber becomes pressurized.
Page 63: Electrical Testing
GENERAL INFORMATION ELECTRICAL TESTING This section describes basic electrical testing and test equipment use. Preliminary Checks and Precautions Refer to the color wiring diagrams at the end of the manual for component and connector identification; Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground.
Page 64: Electrical Component Replacement
GENERAL INFORMATION c. A change in meter readings indicates a poor connection. Fine and repair the problem or replace the part. Check for wires with cracked or broken insulation NOTE An analog ohmmeter is useful when making this type of test. Slight needle movements are apparent when indicating a loose connection Heat –...
Page 65: Test Equipment
GENERAL INFORMATION machine has been operated. All instructions and specifications have been for accuracy: however. Successful test results depend to a great degree upon individual accuracy. Test Equipment A test light can be constructed from a 12-volt light bulb with a pair of test leads carefully soldered to the bulb.
Page 66: Jumper Wire
GENERAL INFORMATION uncrossed, the needle reads zero. When the leads are uncrossed, the needle should move to the other end of the scale indicating infinite resistance. During a continuity test, a reading of infinity indicates that there is an open in the circuit or component.
Page 67: Test Procedures
GENERAL INFORMATION TEST PROCEDURES Voltage test Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing. If the test lead only touches the wire insulation.
Page 68: Peak Voltage Test
GENERAL INFORMATION For example, consider a starting problem where the battery is fully charged but the starter motor turns over slowly. Voltage drop would be the difference in the voltage at the batter (source) and the voltage at the starter (destination) as the engine is being started (current is flowing through the batter cables).
Page 69: Testing For A Short With A Test Light Or Voltmeter
GENERAL INFORMATION Testing for a short with a test light or voltmeter 1. Remove the blown fuse. 2. Connect the test light or voltmeter across the fuse terminals in the starter relay. Turn the ignition switch ON and check for battery voltage. 3.
Page 70: Brake Drag
GENERAL INFORMATION the master cylinder reservoir drops. Whenever adding brake fluid to the reservoir, visually check the brake pads for wear. If it does not appear that there is an increase in pad wear, check the brake hoses, lines and banjo bolts for leaks. 3.
Page 71: Hard Brake Lever Or Pedal Operation
GENERAL INFORMATION Hard Brake Lever or Pedal Operation When applying the brakes and there is sufficient brake performance but the operation of brake lever feels excessively hard, check for the following possible causes: Clogged brake hydraulic system. Sticking caliper piston. Sticking master cylinder piston.
Page 72: Leaking Master Cylinder
GENERAL INFORMATION Leaking Master Cylinder Damaged piston secondary seal. Damaged piston snap ring/ snap ring groove. Worn or damaged master cylinder bore. Loose banjo bolt washers. Damaged banjo bolt washers. Damaged banjo bolt threads in master cylinder body. Loose or damaged reservoir cap. - 59 -...
Page 73: Specifications
SPECIFICATIONS SPECIFICATIONS HOW TO CONVERSION TABLE OF UNIT （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY...
Page 74: Geberar Specifications
SPECIFICATIONS GEBERAR SPECIFICATIONS Item Standard Dimensions : Overall length 3,010 mm（118.5 in） Overall width 1,460 mm（57.5 in） Overall height 1,940 mm（77.2 in） Seat height 818 mm（32.2 in） Wheelbase 1,890 mm（72.4 in） Minimum ground clearance 280 mm（11.0 in） Minimum turning radius 3,900 mm（154 in）...
Page 75 SPECIFICATIONS Item Standard Air filter Wet type element Fuel Unleaded gasoline only Type 30.0L（6.60 lmp gal, 7.93 US gal） Fuel tank capacity Throttle Type/quantity D46-3 / 1 Spark plug DPR8EA / 1 (NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Clutch type Wet ,centrifugal automatic Transmission...
Page 76 SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 185 mm (7.3 in) Rear wheel travel 185 mm (7.3 in) Electrical Ignition system EFI.
Page 77: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder 100.10 mm Bore size 100.005 ~ 100.055 mm (3.9410 in) Measuring point (3.9372 ~ 3.9392 in) ---- 50 mm (1.97 in) Camshaft Drive method Chain drive (Left) ---- Cam dimensions...
Page 78 SPECIFICATIONS Item Standard Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in) Arm-to-shaft clearance 0.009 ~ 0.042 mm ----...
Page 79 SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
Page 80 SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) ---- Measuring point “H” 2.5 mm (0.10 in) ---- Piston off-set 1.0 mm(0.0394 in)
Page 81 SPECIFICATIONS Item Standard Limit Oil ring ---- 2.5×3.4 mm (0.0984× 0 .1339 in) Dimensions (B×T) ---- 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) End gap (installed) ---- 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Side clearance Crankshaft 74.95 ~ 75.00 mm ---- Crank width “A”...
Page 82 SPECIFICATIONS Item Standard Limit Transmission Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Engine oil ---- Oil pump Oil filter type Foam ----...
Page 83: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 108 mm (4.25 in) ---- Spring free length 313 mm (12.32 in) ---- Spring fitting length 247.9 mm (9.76 in) ---- Spring rate 19.4 N/mm(1.94 kg/mm, 108.6 lb/in) ---- Stroke...
Page 84 SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.2 mm 1.5 mm (0.20 in) (0.06 in) Pad thickness outer 5.2 mm 1.5 mm (0.20 in) (0.06 in)
Page 85: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (BTDC) 12°/ 1,500 r/min ---- Advancer type ECU Digital type ---- Ignition coil Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F) ---- Secondary winding resistance 6.32 ~ 9.48 kΩat 20 °C (68 °F)
Page 86 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) ---- 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, 27.5 ~ 36.0 oz)
Page 87: Tightening Torques
SPECIFICATIONS TIGHTENING TORQUES Engine tightening torques Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt —...
Page 88 SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Bolt Bolt Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
Page 89 SPECIFICATIONS Shift arm Bolt Tightening torque Thread Remarks Part to be tightened Part name Q’ty ft · lb size m.kg Left-hand Shift rod locknut (select lever unit) — threads Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) —...
Page 90: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm...
Page 91 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half 26.0 Stake shaft Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt...
Page 92: General Tightening Torque Specifications
SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 93: Lubrication Pionts And Lubricant Types
SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES Engine Lubrication points Lubricant Oil seal lips Bearings O-rings Piston, piston ring Piston pin Buffer boss and balancer drive gear Crankshaft seal and spacer Valve stem Valve stem end Rocker arm shaft Rocker arm Camshaft lobe and journal Oil pump assembly Oil filter cartridge O-ring...
Page 94: Chassis
SPECIFICATIONS CHASSIS Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing Front &...
Page 95: Hydrographic Chart
SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure ：splash...
Page 96: Lubrication Oil Way
SPECIFICATIONS LUBRICATION OIL WAY Hydrographic chart ：Pressure ：splashing oil...
Page 97: Maintenance Schedule
MAINTENANCE AND ADJUSTMENT OF THE UTV MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL Whichever...
Page 98 MAINTENANCE AND ADJUSTMENT OF THE UTV Whichever EVERY INITAL comes first month ITEM ROUTINE 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours · Check condition. · Spark plug Adjust gap and clean. ○ ○ ○ ○ ○ ·...
Page 99: Engine
MAINTENANCE AND ADJUSTMENT OF THE UTV ENGINE Adjusting the valve clearance NOTE: · The valve clearance must be adjusted when the engine is cool to the touch. ·Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke.
Page 100 MAINTENANCE AND ADJUSTMENT OF THE UTV ② Fan impeller ③ As manhole covers 3. calibration Wrench to counterclockwise rotation · crankshaft According rotor turning · counterclockwise, rotor turn to mark the dead spots ② of crank box, namely ①: the dead point position is compressed.
Page 101 MAINTENANCE AND ADJUSTMENT OF THE UTV 5. Adjust: valve clearance ① Lock nut ② Valve thickness gauge （gap Regulation） ③ Regulator ④ Adjust tools · Loosen the locknut ① · Insert a thickness gauge between the ③ adjuster end and the valve end. ·...
Page 102: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE SPARK PLUG 1. Lift the cargo bed up. 2. Remove: pull out the spark plug cap ① and remove the spark plug by sleeve 3. Check: ·spark plug type Incorrect Replace. Standard spark plug DCPR7E /NGK 4.
Page 103 MAINTENANCE AND ADJUSTMENT OF THE UTV ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the cargo bed up. 3. Attach: ·tachometer ·timing light (to the spark plug lead) 4. Remove: Remove the cooling fan according to the ①...
Page 104: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE UTV MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and remove the spark plug. 3.
Page 105: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV Compression pressure (at sea level) Standard: 1,324Kpa (13.24 kg/cm , 188.31Psi) Minimum: 1,150Kpa (11.5 kg/cm , 163.57Psi) Maximum: 1,480Kpa (14.8 kg/cm , 210.50Psi) · Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until...
Page 106: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Recommended oil classification: API Service “SE”, “SF”, “SG” type or equivalent (e.g. “SF—SE—CC”, “SF—SE—SD” etc.) NOTE: Do not allow foreign material to enter the crankcase. 4. Stop the engine and check the oil level again.
Page 107 MAINTENANCE AND ADJUSTMENT OF THE UTV 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ·Remove the oil filter cartridge ① with an oil filter wrench ② ·Lubricate the O-ring of the new oil filter ③...
Page 108 MAINTENANCE AND ADJUSTMENT OF THE UTV 11. Check: ·engine oil pressure a. Slightly loosen the oil gallery bolt ① b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
Page 109: Chassis
MAINTENANCE AND ADJUSTMENT OF THE UTV CHASSIS CLEANING THE AIR FILTER NOTE: There is a check hose at the bottom of the ① air filter case. If dust and/or water collect in this hose, clean the air filter element and air filter case.
Page 110: Checking The Coolant Level
MAINTENANCE AND ADJUSTMENT OF THE UTV clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. Squeeze the excess solvent out of the element and let it dry. NOTE: Do not twist or wring out the element. This could damage the foam material.
Page 111: Changing The Coolant
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE COOLANT 1. Remove: ·driver seat ·passenger seat ·console Lift the hood up.。 ·coolant reservoir cap ① ·Disconnect coolant reservoir hose ② ·Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and if necessary, correct...
Page 112 MAINTENANCE AND ADJUSTMENT OF THE UTV pressing down on it and then remove it. 6. Drain: ·coolant 7. Disconnect: ·coolant outlet hose ① ·water pump inlet hose ② 8. Drain: ·coolant 9. Check: ·copper washer ① ·coolant drain bolt ② Damage Replace.
Page 113 MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the hole for the air bleed bolt. Coolant is potentially harmful and should be handled with special care.
Page 114: Checking The Coolant Temperature Warning Light
MAINTENANCE AND ADJUSTMENT OF THE UTV coolant level Refer to “THE COOLANT” in chapter 4. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. ·Close the hood. ·Install console: ·Install passenger seat ·Install driver seat Refer to “SEATS,”...
Page 115: Checking The V-Belt
MAINTENANCE AND ADJUSTMENT OF THE UTV Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning light does not come on. come on. Turn the main switch to “START” with the transmission in neutral position.
Page 116: Cleaning The Spark Arrester
MAINTENANCE AND ADJUSTMENT OF THE UTV ·Replace V-belt: Install the bolts ① into the secondary fixed sheave hold. NOTE: Tightening bolts ① will push secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. ·Remove the V-belt ①from the primary sheave and secondary sheave.
Page 117: Adjusting The Brake Pedal
MAINTENANCE AND ADJUSTMENT OF THE UTV 3. Remove: ·Remove the bolts ① ·Remove the tailpipe ② by pulling it out of the muffler. 4. Install： ·Insert the tailpipe into the muffler and align ② the bolt holes. ·Insert the bolt ① and tighten it. ·Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the...
Page 118: Adjusting The Parking Brake
MAINTENANCE AND ADJUSTMENT OF THE UTV ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. 2. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter5. 3. Check: ·parking brake cable free play ○ a Out of specification Adjust.。...
Page 119: Checking The Front Brake Pads
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING · Use only the designed quality brake fluid: otherwise, rubber seals deteriorate, causing leakage and poor brake performance. ·...
Page 120: Checking The Brake Hoses And Brake Pipes
MAINTENANCE AND ADJUSTMENT OF THE UTV Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 5. Brake pad wear limit ○ a 1.5 mm (0.06 in) 3. Operate the brake pedal. CHECKING THE BRAKE HOSES AND BRAKE PIPES 1.
Page 121: Bleeding The Hydraulic Brake System
MAINTENANCE AND ADJUSTMENT OF THE UTV BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: · The system has been disassembled. · A brake hose or brake pipe have been loosened or removed. · The brake fluid has been very low. The brake operation has been faulty.
Page 122: Adjusting The Select Lever Shift Rod
MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING Check the operation of the brake after bleeding the brake system. ADJUSTING THE SELECT LEVER SHIFT ROD ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable WARNING Before shifting, you must stop the vehicle and take your foot off the accelerator pedal.
Page 123: Checking The Final Gear Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV ·brake light operation timing a. Hold the main body of the brake light switch ① so that it does not rotate and turn the adjusting ○ ○ in direction a or b until the brake ②...
Page 124: Checking The Differential Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV Periodic oil change 0.25 L (0.22 Imp qt) Total amount 0.28 L (0.25 Imp qt) WARNING Take care not to allow foreign material to enter the final gear case. ·Install: oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHECKING THE DIFFERENTIAL GEAR OIL 1.
Page 125: Checking The Constant Velocity Joint Dust Boots
MAINTENANCE AND ADJUSTMENT OF THE UTV 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 6. Fill: ·differential gear case Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt) NOTE:...
Page 126: Checking The Steering System
MAINTENANCE AND ADJUSTMENT OF THE UTV □ Rear CHECKING THE STEERING SYSTEM 1. Check: Place the vehicle on a level surface. steering assembly bearings Try to the steering wheel up and down, and back and forth. Excessive play Replace the steering shaft assembly.
Page 127: Adjusting The Toe-In
MAINTENANCE AND ADJUSTMENT OF THE UTV ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification Adjust. Toe-in 0 ~ 10 mm (0.00 ~ 0.39 in) (with tires touching the ground) NOTE: Before measuring the toe-in, make sure that the tire pressure is correct.
Page 128: Adjusting The Front Shock Absorbers
MAINTENANCE AND ADJUSTMENT OF THE UTV c. The same number of turns should be given to both the right and left tie-rods ② until the specified toe-in is obtained. This is to keep the length of the rods the same. d.
Page 129: Adjusting The Front And Rear Shock Absorbers(Option 2)
MAINTENANCE AND ADJUSTMENT OF THE UTV preference, weight, operating conditions. 1. Adjust: • spring preload Turn the adjuster to increase ① or decrease the spring preload. Standard position: 2 Minimum (Soft) position: 1 Maximum (Hard) position: 5 ADJUSTING THE FRONT AND REAR SHOCK ABSORBERS (Option 2) WARNING These shock absorber assemblies contain...
Page 130: Spring Preload
MAINTENANCE AND ADJUSTMENT OF THE UTV Spring preload 1. Loosen the locknut. 2. Turn the spring preload adjusting nut in direction ⓐ to increase the spring preload and thereby harden the suspension, and in direction ⓑ to decrease the spring preload and thereby soften the suspension.
Page 131: Compression Damping Force
MAINTENANCE AND ADJUSTMENT OF THE UTV Compression damping force Turn the compression damping force adjusting screw ① (use 3.0 allen wrench) in direction ⓐ to increase the compression damping force and thereby harden the damping, and in direction ⓑ to decrease the compression damping force and thereby soften the damping.
Page 132 MAINTENANCE AND ADJUSTMENT OF THE UTV The following are minimu Front 63Kpa Rear 63Kpa c. Use no more than Front 77Kpa Rear 77Kpa when seating the tire beads. Higher pressure may cause the tire to burst. Inflate the tires slowly and carefully. Fast inflation could cause the tire to burst.
Page 133: Checking The Wheels
MAINTENANCE AND ADJUSTMENT OF THE UTV • Set tire pressures when the tires are cold. • Tire pressures must be equal in both front tires and equal in both rear tires. 2. Check: • tire surfaces Wear/damage○ Replace. Tire wear limit ○ Front and rear: 3.0 mm (0.12 in) WARNING It is dangerous to ride with a worn-out tire.
Page 134: Checking And Charging The Battery
MAINTENANCE AND ADJUSTMENT OF THE UTV Lubricate or replace. NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 2. Apply: • lithium-soap-based grease (onto end of the cable) lithium-soap-based. ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of...
Page 135 MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING • This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. • Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries.
Page 136 MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the open-circuit voltage equals or exceeds 12.8V. b.
Page 137 MAINTENANCE AND ADJUSTMENT OF THE UTV any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed.
Page 138 MAINTENANCE AND ADJUSTMENT OF THE UTV Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 20 ~ 25 V Monitor the amperage for 3 ~ 5 minutes.
Page 139 MAINTENANCE AND ADJUSTMENT OF THE UTV Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging.
Page 140: Checking The Fuses
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ①, and then the negative battery lead ②. •...
Page 141: Adjusting The Headlight Beam
MAINTENANCE AND ADJUSTMENT OF THE UTV related electrical devices. d. If the fuse immediately blows again, check the electrical circuit. Current Description Quantity rating Main 30 A Lighting 15 A system fuse Ignition 10 A Terminal 10 A (Auxiliary DC jack) 4WD(Four wheel drive) Signaling...
Page 142: Changing The Headlight Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE HEADLIGHT BULB Remove: • Lift the hood up. • headlight bulb holder cover ① • headlight bulb holder (with bulb) ① • bulb NOTE: Remove the defective bulb by unhooking the headlight bulb holder tabs ② WARNING Keep flammable products and your hands away from the bulb while it is on, since it will...
Page 143: Changing The Tail/Brake Light Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV • Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel ① • tail/brake light bulb holder (with bulb) ② • bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will...
Page 144: Engine
ENGINE ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air.
Page 145: Engine Removal
ENGINE ENGINE REMOVAL Part Name Remarks Removing Throttle and intake Remove the parts in the order listed. manifold. Water temperature sensor O-ring Fuel injection Washer φ6×2 Seat fuel injection Bolt M6×20 Ducting dampers Inlet Temperature/pressure sensor Bolt M4×8 Pressure plate tmap Clip 50-70 Inlet joint head For installation, reverse the removal...
Page 146 ENGINE Part Name Remarks Removing Throttle and intake Remove the parts in the order listed. manifold. Inlet pipe Bush inlet pipe Bolt stud Nut M6 For installation, reverse the removal procedure. - 133 -...
Page 147 ENGINE 1、NOTE • Removing the drain plug NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. 2、INSTALL • Install intake manifold • Install intake manifold bolt • Install carburetor joint • Install carburetor NOTE: When installed, don't make an object from the intake fell into the cabinet.
Page 148: Cylinder Head And Cylinder Head Cover
ENGINE CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head cover Remove the parts in the order listed. and cylinder head Union bolt Copper washer Oil delivery pipe 3 Oil delivery pipe 2 Spark plug Tappet cover (intake) Tappet cover (exhaust) Timing chain tensioner cap bolt Timing chain tensioner / gasket...
Page 149 ENGINE Part Name Remarks Thermo switch 1 For installation, reverse the removal procedure. - 136 -...
Page 150 ENGINE 1、CHECK 1). Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2). Checking the cylinder head cover • cylinder head cover Cracks/damage Replace the cylinder head cover and cylinder head as a set. 3).
Page 151 ENGINE 5). Checking the cylinder head (1). Eliminate: • carbon deposits (from combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats (2). Check: • cylinder head Scratches/damage Replace the cylinder head cover and cylinder head as a set.
Page 152 ENGINE 2). Installing the cylinder head • cylinder head gasket • cylinder head • bolts (M9: 1 ~ 6, 38Nm) • bolts (M6: 7, 10Nm) NOTE: • Tighten the bolts in the proper sequence. • Follow the numerical order shown in the illustration.
Page 153: Rocker Arms And Camshaft
ENGINE ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Plug/O-ring Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft3/O-ring Rocker arm 4 Rocker arm shaft1/O-ring Rocker arm 1 Rocker arm 2...
Page 154 ENGINE Part Name Remarks Decompress or cam guide plate Camshaft sprocket Camshaft Cylinder head Cylinder head gasket For installation, reverse the removal procedure. - 141 -...
Page 155 ENGINE 1、CHECK 1). Checking the rocker arms • rocker arm lobes ① • valve adjusters ② Blue discoloration/pitting/scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. b.
Page 156 ENGINE 2). Checking the camshaft • cam lobes Pitting/scratches/blue discoloration Replace • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3).
Page 157 ENGINE 2). Installing the camshaft • camshaft • camshaft sprocket a. Turn the crankshaft counterclockwise with a T-sleeve. b. Align the “I” mark ① on the rotor with the stationary pointer ② on the A.C. magneto cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (TDC).
Page 158 ENGINE 1NOTE: Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide (intake side) inward. f. Remove the retaining wire. - 145 -...
Page 159: Valves And Valve Springs
ENGINE VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the removal procedure.
Page 160 ENGINE 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
Page 161 ENGINE • valve stem runout Out of specification Replace. Runout limit 0.01 mm 1NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
Page 162 ENGINE 1NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Install the new valve guide using a valve guide remover ① and valve guide installer ②. b.
Page 163 ENGINE 1NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. e. Install the valve into the cylinder head. g. Press the valve through the valve guide and onto the valve seat to make a clear pattern. h.
Page 164: Cylinder And Piston
ENGINE CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Coolant inlet joint Cylinder/O-ring Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal procedure.
Page 165 ENGINE 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) 1NOTE: Check whether the piston and the piston groove is cracked and abraded.
Page 166 ENGINE • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. 1NOTE: Clean carbon from the piston ring grooves rings before measuring...
Page 167 ENGINE 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) 1NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
Page 168: Engine Cooling Fan And A.c. Magneto
ENGINE ENGINE COOLING FAN AND A.C. MAGNETO Part Name Remarks Removing the engine cooling fan and Remove the parts in the order listed. A.C. magneto Drive belt cover Engine oil Coolant Water pump assembly Engine cooling fan air duct assembly Air shroud 1 Engine cooling fan Air shroud 2...
Page 169 ENGINE Part Name Remarks Pickup coil Stator assembly A.C. magneto rotor Woodruff key Starter wheel gear Washer Starter idle gear shaft Bearing Starter idle gear For installation, reverse the removal procedure. - 156 -...
Page 170 ENGINE 1、CHECK 1). Checking the A.C. magneto • stator coil • pickup coil Damage Replace. 2). Checking the starter clutch • starter clutch ① Cracks/damage Replace. • starter clutch bolts ② Loose Replace with new ones, and clinch the end of the bolts. 1NOTE: •...
Page 171 ENGINE • starter idle gear teeth ① • starter wheel gear teeth ② Burrs/clips/roughness/wear Replace. • starter wheel gear (contacting surface) Damage/pitting/wear Replace. 3). Checking the engine cooling fan • engine cooling fan • air shroud 1 • air shroud 2 Cracks/damage Replace.
Page 172 ENGINE • engine cooling fan pulley ① (55Nm) 1NOTE: Before installing the engine cooling fan pulley, do not forget to install the O-ring. • engine cooling fan ① (7Nm) 1NOTE: Install the bolts in the holes in the collar of the engine cooling fan.
Page 173: Balancer Gears And Oil Pump Gears
ENGINE BALANCER GEARS AND OIL PUMP GEARS Part Name Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Nut/lock washer Balancer driven/oil pump drive gear Chain Straight key Oil pump driven gear Plate Balancer drive gear Spring Timing chain guide (intake side)
Page 174 ENGINE 1、CHECK 1) Checking the oil pump drive gear and oil pump driven gear • oil pump drive gear ① • oil pump driven gear ② Replace Cracks/wear/damage 2).Checking the balancer drive gear and balancer driven gear • balancer drive gear ① •...
Page 175 ENGINE • balancer driven gear 1NOTE: Align the punch mark (a) on the balancer drive gear with the punch mark (b) on the balancer driven gear. • lock washer(new replacement) • balancer driven gear nut ①(110Nm) 1NOTE: • Place an aluminum plate ② between the teeth of the balancer drive gear ③...
Page 176: Primary And Secondary Sheaves
ENGINE PRIMARY AND SECONDARY SHEAVES Part Name Remarks Removing the primary and secondary Remove the parts in the order listed. sheaves Engine assembly Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sheave assembly V-belt Primary fixed sheave Secondary sheave assembly Drive belt case Rubber gasket For installation, reverse the removal...
Page 177: Primary Sheave
ENGINE PRIMARY SHEAVE Part Name Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave O-ring For assembly, reverse the disassembly procedure.
Page 178: Secondary Sheave
ENGINE SECONDARY SHEAVE Part Name Remarks Disassembling the secondary Sheave Remove the parts in the order listed. Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Oil seal For assembly, reverse the disassembly procedure.
Page 179 ENGINE 1、Check 1). Checking the primary sheave • weight outside diameter (a) Out of specification Replace the weight. Weight outside diameter limit: 29.5 mm • primary pulley slider • primary sliding sheave splines Wear/cracks/damage Replace. • spacer • primary pulley cam Cracks/damage Replace.
Page 180 ENGINE 2、Measure • secondary sheave spring free length (a) Out of specification Replace the secondary sheave spring. 3、INSTALL 1). Assembling the primary sheave (1)Clean: • primary sliding sheave face ① • primary fixed sheave face ② • collar ③ • weights ④ •...
Page 181 ENGINE 2). Assembling the secondary sheave (1)Apply: • assembly lube (to the secondary sliding sheave ① inner surface and oil seals)。 • assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ②) (2)Install: • guide pins ① •...
Page 182 ENGINE 1NOTE: • Tightening the bolts ① will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. • Install the V-belt so that its arrow faces the direction show in the illustration. (2)Tighten: •...
Page 183: Clutch
ENGINE CLUTCH Part Name Remarks Removing the clutch Remove the parts in the order listed. Primary and secondary sheaves Clutch housing assembly Gasket/dowel pin One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure. - 170 -...
Page 184: Clutch Housing
ENGINE CLUTCH HOUSING Part Name Remarks Disassembling the clutch housing Remove the parts in the order listed. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. - 171 -...
Page 185 ENGINE 1、CHECK 1). Checking the clutch • clutch housing ① Heat damage/wear/damage Replace. • one-way clutch bearing ② Chafing/wear/damage Replace. 1NOTE: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.
Page 186 ENGINE 3、INSTALL • clutch carrier assembly • nut ① 160Nm) 1NOTE: Use a universal clutch holder to hold the ② clutch carrier assembly. • Lock the threads with a drift punch. • one-way clutch bearing 1NOTE: The one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark (a) facing toward the clutch housing.
Page 187: Crankcase Starter Motorand Oil Filter
ENGINE CRANKCASE STARTER MOTORAND OIL FILTER Part Name Remarks Remove the starter motor, timing Remove the parts in the order listed. chain and oil filter A.C. magneto rotor Primary and secondary sheaves Clutch carrier assembly Starter motor/O-ring Oil filter cartridge/O-ring Oil pipe assembly/O-ring Oil pipe adapter/O-ring Relief valve assembly...
Page 188 ENGINE Part Name Remarks Reverse switch Oil filler cap Oil delivery pipe 1 For installation, reverse the removal procedure. - 175 -...
Page 189: Crankcase
ENGINE CRANKCASE Part Name Remarks Separating the crankcase Remove the parts in the order listed. Shift lever cover/gasket Dowel pin Shift lever 1 Shift lever 2 assembly Right crankcase Dowel pin Left crankcase Spacer Crankshaft seal For installation, reverse the removal procedure.
Page 190: Crankcase Bearings
ENGINE CRANKCASE BEARINGS Part Name Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft and oil pump Transmission Middle drive/driven shaft O-ring/collar Oil seal Bearing retainer Bearing For installation, reverse the removal procedure. - 177 -...
Page 191 ENGINE 1、CHECK 1). Checking the oil delivery pipe • oil delivery pipe Cracks/damage Replace. Clogged Blow out with compressed air. 2). Checking the relief valve • relief valve ① • spring ② Damage/wear Replace the defective part(s). 3). Checking the crankcase (1) Thoroughly wash the case halves in a mild solvent.
Page 192 ENGINE 2、INSTALL 1). Assembling the crankcase (1) Apply: • sealant (Quick Gasket) ① (to the mating surfaces of both case halves) (2) Install: • dowel pins ② (3) Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer CAUTION: Before installing and torque the crankcase holding bolts, be sure to check whether the...
Page 193 ENGINE 2). Installing the shift levers • shift lever 2 assembly ① (14Nm) • shift lever 1 ② 1NOTE: When installing the shift lever 1, align the punch mark (a) on the shift lever 1 with the punch marks (b) on the shift lever 2. - 180 -...
Page 194: Crankshaft And Oil Pump
ENGINE CRANKSHAFT AND OIL PUMP Part Name Remarks Removing the crankshaft and oil pump Remove the parts in the order listed. Crankcase separation Oil strainer/O-ring Oil pump assembly/gasket Balancer Plate Relief valve assembly Crankshaft For installation, reverse the removal procedure. - 181 -...
Page 195: Oil Pump
ENGINE OIL PUMP Part Name Remarks Disassembling the oil pump Remove the parts in the order listed. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. - 182 -...
Page 196 ENGINE 1、CHECK 1). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts. 2). Checking the oil strainer • oil strainer ① • O-ring ② Damage Replace.
Page 197 ENGINE Big end side clearance Limit: 1.0 mm (0.0394 in) • runout (b)(C) Out of specification Replace the crankshaft. Runout limit (b): 0.03 mm (C): 0.03 mm The crankshaft ① and the crank pin ② oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in).
Page 198: Transmission
ENGINE TRANSMISSION Part Name Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Middle driven gear Low wheel gear Shift drum Shift fork assembly Short spring Shift fork 1 Long spring Shift fork 2 Guide bar Secondary shaft Drive axle assembly Chain...
Page 199: Drive Axle Assembly
ENGINE DRIVE AXLE ASSEMBLY Part Name Remarks Disassembling the drive axle Remove the parts in the order listed. Clutch dog High wheel gear Middle drive gear Driven sprocket Drive axle For assembly, reverse the disassembly procedure. - 186 -...
Page 200 ENGINE 1、CHECK 1). Checking the shift forks • shift fork follower ① • shift fork pawl ② Scoring/bends/wear/damage Replace. • guide bar Roll the guide bar on a flat surface. Bends Replace. WARNING ： Do not attempt to straighten a bent guide bar. •...
Page 201 ENGINE 3). Checking the high wheel gear and middle drive gear • gear teeth Blue discoloration/pitting/wear Replace. • mated dogs Rounded edges/cracks/missing portions Replace. • gear movement Unsmooth Repeat steps #1 or replace the defective parts. • circlip Bends/looseness/damage Replace. 4).
Page 202 ENGINE 3、INSTALL 1). Assembling the shift fork • guide bar ① • shift fork 2 ② • long spring ③ • shift fork 1 ④ • short spring ⑤ 2). Installing the transmission • chain ① • drive axle assembly ② •...
Page 203: Middle Gear
ENGINE MIDDLE GEAR Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Bearing housing Middle drive gear Middle drive pinion gear Shim Middle drive shaft Bearing retainer For assembly, reverse the disassembly procedure.
Page 204: Middle Drive Shaft
ENGINE MIDDLE DRIVE SHAFT Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim Middle driven pinion gear For installation, reverse the removal procedure.
Page 205 ENGINE Part Name Remarks Bearing retainer Bearing retainer Middle driven shaft For installation, reverse the removal procedure. - 192 -...
Page 206 ENGINE 1、CHECK 1). Checking the pinion gears • gear teeth (drive pinion gear) ① • gear teeth (driven pinion gear) ② Pitting/galling/wear Replace. • O-ring Damage Replace. • bearings Pitting/damage Replace. • universal joint movement Roughness Replace universal joint. 2). Selecting the middle drive and driven gear shims When the drive and driven gear, bearing housing assembly and/or crankcase replaced,...
Page 207 ENGINE 3、INSTALL 1). Installing the middle driven shaft • bearing retainer ① Bearing retainer 80 Nm 1NOTE: Attach the ring nut wrench ② CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer, turn it counterclockwise. •...
Page 208 ENGINE • universal joint yoke • washer • nut ① 1NOTE: Use the universal joint holder ② to hold the yoke. Universal joint yoke nut 150 Nm • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c.
Page 209 ENGINE • drive shaft coupling • washer • nut ①(97Nm) 1NOTE: Use the coupling gear/middle shaft tool ② to hold the drive shaft coupling. 2). Installing the middle drive shaft (1) Tighten: • middle drive pinion gear nut ① (145Nm) 1NOTE: Secure the middle drive shaft in the vise with a clean rag.
Page 210: Malfunction Inspection
CHASSIS MALFUNCTION INSPECTION Appearance malfunction inspection Phenomenon Measure 1. Replace new plastic cover. 2. Check whether installation supporter deformed, repairing Plastic cover damaged or re-painting is needed before replacing new plastic cover. 3. Re-paste decals and re-rivet warning labels. 1. Replace new bumper. 2.
Page 211 CHASSIS 4. Check whether front wheel and front wheel axle nut loosen or damaged. Off tracking by braking at 5. Check whether front wheel hub inner spline and front high-speed wheel axle outer spline worn or loosen. 6. Check whether rubber cushion connected to front suspension rocker and frame damaged.
Page 212 CHASSIS Phenomenon Measure 1. Check whether front and rear axles splines damaged. 2. Check whether gears of front gearbox and differential over Front and rear axles arise worn. abnormal sound during drive 3. Check whether rear gearbox gears over worn. 4.
Page 213: Direction System The Steering Wheel Parts(Epa Type)
CHASSIS DIRECTION SYSTEM THE STEERING WHEEL PARTS (EPA TYPE) Part Name Remarks Removing the steering wheel parts Steering mechanism comp Driving gear Steering wheel comp Spring washer -8 Up cover for steering wheel Middle cover for steering wheel Socket hexagon screw M6×16 Clip Φ16 Decoration cover for steering wheel - 200-...
Page 214 CHASSIS Part Name Remarks Clip Rubber dust cover Hexagon flange bolt M10×1.25×35 Ball joint, steering mechanism Hexagonal nut M12 Steering drive axle Hexagon flange bolt M8×30 Steering column Hexagon flange bolt M8×25 Hexagon nut M12×1.25 Cotter pin 2×25 Steering wheel body - 201-...
Page 215 CHASSIS Part Name Remarks Hexagon flange nut M12×1.25 Decoration cover for steering column Down cover for steering wheel Washer Φ10×Φ20×2 Spring washer -10 Washer Φ8×Φ16×1.6 Washer Φ15×Φ28×2 Cross small plate head tapping screw ST3.6×10 - 202-...
Page 216: The Steering Wheel Parts(E-Mark Type)
CHASSIS THE STEERING WHEEL PARTS (E-mark TYPE) Part Name Remarks Removing the steering wheel parts Steering mechanism comp Driving gear Steering wheel comp Spring washer -8 Upper cover, steering wheel Middle cover, steering wheel Socket hexagon screw M6×16 Clip Φ16 Decoration cover, steering wheel - 203-...
Page 217 CHASSIS Part Name Remarks Clip Rubber dust cover Hexagon flange bolt M10×1.25×35 Ball joint, steering mechanism Hexagonal nut M12 Steering drive axle Hexagon flange bolt M8×30 Steering column Hexagon flange bolt M8×25 Hexagon nut M12×1.25 Cotter pin 2×25 Steering wheel body - 204-...
Page 218 CHASSIS Part Name Remarks Hexagon flange nut M5 Screw M5×12 Ignition switch Hexagon flange nut M12×1.25 Washer Φ5 Small washer d=5 Screw Light switch assy Cross big plate head screw M5×16 Cross plate head tapping screw ST4.8×13 Upper cover, ignition switch - 205-...
Page 219 CHASSIS Part Name Remarks Lower cover, ignition switch Tapping Clamp F4.2 Washer Φ5×Φ15×1.2 Decoration cover, steering column Rubber cushion, ignition switch cover Lower cover, steering wheel Washer Φ10×Φ20×2 Spring washer -10 Washer Φ8×Φ16×1.6 Washer Φ15×Φ28×2 Cross small plate head tapping screw ST3.6×10 - 206-...
Page 220 CHASSIS THE STRUCTURE OF STEERING WHEEL PART DIASSEMBLING THE PARTS OF THE STEERING WHEEL Remove: ·plastic center lid ① ·flange nut, washer ② ·steering wheel ③ a. Takes down the plastic center lid ① b. Takes down the steering wheel flange nut, the washer Attached figure ②...
Page 221 CHASSIS • Flange nut ④ Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering wheel.
Page 222 CHASSIS CHECKING AND SERVICE THE STEERING COLUMN PARTS 1. Check: • steering column tube ① • bearing ② • central axis of the steering shaft ③ • spline ④ • loosening ⑤ • rocky ledge ⑥ The central axis of the steering shaft whether flexible and moves.
Page 223 CHASSIS STEERING MACHINE PARTS DIASSEMBLING THE STEERING MACHINE PART 1. Check: • pressure pad ① • dust boots ② Wear/damage Replace. Damage/degradation Replace 1NOTE: When replace the dust boots of the ball , must enter 1/2 volume in lithium grease in to the dust boots.
Page 224 CHASSIS 6. Check: Whether the inspection gear drive reverse gap does surpass the rating, If it does, adjust the gap and the bolt . If cannot reduce the gap through the adjustment, instead the drive gear and spline gear. WARNING Do not use the welding to repair the steering joint.
Page 225 CHASSIS Bolt M8×16 24 Nm (2.4m · kg,17 ft · lb) 4. Use one piece of flange self-lock nut M12×1.25 fix the steering wheel on the steering column tube, then cover the direction column plastic center lid. Steering wheel tight of force 48 Nm(4.8m ·...
Page 226: Brake System
CHASSIS BRAKE SYSTEM PREPARATION FOR CHECKING BEFORE THE MAINTENANCE OF THE BRAKE SYSTEM Brake system is crucial to the life safety of the operator and therefore must be periodically in- spected and maintained. This vehicle uses the double return route hydraulic pressure disc brake system.
Page 227: Disk Brake Components
CHASSIS DISK BRAKE COMPONENTS Part Name Remarks Removing disk brake components Front brake hose Rear brake hose Hexagon flange bolt M6×25 Hexagon flange bolt M6×12 Oil pipe clip, front disc brake Clip, oil pipe Rear right brake caliper Rear left brake caliper Rear right brake plate Rear left brake plate Hexagon step bolt M8×20...
Page 228 CHASSIS Part Name Remarks Front brake pad Cooper seal Strainer bolt Cooper seal Rear right Brake Hose Rear left Brake Hose - 215-...
Page 229: Front And Rear Brake Discs
CHASSIS FRONT AND REAR BRAKE DISCS Remarks Part Name Removing the brake discs Brake caliper assembly Brake disc Bolt Turn join Bolt Brake disc guard - 216-...
Page 230 CHASSIS CHECKING THE FRONT AND REAR BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
Page 231: Front And Rear Brake Pads
CHASSIS FRONT AND REAR BRAKE PADS Part Name Remarks Removing the brake pads Remove the parts in the order listed. Brake caliper mounting bolt Brake pad holding bolt Brake pad For installation, reverse the removal Pad spring procedure. - 218-...
Page 232 CHASSIS REPLACING THE FRONT AND REAR BRAKE PADS 1NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set.
Page 233: Front And Rear Brake Caliper
CHASSIS FRONT AND REAR BRAKE CALIPER Part Name Remarks Removing the brake caliper Remove the parts in the order listed. Brake fluid Union bolt Copper washer Brake hose Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly For installation, reverse the removal procedure.
Page 234 CHASSIS Part Name Remarks Disassembling the brake caliper Remove the parts in the order listed. Brake pad holding bolt Brake pad Pad spring Brake caliper piston Dust seal Caliper piston seal Bleed screw For assembly, reverse the disassembly procedure. - 221-...
Page 235 CHASSIS DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS WARNING: • Brake caliper is one of the most important security components. Disassembly and maintenance must have a rich experience in technology and complete tool. •Wrong disassembly and reassembly may cause serious injury and even death. Replace damaged brake caliper.
Page 236 CHASSIS assembly. • brake caliper body ③ Cracks/damage Replace. • brake fluid delivery passage (brake caliper body) Blockage Blow out with compressed air. WARNING ： Replace the caliper piston seals and dust seals whenever brake caliper disassembled. ASSEMBLING FRONT REAR BRAKE CALIPERS WARNING ：...
Page 237 CHASSIS INSTALLING THE FRONT AND REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 48Nm (4.8m · kg,35 ft · lb) • brake hose ① •...
Page 238: Parking Brake Disc
CHASSIS PARKING BRAKE DISC Part Name Remarks Removing the parking brake disc Remove the parts in the order listed. Brake caliper assembly Final drive gear Parking brake disc For installation, reverse the removal procedure. - 225-...
Page 239 CHASSIS CHECKING THE PARKING BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Replace. Brake disc maximum deflection 0.10 mm (0.004 in) • brake disc thickness ○ Out of specification Replace. Brake disc minimum thickness 4.5 mm (0.18 in) - 226-...
Page 240: Parking Brake Caliper And Brake Pads
CHASSIS PARKING BRAKE CALIPER AND BRAKE PADS Part Name Remarks Removing the parking brake caliper and brake pads parking skid plate Brake fluid Parking brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting Bolt Parking brake lever assembly Union bolt Copper washer Brake hose...
Page 241 CHASSIS Part Name Remarks Brake caliper assembly Brake pad (piston side) Brake pad Insulator/pad shim Pad spring Brake caliper bracket Parking brake arm nut Parking brake arm Set bolt Parking brake arm shaft Parking brake case bolt Parking brake case Gasket Brake caliper piston - 228-...
Page 242 CHASSIS Part Name Remarks Dust seal Caliper piston seal Bleed screw - 229-...
Page 243 CHASSIS REPLACING THE PARKING BRAKE PADS 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring 1NOTE: Always install new brake pads, new brake pad shims, new insulators, and a new brake...
Page 244 CHASSIS b. Remove the dust seal and caliper piston seal. 1WARNING ： All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Check: • brake caliper pistons ① Scratches/rust/wear Replace the brake caliper assembly.
Page 245 CHASSIS 2. Install: • brake caliper piston Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. 1NOTE: Align an end ○ of the groove in the brake caliper piston with the punch mark ○...
Page 246 CHASSIS c. Install the parking brake arm to the parking brake arm shaft so that the punch mark ⓒ on the parking brake arm is aligned with the punch mark ⓐon the parking brake arm shaft. d. Turn the parking brake arm until it contacts the pin ⓓ.
Page 247 CHASSIS Must use DOT4 Brake Fluid 1NOTE: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. 3. Air bleed: • brake system 4. Check: • brake fluid level Brake fluid level is below the “MIN” level line Add the recommended brake fluid to the proper level.
Page 248: Brake Master Cylinder
CHASSIS BRAKE MASTER CYLINDER Part Name Remarks Removing the brake master cylinder Brake fluid Brake master cylinder Hexagon flange bolt M6×16 Hexagon flange bolt M6×20 Oil pipe hoop Connecting fork Split pin Pin, connecting fork - 235-...
Page 249 CHASSIS CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder ① Wear/scratches Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air. 2.
Page 250 CHASSIS • union bolt 27Nm (2.7 m · kg,19 ft · lb) 3. Fill: • brake fluid reservoir Must use DOT4 Brake Fluid 1NOTE: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. 4.
Page 251: Footrest Assembly
CHASSIS FOOTREST ASSEMBLY Part Name Remarks Removing the footrest Left footrest protector Cross large plate head screw M5×16 Axle cover Insulation paper Ⅲ Lamp switch, rear break Hexagon flange self-lock nuts M6 Nut Clip M6 Right footrest protector Dustproof plate, brake pedal Cross large plate head screw M6×16 Rear brake pump bracket assy Hexagon flange bolt M8×16...
Page 252 CHASSIS Part Name Remarks Washer Φ15×Φ22×1.5 Washer Φ12×1 Spring Φ2×Φ12.5×47 Welding, parking pedal Spring Φ2×φ12.5×52 Throttle cable Washer Φ5×Φ10×1.0 Parking system Parking sensor Screw M4×12 Spring Φ1.2×Φ7×28 Parking brake cable Hexagon flange bolt M6×16 Clip for cable - 239-...
Page 253 CHASSIS Part Name Remarks Expansion bolt(plastic) Mudguard for brake pump Hexagon flange bolt M8×20 Clamp Ⅳ （L=370） Clamp Ⅴ（L=200） Clamp Ⅲ （L=300） Push ties Cross large plate head screw M6×20 - 240-...
Page 254: Wheel And Tyre Parts
CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Part Name Remarks Removing the front wheel Front rim Front tyre Nut M10 Wheel decoration cover Ⅳ Nut M22×1.5 1WARNING ： Front hub Securely support the vehicle so There is no danger of it falling over. cotter pin 3.2×50 Bolt M10×30 - 241-...
Page 255: Rear Wheels
CHASSIS REAR WHEELS Part Name Remarks Removing the rear wheel Rear rim Rear tyre Rear hub Bolt M10×30 Nut M10 1WARNING ： Wheel decoration cover Ⅳ Securely support the vehicle so There is no danger of it falling over. Nut M22×1.5 Cotter pin 3.2×50 - 242-...
Page 256 CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play ① 3. Check: • wheel balance Out of balance Adjust. Wheel runout limit Radial ②: 2.0 mm (0.08 in) Lateral ③: 2.0 mm (0.08 in) 1WARNING...
Page 257 CHASSIS INSTALLING THE WHEEL TYRE 1. Install: • wheel 1NOTE: The arrow mark ① on the tyre must point in the direction of rotation □ of the wheel. 2. Tighten: • wheel nuts ① The angle of the conical bores is 60° ：...
Page 258: Transmission System
CHASSIS TRANSMISSION SYSTEM Front Axle Part Name Remarks Circlip Double off-set joint assembly Circlip Circlip Hoop A, dust P shed Φ80 Outer rubber dust-P cover (C-1610) Hoop B, dust P shed Φ32 Joint shaft Inner rubber dust-p cover (C-1605) Front left C.V axle Front right C.V axle - 245-...
Page 259: Front Bridge
CHASSIS Front Bridge Part Name Remarks Removing the front bridge Front differential assy Front differential case Ⅱ Front differential caseⅠ Drive & driven gears assy Connection fork Ⅰ Hexagon flange nut M14×1.5 O-type ring Φ6.8×Φ14 Oil seal Φ48ΧΦ65Χ9 Oil seal Φ24ΧΦ38Χ8 Washer ⅠΦ50ΧΦ61.5 Socket hexagon screw M8×25 - 246-...
Page 260 CHASSIS Part Name Remarks Connection Fork Ⅱ Socket hexagon screw M8×10 Hexagon flange bolt M10×1.25×15 Clip D0=62 Pin Φ5×75 Transfer case assembly Divide device connection Rack O-Ring Φ2×Φ81,transfer case O-Ring Φ2.62×Φ139.37 Bearing Φ35×Φ62×14 Bearing Φ60×Φ85×13 - 247-...
Page 261 CHASSIS Part Name Remarks Bearing Φ35×Φ62×9 Bolling bearing Φ15×Φ21×12 Screw Copper washer Φ13×1.5 Hexagon flange nut M10×1.25 Shaft fork Ⅳ Clampφ20-32 Universal jointⅠ Clip D0=62 Vent pipe L=700 Oil pipe clip Φ8 Criss-cross shaft (Φ20) - 248-...
Page 262 CHASSIS Part Name Remarks Front transmission shaft Circlip D0=19 Circlip Φ20×Φ26×1 Spring Φ25ΧΦ2.3Χ28 Rear dustproof rubber cover Φ19×Φ31×28 Front dustproof rubber cover Φ19×Φ38×50 Hexagon flange bolt M10×1.25×30 Hexagon flange bolt M10×1.25×142 Block ring Front transmission shaft comp Sliding sleeve O-ring1.5×9 Hexagon flange bolt M8×28 - 249-...
Page 263 CHASSIS DISASSEMBLING THE FRONT BRIDGE 1. Take down the left and right front wheel parts. 2. Sequently remove the front disk brake clip, cotter pin, open-groove nut, cushion and front wheel hub. 3. Disassembly the left and right arm rocker and cross steering knuckle.
Page 264 CHASSIS CHECKING THE JOINTS 1.Check • Dust boots Cracks/damage Replace 2.Check • double off-set joint spline • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set joint Pitting/wear/damage Replace. • Check whether the inner and outer ball cage of the left and right transmission shaft movement is Smooth, ceaseless.
Page 265 CHASSIS • oil seals • O-rings Damage Replace. 2.Check: • drive shaft splines • universal joints • drive pinion gear splines Wear/damage Replace. • spring Fatigue Replace. Move the spring up and down. 3.Check: • front drive shaft Bends Replace. •...
Page 266 CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
Page 267 CHASSIS ASSEMBLING THE DIFFERENTIAL GEAR 1. Measure: • gear lash 2. Install : • gear motor a. Installed to the differential gear, to the right to put it into the 2WD mode. b. Connect two C size batteries to the gear motor terminal ①...
Page 268 CHASSIS INSTALLING THE FRONT BRIDGE PARTS 1. Put the left and right transmission shaft in the front bridge differential device. 2. Pour 0.32L SAE 80 API GL-4 the high quality gear grease into the front bridge differential device and screws tight the oil filler bolt.
Page 269: Rear Axle
CHASSIS Rear Axle Part Name Remarks Removing the rear axle Circlip Double off-set joint assembly Hoop A, dust P shed Φ80 Inner rubber dust-P cover (C-1520) Hoop B, dust P shed Φ32 Double off-set joint assembly Inner rubber dust-p cover (C-1605) Half axle assembly Rear left C.V axle Rear right C.V axle...
Page 270: Rear Bridge
CHASSIS Rear Bridge Part Name Remarks Removing the rear bridge Rear reducer assy Rear reducer caseⅠ Bearing Φ22ΧΦ30Χ13 Bearing 55Bm6720 Φ55ΧΦ67Χ20 Drive & driven gears Bearing Φ25ΧΦ62Χ17 Mount bracket, rear disk brake plate Oil seal Φ61ΧΦ35Χ9 Fuel drain O-seal Φ13ΧΦ1.5 O-ring gasket Φ3ΧΦ71 Washer Φ12ΧΦ30Χ4 Hexagon flange nut M12×1.25...
Page 271 CHASSIS Part Name Remarks Rear adjustment gasketⅠ Hexagon bolt with washer Socket hexagon screw M8×25 Rear adjustment gasket Ⅱ Speed sensor comp. O-ring gasket, fuel injection Φ2.3ΧΦ19.4 Vent pipe, rear reducer Rear reducer case Ⅱ Socket hexagon screw M8×45 Washer Φ8.2Χ1 Hexagon flange nut M8 Oil seal Φ65×Φ90×9 Bearing 16017C2 Φ85ΧΦ130Χ14...
Page 272 CHASSIS Part Name Remarks O-ring Φ3ΧΦ150 Adjustment gasket Ⅲ Oil seal Φ65×Φ90×9 Fuel drain screw plug Hexagon flange nut M10×1.25×25 Hexagon flange bolt M8×12 Rear transmission shaft comp Spring Φ18.5×Φ2×30 Rear transmission shaft Circlip D0=19 Jointsleeve, rear axle transmission shaft Elasticity block ring D0=22 Hexagon flange nut M10×1.25 - 259-...
Page 273 CHASSIS Part Name Remarks Front dust cover Φ25×Φ53×35 Rear dust cover Φ20.5×Φ48×30 Vent pipe, rear reducer Steel wire clamp Φ8 Clip Φ11 Clamp Φ20-32 Hexagon flange bolt M10×1.25×120 Impaction ring Rubber washer of shaft - 260-...
Page 274: Speed Reducer Component With Differential
CHASSIS Speed Reducer Component With Differential Part Name Remarks Removing the speed reducer Rear differential case Ⅰ Rear differential case Ⅱ Oil seal Φ52×Φ35×7 Bearing 32008E C.V Axle, rear right axle Rear axle transmission shaft Circlip D0=19 Rear differential comp. Circlip Φ20×Φ26×1 - 261-...
Page 275 CHASSIS Part Name Remarks Spring Φ18.5×Φ2×30 Bearing 32010E Bearing seat Metal bushing Fuel drain O type seal Fuel drain screw plug Welding combination of shift fork U type spring Fix bracket Returning spring Sleeve of shift fork - 262-...
Page 276 CHASSIS Part Name Remarks Column pin of shift fork Dustproof rubber cover Φ19×Φ38×50 Oil fill plug O-ring gasket, fuel injection Block ring Hexagon flange nut M10×1.25 Rear axle transmission assy Criss-cross shaft Spring Φ18.5×Φ2×30 Clamp Φ20-32 - 263-...
Page 277 CHASSIS Part Name Remarks Drive & driven gears Rear adjustment gasketⅠ Front dust cover, rear axle transmission shaftΦ25×Φ53×35 Adjust bushing Ⅰ Gasket, adjust bushing Adjust bushing Ⅱ Bearing 32206E O-ring gasket Universal joint Ⅲ Joint cross shaft Washer Φ12ΧΦ30Χ4 - 264-...
Page 278 CHASSIS Part Name Remarks Hexagon flange locked nut M14×1.5 Magnetic valve Hexagon flange bolt M10×1.25×20 Overflow pipe Steel wire clamp Φ8 Bushing Φ10.5×Φ22×15 Connection fork Ⅱ Connection forkⅠ Needle sleeve Rear left C.V axle Rear differential - 265-...
Page 279 CHASSIS （ The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.） 1NOTE: Apply lithium-soap-based grease to the bearing assembly and o-ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing.
Page 280: Reverse Mechanism Parts
CHASSIS REVERSE MECHANISM PARTS Part Name Remarks Removing reverse mechanism Gearshift knob Gearshift boot Gearshift assy Gear shift rod Adjust nut M8 Gearshift tie assy Washer Φ6×Φ18×1.6 Hexagon flange bolt M6×16 Hexagon flange bolt M8×16 Plastic screw Rubber cover clamp Gearshift knob - 267-...
Page 281 CHASSIS Part Name Remarks Clip Φ14 Draining tube Adjust nut M8（L) Gear shifting support Hexagon flange bolt M6×12 Reverse cable Spring washer -6 Plug Hexagon flange nut M8 - 268-...
Page 282 CHASSIS ADJUSTING REVERSE MECHANISM PARTS ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable 1NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. 1.
Page 283 CHASSIS try again., if still not good to inform the special serviceman to service the reverse mechanism. 2. If the reverse mechanism appears lacks files, adjust the connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again.
Page 284: Suspension
CHASSIS SUSPENSION Front Suspension and arm Part Name Remarks Removing front suspension and arm Left front upper swing arm Joint A，suspension Circlip D0=30 Right front upper swing arm Left front lower swing arm Right front lower swing arm Middle rubber tube, swing arm Hexagon flange bolt M10×1.25×70 - 271-...
Page 285 CHASSIS Part Name Remarks Hexagon flange nut M10×1.25 Dust cover B Hexagon nut M12×1.25 Cotter Pin 2.5×30 Front shock absorber Hexagon flange bolt M10×1.25×50 Protective board, swing arm Screw thread clip M6×5 Cross big plate head screw M6×12 Tie-rod, front anti-roll bar Hexagon flange bolt M10×1.25×45 - 272-...
Page 286 CHASSIS Part Name Remarks "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 Front anti-roll bar Spring washer -8 Hexagon flange bolt M10×1.25×75 Dust proof rubber boot Washer Φ13×Φ24×2 Spring washer -12 Washer Φ8×Φ16×1.6 Hexagon flange lock nut M8 - 273-...
Page 287 CHASSIS DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and Service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. • If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
Page 288 CHASSIS To check whether put on the butter before fix, then fix the upper and lower rockers and L/R front shock absorber, etc . CHECKING THE FRONT ARMS 1. Check: • front arms Bends/damage Replace. 2. Check: • Middle bushing Wear/damage Replace.
Page 289 CHASSIS I NSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber a. Install the front upper arm ① and front lower arm ②. 1NOTE: • Lubricate the bolts ③with lithium-soap-based grease. • Be sure to position the bolts ③ so that the bolt head faces outward.
Page 290: Rear Suspension
CHASSIS Rear Suspension Part Name Remarks Removing the rear suspension Rear shock absorber Hexagon flange bolt M12×1.25×70 Hexagon flange bolt M12×1.25×65 Hexagon flange nut M12×1.25 Rear anti-roll bar Left tie-rod, anti-roll bar Right tie-rod, anti-roll bar Hexagon flange nut M10×1.25 "U"...
Page 291 CHASSIS Part Name Remarks Spring washer -8 Washer Φ8×Φ16×1.6 Washer Φ10×Φ20×2 - 278-...
Page 292: Rear Arm Shaft
CHASSIS Rear arm shaft Part Name Remarks Removing the rear arm shaft Rear right upper swing arm Rear left lower swing arm Rear right lower swing arm Middle rubber tube, swing arm Hexagon flange bolt M10×1.25×70 Hexagon flange nut M10×1.25 Rear left upper swing arm Dust cover B Protective board, rear right lower swing arm...
Page 293 CHASSIS Part Name Remarks Cross large plate head screw M6×16 Nut clip M6 - 280-...
Page 294: Rear Suspension And Arm
CHASSIS Rear Suspension and arm CHECKING AND SERVICE OF REAR SUSPENSION 1. It is similar to the front suspension ,Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2.
Page 295 CHASSIS CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue Replace the shock absorber assembly.
Page 296: Cooling System
CHASSIS COOLING SYSTEM RADIATOR 1 Part Name Remarks Removing the radiator 1 Rear right water pipe Φ Clamp 20-32 Clip , metal water pipe Hexagon flange bolt M6×16 Metal water pipe Front water pipe Rear left water pipe Radiator fan assy Installation bracket I, oil cooler Installation bracket II, oil cooler Radiator assy...
Page 297 CHASSIS Part Name Remarks Cap, radiator Water temperature sensor Auxiliary water tank cover Rubber pipe Φ7×Φ11×750 Clip Φ10 Flanging bushing Φ6×Φ9×Φ22×6.5 Clip Φ9 Rubber pipe Φ5×Φ9×550 Radiator cover Auxiliary water tank assy Radiator fan assy Hexagon flange bolt M6×20 Hexagon flange nut M6 - 284-...
Page 298: Radiator 2
CHASSIS RADIATOR 2 Part Name Remarks Removing the radiator 2 Oil cooler cover Oil cooler Oil cooler assy Screw hoop Φ12-20 Pressure-proof rubber oil pipe Φ10×Φ17×260 Hexagon flange bolt M6×12 M-shaped fixed pipe clamps M-shaped fixed pipe clamps Hexagon flange nut M6 Hexagon bolt M6 Pressure-proof rubber oil pipe C - 285-...
Page 299 CHASSIS Part Name Remarks Pressure-proof rubber oil pipe Φ10×Φ17×150 工-shaped rubber washer Front right metal oil pipe Front left metal oil pipe Rear right metal oil pipe Rear left metal oil pipe - 286-...
Page 300 CHASSIS CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator Damage Repair or replace. 1NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • all rubber hose Cracks/damage Replace.
Page 301: Oil Cooler
CHASSIS the refrigerating fluid until the water level stop to change, then screw the exhaust nut, cover the water tank lid. The water tank inspection is finished. . 2. Check: • cooling system Leaks Repair or replace any faulty part. Recommended antifreeze: High quality ethylene glycol antifreeze containing...
Page 302: Water Pump
CHASSIS WATER PUMP 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Water pump assembly Bolt M6×45 Bolt M6×65 Bolt M6×10 Water pipe Ⅱ O-ring 20.7×2.6 Water pipe Ⅲ Water pipe clip Cylinder inlet water joint Bolt M6×20 O-ring 33.4×2.4...
Page 303 CHASSIS 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Pipe clip Ⅱ Save temperature Save temperature cover Bolt M6×20 Water pump housing cover Gasket Circlip Impeller assembly Water pump seal Oil seal Bearing Water pump housing O-ring...
Page 304 CHASSIS DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder ① • rubber damper ② 1NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal ① • Water pump housing ② 1NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 305 CHASSIS 2. Check: • water pump seal ① • oil seal ② • water pipe ③ Cracks/damage/wear Replace. • bearing ④ Rough movement Replace. 1NOTE: Apply lithium-soap-based grease to the oil seal and Apply engine oil to the bearing 3. Measure: •...
Page 306 CHASSIS 3. Install: • rubber damper ① • rubber damper holder ② 1NOTE: • Before installing the rubber damper, apply tap water or coolant onto its outer surface. • Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Page 307: Seat
CHASSIS SEAT Part Name Remarks Removing the seat Seat assy Safety belt placing plate Seat mounting board Hexagon flange bolt M8×30 Hexagon flange Nut M8 Seat locker Hexagon flange bolt M6×40 Hexagon flange Nut M6 Locker bracket, seat Rubber cushion Φ30-3 Rubber cushion Φ24-15 - 294-...
Page 308 CHASSIS Part Name Remarks Side armrest Hexagon flange bolt M6×25 Head rest Washer Φ8×Φ28×1.5 Hexagon flange nut M10×1.25 Hexagon flange step bolt M10×1.25×20-Φ14×5 Hexagon flange bolt M10×1.25×20 Washer Φ10×Φ25×3 Safety belt buckle Safety belt assy (3-point type) Washer Φ6×Φ18×1.6 Washer Φ8.5×Φ22×1.2 Hexagon flange step bolt M10×1.25×15-Φ14×5 Collar bush Φ8×Φ25×Φ36×7 - 295-...
Page 309: Oil System
CHASSIS OIL SYSTEM FUEL TANK Part Name Remarks Removing the fuel tank Fuel tank Insulation paper Ⅸ Shock absorption rubber Φ15-6 Fuel pump connection wire assy Cover, fuel pump Rubber tube Ⅵ Plug for fuel outlet Clip Φ11 Clamp - 296-...
Page 310 CHASSIS Part Name Remarks triplet joint fuel pipe fuel pipe Φ8×Φ14-885 fuel pipe Φ8×Φ14-330 fuel pump assy plug, fuel inlet lid for fuel tank seal gasket for fuel pump high voltage fuel filter Clip Φ16 Fuel pipe Φ8×Φ14-130 Aluminum foil insulation bellows Φ14×Φ17×330 - 297-...
Page 311 CHASSIS Part Name Remarks Aluminum foil insulation bellows Φ14×Φ17×100 Aluminum foil insulation bellows Φ14×Φ17×855 Vent pipe Φ7×Φ11-690, fuel tank - 298-...
Page 312 CHASSIS CHECKING THE FUEL PUMP OPERATION 1. Remove: • driver seat • passenger seat • console • right protector 2. Place a container under the end of the fuel hose ①. 3. Check: • fuel pump operation a. Suck on the end of the vacuum hose. 4.
Page 313 CHASSIS Oil Cooling System INSTALLING OIL COOLING SYSTEM 1. To take a pressure resistance inspection to the Cooling System after maintain, pressure is 0.3MPA. 2. After take the pressure resistance inspection, pass over 0.03MPA compressed air through the connecting oil cooler, steel oil pipe and Rubber Pipe for 3 minutes, do not leak.
Page 314: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Phenomenon Measure 1、 Check whether switches normal. Abnormal lights 2、 Check whether cables damaged. 3、 Check whether lights damaged. Fail to shift into 1、 Check whether four wheel drive switch normal. four-wheel-drive or 2、 Check whether rear bridge reducer differential mechanical conversion lock differential.
Page 315: Electrical
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICALCOMPONENTS 1. Thermo switch 2 2. Radiator fan 3.Gear motor 4.Brake light switch 5.Parking brake switch 6.Pickup coil/stator assembly 7.Speed sensor 8. Diode 1 9. Circuit breaker(radiator fan motor) 10.Thermo switch 1 11. Ignition coil 12. Gear position switch 13.Reverse switch 14.ECU unit 15.
Page 316 ELECTRICAL COMPONENTS 1. Relay assy 2. Starter relay 3. Battery 4. Rectifier/regulator 5. Speedmeter 6. On-Command four-wheel drive switch and differential gear lock switch 7. Main switch 8. Light switch - 303 -...
Page 317: Checking The Switch
ELECTRICAL COMPONENTS CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. NOTE: • Set the pocket tester to “0” before starting the test. •...
Page 318: Checking The Switch Continuity
ELECTRICAL COMPONENTS Checking the switch continuity Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. 1. Fuse 2. Brake light switch 3.On-Command four-wheel drive switch and differential gear lock switch 4.Main switch 5.Light switch 6.Parking brake switch...
Page 319: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
Page 320: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure 7. Main switch Check: 8. Pickup coil resistance 1. Fuses (main, ignition) 9. Rotor rotation direction detection coil resistance 2. Battery 10.Wiring connection (the entire ignition system) 3.
Page 321 ELECTRICAL COMPONENTS 4. Ignition spark gap INCORRECT • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker ① as shown. Repair or replace the spark plug. ② Spark plug cap •...
Page 322 ELECTRICAL COMPONENTS Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead Orange lead terminal Tester (–) lead Spark plug lead • Check that the secondary coil has the specified resistance.
Page 323: Electric Starting System
ELECTRICAL COMPONENTS resistance OUT OF SPECIFICATION 0.063 ~ 0.077 Ω at 20 °C (68 °F) (Red – White/Blue) MEETS SPECIFICATION Replace the pickup coil/stator assembly. 10.Wiring connection POOR CONNECTION • Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the ignition system.
Page 324: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure 6. Gear position switch Check: 7. Brake light switch 1. Fuses (main, ignition, signaling system) 8. Diode 1 2. Battery 9. Wiring connection (the entire starting system) 3. Starter motor 1NOTE: 4.
Page 325 ELECTRICAL COMPONENTS DOSE NOT TURN Repair or replace the starter motor. Small testers and battery and (12V) and start relay terminal connection Check continuity of the start relay TURNS 4. Starter relay • Remove the starter relay from the wire harness.
Page 326 ELECTRICAL COMPONENTS Tester (+) lead Yellow/Blue terminal ① Tester(–)lead Continuity Black/Yellow terminal ② Tester(+) lead Yellow/Blue terminal ① Tester (–) lead Blue/White terminal ③ 1NOTE: Tester (+)lead When you switch the tester’s positive and B lack/Yellow terminal ② negative probes, the readings in the left chart Tester (–) lead will be reversed.
Page 327: Starter Motor
ELECTRICAL COMPONENTS STARTER MOTOR Part Name Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor/O-ring installation, reverse removal procedure. Disassembling the starter motor Remove the parts in the order listed. Bracket 1 ①...
Page 328: Checking The Starter Motor
ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter Out of specification Replace the starter motor. 3. Measure: • mica undercut ⓑ Out of specification Scrape the mica using a hacksaw blade.
Page 329: Assembling The Starter Motor
ELECTRICAL COMPONENTS ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 ① 1NOTE: Align the projection ⓐ on the brush seat 1 with the slot ⓑ on the yoke. 2. Install: • yoke • brackets 1NOTE: Align the match marks ⓐ on the yoke with the match marks ⓑ...
Page 330: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING Procedure IF THE BATTERY IS NOT CHARGED: Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage 1NOTE: Remove some parts before maintenance 1. Cushion Repair with following special toolings 1.
Page 331: Lighting System
ELECTRICAL COMPONENTS 4. Charging coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. Tester (+) lead White terminal ① Tester (–) lead White terminal ② Tester (+) lead White terminal ①...
Page 332: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure 4. Light switch Check 5. Wiring connections(the entire lighting system) 1. Fuses (main, lighting system) 2. Battery 1NOTE: 3. Main switch • Remove following part(s) before troubleshooting: 1.
Page 333: Checking The Lighting System
ELECTRICAL COMPONENTS CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 334: Signaling System
ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2) . Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light couplers.
Page 335: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure 3. Main switch Check: 4. Wiring connections (the entire signal system) 1. Fuses (main, signaling system) 1NOTE: 2. Battery Remove following part(s) before •...
Page 336: Checking The Signal System
ELECTRICAL COMPONENTS CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Bake light switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 337 ELECTRICAL COMPONENTS 2. If the neutral lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Gear position switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 338 ELECTRICAL COMPONENTS 3. If the parking brake indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Parking brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 339 ELECTRICAL COMPONENTS 4. If the reverse indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Reverse switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 340 ELECTRICAL COMPONENTS 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F): (1).
Page 341 ELECTRICAL COMPONENTS Test steps 1 & 2: Heating phase Test steps 3 & 4: Cooling phase 1WARNING： BAD CONDITION Handle the thermo switch 1 with special care. Never subject it to a strong shock or allow it Replace the thermo switch 1 to be dropped.
Page 342 ELECTRICAL COMPONENTS 6. If the differential gear lock indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Differential gear lock indicator light relay •...
Page 343 ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead Black/Green terminal ② OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 344 ELECTRICAL COMPONENTS 7. If the four-wheel drive indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). four-wheel drive indicator light relay •...
Page 345: Cooling System
ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead White/Yellow terminal ② OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 346 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure 5. Thermo switch 3 Check: 6. Wiring connection(the entire cooling system) 1. Fuse (main) 2. Battery 3. Main switch 4. Radiator fan motor 1NOTE: • Remove following part(s) before troubleshooting.
Page 347 ELECTRICAL COMPONENTS 4.Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead Blue terminal ① Battery (–) lead Black terminal ② DOES NOT TURN Replace the radiator fan motor. •...
Page 348: 2Wd/4Wd Selecting System
ELECTRICAL COMPONENTS 1WARNING： Handle the thermo switch 3 with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. BAD CONDITION Thermo switch 3 28 Nm (2.8 m · kg, 20 ft · lb) GOOD CONDITION Replace the thermo switch 3 6.
Page 349 ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR FAILS TO COME ON: Procedure 7. On-Command four-wheel drive switch and Check: differential gear lock switch 1. Fuses (main, four-wheel drive) 8. Gear motor 2. Battery 9. Wiring connections 3. Main switch (the entire 2WD/4WD selecting system) 4.
Page 350 ELECTRICAL COMPONENTS 4. Four-wheel drive relay 1 • Remove the four-wheel drive relay 1 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals. Tester (+) lead Black/Yellow terminal ①...
Page 351 ELECTRICAL COMPONENTS 6. Four-wheel drive relay 3 • Remove the four-wheel drive relay 3 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Battery (+) terminal Brown/Red terminal ①...
Page 352 ELECTRICAL COMPONENTS 8. Gear motor • Disconnect the gear motor coupler. • Remove the gear motor from the differential gear case. Refer to “FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT” in chapter 3. • Connect two C size batteries to the gear motor terminals ①...
Page 353: Engine Management System
ENGINE MANAGEMENT SYSTEM INTRODUCTION EMS (Engine Management System) EMS is a self contained set of components including a custom built computer and sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature and providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.
Page 354: Layout Of Ems Components
ENGINE MANAGEMENT SYSTEM Layout of EMS Components Legend: Dotted line indicates inputs Solid line indicates outputs COMPONENTS OF EMS Electronic Control Unit 1．Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions.
Page 355: Multec 3.5 Injectors
ENGINE MANAGEMENT SYSTEM 2．Handling – DOs & DONTs ECU Handing ACTION REASON DO NOT: Place the ECU close to the exhaust High temperature might reduce the life of the pipe or Engine when removed ECU and also can damage the ECU DO NOT: Place the ECU close to or pour ECU is susceptible to water and liquids...
Page 356 ENGINE MANAGEMENT SYSTEM 2．Handling - DOs & DONTs 3.5 FUEL INJECTOR HANDLING ACTION REASON DO NOT: Re-use injector seal rings if at all Leakage. possible. If no other choice exists, take extra care in inspecting the seal rings for damage. DO NOT: Dip injector tips into lubricants.
Page 357 ENGINE MANAGEMENT SYSTEM Use proper lubricants on seal ring Avoid damage to seal ring during installation. surfaces to install injector in engine. Avoid contamination at seal. Minimize time between applying lubricant and inserting injector / rail. DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure suspected injector (Actuate consists of one pulse <5 sec duration at 9 to 15V).
Page 358 ENGINE MANAGEMENT SYSTEM • Remove the fuel line connection from the injector • Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces. • Remove the injector from the manifold • Apply a light coating of a lubricant to both the upper and lower injector seal ring of the replacement injector.
Page 359: Throttle Body Assembly(With Stepper Motor)
ENGINE MANAGEMENT SYSTEM 5．Plugging Fuel deposits cause plugging resulting in flow shifts over the life of the injector. Fuel varnish or gumming, a type of injector deposit, is created when certain types of fuel are heated by high injector tip temperatures at soak (no fuel flow). Deposit build up in the director holes causes the flow shifts •...
Page 360 ENGINE MANAGEMENT SYSTEM 2．Handling – DOs and DONTs THROTTLE BODY ASSEMBLY HANDLING ACTION REASON DO: Use care during assembly of harness to throttle Avoid terminal damage. body. DO: Avoid any liquid contamination in the throttle Ensure proper operation. body area. DO: Unload and install units one at a time from Damage may be done to critical components.
Page 361: Engine Coolant Temperature Sensor
ENGINE MANAGEMENT SYSTEM 4．Cleaning Procedure If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and varnish that are present.
Page 362: Oxygen Sensor
ENGINE MANAGEMENT SYSTEM 2．Sample Cleaning • When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one minute with mating connectors in place and then air-dried Oxygen Sensor 1．Description and Working Principle This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine.
Page 363 ENGINE MANAGEMENT SYSTEM 3．DOs and DONTs Ignition Coil Handing Action Reason DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing, the power applied possibly leading to personal injury DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in secondary boots from the secondary tower.
Page 364 ENGINE MANAGEMENT SYSTEM DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or plug boot to the ignition secondary towers. mating connection surfaces might occur. Installation of the high voltage secondary leads by hand is preferred.
Page 365 ENGINE MANAGEMENT SYSTEM DO: Ignition secondary leads should not be Voltage spikes can be transmitted from the routed with the ignition primary harness or any secondary cables into other leads which are in other electrical harness. close. This could create a component performance degradation or failure condition DO: Spark plug wires(secondary leads) &...
Page 366: Fuel Pump Module
ENGINE MANAGEMENT SYSTEM deposits, clean with wire brush, taking care to injure the electrode or the insulator tip Regap spark plugs exact -Too wide a gap could cause the plug to measurement specified by the engine misfire(higher required ignition voltage). manufacturer to keep the best fuel economy and -Too narrow of a gap could affect idle stability proper engine performance...
Page 367 ENGINE MANAGEMENT SYSTEM Fuel Pump When power is supplied to fuel pump, motor in pump assembly rotates the impeller. Impeller in turn draws the fuel from strainer and pumps the flow to generate the system pressure. Pressure Regulator Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the inlet of pressure regulator.
Page 368 ENGINE MANAGEMENT SYSTEM Connect power supply 1. Check Fuel (battery) to fuel module. 1. Check electrical Pump Harness Make sure that enough fuel available in circuit from fuel integrity fuel tank to avoid fuel pump running module to ECU 2. Check Fuel dry.Is the fuel pump running 2.
Page 369 ENGINE MANAGEMENT SYSTEM • Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque: 3~4 Nm. Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow the tightening torque and tightening sequence instruction.Over torque and miss-sequence can cause unequal compression of gasket and leakage.
Page 370 ENGINE MANAGEMENT SYSTEM After making sure that engine is cold, relieve fuel pressure as follows. • Place vehicle gear in ‘Neutral’. • Disconnect fuel module electrical coupler from vehicle harness. • Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3 times of about 3 seconds each time to relieve fuel pressure in lines.
Page 371 ENGINE MANAGEMENT SYSTEM DO NOT: Use Fuel Module if the strainer Contamination enters fuel pump thru with excessive damage/ cut. damaged strainer damages the Fuel Pump DO NOT: Use Fuel Pump for draining duel Not intended function of fuel module. in fuel tank.
Page 372: Ems Fault Diagnosis
ENGINE MANAGEMENT SYSTEM EMS FAULT DIAGNOSIS EME Fault Diagnosis When fault comes up, the odometer's clock will turn into a number， which is a fault code, find out the cause with this numbe;press clock button,then it will turn back to clock mode, and five second later,the fault code will show again.
Page 373 ENGINE MANAGEMENT SYSTEM 0562 System Voltage Low KsDGDM_SysVoltLow System Voltage 0563 System Voltage High KsDGDM_SysVoltHigh 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer 1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow Oxygen Sensor 2 0138 O2S 2 Circuit High Voltage...
Page 374: Troubleshooting
TROUBLESHOOTING NOTE: The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to relevent contents for the inspection, adjustment and replacement of part. STARTING FAILURE/HARD STARTING FUEL SYSTEM 1、No oil 2、Fuel filter is clogged Fuel tank 3、Fuel pump filter net is clogged 4、Breather tube is clogged...
Page 375: Compression System
TROUBLESHOOTING 1、Faulty starter motor 2、Faulty starter relay Starter motor 3、Faulty overrunning clutch in engine 4、Broken main switch 5、Broken main fuse 1、Low battery voltage Battery 2、Faulty battery COMPRESSION SYSTEM 1、Loose spark plug 2、Loose cylinder head or cylinder 3、Broken cylinder head gasket Cylinder and cylinder head 4、Broken cylinder gasket 5、Worn, damaged or seized cylinder...
Page 376: Poor Medium And High-Speed Performance
TROUBLESHOOTING 1、Faulty ignition plug Electrical system 2、The performace of speed sensor become poor 3、Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element POOR MEDIUM AND HIGH-SPEED PERFORMANCE POOR MEDIUM AND HIGH-SPEED PERFORMANCE 1、 Broken ECU 2、...
Page 377: Engine Overheating
TROUBLESHOOTING ENGINE OVERHEATING OVERHEATING 1、Improper spark plug gap Ignition system 2、Improper spark plug heat range 1、Improper fuel level Fuel system 2、Clogged air filter element Compression system Heavy carbon deposit 1、Improper oil level 2、Improper oil viscosity Engine oil 3、Inferior oil quality Brake Brake drag 1、Low coolant level...
Page 378: Shock Absorber Malfunction
TROUBLESHOOTING SHOCK ABSORBER MALFUNCTION Loss of damping function 1、Bent or damaged damper rod Shock absorber 2、Damaged oil seal lip 3、Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Steering column Improperly installed or bent 1、Incorrect toe-in 2、Bent steering shaft Steering 3、Improperly installed steering shaft 4、Damaged bearing 5、Bent tie-rods 1、Uneven tire pressures on both sides...
Page 379: Bulb Burnt Out
TROUBLESHOOTING BULB BURNT OUT 1、Improper bulb 2、Faulty battery 3、Faulty rectifier/regulator Bulb burnt out 4、Improperly grounded 5、Faulty main and/or lights switch 6、Bulb life expired ERROR DISPLAY OF METER 1、 Then sensor on rear axle is damaged or polluted by iron powder Wrong Speed 2、...

Hisun HS700UTV-4 Maintenance Handbook

Chapter 1 General Information

Watnings , Cautions and Notes

Description

Identification Code

Safety

Serial Numbers

Fasteners

Shop Supplies

Basic Tools

Precision Measuring Tools

Electrical System Fundamentals

Basic Service Methods

Storage

Trovbleshooting

Engine Principles and Operating Requirements

Starting the Engine

Engine will Not Start

Poor Engine Performance

Fuel System

Engine

Englne Lubrication

High Oil Consumption or Excessive

Cylinder Leak down Test

Electrical Testing

Test Procedures

Brake System

Chapter 2 Specifications

How to Use Conversion Table of Unit

Geberar Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Tightening Torques

General Tightening Torque Specifications

Lubrication Pionts and Lubricant Types

Hydrographic Chart

Lubrication Oil Way

Maintenance Schedule

CHAPTER 3 Adjusting the Valve Clearance

Engine

Chassis

Chapter 4 Engine

Engine Note

Engine Removal

Cylinder Head and Cylinder Head Cover

Rocker Arms and Camshaft

Valves and Valve Springs

Cylinder and Piston

Engine Cooling Fan and A.C. Magneto

Balancer Gears and Oil Pump Gears

Primary and Secondary Sheaves

Clutch

Clutch Housing

Crankcase Starter Motorand Oil Filter

Crankcase

Crankshaft and Oil Pump

Middle Gear

Chapter 5

Malfunction Inspection

DIRECTION SYSTEM the Steering Wheel Parts(EPA Type)

Brake System

Footrest Assembly

Wheel and Tyre Parts

Transmission System

Reverse Mechanism Parts

Suspension

Cooling System

Seat

Oil System

Fuel Tank

Chapter 6 Electrical Components

Electrical System Malfunction Inspection

Electrical

Electricalcomponents

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Starter Motor

Charging System