Linhai ARCHON 400 Service Manual
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Linhai ARCHON 400 Service Manual

Linhai ARCHON 400 Service Manual

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SERVICE MANUAL
ARCHON 400

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Summary of Contents for Linhai ARCHON 400

  • Page 1 SERVICE MANUAL ARCHON 400...
  • Page 2 NOTICE This manual was produced by the Linhai Group primarily for use by Linhai dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Linhai vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.

  • Page 3: Table Of Contents

    CONTENTS CHAPTER1 ……………………………………………………….General Information CHAPTER2 ………………………………………….……………………Maintenance CHAPTER3…………………………………….……….….…………………….Engine CHAPTER4…………………………………………..…………………………Chassis CHAPTER5………………………………………………….……………….Final Drive CHAPTER6……………………………………………….………………Transmission CHAPTER7………………………………………………………………………Brakes CHAPTER8………………………………………………….….……………..Electrical...
  • Page 4 Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 5 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 CHAPTER 1 GENERAL INFORMATION The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 6 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
  • Page 7 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives.
  • Page 8 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
  • Page 9 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 V.I.N AND ENGINE SERIAL NUMBER ○ The vehicle identification number 1 is stamped into the front of the frame tube. The engine serial number ○ is stamped into left side of engine crankcase. CHAPTER 1 GENERAL INFORMATION PAGE.
  • Page 10 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 1.3 VEHICLE DIMENSIONS CHAPTER 1 GENERAL INFORMATION PAGE. 1- 6...
  • Page 11 CHAPTER 1 GENERALINFORMATION BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 1 GENERAL INFORMATION PAGE. 1- 7...
  • Page 12 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 CHAPTER 2 MAINTENANCE The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 2.1 PERIODIC MAI NTENANCE 2.2 THROTTLE PEDAL INSPECTION 2.3 FUEL SYSTEM...
  • Page 13 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart D ：Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer. ...
  • Page 14 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 Item Hours When Remarks Coolant/Level Inspection Daily Daily Replace engine coolant every one year  Air Box Sediment Tube Daily Daily Drain deposits whenever visible Headlamp Inspection Daily Daily Check operation daily; apply dielectric grease to connector when replaced Tail/...
  • Page 15 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 Item Hours When Remarks Steering system 50 hrs 6 months Check operation looseness, worn, damage, binding feeling / Adjust, repair, Replace if necessary. Check toe alignment /Adjust if necessary. Toe adjustment Periodic inspection, required required adjust when parts are...
  • Page 16 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 Item Hours When Remarks Headlight Aim Adjust if necessary required required LUBRICATION RECOMMENDATIONS Item Lube Rec Method Frequency 1. Engine Add to proper Check level daily  15W/40SJ level on dipstick 2.Brake Fluid DOT 3 Only Add to proper level As require;...
  • Page 17 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 Item Lube Rec Method Frequency  6.Steering system Grease Lubricate the pivoting Every 3 months and sliding parts or 50 hours  7.Tie rods Grease Grease Semi-annually  8.Shift Grease Locate fittings Semi-annually Linkages and Grease...
  • Page 18 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 2.2 THROTTLE PEDAL INSPECTION THROTTLE FREEPLAY If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.
  • Page 19 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 2.3 FUEL SYSTEM Always stop the engine and refuel outdoors or in a well venltilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 20 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 CAUTION: Make sure lines are not kinked or pinched. NOTE: Make sure the↑mark on the roll over valve is upwards. 2.4 TOE ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure the steering wheel in a straight ahead position.
  • Page 21 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 BRAKE PAD INSPECTION Pads should be changed when friction material is worn to 3/64" (1mm). HOSE/FITTING INSPECTION Check braking system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.
  • Page 22 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 the lever. While adjusting, it is important you apply the lever back and forth for operation, free play and the locking of the parking position. 7. Make sure the rear wheels turns freely without dragging and parking brake works properly.
  • Page 23 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 Always adjust both shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. Turn the adjuster ○ to increase or decrease the spring preload. Standard position: 3 Minimum (Soft) position: 1 Maximum (Hard) position: 5...
  • Page 24 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 CAUTION: If wheels are improperly installed it could affect Vehicle handling and tire wear. 2.8 TIRE PRESSURE TIRE INSPECTION CAUTION:  Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the Tire Pressure Inspection vehicle.
  • Page 25 CHAPTER 2 MAINTENANCE BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 14...
  • Page 26 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 CHAPTER 3 ENGINE 3.1 MAI NTEN ANCE SPECIFICATIONS 3.1.1 SPECIFICATIONS 3.1.2 TIGHTENING TORQUES 3.2 PARTS INSPECTION AND SERVICE 3.2.1 VALVE CLEARANCE ADJUSTMENT 3.2.2 SPARK PLUG INSPECTION 3.2.3 COMPRESSION PRESSURE 3.2.4 ENGINE OIL LEVEL INSPECTION 3.2.5 COOLANT LEVEL INSPECTION 3.3 CYLINDER HEAD 3.4 CAMSHAFT AND ROCKER ARMS...
  • Page 27 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.1 MAINTENANCE SPECIFICATIONS 3.1.1SPECIFICATIONS Item Standard Limit Cylinder head : 0.03 mm Warp limit Cylinder: 80.000- 80.014 mm 80.025 mm Bore size Out of round limit 0.03 mm Camshaft: Cam dimensions Intake "A" 36 .545- 36 .645 mm 36 .45 mm "B"...
  • Page 28 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Standard Limit I te m Stem-to-guide clearance 0.010- 0.037 mm 0.08 mm 0.025-0.052 mm 0.1 mm Stem runout limit … 0.01 mm Valve seat width 0.9-1.1 mm 1.6 mm 0.9-1.1 mm 1.6 mm Valve spring : Free length (Inner) IN/EX...
  • Page 29 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Standard Limit I te m Automatic centrifugal clutch: 3.0 mm 2.0 mm Clutch shoe thickness 135 mm 135.5 mm Clutch hosing inside diameter 28.1 mm … Clutch shoe spring free length 20 mm 19 .5 mm W eight outside diameter 2 ,100- 2,700 r/m in...
  • Page 30 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.1.2TIGHTENING TORQUES Tightening Part name Thread Part to be tightened Q’ty Remarks Torque size m.kg Oil check bolt Spark plug Cam sprocket cover Bolt Cylinder head and cylinder 2 .2 Cylinder head and cylinder Bolt (Cam chain side) Valve cover...
  • Page 31 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Tightening Part to be tightened Part Thread Q’ty Remarks torque name size m.kg Cover (oil pump) Bolt Plug 0 .8 Timing check plug One way clutch Bolt Clutch housing 0 .3 Grease stopper (Primary sheave) Primary fixed sheave Clutch carrier assembly Stator...
  • Page 32 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.2 PARTS INSPECTION AND SERVICE 3.2.1VALVE CLEARANCE ADJUSTMENT NOTE: Valve clearance adjustment should be made with the engine cool, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression.
  • Page 33 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Measure the valve clearance. If the clearance is incorrect, repeat above steps until specified clearance is obtained. 7. Install: Valve cover (intake side)  O-ring 8. Install: Valve cover(exhaust side) O-ring Spark plug Timing check window screw Crankcase cover 3.2.2 SPARK PLUG INSPECTION...
  • Page 34 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 (with spark plug cleaner or w ire brush) 5.Measure: Spark plug gap ③ (with a wire gauge) Out of specification Adjust gap. Spark plug gap : 0.6-0.7 mm 6. Install: Spark plug NO TE: Before installing a spark plug, clean the Gasket surface and plug surface.
  • Page 35 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 If it exceeds the maximum pressure allowed→ Inspect the cylinder head, valve surfaces and piston crown for carbon deposits. If it is below the minimum pressure → Squirt a few drops of oil into the affected cylinder and measure again.
  • Page 36 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.2.4 ENGINE OIL LEVEL INSPECTION 1. Start the engine and let it warm up for a few minutes . 2. Turn off the engine. 3. Inspect: (Do not thread dipstick in) Engine oil level Oil level should be between maximum and ○...
  • Page 37 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 O-ring Drain the crankcase of its oil. 4. Install: O-ring  Compression spring  Oil strainer  Drain plug  Oil filer plug NOTE : Check the drain plug O-ring. If damaged, replace it with a new one.
  • Page 38 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.2.5 COOLANT LEVEL INSPECTION Inspect: Coolant level Coolant level should be between the ○ ○ maximum a nd minimum marks. Coolant level is below the "LOWER" level line Add soft water (tap water) up to the proper level. CAUTION: Hard water or salt water is harmful to engine parts.
  • Page 39 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 NOTE: Remove the radiator cap after removing the drain bolt. 4. Clean: Radiator Fill soft water into the filer neck support  (reservoir tank). 5. Install: Gasket   Drain bolt 6. Loosen: Hose...
  • Page 40 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 WARNING: splashes in your eyes: Thoroughly wash your eyes with water and consult a doctor. If coolant splashes on your clothes: Quickly wash it away with water and then with soap and water. If coolant is swallowed: Vomit immediately and see a physician.
  • Page 41 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.3 CYLINDER HEAD CHAPTER 3 ENGINE PAGE. 3- 16...
  • Page 42 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Order Job name/Part name Q ’ty Remarks Cylinder head removal Remove the parts in order. Drain the coolant. Side panel Footrest board Thermo unit lead Plug cap Crankcase breather hose Outlet hose (cylinder head) Breather hose (crankcase) Injector seat Joint...
  • Page 43 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 CYLINDER HEAD REMOVAL 1. Align: ○ "I" mark on the rotor ○ (with stationary pointer on the crankcase cover ) NOTE: If any special mark found, contact the UTV manufacture via the agent for the parts and special instruction.
  • Page 44 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 2. Inspect: Cylinder head Scratches/damage → Replace. 3. Measure: Cylinder head warpage Out of secification → Resurface . Cylinder head warpage : Less than 0.03 mm Warpage measurement and resurfacement steps: Place a straight edge and a feeler gauge across the cylinder head.
  • Page 45 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 NOTE: If any special mark found, contact the UTV manufacture via the agent for the parts and special instruction. Fit the timing chain onto the cam sprocket and install the cam sprocket on the camshaft. NOTE: When installing the cam sprocket, keep the timing chain as tense as possible on the exhaust...
  • Page 46 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 6. Tighten: Bolt (cam sprocket) 7. Check: Valve timing Out of alignment → Adjust. 8. Check: Valve clearance Out of specification → Adjust. Refer "VALVE CLEARANCE ADJUSTMENT"section. CHAPTER 3 ENGINE PAGE. 3- 21...
  • Page 47 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.4 CAMSHAFT AND ROCKER ARMS Order Job name/Part name Q ’ty Remarks Cam shaft and rocker arms Remove the parts in order. removal Refer to "CYLINDER HEAD" section. Cylinder head Lock washer Plate Refer to "ROCKER ARM AND ROCKER Rocker arm shaft (intake)
  • Page 48 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ROCKER ROCKER SHAFTRE MOVAL 1. Remove: Rocker arm shaft (intake) Rocker arm shaft (exhaust) NOTE: Attach a rocker arm shaft puller bolt  and weight  to the rocker arm shaft and slide out the shaft.
  • Page 49 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Inspection steps: Inspect the two contact areas on the rocker arms for signs of unusual wear. Rocker arm shaft hole. Cam-lobe contact surface. Excessive wear → Replace. Inspect the surface condition of the rocker arm shafts.
  • Page 50 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 4. Install: Rocker arm  Rocker arm shaft  (exhaust) NOTE: Exhaust: Install the rocker arm shaft (exhaust) completely pushed in. 5. Install: Rocker arm  Rocker arm shaft  (intake) NOTE: Intake: Insert the guide shaft (8 mm) ...
  • Page 51 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.5 VALVES AND VALVE SPRINGS Order Job name / Part name Q ’ty Remarks Valves and valve springs removal Remove the parts in order. Cylinder head Refer to "CYLINDER HEAD " section . Rocker arm , rocker arm shaft Refer to "ROCKER ARM SHAFT AND ROCKER ARMS"...
  • Page 52 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 VALVES AND VALVE SPRINGS REMOVAL 1. Remove:  Valve cotters  NOTE: Attach a valve spring compressor and attachment  between the valve spring retainer and cylinder head to remove the valve cotters. CAUTION: Do not compress so much as to avoid damage to the valve spring.
  • Page 53 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 4. Measure: Spring tilt Out of specification → Replace. Spring tilt limit: 1.7mm (2.5º) 5. Inspect:  Spring contact face Wear/Pitting/Scratches → Replace. 6. Measure: Valve guide inside diameter Out of specification → Replace. Valve guide inside diameter: Intake: 6.000-6.012 mm...
  • Page 54 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3. Measure: Valve seat width ○ Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9-1.1mm <Limit:1.6mm> Exhaust: 0.9-1.1mm <Limit:1.6mm> Measurement step: Apply Mechanic’s blueing dye (Dykem)  to the valve face.
  • Page 55 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: Make sure to clean off all compound from the valve face and valve seat after every lapping operation.
  • Page 56 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 4. Instal: Valve cotters  NOTE: Install the valve cotters while com pressing the valve spring with a valve spring compressor and attachment . 5. Secure the valve cotters onto the valve stem by tapping lightly with a piece of wood.
  • Page 57 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.6 CYLINDER AND PISTON Order Job name / Part name Q ’ty Remarks Cylinder and piston removal Remove the parts in order. Cylinder head Refer to " CYLINDER HEAD " Joint section . O-ring Timing chain guide (exhaust side) Refer to "...
  • Page 58 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 PISTON AND PISTON RINGS REMOVAL 1. Remove: Piston pin circlip  Piston pin  Piston  NOTE: Before removing the piston pin circlip, cover the crankcase opening with a clean tow el or rag to prevent the circlip from falling into the crankcase cavity.
  • Page 59 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 PISTON AND PISTON PIN INSPECTION 1. Measure: Piston skirt diameter Out of specification → Replace . ○ 5.0mm from the piston bottom edge. Valve skirt diameter: 69.965-69.980 mm 2. Calculate: Piston-to-cylinder clearance Piston-to-cylinder clearance= Cylinder bore-Piston skirt diameter Refer to “CYLINDER”...
  • Page 60 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 PISTON RINGS INSPECTION 1. Measure: Side clearance ○ Out of specification → Replace the piston and the piston rings as a set. NOTE: Eliminate the carbon deposits from the piston ring grooves and rings before measuring the side clearance.
  • Page 61 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 NOTE: Make sure to install the piston rings so that the manufacturer’s m arks or numbers are located on the upper side of the rings. Lubricate the pistons and piston rings liberally with engine oil.
  • Page 62 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 5. Lubricate: Piston outer surface Piston ring Cylinder inner surface Engine oil 6. Install: Cylinder NOTE: Install the cylinder with one hand while com pressing the piston rings with the other hand. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.
  • Page 63 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.7 V-BELT,CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE COVER (LEFT) Order Job name / Part name Q ’ty Remarks Crankcase cover (left) Remove the parts in order. removal Crankcase cover (left) Front cover Hose clamp B Joint B Air strainer B Hose clamp A...
  • Page 64 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 PRIMARY SHEAVE Order Job name/ Part name Q ’ty Remarks V-belt, clutch and secondary/ Remove the parts in order primary sheave removal Nut/Plain washer Primary fixed sheave Clutch housing Clutch assembly V-belt Primary sliding sheave Collar Weight...
  • Page 65 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 SECONDARY SHEAVE **Apply lightweight lithium-soap base grease Order Job name / Part name Q ’ty Remarks Secondary sheave disassembly Disassemble the parts in order. Clutch carrier Refer to "SECONDARY SHEAVE Clutch shoe spring DISASSEMBLY"...
  • Page 66 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 PRIMARY SHEAVE REMOVAL 1. Remove: Nut (primary sheave) Plate washer Primary fixed sheave NOTE: Loosen the nut (primary fixed sheave) while holding the primary fixed sheave with the rotor holder. SECONDARY SHEAVE V-BELT REMOVAL 1.
  • Page 67 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 SECONDARY SHEAVE DISASSEMBLY 1. Remove:  Nut  (secondary sheave) NOTE: Loosen the nut  while attaching the clutch spring compressor  and clutch spring holder arm  and release the compressed spring after removing the nut.
  • Page 68 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 WEIGHT INSPECTION 1. Inspect:  Weight minimum outside diameter Cracks/Wear /Scaling /Chipping → Replace. Out of specification → Replace Weight out side diameter: 20.0 mm <Limit: 19.5mm> SECOMDARY SHEAVE INSPECTION 1. Inspect: Secondary fixed sheave smooth operation Secondary sliding sheave smooth operation 2.
  • Page 69 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 SECOMDARY SHEAVE INSTALLATION 1. Apply: Lightweight lithium-soap base grease (to the secondary sliding sheave  inner surface, grease nipple groove, and oil seals)  Lightweight lithium-soap base grease (to the bearings, oil seals and inner surface of the secondary fixed sheave ...
  • Page 70 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 CAUTION: Use the spacer  (30mm, thickness: 2-3mm). 6. Install: V-belt  Clutch assembly  NOTE: Install the V-bet with clutch assembly to the primary sheave side. CAUTION: Never smear grease to the V-belt, secondary sheave and clutch.
  • Page 71 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.8 A.C. MAGNETO AND STARTER CLUTCH MAGNETO COVER AND STATOR COIL Order Job name/ Part name Q'ty Remarks Magneto cover and stator coil Remove the parts in order. removal Refer to "ENGINE OIL REPLACEMENT" Drain the engine oil.
  • Page 72 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 A. C. MAGNETO AND STARTER CLUTCH Order Job name/ Part name Q'ty Remarks A.C. magneto and starter clutch Remove the parts in order. removal Rotor Refer to "A.C. MAGNETO ROTOR REMOVAL /INSTALLATION" section. Shaft (idle gear) Idler gear Starter one way clutch assembly...
  • Page 73 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 A.C. MAGNETO ROTOR REMOVAL 1. Remove: Nut  (rotor) Plain washer NOTE: Loosen the nut (rotor) while holding the rotor with a sheave holder . Do not allow sheave the holder touch to the projection on the rotor.
  • Page 74 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 A.C. MAGNETO ROTOR INSTALLATION 1. Install: Starter wheel gear . Woodruff key  NOTE: Install the starter wheel gear, then install the woodruff key. 2. Install: Plain washer Rotor  NOTE: Clean the tapered portion of the crankshaft and the rotor hub.
  • Page 75 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.9 OIL PUMP Order Job name/ Part name Q'ty Remarks Oil pump removal Remove the parts in order. A.C. magneto Refer to "A.C. MAGNETO AND STARTER Cover CLUTCH" section. Pump driven gear Dowel pin Oil pump assembly Gasket...
  • Page 76 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 OIL PUMP INSPECTION 1. Inspect: Drive gear (oil pump)  Pump housing Pump housing cover Wear /cracks/ damage → Replace. 2. Measure:  Tip clearance (between the inner rotor  and the outer rotor) Side clearance (between the outer rotor ...
  • Page 77 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.10 CRANKCASE AND CRANKSHAFT Order Job name/ Part name Q'ty Remarks Remove the parts in the order. Crankcase and crankshaft removal Refer to "ENGINE REMOVAL" section. Engine removal Refer to "CYLINDER HEAD" section. Cylinder head Refer to "CYLINDER AND PISTION"...
  • Page 78 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Order Job name/ Part name Q'ty Remarks Timing chain Crankcase (right) Dowel pin Crankshaft assembly Balancer assembly Crankcase (left) Timing chain guide (intake) Bracket shift Oil seal Reverse the removal procedure for installation.
  • Page 79 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 CRANKSHAFT&BALANCER REMOVAL 1. Remove: Crankshaft assembly Balancer assembly Timing chain NOTE: Before removing the crankshaft assembly, remove the timing chain from the crankshaft sprocket. If the timing chain hooks to the crankshaft sprocket, the crankshaft cannot be removed.
  • Page 80 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 4. Inspect: Crankshaft sprocket  Wear/ Damage → Replace crankshaft. Bearing  Wear/ Crack /Damage → Replace crankshaft. Pump drive gear  Wear/ Damage → Replace crankshaft.  Balancer drive gear ○ Wear/ Damage →...
  • Page 81 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.11 COOLING SYSTEM 3.11.1RADIATOR Remarks Order Job name/ Part name Q'ty Radiator removal Remove the parts in order. Drain the coolant. Refer "COOLANT REPLACEMENT" section. Fan motor leads Thermo switch leads Outlet hose (radiator) Inlet hose (radiator) Radiator Radiator cap...
  • Page 82 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 INSPECTION 1. Inspect: Radiator  Obstruction → Blow out with compressed air through the rear of the radiator. Flattened fins → Repair or replace. If flattened over the 20% of radiator fin, repair or replace the radiator.
  • Page 83 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.11.2WATER PUMP Remarks Order Job name/ Part name Q'ty Water pump removal Remove the parts in order. Drain the coolant. Refer to "COOLANT REPLACEMENT" section. A.C. magneto Refer to "A.C. MAGNETO AND STARTER CLUTCH"...
  • Page 84 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Order Job name/Part name Q’ty Remarks Impeller shaft Refer to “WATER PUMPINSTALLATION” O-ring section. O-ring Reverse the removal procedure for installation. CHAPTER 3 ENGINE PAGE. 3- 59...
  • Page 85 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant temperature and/ or level, discoloration of coolant, or milky transmission oil. If necessary, replace water pump as an assembly.
  • Page 86 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3. Inspect: Mechanical sea , slip ring side  Inspect the slip ring side of the mechanical seal and the impeller  for level installation. Incorrect level → Reinstall. 4. Install: Impeller shaft Circ lip ...
  • Page 87 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.11.3THERMOSTAT Remarks Order Job name/ Part name Q'ty Remove the parts in order. Thermostat removal Refer "COOLANT REPLACEMENT" Drain the coolant section. Clip Hose Hose clamp Inlet hose (radiator) Thermostatic cover Refer to "THERMOSTAT INSTALLATION" Thermostatic valve section.
  • Page 88 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 INSTALLATION 1. Inspect: Thermostatic valve Valve does not open at 70-74℃→Replace. Inspection steps: Suspend the thermostatic valve in a vessel. Place a reliable thermometer in water.  Observe the thermometer, while continually stirring the water.
  • Page 89 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Fuel Injection System 3.12 3.12.1 3.12.1.1 Description & Working Principle 3.12.1.2 Appearance 3.12.1.3 Handling – Don’ts & Do’s 3.12.1.4 Installation requirements 3.12.1.5 Power Requirements 3.12.1.6 Temperature Requirements 3.12.1.7 Maintenance service and Repair 3.12.2 Injector 3.12.2.1 Appearance...
  • Page 90 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.7.7 Fuel Leakage Check Procedure 3.12.8 Motor Scanner ( for MT05 EMS) 3.12.8.1 Precautions 3.12.8.2 Configurations 3.12.8.3 Preparations Connection 3.12.8.4 Functions 3.12.8.5 MT05 ECU Malf Code CHAPTER 3 ENGINE PAGE. 3- 65...
  • Page 91 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.1 ECU 3.12.1.1 Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. also provides 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 92 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.1.4 Installation requirements The ECU shall be mounted using M6 machined screws with a torque of 8 Nm ±10%. The mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and warping the PCB.
  • Page 93 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.2 Injector 3.12.2.1 Appearance The figure below shows the standard M3.5 Fuel Injector appearance. 3.12.2.2 Temperature Requirements : Typical injector temperature environments are defined below. The injector will not experience any loss of the ability to comply with the flow tolerance requirements after exposure to the following temperature environments.
  • Page 94 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ● Lubrication: Apply a light coating of lubricant to the lower injector seal ring. ISO 10 light mineral oil or equivalent is recommended. ● The preferred technique is to apply the lubricant to the sockets the injectors are being installed into, rather than directly to the seal ring itself.
  • Page 95 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.2.5 Replacement Techniques The following procedure outlines standard the Injector removal and replacement. 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;...
  • Page 96 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 line; ● Tighten the injector mounting to the desired torque as mentioned in the manufacturer manual; ● Tighten the fuel line; ● Re-install the injector electrical connector; ● Turn the key on and off to check if the fuel is leaking;...
  • Page 97 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 mounted on the throttle body); ● Disconnect accelerator cable from throttle body; ● Remove air cleaner outlet hose and throttle body outlet hose. 3.12.3.3 Cleaning Procedure It may be removed and cleaned using carburetor cleaner (3M make recommended).
  • Page 98 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.4.2 Installation Requirements Dynamic Torque Requirement: The sensor shall be hand into the application and then driven by a driver with a maximum no load speed of 400 rpm or installed to the desired torque by a hand torque wrench (5/8”...
  • Page 99 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.6 Ignition Coil 3.12.6.1 Description and Working Principle This coil provides energy to the spark plug in the combustion chamber. The coil itself doesn’t have a driver. The high voltage tower of the coil is connected to the spark plug using a high voltage cable assembly.
  • Page 100 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ACTION REASON This creates an electrical path to outside the system DO NOT: Pierce or probe the secondary leads. permitting improper system operation, misfire, or even possible personal injury if arcing occurs. If a technician or mechanic comes in contact with the high voltage generated during operation, personal DO NOT: Operate without the spark plug attached.
  • Page 101 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ACTION REASON The high level of voltage and current which the DO: The module heat sink and back plate must not be used as a connection point when jump starting module could be subjected to, could cause module the engine.
  • Page 102 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ACTION REASON DO: Cleaning a spark plug could be done as follow: Cleaning a spark plug will reduce the voltage required 1- Wipe all spark plug surfaces clean….remove oil, for an electrical arc(spark) across the electrodes. water, dirt and moist residues.
  • Page 103 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.7 Fuel Pump 3.12.7.1 Description and Working Principle Fuel Pump supplies fuel to engine at system pressure. Fuel Pump is mounted to fuel tank at top and supplies fuel to engine through hoses. Fuel Pump consists of Fuel Pump to generate the fuel flow and pressure regulator to regulate the fuel pressure.
  • Page 104 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ● 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 fuel filler neck and then reinstall it.
  • Page 105 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Step Action Connect 12V DC power supply (battery) to Fuel Pump. 1. Check electrical circuit 1. Check Fuel Pump Make sure that enough fuel available from Fuel Pump to ECU. Harness integrity. in fuel tank to avoid fuel pump running 2.
  • Page 106 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.7.5 Fuel Pump Installation ● Replace the Fuel Pump gasket in Fuel Pump assembly with a new one. Old / Used gaskets can cause leakages. ● Place the bolts on Fuel Pump cover and tighten the bolts gradually in star pattern sequence to apply equal compression on gasket.
  • Page 107 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines. ● In this state, check to see that there are no fuel leakage from any part of fuel system (Fuel Tank, Hoses, Hose Joints, etc) 3.12.8 Motor Scanner ( for MT05 EMS) Delphi Motor scanner...
  • Page 108 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 ● Connect one end of the diagnostic main cable to the main unit, and the other end to diagnostic socket on the motor, tighten the screws. Normal Power – on Display When power is on normally, the unit will display: Seconds later, the unit will display: 3.12.8.4 Functions Delphi Motor-Scanner can be used to diagnose Delphi...
  • Page 109 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 Diagnostic Function Here, we take ‘diagnostic function’ for demonstration. Select ‘diagnostic function’ and press , the screen will display an interface to indicate ‘Delphi-3’ diagnostic connector should be used. Press , the screen will display engine information as right;...
  • Page 110 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 2. Clear DTC Select ‘Clear DTC’ and press, it will display as right; 3. Data Stream Select ‘Data Stream’ and press , it will display as right; Press key for page up/down to view more. Press key to exit.
  • Page 111 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 3.12.8.5 MT05 ECU Malf Code Malf code Description P0107 MAP Circuit Low Voltage or Open P0108 MAP Circuit High Voltage P0112 IAT Circuit Low Voltage P0113 IAT Circuit High Voltage or Open P0117 Coolant/Oil Temperature Sensor Circuit Low Voltage P0118...
  • Page 112 CHAPTER 3 ENGINE BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 3 ENGINE PAGE. 3- 87...
  • Page 113 CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 CHAPTER 4 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 4.1 FRONT A-ARM REPLACEMENT 4.2 REAR A-ARM REPLACEMENT 4.3 REAR STABILIZER BAR REMOVAL/INSTALLATION...

  • Page 114: Front A-Arm Replacement

    CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.1 FRONT A-ARM REPLACEMENT 1. Carrier Bearing,Front,Lh； 2. Bearing； 3. Circlip 55 4. Nut M12×1.25； 5. Pin 3.2×22； 6. Arm Upper Frt Lh 7. Ball Joint,Upper； 8. Circlip 32； 9. Scr Hxfl,Frt Arm 10.
  • Page 115 CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.Remove the spindle nut, and washer. Remove the hub assy by sliding it off of the shaft. 5.Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud.

  • Page 116: Rear A-Arm Replacement

    CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.2 REAR A-ARM REPLACEMENT 1. Carrier Bearing Wheel Rear Lh；2. Grease Fitting M6； 3. Bearing 4. Circlip 63； 5. Shaft Pivot ,Lwr； 6. Scr Hxfl,Rear Arm,Lwr 7. Shaft Pivot ,Upper； 8. Bolt M10X1.25X90； 9.Nut M10 10.
  • Page 117 CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 3. Remove the brake caliper. Suspend the brake caliper from the frame with a wire. NOTE: Do not let the brake caliper hand from the brake line or damage may occur. 4. Remove the spindle nut, and washer. Remove the hub assy by sliding it off of the shaft.
  • Page 118 CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 8. Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware. 9. Remove the bottom stabilizer bar nut. 10. Loosen two bolts that secure the A –arm bushing to frame by alternating each about 1/3 of the way until the A-arm can be removed.

  • Page 119: Rear Stabilizer Bar Removal/Installation

    CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.3 REAR STABILIZER BAR REMOVAL/INSTALLATION 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the rear wheel to gain access to the stabilizer bar, each side. 3.

  • Page 120: Box Removal/Installation

    CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.4 BOX REMOVAL/INSTALLATION Box Removal 1. Disconnect taillight transition line at lower right of the Box from the wiring harness. 2. Lift the box into the dump position. 3. Remove the box shock pin from the frame. 4.

  • Page 121: Steering Assembly Removal/Installation

    CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 4.5 STEERING ASSEMBLY REMOVAL/INSTALLATION 1. Pin 2.5×25； 2. Nut M10X1.25； 3. Steering Tie-Rod,Rh 4. Tie； 5. Steering Motor； 6. Bolt M8X95 7. Bolt M8X80； 8. Bolt M8X20； 9. Nut M8 10. Steering Tie-Rod,Lh； 11.
  • Page 122 CHAPTER 4 CHASSIS BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 4 CHASSIS PAGE. 4- 10...
  • Page 123 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 CHAPTER 5 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 124 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification Front heel Nuts 55 Ft.Lbs 75 Nm Rear heel Nuts 55 Ft.Lbs 75 Nm Front Hub Nut on Spindle/ outer CV joint 103 Ft.Lbs 140 Nm Rear Hub Retaining Nut 103Ft.Lbs 140 Nm...
  • Page 125 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 3. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots. 4. Remove wheel nuts and wheel. 5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line.
  • Page 126 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.5 FRONT HUB BEARING REPLACEMENT 1. Remove outer snap ring. 2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. 3. Drive bearing out evenly by tapping on outer race only.
  • Page 127 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Drive Axle/Outer CV Joint Assembly. 2. Boot Band “A”. 3.

  • Page 128: Chapter2

    CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 chapter. 2. Move each end of the drive shaft in a circular motion (and also a reciprocate for inner one) and check the drive shaft joints for excessive wear or play. 3.
  • Page 129 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Discard the boot band, it cannot be reused. 2. Carefully slide the boot (A) onto the drive axle and off the inboard joint. 3. Wipe out all of the molybdenum disulfide grease within the inboard joint cavity.
  • Page 130 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 9. Inspect the splines on the inner CV joint for wear or damage. 10. Check the stopper ring in the end of the inboard joint. Make sure it seats in the groove correctly, if damage the ring must be replaced.
  • Page 131 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 clips and tap them with a plastic hammer. Make sure they are locked in place. 5. If the bearing assembly was disassembled, assemble the bearing as follows: a. Position the bearing race and install the race into the bearing case.
  • Page 132 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 CAUTION: It is critical to avoid undue stress on the rubber boots after the drive axle is installed and the vehicle is run. Don’t twist the boot, and always set the both ends in designed position. 16.
  • Page 133 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 4. Remove rear spindle nut, and washer. 5. Remove the upper and lower control arm bolts. 6. Slide the rear hub and knuckle from the rear drive shaft. 7. Inspect the rear hub and knuckle assembly by hand for smoothness and side to side movement, replace as needed.
  • Page 134 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.13 REAR DRIVE SHAFT REMOVAL 1. Repeat of the steps in the “REAR HUB AND KNUCKLE REMOVAL” section. 2. Slide the rear drive axle out of the knuckle by pulling the hub and knuckle assembly outward and down.
  • Page 135 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 3. Slide the rear drive axle into the knuckle. 4. Lift knuckle into place and install bolt to upper and lower control arm. Torque bolt to 45 ft.lbs (60 Nm). 5. Install the washer and the new spindle nut. 6.
  • Page 136 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.15 REAR GEARCASE EXPLODED VIEW REAR GEARCASE EXPLODED VIEW CHAPTER 5 FINAL DRIVE. 5- 14...
  • Page 137 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 REAR AXLE ASSEMBLY O-RING 69×3 REAR GEAR CASE BEVEL GEAR BEARING HOUSING VENT NOZZLE BEARING 6305 CLAMPS OIL SEAL Φ35×Φ61×9 VENT PIPE BOLT M8×30 WASHER 18 COUPLER, REAR AXLE BOLT M18x1.5 WASHER 12.5×30×4 OIL SEAL30x60x15 NUT M12×1.25...
  • Page 138 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Important: Before staring any operation On the gearbox， make sure that never clean the gearbox with a high pressure water jet. 1. Remove the oil drain plug A and let the oil drain from the gearbox.
  • Page 139 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 4 2. Remove the six bolts M8×25 Q and the two bolts M10×1.25×25 R. Remove the ring gear bearing housing T from the rear gear case S. →Fig 5 Fig 3 1.
  • Page 140 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 6 4. Remove the adjust shim W from the bevel gear comp.-driven X. Remove the bevel gear comp.-driven X from the ring gear bearing housing T. Remove the adjust shim Y from the bevel gear comp.-driven X.
  • Page 141 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 2 3. Mount the needle bearing H and the needle bearing Ⅰ into the suited hole of the rear gear case G. →Fig 3 Fig 1 2. Mount the adjust shim D in the shaft neck of the bevel gear comp.-driven E.
  • Page 142 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 6 Fig 4 7. Tighten the six bolts M8×25 Q to a torque of 5. Apply some Loctite 510 silicone sealant on 20~25N.m. the shaft neck of pipe joint N for the Tighten the two bolts M10×1.25×25 P to a installation.
  • Page 143 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 11 12. Apply some Loctite 242 threadlocker on screw thread. Tighten the four bolts M8×35 e to a torque of 20~25N.m. →Fig 12 Fig 9 10. Mount the adjust shim b in the shaft neck of the bevel gear-driving V.
  • Page 144 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 14 15. Mount the oil seal k in the ring gear bearing housing G on the left. Fig 13 Make the O-ring m on the fill plug n . 14. Mount the oil seal 65×90×9 j in the ring Tighten the fill plug n to a torque of gear bearing housing C on the right.
  • Page 145 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.18 FRONT GEARCASE EXPLODED VIEW FRONT GEARCASE EXPLODED VIEW CHAPTER 5 FINAL DRIVE. 5- 23...
  • Page 146 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Nut, Front Output Shaft Bearing 16007 Washer, Front Output Shaft O-Ring 141×2.4 O-Ring Gear Case, Front Axle Coupler, Front Axle Bolt M8×25 Oil Seal 48×65×9 Screw M8×8 Bearing Retainer Washer 8 Bearing 6007 Vent Nozzle Bevel Gear -Driving...
  • Page 147 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5.19 FRONT GEARCASE DISASSEMBLY Important: Before staring any operation On the gearbox make sure GEAR MOTOR (NO.36) is protected (if mounted). Never clean the gearbox with a high pressure water jet. →Fig 0.
  • Page 148 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 5. Remove the OIL SEAL (NO.5) and repalce with a new seal. →Fig 5. Fig 5 6. Remove the four SCREW (NO.37). Fig 7 →Fig 6. 8. Remove the six bolts M8 X L28 （NO.29）. →Fig 8.
  • Page 149 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 9 Fig 11 10. Remove the DIFFERENTIAL GEAR ASSY 12. Remove the shims from the differential A from the housing. assembly. Be sure to keep the shims →Fig 10 together for reassembly. →Fig 12.
  • Page 150 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 13. Remove the PIN SHAFT (NO.38), SHIFT FORK (NO.39). →Fig 14 Fig 16 16 ． Remove the DRIVE CLUTCH COVER Fig 14 (NO.24). →Fig 17. 14．Remove the DRIVE CLUTCH (NO.23). →Fig 15. Fig 17 Fig 15 15．Inspect the bearing (NO.26).
  • Page 151 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 18 19． Remove the BEARING RETAINER (NO.6) Fig 20 with special tool. NOTE: The DIFFERENTIAL GEAR ASSY (A) →Fig 19. AND THE DRIVE PINION GEAR B MUST BE REPLACED SIMULTANEOUSLY,NOT SEPARAT 5.20 FRONT GEARCASE ASSEMBLY Note:Grease all seals and O-rings with all...
  • Page 152 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 2. Mount the retainer 62 (NO.25) . →Fig 2. Fig 4 5.Install the screw (NO.30) and washer (NO.29), then mount the screw (NO.30) . Fig 2 →Fig 5. 3. Mount the drive clutch (NO.23). →Fig3.
  • Page 153 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 8 9.Install a new OIL SEAL (NO.5) Fig 6 .→Fig 9 7.Install the DIFFERENTIAL GEAR ASSY A into the carrier housing. →Fig 7 Fig 9 10.Mount the adjust shim (NO.16). →Fig 10 Fig 7 8.Install the DRIVE PINION GEAR B and...
  • Page 154 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 Fig 10 11.Assemble the gearcase halves and install the bolts (NO.29) that secure the cover to the housing. Torque the bolts in a criss cross pattern to 20~25Nm. →Fig 11 Fig 12 13.
  • Page 155 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 14. Mount the coupler (NO.4) . →Fig 14 Fig 16 17.Add 200-250mL oil(85W/90GL-4). Fig 14 15. Mount the O-ring(NO.3). →Fig 15 Fig 15 16. Apply some Loctite 263 thread locker on screw thread, mount the nut(NO.3), tighten it to a torque of 50~60Nm.
  • Page 156 CHAPTER 5 FINAL DRIVE BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 5 FINAL DRIVE. 5- 34...
  • Page 157 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 CHAPTER 6 TRANSMISSION WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 6.1 GEAR SHIFTER REMOVAL 6.2 SHIFTER DISASSEMBLY 6.3 SHIFTER INSTALLATION...
  • Page 158 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 6.1 GEAR SHIFTER REMOVAL 1. Remove parts that interfere with access to shift selector (seat, cover etc.) 2. Disconnect the two linkage rods from transmission slides. 3.Remove the four screws from the instrument panel CHAPTER 6 TRANSMISSION PAGE.
  • Page 159 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 4. Remove the screw from the shifter 5. Remove the three bolts from the frame 6. Remove shift support assembly CHAPTER 6 TRANSMISSION PAGE. 6-...
  • Page 160 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 6.2 SHIFTER DISASSEMBLY Disassemble the gear shift mechanism as shown NOTE: Pay attention to the falling springs and steel balls 6.3 SHIFTER INSTALL ATION The assembly process is the reverse of the disassembly process NOTE:Replace all removed bolts CHAPTER 6...
  • Page 161 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 6.4 SHIFT ADJUSTMENT OF STAY CABLE Lasso adjustment is necessary when symptoms include：  Noise on deceleration  Inability to engage a gear  Excessive gear clash(noise)  Shift selectors moving out of desired range NOTE: When adjusting Lasso, always adjust both Lasso.

  • Page 162: Chapter3

    CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 6.5 ENGINE AND TRANSMISSION REMOVAL 1. Remove seat, side panel cover L, side panel cover R, protect cover, seat frame cross brace， seat frame pipe, fuel tank, shift rods, tool box and plates.
  • Page 163 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 9. Remove engine, transmission and engine mount bracket installation assembly from frame. 10. Remove four bolts (M12X1.25X25) and rubber dampers from engine mount bracket. Remove transmission bracket, two bolts (M10X1.5X20), two bracket bolts (M8X20), front mount bolt (M10X1.25X120) and right mount bolt (M10x1.25x70).
  • Page 164 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 5. Remove bearing and helical gear. 6. Remove input shaft, reverse shaft, and both shift fork shafts as an assembly. 7. Remove pinion shaft retainer plate and pinion shaft. 8. Remove front drive output housing cover screws. Carefully remove the cover with a soft face hammer tap on the cover bosses.
  • Page 165 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 broken teeth. 14. Remove seals from transmission case. IMPORTANT: New seals should be installed after the transmission is completely assembled. 15. Inspect bearings for smooth operation. Check for excessive play between inner and outer race. 6.8 TRANSMISSION ASSEMBLY 1.
  • Page 166 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 7. Install pinion shaft with bearing. 8. Install retainer plate with flat side toward bearing. 9. Apply LoctiteTM 242(Blue) to screw threads and torque screws to 8 ft-lb. (12Nm). 10. Assemble shafts with chain and shift forks. 11.

  • Page 167: Chapter4

    CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 13. Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon to mating surfaces. 14. Reinstall main cover and torque bolts in a cross pattern in 3 step to 14 ft.lbs.
  • Page 168 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 4X4 TRANSMISSION EXPLODED VIEW CHAPTER 6 TRANSMISSION PAGE. 6- 12...
  • Page 169 CHAPTER 6 TRANSMISSION BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 6 TRANSMISSION PAGE. 6- 13...
  • Page 170 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 CHAPTER 7 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of eachUTV model for spare parts information and service. NOTE: Also See Chapter 2 for Maintenance Information.
  • Page 171 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 7.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 5.5mm 0.04"/ 1mm Thickness Brake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ 0.051m m Between Measurements Brake Disc Runout 0.005 "/ 0.127mm...
  • Page 172 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0  Check and adjust master cylinder reservoir fluid level after pad service.  Make sure atmospheric vent on reservoir is unobstructed.  Adjust foot brake after pad service.  Test for brake drag after any brake system service and investigate cause if brake drag is evident.
  • Page 173 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 This procedure should be used to change fluid or bleed brakes during regular maintenance. 1. Clean reservoir cover thoroughly. 2. Remove cover from reservoir. 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool.

  • Page 174: Chapter7

    CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 calipers. 11. Add brake fluid to MAX level inside reservoir. Master Cylinder Fluid Level Between the MIN line and the MAX line of reservoir. 12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service.
  • Page 175 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3. Inspect the brake lines and brake line connections for possible leaks or loose lines. 7.7 PARKING BRAKE ADJUSTMENT Parking Brake Inspection 1.
  • Page 176 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 7.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads. Damage to the pads may cause the pads to function improperly.
  • Page 177 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the front wheel. 3. Remove the two caliper bolts and caliper from mounting bracket.
  • Page 178 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 of All Season Grease, and install rubber dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease.
  • Page 179 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 difference between measurements 3. Mount dial indicator as shown to measure disc runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit 0.005" (0.127 mm) REMOVAL/ REPLACEMENT 1.
  • Page 180 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 Replace caliper as an assembly if any problem exists. INSTALLATION 1. Install caliper on hub strut, Apply Loctite™ 243 to screw threads and Install new bolts. Front Caliper Mounting Bolt Torque 18 ft. lbs. (25 Nm ) 2.
  • Page 181 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 INSPECTION Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Service Limit 0.3/64"(1 mm) INSTALLATION 1. Install new pads in caliper body. 2. Install caliper and torque mounting bolts. Brake Caliper Torque: 18 ft.
  • Page 182 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 remove the caliper mounting bolts and remove caliper. 4. Remove brake pad as described above. 5. Inspect surface of caliper for nicks, scratches or damage and replace if necessary. 6. Install brake pads in caliper body with friction material facing each other, with the spacer between the pads.
  • Page 183 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit 0.005" (0.127 mm) REMOVAL/ REPLACEMENT 1. Remove the cargobox . 2. Remove calipers. 3. Remove bolts and disc from the flange. 4.
  • Page 184 CHAPTER 7 BRAKES BUCK 450 SERVICE MANUAL 20.0 NOTES CHAPTER 7 BRAKES PAGE. 7- 15...

  • Page 185: Chapter8

    CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 CHAPTER 8 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM COOLING SYSTEM LIGHTING SYSTEM GEAR POSITION INDICATOR SWITCH TEST SPEEDOMETER SYSTEM 8.10 MAIN SWITCH AND HANDLE SWITCH 8.11 FUEL GAUGE/ FUEL LEVEL SENSOR 8.12...
  • Page 186 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.1　PARTS INSPECTION AND SERVICE HEADLIGHT LAMP REPLACEMENT 1. Use LED 12V 7.2W. 2. Pull the Headlight plug off the wire harness ①、②、③、④ remove the screw 3. Replace a new headlight assy. 4. Test the headlight . Note: can not replace the bulb separately HEADLIGHT ADJUSTMENT...
  • Page 187 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT ①、②、③、④ 1.Pull the Taillight plug off the wire harness ,remove the screw ⑤ ⑥ 2.Turn and remove the lamp base ,Remove bulb and replace it with recommended bulb. 3.Reinstall the lamp base removed in step 2.
  • Page 188 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 189 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Load test CAUTION: Remove spark plug high tension leads and connect securely to engine ground before proceeding. NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly.
  • Page 190 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.3 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark  Spark plug gap incorrect  Fouled spark plug  Faulty spark plug cap or poor connection to high tension lead ...
  • Page 191 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 IF THE IGNITION SYSTEM FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 7.Pickup coil resistance 2. Battery 8.Main switch 3. Spark plug 9.Wiring connection 4. Ignition spark gap (entire ignition system) 5. Spark plug cap resistance 6.
  • Page 192 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 4.lgnition spark gap  Disconnect the spark plug cap from the spark plug Connect the ignition tester 1 as shown. 2 Spark plug Turn the main switch to "ON". Check the ignition spark gap . Check the spark by pushing the MEETS SPECIFICATION starter switch, and increase the spark...
  • Page 193 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Spark plug cap OUT OF SPECIFICATION resistance: 5.2KΩ(20 ℃) Replace the spark plug cap CORRECT 6. Ignition coil resistance Tester (+) lead Right Terminal Disconnect the ignition coil Tester (－) lead connector from the wire Left Terminal harness.
  • Page 194 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 7. Pickup coil resistance  Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead → BI Terminal  Tester (- ) lead→...
  • Page 195 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 1.Magneto 2.Voltage Regulator 3.Fuse 4.Battery 5.Load CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs and speed limiter.
  • Page 196 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 CHARGING SYSTEM Procedure Check: 1. Fuse (Main) 4.Stator coil resistance 2. Battery 5.Wiring system (entire charging system) 3.Charging voltage 1. fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY INSPECTION"...
  • Page 197 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) 　 to the stator coil Tester (+) lead –yellow terminal Tester (-) lead –yellow terminal OUT OF SPECITICATION 　　...
  • Page 198 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.5 ELECTRICS STARTING SYSTEM D I A G R A M TROUBLESHOOTING THE STARTER MOTOR OPERATES WHEN THE BRAKE SWITCH IS ON IF THE STARTER MOTOR FAILS TO OPERATE CHAPTER 8 ELECTRICAL PAGE 8- 14...
  • Page 199 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Procedure Check: 5. main switch 1. Fuse (Main) 6. brake switch 2. Battery 7. starter switch 3. starter motor 8. wiring connection (entire starting system) 4. starter relay 1. fuse refer “CHECKING SWITCHES”...
  • Page 200 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Check the starter relay for continuity. DOESNOTCONDUCTI Test (+) lead →  terminal DOES NOT CONDUCTION Test (-) lead →  terminal Replace the starter replay CONTINUITY 4. Main switch CHECK SWITCHES NO CONTINUITY Replace the main switch 1.
  • Page 201 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.6　COOLING SYSTEM CHAPTER 8 ELECTRICAL PAGE 8- 17...
  • Page 202 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 IF THE FAN MOTOR FAILS TO TURN Procedure Check: 1. Fuse (Main, Fan) 4. Fan motor (inspection) 2. Battery 5. Thermo switch 3. Main switch 6. Relay 7.Wiringconnection(entire cooling system) 1.Fuse CHECK SWITCHES NO CONTINUITY Replace the fuse 2.
  • Page 203 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 1.2 Fan motor (inspection 2) Turn the main switch to off. Remove the thermo switch lead DOES　NOT　MOVE from thermo switch. Connect the two wires of the thermo switch. Turn the main switch to on The wiring circuit from battery to fan motor is faulty.
  • Page 204 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 6.Relay Disconnect the starting circuit cut-off relay coupler from the wire harness. Connect the pocket tester (Ωx1) and battery (12V) to the starting circuit cut-off relay coupler terminals. Battery (+) lead→ terminal  Battery (-) lead→...
  • Page 205 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 3.Main switch CHECKING SWITCHES NO CONTINUITY Replace the main switch Handle the thermo unit with 4.Thermo unit special care. Drain the coolant and remove the Never subject it to strong thermo unit from the cylinder head. shocks or allow it to be Immerse the thermo unit in the dropped.
  • Page 206 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 POOR CONNECTION 6.Wiring connection check the connections of the entire cooling system. Refer to “CIRCUIT DIAGRAM” CORRECT Replace the temperature gauge 8.7　LIGHTING SYSTEM CHAPTER 8 ELECTRICAL PAGE 8- 22...
  • Page 207 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.High/low beam switch and turn switch 2. Battery 5.Flasher relay 3. Main switch 6. Wiring connection (entire lighting system) 1.fuse refer “CHECKING SWITCHES” NO CONTINUITY section Replace the fuse 2.
  • Page 208 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 6.Wiring connection POOR CONNECTIONS Check the connection of the entire lighting system correct check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1. If the high/low beam light and direction indicator fail to come on NO CONTINUITY 1.Blub and bulb socket CHECK...
  • Page 209 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Front/rear turn left light(LED) Tester (+) lead →Orange lead Tester negative (-) lead →Green lead Check for voltage (12V) on the lead at bulb socket connectors This circuit is not faulty Replace the bulb. If the light is LED,replace the light directly 2.
  • Page 210 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.8 GEAR POSITION INDICATOR SWITCH TEST Switch table This sensor is used to provide the gear position signal for meter display . When the gearbox is in one gear position, there is continuity between this terminal and engine， otherwise no continuity.
  • Page 211 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 Switch schematic CHAPTER 8 ELECTRICAL PAGE 8- 27...
  • Page 212 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.9　SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the gearbox Operation Instructions of LCD Meter and Speed Sensor 1. Ground Power DC 5V(+) 2. Ground 3. Output voltage signal Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
  • Page 213 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 LCD METER 1. Turn Left Indicator Light 10. The Odometer and Engine Working Hour Counter 2. Position Lamp Indicator 11. Km/ Mile Selector 3. High Beam Indicator Light 12. Gear Position Indicator 4.
  • Page 214 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.10 MAIN SWITCH AND HANDLE SWITCH Optional CHAPTER 8 ELECTRICAL PAGE 8- 30...
  • Page 215 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.11 FUEL GAUGE/ FUEL LEVEL SENSOR Remove seat, and then remove fuel sensor attached to fuel tank Hold fuel sensor in an upright position after removing it. It is normal if indicator shows “...
  • Page 216 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 RESISTANCE(20℃/ FLOAT POSITION 68°F) Fuel sensor resistance range TOP(FULL) ＜16Ω BOTTOM(RESERVE) ＞100Ω CHAPTER 8 ELECTRICAL PAGE 8- 32...
  • Page 217 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.12 THE OPERATION PRINCIPLE OF THE ELECTRIC 4WD SHIFT 1, The rider shifts 2WD to 4WD by the Switch on panel. 2. When shift 2WD/ 4WD or Diff Lock, the mechanics in the front gear box maybe still engaged/ disengaged, the mechanics would finally disengaged/ engaged when rides on a hard surface or rides in reverse.
  • Page 218 CHAPTER 8 ELECTRICAL BUCK 450 SERVICE MANUAL 20.0 8.13 WIRING DIAGRAM CHAPTER 8 ELECTRICAL PAGE 8- 34...

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