cectek Gladiator Service Manual
  1. Manuals
  2. Brands
  3. cectek Manuals
  4. Offroad Vehicle
  5. Gladiator
  6. Service manual

cectek Gladiator Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

GLADIATOR
&
QUADRIFT
SERVICE MANUAL

Advertisement

Table of Contents
loading

Related Manuals for cectek Gladiator

Summary of Contents for cectek Gladiator

  • Page 1 GLADIATOR & QUADRIFT SERVICE MANUAL...
  • Page 2 TOPIC Ⅰ - Power-train & Control System Introduction……………………………P1 Ⅱ - 500cc EFI Engine Service Manual…P20 Ⅲ - GLADIATOR & QUADRIFT Chassis Service Manual…………….P80 Ⅳ - Special Tools………………………….P141...

  • Page 3: Table Of Contents

    ▲ Power-train & Control System Introduction Engine Specification …….……..……….……… Engine Lubrication System …….……………….. Engine Breather System ………………………… CVT System ………………………..………………. Start System ………………………..……………… Injection System ……………………………...…… Emission Control System ……………………….. Cylinder Head/Block ……………………………… EMS System ……………………………………….. Electricity wiring Circuit ……….……..………….
  • Page 4 ▲ 500cc EFI Engine Service Manual DISMANTLE CVT Cover Dismantle ………..…..………..……… CVT Belt Dismantle ………………..…………..….. CVT Driven Pulley Dismantle ……..……………... CVT Driving Pulley Dismantle …..……………….. Rewind Starter Dismantle ……..……………..…... Timing Check ……………………..………………... Accessory Cover Dismantle.…………………….. Start Pressure Release Mechanism Dismantle.. Alternator Rotor Dismantle …………………..…...
  • Page 5 ▲ 500cc EFI Engine Service Manual ASSEMBLY The Piston And Connection Rod Assembly ..… The Balancer Assembly ..……………………..… The Balancer Assembly ………………….………. The Main Shaft Assembly ……………………...… The Lay Shaft Assembly ……………………….… The Rear Driveshaft Assembly ………………..… The Cylinder Head Assembly ………………..… The Water Pump Assembly …………………..….
  • Page 6 ▲ Chassis Service Manual SEAT REMOVAL........... INSTRUMENT COVER REMOVAL ...... SADDLE REAR COVER REMOVAL....SIDE SADDLE COVERS REMOVAL ....FRONT BUMPER COVER REMOVAL……….….. MAINTENANCE ACCESS PANEL REMOVAL..KEY POSITION COVER REMOVAL……………... FRONT RACK REMOVAL........FRONT COVER REMOVAL………………………. BATTERY REMOVAL........... DIRECTION INDICATION LIGHTER FLASHER REMOVAL……………………………………..…...
  • Page 7 ▲ Chassis Service Manual P115 LHS & RHS STEERING LINK REMOVAL..FRONT LHS & RHS BRAKE CALIPER P118 REMOVAL.…………………………………….…… FRONT LHS & RHS SHOCK ABSORBER P119 REMOVAL………………………………………….. P120 FRONT LHS & RHS HUB REMOVAL....P121 FRONT LHS & RHS A-ARM ASSY. REMOVAL.. P124 FRONT DIFFERENTIAL REMOVAL……………..

  • Page 8: Introduction

    Power Train & Control Power Train & Control Introduction Introduction...

  • Page 9: Engine Specification

    Engine Specification Type: 4 Stroke、Single Cylinder SOHC 、 4 Valve Displacement: 497 ㏄ Bore x Stroke: 90 x 78 mm Compression Radio: 10.0 Power: 15kW@5000rpm (homologation) Max Power: 30kW@7000rpm Torque: 40Nm@5500rpm Max. rev.: 7500rpm Transmission: CVT 、 V-belt Emission: 2002/51/EC Weight: 67kg...

  • Page 10: Engine Lubrication System

    Engine Lubrication System Left Side Right Side Piston、Liner Camshaft Lubrication: Wet Sump Oil Pump: Rotor Type Cylinder Con-Rod Oil Filter: Paper Type Crankshaft Crankshaft Oil Type: 10W40 SJ Pressure S/W Oil Volume: 3.0 L Balancer Balancer 3.5 L (Replace Filter) Gear Box Pressure Release: 4.5 kg/cm2 Oil Filter...

  • Page 11: Engine Breather System

    Engine Breather System Intake Side Exhaust Side Blow-by Gas Spec.: ≦10 L/min Air Box Piston Air Filter Con-Rod Breather Hose Blow-by gas Crankshaft Engine Oil...

  • Page 12: Cvt System

    CVT System CVT Belt Type: - DAYCO P/N: Off Road: 5324 CVT Belt On Road: 5324 - CVT: Drive Wheel Tightening Torque 40~45Nm Driven Wheel Tightening Torque 120Nm Ratio: Min. Max. 0.316 ~ 1.581 Engine Speed Limit: 7500rpm Drive Wheel Driven Wheel...

  • Page 13: Start System

    Start System Starter Specification: - CECTEK Type: 40196007 - Output: 0.7 kW - Operation Voltage: 12 V Ring Gear - Temperature Range: -10~+120℃ Starter Circuit Diagram : Key S/W Starter S/W Starter Relay Spin Nose Starter Rewind Starter Handler Battery...

  • Page 14: Injection System

    Injection System Cylinder Head Injector Air Flow Temperature Idle Air Control Valve air temp. IACV or TPS Intake Valve (IACV) coolant temp. … To calculate air flow and necessary fuel flow Fuel injection control Fuel Injection Intake Port Intake Air Injector Throttle Body ASM...

  • Page 15: Emission Control System

    Emission Control System Emission relational part: - ECU - Throttle Body ASM - Injector Throttle Body ASM - Spark Plug - Ignition Coil ASM - O2 Sensor Injector - Catalyst Catalyst : - 100 cells/in2 - Volume: 116 ㏄ O2 Sensor Emission: - Updated 2002/51/EC Ignition Coil ASM...

  • Page 16: Cylinder Head/Block

    Cylinder Head/Block Cylinder Head ASM Intake Valve *2 - Aluminum Alloy: AC4B+T6 - SOHC (Chain Drive) - 4 Valves - Spark Plug: Champion PRG7C Spark Plug Cylinder Block ASM - Liner Material: FC250 Exhaust Valve - Aluminum Alloy: ADC12 Cast-in Liner Spark Plug...

  • Page 17: Ems System

    EMS System Block Diagram Pin Assignment...
  • Page 18 Part Introduction ECU Type: MC21 1030 Assembly: Map Sensor Connector Connector Electrical Characteristic: Operation Voltage Range: 9~16V ECU Type: Storage Temperature Range: -40~70℃ MC21 1030 Operation Current: <500mA ECU Pin 28:...
  • Page 19 Injector Part Introduction Identification Code: 28140652 Identification Code: 28140652 Injector holes: 4ea Circuit Diagram : Main Power Relay Injector MPR: Pin 28 Measurement ECU Pin 28: Resistance: 12.0±0.6Ω...
  • Page 20 Throttle Body ASM Throttle Body Idle Air Control Valve (IACV) (Step Motor) Throttle Position Sensor (TPS)

  • Page 21: Throttle Body

    Throttle Body - TPS、Step Motor Part Introduction ECU Pin 21 TPS Circuit Diagram Pin 6 ECU Pin6: 5V Pin 21 Step Motor Circuit Diagram Step Motor Pin 24 Pin 25 Pin 34 Pin 33 Pin 33 Pin 34 Pin 25 Pin 24 Measurement (ECU Pin 21、GND) TPS Resistance: 1~2 kΩ...
  • Page 22 Rollover Sensor (Fuel-cut Sensor) OUTPUT Part Introduction Sensor Characteristic - Voltage: 12V (Vcc) - Pitch Angle: 65±10° - Roll Angle: -20~+20 ° - Temperature: -10~+60 ℃ Circuit Diagram Vcc: Left View Rollove OUTPUT Pin 11 Sensor Assembly - Bolt: M4 (2ea) - Tighten Torque: 1.5~2.5Nm Measurement - Vcc–OUTPUT: 3.9 kΩ...

  • Page 23: Fuel Pump

    Fuel Pump Sensor + Pump + Part Introduction meter Pin24 Pump Characteristic - Voltage: 12V (Pump -) - Feed Fuel Pressure: 250±10 kpa Pump - Sensor - - Feed Fuel Rate: 30.6 L/hr Min. Circuit Diagram meter Sensor + Sensor - Fuel Pump + Fuel Connector...

  • Page 24: Ignition Coil

    Ignition Coil Part Introduction Sensor Characteristic - Voltage: 12V (Vcc) - Temperature: -10~+60 ℃ Circuit Diagram Primary Secondary Spark Side PBT Black 12 V PBT Black + Coil Spark Side PBT Black Assembly Pin 27 - Bolt: M6 (2ea) - Tighten Torque: 10±2Nm Measurement - Primary: 2.9 Ω±10% - Secondary : 15 kΩ±10%...
  • Page 25 Alternator Part Introduction Crank Sensor Electric Characteristic Connector Rectifier - Voltage: 12V CNKN Connector - Output: 16V/1500rpm↑ CNKP Circuit Diagram Rectifier Vehicle Crank Sensor Crank Sensor...
  • Page 27 SERVICE MANUAL FOR 500cc EFI ENGINE...

  • Page 28: Cvt Cover Dismantle

    Only trained and certificated technician can disassembly the CECTEK RSGA 500 EFI ENGINE. Improper disassembly may damage the engine. CECTEK can not provide the warranty to the engine which has not been properly disassembled and assembled by trained and certificated technician.

  • Page 29: Cvt Belt Dismantle

    CVT BELT DISMANTLE Screw the Belt Removal Tool to end to open the driven pulley , then removal the belt The belt ※Reinstall , the installer must can read the printed word on the belt CVT DRIVEN PULLEY DISMANTLE Loosen the driven pulley bolt , then remove the driven pulley The Driven pulley...

  • Page 30: Cvt Driving Pulley Dismantle

    CVT DRIVING PULLEY DISMANTLE Loosen the driving pulley bolt Screw the CVT Puller by air wrench to remove the drive pulley The drive pulley REWIND STARTER DISMANTLE Loosen the rewind starter bolt*5...

  • Page 31: Timing Check

    The rewind starter TIMING CHECK before dismantle engine must be check the chain timing ※ Loosen the cam cover bolts*4 , then remove the cam cover Loosen the taper plug for check the timing Use the Rewind Starter Stooper clockwise rotate crankshaft then check chain timing...
  • Page 32 ALT rotor mark meet the accessory cover mark When ALT mark correct , then check cylinder head sprocket have six pieces counter from cylinder head six pieces...

  • Page 33: Accessory Cover Dismantle

    ACCESSORY COVER DISMANTLE Loosen the accessory cover bolt*11 Raise the accessory cover by screwdriver from the prominence of case When remove the accessory cover be care the spin nose antithrust spring and washer...
  • Page 34 START PRESSURE RELEASE MECHANISM DISMANTLE Loosen the discompressor mechanism bolt by open wrench Pull out the discompressor mechanism The discompressor mechanism , and notice the spring...
  • Page 35 ALTERNATOR ROTOR DISMANTLE Loosen the ALT rotor nut by air wrench ※The socket deep 85mm Screw Crankshaft Protector to end on crankshaft Screw the ALT Puller to end on ALT rotor Screw the CVT Puller on ALT Puller by air wrench , then remove the ALT rotor...

  • Page 36: Cam Shaft Dismantle

    CAM SHAFT DISMANTLE Loosen the tensioner cover , and O-ring notice the spring and O-ring cover spring Loosen the tensioner bolts*2 , then remove the tensioner Loosen the cam sprocket bolts*2 , then remove the cam sprocket Loosen the cam antitrust plate Bolt , then remove the plate...
  • Page 37 Pull out intake and exhaust rock arm shaft by magnet Pull out the cam shaft The rock arms and cam trust plate The cam shaft...

  • Page 38: Chain Dismantle

    CHAIN DISMANTLE Loosen the chain guide bolt , then remove the chain Notice the bosh The chain...

  • Page 39: Cylinder Head Dismantle

    CYLINDER HEAD DISMANTLE Loosen the cylinder head bolts*4 Remove the cylinder head , and notice the lock pins Remove the gasket and chain guide The cylinder head gasket and gasket chain guide guide...

  • Page 40: Balancer Dismantle

    BALANCER DISMANTLE Loosen the balancer cover bolts*8 Raise the balancer cover by screwdriver from the prominence of case Loosen the water pump idle bolt pulley bolt and unclip the oil pump gear clip clip The oil pump gear The water pump idle gear...

  • Page 41: The Oil Pump Dismantle

    Loosen the balancer bolts by use screwdriver stop the balancer The balancer THE OIL PUMP DISMANTLE Loosen the oil pump bolts*3 and unclip the oil pump gear clip The oil pump and back plate...

  • Page 42: The Driveshaft Dismantle

    Remove the spin nose and washer THE DRIVESHAFT DISMANTLE Loosen the front driveshaft yoke bolts , then remove the yoke Loosen the front driveshaft seal cover bolt*3 , then remove the cover The yoke The seal cover...
  • Page 43 Use the box end ( loosen ALT rotor nut ) , screw the Pull the front driveshaft and remove the 4WD gear The 4WD gear Remove the rear driveshaft yoke and seal cover ( same procedure of front driveshaft ) Loosen the front driveshaft yoke Loosen the starter bolts*2 , then bolts , then remove the yoke...

  • Page 44: The Oil Main Circuit Dismantle

    Loosen the shift drum cover bolts*7 Loosen the shift drum antitrust plate THE OIL MAIN CIRCUIT DISMANTLE Loosen the oil filiter cover Remove the oil filter...

  • Page 45: The Cylinder Block Dismantle

    Loosen the main circuit bolt , then remove the main circuit The main circuit THE CYLINDER BLOCK DISMANTLE Remove the rear driveshaft yoke and seal cover Reversal the engine , and loosen the oil sump bolts*12...
  • Page 46 Use scraper and hammer to open the oil sump The oil sump ※When reinstall must clean the surface of the oil sump Loosen the crankcase bolts*12 Raise the crankcase by screwdriver from the prominence of case...

  • Page 47: The Transmission Gear Dismantle

    The crankcase ※When reinstall must clean the surface of the crankcase THE TRANSMISSION GEAR DISMANTLE Remove the main shaft Remove the layshaft Remove the rear shaft...
  • Page 48 The cylinder block ※When reinstall must clean the surface of the crankcase Loosen the shift fork bolt , then pull out the shift fork shaft and remove the fork The shift fork Loosen the shift position rotor bolt , then remove the parking shaft plate...

  • Page 49: The Oil Release Valve Dismantle

    The shift position rotor and parking shaft plate THE PARTS ONLY APPLY THE VEHICLE HAVE GEAR PARKING FUNCTION Pull out the shift drum from the cylinder block The shift drum THE OIL RELEASE VALVE DISMANTLE Loosen the oil release valve bolt , then remove the oil release valve by magnet...

  • Page 50: The Crankshaft Dismantle

    The oil release valve THE CRANKSHAFT DISMANTLE Loosen the connecting rod bolts*2 Remove the connecting rod cap , then remove the crankshaft The cylinder block ※When reinstall must clean the surface of the crankcase...

  • Page 51: The Piston Dismantle

    THE PISTON DISMANTLE Pull out the piston ※Must clean the carbon on piston Piston ring inspection The second ring top side Loosen the speed sensor bolt , then remove the speed sensor...

  • Page 52: The Piston And Connection Rod Assembly

    Only trained and certificated technician can disassembly the CECTEK RSGA 500 EFI ENGINE. Improper disassembly may damage the engine. CECTEK can not provide the warranty to the engine which has not been properly disassembled and assembled by trained and certificated technician.
  • Page 53 5.The piston size mark on top ( A or B ) 6.Confirm： when you face the piston , the piston (4,5) exhaust mark is in the down side 7.Confirm：the connecting rod (1) right side mark R is same side of piston 8.Install one clip (3) into the piston clip groove firmly 9.Install pin (2) into pin groove...

  • Page 54: The Balancer Assembly

    THE BALANCER ASSEMBLY PART NAME PART NO. RETAIN E-RING RES009 GEAR (37T) 40150030 40130083 BALANCER SHAFT ASSY. 40128004 1.Install pin (2) into balancer shaft (1) 2.Install gear-oil pump driver (3) into balancer , reference to figure A 3.Clip the E-ring (4) check the retain E-ring install into the groove of balancer shaft...

  • Page 55: The Balancer Assembly

    THE BALANCER ASSEMBLY PART NAME PART NO. CRANKSHAFT 40110023 40110108 GEAR (36T) 40120018 PCAM CHAIN SPROCKET 41010004 NUT (M30) 40110024 1.Install key (2) into crankshaft (1) , keep the key parallel with crankshafttaper 2.Install gear (3) into crankshaft (1) , gear groove must be alignment key of crankshaft 3.Install cam chain sprocket (4) into crankshaft (1) , be shall...

  • Page 56: The Main Shaft Assembly

    THE MAIN SHAFT ASSEMBLY PART NAME PART NO. MAIN SHFAT 46030001 BEARING 46030034 SPACER 46010003 LIP SEAL 40016004 RETAIN C-RING RCS025 WASHER 46030010 NEEDLE BEARING (CAGE TYPE) 46030030 HIGH SPEED DRIVE GEAR (27T) 46030003 LOW SPEED DRIVE GEAR (18T) 46030004 NEEDLE BEARING (OPEN TYPE) 46030028 Before install gear and bearing , please lubricate with 10W/40 oil...

  • Page 57: The Lay Shaft Assembly

    THE LAY SHAFT ASSEMBLY PART NAME PART NO. LAY SHFAT 46030002 CYLINDRICAL ROLLER BEARING CRBNU1007NR NEEDLE BEARING (HALF CAGE TYPE) 46030031 LOW SPEED DRIVEN GEAR (45T) 46030007 RETAIN C-RING RCS030 HIGH SPEED DRIVEN GEAR (36T) 46030005 WASHER 46030010 HNEEDLE BEARING (CAGE TYPE) 46030030 REVERSE DRIVEN GEAR (34T) 46030008...
  • Page 58 Before install gear and bearing , please lubricate with 10W/40 oil 5.Install washer (7) into lay shaft , then install needle bearing (8) into lay shaft 6.Install reversal gear (9) into lay shaft , then put a washer (7) into lay shaft , be shall install reversal gear (9) of groove side into bevel gear side 7.Install retain C-ring (10) into lay shaft of groove...

  • Page 59: The Rear Driveshaft Assembly

    THE REAR DRIVESHAFT ASSEMBLY PART NAME PART NO. DRIVE SHAFT ASSY. 46058001 BEARING DGB6205 GEAR 46050023 WASHER 46050007 BOLT BFH080251094 WASHER 46050009-19 BEARING DGB6305 O-RING 46050025 Before install gear and bearing , please lubricate with 10W/40 oil 1.Press the bearing (2) into the shaft (1) thoroughly. 2.Install the gear (3) into shaft (1).

  • Page 60: The Cylinder Head Assembly

    THE CYLINDER HEAD ASSEMBLY (1/3) PART NAME PART NO. CYLINDER HEAD ASSY. 40058011 VALVE STEM SEAL 40056002 SEALING BALL 40070031 HEXAGON SOCKET SCREW SC050121291 VALVE SPRING WASHER 40050140 Please clean up correlative parts and lubricate with 10W/40 oil 1.Knock the 2 balls (2) into cylinder head (1) 2.Paste the screw (4) with LT272 , tighten to cylinder head with 5Nm 3.Install the washer (5) on the valve spring seat 4.knock valve stem seal (6) into valve guide , keep distance between...
  • Page 61 THE CYLINDER HEAD ASSEMBLY (2/3) PART NAME PART NO. VALVE (INTAKE) 40050133 VALVE (EXHAUST) 40050134 SPRING 40050135 SRIING CAP 40050136 VCOTTER 40056003 Please clean up correlative parts and lubricate with 10W/40 oil 1.Install valve spring (3) x4 on the valve spring washer 2.Install cotter (5) x2 on the spring cap (4) (4pcs) 3.Install assembled spring cap (3) on the spring , with jig press it into the valve stems until a clear "clik"...
  • Page 62 THE CYLINDER HEAD ASSEMBLY (3/3) PART NAME PART NO. CAM SHAFT 40070068 ROCKER ARM ASSY. (INTAKE) 40078016 ROCKER ARM ASSY. (EXHAUST) 40078017 SHAFT 40070063 PLATE 40070065 FLAT HEAD SCREW SCF060160883 Please clean up correlative parts and lubricate with 10W/40 oil 1.Install cam (1) through cam bore 2.Install intake rocker (2) on the cam shaft , the rocker face toward intake side.

  • Page 63: The Water Pump Assembly

    THE WATER PUMP ASSEMBLY PART NAME PART NO. ACCESSORY COVER 40010053 MACHANICLA SEAL 40136011 SHAFT 40130075 PROPELLER 40130071 WASHER 40130077 40130083 GEAR (35T) 40130063 40070064 RETAIN C-RING RCS012 12.1mm Please clean up correlative parts and keep dry 1.After install machianicla seal (2) on water pump shaft (3) and check the shaft have 12.1mm between macanicla seal and water pump shaft...

  • Page 64: The Shift Drum And Fork Assembly

    THE SHIFT DRUM AND FORK ASSEMBLY PART NAME PART NO. SHIFT DRUM ASSY. 46078002 SHAFT (SHIFT FORK) 46070013 SHIFT FORK (MAIN SHAFT) 46070001 SHIFT FORK (LAY SHIFT) 46070002 ＊ PARKING BREAK SHAFT 46070005 ＊ PARKING BREAK LEVEL 46070006 THRUST PLATE 46070022 BOLT BFH060120884...

  • Page 65: The Transmission Gear Assembly

    Shift locating rotor install position Install fork shift by plastic hammer and all parts lubricate THE TRANSMISSION GEAR ASSEMBLY Install lay shaft to cylinder block Then push it to position...
  • Page 66 Install rear drive shaft to cylinder block , then push it to position Install main shaft and push the needle bearing to position Lubricate oil release valve and install valve、spring guide into cylinder block Then screw the bolt ※Torque 10Nm...
  • Page 67 THE REAR IDLE GEAR ASSEMBLY PART NAME PART NO. SHAFT 46030009 O-RING 46030027 NEEDLE BEARING 46030032 REVERSE GEAR (27T) 46030006 WASHER 46030011 RETAIN C-RING RCH020 Please clean up correlative parts and lubricate with 10W/40 oil...
  • Page 68 THE CRANKCASE AND CYLINDER BLOCK ASSEMBLY PART NAME PART NO. CRANKCASE 40018014 MAIN BEARING (BLACK) 888.4001.607 MAIN BEARING (NO COLOR) 888.4001.608 MAIN BEARING (GREEN) 888.4001.609 No groove bearing for low crankcase The crankshaft mark position , have 3 marks EX：A 2 B ALT side CVT side...
  • Page 69 The cylinder block mark position , CVT side have 3 number EX：1 A 1 ALT side CYLINDER BLOCK CRANKCASE N：No color G：Green B：Black Choose bearing color and install to crankcase EX：cylinder block mark is 1 A 1 crankcase mark is A 2 B so we choose ALT side bearing color is No color (1&A) 1 A 1...
  • Page 70 THE CRANKCASE AND CYLINDER BLOCK ASSEMBLY PART NAME PART NO. CYLINDER BLOCK 40018014 MAIN BEARING (BLACK) 888.4001.613 MAIN BEARING (NO COLOR) 888.4001.614 MAIN BEARING (GREEN) 888.4001.615 CONROD ASSY. 40098013 BEARING (BLACK) 40096025 BEARING (YELLOW) 40096024 BEARING (BLUE) 40096023 Groove bearing for cylinder block...
  • Page 71 The connecting rod mark position EX：A CONNECTING ROD CRANKCASE Y：Yellow BL：Blue B：Black Choose bearing color and install to connecting rod EX：connecting rod mark is crankcase mark is A 2 B so we choose the bearing color is blue (A&2) A 2 B ※up and low bearing install the same color...
  • Page 72 THE BEARING AND CRANKSHAFT ASSEMBLY Lubricate all bearing Install crankshaft Lubricate all rotation position Before screw the two bolts , be lubricate connecting rod bolts ※Torque 20Nm + 90° + 90° (screw the two bolts equally)
  • Page 73 Lay the Case Assembly Glue on cylinder block according figure A and glue diameter about 1mm Figure A Keep away the main gallery Lay the glue diameter about 1mm Glue Path Main Gallery Install crankcase to cylinder block...
  • Page 74 Lubricate the bolt and washer , then screw it ※Torque 35Nm + 90° (screw the bolts equally) Install the cylinder block bolts The tighten torque 35Nm Install shift drum antithrust plate ※Torque 10Nm...
  • Page 75 Lay the Case Assembly Glue on shift drum cover ※Glue diameter about 1mm Install the shift drum cover ※The bolts torque 10Nm Reverse the engine , then screw the cylinder bolt ※The bolts torque 20Nm Install the main circuit ※The bolt torque 20Nm...
  • Page 76 Lubricate the balancer Install balancer gear , then check crankshaft gear mark to balancer half of gear position Lay the Bolt Glue on the bolt , then install the balancer plate ※The bolts torque 20Nm Lubricate the oil pump and rotor...
  • Page 77 The bolts torque 10Nm Install the oil pimp gear , then clip the E-clip Install the water pump idle gear , then tighten the bolt ※The bolts torque 10Nm Install the chain guide ※Torque 10Nm...
  • Page 78 Install the chain guide into cylinder block and notice the lock position Install the cylinder head gasket and lock pins Install the cylinder head Lubricate the cylinder head bolts and washer...
  • Page 79 Screw the cylinder bolts ※Torque 35Nm + 90° + 90° (screw the four bolts equally) ※The M6 bolts torque 10Nm Lubricate cam shaft Install the cam shaft into cylinder head Lubricate the rock arms and shafts , then install into cylinder head...
  • Page 80 Check the crankshaft gear mark the mark and balancer mark Between balancer mark to five gears crankcase mark line have five gears crankshaft sprocket mark Crank sprocket mark must correct to blue mark of chain When crank sprocket mark correct , then check cylinder head sprocket have six pieces counter from cylinder head six pieces...
  • Page 81 Install the tensioner and screw the bolts , then put the spring and screw the cover ※The bolts torque 10Nm ※The cover torque 10Nm Install discompressor Lay Bolt Glue on discompressor bolt , then screw it ※Torque 5Nm Install the thermostat ※Torque 10Nm...
  • Page 82 Install the cylinder head cover , then screw the bolts ※Torque 10Nm Install the spark plug ※Torque 10~12Nm Lubricate the spin nose and , then install into cylinder block Install the fly wheel assy. and ALT rotor , then screw the nut ※Torque 200Nm...
  • Page 83 Check 4WD gear groove correct to low crankcase groove Lay the Case Assembly Glue on accessary cover ※Glue diameter about 1mm Install accessary cover , then screw the bolts ※The bolts torque 10Nm Install the drive shaft seal cover , then screw the bolts ※The bolts torque 10Nm...
  • Page 84 Lay the Bolt Glue on drive yoke bolt , then install drive yoke ※The bolts torque 20Nm Lay the Case Assembly Glue on balancer cover ※Glue diameter about 1mm Install balancer cover , then screw the bolts ※The bolts torque 10Nm Lay the Case Assembly Glue on oil sump cover ※Glue diameter about 2mm...
  • Page 85 Install oil sump , then screw the bolts ※The bolts torque 10Nm Install the CVT drive pulley , then screw the bolt ※The bolts torque 120Nm Install the driven pulley , then screw the bolt ※The bolts torque 45Nm Screw the Belt Removal Tool to end to open the driven pulley , then install the belt...
  • Page 86 Then rotate driven pulley check the belt on position Install the CVT cover , then screw the bolts ※The bolts torque 10Nm The engine assembly complete...
  • Page 87 SERVICE MANUAL FOR GLADIATOR & QUADRIFT CHASSIS...

  • Page 88: Seat Removal

    SEAT REMOVAL 1. Turn the steering handle to the dead left position. 2. Push the key and turn it to “SEAT OPEN” position. 3. Then you will hear the latch release sound “Click”. 4. Lift the seat up and draw the seat backward to remove the seat.
  • Page 89 2. Lift the front instrument cover up from the bottom and separate if from the rear instrument cover. 3. Remove the 4 screws on the rear instrument covers. 4. The screws may fall into the chassis, be careful in catching the screws.

  • Page 90: Saddle Rear Cover Removal

    SADDLE REAR COVER REMOVAL 1. Turn the steering handle to the dead left position. 2. Remove the screw latch on the right forward corner of saddle upper cover. 3. Remove the screw latch on the left forward corner of saddle upper cover.

  • Page 91: Side Saddle Covers Removal

    5. Pull the upper saddle cover backward and the lift it up to remove the cover. SIDE SADDLE COVERS REMOVAL (LHS & RHS are in same process) 1. Must remove the upper saddle cover before removing side saddle cover. 2. Remove the frame fastening screw.

  • Page 92: Front Bumper Cover Removal

    6. Remove the front upper latch screw. 7. Pull the cover backward (direction 1). 8. Slightly lift the cover up and pull the cover upward (direction 2) for removing the cover. Reversely perform the below FRONT BUMPER COVER REMOVAL process to install. 1.
  • Page 93 3. Remove the RHS screw on the cover. 4. When install torque 10Nm 5. Remove the LHS screw on the cover. 6. When install torque 10Nm 7. Pull the cover forward to remove the cover from bumper.

  • Page 94: Maintenance Access Panel Removal

    Reversely perform the below MAINTENANCE ACCESS PANEL REMOVAL process to install. 1. Insert your two fingers into the latch hole. Press the latch to release the panel. 2. Slide the panel out under the front rack. 3. Note: for ATV Quadrift 500 EFI, There is not rack above the maintenance access panel.

  • Page 95: Front Rack Removal

    2. Hold the key position cover and turn it counterclockwise to dead left point. 3. Pull the key position cover out from the key hub. It could be easier that using you finger as a stop then drawing the cover out.

  • Page 96: Front Cover Removal

    3. Remove the two bolts under the LHS front cover. 4. When install torque 10Nm. 5. Remove the front rack. FRONT COVER REMOVAL Reversely perform the below process to install. 1. Remove 12V accessory plug connector.
  • Page 97 2. Disconnect the headlight and direction light connectors. headligh direction 3. The connectors are latched, pull the latch outward and disconnect the connectors. 4. Remove the RHS 3 front cover latch screws and LHS 3 front cover latch screws. 5. Remove the RHS front mask cover bolt above the bumper.
  • Page 98 6. Remove the LHS front mask cover bolt above the bumper. 7. Pull the foot brake fluid reservoir out from the cover. 8. Release the foot brake fluid reservoir latch. 9. Pull the foot brake fluid reservoir tube out from the latch gap.

  • Page 99: Battery Removal

    10.Put the reservoir on the upper right corner of the front cover. 11. Pull the cove up and make sure and make sure there are no connected wires and tubes. 12. Separate the cover and frame. BATTERY REMOVAL Reversely perform the below process to install.
  • Page 100 2. Remove the strip form the other hook. 3. Remove the Negative(－) pole screw of harness. 4. Remove the Positive (+) pole screw of harness. 5. Pull the battery out form the chamber.

  • Page 101: Direction Indication Lighter Flasher Removal

    DIRECTION INDICATION LIGHTER Reversely perform the below FLASHER REMOVAL process to install. 1. Press the connector latch down and pull the connector out form the flasher. 2. Pull the rubber mount form the cover. 3. Remove the flasher form the rubber mount.

  • Page 102: Relays Removal

    3. Remove the Front mounting screw. 4. Remove the rear mounting screw. RELAYS REMOVAL Reversely perform the below process to install. 1. Press down the relay connector latch. 2.Remove the connector out form the relay.

  • Page 103: Rear Rack Removal

    3. There are totally 7 relays in the chamber under the seats. Relay 1 to 6 are exactly same specifications. Relay 7 is the main switch relay. REAR RACK REMOVAL Reversely perform the below process to install. 1. Remove 2 RHS bolts under the rear cover.

  • Page 104: Rear Cover Removal

    Reversely perform the below REAR COVER REMOVAL process to install. 1. Remove the RHS tail lights connector. 2. Remove the LHS tail lights connector. 3. Cut the RHS & LHS taillight harness strip. 4. Remove the latch screws between rear cover and rear fender.
  • Page 105 5. Remove the LHS screw on the license plate frame under rear cover. 6. Remove the RHS screw on the license plate frame under rear cover. 7. Remove the LHS screw near the taillight. 8. Remove the RHS screw near the taillight.
  • Page 106 9. Remove the fuel tank cap. 10. Install the fuel tank back but under the cover. 11. Pull the harness out form the rear cover. 12. Remove the rear cover.
  • Page 107 Reversely perform the below LHS & RHS FOOT REST COVERS process to install. REMOVAL 1. Remove the screw on the passenger foot rest mount cover. 2. Remove the passenger foot rest chamber mount cover. 3. Remove the 5 bolts on the foot rest cover.
  • Page 108 REAR BOTTOM PROTECTOR Reversely perform the below REMOVAL process to install. 1. Remove the 2 bolts on the rear side of rear bottom protector. 2. When install torque 10Nm 3. Remove the 2 bolts on the LHS and RHS of rear bottom protector.
  • Page 109 FRONT LHS & RHS FENDER Reversely perform the below REMOVAL process to install. 1. Remove the 4 bolts on the fender and lift the fender up to remove it. 2. When install torque 10Nm FRONT LHS & RHS A-ARM Reversely perform the below PROTECTOR REMOVAL process to install.

  • Page 110: Air Filter Box Removal

    Reversely perform the below AIR FILTER BOX REMOVAL process to install. 1. Remove the 2 bolts on the from seat clamp. 2. When install torque 10Nm. 3. Remove the seat clamp. 4. Release the air filter upper cover latches. 5. Remove the air filter upper cover.
  • Page 111 6. Cover the air filter by clean lining to prevent foreign object. 7. Remove the bolt in the front side of air filter box. 8. Remove the LHS bolt on the lower air filter box. 9. Remove the RHS bolt on the lower air filter box.
  • Page 112 11. Reinstall the upper air filter box 12. Press the latch down and disconnect harness form the IAT sensor connector. 13. Release the clamp between throttle body and inlet. 14. Release the clamp on engine blow-by tube.
  • Page 113 15. Remove engine blow-by tube. 16. Cover the engine blow-by outlet by tape. 17. Turn the air filter box counterclockwise along the engine center datum. 18. Lift the air filter box up to remove it.

  • Page 114: Fuel Tank Removal

    19. Cover the throttle body inlet by tape. FUEL TANK REMOVAL 1. Disconnect the fuel pump power harness connector. 2. Press the latch on the both side of fuel line connector to remove fuel line from fuel pump outlet. 3. Cover the fuel line connector by tape.
  • Page 115 4. Cover the fuel pump outlet by tape. 5. Release the CVT ventilation outlet tube clamp. 6. Press the CVT ventilation outlet rubber adapter to remove the CVT ventilation outlet tube. 7. Remove the CVT ventilation outlet tube from the fuel tank protector.
  • Page 116 8. Pull the CVT ventilation outlet tube out form the frame. 9. Cover the CVT cover outlet by tape. 10. Remove RHS front fuel tank mounting bolt. 11. Remove RHS rear fuel tank mounting bolt.
  • Page 117 12. Remove LHS fuel tank mounting bolt. 13. When install torque 10Nm. 14. Slightly lift the LHS of fuel tank up and push the RHS of fuel tank down. 15. Slightly rotate the fuel tank along the center datum of ATV and pull the tank out from the frame.

  • Page 118: Exhaust Pipe Removal

    17. Confirm no fuel spilled on the frame. EXHAUST PIPE REMOVAL 1. Release the exhaust pipe clamp bolt. 2. Release the font bolt of muffler mounting but not remove. 3. When install torque 20Nm. 4. Remove the rear bolt of muffler mounting but not remove.
  • Page 119 5. Hold the muffler and then remove the mounting bolts. 6. Slightly rotate the muffler and pull it back to remove the muffler. 7. Press the connector latch and disconnect the O2 sensor harness connector. 8. Hold the front exhaust pipe and remove the mounting nut on the cylinder head.

  • Page 120: Front &Rear Wheel Removal

    9. Confirm: the exhaust pipe gasket is complete without crack, damage, or break. FRONT & REAR WHEEL REMOVAL 1. Release the wheel nut by the sequences as the mark: (1)-(2)-(3)-(4). 2. Remove the wheel nut to remove the wheel from the hub. 3.

  • Page 121: Front Propeller Shaft Removal

    FRONT PROPELLER SHAFT REMOVAL 1. Remove the cutter pin on the hub nut. 2. Remove the hub nut. 3. When install torque 100Nm. 4. Remove the 4 bolts on the front engine output shaft coupling. 5. When install torque 25Nm. 6.
  • Page 122 7. Remove 4 bolts on the differential propeller shaft coupling and then remove the propeller shaft. REAR PROPELLER SHAFT REMOVAL 1. Remove the cutter pin on the hub nut. 2. Remove the hub nut. 3. When install torque 100Nm. 4. Remove the 4 bolts on the rear engine output shaft coupling.

  • Page 123: Lhs & Rhs Steering Link Removal

    5. Slide the propeller shaft out form the engine output coupling. 6. Remove 4 bolts on the differential propeller shaft coupling. 7. When install torque 25Nm. 8. Slide the propeller shaft out form the differential input coupling. LHS & RHS STEERING LINK REMOVAL 1.
  • Page 124 2. Remove the cutter pin on the ball joint mounting nut. 3. When install torque 30Nm. 4. Remove the ball joint mounting nut. 5. When install torque 30Nm. 6. Remove the nut and washer. 7. Remove the ball joint form knuckle by ball joint puller.

  • Page 125: Front Lhs & Rhs Brake Caliper Removal

    8. Remove the steering link. 9. Remove the cutter pin form the ball joint nut on the steering column plate. 10. Remove the ball joint nut on the steering column plate. 11.When install torque 30Nm. FRONT LHS & RHS BRAKE CALIPER REMOVAL 1.

  • Page 126: Front Lhs & Rhs Shock Absorber Removal

    3.Release brake tube clamp. 4.Remove the brake caliper. FRONT LHS & RHS SHOCK ABSORBER REMOVAL 1. Hang the front upper A-arm by rope. 2.Remove the shock upper mounting bolt and nut. 3.When install torque 40Nm.

  • Page 127: Front Lhs & Rhs Hub Removal

    4.Remove the shock lower mounting bolt and nut. 5.When install torque 40Nm. 6.Remove the shock absorber. FRONT LHS & RHS HUB REMOVAL 1.Hang the front upper A-arm by rope. 2.Remove the hub nut. 3.When install torque 100Nm.
  • Page 128 4.Remove the hub nut and washer. 5.Use the hub CV joint bolt as the support to pull the hub out with the brake disk. FRONT LHS & RHS A-ARM ASSY. REMOVAL 1.Remove the cutter pin on lower A-arm knuckle ball joint bolt. 2.Remove the nuts and washers.
  • Page 129 4.Use ball joint puller to remove the front knuckle from the lower A-arm. 5.Remove the cutter pin on the upper A-arm ball joint bolt. 6.Remove the nut and washer on the upper A-arm ball joint bolt. 7.When install torque 30Nm. 8.Remove the knuckle form the upper A-arm.
  • Page 130 9.Remove the upper A-arm mounting bolt and washer. 10.Remove the upper A-arm. 11.Remove the lower A-arm front mounting bolt and nut. 12.When install torque 40Nm. 13.Remove the lower A-arm rear mounting bolt and nut. 14.When install torque 40Nm.
  • Page 131 FRONT DIFFERENTIAL REMOVAL 1.Drain the differential oil. 2.Re-add 325 ± 20c.c Recommend oil type PENNZOIL 4096 80W-90 GL-5 3.Hold the drive shaft and tug the drive shaft horizontally. 4.Cover the differential by tape. 5.Disconnect the differential lock motor harness.
  • Page 132 6. Remove the front differential mounting bolts. 7.When install torque 40Nm. 8. Remove the rear differential mounting bolts. 9.When install torque 40Nm. 10. Lift the differential up from the mounting bracket. 11. Rotate the differential vertically and horizontally by 90 degree.

  • Page 133: Rear Lhs & Rhs Brake Caliper Removal

    12. Pull the differential out from the frame. 13.Remove the differential. REAR LHS & RHS BRAKE CALIPER REMOVAL 1.Remove the 2 brake caliper mounting bolts. 2.When install torque 25Nm. 3.Release the brake tube clamp and remove the caliper.

  • Page 134: Rear Lhs & Rhs Hub Removal

    REAR LHS & RHS HUB REMOVAL 1.Hang the rear A-arm by rope. 2.Remove the hub nut. 3.When install torque 100Nm. 4.Remove hub nut and washer. 5.use the hub bolt as a support to pull the hub with disk out.

  • Page 135: Rear Lhs & Rhs Shock Absorber Removal

    REAR LHS & RHS SHOCK ABSORBER REMOVAL 1.Hang the A-arm by rope. 2.Remove the shock absorber upper mounting bolt and nut. 3.When install torque 40Nm. 4.Remove the shock absorber lower mounting bolt and nut. 5.When install torque 40Nm. 6.The nut of rear RHS shock upper mounting should be put toward front of ATV.

  • Page 136: Rear Lhs & Rhs A-Arm Assy. Removal

    7.The nut of rear LHS shock upper mounting should be put toward rear of ATV. REAR LHS & RHS A-ARM ASSY. REMOVAL 1.Remove the knuckle upper mounting bolt and nut. 2.When install torque 40Nm. 3.Remove the knuckle lower mounting bolt and nut. 4.When install torque 40Nm.
  • Page 137 7.Remove the rear upper A-arm Assy. 8.Remove the lower A-arm front mounting bolt and nut. 9.When install torque 40Nm. 10.Remove the rear lower A-arm after mounting bolt and nut. 11.When install torque 40Nm. 12.Remove the rear lower A-arm assy.

  • Page 138: Rear Differential Removal

    REAR DIFFERENTIAL REMOVAL 1.Drain the differential oil. 2.Re-add 325 ± 20c.c Recommend oil type PENNZOIL 4096 80W-90 GL-5 3.Hold the drive shaft and tug the drive shaft horizontally. 4.Cover the differential by tape. Rear Differential Removal and Installation...
  • Page 139 1.Disconnect the rear differential lock harness. 2.Remove the rear mounting bolt and nut. 3.When install torque 40Nm. 4.Remove the front mounting bolt and nut. 5.When install torque 40Nm. 6.Lift the differential up from the mounting bracket.

  • Page 140: Ecu Removal

    7.Rotate differential along the center datum of ATV. 8.Pull the differential backward to remove it from frame. ECU REMOVAL 1.Remove the MAP tube from the ECU. 2.Press the connector latch down and pull the harness down.

  • Page 141: Radiator Removal

    3.Remove the ECU harness connector. 4.Remove rear ECU mounting bolts. 5.When install torque 10Nm. 6.Remove front ECU mounting bolts. RADIATOR REMOVAL 1.Release the lower radiator outlet tube clamp.
  • Page 142 2.Remove the lower radiator outlet tube. 3.drain all of the coolant. 4.Disconnect the coolant temperature sensor connector. 5.Remove the radiator cap mounting bolt.

  • Page 143: Instrument Removal

    6.Remove the 4 radiator mounting bolts. 7.When install torque 40Nm. 8.Pull the radiator forward to remove it. INSTRUMENT REMOVAL 1.Press the connector latch down. 2.Pull the harness connector down to remove it.

  • Page 144: Front Brake Pad Removal

    3.Remove the two mounting bolts to remove the instrument. FRONT BRAKE PAD REMOVAL 1.Remove the 2 front brake pad mounting 2.Push the brake pad piston to retract position. 3.Pull the brake pad (1) out.

  • Page 145: Rear Brake Pad Removal

    4.Remove the brake pad (1). 5.Remove the brake pad (2). 6.Inspect the brake pads. REAR BRAKE PAD REMOVAL 1.Push the caliper bracket to retract the piston.

  • Page 146: Foot Brake Paddle Removal

    2.Push the caliper bracket to retract the piston. 3.Remove the brake pads. FOOT BRAKE PADDLE REMOVAL 1.Remove the cutter pin on the foot brake cylinder link pin. 2.Remove the foot brake cylinder link pin.
  • Page 147 3.Remove the foot brake paddle hub screw. 4.When install torque 10Nm. 5.Remove the brake switch spring. 6.Push the cylinder piston back. 7.Pull the paddle backward to remove it.

  • Page 148: Special Tools

    SPECIAL TOOLS...
  • Page 149 TOOL PHOTO TOOL NUMBER & NAME 991000001 EMS DIAGNOSTIC KIT ASSY. ◎ Include： 991000002 991000003 991000004 991000002 EMS DIAGNOSTIC SOFTWARE 991000003 EMS DIAGNOSTIC CABLE 991000004 EMS DIAGNOSTIC USB ADAPTOR...
  • Page 150 TOOL PHOTO TOOL NUMBER & NAME 991000005 REMOVER – ALTERNATOR ROTOR ASSY. ◎ Include：991000006 991000007 991000008 991000006 CRANKSHAFT PROTECTOR 991000007 HOLDER – ALTERNATOR REMOVER 991000008 PULLER – CVT & ALTERNATOR M12＊1.5...
  • Page 151 TOOL PHOTO TOOL NUMBER & NAME 992000001 SPANNER – FUEL RETAINER 992000002 REWIND STARTER STOPPER 888.4002.653.B1 CASE ASSEMBLY GLUE ( 1207F ) Brand：ThreeBond Type：1207F (Liquid Gasket Black Silicone Type) Volume：333ml 888.4002.670.B BOLT GLUE ( T272 ) Brand：Loctie Type：272 Volume：250ml...

This manual is also suitable for:

Quadrift

Table of Contents