Page 1 SERVICE MANUAL Challenger 500 Challenger 700...
Page 2 Foreword Brief Introduction to the Service and Maintenance Handbook 500/700 Challenger Utility Vehicles This manual gives methods to check, maintain and repair the Cub Cadet 500 & 700 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 I ndex Chapter 1 General Chapter 2 Chapter 3 Specifications Periodic Maintenance Adjustments Chapter 4 Chapter 5 Engine Chassis Chapter 6 Chapter 7 Electrical Engine Management System Chapter 8 Wiring Troubleshooting Diagram...
Page 4 INDEX Electrical System Fundamentals 1-24 General Information 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 3-19 Crankcase, Starter Motor and Oil 4-30 Select Lever Shift Rod adjustment 3-20 Filter Brake light switch adjustment 3-20 Crankcase 4-31 Final Gear oil Change 3-21 Bearings 4-32 Tow In adjustment 3-22 Inspection 4-33 CV Boot inspection 3-23 Assembly...
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 5-37 Charging Circuit Diagram 6-18 CV Joint Inspection...
Page 7: Vehicle Identification Number
Vehicle Identification Number 123456 Manufacturer UV below 750 cc UV above 750 cc 500cc 700cc DOT Check Digits 2010 Model Year 2011 Model year 2012 Model Year 2013 Model Year 2014 Model Year Manufacturing Plant A Manufacturing Plant B 123456 Sequential Serial Number...
Page 8: General Information
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. Headlights 2. Front shock absorber adjusting ring 3. Brake fluid reservoir 4. Air filter element (inside air intake duct) 5. V‐belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9. Cargo bed 10. Tail/brake lights 11. Rear shock absorber adjusting ring 12. Cargo bed release lever 13. Spark arrester 14. Passenger seat belt 15. Passenger seat 16. Oil filter 17. Engine oil dipstick 18. Battery 19. Fuses 20.
Page 10: Identification Code
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 11 General Information Safety 9. Keep your work area clean and 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 12: Cleaning Parts
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 13: Warning Labels
General Information Fasteners 9. Thoroughly clean all oil, grease 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 UV parts. Metal brushes may cause operates as designed and can be a spark.
Page 14: Self-Locking Fasteners
General Information Self-Locking Fasteners applications, a cotter pin and castellated (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 15 General Information Observe the following when installing snap rings 1. Remove and install snap rings with snap rings pliers. Refer to Basic Tools in this chapter. 2. In some applications, it may be necessary to replace snap rings after removing them. E-clips are used when it is not practical 3.
Page 16: Engine Oils
General Information Engine Oils Greases Engine oil for the UV four stroke engine Grease is lubricating oil with thickening is classified by two standards: the agents added to it. The National American Petroleum Institute (API) Lubricating Grease Institute (NLGI service classification and The Society of grades grease.
Page 17: Cleaners, Degreasers And Solvents
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 Warning only nonflammable or high flash point Never put mineral based petroleum...
Page 18: Thread Locking Compound
General Information Thread locking Quality tools are a good investment. 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 19 General Information Wrenches Quality Phillips screwdrivers are manufactured with their cross-head 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 20 General Information Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers.
Page 21 General Information Socket Wrenches, Adjustable 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: Allen Wrenches
General Information Allen Wrenches Use hex keys or Allen® wrenches (Figure 11) 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 UV’s. Allen bolts are sometimes called socket head screws.
Page 23: Snap Ring Pliers
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 24: Precision Measuring Tools
General Information Hammers Make the tool shown from a No.6 screw and nut, two washers, a length of Various types of hammers are available tubing, an alligator clip, an electrical to fit a number of applications. Use a eyelet and a length of wire ball-peen hammer to strike another tool, such as a punch or chisel.
Page 25: Feeler Gauge
General Information component. 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 26 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 27: Metric Micrometer
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 28 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 1.25 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 so on. When reading a metric micrometer, add the number of millimeters and half- The tapered end of the thimble has 25...
Page 29: Telescoping And Small Bore Gauges
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 0.01 in. 4. Add the readings from Steps 1-3. Telescoping and Small To use a telescoping gauge, select the correct size gauge for the bore.
Page 30: Dial Indicator
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 31: Electrical System Fundamentals
General Information Multimeter 4. If necessary, rotate the meter ohms adjust knob until the needle and 0 mark align. A multimeter (Figure 34) is an essential Electrical System tool for electrical system diagnosis. The voltage function indicates the voltage Fundamentals applied or available to various electrical components.
Page 32 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 performed by anyone reasonably is measured in ohms. Resistance causes a competent with tools.
Page 33 General Information where possible. Heat can warp, available, have these operations melt or affect the temper of performed by a shop equipped parts. Heat also damages the with the necessary equipment. finish of paint and plastics. Do not use makeshift equipment that may damage the UV.
Page 34: Removing Frozen Fasteners
General Information Removing Broken 17. Whenever rotating parts contact a stationary part, look for a shim Fasteners or washer. 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 35: Removing Hoses
General Information Stud brush. Clean the inside of the hose 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 36 General Information Removing Bearings wooden or aluminum spacer (Figure 41). 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 37: Installation
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 (Figure 44). 4. Step 1 describes how to install a bearing in a case half or over a shaft.
Page 38: Interference Fit
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 39: Seal Replacement
General Information Seal Replacement Storage Seals (Figure 47) contain oil, water, 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 40 General Information Preparing the UV for for each type of product being used. Storage 8. Place the UV on work stands with all the wheels off the ground. The amount of preparation a UV should 9. Cover the UV with old bedsheets undergo before storage depends on the or something similar.
Page 41: Oil Capacity
Specifications General Specifications Dimensions: Basic Weight: Overall Length 3,010mm 118.5 in With oil and full fuel tank 543 kg Overall width 1,670mm 1,197 lbs 65.75 in Overall Height 1,940mm 76.38 in Seat Height 790mm 31.1 in Wheelbase 1,890mm 74.4in Ground Clearance 270mm 10.63 in Minimum Turning...
Page 42: Specifications
Specifications Fuel Delivery: Fuel: Type Unleaded fuel 91 Octane or Electronic Fuel Injection higher Tank Capacity 7.66 US gal Spark Plug: Clutch Type: Type/Manufacture r DPR8EA 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...
Page 43 Specifications Lights: Type Wattage Quantity Headlight: Krypton Bulb 12V35w/35w Taillight/Brake Krypton Bulb 12V5.0/21.0w Position Light Krypton bulb 12V5w Turn Signal Krypton Bulb 12V10w Neutral- Reverse Coolant Temp Parking Brake Four-Wheel Drive Light LED Differential gear lock 700 UV Engine Specifications Service wear Item Metric...
Page 44 700 UV Engine Specifications Service Wear Item Metric Standard Limit Dimensions “A” 30.06-30.16 mm (1.1835-1.1874 in) 29.96 mm(1.1795 in) Intake “B” 35.69-35.79 mm (1.4051-1.4091 in) 35.59 mm(1.4012 in) Exhaust “A” 30.11-30.21 mm (1.1854-1.1894 in) 30.01 mm (1.1815 in) “B” 36.50-36.60 mm (1.4370-1.4409 in) 36.40 mm (1.4331 in) Camshaft Runout limit...
Page 45 700 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) 5.945 mm 0.85-1.15 mm (0.0335-0.0453 in)
Page 46 700 UV Engine Specifications Service Wear Item Metric Standard Limit Valve Spring: Inner Spring 32.63 mm (1.28 in) 31.0 mm (1.22in) Free Length 36.46 mm (1.44 in) 34.6 mm (1.36 in) Set Length (Valve Closed) 27.5 mm (1.08 in) 31.0 mm (1.22 in) Compressed pressure (Installed)
Page 47 700 UV Engine Specifications Item Metric Standard Service Wear Limit Piston: Piston to Cylinder 0.050 - 0.070 mm (0.0020 - 0.0028 in) 0.15 mm (0.0059 in) Clearance Piston size “D” 99.945 - 99.995 mm (3.9348 - 3.936 in) 2.5 mm (0.10 in) Measuring point “H”...
Page 48 700 UV Engine Specifications Item Metric Standard Service Wear Limit 2nd ring: Type: Taper 1.2×4.0 mm (0.0472 X0.1575 in) Dimensions (B ×T) 0.30 - 0.45 mm (0.0118 -0.0177 in 0.80 mm (0.0315 in) End gap (installed) 0.03 - 0.07 mm (0.0012 - 0.0028 in) 0.13 mm (0.0051 in) Side clearance Oil ring: Dimensions (B×T)
Page 49 500 UV Engine Specifications Item Standard Engine : Engine type Liquid cooled 4-stroke, Water cool Cylinder arrangement Forward-inclined single cylinder Displacement 471cm Bore stroke 84.5 84.0mm (3 33 3.31in) Compression ratio Starting system ctri c starter Lubri cation system sump Carburetor (If equipped) Type/quantity PD33J-A /...
Page 50 500 UV Engine Specifications 2-10...
Page 51 500 UV Engine Specifications 2-1 1...
Page 52 500 UV Engine Specifications 2-12...
Page 53 500 UV Engine Specifications 2-13...
Page 54 Specifications Item Metric Standard Service Wear Limit Balancer: Balancer drive method Gear Automatic centrifugal clutch 1.0 mm (0.04 in) Clutch shoe thickness 1.5 mm (0.06 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) Drive axle deflection limit...
Page 55 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 - 0.3 mm (0.004 - 0.012 in) Final gear backlash 0.1 - 0.3 mm (0.004 - 0.012 in) Differential gear backlash 0.05 - 0.25 mm(0.00 2 - 0.010 in) Cooling system...
Page 56 Specifications Service Wear Item Metric Limit Standard Front wheel Type Panel wheel Rim size 12 X6.0 AT Rim material Alum. Rim runout limit Radial 2.0 mm (0.08 in) Lateral 2.0 mm (0.08 in) Front wheel Type Panel wheel Rim size 12 X8.0 AT Rim material Alum...
Page 57 Specifications Service Wear Item Metric Standard Limit Rear disc brake Type Dual Ventilated Hydraulic Disc Disc outside diameter X 165 × 5.0 mm (6.50 × 0.20 in) thickness Pad thickness inner 1.5 mm (0.06 in) 5.6 mm (0.22 in) Pad thickness outer 1.5 mm (0.06 in) 5.6mm...
Page 58: Engine Tightening Torques
Specifications ENGINE TIGHTENING TORQUES Part to be tightened Part Thread Torque Torque Name Size Ft-lbs Cylinder head Bolt 6 mm Bolt 9 mm Spark plug — 12 mm Cylinder head (exhaust pipe) Stud bolt 8 mm Cylinder head cover Bolt 6 mm Tappet cover (exhaust) —...
Page 59 Specifications ENGINE TIGHTENING TORQUES Part to be Tightened Part Thread Torque Torque Ft Name Size Crankcase Bolt 8 mm Bolt 6 mm Bolt Bearing Housing (clutch housing Bolt assembly) Air duct assembly bracket Bolt 6 mm Oil seal (engine cooling fan pulley) Bolt 5 mm retainer...
Page 60 Specifications ENGINE TIGHTENING TORQUES Part to be Tightened Part Thread Torque Torque Name Size Ft Lbs Shift arm Bolt 6 mm Shift rod locknut (select lever unit) 8 mm Shift rod locknut (shift arm side) 8 mm Select lever unit Bolt 8 mm Plug (right crankcase)
Page 61: Chassis Tightening Torques
Specifications CHASSIS TIGHTENING TORQUES Part to be Tightened Thread Torque Torque Size Ft Lbs Rubber connecting bracket 1(or 2) and frame 10 mm Engine and Rubber connecting bracket 2 (front) 10 mm 6 mm Engine and Rubber connecting bracket 1 (rear) 8 mm 6 mm Rear upper arm and frame...
Page 62 Specifications CHASSIS TIGHTENING TORQUE Torque Part to be Tightened Thread Torque Ft Lbs Size Steering knuckle and front lower arm 12 mm Tie-rod locknut 12 mm Steering knuckle and tie-rod 12 mm Front lower arm protector board and front lower arm 6 mm Seat belt and frame 10 mm...
Page 63 Specifications CHASSIS TIGHTENING TORQUES Part to be tightened Thread Torque Torque Size Ft Lbs Front bumper and frame 10 mm Upper instrument panel and frame 6 mm Ceiling side frame (enclosure) and frame 10 mm Support frame 10 mm Top frame 10 mm Side Frame 10 mm...
Page 64 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...
Page 65: Periodic Maintenance
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 66 Periodic Maintenance Initial Every ITEM Month Work to be performed Miles 1500 1500 3000 Hours * Check Operation Front and Rear *Correct if Suspension Necessary * Check Bearings for looseness or Wheel Bearings damage * Replace if Necessary * Check Condition Spark Plugs * Adjust Gap and Clean * Replace if Necessary Steering System *Check Operation/ Replace if Necessary * Check Toe‐In/ Adjust if Necessary Cooling System * Check for coolant leaks * Repair if Necessary...
Page 67 Periodic Maintenance NOTE Recommended Brake Fluid: DOT 3  Caution (DO NOT MIX DIFFERENT BRAKE FLUIDS)  Brake Fluid Replacement every 24 months  When disassembling the master cylinder or caliper, replace the  fluid. Check the fluid level and add brake fluid as needed.
Page 68 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.
Page 69 Periodic Maintenance Maintenance and Adjustment of the UV 4. To adjust: Reassembly is in reverse order. 1. Loosen the lock nut (1). 1. Timing Plug cover 2. Insert feeler gauge of proper 2. Engine fan components thickness for valve clearance (2). 3.
Page 70 Periodic Maintenance Maintenance and Adjustment of the UV  Measuring the Compression Pressure Check the electrode (1) for carbon deposits or a burned Note: condition. Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes.
Page 71 Periodic Maintenance Maintenance and Adjustment of the UV 3. Unscrew the dipstick and check the Standard compression pressure data oil level. Compression pressure (at sea level) Oil level should be between the Standard: 1,324 Kpa (188.31Psi) Maximum ①and Minimum Level ② Minimum: 1,150 Kpa (163.57 Psi) Maximum: 1,480 Kpa...
Page 72 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. 2.
Page 73 Periodic Maintenance Maintenance and Adjustment of the UV Chassis 7. Check the oil pressure  Slightly loosen the oil galley bolt ①. Cleaning the Air Filter 1) Remove:  Driver’s seat  Passenger’s seat  Console  Air filter case cover ①...
Page 74 Periodic Maintenance Maintenance and Adjustment of the UV Note 3) Clean the Element  Never operate the engine with the air filter Wash the element gently but element removed. This will allow thoroughly with solvent designed unfiltered air to enter, causing rapid wear for foam air filters.
Page 75 Periodic Maintenance Maintenance and Adjustment of the UV 6) Remove the radiator cap (1) Changing the Coolant 1) Remove:  Driver’s seat  Passenger’s seat  Console  Lift up the hood  Remove coolant reservoir cap (1) 7) Drain the coolant: ...
Page 76 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 77 Periodic Maintenance Maintenance and Adjustment of the UV Checking the V-Belt 1) Remove:  Driver’s seat  Passenger’s seat  Console  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 78 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  Drive belt cover as shown in the figure.
Page 79 Periodic Maintenance Maintenance and Adjustment of the UV Adjusting the Brake Pedal Adjusting the Parking Brake 1) Check Brake Pedal Free Play. 1) Shift the drive select lever into Low gear “L”. 2) Remove:  Driver’s seat  Passenger’s seat ...
Page 80 Periodic Maintenance Maintenance and Adjustment of the UV Caution: Adjust:  Do not mix different type of brake Pull back the adjuster cover fluid. (1). Use Dot 3 brake fluid only as  Loosen the locknut (2). mixing can cause brake failure and ...
Page 81 Periodic Maintenance Maintenance and Adjustment of the UV Checking the Brake Hoses and Brake 1. Locate the brake fluid reservoir. Lines 2. Add the proper brake fluid to the 1. Remove: reservoir. ·Driver seat 3. Install the diaphragm. Be careful not to ·Passenger seat spill any fluid or allow the reservoir to overflow.
Page 82 Periodic Maintenance Maintenance and Adjustments of the UV Warning: 12. Make sure the bleed screw is tight and The vehicle must be stopped and your add fluid to the reservoir to the full line. foot off the accelerator pedal before shifting to prevent damage to the transmission.
Page 83 Periodic Maintenance Maintenance and Adjustment of the UV 3. Remove the final gear oil drain bolt (1). 1. Install the drain bolt. 2. Remove the oil filler plug. 3. Fill until oil reaches the bottom of the filler hole. 4. Install the filler plug. Checking the Final Gear Oil Level Drain Bolt Torque 10 Nm (1.0 m ·...
Page 84 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. 4. Measure (A) with tires on the ground. ...
Page 85 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 is or cracking.
Page 86: Changing The Headlight Bulb
Periodic Maintenance Maintenance and Adjustment of the UV Changing the headlight bulb Adjusting the Rear Shock Absorbers Adjust spring preload by turning the Remove: adjuster. 1 setting is soft to 5 setting for Lift the hood. hardest. Headlight bulb holder cover (1). Warning: Always adjust the shock spring preloads equally on each side of the...
Page 87 Periodic Maintenance Maintenance and Adjustment of the UV Install Headlight holder (with bulb). Headlight bulb holder cover. New bulb into the tail/brake light bulb Close the hood. holder. Tail/brake light bulb holder (with bulb). Cargo bed panel. Changing the Tail/Brake Light Bulb Remove: ...
Page 88: Special Notes
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 their original position for reassembly.
Page 89 Engine Engine Removal Figure 2 Figure 1 Part Name Remarks Remove the parts in the order Remove Intake Assembly listed Intake assembly (Fig 1) For installation, reverse the order Drain Plug (Fig 2) listed After removal of the intake system, cover the opening so that no foreign debris can fall into the engine.
Page 90 Engine Cylinder Head and Cylinder Head Cover Part Name Remarks Remove the following: Remove the parts in the order listed 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 91 Engine 1. Check the Valve Clearance 5. Inspect the cylinder head.  (Refer to Chapter 3). Remove carbon deposits (Use a good quality 2. Inspect the cylinder head cover for combustion chamber cracks or damage. If replacement is cleaner). Note: necessary replace cylinder head Do not use a sharp instrument to avoid cover and cylinder head as a set.
Page 92 Engine 2. Install the cylinder head. Tighten the tensioner bolt to the  correct torque. Cylinder head gasket  Cylinder Head Timing chain tensioner bolt  9mm bolts (1-6) (10 Nm or 7 ft lbs) Torque 38 Nm or 28 ft lbs ...
Page 93 Engine Rocker Arms and Camshaft Part Name Remarks Removing the rocker arms and camshaft Remove parts in order 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 94 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 ...
Page 95 Engine Installation Temporarily install the camshaft sprocket on the camshaft. (Do not install the bolts) 1. Installing the rocker arms: Install the timing chain on the sprocket.  Rocker arms (1) NOTE:  Rocker arm shafts (2) UPDATED TIMING PROCEDURE ON PAGE 4-48 Note: The thread hole (a) of the rocker arm shaft must face the outside.
Page 96 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 97 Engine Inspect Measure valve stem runout  Valve Sealing: Runout 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 98 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 99 Engine Cylinder and Piston Part Name Remarks Removing the cylinder and piston Remove parts in the order Water Pump 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 100 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 ...
Page 101 Engine Caution: Install Be careful not to damage the timing 1. Piston rings (onto the piston):  chain guide during installation. Pass Install rings so that the timing chain through the timing manufacturer’s numbers or chain cavity. markings face upward. ...
Page 102 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 103 Engine 1. Inspect the A.C. Magneto:  Stator coil  Pickup coil Look for wear, damage, burnt, frayed wires. If damaged, replace. Turn the starter wheel gear counterclockwise (1), to check that the starter clutch and wheel gear engage. If the starter clutch and wheel gear do not engage, 2.
Page 104 Engine  Inspect the engine cooling fan: Engine cooling fan (1)  Engine cooling fan Install the bolts in the holes in the  Air shroud 1 collar of the engine cooling fan.  Air shroud 2 7 Nm or 5 ft lbs Look for cracks or damage, if necessary replace.
Page 105 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 106 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 ...
Page 107 Engine Primary and Secondary Sheaves 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 Secondary sheave assembly Drive belt case For installation, reverse the Rubber gasket...
Page 108 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 4‐21...
Page 109 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 4‐22...
Page 110 Engine 1. Inspect: 2. Inspect the Secondary sheave:  Secondary fixed sheave  Primary sheave outside  Secondary sliding sheave diameter (a). Check outside diameter wear limit: Look for smooth operation, 29.5 mm scratches or damage, If replacement is necessary replace as a set.
Page 111 Engine Install 3. Assembling the secondary Sheave:  Apply assembly lube to: 1. Assembling the primary sheave:  Clean the primary sliding sheave face (1) The secondary sliding  The primary fixed sheave face sheave (1) inner surface and oil seals. ...
Page 112 Engine Install the nut (2) and tighten it to Tighten the primary sheave nut (1). the specified torque using the locknut wrench, and sheave fixed 120 Nm or 88 ft lbs block. Tighten the secondary sheave nut (2). 100 Nm or 74 ft lbs Note: 4.
Page 113 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 Clutch carrier assembly For installation, reverse the order listed 4‐26...
Page 114 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 4‐27...
Page 115 Engine Inspect the clutch:  Inspect the clutch housing (1)  Look for heat damage or wear.  Inspect the one way clutch bearing Inspect the clutch shoe assembly:  • Look for heat damage or wear. Look for chaffing, wear or damage. Note: •...
Page 116 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. 4‐29...
Page 117 Engine Crankcase Starter motor and oil filter Part Name Remarks Remove the Starter Motor, Remove the parts in the order listed Timing Chain and Oil Filter A.C. magneto rotor Primary and secondary sheaves Clutch carrier assembly Starter Motor / O-ring 1 / 1 Oil Filter / O-ring Oil Line assembly / O-ring...
Page 118 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 119 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 4‐32...
Page 120 Engine Assembling the crankcase Inspect  Oil Line Apply sealant (quick gasket) (1) to Look for cracks or damage. the mating surfaces of both halves. Use only a thin bead of sealant. Install the dowel pins (2). Fit the left crankcase half onto the ...
Page 121 Engine  Tighten the crankcase bolts (1) in a Installing the shift levers: cross pattern in stages.  Shift lever 2 assembly (1) 10 Nm or 7 ft lbs  Apply sealant (4) to crankcase bolt 14 Nm or 10 ft lbs (2) and install: ...
Page 122 Engine Crankshaft and Oil Pump Part Name Remarks Removing the Crankshaft and Remove the parts in the order Oil 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 123 Engine Oil Pump Part Name Remarks Disassembling the Oil Remove the parts in the order listed Pump Rotor cover Shaft Inner rotor For installation, reverse the order Outer rotor listed Oil Pump housing 4‐36...
Page 124 Engine Inspect the oil pump  Rotor housing  Rotor cover Look for cracks, wear or damage.  Oil pump operation Tip clearance Limit: 0.23 mm Side clearance Limit: 0.17 mm Body clearance Limit: 0.24 mm Look for smoothness.  Inspect the oil strainer (1) Measure the crankshaft O- ring (2) ...
Page 125 Engine  The crankshaft (1) and the crank pin (2) oil passageways must be properly aligned with a tolerance of less than 1mm or 0.04 in. Caution: The buffer boss and woodruff key should be replaced whenever removed from the crankshaft. Install;...
Page 126 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 127 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 4‐40...
Page 128 Engine  Inspect the shift forks Springs  Shift fork follower (1) Look for cracks or damage.  Shift fork pawl (2) Look for scoring, bends, wear or damage.  Shift drum Inspect the grooves Look for scratches, wear or damage.
Page 129 Engine Inspect the secondary shaft and driven Install  Assembling the shift fork sprocket.  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 Look for smooth operation.
Page 130 Engine Middle Gear Middle drive shaft Part Name Remarks Removing the Middle Drive Remove the parts in the order listed Shaft Crankcase separation Bearing housing Middle drive gear Middle drive pinion gear Shim For installation, reverse the order Middle drive shaft listed Bearing retainer 4‐43...
Page 131 Engine Middle Driven Shaft Part Name Remarks Remove the parts in the order listed. Removing the middle drive shaft Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing / O-ring 1 / 1 Shim Middle driven pinion gear Bearing retainer Bearing retainer For installation, reverse the order...
Page 132 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 133 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  ...
Page 134 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 (1) to 145 Nm or 107 ft lbs ...
Page 135 CX700 Updated Timing Procedure 4-48...
Page 136 Chassis Inspection 2. Loss of Brake performance Appearance Inspection  Check for brake rotor 1. Plastic body panels damaged wear. Has it exceeded  the wear limit? Replace with new plastic  Check for brake pad body panel  wear. Is the master Check for any supports that cylinder locked up? Has...
Page 137 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 on the anti-sway bar for damage or wear.
Page 138 Chassis Inspection 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. Check the gears of the rear gearbox for wear or damage.
Page 139: Steering System
Chassis Steering System Part Name Remarks Removing the Steering Assembly Rack assembly Pinion Circlip Bearing Adjuster Spring Pressure pad Circlip Oil seal Zip tie L-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 140: Steering Wheel Assembly
Chassis Steering Wheel assembly Part Name Remarks Removing the Steering Wheel Assembly Flange bolt 8mm X 16mm Steering shaft Steering wheel Washer Flange nut 12mm X 1.25 Plastic center cap. 5‐5...
Page 141 Chassis Warning: Disassembly of the steering wheel This is a safety area, and any damage assembly or wear needs to be repaired immediately. 1. Remove  Do not let vehicle leave without proper Plastic center cap (1)  repairs being performed. Flange nut, washer (2) ...
Page 142 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 143 Chassis 5. Inspect the Tie Rods 2. Connect the steering joint Bolt M8×20  Look for bends or damage. 32 Nm (3.2m · kg, 23 ft · lb) 6. Inspect the steering Joint 3. Attach the steering tube to the frame.
Page 144 Chassis 4. Check the rear brake disc (1) for thickness (2). Brake discs wear as well as brake pads, therefore a periodic inspection may reveal scoring, or wear to a disc. Replacement is necessary if this is found. 5. Check the brake lines for cracks or distortion.
Page 145: Front Disc Brake Components
Chassis Front Disc Brake Components Part Name Remarks 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 146: Front Disc Brakes
Chassis Front Disc Brakes Part Name Remarks Removing the Brake Discs Brake caliper assembly Brake disc Bolt Axle housing Bolt Brake disc guard 5‐11...
Page 147 Chassis Inspect the Front Brake Discs  Inspect for galling or damage.  Measure brake disc deflection in 4 spots approximately 90 degrees from each other. Brake disc maximum deflection 0.10 mm (0.004 in)  Brake disc thickness (1)  Wheel hub (2) ...
Page 148 Chassis Front Brake Pads Part Name Remarks Removing the Front Brake Remove parts in the order listed Pads Brake caliper mounting bolt Brake pad holding bolt For installation, reverse the order Brake pad listed Pad spring 5‐13...
Page 149 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 the brake pads. 18 Nm (1.8 m · kg, 13 ft · lb) Brake caliper mounting bolt 1.
Page 150 Chassis Front brake caliper Part Name Remarks Removing the Front Brake Remove the parts in the order Caliper 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 151 Chassis Brake Caliper Disassembly Part Name Remarks Remove the parts in the order Disassembling the Front Brake Caliper 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 152 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) piston.
Page 153 Chassis Caution: 3. Install the brake caliper pistons (1) 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) ...
Page 154 Chassis Rear Brake Disc Part Name Remarks Remove the parts in the order listed Removing the Rear Brake Disc Brake caliper assembly Final drive gear For installation, reverse the order Rear brake disc listed 5‐19...
Page 155 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 156 Chassis Rear Brake Caliper and Brake Pads Part Name Removing the Rear Brake Caliper and Brake Pads Rear skid plate Brake fluid Parking Brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting bolt Parking brake lever assembly Union bolt Copper washer Brake hose...
Page 157 Chassis Rear Brake Caliper and Brake Pads Part Name Brake caliper bracket Parking brake arm nut Parking brake arm Set bolt Parking brake arm shaft Parking brake case bolt Parking brake case Gasket Brake caliper piston Dust seal Caliper piston seal Bleed screw 5‐22...
Page 158 Chassis Warning: Replacing the Rear Brake Pads All internal brake components should be cleaned in new brake fluid only. Do 1. Measure the brake pad thickness not use solvents as they will cause seals to swell and distort. Brake pad wear limit: 1.5 mm (0.06 in) 2.
Page 159 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 160 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 ...
Page 161 Chassis Brake Master Cylinder Part Name Remarks Removing the Brake Master Cylinder Remove the parts in the order listed. 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 162 Chassis 2. Install the brake line: Inspecting the Brake Master Cylinder 1. Inspect 19Nm (1.9 m · kg, 13 ft · lb)  Brake master cylinder (1). 3. Install the copper washers, brake Look for scratches or wear. hose and union bolt. 27Nm (2.7 m ·...
Page 163 Chassis Footrest Assembly Part Name Protective cover Screw 5mm X 16 Transmission shaft cover Sheathing paper Sheathing film Self-locking flange nut 6mm Clip 6mm Right footrest cover Dust guard plate Screw 6mm X 16mm Brake pedal mount Flange bolt 8mm x 16mm Accelerator pedal assembly Flat washer Split washer...
Page 164 Chassis Footrest Assembly Part Name Throttle cable Flat washer Parking brake lever assembly Micro switch Screw 4mm X 12mm Parking brake dust cover Parking brake cable Flange bolt 6mm X 16mm Cable clip Choke cable Anchor Brake pedal mud guard Flange bolt 8mm X 20mm Wire strap Wire strap...
Page 165 Chassis Front Wheel and Tire Part Name Removing the Front Wheel Tire Valve cap Center cap Axle nut Front wheel hub 5‐30...
Page 166 Chassis Rear wheel Part Name Removing the rear wheel Rear wheel Center cap Axle nut Rear wheel hub 5‐31...
Page 167 Chassis Inspect the Rim Installing the wheel hub  Axle nut 1. Measure runout Look for bends or damage. 260 Nm (26.0 m · kg, 190 ft · lb Check wheel bearing end play. Installing the Wheel Assembly Wheel runout limit: Radial ②: 2.0 mm (0.08 in) 1.
Page 168 Chassis Transmission System Front Bridge Part Name Circlip CV joint Circlip Circlip Boot band Dust boot Boot band Joint shaft Half axle assembly 5‐33...
Page 169 Chassis Part Name Removing the front bridge Front bridge assembly Differential gear case Differential gear case cover Drive pinion gear Universal joint yoke 14mm X 1.25 O-ring Oil seal Oil seal, front box input shaft Shim 0.1T Shim 0.2T Shim 0.5T Bolt 8mm X 25mm...
Page 170 Chassis Part Name Column pin 5 X 80 Gear motor Shaft coupling Rack O-ring 2 X 81 O-ring 2.4 X 140 Bearing 6007 Bearing 6912 Bearing 16007 Bearing 152112 Bolt M14X15X10 Washer 14 X 2 10mm Washer Shaft fork 4 Universal joint Bolt 14mm X 15mm...
Page 171 Chassis Part Name Clamp Intermediate shaft Circlip Cushion Spring 25 X 2.3 X 28 Dust boot Dust boot Bolt 10mm X 25mm Washer Screw 5‐36...
Page 172 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 4.
Page 173 Chassis 3. Inspect the balls and ball races. 6. Inspect the front drive shaft. Look for pitting, wear or damage. Look for bends. Check that the movement of the joint is smooth in all directions, in, 7. Inspect the torque limiter. out and around.
Page 174 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 175 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 · lb) 3. Install the front bridge differential onto the frame ...
Page 176 Chassis Rear Bridge Part Name Remarks Circlip Boot band Boot band Dust boot Circlip Double off-set joint assembly Circlip Circlip Double off-set joint assembly Joint shaft Half axle assembly 5‐41...
Page 177 Chassis Part Name Speed reducer assembly Final gear case Bearing assembly Bearing Hk556720 Final drive pinion gear Bearing 6305 Drive shaft coupling Oil seal 61 X 35 X 9 Bearing 65BM6720 O-ring 3.1 X 63.8 Flat gasket 12 X 4 X 30 Flange nut 12mm X 1.25 Pinion gear bearing housing...
Page 178 Chassis Part Name Gasket 1.9T Gasket 2.0T Gasket 2.1T Speed sensor assembly O-ring 2.3 X 19.4 Vent rear speed reducer Ring gear bearing housing Ring gear stopper 8mm Washer Flange nut Oil seal 65 X 90 X 9 Bearing 16017 O-ring 3.1 X 150 Washer...
Page 179 Chassis Part Name Spring Middle drive axle, rear bridge Circlip Cover Circlip Self-locking flange nut Dust cover 2 Dust cover 1 Oil line Oil line clip Washer Clip Clip Driven gear Boot band Flange bolt For servicing, refer to the Front Bridge 5‐44...
Page 180 Chassis Gear Shift Mechanism Part Name Gear assembly Lever sheath of gearshift Gearshift dust boot Gearshift assembly Gearshift rod Heim joint Lever Washer Bolt 8mm X 12mm Bolt 8mm X 16mm Plastic bolt Clip clamp Spring clamp Drain hose vv6mm vv6mmL 5‐45...
Page 181 Chassis  Adjust the shift rod length for Adjusting the Gearshift Mechanism smooth and correct shifting.  Neutral (1) Tighten the locknuts. Locknut High (2) 15 Nm (1.5 m · kg, 11 ft · lb) Low (3) Reverse (4) Select lever shift rod (5) Shift control cable (6) Note: Before shifting you must stop the...
Page 182 Chassis Suspension Front Suspension and A-arm Part Name Upper left A-arm Front upper ball joint Elasticity block ring Upper right A-arm Front upper ball joint Block ring, shaft Front lower left A-arm Front lower right A-arm Middle bushing Flange bolt 10mm X 70mm Locknut 10mm X 1.25...
Page 183 Chassis Part Name Front shock absorber left and right Locknut 10mm X 1.25 Flange bolt 10mm X 1.25 X 52 Rocker baffle Flange nut Flange bolt 6mm X 12mm Front upper ball joint 5‐48...
Page 184 Chassis Front Suspension Components Installing the front A-arms and shock absorbers 1. Inspect the front A-arms. 1. Install both the upper arm (1) and Look for bends or damage. the lower arm (2). 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 185 Chassis Rear Suspension Part Name Rear shock absorber left and right Flange bolt 12mm X 1.25 X 70 Flange bolt 12mm X 1.25 X 65 12mm X 1.25 Stabilizer Left idler arm Right idler arm Locknut Rubber isolator Isolator mount Flange bolt 8mm X 16mm Cushion plate...
Page 186 Chassis Rear A-Arm Part Name Rear upper A-arm assembly Rear Lower right A-arm assembly Rear Lower left A-arm assembly Bushing Flange bolt 10mm X 1.25 X 70 Locknut 10mm X 1.25 Rear upper A-arm Bushing gasket Right rock deflector Left rock deflector 5‐51...
Page 187 Chassis Checking the Components of the Rear 2. Install the rear shock absorber (5). Suspension Nut (6) 45 Nm (4.5 m · kg, 32 ft · lb) 1. Inspect the stabilizer bar. Look for bends, cracks or damage. 3. Install the rear knuckle. Nut (7) 45 Nm (4.5 m ·...
Page 188 Chassis Cooling System Part Name Remarks Formed left radiator hose Metal hose After left rubber hose Right rubber hose Right metal hose Formed right rubber hose Bolt clip Clip Bolt Radiator assembly Radiator fan assembly Phillips screw 6mm X 25 Quad seal Nut clip Radiator cap...
Page 189 Chassis Part Name Remarks Radiator Radiator cover Oil cooler Bolt 6mm X 20mm Quad seal Bolt 6mm X 20mm Quad seal Bushing Grommet Radiator fill reservoir Oil cooler shield Hose Clip Overflow hose Clip 5‐54...
Page 190 Chassis Checking the Radiator 4. Loosen the radiator drain bolt. 1. Inspect the radiator fins. 5. Pour in new antifreeze mixture while Look for obstruction or leaks. draining. 6. When color changes at the drain, tighten the drain plug and top off the radiator with the new coolant.
Page 191 Chassis Water Pump Part Name Water pump assembly Bolt 6mm X 45mm Bolt 6mm X 65mm Bolt 6mm X 10mm Water pipe 2 O-ring 20.7 X 2.6 Water pipe 3 Hose clamp Cylinder inlet water joint Bolt 6mm X 20mm O-ring 33.4 X 2.4 Water pipe 1...
Page 192 Chassis Part Name Water pump housing cover Gasket Circlip Impeller assembly Water pump seal Oil seal Bearing Water pump housing O-ring 5‐57...
Page 193 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). Be cover (1), the water pump housing careful not to scratch the impeller (2), the impeller (3), the rubber shaft.
Page 194 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 195 Chassis Seat Part Name Seat assembly Plate cushion Seat pan Flange bolt 8mm X 30mm Flange locknut 8mm X 1.25 Flange bolt 8mm X 30mm Seat latch Bolt 6mm X 38mm Seat latch stud Grommet 1 Grommet 2 Bushing 10.5 Side armrest Flange bolt 6mm X 25mm...
Page 196 Chassis Seat Part Name 10mm X 1.25 Bolt Flange locknut Cover Seat belt latch Seat belt Bolt 10mm X 1.25 X 22mm Bolt 10mm X 1.25 X 25mm Washer Cushion 5‐61...
Page 197 Chassis Fuel System Part Name Fuel tank Insulation paper Shock absorber cushion Binder plate Fuel pump cover Rubber tube Fuel outlet plug Clip 10 Clip Three-way pipe High pressure pipe Fuel pipe Fuel pump assembly fuel inlet plug Fuel cap Fuel cap seal Hex flange bolt M8x20 5-62...
Page 198 Chassis Checking the Fuel Pump Operation 1. Remove the driver’s seat, passenger’s seat, console, and the right protector 2. Place a container under the end of the fuel hose (1). 3. Turn the ignition switch to the run position. Do not start the engine. 4.
Page 199: Electrical Components
Electrical Electrical Components 1. Thermo switch 2 2. Radiator fan 3. Gear motor 4. Brake light switch 5. Parking brake switch 6. Pickup coil/stator assembly 7. Speed sensor 8. Diode 1 9. Circuit breaker (radiator fan motor) 10. Thermo switch 1 11.
Page 200 Electrical Electrical Components 1. Four-wheel drive relay 1 2. Four-wheel drive relay 2 3. Starter relay 4. Four-wheel drive relay 3 5. Differential gear lock indicator light relay 6. Four-wheel drive indicator light relay 7. Fuse box 8. C.D.I. unit 9.
Page 201 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 UV’s. ...
Page 202 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, an eye shield or safety glasses with side shields. ...
Page 203 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. Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging amperage drops all the way down, usually 1 amp. This type of battery charger cannot Set charge time to a maximum of charge a maintenance free battery. A variable rate charger is needed. 20 hours Leave battery for 30 minutes to settle before measuring the open circuit voltage. 12.8 V fully charged 12.0‐12.7 V not fully charged Under 12.0 V Replace the Battery 6‐5...
Page 204 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. on the battery? Adjust the voltage to obtain the Monitor the amperage for 3‐5 standard charging amperage. minutes. Is the standard charging amperage exceeded? Set the timer to the charging time If the amperage does not exceed the determined by the open circuit standard charging amperage after 5 voltage. minutes, replace the battery. If the required charging time exceeds 5 hours, recheck the charging ...
Page 205 Electrical Checking the Fuses Note: Always turn the main switch off when checking or replacing a fuse. Set tester to Ohms X 1 position. If the tester indicates ∞ or OL replace the fuse. Fuses will be found in 2 places on the UV. ...
Page 206 Electrical Checking the switch Use a multimeter to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. Note: Set the multimeter to “0” before • starting the test. The multimeter should be set to the •...
Page 207 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 208 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 209 Electrical Ignition System Circuit Diagram 1. High tension coil 2. C.D.I 3. Magneto 6‐11...
Page 210 Electrical Troubleshooting No spark or intermittent spark (ignition circuit) Procedure: Check: 1) Fuses (main, ignition) 2) Battery 3) Spark plug 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 211 Electrical Check the spark plug wire resistance. 10K ohms Check the ignition coil resistance. Replace the spark plug wire 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. Connect multimeter as shown. Positive lead to the orange lead terminal. Negative lead to Spark Plug Lead. Secondary coil resistance 6.32 – 9.48 K Ohms Out of Specification Both Tests meet specification Test the main switch for continuity. Replace the ignition coil correct Incorrect Replace the main switch Test the A.C magneto coupling resistance. Connect multimeter as shown. Positive lead to white/red terminal (1) Negative lead to white/green terminal (2) Pickup coil resistance 459 – 561 Ohms Test the A.C magneto coupling resistance. Connect multimeter as shown. Positive lead to red terminal (3) Negative lead to white/blue terminal (4) Pickup coil resistance secondary Replace the pickup 0.063 – 0.077 Ohms ...
Page 212 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 213 Electrical Electric Starting System 6‐15...
Page 214 Electrical Troubleshooting a starter motor failure Check: 1. Fuses (main, ignition, signaling) for continuity. 2. Battery for 12.8V or more 3. Starter motor Connect a jumper of equal size from the battery positive post to the starter motor. Warning: If the size of jumper wire is too small the jumper could burn and or cause injury.
Page 215 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 216 Electrical Charging System 6‐18...
Page 217 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 multimeter 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 218 Electrical Lighting System 6‐20...
Page 219 Electrical Signaling System 6‐21...
Page 220 Electrical Cooling System 6‐22...
Page 221 Electrical 2WD / 4WD Selecting System 6‐23...
Page 222: Engine Management System
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 223 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 224 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 number, serial number, vehicle model &...
Page 225 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- use of seal rings is not preferred when replacing an injector.
Page 226 Engine Management System 4) Replacement of the Injector Warning: The injector and all associated hardware may be extremely hot.  Shut off the ignition.  Disconnect the negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine. ...
Page 227 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 injector.
Page 228 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).  Disconnect accelerator cable from throttle body.
Page 229 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 230 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 the fuel tank, remove the fuel filler cap and then reinstall it. ...
Page 231 Engine Management System Fuel Module Removal  Relieve fuel pressure by disconnecting the power to the pump, pull the spark plug boot off of the plug and place it away from the plug. Crank the engine to release the fuel pressure in the lines. ...
Page 232 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. Use the chart below to find the cause of the fault, then find out the cause with this number. Press the clock button, and the display turn back to clock mode, and five seconds later the fault code will show again.
Page 233: Troubleshooting
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 234 Troubleshooting 5. Turn the engine over using the key switch. A strong, 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: ...
Page 235 Troubleshooting 2. Cylinder head:  Loose spark plug or damaged spark plug hole.  Damaged cylinder head gasket.  Warped or cracked cylinder head.  Damaged decompression assembly. See Maintenance and Adjustment section for procedure. Standard 188.31 Psi Minimum 163.57 Psi Maximum 210.50 Psi Upon completion of these three tests you should know which system is in question and the direction of further testing or repair.
Page 236 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 237 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 the guide. 7) Broken valve spring. 8) Low oil pressure.
Page 238 Troubleshooting marks in Step 7, 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 239 Troubleshooting Note: If a large amount of air escapes from the exhaust pipe or through the carburetor, the air is leaking through an 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 240 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. ...
Page 241 Troubleshooting 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, 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 component for a refund.
Page 242 NOTES: MAIN HARNESS PART NUMBER Wire Colors Listed In Black Font (#4 Regular) Above Wire Or To The Right Of Wire. 34100-115N-0100 Light Switch Wire Function Listed In Red Font (#5 Semi Bold) Above Wire. Horn Horn (A) The EPS (Power Assist Steering) Is Optional On The CX500 & CX700. 4WD / Di erential Switch Main Main...
Page 243 Purple ECU Gray Plug ECU Black Plug White/ Black Diagnostic Plug Black Gray (White Plug With Sealing Cap) Main Harness Green/ Light Purple/ Black White Purple White/ Black Gray Blue Blue Purple Plug Black NOTE (A) Black/ Brown/ Light/ Red/ Black/ Light Black...
Page 244 MTD Products Inc - Product Training and Education Department FORM NUMBER - 769-10856 05/2015...

This manual is also suitable for:

Challenger 500 Challenger 700

Cub Cadet Challenger Series Service Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Cub Cadet Challenger Series

Summary of Contents for Cub Cadet Challenger Series

This manual is also suitable for:

Table of Contents