@Jodi Looks like a one way bearing. Amazon is the place to get it. Make sure that when you install the new one, that the letters on the bearing are facing towards you (away from the engine). We replaced the whole wet clutch system and ours now works great. There is a great video on youtube on how to do it. Took about 4 hours with me and the kids. Here is a link to the part we used. https://www.amazon.com/dp/B07DNQMT9L?ref=fed_asin_title Also here is a link to the sheave that we also replaced while doing this. https://www.amazon.com/dp/B0C1JLSX2C?ref=fed_asin_title Here is a link to the belt that we used. https://www.amazon.com/dp/B092YZ69T5?ref=fed_asin_title Ours is a Cub Cadet challenger 700. They are all the same for the most part.

Dale

March 27, 2025

@Dale My mistake. It is a seal. I can tell better once i opened the picture. That seal is in the parts that the link leads to.

Dale

March 27, 2025

@Jodi link to seal is: https://www.amazon.com/Chikia-Massimo-Coleman-Challenger-2004-2007/dp/B0822FDLDM/ref=sr_1_5?crid=35T7B1T9YPQY4&dib=eyJ2IjoiMSJ9.HLZFWOi2KItDuMyQOTNwZqknHQNtPgpXGVy6Br0WpTjMis1seC087RLMclZXK1NGyYOgX7CMNDBn9cjN1lMXdV_2Nwxd2_MXV4EBxpZwr-_3vaDyEDiHe79QPdQ7rsIas0j27rjkseR2xhkOj_O_I5Bn1vXREEN3yxaeWTlG_tYlJ8bPJq-LxbatsxBejUSgA_FYRqV8Zf5oG5Al1CxaBu9u_6IKHrDMOHJWtzo24QruEVhBMBuAM_KlTy44wjOsG5YcKDhOg_pPadSajA68NYJjJDfEZAvfNWA-8Mqg1cSLm-ZRpjJg_KAdnQCxLjPbJlIiy0-RlcLPVNmFPnCSbanFXnv9vUi96_OV5jYJEqY.0k-Up5O5O96NJgwQuUN7Af85TmVECZ_IYCum2JovDaQ&dib_tag=se&keywords=hisun+700+wet+clutch+seal&qid=1743113630&s=automotive&sprefix=hisun+700+wet+clutch+seal%2Cautomotive%2C164&sr=1-5

Ashley

March 14, 2025

What is FOO 14

Chick

March 25, 2025

Which way does the air filter go with the hole at the top or bottom?

Summary of Contents for Cub Cadet Challenger Series

Page 1 SERVICE MANUAL Challenger 550 & 750...
Page 2 Foreword Brief introduction to the service and maintenance handbook for 550/750 Challenger UV This manual gives methods to check, maintain and repair the Cub Cadet 550 & 750 utility vehicles (UV’s), and supplies some relevant techniques and performance data. Please read the handbook through and fully understand it; otherwise, any improper repairing could cause problems, and or an accident may occur.
Page 3 INDEX Chapter 1 Chapter 1 General General Chapter 3 Chapter 2 Periodic Specifications Maintenance and Adjustments Chapter 5 Chapter 4 Chassis Engine Chapter 6 Chapter 7 Engine Electrical Management System Chapter 8 Diagram Troubleshooting...
Page 4 INDEX General Information Electrical System Fundamentals 1-24 Voltage 1-24 Chapter 1 Resistance, Amperage 1-25 Basic Service Methods 1-25 Warning, Caution, Note Removing Frozen Fasteners 1-27 Description Removing Broken Fastener 1-27 Vehicle Identification Code, Engine Stud Removal, Removing Hoses 1-28 Number Bearings 1-28 Safety...
Page 5 INDEX Brake lines, Bleeding the Brake 3-21 Crankcase, Starter Motor and Oil 4-31 Select Lever Shift Rod adjustment 3-24 Filter Checking Final Gear Oil 3-25 Crankcase 4-32 Adjusting Toe In 3-26 Bearings 4-33 Front Shock Adjustment 3-27 Inspection 4-34 Brake light switch adjustment 3-27 Assembly 4-35...
Page 6 INDEX Front Wheel and Tire 5-30 Brake Master Cylinder 5-26 Rear Wheel 5-31 Inspection, Installation 5-27 Inspection, Installation 5-32 Footrest Assembly 5-28 Transmission Front Bridge 5-33 Starter Motor Troubleshoot 6-16 Front Bridge Removal 5-34 Starter Motor Removal 6-17 Disassembly 5-38 Charging Circuit Diagram 6-18 CV Joint Inspection...
Page 7 Vehicle Identification Number 123456 Manufacturer UV below 750cc UV above 750 cc 550cc 750cc DOT Check Digits 2017 Model Year 2018 Model year 2019 Model Year 2020 Model Year 2021 Model Year Manufacturing Plant A Manufacturing Plant B 12345 123456 Sequential Serial Number...
Page 8 General Information This manual provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photographs and illustrations created during the complete disassembly of Utility Vehicles (UV) 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 UV for the first time.
Page 9 General Information Description 1. Front bumper assy. 2. Headlights 3. Front shock absorber 4. Brake pump 5. Steering wheel 6. Left door comp. 7. Driver seat belt 8. Cargo bed 9. Rear shock absorber 10. Tail lights 11. Muffler 12. Invert bracket assy 13.
Page 10 General Information Engine Identification Number Part Three consists of Feature code I, year code, Feature code II, month code and serial number Rear Spacer Serial Number Month Code Feature Code II Year Code Feature Code I Spacer Feature Code I Configuration Code Configuration...
Page 11 General Information Identification Code Vehicle Identification Number Vehicle Identification number is stamped in the lower right side of the frame. Engine Number Engine number is printed on a white tag on top of the clutch cover. 1‐3...
Page 12 General Information 9. Keep your work area clean and Safety organized. 10. Wear eye protection anytime the Professional mechanics can work for safety of the eyes is in question. many years and never sustain a serious This includes procedures that injury or mishap.
Page 13 General Information fire and makes it more difficult to Handling Gasoline put out. Use a class B, BC or ABC fire extinguisher to safely extinguish the fire. 8. Always turn off the engine before Gasoline is a volatile flammable liquid refueling.
Page 14 General Information 9. Thoroughly clean all oil, grease Fasteners and cleaner residue from any part that must be heated. Proper fastener selection and 10. Use a nylon brush when cleaning installation is important to ensure the parts. Metal brushes may cause UV operates as designed and can be a spark.
Page 15 General Information Applications, a cotter pin and castellated Self-Locking Fasteners (slotted) nut is used. To use a cotter pin, first make sure the diameter is correct Several types of bolts, screws and nuts for the hole in the fastener. After incorporate a system that creates correctly tightening the fastener and interference between the two fasteners.
Page 16 General Information E-clips are used when it is not practical Observe the following when installing to use a snap ring. Remove E-clips with snap rings a flat blade screwdriver by prying between the shaft and E-clip. To install an E-clip, center it over the shaft groove 1.
Page 17 General Information based, but synthetic and semi-synthetic Engine Oils types are used more frequently. When selecting engine oil, follow the Engine oil for the UV four stroke engine manufacturer’s recommendation for is classified by two standards: the type, classification and viscosity. American Petroleum Institute (API) service classification and The Society of Greases...
Page 18 General Information and moisture free brake fluid. Never as it may damage finishes. Most reuse brake fluid. Keep containers and solvents are designed to be used with a reservoirs properly sealed. parts washing cabinet for individual component cleaning. For safety, use only nonflammable or high flash point Warning solvents.
Page 19 General Information Quality tools are a good investment. Thread locking Some of the procedures in this manual Compound specify special tools. In many cases the tools is illustrated in use. Those with a large tool kit may be able to perform the A thread locking compound is a fluid jobs, however, in some cases, the applied to the threads of fasteners.
Page 20 General Information Quality Phillips screwdrivers are Wrenches manufactured with their crosshead tip machined to Phillips Screw Company Open-end, box-end and combination specifications. Poor quality or damaged wrenches (figure 5) are available in a Phillips screwdrivers can back out and variety of types and sizes. round over the screw head.
Page 21 General Information Adjustable Wrenches Socket Wrenches, Ratchets and Handles An adjustable wrench or Crescent wrench (Figure 6) can fit nearly any nut Sockets that attach to a ratchet handle or bolt head that has clear access (Figure 7) are available with 6-point or around its entire perimeter.
Page 22 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 bit (Figure 10) are available from most tool suppliers.
Page 23 General Information Allen Wrenches Use Allen or setscrew wrenches (Figure on fasteners with hexagonal recesses in the fastener head. These wrenches are available in L-shaped bar, Socket and T-handle types. A metric set is required when working on most UTV’s. Allen bolts are sometimes called socket bolts.
Page 24 General Information Pliers Snap Ring Pliers Pliers come in a wide range of types and sizes. Pliers are useful for holding, Snap ring pliers are specialized pliers cutting, bending, and crimping. Do not with tips that fit into the ends of snap use them to turn fasteners.
Page 25 General Information Hammers Make the tool shown from a No.6 screw and nut, two washers, length of tubing, Various types of hammers are alligator clip, electrical eyelet and a available to fit a number of length of wire applications. Use a ball-peen hammer to strike another tool, such as a punch Precision Measuring or chisel.
Page 26 General Information Refer to the following sections for specific measuring tools. Feeler Gauge Calipers are available in dial, Vernier or digital versions. Dial calipers have a dial readout that provides convenient reading. Vernier calipers have marked scales that must be compared to determine the measurement.
Page 27 General Information Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter (Figure 22). While there are many types and styles of micrometers, most of the procedures in this manual call for an outside micrometer.
Page 28 General Information Adjustment Care Micrometers are precision instruments. Before using a micrometer, check its They must be used and maintained with adjustment as follows: great care. Note the following: Clean the anvil and spindle faces. 1. Store micrometers in their To check a 0-1 in.
Page 29 General Information Standard Inch Micrometer The standard inch micrometer (Figure 26) is accurate to one-thousandth of an inch or 0.001. The sleeve is marked in 0.25 in. increments. Every fourth sleeve mark numbered 1,2,3,4,5,6,7,8,9. These numbers indicate 0.100, 0.200, 0.300, and soon. When reading a metric micrometer, add the number of millimeters and half- The tapered end of the thimble has 25...
Page 30 General Information 2. Count number lines between the numbered sleeve mark and the edge of the thimble. Each sleeve mark equals 0.025 3. Read the thimble mark that aligns with the sleeve line. Each thimble mark equals 0.01in 4. Add the readings from Steps1-3. Telescoping and Small To use a telescoping gauge, select the correct size gauge for the bore.
Page 31 General Information Dial Indicator A dial indicator (Figure 31) is a gauge with a dial face and needle used to measure variations in dimensions and movements. Measuring brake rotor run out is a typical use for a dial indicator. Dial indicators are available in various ranges and graduations and with three basic types of mounting bases: magnetic (B.
Page 32 General Information 4. If necessary, rotate the meter ohms Multi meter adjust knob until the needle and 0 mark align. A multi meter (Figure 34) is an essential tool for electrical system Electrical System diagnosis. The voltage function indicates the voltage applied or Fundamentals available to various electrical components.
Page 33 General Information Resistance Basic Service Methods Most of the procedures in this manual Resistance is the opposition to the flow of electricity within a circuit or component and are straightforward and can be is measured in ohms. Resistance causes a performed by anyone reasonably reduction in available current and voltage.
Page 34 General Information Where possible. Heat can available, have these operations warp, melt or affect the temper performed by a shop equipped of parts. Heat also damages with the necessary equipment. the finish of paint and plastics. Do not use makeshift equipment that may damage the UV.
Page 35 General Information 17. Whenever rotating parts contact Removing Broken a stationary part, look for a shim or washer. Fasteners 18. Use new gaskets if there is any If the head breaks off a screw or bolt, doubt about the condition of old several methods available...
Page 36 General Information brush. Clean the inside of the hose Stud thoroughly. Do not use any lubricant Removal/Installation when installing the hose. Lubricant may allow the hose to come off the fitting, even with the clamp secure. A stud removal tool (Figure 38) is available from most tool suppliers.
Page 37 General Information wooden or aluminum spacer (Figure 41). Removing Bearings 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 38 General Information Installation 1. When installing a bearing in a housing, apply pressure to the outer bearing race (Figure 43). When installing a bearing on a shaft, apply pressure to the inner bearing race (Figure44). 4. Step 1 describes how to install a bearing in a case half or over a shaft however, when installing a bearing over a shaft and into the housing at...
Page 39 General Information Interference Fit Remove the housing from the oven or Follow this procedure when installing a hot plate, and hold onto the housing with bearing over a shaft. When a tight fit is welding gloves. It is hot! Hold the required, the bearing inside diameter is housing with the bearing side down and smaller than the shaft.
Page 40 General Information Seal Replacement Storage Seals (Figure 47) contain oil, water, and Several months of non-use can cause a grease or combustion gasses in a general deterioration of the UV. This is housing or shaft. Improperly removing a especially true in areas of extreme seal can damage the housing or shaft.
Page 41 General Information for each type of product being Preparing the UV for used. Storage 7. Place the UV on a work stands with all the wheels off the The amount of preparation a UV should ground. undergo before storage depends on the Cover the UV with old bed expected length of non-use, storage sheets or something similar.
Page 42 Specifications General Specifications Dimensions: Basic Weight: Overall Length 3,000mm 118.1 in With oil and full fuel tank 749 kg Overall width 1560mm 1648lbs 61.4 in Overall Height 2025mm 79.7 in Seat Height 550mm 21.6 in Wheelbase 1,950mm 76.8in Ground Clearance 305mm 12in Curb to Curb...
Page 43 Specifications Fuel: Fuel Delivery: Type Unleaded fuel 91Octane or higher Electronic Fuel Injection Tank Capacity 7.66 US Spark Plug: Clutch Type: Type/Manufacturer DCPR7E NGK Wet, centrifugal automatic Spark Plug Gap 0.8-0.9mm 0.031-0.035 in Transmission: Chassis: Continuously Variable Frame Type Steel Tube Frame Transmission (0.7-1.66:1) Toe In 0-10mm...
Page 44 Specifications Lights: Type Wattage Quantity Headlight: 12V34w Taillight/Brake 12V 2.5w Position Light 12V 1w Turn Signal 12V1.25w Neutral- Reverse LCD screen ,digital Coolant Temp LCD screen ,Code Parking Brake Four-Wheel Drive Light LCD Differential gear lock screen ,Symbol display 750 UV Engine Specifications Service wear Item Metric...
Page 45 750 UV Engine Specifications Service Wear Item Metric Standard Limit Dimensions Intake “A” 30.06-30.16mm (1.1835-1.1874in) 29.96mm(1.1795in) “B” 35.69-35.79mm (1.4051-1.4091in) 35.59mm(1.4012in) Exhaust “A” 30.11-30.21mm (1.1854-1.1894in) 30.01mm(1.1815in) “B” 36.50-36.60mm (1.4370-1.4409in) 36.40mm(1.4331in) Camshaft Run out 0.03mm (0.0012in) limit Cam Chain: Number of links Adjustment Method Automatic Rocker arm...
Page 46 750 UV Engine Specifications “B” Face Width 2.25 mm (0.0885 in) 2.26 mm (0.0889 in) “C” Seat Width 0.9-1.1mm (0.0354-0.0433 in) 1.6 mm (0.0630 in) 0.9-1.1 mm (0.0354-0.0433 in) 1.6 mm (0.0630 in) “D” Margin Thickness 0.85-1.15 mm (0.0335-0.0453 in) 5.945mm 0.85-1.15 mm (0.0335-0.0453 in)
Page 47 750 UV Engine Specifications Service Wear Item Metric Standard Limit Valve Spring: Inner Spring 32.63mm (1.28in) 31.0mm (1.22in) Free Length 36.46mm (1.44in) 34.6mm (1.36in) 27.5mm (1.08in) Set Length (Valve Closed) 31.0mm (1.22in) 100.0 ~115.7N (22.49 ~ 26.01lb) Compressed pressure (Installed) 120.6 ~138.3N (27.12 ~ 31.09lb) 2.5°/ 1.4 mm...
Page 48 750 UV Engine Specifications Item Metric Standard Service Wear Limit Piston: Piston to Cylinder Clearance 0.050 ~ 0.070 mm (0.0020 - 0.0028in) 0.15 mm (0.0059 in) Piston size “D” 101.95 ~ 101.97 mm (4.0138 -4.0146 in) Measuring point “H” 10 mm (0.394 in) 1.0 mm (0.0394 in)
Page 49 750 UV Engine Specifications Item Metric Standard Service Wear Limit 2nd ring: Type: Taper 4.0×1.2mm (0.1575X0.0472in) Dimensions (B ×T) End gap (installed) 0.30 - 0.45mm (0.0118 -0.0177in 0.80 mm (0.0315 in) 0.03 - 0.07mm (0.0012 - 0.0028in) Side clearance 0.13 mm (0.0051 in) Oil ring: Dimensions (B×T) 3.4×2.5mm...
Page 50 550 UV Engine Specifications Item Standard Engine : Engine Type Liquid cooled 4-stroke Water cool Cylinder arrangement Forward-inclined single cylinder Displacement 546cm Bore stroke 84..0mm 3.58 3.31i Compression ratio 9.6:1 Starting system Electric starter Lubrication system Wet sump Engine Specifications Item Standard Limit...
Page 51 550 UV Engine Specifications Intake "A" 32.30~32.20mm ( 1.271~1.268Iin) "B" 40.88~40.78mm (1.6094~1.6055in) 32.30-32.30mm Exhaust "A" ( 1.272~1.268in) , "B"' 40.95~40.85mm (1.6122~1.6083in) Camshaft run out limit Cam chain Number of links Cam chain adjustment method Automatic Valve spring Inner spring Free length 42.5mm(1.67in) Outside spring 42.5mm(1.67in)
Page 52 550 UV Engine Specifications IN EX Clockwise Valve Dimensions Head diameter face width seat width Margin thickness "A" head diameter 39.9- 40.1 mm (1.5709~1.5787 in) 3 3.9 - 33 .98 mm (1.3346~1.3378 in) 2.25 mrn (0.0900 in) "B" face width 2 .26 mm (0.0890in) 0.9~1.1mm...
Page 53 550 UV Engine Specifications 2-12...
Page 54 550 UV Engine Specifications 2-13...
Page 55 Specifications Item Metric Standard Service Wear Limit Balancer: Balancer drive method Gear Automatic centrifugal clutch. Clutch shoe thickness 1.5 mm (0.06 in 1.0 mm (0.04 in) 1,900- 2,300 r/min Clutch-in revolution 3,350 -3,850 r/min Clutch-stall revolution Axle: Main axle deflection limit 0.06 mm (0.0024 in) 0.06 mm (0.0024 in) Drive axle deflection limit...
Page 56 Specifications Item Metric Service Wear Limit Standard Water pump Type Single-suction centrifugal pump Reduction ratio 32/31 (1.032 Shaft drive Middle gear backlash 0.1 -0.3mm (0.004 - 0.012in) Final gear backlash 0.1 -0.3mm (0.004 - 0.012in) Differential gear backlash 0.05 - 0.25 mm(0.00 2 - 0.010 in) Cooling system Radiator core Width...
Page 57 Specifications Service Wear Item Metric Limit Standard Front wheel Type 6 spoke Rim size 14 x 7.0 Rim material Alum. Rim run out limit Radial 2.0 mm (0.08 in) Lateral 2.0 mm (0.08 in) Front wheel Type 6 spoke Rim size 14 x 9.0 Rim material Alum...
Page 58 Specifications Service Wear Item Metric Standard Limit Rear disc brake Type Dual Ventilated Hydraulic Disc Disc outside diameter X 165 ×5.0mm (6.50 × 0.20in) thickness Pad thickness inner 1.5 mm (0.06 in) 5.6mm (0.22in) Pad thickness outer 1.5 mm (0.06 in) 5.6mm (0.22in) Master cylinder inside...
Page 59 Specifications ENGINE TIGHTENING TORQUES Part to be tightened Part Thread Torque Torque Name Size Ft-lbs Cylinder head Bolt Bolt 32.8 Spark plug — 12mm Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt Tappet cover (exhaust) — 32mm Tappet cover (intake) Bolt Oil gallery bolt —...
Page 60 Specifications ENGINE TIGHTENING TORQUES Part to be Tightened Qty Torque Part Thread Torque Ft Name Size Crankcase Bolt Bolt Bolt Bearing Housing (clutch housing Bolt assembly) Air duct assembly bracket Bolt Oil seal (engine cooling fan pulley) Bolt retainer Drive belt case Bolt Drive belt cover Bolt...
Page 61 Specifications ENGINE TIGHTENING TORQUES Part to be Tightened Part Thread Qty Torque Torque Name Size Ft Lbs Shift arm Bolt Shift rod locknut (select lever unit) Shift rod locknut (shift arm side) Select lever unit Bolt Plug (right crankcase) Plug 14mm Water pump assembly Bolt...
Page 62 Specifications CHASSIS TIGHTENING TORQUES Part to be Tightened Thread Torque Torque Size Ft Lbs Rubber connecting bracket 1(or 2) and frame 10mm Engine and Rubber connecting bracket 2 (front) 10mm Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame 10mm Rear lower arm and frame 10mm...
Page 63 Specifications CHASSIS TIGHTENING TORQUE Part to be Tightened Thread Torque Torque Size Ft Lbs Steering knuckle and front lower arm 12mm Tie-rod locknut 12mm Steering knuckle and tie-rod 12mm Front lower arm protector board and front lower arm Seat belt and frame 10mm Seat belt and ceiling (enclosure) 10mm...
Page 64 Specifications CHASSIS TIGHTENING TORQUES Part to be tightened Thread Torque Torque Size Ft Lbs Front bumper and frame 10mm 12mm Upper instrument panel and frame Ceiling side frame (enclosure) and frame 10mm Support frame 10mm Top frame 10mm Side Frame 10mm Seat Support Footrest plate...
Page 65 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 Wheel bearing grease Dust-proof ring of brake...
Page 66 Periodic Maintenance Introduction This chapter should be used as a guide, in order to perform all the recommended maintenance checks and adjustments. These recommended maintenance procedures, if followed will allow you to have a more reliable vehicle and the need for major service work should be greatly reduced.
Page 67 Periodic Maintenance Maintenance Chart Every Every Every Every Every Every Every Items First 20 First 50 Every Every Every 3900 hours hours Year 2 years 4 years hours hours hours hours hours hours hours Grease utility vehicle  Clean muffler/Spark Arrestor ...
Page 68 Periodic Maintenance Maintenance Chart Every Every Every Every Every Every Every First 20 First 50 Every Every Every Items 3900 hours hours Year 2 years 4 years hours hours hours hours hours hours hours Check Exhaust System  Check Wheel Bearings ...
Page 69 Periodic Maintenance NOTE Recommended Brake Fluid: DOT3  Caution (DO NOT MIX DIFFERENT BRAKE FLUIDS)  Brake Fluid Replacement every 24 months  When disassembling the master cylinder or caliper, replace  the fluid. Normally check the fluid level and add brake fluid as needed.
Page 70 Periodic Maintenance Maintenance and Adjustments of the UV Valve Adjustment 1. Remove the following parts: 1. Valve Cover (Intake)(1) 2. Valve Cover (Exhaust)(2) 3. Spark Plug Cap(3) 4. Spark Plug 3. Rotate the crankshaft counterclockwise until the timing mark for TDC is aligned in the window 2.
Page 71 Periodic Maintenance Maintenance and Adjustment of the UV 4. To adjust: Reassembly is in reverse order. 1. Loosen the locknut(1) 1. Timing Plug cover 2. Insert Feeler gauge of proper 2. Engine fan components thickness for valve clearance (2). 3. Fan cover (Within range for Intake or Exhaust 4.
Page 72 Periodic Maintenance Maintenance and Adjustment of the UV Measuring the compression Pressure Check the electrode (1) for • carbon deposits or a burned condition Note: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes.
Page 73 Periodic Maintenance Maintenance and Adjustment of the UV Standard compression pressure 3. Unscrew the dipstick and check the oil level. data Compression pressure Oil level should be between the (At sea level) Maximum ①and Minimum Level ② Standard:950Kpa(135.14Psi) Minimum:900Kpa(128.02Psi) on the dipstick. Maximum:1000Kpa(142.25Psi) If low add oil to the proper level.
Page 74 Periodic Maintenance Maintenance and Adjustment of the UV Lubricate the O-ring ③of the new Oil Changing the engine oil • Filter with a thin coat of clean engine 1. Place the vehicle on a level surface. oil. Hand tighten on the new oil filter. •...
Page 75 Periodic Maintenance Maintenance and Adjustment of the UV 7. Check oil pressure Chassis Slightly loosen the oil galley • Cleaning the Air Filter bolt ①. 1) Remove: Seat bottom • Engine Access Panel • Air filter case cover Remove air filter: ·air filter Holder ·air filter check hose ·air filter case cover...
Page 76 Periodic Maintenance Maintenance and Adjustment of the UV Note: Note Vehicle should not be warmed up for Never operate the engine with the this check. Check coolant before starting air filter element removed. This will the vehicle. allow unfiltered air to enter, causing rapid wear and possible engine •...
Page 77 Periodic Maintenance Maintenance and Adjustment of the UV Changing the Coolant 6) Remove the radiator cap(1) • Locate coolant tank Remove coolant reservoir cap(1) • 7) Drain the coolant • Disconnect the coolant outlet hose(1) 2) Disconnect coolant reservoir hose(2) 3) Drain coolant from the reservoir 4) Reconnect coolant reservoir hose Disconnect the water pump inlet...
Page 78 Periodic Maintenance Maintenance and Adjustment of the UV 9) Connect water pump inlet hose 10)Connect coolant outlet hose 11)Remove the air bleed bolt(1) 12) Fill the cooling system with the recommended coolant until coolant comes out of the hole for the air Note: bleed bolt.
Page 79 Periodic Maintenance Maintenance and Adjustment of the UV Bleeding the Cooling System. 1)Chock the rear wheel, engage the parking brake, place the shift lever in NEUTRAL or PARK and the parking brake, place the shift lever in NEUTRAL or PARK and jack up the front of the utility vehicle approximately 6”.
Page 80 Periodic Maintenance Maintenance and Adjustment of the UV Checking the coolant temperature warning light Coolant temperature indicator light (1) 3‐15...
Page 81 Periodic Maintenance Maintenance and Adjustment of the UV Checking the V-Belt 1) Remove: Seat bottom • Engine Cover • Drive belt cover • 2) Check the V-belt for cracks, wear, scaling or chipping. Replace if necessary. 3) Check for oil or grease inside v- belt housing.
Page 82 Periodic Maintenance Maintenance and Adjustment of the UV 1) Replacing the V-Belt 3) Remove the bolts used to widen the gap on the secondary sheaves. • Install bolts (1) into the 4) Install the following: secondary fixed sheave holes as shown in the figure. Drive belt cover •...
Page 83 Periodic Maintenance Maintenance and Adjustment of the UV Adjusting the Parking Brake Free Play Adjusting the Brake Pedal 1) Shift the drive select lever into Low 1) Check Brake pedal Free play gear “L”. 2) Remove: 1-4 mm Hood Cover •...
Page 84 Periodic Maintenance Maintenance and Adjustment of the UV Checking and Adjusting the Parking Brake To Check the parking brake place drive the vehicle up a slope roughly 20 degrees. Engage the parking brake. The handle should click no more than 3 times and the brake should hold the vehicle. Locate the parking brake adjustment nut (1) on the rear differential.
Page 85 Periodic Maintenance Maintenance and Adjustment of the UTV Caution: Checking the Brake fluid Level Do not mix different type of brake fluid. 1) Place the vehicle on a level surface Use Dot 3 brake fluid only as 2) Locate reservoir by left front tire mixing can cause brake failure and 3) Check the reservoir level line (1).
Page 86 Periodic Maintenance Maintenance and Adjustment of the UV Engine Cover • CHECKING THE BRAKE HOSES AND • Seat bottom BRAKE LINES 1. Remove: Seat bottom and Engine Cover · 2. Lift the hood up. 3. Lift the cargo bed. 4. Check the following for cracks, wear or damage and if needed replace.
Page 87 Periodic Maintenance BLEEDING THE HYDRAULIC BRAKE SYSTEM Warning: Bleed the brake system if any of the following have occurred. The system has been disassembled. • • The brake hose or brake lines have been loosened or removed. • The brake fluid has been very low. •...
Page 88 Periodic Maintenance 7. Two technicians are required for the following steps. Technician #1 should be located at the caliper. Technician #2 should be sitting in the vehicle to pump the brakes. 8. Have Technician #2 slowly press and release the brake pedal 3 times. At the end of the depression, the pedal should be held as if the brakes were applied.
Page 89 Periodic Maintenance Procedure if No Fluid is Passing Through the Right Rear Caliper 20. Confirm that the Master Cylinder reservoir is full. 21. Perform the brake bleeding procedure on the right front caliper as described in Steps 4 through 14 until brake fluid flows. 22.
Page 90 Periodic Maintenance Maintenance and Adjustments of the UV Warning: 1. Make sure the bleed screw is tight and The vehicle must be stopped and your add fluid to the reservoir to the full foot off the accelerator pedal before line. shifting to prevent damage to the transmission.
Page 91 Periodic Maintenance Maintenance and Adjustment of the UV 1. Remove the Final Gear oil drain bolt (1). CHECKING THE FINAL GEAR OIL 1. Install the drain bolt LEVEL 2. Remove the oil filler plug 3. Fill until oil reaches the bottom of the 1.
Page 92 Periodic Maintenance Maintenance and Adjustment of the UV ADJUSTING THE TOE-IN 1. Place vehicle on a level surface. 2. Make sure the tires are inflated to the proper air pressure. 3. Mark both front tire tread centers. Tighten the tie rod end locknuts on •...
Page 93 Periodic Maintenance ADJUSTING THE SHOCK ABSORBERS Note: This adjustment requires a spanner wrench to complete. A spanner wrench is included in the tool kit shipped There are three adjustment points with this utility vehicle. on the shocks. The rebound (a), 1.
Page 94 Periodic Maintenance 3‐29...
Page 95 Periodic Maintenance Maintenance and Adjustment of the UV Checking the Constant Velocity Joint Check the Tie-rod ends. Dust Boots Inspect for vertical play, if any then replace Inspect (1) looking for any damage, tears, the Tie-rod end in question. Replacement or cracking.
Page 96 Periodic Maintenance Maintenance and Adjustment of the UV CHECKING THE TIRES Changing the Tail/Brake Light 1. Check the tires for bulges, wear or Assembly cracking. If needed replace with manufacturer All light assemblies utilize LEDs and recommended tire combinations. have no bulbs to replace. A burnt out or nonfunctioning light requires Tire wear limit ○...
Page 97 Engine Special Notes 1. Make sure to use only manufacturer recommended parts, oils, adhesives and sealants. 2. After removal of oil seals, gaskets, O-rings, and piston rings, replace with new parts. 3. Pay attention to keep disassembled parts orderly. Make sure of the original position for reassembly.
Page 98 Engine Engine Removal Figure2 Figure1 Part Name Remarks Remove the parts in the order Remove Intake assembly listed Seat and Seatback Engine Cover Intake assembly (Fig 1) For installation, reverse the order Drain Plug (Fig 2) listed Seat box top panel Engine wiring harness Cross member Bed assembly...
Page 99 Engine Cylinder Head and Cylinder Head Cover Remarks Part Name Remove the parts in the order listed Remove the following: Union bolt Copper washer Oil Line 3 Oil Line 2 Spark plug Tappet Cover (Intake) Tappet Cover (Exhaust) Timing Chain Tensioner Cap Bolt Timing Chain Tensioner / Gasket Timing Chain Guide (Exhaust Side) Thermo switch...
Page 100 Engine 1. Check the Valve Clearance 5. Inspect the cylinder head (Refer to Chapter3) Remove carbon deposits • (Use a good quality 2. Inspect the cylinder head cover for combustion chamber cracks or damage. If replacement is cleaner) necessary, replace cylinder head Note: cover and cylinder head as a set.
Page 101 Engine 2. Install the cylinder head Cylinder head gasket • Timing chain guide (exhaust • Side) • Cylinder Head Timing chain tensioner • 9mm bolts(1-6) • Torque 38 Nm or 28 ft lbs Lightly press the timing chain 6mm bolts(7) •...
Page 102 Engine Rocker Arms and Camshaft Part Name Remarks Remove parts in order Removing the rocker arms and camshaft listed Cylinder head cover Plug / O-ring 1 / 1 Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft 3 / O-ring 1 / 1 Rocker arm 4 Rocker arm shaft 1 / O-ring...
Page 103 Engine Inspect the rocker arms Rocker arm lobes(1) • Valve adjusters(2) • Look for discoloration, scratches or pitting. Subtract the rocker arm shaft outer diameter from the rocker arm inside diameter to determine the clearance. Clearance Limit 0.05mm Inspect the Camshaft •...
Page 104 Engine Installation Caution: Do not turn the crankshaft during the camshaft 1. Installing the rocker arms installation. Rocker arms(1) • Rocker arm shafts(2) • Temporarily install the camshaft sprocket on the Note: camshaft. (Do not install the bolts) Install the timing chain The thread hole (a) of the rocker arm on the sprocket.
Page 105 Engine Valves and Valve springs Part Name Remarks Removing the Valves and Valve springs Remove the parts in the order listed Valve Keeper Valve spring collar Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the order listed 4‐9...
Page 106 Engine Inspect Measure valve stem run out Valve Sealing • Run out Limit 0.01 mm (Look for leaks at the seat) Pour a combustion chamber cleaner into the intake track. Check The intake side (1), there should be no leakage at the valve seat (2).
Page 107 Engine Remove the Valve Guide Clean off all of the lapping compound and install a new valve guide seal. This process is easier if the • cylinder head is heated to 212 degrees Fahrenheit in an oven. Install a new valve guide with a valve guide installer (2) and removal (1) tool.
Page 108 Engine Cylinder and Piston Part Name Removing Remarks the cylinder and piston Water Pump Remove parts in the order outlet Hose listed Cylinder Head Coolant inlet joint Cylinder / O-ring 1 / 1 Cylinder gasket Dowel pin Wrist pin clip Wrist pin Piston Piston ring set...
Page 109 Engine 1. Measure the cylinder bore 4. Measure piston ring side clearance • Use a feeler gauge • • Middle Bottom • Out of roundness: 0.005mm Taper:0.005mm 2. Measure the piston Rings end gap 5. Measure the piston pin outside Place the ring inside the •...
Page 110 Engine Install Caution: 1. Piston rings (onto the piston) Be careful not to damage the timing chain guide during installation. Pass Install rings so that • manufacturer’s numbers or the timing chain through the timing markings face upward. chain cavity. Lubricate with engine oil •...
Page 111 Engine Engine cooling Fan and A.C. Magneto Part Name Remarks Removing the engine cooling fan Remove the parts in the order listed. and 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 112 Engine 1. Inspect the A.C. Magneto Stator coil • Pickup coil • Look for wear, damage, burnt, frayed wires. Look for damage to insulation on windings. If damaged replace. Turn the starter wheel gear Counterclockwise (1) to check that the starter clutch and wheel gear engage.
Page 113 Engine Installing Rotor to Crankshaft. 75 Nm or 55 ft lbs Inspect tapered portion of crankshaft for damage. If small imperfections or burrs exist clean with a fine file or emery cloth. If necessary, lap crankshaft and rotor with 180 grit lapping compound. Clean tapered surfaces of crankshaft and rotor with brake parts cleaner or other quick evaporating cleaner.
Page 114 Engine Engine Cooling Fan Inspect the engine cooling fan Engine cooling fan • Air shroud1 • Air shroud2 • Look for cracks or damage, if necessary, replace. 1. Install In the following order. Air Shroud 1 • Engine cooling fan •...
Page 115 Engine Balancer Gears and Oil Pump Gears Part Name Remarks Removing the balancer gears and Remove the parts in the order oil pump gears listed Nut / Lock washer 1 / 1 Balancer driven / oil pump drive gear Chain Straight key Oil pump driven gear Plate...
Page 116 Engine 1. Inspect 2. Install Oil pump drive gear(1) Pins • • Oil pump driven gear(2) Springs • • • Balancer drive gear Look for cracks, wear or damage. (on the buffer boss) Replace if necessary. • Plate Cir clip •...
Page 117 Engine Primary and Secondary Sheaves Use high strength thread locker Loctite 262 or equivalent Part Name Remarks Removing the Primary and Secondary Remove the parts in the Sheaves order listed Engine assembly Drive Belt cover Rubber gasket Bearing Housing Dowel pin Primary sheave assembly V-belt Primary fixed sheave...
Page 118 Engine Primary Sheave Part Name Remarks Disassembly of 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 For installation, reverse the order O-ring listed 4‐22...
Page 119 Engine Secondary Sheave Part Name Remarks Disassembly of 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 For installation, reverse the Oil seal order listed 4‐23...
Page 120 Engine 2. Inspect the Secondary sheave 1. Inspect Secondary fixed sheave • Primary sheave outside • diameter (a). Secondary sliding sheave • Check outside diameter wear limit: Look for smooth operation, 29.5 mm scratches or damage, If replacement is necessary replace as a set.
Page 121 Engine Install 3. Assembling the secondary sheave 1. Assembling the primary sheave Apply assembly lube to •  Clean the primary sliding sheave face (1) The secondary sliding The primary fixed sheave face sheave (1) inner surface and  oil seals. The collar(3) ...
Page 122 Engine Install the nut (2) and tighten it to Tighten the primary sheave nut (1) the specified torque using the 120 Nm or 88 ft lbs locknut wrench, and sheave fixed block. Tighten the secondary sheave nut (2). 100 Nm or 74 ft lbs Note: 4.
Page 123 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 1 / 2 One-way clutch bearing Apply High strength (red) thread locker and stake nut to crankshaft. Clutch carrier assembly For installation, reverse the order listed 4‐27...
Page 124 Engine Part Name Remarks Disassembling the clutch housing Remove the parts in the order listed Oil seal Circlip Bearing Housing Circlip Bearing Circlip Bearing For installation, reverse the order Clutch Housing listed 4‐28...
Page 125 Engine Inspect the clutch • Inspect the clutch housing (1) Look for heat damage or wear. Some grooves are expected. A blackened O.D. is a sign of excessive heat. Inspect the one way clutch bearing • (2). Look for chaffing, wear or damage.
Page 126 Engine Install Dowel pins • • Gasket Clutch housing assembly • 10 Nm or 7 ft lbs Tighten the bolts in stages, using a cross pattern. After tightening check the operation of the clutch housing assembly that it rotates counterclockwise smoothly.
Page 127 Engine Crankcase Starter motor and 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 1 / 1 Starter Motor / O-ring Oil Filter / O-ring Oil Line assembly / O-ring 1 / 2...
Page 128 Engine Crankcase Part Name Remarks Separating the crankcase Remove the parts in the order listed Shift lever cover / gasket 1 / 1 Dowel pin Shift lever 1 Shift lever 2 assembly Right crankcase half Dowel pin Left crankcase half Spacer Crankshaft seal For installation, reverse the order listed...
Page 129 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 1 / 1 Oil seal Bearing retainer For installation, reverse the order Bearing listed 4‐33...
Page 130 Engine Assembling the crankcase Inspect 1. Oil Line 1. Apply sealant (Quick gasket) (1) Look for cracks or damage. To the mating surfaces of both halves. Use only a thin bead of sealant. 2. Install the dowel pins (2) 3. Fit the left crankcase half onto the 2.
Page 131 Engine 4. Tighten the crankcase bolts (1) in a Installing the shift levers cross pattern in stages. 1. Shift lever 2 assembly (1) 10 Nm or 7 ft lbs 14 Nm or 10 ft lbs 5. Apply sealant (4) to crankcase bolt (2) And install 2.
Page 132 Engine Crankshaft and Oil Pump Part Name Remarks Removing the crankshaft and Oil Remove the parts in the order Pump listed Crankcase separation 1 / 1 Oil Strainer / O-ring 1 / 1 Oil pump assembly / gasket Balancer Plate For installation, reverse the Relief valve assembly order listed.
Page 133 Engine Oil Pump Part Name Remarks Disassembling the oil pump Remove the parts in the order listed Rotor cover Shaft Inner rotor Outer rotor For installation, reverse the order Oil Pump housing listed 4‐37...
Page 134 Engine Inspect the oil pump 1. Rotor housing 2. Rotor cover Look for cracks, wear or damage. Tip clearance Limit: 0.23 mm 3. Oil pump operation Side clearance Limit: 0.17 mm Body clearance Limit: 0.24 mm Look for smoothness Measure the crankshaft 4.
Page 135 Engine The crankshaft (1) and the crank • pin (2) oil passageways must be properly aligned with a tolerance of less than 1mm or 0.04in. Caution: The buffer boss and woodruff key should be replaced whenever removed from the crankshaft. Install Assemble the oil pump •...
Page 136 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 137 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 For installation, reverse the order Drive axle listed 4‐41...
Page 138 Engine Inspect the shift forks Springs • 1. Shift fork follower (1) Look for cracks or damage. 2. Shift fork pawl (2) Look for scoring, bends, wear or damage. Shift drum • Inspect the grooves Look for scratches, wear or damage.
Page 139 Engine Inspect the secondary shaft and driven Install sprocket. Assembling the shift fork • Gear teeth • Guide bar (1) Look for discoloration, pitting or Shift fork (2) wear. Long Spring (3) Shift fork (4) Short Spring (5) Gear movement •...
Page 140 Engine Middle Gear Middle drive shaft Stake nut during installation Part Name Removing Remarks 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 For installation, reverse the order Bearing retainer listed...
Page 141 Engine Middle Driven Shaft Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Drive shaft coupling Cir clip Bearing Universal joint Universal joint yoke Bearing housing / O-ring 1 / 1 Shim Middle driven pinion gear Bearing retainer Bearing retainer...
Page 142 Engine Inspect the pinion gears Measure gear lash Temporarily install the left • Drive pinion gear(1) • crankcase half. Driven pinion gear(2) • Wrap a rag around a screwdriver • and insert it into the right crankcase Look at the teeth for pitting, galling speed sensor hole to hold the or wear middle driven gear.
Page 143 Engine Universal joint Place a rag in a vise(2) • Install the opposite yoke onto the • universal joint. Secure the bearing housing • Apply wheel bearing grease to the • • Attach the bearing retainer wrench bearings Install the bearing (1) onto the yoke. •...
Page 144 Engine • Drive Shaft coupling • Washer Nut(1) • Note: Use the coupling gear / middle shaft tool (2) to hold the drive shaft coupling. Nut Torque 97 Nm or 71 ft lbs Install the middle drive shaft Tighten the middle pinion gear nut •...
Page 145 Chassis Inspection Appearance Inspection 2. Loss of Brake performance 1. Plastic body panels damaged Check for brake rotor • wear. Has it exceeded Replace with new plastic the wear limit. • body panel Check for brake pad • • Check for any supports that wear.
Page 146 Chassis Inspection Check the front wheel and Check the front wheel • • axle nut for damage or splines for damage or wear. looseness. Check the rubber dampers • Check the wheel splines for • damage or wear. on the anti-sway bar for damage or wear.
Page 147 Chassis Inspection 11. Abnormal noise from front or rear axle area. Check the wheel splines for • damage or wear. Check the splines on the mid • shaft for damage or wear. Check the gears of the front • gearbox and differential for wear or damage.
Page 148 Chassis Steering System Remarks Part Name Removing the steering assembly Rack assembly Pinion Circlip Bearing Adjuster Spring Pressure pad Circlip Oil seal Zip TieL-200 Dust Boots Flange Bolt 10mm X 30mm Tie Rod end Locknut 10mm Steering Joint Flange Bolt 8mm X 20mm Castle nut Zip Tie 5‐4...
Page 149 Chassis Steering Wheel assembly Part Name Remarks Removing the steering Wheel assembly Hex Socket Bolt 5mm X 16mm Steering Wheel Cap Horn Switch Steering Wheel Flange nut 12mm X 1.25 Steering Wheel Hub 5‐5...
Page 150 Chassis Disassembly of the steering wheel Warning: assembly This is a safety area, and any damage or wear needs to be repaired 1. Remove immediately. Do not let vehicle leave without proper • screw M5×16 ① repairs being performed. • Decoration cover for steering wheel ②...
Page 151 Chassis 2. Inspect the Steering Knuckle • Up and Down movement • In and out movement Steering joint(1) • Turn direction • Check for smooth operation. For bearing fitment check for excessive play up and down or in and out. Check the splines on both ends of the shaft for wear or damage.
Page 152 Chassis 1. Install the rack and pinion assembly to the 5. Inspect the Tie Rods frame. • Look for bends or damage. Bolt M10×30 48 Nm (4.8m · kg,35 ft · lbs) 6. Inspect the steering Joint Nut M10 Look for cracks or distortion. •...
Page 153 Chassis 3. Check for spongy feel of the pedal If feel becomes soft, a brake fluid change The Brake System is necessary or the system needs to be bled of air. When bleeding be sure to The brake system is crucial to keep the reservoir full so not to allow the safety of the operator and more air into the system.
Page 154 Chassis Front Disc Brake Components Remarks Part Name Removing the front Brake line attachment hardware Belt 3 (L – 150) Belt 4 (L – 200) Belt 6 (L – 150) Bolt 6mm X 30mm Bolt 6mm X 20mm Disc brake line clip Flange bolt 6mm X 20mm Wire Clip fixed plate Brake line assembly...
Page 155 Chassis Front Disc Brakes Remarks Part Name Removing the brake discs Brake Caliper assembly Brake Disc Bolt Axle housing Bolt Brake disc guard 5‐11...
Page 156 Chassis Inspect the Front Brake Discs Inspect for galling or damage • Measure brake disc runout. • Brake disc runout. 0.10 mm (0.004 in) • Brake disc thickness (1) Wheel Hub (2) • • Rim (3) Brake disc minimum thickness 3.0 mm (0.12 in) 5‐12...
Page 157 Chassis Front Brake Pads Part Name Remarks Removing the front brake pads Remove parts in the order listed Brake caliper mounting bolt Brake pad holding bolt For installation, reverse the order Brake pad listed Pad spring 5‐13...
Page 158 Chassis Replacing the Front Brake Pads Install the retaining bolts and Brake • caliper. It is not necessary to disassemble the brake caliper and brake hose to replace Brake pad holding bolt 18 the brake pads. Nm (1.8 m · kg, 13 ft · lbs) Brake caliper mounting bolt 1.
Page 159 Chassis Front brake caliper Part Name Remarks Removing the front 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 For installation, reverse the order Brake caliper assembly listed 5‐15...
Page 160 Chassis Brake Caliper Disassembly Part Name Remarks Disassembling the front 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 For installation, reverse the Bleed screw order listed.
Page 161 Chassis Disassembling the front brake calipers 3. Inspect Brake caliper pistons (1) • 1. Remove the brake caliper pistons look for scratches, rust or wear. Blow compressed air into the hose joint opening to force out the caliper Brake caliper cylinders (2) •...
Page 162 Chassis 3. Install the brake caliper pistons(1) Caution: Brake fluid will damage painted surfaces and plastic parts. Always clean up spills immediately. Installing the Front Brake calipers 1. Install • Brake caliper assembly Brake caliper mounting bolts • 48Nm (4.8m · kg,35 ft · lb) Brake hose(1) •...
Page 163 Chassis Rear Brake Disc Part Name Remarks Removing the Rear brake disc Remove the parts in the order listed Brake caliper assembly Final drive gear For installation, reverse the order Rear brake disc listed 5‐19...
Page 164 Chassis Inspecting the Rear Brake Disc 1. Inspect the disc Look for galling or damage 2. Measure the rear brake disc deflection Brake disc maximum deflection 0.10 mm (0.004 in) 3. Measure the Brake disc thickness (a). Brake disc minimum thickness 4.5 mm (0.18 in) 5‐20...
Page 165 Chassis Rear Brake Caliper and Brake Pads Part Name Removing the rear brake caliper and brake pads Adjusting Screw Hex Flange Nut Parking arm Parking Brake Plunger Assembly Parking Cable Bracket Tension Spring Tension spring mounting plate Lower Slide Shaft Rubber Cover Lower Slide Shaft Spring Washer Support Plate...
Page 166 Chassis Rear Brake Caliper and Brake Pads Part Name Piston Cone Compression Spring Inside Brake Pad Pad Guide pin Ball Bearing Parking brake case bolt Sliding shaft rubber cover Mounting Bracket Bolts Ball Bearing Dust seal Guide pin 5‐22...
Page 167 Chassis Replacing the Rear Brake Pads Warning: All internal brake components should 1. Measure the brake pad thickness be cleaned in new brake fluid only. Do not use solvents as they will cause Brake pad wear limit seals to swell and distort. 1.5 mm (0.06 in) 2.
Page 168 Chassis Assembling the Rear Brake Caliper 4. Install the parking brake arm shaft (1), Parking brake arm (2), set bolt 1. Install the caliper piston seal (1) and (3), and parking brake arm nut (4). the dust seal(2). Apply lithium-soap-based grease to the parking brake arm shaft and set bolt.
Page 169 Chassis 5. Install the brake pad (piston side) 3. Bleed the brake system (1)(with insulator and pad shim) 4. Check for proper brake fluid level in the reservoir. Align the projection (a) on the piston • side of the brake pad with the groove in the caliper piston.
Page 170 Chassis Brake Master Cylinder Remarks Remove Part Name the parts in the order listed. Removing the Brake Master Cylinder Brake Fluid Drain Brake Fluid Reservoir cap Brake Fluid Reservoir diaphragm Brake Fluid Reservoir float Union bolt Copper washer Brake hose Disconnect Brake Line Disconnect...
Page 171 Chassis Inspecting the Brake Master Cylinder 2. Install the Brake line 19Nm (1.9 m · kg,13 ft · lbs) 1. Inspect • Brake Master Cylinder (1). 3. Install the copper washers, Brake Look for scratches or wear. Hose and Union bolt. 27Nm (2.7 m ·...
Page 172 Chassis Footrest Assembly Part Name Remarks Removing the footrest Footrest Seating support Ⅰ Seating support Ⅱ Cover battery Cover engine Cover battery box Front panel footrest Washer rubber 8×17 Side Pane l(front left) Side Panel (middle left) Side protector (left) Side Panel (middle right) Side Panel (front right) Side protector (right)
Page 173 Chassis Footrest Assembly Part Name Remarks Nut flange head M6 Fender (rear left) Fender (rear right) Lock battery box cover Washer rubber Lock engine cover Screw cross head self drilling ST3.9×13 Screw thread clip M6×2 Bolt hexagon socket M6×16 Bolt hexagon socket M6×20 Screw cross large head M6×16 Turn lamp (front left) Turn lamp (front right)
Page 174 Chassis Front Wheel and Tire Remarks Part Name Removing the front wheel Front rim Front tire Nut M10 Wheel decoration cover Nut M22×1.5 Front hub cotter pin 3.2×50 Bolt M10×30 5‐30...
Page 175 Chassis Rear wheel Part Name Remarks Removing the rear wheel Rear rim Rear tire Rear hub Bolt M10×30 Nut M10 Wheel decoration cover Nut M22×1.5 Cotter pin 3.2×50 5‐31...
Page 176 Chassis Inspect the Rim Installing the wheel hub 1. Measure run out Axle nut • Look for bends or damage. 260 Nm (26.0 m · kg, 190 ft · lb Check wheel bearing endplay. Installing the Wheel assembly Wheel run out limit Radial ②: 2.0 mm (0.08 in) 1.
Page 177 Chassis Transmission System Front Bridge Part Name Cir clip CV Joint Cir clip Cir clip Boot band Dust boot Boot band Joint shaft Half axle assembly 5‐33...
Page 178 Chassis Front Bridge Part Name Remarks Removing the front bridge Front differential assy Front differential case Front differential case Drive & driven gears assy(with rear differential status) Connection fork Ⅰ Hexagon flange nut m14×1.5 O-type ring 6.8×14 Oil seal 48×65×9 Oil seal 24×38×8 Washer Ⅰ50×61.5 5‐34...
Page 179 Chassis Front Bridge Part Name Remarks Socket hexagon screw M8×25 Connection fork Ⅱ Socket hexagon screw M8×10 Hexagon flange bolt M10×1.25×15 Clip D0=62 Pin 5×75 Transfer case assembly Divide device connection Rack O-ring 2×81,transfer case O-ring 2.62×139.37, front tank cover Bearing 35×62×14 5‐35...
Page 180 Chassis Front Bridge Part Name Remarks Bearing 60×85×13 Bearing 35×62×9 Rolling bearing 15×21×12 Screw Copper washer 13×1.5 Hexagon flange nut M10×1.25 Shaft fork Ⅳ Clamp 20-32 Universal joint Clip D0=62 Vent pipe l=700 Oil pipe clip 8 Cross shaft (20) 5‐36...
Page 181 Chassis Front Bridge Part Name Remarks Front transmission shaft Cir clip D0=19 Cir clip 20×26×1 Spring 25×2.3×28 Hexagon flange bolt M8×28 Front dustproof rubber cover 19×38×50, front transmission shaft Hexagon flange bolt M10×1.25×30 Hexagon flange bolt M10×1.25×142 Block ring Front transmission shaft comp Sliding sleeve O-ring 1.5×9 5‐37...
Page 182 Chassis Disassembling the front bridge 1. Remove the left and right front wheels. 2. Remove the front disc brake clip, Cotter pin, open-groove nut, cushion and front wheel hub. 3. Disassemble the left and right rocker arm and cross steering knuckle.
Page 183 Chassis 3. Inspect the balls and ball races. 6. Inspect the front driveshaft. Look for pitting, wear or damage. Look for bends. Check the movement of the joint is smooth in all directions, in and out 7. Inspect the torque limiter. and round.
Page 184 Chassis Assembling the Universal joint Assembly of the Differential Gear 1. Place the universal joint into the 1. Slide the differential gear all the yoke. way to the right to put it into the 2 WD mode. 2. Connect two C size batteries to the gear motor terminal (1) to rotate the pinion gear (2) until the paint mark (3) is aligned with the paint mark (4)
Page 185 Chassis Installing the Front Bridge 1. Install the right and left transmission shafts into the front bridge differential. 2. Fill with 0.32L 80w90 gear lube and tighten the filler bolt. 23 Nm (2.3m · kg,17 ft · lbs) 3. Install the front bridge differential onto the frame ...
Page 186 Chassis Rear Bridge Part Name Remarks Cir clip Boot band Boot band Dust boot Cir clip Double off-set joint assembly Cir clip Cir clip Double off-set joint assembly Joint shaft Half axle assembly 5‐42...
Page 187 Chassis Rear Bridge Remarks Part Name Removing the rear bridge Rear reducer assy Rear reducer case. Bearing 22×30×13 Bearing 55b M6720 55×67×20 Drive & driven gears Bearing 25×62×17 Mount bracket, rear disk brake plate Oil seal 61×35×9 Fuel drain O-ring seal 13×1.5 O-ring gasket 3×71 5‐43...
Page 188 Chassis Rear Bridge Part Name Remarks Washer 12×30×4 Hexagon flange nut M12×1.25 Mount bracket, rear brake caliper Rear adjustment gasket Hexagon bolt with washer Socket hexagon screw M8×25 Rear adjustment gasket Ⅱ Speed sensor comp. O-ring gasket, fuel injection 2.3×19.4 Vent pipe, rear reducer Rear reducer case Ⅱ...
Page 189 Chassis Rear Bridge Part Name Remarks Hexagon flange nut M8 Oil seal 65×90×9 Bearing 16017C2 85×130×14 O-ring 3×150 Adjustment gasket Ⅲ Oil Seal 65×90×9 Fuel drain screw plug Hexagon flange nut M10×1.25×25 Hexagon flange bolt M8×12 Rear transmission shaft comp Cir clip D0=19 Rear transmission shaft 5‐45...
Page 190 Chassis Rear Bridge Part Name Remarks Cir clip D0=19 Joint sleeve, rear axle transmission shaft Elasticity block ring D0=22 Hexagon flange nut M10×1.25 Cir clip 20×26×1 Rear dust cover 20.5×48×30, Vent pipe, rear reducer Steel Wire Clamp 8 Clip 11 Spring 25×2.3×28 Hexagon flange bolt M10×1.25×120 Impaction ring...
Page 191 Chassis Gear Shift Mechanism Part Name Remarks Removing mechanism Gear Shifter Assembly Gearshift cable assy Hexagon flange bolt M6×30 Gearshift arm Reverse cable Hexagon Flange Nut M8 Gearshift cable fix plate Ⅱ Gearshift cable fix plate Ⅰ Hexagon Flange Bolt M6×20 Hexagon Flange Locked Nut M6 Hexagon Flange BoltM8×45 Gear Shift Rod II...
Page 192 Chassis Adjusting the gearshift mechanism  Adjust the shift rod length for smooth and correct shifting. Tighten the locknuts. Neutral (1)  Locknut High (2) 15 Nm (1.5 m · kg, 11 ft · lb) Low (3) Reverse (4) Parking (5) Shift control cable (6) Note: Before shifting you must stop the...
Page 193 Chassis Suspension Front Suspension and A arm Part Name Remarks Removing front suspension and arm B frame welding kit (front left) B frame welding kit (front right) Bolt hexagon flange head M10×1.25-78 tube 10.3×23×50 Bushing 23×28 Nut lock M10×1.25 Shield CV basic Ⅰ Hexagon flange bolt M6×16 Bolt hexagon flange head M6×16 ４...
Page 194 Chassis Front Suspension and A arm Remarks Part Name Pin cotter 2.5×30 ４ Stabilizer bar welding kit(front) １ Rod ball kit (right) １ Rod ball kit (left) １ Buffer stabilizer bar 20×45 Strap buffer plated Washer spring lock 8 Bolt hexagon flange head M8×20 A frame welding kit (front left) A frame welding kit (front right) B frame kit(front left) assembly...
Page 195 Chassis Installing the front A arms and shock Front Suspension components absorbers 1. Inspect the front A arms. 1. Install both the upper arm (1) and the lower arm (2). Look for bends or damage. Note: 2. Inspect the middle bushing. Lubricate the bolts (3) with lithium grease, and position them with the bolt Look for wear or damage.
Page 196 Chassis Rear Suspension and A arm Remarks Part Name Removing the rear suspension B frame welding kit (rear right) B frame welding kit (rear left) Bolt hexagon flange head M10×1.25-78 bushing 23×28 tube 10.3×23×50 Nut lock M10×1.25 Stabilizer bar welding kit(rear) Buffer stabilizer bar 20×45 Strap buffer plate Bolt hexagon flange head M8×20...
Page 197 Chassis Rear Suspension and A arm Part Name Qty Remarks B frame kit(rear right) assembly Rear shock absorber Q Bolt hexagon flange head M6×16 Bolt hexagon flange head M10×1.25-65 Washer spring 8 Bolt hexagon flange head M10×1.25-60 Nut lock M12×1.25 A frame welding kit(rear right) A frame welding kit(rear left) Cap bushing Ⅰ...
Page 198 Chassis Checking the components of the rear 2. Install the rear shock absorber(5). suspension Nut (6) 90-100 Nm (66-74 ft · lbs) 1. Inspect the stabilizer bar. Look for bends, cracks or damage. 3. Install the rear knuckle. Nut (7) 90-100 Nm (66-74 ft ·...
Page 199 Chassis Cooling System Part Name Remarks Removing the radiator 1 Water tank Radiator cover Oil cooler Radiator assy Radiator fan assy M-shaped fixed pipe clamps H-shaped rubber washer Hexagon flange bolt M6×20 Hexagon flange nut M6 Secondary water tank Secondary water tank cover Collar bushing 6×9×22×6.5 Hexagon flange bolt M6×16 Clip 9...
Page 200 Chassis Cooling System Part Name Qty Remarks Hexagon flange bolt M6×16 Water pipe Pressure-proof rubber oil pipe 10×17×300 Metal oil pipe Metal oil pipe Screw hoop 12-20 Hexagon flange bolt M6×12 5‐56...
Page 201 Chassis Checking the Radiator 4. Loosen the radiator and thermostat bleed 1. Inspect the radiator fins. bolts. Look for obstruction or leaks. 5. Pour in new antifreeze mixture until the coolant flows out each bleed opening. 6. Replace the bleed bolts. 7.
Page 202 Chassis Water Pump Part Name Water Pump assembly Bolt 6mm X45mm Bolt 6mm X65mm Bolt 6mm X10mm Water pipe 2 O-ring 20.7 X2.6 Water pipe 3 Hose clamp Cylinder inlet water joint Bolt 6mm X20mm O-ring 33.4 X2.4 Water pipe 1 Clamp Pipe clamp 2 Thermostat...
Page 203 Chassis Water Pump Part Name Water pump housing cover Gasket Cir clip Impeller assembly Water pump seal Oil seal Bearing Water pump housing O-ring 5‐59...
Page 204 Chassis Disassembling the Water Pump Inspecting the Water pump 1. Remove the rubber damper holder 1. Inspect the water pump housing (1) And the rubber damper (2). cover (1), the water pump housing Be careful not to scratch the (2), the impeller (3), the rubber impeller shaft.
Page 205 Chassis Assembling the Water pump 1. Install the oil seal (1) using a socket of the correct size (3) into the water pump housing (2). Use coolant as a lubricant for installation. 2. Install the water pump seal (1) into the housing (2) using a mechanical seal installer (3) and water pump seal installer (4).
Page 206 Chassis SEAT Remarks Part Name Removing the seat Bench seat Hexagon flange nut M10×1.25 Backrest assy Baffle plate Safety belt assy Hexagon socket head bolt M6×20 Hexagon flange step bolt M10×1.25×20-Φ14×5 Hexagon flange bolt M10×1.25×20 Hexagon flange nut M10×1.25 Cross large plate head screw M6×16 Head rest Safety belt buckle Hexagon flange bolt M10×1.25×20...
Page 207 Chassis FUEL TANK Part Name Remarks Removing the fuel tank Fuel tank assembly Fuel tank Cap gas tank Cap fuel pump Gasket pump Fuel pump Connector outlet fuel Connector inlet fuel Climp A Line fuel(0.05MPa)Ⅰ Hose heat insulation 5‐63...
Page 208 Chassis FUEL TANK Part Name Remarks Hose tee coupling Line fuel(0.05MPa) Hose heat insulation Clip line brake Ⅰ Bolt hexagon flange head M6×16 Fuel cleaner Clamp tank Bolt hexagon flange head M8×30 Line fuel(EPA)φ7×φ11×700 Clamp D Foam tank 5‐64...
Page 209 Chassis Checking the fuel pump operation 1. Remove the seat bottom and cover 2. Disconnect the pressure feed fuel hose. 3. Connect a fuel pressure gauge. 4. Turn the ignition switch to the run position. Do not start the engine. 5.
Page 210 Electrical Electrical Components 1. Thermo switch 2 2. Radiator fan 3.Gear motor 4. Winch 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 6‐1...
Page 211 Electrical Electrical Components 1. Fuse/Relay Box 2. Starter relay 3. Battery 4. Rectifier/regulator 5. Speedometer 6. On-Command four-wheel drive switch and differential gear lock switch 7. Ignition switch components 6‐2...
Page 212 Electrical Whenever performing any type of electrical test it is very important to start off with a known good Battery! Check the charge State of the Battery. It needs to be fully charged. There are 2 types of Batteries commonly used on UTV’s. •...
Page 213 Electrical Warnings: Batteries generate explosive gas and contain electrolyte, which is made of sulfuric acid, a highly poisonous and caustic chemical. Whenever working with batteries always follow these preventative measures: • Wear eye protection, Eye shield or safety glasses with side shields. •...
Page 214 Electrical Using a Constant Voltage Charger (Lead Acid Battery) Measure the open circuit voltage prior to charging. Connect the charger and ammeter to the battery and start charging. Make sure the setting is at 1/10 the amp hour rating of the battery. This is typically 2 amp 12 Volts.
Page 215 Electrical Charging a Maintenance Free Battery Using a Variable Rate Charger (Maintenance Free Batteries) Set the charging voltage to 16-17 V. Measure the open circuit voltage. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written Adjust the charging voltage to 20‐25 V.
Page 216 Electrical Checking the Fuses After testing and replacement of the fuse, turn on the Main switch to energize and check the circuit that Note: was affected. Always turn the main switch off when checking or replacing a fuse. If the fuse blows immediately check the rest of the circuit for a short.
Page 217 Electrical 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. • The pocket tester should be set to the “Ω...
Page 218 Electrical 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.
Page 219 Electrical 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. Caution; Avoid touching the glass part of the bulb as the oils in your skin transfer to the bulb.
Page 220 Electrical Ignition System Circuit Diagram 1. High tension Coil 2. C.D.I 3. Magneto 6‐11...
Page 221 Electrical Troubleshooting No spark or intermittent spark (Ignition circuit) Procedure: Check: 1) Fuses (Main, Ignition) 2) Battery 3) Sparkplug 4) Ignition spark cap 5) Spark plug cap resistance 6) Ignition coil resistance 7) Main switch 8) Pickup coil resistance 9) Rotor pickup coil resistance 10) Wiring connections (The entire Ignition circuit).
Page 222 Electrical Check the Spark Plug Cap resistance. 10K ohms Check the Ignition coil resistance. Replace the Spark Plug Cap Connect multimeter as shown. Positive lead to Orange lead terminal. Negative lead to Ignition coil base. Primary coil resistance 0.18 – 0.28 Ohms Test Secondary coil resistance.
Page 223 Electrical Check the wiring of the entire ignition Incorrect Repair wiring or replace connectors as circuit. necessary. Replace the C.D.I. unit 6‐14...
Page 224 Electrical Electric Starting System 6‐15...
Page 225 Electrical Troubleshooting a starter motor failure Check: 1. Fuses (Main, Ignition, and Signaling) for continuity. 2. Battery for 12.8V or more 3. Starter motor Connect a jumper of equal size from battery positive to the starter motor. Warning: If the size of jumper wire is too small the jumper could burn and or cause injury.
Page 226 Electrical Starter Motor Part Name Remarks Removing the starter motor Remove the parts in the order Starter motor lead listed Starter motor / O-ring 1 / 1 Disassembling the starter motor Bracket 1 Washer kit Bracket 2 Shims Brush seat 1 / Brush seat 2 1 / 1 Armature coil 1 Yoke...
Page 227 Electrical Charging System 6‐18...
Page 228 Electrical Troubleshooting the charging system Condition: Battery is not charging. Check connections and wires from the stator to the regulator to the battery. Connect a multi meter to the leads coming from the stator. (3 White wires). Test for an external short. test in ohms # 1 white wire to ground #2 white wire to ground #3 white wire to ground...
Page 229 Electrical Lighting System 6‐20...
Page 230 Electrical Signaling System 6‐21...
Page 231 Electrical Cooling System 6‐22...
Page 232 Electrical 2WD / 4WD Selecting System 6‐23...
Page 233 Engine Management System Introduction EMS (Engine Management System) EMS is a self-contained set of components including a custom built computer, sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature, then 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 234 Engine Management System Layout of EMS Components COMPONENTS OF EMS 1) Electronic Control Unit 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 235 Engine Management System Software/calibration re-flashing procedure. In the event of ECU hardware failure or malfunction (during warranty period only) the ECU should be sent back to the vehicle manufacturer giving complete details of the ECU Part No, Serial number, Vehicle Model &...
Page 236 Engine Management System Avoid applying lubricant over the director plate holes – this may restrict injector • flow. Do not dip the injector tip in lubricant. Multec 3.5 injectors come from the factory with the seal rings attached. The re- •...
Page 237 Engine Management System 4) Replacement of the injector Warning: The injector and all associated hardware may be extremely hot. • Shut off ignition. • Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine. Disconnect the electrical connector from the injector wiring harness.
Page 238 Engine Management System In case of plugging of injector follow the injector cleaning procedure mentioned in • the next section. 6) Cleaning Procedure Electrically disable the fuel pump by removing the fuel pump connection. • Relieve the fuel pressure in the system and disconnect the fuel connection at the •...
Page 239 Engine Management System Throttle Body Removal Disconnect negative terminal of the battery • • Disconnect electric lead wire of throttle position sensor coupler, stepper motor coupler and MAP/MAT sensor coupler ( if this sensor is mounted on the throttle body) •...
Page 240 Engine Management System Oxygen Sensor This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine. It consists of the wide range sensor and stoichiometric sensor. We typically use a stoichiometric sensor on a small engine. It is the feedback element for engine closed loop control.
Page 241 Engine Management System Make sure to perform work in well-ventilated area and away from any • open fire/flames. • Wear Safety glasses To relieve fuel vapor pressure in fuel tank, remove fuel filler cap and then • reinstall it. To relieve pressure in the fuel lines, disconnect the power to the pump, pull the •...
Page 242 Engine Management System Fuel Module Removal Relieve fuel pressure by disconnecting the power to the pump, pull the spark • plug boot off the plug and place it away from the plug. Crank the engine to release the pressure in the lines. Disconnect Battery negative cable.
Page 243 Engine Management System Ems Fault Codes When a fault occurrence happens, the odometer's clock will turn into a number, which is a fault code, find out the cause with this number, press the clock button, then it will turn back to clock mode, and five second later, the fault code will show again. Fault Code List System or DTC Description...
Page 244 Troubleshooting When Troubleshooting or diagnosing a problem on a UV, it is always good to use a systematic approach to solving the issue. There are 3 main things to look for to have a running motor. A Fuel air mixture being delivered to the cylinder. •...
Page 245 Troubleshooting 5. Turn the engine over using the Key switch. A fat blue spark must be evident between the spark tester or spark plug terminals. 6. If there is a strong, blue spark, the ignition system is functioning properly, Check for one or more of the following possible malfunctions: Faulty fuel system component.
Page 246 Troubleshooting 2. Cylinder head: Loose spark plug or damaged spark plughole. • • Damaged cylinder head gasket. Warped or cracked cylinder head. • Damaged decompression assembly. • See Maintenance and Adjustment section for procedure. Standard 135.14 Psi Minimum 128.02 Psi Maximum 142.25 Psi Upon completion of these 3 tests you should know which system is in question and the direction of further testing or repair.
Page 247 Troubleshooting Pre-ignition Pre-ignition 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 pre-ignition. This is first noticed as a power loss but eventually causes damage to the internal parts of the engine because of the high combustion chamber temperature.
Page 248 Troubleshooting Valve train noise—Check for the following: • 1) Excessive valve clearance. 2) Worn or damaged camshaft. 3) Damaged camshaft. 4) Worn or damaged valve train components. 5) Damaged valve lifter bore(s). 6) Valve sticking in guide. 7) Broken valve spring. 8) Low oil pressure.
Page 249 Troubleshooting marks in Step7, listen for pressure building inside the combustion chamber, indicating that the piston is moving to TDC on its compression stroke. Second, view the gauge on the leak down tester when turning the engine. As the piston moves toward TDC on its compression stroke, compression building inside the combustion chamber may cause the gauge needle to move slightly.
Page 250 Troubleshooting Note: If a large amount of air escapes from the exhaust pipe or through the throttle body, the air is leaking through on open valve, Check the index mark to make sure the engine is at TDC on the compression stroke, If the engine is remaining at TDC but there is still a large amount of air escaping from the engine, the crankshaft is off one revolution.
Page 251 Troubleshooting Make sure all terminals within the connector are clean and free of corrosion. • Clean them. If necessary. And pack the connectors with dielectric grease • Push the connectors with dielectric grease together so that they are fully engaged and locked together. Too much dielectric grease can create a hydro-lock and make it difficult to assemble the connectors.
Page 252 Electrical component replacement Most UV dealerships and parts suppliers will not accept the return of any electrical part. If you can’t determine the exact cause of any electrical system malfunction, then you purchase a new electrical component(s), install it, and then find that the system still does not work properly, you will probably be unable to return the unit for a refund.
Page 253 MY2017/2018 •- Wiring L)<.. • « ♦ f « ♦ !]}@ - - - - - - - .:JI _._IA_ » ¥...
Page 254 MY 2019 Forward Wiring...
Page 255 Form Number 769-12198_06...

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