Table of Contents
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Brief introduction to maintenance handbook of HS750UTV-2
The handbook is edited by Technical Center of Chongqing Huansong Science And
Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of
technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain
vehicles （UTV）, and supplies some relevant technique and performance data. Some
techniques and method inside may be used to check, maintain and repair other models of
UTV, although it is mainly for HS750UTV-2.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee UTV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are
based on the sample in design, and they are subject to changes according to the
product's improvement without prior notice.
First version , November,2015
Published by Chongqing Huansong Science And Technology Industrial Co.,Ltd
Chongqing Huansong Science And Technology Industrial Co.,Ltd holds the copy right.
No publishing and reprinting without permission.
FOREWORD
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Table of Contents
Troubleshooting
Related Manuals for Hisun Motors HS750UTV-2
Summary of Contents for Hisun Motors HS750UTV-2
- Page 1 FOREWORD Brief introduction to maintenance handbook of HS750UTV-2 The handbook is edited by Technical Center of Chongqing Huansong Science And Technology Industrial Co.,Ltd, and is supplied to dealers and technicians as document of technique.Mainly, the handbook gives methods to check, maintain and repair utility terrain vehicles （UTV）, and supplies some relevant technique and performance data.
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Page 2: Table Of Contents
CONTENT CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION ....................1 DESCRIPTION ......................... 2 IDENTIFICATION CODE ....................3 Frame No........................3 Engine No........................3 SAFETY ........................... 4 Handling Gasoline Safely ................... 5 Cleaning Parts ......................5 Warning Labels ......................6 SERIAL NUMBERS ...................... - Page 3 Hammers ........................17 Ignition Grounding Tool .................... 17 PRECISION MEASURING TOOLS ................17 Feeler Gauge ......................18 Calipers ........................18 Micrometers......................19 Adjustment ....................... 20 Care ......................... 20 Metric micrometer ..................... 20 Standard inch micrometer ..................21 Telescoping and Small Bore Gauges ............... 22 Dial Indicator: ......................
- Page 4 Spark Test ........................ 37 The Starter Cannot Work Repeatedly Or Can Only Work Slowly ......38 POOR ENGINE PERFORMANCE ................. 38 The Engine Starts Slowly Or Difficultly ..............38 Engine Backfires, Cuts Out or Misfires During Acceleration ........39 Engine Backfires on Deceleration ................39 Poor Fuel Mileage ....................
- Page 5 Ohmmeter ........................ 52 Jumper wire ......................53 TEST PROCEDURES ....................54 Voltage test ......................54 Voltage drop test ...................... 54 Peak voltage test ...................... 55 Continuity test ......................55 Testing for a short with a self-powered test light or ohmmeter ......... 55 Testing for a short with a test light or voltmeter ............
- Page 6 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE ..................84 ENGINE .......................... 86 Adjusting the valve clearance ................... 86 Checking the spark plug ................... 89 Checking the ignition timing ..................89 Measuring the compression pressure ..............91 Checking the engine oil level ..................92 Changing the engine oil ....................
- Page 7 CHAPTER 4 ENGINE ENGINE NOTE ......................128 ENGINE REMOVAL ..................... 129 CYLINDER HEAD AND CYLINDER HEAD COVER ........... 132 ROCKER ARMS AND CAMSHAFT ................137 VALVES AND VALVE SPRINGS ................142 CYLINDER AND PISTON .................... 147 ENGINE COOLING FAN AND A.C. MAGNETO ............151 BALANCER GEARS AND OIL PUMP GEARS ............
- Page 8 FOOTREST ASSEMBLY ....................234 WHEEL AND TYRE PARTS ..................237 Front wheels ......................237 Rear wheels ......................238 TRANSMISSION SYSTEM ..................241 Front axle ....................... 241 Front bridge ......................242 Rear axle ........................ 252 Rear bridge ......................253 Reverse mechanism parts ..................257 SUSPENSION ......................
- Page 9 SIGNALING SYSTEM ....................308 Circuit diagram（see348 page） ................308 Troubleshooting ...................... 309 Checking the signal system ..................310 COOLING SYSTEM ..................... 316 Circuit diagram ....................... 316 Troubleshooting ...................... 317 2WD/4WD SELECTING SYSTEM ................319 CIRCUIT diagram（see348 page） ............... 319 TROUBLESHOOTING ....................320 1.
- Page 10 UNSTABLE HANDLING ....................346 Unstable handling ....................346 LIGHTING SYSTEM ..................... 346 Head light is out of work ..................346 Bulb burnt out ......................347 Error display of meter ..................... 347 CHAPTER 9 HS750UTV-2 WIRING DIAGRAM HS750UTV-2 WIRING DIAGRAM………………………………………………………… 348 - 9 -...
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Page 11: General Information
GENERAL INFORMATION GENERAL INFORMATION The text provides complete information on maintenance， tune-up repair and overhaul， Hundreds of photographs and illustrations created during the complete disassembly of four wheel utility terrain venires (UTV) guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time. -
Page 12: Description
GENERAL INFORMATION DESCRIPTION 1. Headlights 2. Front shock absorber assembly adjusting ring 3. Brake fluid reservoir 4. Driver seat 5. Driver seat belt 6. Air filter element(engine and air intake duct) 7. Spark plug 8. Oil filter cartridge 9. Passenger seat belt 10. -
Page 13: Identification Code
GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved in the lower right side of Figure. Engine No. Engine No. is carved on the right side of the Engine, Figure. - 3 -... -
Page 14: Safety
GENERAL INFORMATION SAFETY Professional mechanics can work for years and never sustain a serous injury or mishap. Follow these guidelines and practice common sense to safely service the utility terrain venires Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide. -
Page 15: Handling Gasoline Safely
GENERAL INFORMATION Handling Gasoline Safely Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is always present in the fuel tank, fuel line and throttle. -
Page 16: Warning Labels
GENERAL INFORMATION Warning Labels Most manufacturers attach information and warning labels to the UTV. These labels contain instructions that are important to personal safety when operating, servicing, transporting and storing the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement labels from the dealers or manufacturer if they are missing or damaged. -
Page 17: Washers
GENERAL INFORMATION Washers The two basic types of washers are flat washers and lock washers. Flat washers are simple discs with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose. Washers can be used as spacers and seals. -
Page 18: Shop Sipplies
GENERAL INFORMATION Remove and install snap rings with snap rings pliers. Refer to Basic Tools in this chapter In some applications. it may be necessary to replace snap rings after removing them Compress or expand snap rings only enough to install them. -
Page 19: Greases
GENERAL INFORMATION Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide range of operating conditions. Multi-grade oils are identified by a W after the first number, which indicates the low-temperature viscosity. Engine oils are most commonly mineral (petroleum) based, but synthetic and semi-synthetic types are used more frequently. -
Page 20: Gasket Sealant
GENERAL INFORMATION water-soluble. Local ordinances may types of cleaning chemicals. Refer to Safer in this chapter. Use brake parts cleaner to brake system components. Brake parts cleaner leaves no residue. Use electrical contact cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel system components. -
Page 21: Basic Tools
GENERAL INFORMATION BASIC TOOLS Most of the procedures in this manual can be carried out with basic hand tools and test equipment familiar to the home mechanic. Always use the correct tools for the job. Keep tools organized and clean. Store them in a tool chest with related tools organized together. Quality tools are essential. -
Page 22: Wrenches
GENERAL INFORMATION NOTE Another way to prevent cam out and to increase the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw ＆ socket Gripper onto screwdriver tip. After loosening/tightening the screw, clean the screw recess to prevent engine oil contamination. -
Page 23: Socket Wrenches, Ratchets And Handles
GENERAL INFORMATION off the fastener. Because one jaw is adjustable and may become loose, this shortcoming is aggravated. Make certain the solid jaw is the one transmitting the force. Socket Wrenches, Ratchets Handles Sockets that attach to a ratchet handle (Figure 7) are available with 6-point or 12-point openings (Figure 8) and different drive sizes. -
Page 24: Impact Drivers
GENERAL INFORMATION Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers. -
Page 25: Torque Adapters
GENERAL INFORMATION A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Please refer to the followed manufacturer’s instructions for their care and calibration. Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench. -
Page 26: Pliers
GENERAL INFORMATION The effective length is the sum of L and A. Example: TA=20 ft.-lb. A=3in. L=14in. =16.5 ft. - lb. In this example, the torque wrench would be set to the recalculated torque value (TW = 16.5 ft. –lb.). -
Page 27: Hammers
GENERAL INFORMATION WARNING Snap rings can slip and fly off when removing and installing them. Also, the snap ring pliers tips may break. Always wear eye protection when using snap ring pliers. Hammers Various types of hammers are available to fit a number of applications. Use a ball-peen hammer to strike another tool, such as a punch or chisel. -
Page 28: Feeler Gauge
GENERAL INFORMATION Precision measurements can vary according to the experience of the person performing the procedure. Accurate results are only possible if the mechanic possesses a feel for using the tool. Heavy-handed use of measuring tools produces less accurate results. Hold the tool gently by the fingertips to easily feel the point at which the tool contacts the object. -
Page 29: Micrometers
GENERAL INFORMATION increments. To obtain a reading, establish the first number by the location of the 0 line on the movable scale in relation to the first line to the left on the fixed scale. In this example, the number is 10 mm. To determine the next number, note which of the lines on the movable scale align with a mark on the fixed scale. -
Page 30: Adjustment
GENERAL INFORMATION around an object. Close the micrometer around the highest point so it can be removed with a slight drag. Adjustment Before using a micrometer, check its adjustment as follows: Clean the anvil and spindle faces. 2A. To check a 0-1 in. or 0-25 mm micrometer: Turn the thimble until the spindle contacts the anvil. -
Page 31: Standard Inch Micrometer
GENERAL INFORMATION mm increments. This numbering sequence continues with larger micrometers. On all metric micrometers, each mark on the lower half of the sleeve equals 0.50 mm. The tapered end of the thimble has 50 lines marked around it. Each mark equals 0.01 mm. One completer turn of the thimble aligns its 0 mark with the first line lower half of the sleeve line or 0.50mm. -
Page 32: Telescoping And Small Bore Gauges
GENERAL INFORMATION 2. Count the number of lines between the numbered sleeve mark and the edge of the thimble. Each sleeve mark equals 0.025 in. 3. Read the thimble mark that aligns with the sleeve line. Each thimble mark equals 0.01 in. NOTE If a thimble mark does not align exactly with the sleeve line, estimate the amount between the... -
Page 33: Compression Gauge
GENERAL INFORMATION Dial indicators are available in various ranges and graduations and with three basic types of mounting bases: magnetic (B. Figure 31). Clamp, or screw-in stud. When purchasing a dial indicator, select on with a continuous dial (A, Figure 31). Cylinder Bore Gauge A cylinder bore gauge is similar to a dial indicator. -
Page 34: Clip-On Ammeter
GENERAL INFORMATION needle location on the ohms scale. The needle must Align with the 0 mark to obtain accurate measurements. 4. If necessary, rotate the meter ohms adjust knob until the needle and 0 mark align. Clip-on ammeter Clip-on ammeter (Figure 35) is the basic tool for electrical system diagnosis which is used to measure the current of charging system and other electrical components work current. -
Page 35: Amperage
GENERAL INFORMATION Resistance is measured in an inactive circuit with an ohmmeter. The ohmmeter sends a small amount of current into the circuit and measures how difficult it is to push the current through the circuit. An ohmmeter, although useful, is not always a good indicator of a circuit’s actual ability under operating conditions. -
Page 36: Removing Frozen Fasteners
GENERAL INFORMATION before proceeding. 8. To prevent objects or debris from falling into the engine, cover all openings. 9. Read each procedure thoroughly and compare the illustrations to the actual components before starting the procedure. Perform the procedure in 10. Recommendations are occasionally made to refer service to a dealership or specialist. In these cases, the work can be performed more economically by the specialist than by the home mechanic. -
Page 37: Removing Broken Fasteners
GENERAL INFORMATION For frozen screws, apply penetrating fluid as described, the insert a screwdriver in the slot and rap the top of the screwdriver with a hammer. This loosens the rust so the screw can be removed in the normal way. If the screw head is too damaged to use this method, grip the head with locking pliers and twist the screw out. -
Page 38: Removing Hoses
GENERAL INFORMATION against each other. Remove the stud by turning the lower nut (Figure41). Measure the height of the stud above the surface. Thread the stud removal tool onto the stud and tighten it, or thread two nuts onto the stud. Remove the stud by turning the stud remover or the lower nut. -
Page 39: Removal
GENERAL INFORMATION NOTE Unless otherwise specified, install bearings with the manufacturer’s mark or number facing outward. Removal While bearing are normally removed only when damaged, there may be times when it is necessary to remove a bearing that is in good condition. However, improper bearing removal will damage the bearing and possibly the shaft or case. -
Page 40: Interference Fit
GENERAL INFORMATION When installing a bearing as described in Step 1, some type of driver is required. Never strike the bearing directly with a hammer or it will damage the bearing. When installing a bearing, use a piece of pipe or a driver with a diameter that matches the bearing inner race. - Page 41 GENERAL INFORMATION bearing chills, it will tighten on the shaft, so install it quickly. Make sure the bearing is installed completely. 2. Follow this step when installing a bearing in a housing. Bearings are general installed in a housing with a slight interference fit Driving the bearing into the housing using normal methods may damage the housing or cause bearing damage.
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Page 42: Seal Replacement
GENERAL INFORMATION inner-bearing race. Install the bearing(s) until it seats completely. Seal Replacement Seals (Figure 49) contain oil, water, grease or combustion gasses in a housing or shaft. Improperly removing a seal can damage the housing or shaft. Improperly installing the seal can damage the seat. Note the following: Prying is generally the easiest and most effective method of removing a seal from the... -
Page 43: Returning The Utv To Service
GENERAL INFORMATION 5. Remove the spark plug and ground the ignition system with a grounding tool as described in this chapter. Then pour a teaspoon (15-20ml) of engine oil into the cylinder. Place a rag over the opening and Start the engine over to distribute the oil. Remove the grounding tool and reinstall the spark plug. -
Page 44: Engine Principles And Operating Requirements
GENERAL INFORMATION By following a systematic approach, the possibility of unnecessary parts replacement can be avoid, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting. -
Page 45: Engine Is Cold
GENERAL INFORMATION 2.Special fault： Idle instability, CH and CO of off-gas out of limits Reason：Oxygen sensor loosing cause slight leakage or pipe slight leakage and makes the oxygen sensor collect too much oxygen ion signal. The wrong signal transmits to the ECU which result the increasing of oil supply. -
Page 46: Flooded Engine
GENERAL INFORMATION the engine speed has reduced to idle speed (1450RPM). Flooded engine If the engine fails to start after several attempts, it is probably flooded. This occurs when too much fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident when the engine is flooded. -
Page 47: Spark Test
GENERAL INFORMATION insulating material, causing an engine misfire. NOTE Engine misfire can also be caused by water that enters through connectors. Check the connectors for loose wire ends. On waterproof connectors, check for damage where the wires enter the connector. Perform the Spark Test in this section. -
Page 48: The Starter Cannot Work Repeatedly Or Can Only Work Slowly
GENERAL INFORMATION can ignite fuel ejected through the spark plug hole. Shift the transmission into neutral. WARNING Do not hold the spark tester, spark plug or connector or a serious electrical shock may result. Turn the engine over using the starter and push the starter button. A fat blue spark must be evident between the spark tester or spark plug terminals. -
Page 49: Engine Backfires, Cuts Out Or Misfires During Acceleration
GENERAL INFORMATION Contaminated or stale fuel. Clogged air filter. Intake pipe air leak. Plugged exhaust system. Check the silencer or muffler, especially if the utility terrain vehicle was just returned from storage. 10. Faulty ignition system component. Engine Backfires, Cuts Out or Misfires During Acceleration A backfire occurs when fuel is burned or ignited in the exhaust system. -
Page 50: Poor Fuel Mileage
GENERAL INFORMATION Poor Fuel Mileage 1. Clogged fuel system. 2. Dirty or clogged air filter. 3. Incorrect ignition timing. Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4. -
Page 51: Poor Idle Or Low Speed Performance
GENERAL INFORMATION A clogged exhaust system will prevent some of the burned exhaust gasses from exiting the exhaust port at the end of the exhaust stroke. This condition effects the incoming air/fuel mixture on the intake stroke and reduces engine power Check for retarded ignition timing. -
Page 52: Poor High Speed Performance
GENERAL INFORMATION Poor High Speed Performance Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. Perform the Peak Voltage Check the fuel system as described in this chapter Check the valve clearance as described. Note the following: If the valve clearance as correct. -
Page 53: Lean Mixture
GENERAL INFORMATION ECU program error or damage Lean Mixture The following conditions can cause a lean air/fuel mixture: 1. The injector is clogged 2. The pump pressure is not enough 3. ECU program chaos 4. ECU damage 5. The pressure sensor, oxygen sensor, solar term door position sensor fault ENGINE Engine Smoke The color of engine smoke can help diagnose engine problems or operating conditions... -
Page 54: High Engine Compression
GENERAL INFORMATION 1. Valves: The gap between the valve is not suitable. b. Incorrect valve timing. Worn or damaged valve seat surfaces. d. Bent valves. e. Weak or broken valve springs. 2. Cylinder head: Loose spark plug or damaged spark plug hole. Damaged cylinder head gasket. -
Page 55: The Ignition Advance Angle Is Too Large
GENERAL INFORMATION 3. Oil not circulating properly. 4. Valves leaking. 5. Heavy carbon deposits in the combustion chamber. 6. Dragging brake(s). 7. Slipping clutch. The Ignition Advance Angle Is Too Large Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber. Glowing deposits in the combustion chamber, inadequate Cooling or an overheated spark plug can all cause preignition. -
Page 56: Englne Lubrication
GENERAL INFORMATION the engine has warmed up, piston expansion reduces piston-to-cylinder clearance. 3. Knocking or rapping while decelerating—Usually caused by excessive rod bearing clearance. 4. Persistent knocking and vibration occurring every crankshaft rotation—Usually caused by worn rod or main bearing(s). Can also be caused by broken piston rings or a damaged piston pin. -
Page 57: No Oil Pressure
GENERAL INFORMATION Clogged oil gallery or metering orifices. No Oil Pressure Low oil level. The lubrication oil pressure valve is stuck and closed. Damaged oil pump. Incorrect oil pump installation. Internal oil leak. Oil Level Too Low The lubrication oil does not keep at the normal level. Worn piston rings. - Page 58 GENERAL INFORMATION Remove the air filter assembly Open and secure the throttle so it is at its wide-open position. Remove the spark plug. Install the threaded hose adapter from the leak down kit. Then install the leak down gauge onto the hose. Remove the ignition timing hole cap from the left crankcase cover.
- Page 59 GENERAL INFORMATION a. Turn the drive sprocket by hand and shift the transmission into top gear with the shift pedal. b. Mount a holding tool or equivalent onto the drive sprocket. Use a wooden block and clamp to hold the holding tool so it cannot move when the combustion chamber becomes pressurized.
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Page 60: Electrical Testing
GENERAL INFORMATION ELECTRICAL TESTING This section describes basic electrical testing and test equipment use. Preliminary Checks and Precautions Refer to the color wiring diagrams at the end of the manual for component and connector identification; Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground. -
Page 61: Electrical Component Replacement
GENERAL INFORMATION c. A change in meter readings indicates a poor connection. Fine and repair the problem or replace the part. Check for wires with cracked or broken insulation NOTE An analog ohmmeter is useful when making this type of test. Slight needle movements are apparent when indicating a loose connection Heat –... -
Page 62: Test Equipment
GENERAL INFORMATION machine has been operated. All instructions and specifications have been for accuracy: however. Successful test results depend to a great degree upon individual accuracy. Test Equipment A test light can be constructed from a 12-volt light bulb with a pair of test leads carefully soldered to the bulb. -
Page 63: Jumper Wire
GENERAL INFORMATION uncrossed, the needle reads zero. When the leads are uncrossed, the needle should move to the other end of the scale indicating infinite resistance. During a continuity test, a reading of infinity indicates that there is an open in the circuit or component. -
Page 64: Test Procedures
GENERAL INFORMATION TEST PROCEDURES Voltage test Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing. If the test lead only touches the wire insulation. -
Page 65: Peak Voltage Test
GENERAL INFORMATION For example, consider a starting problem where the battery is fully charged but the starter motor turns over slowly. Voltage drop would be the difference in the voltage at the batter (source) and the voltage at the starter (destination) as the engine is being started (current is flowing through the batter cables). -
Page 66: Testing For A Short With A Test Light Or Voltmeter
GENERAL INFORMATION Testing for a short with a test light or voltmeter 1. Remove the blown fuse. 2. Connect the test light or voltmeter across the fuse terminals in the starter relay. Turn the ignition switch ON and check for battery voltage. 3. -
Page 67: Brake Drag
GENERAL INFORMATION the master cylinder reservoir drops. Whenever adding brake fluid to the reservoir, visually check the brake pads for wear. If it does not appear that there is an increase in pad wear, check the brake hoses, lines and banjo bolts for leaks. 3. -
Page 68: Hard Brake Lever Or Pedal Operation
GENERAL INFORMATION Hard Brake Lever or Pedal Operation When applying the brakes and there is sufficient brake performance but the operation of brake lever feels excessively hard, check for the following possible causes: Clogged brake hydraulic system. Sticking caliper piston. Sticking master cylinder piston. -
Page 69: Leaking Master Cylinder
GENERAL INFORMATION Leaking Master Cylinder Damaged piston secondary seal. Damaged piston snap ring/ snap ring groove. Worn or damaged master cylinder bore. Loose banjo bolt washers. Damaged banjo bolt washers. Damaged banjo bolt threads in master cylinder body. Loose or damaged reservoir cap. - 59 -... -
Page 70: Specifications
SPECIFICATIONS SPECIFICATIONS HOW TO CONVERSION TABLE OF UNIT （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY... -
Page 71: Geberar Specifications
SPECIFICATIONS GEBERAR SPECIFICATIONS Item Standard Dimensions : Overall length 3920 mm（154.3 in） Overall width 1640 mm（64.6 in） Overall height 1,950 mm（76.8 in） Seat height 818 mm（32.2 in） Wheelbase 2860 mm（112.6 in） Minimum ground clearance 330mm（13 in） Minimum turning radius 5600 mm（220.5 in） Basic weight : With oil and full fuel tank 770kg (1694 lb) - Page 72 SPECIFICATIONS Item Standard Air filter Wet type element Fuel Unleaded gasoline only Type 28.0L（6.17 lmp gal, 7.40 US gal） Fuel tank capacity Throttle Type/quantity D46-3 / 1 Spark plug DCPR7E / 1 (NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Clutch type Wet ,centrifugal automatic Transmission...
- Page 73 SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 200 mm (7.87 in) Rear wheel travel 220 mm (8.66 in) Electrical Ignition system EFI.
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Page 74: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder 100.10 mm Bore size 100.005 ~ 100.055 mm (3.9410 in) Measuring point (3.9372 ~ 3.9392 in) ---- 50 mm (1.97 in) Camshaft Drive method Chain drive (Left) ---- Cam dimensions... - Page 75 SPECIFICATIONS Item Standard Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in) Arm-to-shaft clearance 0.009 ~ 0.042 mm ----...
- Page 76 SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
- Page 77 SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) ---- Measuring point “H” 2.5 mm (0.10 in) ---- Piston off-set 1.0 mm(0.0394 in)
- Page 78 SPECIFICATIONS Item Standard Limit Oil ring ---- 2.5×3.4 mm (0.0984× 0.1339 in) Dimensions (B×T) ---- 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) End gap (installed) ---- 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Side clearance Crankshaft 74.95 ~ 75.00 mm ---- Crank width “A”...
- Page 79 SPECIFICATIONS Item Standard Limit Transmission Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Engine oil ---- Oil pump Oil filter type Foam ----...
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Page 80: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 108 mm (4.25 in) ---- Spring free length 313 mm (12.32 in) ---- Spring fitting length 247.9 mm (9.76 in) ---- Spring rate 19.4 N/mm(1.94 kg/mm, 108.6 lb/in) ---- Stroke... - Page 81 SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.2 mm 1.5 mm (0.20 in) (0.06 in) Pad thickness outer 5.2 mm 1.5 mm (0.20 in) (0.06 in)
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Page 82: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (BTDC) 12°/ 1,500 r/min ---- Advancer type ECU Digital type ---- Ignition coil Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.18 ~ 0.28 Ωat 20 °C (68 °F) ---- Secondary winding resistance 6.32 ~ 9.48 kΩat 20 °C (68 °F) - Page 83 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) ---- 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, 27.5 ~ 36.0 oz)
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Page 84: Tightening Torques
SPECIFICATIONS TIGHTENING TORQUES Engine tightening torques Tightening torque Thread Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt Tappet cover (exhaust) —... - Page 85 SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Bolt Bolt Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
- Page 86 SPECIFICATIONS Shift arm Bolt Tightening torque Thread Remarks Part to be tightened Part name Q’ty ft · lb size m.kg Left-hand Shift rod locknut (select lever unit) — threads Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) —...
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Page 87: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Tightening torque Thread Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm... - Page 88 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half 26.0 Stake shaft Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt...
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Page 89: General Tightening Torque Specifications
SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. -
Page 90: Lubrication Pionts And Lubricant Types
SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES Engine Lubrication points Lubricant Oil seal lips Bearings O-rings Piston, piston ring Piston pin Buffer boss and balancer drive gear Crankshaft seal and spacer Valve stem Valve stem end Rocker arm shaft Rocker arm Camshaft lobe and journal Oil pump assembly Oil filter cartridge O-ring... -
Page 91: Chassis
SPECIFICATIONS CHASSIS Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing Front &... -
Page 92: Hydrographic Chart
SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure ：splash... -
Page 93: Lubrication Oil Way
SPECIFICATIONS LUBRICATION OIL WAY Hydrographic chart ：Pressure ：splashing oil... -
Page 94: Maintence And Adjustment Of The Utv
MAINTENANCE AND ADJUSTMENT OF THE UTV MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL Whichever... - Page 95 MAINTENANCE AND ADJUSTMENT OF THE UTV Whichever EVERY INITAL comes first month ITEM ROUTINE 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours · Check condition. · Spark plug Adjust gap and clean. ○ ○ ○ ○ ○ ·...
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Page 96: Engine
MAINTENANCE AND ADJUSTMENT OF THE UTV ENGINE Adjusting the valve clearance NOTE: · The valve clearance must be adjusted when the engine is cool to the touch. ·Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke. - Page 97 MAINTENANCE AND ADJUSTMENT OF THE UTV ② Fan impeller ③ As manhole covers 3. calibration Wrench to counterclockwise rotation · crankshaft According rotor turning · counterclockwise, rotor turn to mark the dead spots ② of crank box, namely ①: the dead point position is compressed.
- Page 98 MAINTENANCE AND ADJUSTMENT OF THE UTV 5. Adjust: valve clearance ① Lock nut ② Valve thickness gauge （gap Regulation） ③ Regulator ④ Adjust tools · Loosen the locknut ① · Insert a thickness gauge between the ③ adjuster end and the valve end. ·...
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Page 99: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE UTV CHECKING THE SPARK PLUG 1. Lift the cargo bed up. 2. Remove: pull out the spark plug cap ① and remove the spark plug by sleeve 3. Check: ·spark plug type Incorrect Replace. Standard spark plug DCPR7E /NGK 4. - Page 100 MAINTENANCE AND ADJUSTMENT OF THE UTV ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the cargo bed up. 3. Attach: ·tachometer ·timing light (to the spark plug lead) 4. Remove: Remove the cooling fan according to the ①...
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Page 101: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE UTV MEASURING COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes. 2. Stop the engine and remove the spark plug. 3. -
Page 102: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV Compression pressure (at sea level) Standard: 1,324Kpa (13.24 kg/cm , 188.31Psi) Minimum: 1,150Kpa (11.5 kg/cm , 163.57Psi) Maximum: 1,480Kpa (14.8 kg/cm , 210.50Psi) · Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until... -
Page 103: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Recommended oil classification: API Service “SE”, “SF”, “SG” type or equivalent (e.g. “SF—SE—CC”, “SF—SE—SD” etc.) NOTE: Do not allow foreign material to enter the crankcase. 4. Stop the engine and check the oil level again. - Page 104 MAINTENANCE AND ADJUSTMENT OF THE UTV 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ·Remove the oil filter cartridge ① with an oil filter wrench ② ·Lubricate the O-ring of the new oil filter ③...
- Page 105 MAINTENANCE AND ADJUSTMENT OF THE UTV 11. Check: ·engine oil pressure a. Slightly loosen the oil gallery bolt ① b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
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Page 106: Chassis
MAINTENANCE AND ADJUSTMENT OF THE UTV CHASSIS CLEANING THE AIR FILTER NOTE: There is a check hose at the bottom of the ① air filter case. If dust and/or water collect in this hose, clean the air filter element and air filter case. -
Page 107: Checking The Coolant Level
MAINTENANCE AND ADJUSTMENT OF THE UTV clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. Squeeze the excess solvent out of the element and let it dry. NOTE: Do not twist or wring out the element. This could damage the foam material. -
Page 108: Changing The Coolant
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE COOLANT 1. Remove: ·driver seat ·passenger seat ·console Lift the hood up.。 ·coolant reservoir cap ① ·Disconnect coolant reservoir hose ② · Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead coolant,... - Page 109 MAINTENANCE AND ADJUSTMENT OF THE UTV down on it and then remove it. 6. Drain: ·coolant 7. Disconnect: ·coolant outlet hose ① ·water pump inlet hose ② 8. Drain: ·coolant 9. Check: ·copper washer ① ·coolant drain bolt ② Damage Replace.
- Page 110 MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The specified amount of coolant is a standard amount. Fill the cooling system with coolant until coolant comes out of the hole for the air bleed bolt. Coolant is potentially harmful and should be handled with special care.
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Page 111: Checking The Coolant Temperature Warning Light
MAINTENANCE AND ADJUSTMENT OF THE UTV Refer to “THE COOLANT” in chapter 4. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. ·Close the hood. ·Install console: ·Install passenger seat ·Install driver seat Refer to “SEATS,” in chapter 5. CHECKING THE COOLANT TEMPERATURE WARNING LIGHT Coolant temperature indicator light ①... -
Page 112: Checking The V-Belt
MAINTENANCE AND ADJUSTMENT OF THE UTV Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning light does not come on. come on. Turn the main switch to “START” with the transmission in neutral position. -
Page 113: Cleaning The Spark Arrester
MAINTENANCE AND ADJUSTMENT OF THE UTV Install the bolts ① into the secondary fixed sheave hold. NOTE: Tightening the bolts ①will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. ·Remove the V-belt ①from the primary sheave and secondary sheave. -
Page 114: Adjusting The Brake Pedal
MAINTENANCE AND ADJUSTMENT OF THE UTV ·Remove the bolts ① ·Remove the tailpipe ② by pulling it out of the muffler. 4. Install： · Insert the tailpipe ② into the muffler and align the bolt holes. ·Insert the bolt and tighten it. ①... -
Page 115: Checking The Brake Fluid Level
MAINTENANCE AND ADJUSTMENT OF THE UTV 1. Shift the drive select lever into low gear “L”. 2. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter5. 3. Check: ·parking brake cable free play ○ a Out of specification Adjust.。... -
Page 116: Checking The Front Brake Pads
MAINTENANCE AND ADJUSTMENT OF THE UTV plastic parts. Always clean up spilled fluid immediately. WARNING · Use only the designed quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage poor brake performance. · Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance. -
Page 117: Checking The Brake Hoses And Brake Pipes
MAINTENANCE AND ADJUSTMENT OF THE UTV Brake pad wear limit ○ a 1.5 mm (0.06 in) 3. Operate the brake pedal. CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. -
Page 118: Adjusting The Select Lever Shift Rod
MAINTENANCE AND ADJUSTMENT OF THE UTV · The system has been disassembled. · A brake hose or brake pipe have been loosened or removed. · The brake fluid has been very low. The brake operation has been faulty. A loss of braking performance may occur if the brake system is not properly bled. -
Page 119: Checking The Final Gear Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable WARNING Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged 1. -
Page 120: Changing The Final Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV 4. Install: ·oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHANGING THE FINAL GEAR OIL 1. Place the vehicle on a level surface. 2. Place a container under the final gear case to collect the used oil. -
Page 121: Changing The Differential Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV 23 Nm (2.3 m · kg, 17 ft · lb) CHANGING THE DIFFERENTIAL GEAR OIL 1. Place the vehicle on a level surface. 2. Place a receptacle under the differential gear case. 3. Remove: ·oil filler plug ①... -
Page 122: Checking The Steering System
MAINTENANCE AND ADJUSTMENT OF THE UTV Damage Replace. Refer to “FRONT CONSTANT VELOCITY JOINTS,” in chapter 5. □ Front □ Rear CHECKING THE STEERING SYSTEM 1. Check: Place the vehicle on a level surface. steering assembly bearings Try to the steering wheel up and down, and back and forth. -
Page 123: Adjusting The Toe-In
MAINTENANCE AND ADJUSTMENT OF THE UTV play Replace the front arms (upper and lower) and/or wheel bearings. ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification Adjust. Toe-in 0 ~ 10 mm (0.00 ~ 0.39 in) (with tires touching the ground) NOTE: Before measuring the toe-in, make sure that... -
Page 124: Adjusting The Front Shock Absorbers
MAINTENANCE AND ADJUSTMENT OF THE UTV • After setting the toe-in to specification, run the vehicle slowly for some distance with both hands lightly holding the steering wheel and check that the steering wheel responds correctly. If not, turn either the right or left tie-rod within the toe-in specification. -
Page 125: Checking The Tires
MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING Always adjust both shock absorber spring preload same setting. Uneven adjustment can cause poor handling and loss of stability. NOTE: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight, and the operating conditions. -
Page 126: Checking The Wheels
MAINTENANCE AND ADJUSTMENT OF THE UTV c. Use no more than Front 77Kpa Rear 77Kpa when seating the tire beads. Higher pressure may cause the tire to burst. Inflate the tires slowly and carefully. Fast inflation could cause the tire to burst. •... - Page 127 MAINTENANCE AND ADJUSTMENT OF THE UTV Damage/bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced. WARNING • Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim.
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Page 128: Electrical
MAINTENANCE AND ADJUSTMENT OF THE UTV Lubricate or replace. NOTE: Hold the cable end up and apply several drops of lubricant to the cable. 2. Apply: • lithium-soap-based grease (onto end of the cable) lithium-soap-based. ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of... - Page 129 MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING • This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. • Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries.
- Page 130 MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the open-circuit voltage equals or exceeds 12.8V. b.
- Page 131 MAINTENANCE AND ADJUSTMENT OF THE UTV any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed.
- Page 132 MAINTENANCE AND ADJUSTMENT OF THE UTV Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 20 ~ 25 V Monitor the amperage for 3 ~ 5 minutes.
- Page 133 MAINTENANCE AND ADJUSTMENT OF THE UTV Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging.
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Page 134: Checking The Fuses
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ①, and then the negative battery lead ②. •... -
Page 135: Adjusting The Headlight Beam
MAINTENANCE AND ADJUSTMENT OF THE UTV related electrical devices. d. If the fuse immediately blows again, check the electrical circuit. Current Description Quantity rating Main 30 A Lighting 15 A system fuse Ignition 10 A Terminal 10 A (Auxiliary DC jack) 4WD(Four wheel drive) Signaling... -
Page 136: Changing The Headlight Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE HEADLIGHT BULB Remove: • Lift the hood up. • headlight bulb holder cover ① • headlight bulb holder (with bulb) ① • bulb NOTE: Remove the defective bulb by unhooking the headlight bulb holder tabs ② WARNING Keep flammable products and your hands away from the bulb while it is on, since it will... -
Page 137: Changing The Tail/Brake Light Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV • Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel ① • tail/brake light bulb holder (with bulb) ② • bulb NOTE: Turn the bulb holder counterclockwise and remove the defective bulb. WARNING Keep flammable products and your hands away from the bulb while it is on, since it will... -
Page 138: Engine Note
ENGINE ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air. -
Page 139: Engine Removal
ENGINE ENGINE REMOVAL Part Name Remarks Removing Throttle and intake Remove the parts in the order listed. manifold. Water temperature sensor O-ring Fuel injection Washer φ6×2 Seat fuel injection Bolt M6×20 Ducting dampers Inlet Temperature/pressure sensor Bolt M4×8 Pressure plate tmap Clip 50-70 Inlet joint head For installation, reverse the removal... - Page 140 ENGINE Part Name Remarks Removing Throttle and intake Remove the parts in the order listed. manifold. Inlet pipe Bush inlet pipe Bolt stud Nut M6 For installation, reverse the removal procedure. - 130 -...
- Page 141 ENGINE 1、NOTE • Removing the drain plug NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. 2、INSTALL • Install intake manifold • Install intake manifold bolt • Install carburetor joint • Install carburetor NOTE: When installed, don't make an object from the intake fell into the cabinet.
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Page 142: Cylinder Head And Cylinder Head Cover
ENGINE CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head cover Remove the parts in the order listed. and cylinder head Union bolt Copper washer Oil delivery pipe 3 Oil delivery pipe 2 Spark plug Tappet cover (intake) Tappet cover (exhaust) Timing chain tensioner cap bolt Timing chain tensioner / gasket... - Page 143 ENGINE Part Name Remarks Thermo switch 1 For installation, reverse the removal procedure. - 133 -...
- Page 144 ENGINE 1、CHECK 1). Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2). Checking the cylinder head cover • cylinder head cover Cracks/damage Replace the cylinder head cover and cylinder head as a set. 3).
- Page 145 ENGINE 5). Checking the cylinder head (1). Eliminate: • carbon deposits (from combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats (2). Check: • cylinder head Scratches/damage Replace the cylinder head cover and cylinder head as a set.
- Page 146 ENGINE 2). Installing the cylinder head • cylinder head gasket • cylinder head • bolts (M9: 1 ~ 6, 38Nm) • bolts (M6: 7, 10Nm) NOTE: • Tighten the bolts in the proper sequence. • Follow the numerical order shown in the illustration.
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Page 147: Rocker Arms And Camshaft
ENGINE ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Plug/O-ring Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft3/O-ring Rocker arm 4 Rocker arm shaft1/O-ring Rocker arm 1 Rocker arm 2... - Page 148 ENGINE Part Name Remarks Decompress or cam guide plate Camshaft sprocket Camshaft Cylinder head Cylinder head gasket For installation, reverse the removal procedure. - 138 -...
- Page 149 ENGINE 1、CHECK 1). Checking the rocker arms • rocker arm lobes ① • valve adjusters ② Blue discoloration/pitting/scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. b.
- Page 150 ENGINE • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3). Checking the camshaft sprocket • camshaft sprocket Wear/damage Replace camshaft...
- Page 151 ENGINE T-sleeve. b. Align the “I” mark ① on the rotor with the stationary pointer ② on the A.C. magneto cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (TDC). CAUTION: Do not turn the crankshaft during the camshaft installation.
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Page 152: Valves And Valve Springs
ENGINE VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the removal procedure. - Page 153 ENGINE 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
- Page 154 ENGINE • valve stem runout Out of specification Replace. Runout limit 0.01 mm 1NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
- Page 155 ENGINE 1NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Install the new valve guide using a valve guide remover ① and valve guide installer ②. b.
- Page 156 ENGINE 1NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. e. Install the valve into the cylinder head. g. Press the valve through the valve guide and onto the valve seat to make a clear pattern. h.
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Page 157: Cylinder And Piston
ENGINE CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Coolant inlet joint Cylinder/O-ring Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal procedure. - Page 158 ENGINE 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) 1NOTE: Check whether the piston and the piston groove is cracked and abraded.
- Page 159 ENGINE • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. 1NOTE: Clean carbon from the piston ring grooves rings before measuring...
- Page 160 ENGINE 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) 1NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
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Page 161: Engine Cooling Fan And A.c. Magneto
ENGINE ENGINE COOLING FAN AND A.C. MAGNETO Part Name Remarks Removing the engine cooling fan and Remove the parts in the order listed. A.C. magneto Drive belt cover Engine oil Coolant Water pump assembly Engine cooling fan air duct assembly Air shroud 1 Engine cooling fan Air shroud 2... - Page 162 ENGINE Part Name Remarks Pickup coil Stator assembly A.C. magneto rotor Woodruff key Starter wheel gear Washer Starter idle gear shaft Bearing Starter idle gear For installation, reverse the removal procedure. - 152 -...
- Page 163 ENGINE 1、CHECK 1). Checking the A.C. magneto • stator coil • pickup coil Damage Replace. 2). Checking the starter clutch • starter clutch ① Cracks/damage Replace. • starter clutch bolts ② Loose Replace with new ones, and clinch the end of the bolts. 1NOTE: •...
- Page 164 ENGINE • starter idle gear teeth ① • starter wheel gear teeth ② Burrs/clips/roughness/wear Replace. • starter wheel gear (contacting surface) Damage/pitting/wear Replace. 3). Checking the engine cooling fan • engine cooling fan • air shroud 1 • air shroud 2 Cracks/damage Replace.
- Page 165 ENGINE • engine cooling fan pulley ① (55Nm) 1NOTE: Before installing the engine cooling fan pulley, do not forget to install the O-ring. • engine cooling fan ① (7Nm) 1NOTE: Install the bolts in the holes in the collar of the engine cooling fan.
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Page 166: Balancer Gears And Oil Pump Gears
ENGINE BALANCER GEARS AND OIL PUMP GEARS Part Name Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Nut/lock washer Balancer driven/oil pump drive gear Chain Straight key Oil pump driven gear Plate Balancer drive gear Spring Timing chain guide (intake side) - Page 167 ENGINE 1、CHECK 1) Checking the oil pump drive gear and oil pump driven gear • oil pump drive gear ① • oil pump driven gear ② Cracks/wear/damage Replace 2).Checking the balancer drive gear and balancer driven gear • balancer drive gear ① •...
- Page 168 ENGINE • balancer driven gear 1NOTE: Align the punch mark (a) on the balancer drive gear with the punch mark (b) on the balancer driven gear. • lock washer(new replacement) • balancer driven gear nut ①(110Nm) 1NOTE: • Place an aluminum plate ② between the teeth of the balancer drive gear ③...
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Page 169: Primary And Secondary Sheaves
ENGINE PRIMARY AND SECONDARY SHEAVES Part Name Remarks Removing the primary and secondary Remove the parts in the order listed. sheaves Engine assembly Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sheave assembly V-belt Primary fixed sheave Secondary sheave assembly Drive belt case Rubber gasket For installation, reverse the removal... -
Page 170: Primary Sheave
ENGINE PRIMARY SHEAVE Part Name Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap Primary pulley slider Spacer Primary pulley cam Primary pulley weight Collar Oil seal Primary sliding sheave O-ring For assembly, reverse the disassembly procedure. -
Page 171: Secondary Sheave
ENGINE SECONDARY SHEAVE Part Name Remarks Disassembling the secondary Sheave Remove the parts in the order listed. Spring seat Compression spring Spring seat Guide pin Secondary sliding sheave O-ring Secondary fixed sheave Oil seal Oil seal For assembly, reverse the disassembly procedure. - Page 172 ENGINE 1、Check 1). Checking the primary sheave • weight outside diameter (a) Out of specification Replace the weight. Weight outside diameter limit: 29.5 mm • primary pulley slider • primary sliding sheave splines Wear/cracks/damage Replace. • spacer • primary pulley cam Cracks/damage Replace.
- Page 173 ENGINE 2、Measure • secondary sheave spring free length (a) Out of specification Replace the secondary sheave spring. 3、INSTALL 1). Assembling the primary sheave (1)Clean: • primary sliding sheave face ① • primary fixed sheave face ② • collar ③ • weights ④ •...
- Page 174 ENGINE 2). Assembling the secondary sheave (1)Apply: • assembly lube (to the secondary sliding sheave ① inner surface and oil seals)。 • assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ②) (2)Install: • guide pins ① •...
- Page 175 ENGINE 1NOTE: • Tightening the bolts ① will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. • Install the V-belt so that its arrow faces the direction show in the illustration. (2)Tighten: •...
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Page 176: Clutch
ENGINE CLUTCH Part Name Remarks Removing the clutch Remove the parts in the order listed. Primary and secondary sheaves Clutch housing assembly Gasket/dowel pin One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure. - 166 -... -
Page 177: Clutch Housing
ENGINE CLUTCH HOUSING Part Name Remarks Disassembling the clutch housing Remove the parts in the order listed. Oil seal Circlip Bearing housing Circlip Bearing Circlip Bearing Clutch housing For assembly, reverse the disassembly procedure. - 167 -... - Page 178 ENGINE 1、CHECK 1). Checking the clutch • clutch housing ① Heat damage/wear/damage Replace. • one-way clutch bearing ② Chafing/wear/damage Replace. 1NOTE: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.
- Page 179 ENGINE 3、INSTALL • clutch carrier assembly • nut ① 160Nm) 1NOTE: Use a universal clutch holder to hold the ② clutch carrier assembly. • Lock the threads with a drift punch. • one-way clutch bearing 1NOTE: The one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark (a) facing toward the clutch housing.
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Page 180: Crankcase Starter Motorand Oil Filter
ENGINE CRANKCASE STARTER MOTORAND OIL FILTER Part Name Remarks Remove the starter motor, timing Remove the parts in the order listed. chain and oil filter A.C. magneto rotor Primary and secondary sheaves Clutch carrier assembly Starter motor/O-ring Oil filter cartridge/O-ring Oil pipe assembly/O-ring Oil pipe adapter/O-ring Relief valve assembly... - Page 181 ENGINE Part Name Remarks Reverse switch Oil filler cap Oil delivery pipe 1 For installation, reverse the removal procedure. - 171 -...
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Page 182: Crankcase
ENGINE CRANKCASE Part Name Remarks Separating the crankcase Remove the parts in the order listed. Shift lever cover/gasket Dowel pin Shift lever 1 Shift lever 2 assembly Right crankcase Dowel pin Left crankcase Spacer Crankshaft seal For installation, reverse the removal procedure. -
Page 183: Crankcase Bearings
ENGINE CRANKCASE BEARINGS Part Name Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft and oil pump Transmission Middle drive/driven shaft O-ring/collar Oil seal Bearing retainer Bearing For installation, reverse the removal procedure. - 173 -... - Page 184 ENGINE 1、CHECK 1). Checking the oil delivery pipe • oil delivery pipe Cracks/damage Replace. Clogged Blow out with compressed air. 2). Checking the relief valve • relief valve ① • spring ② Damage/wear Replace the defective part(s). 3). Checking the crankcase (1) Thoroughly wash the case halves in a mild solvent.
- Page 185 ENGINE 2、INSTALL 1). Assembling the crankcase (1) Apply: • sealant (Quick Gasket) ① (to the mating surfaces of both case halves) (2) Install: • dowel pins ② (3) Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer CAUTION: Before installing and torque the crankcase holding bolts, be sure to check whether the...
- Page 186 ENGINE 2). Installing the shift levers • shift lever 2 assembly ① (14Nm) • shift lever 1 ② 1NOTE: When installing the shift lever 1, align the punch mark (a) on the shift lever 1 with the punch marks (b) on the shift lever 2. - 176 -...
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Page 187: Crankshaft And Oil Pump
ENGINE CRANKSHAFT AND OIL PUMP Part Name Remarks Removing the crankshaft and oil pump Remove the parts in the order listed. Crankcase separation Oil strainer/O-ring Oil pump assembly/gasket Balancer Plate Relief valve assembly Crankshaft For installation, reverse the removal procedure. - 177 -... -
Page 188: Oil Pump
ENGINE OIL PUMP Part Name Remarks Disassembling the oil pump Remove the parts in the order listed. Rotor cover Shaft Inner rotor Outer rotor Oil pump housing For assembly, reverse the disassembly procedure. - 178 -... - Page 189 ENGINE 1、CHECK 1). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts. 2). Checking the oil strainer • oil strainer ① • O-ring ② Damage Replace.
- Page 190 ENGINE Big end side clearance Limit: 1.0 mm (0.0394 in) • runout (b)(C) Out of specification Replace the crankshaft. Runout limit (b): 0.03 mm (C): 0.03 mm The crankshaft ① and the crank pin ② oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in).
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Page 191: Transmission
ENGINE TRANSMISSION Part Name Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Middle driven gear Low wheel gear Shift drum Shift fork assembly Short spring Shift fork 1 Long spring Shift fork 2 Guide bar Secondary shaft Drive axle assembly Chain... -
Page 192: Drive Axle Assembly
ENGINE DRIVE AXLE ASSEMBLY Part Name Remarks Disassembling the drive axle Remove the parts in the order listed. Clutch dog High wheel gear Middle drive gear Driven sprocket Drive axle For assembly, reverse the disassembly procedure. - 182 -... - Page 193 ENGINE 1、CHECK 1). Checking the shift forks • shift fork follower ① • shift fork pawl ② Scoring/bends/wear/damage Replace. • guide bar Roll the guide bar on a flat surface. Bends Replace. WARNING ： Do not attempt to straighten a bent guide bar. •...
- Page 194 ENGINE 3). Checking the high wheel gear and middle drive gear • gear teeth Blue discoloration/pitting/wear Replace. • mated dogs Rounded edges/cracks/missing portions Replace. • gear movement Unsmooth Repeat steps #1 or replace the defective parts. • circlip Bends/looseness/damage Replace. 4).
- Page 195 ENGINE 3、INSTALL 1). Assembling the shift fork • guide bar ① • shift fork 2 ② • long spring ③ • shift fork 1 ④ • short spring ⑤ 2). Installing the transmission • chain ① • drive axle assembly ② •...
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Page 196: Middle Gear
MIDDLE GEAR Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Bearing housing Middle drive gear Middle drive pinion gear Shim Middle drive shaft Bearing retainer For assembly, reverse the disassembly procedure. - 186 -... -
Page 197: Middle Drive Shaft
MIDDLE DRIVE SHAFT Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim Middle driven pinion gear For installation, reverse the removal procedure. - Page 198 Part Name Remarks Bearing retainer Bearing retainer Middle driven shaft For installation, reverse the removal procedure. - 188 -...
- Page 199 1、CHECK 1). Checking the pinion gears • gear teeth (drive pinion gear) ① • gear teeth (driven pinion gear) ② Pitting/galling/wear Replace. • O-ring Damage Replace. • bearings Pitting/damage Replace. • universal joint movement Roughness Replace universal joint. 2). Selecting the middle drive and driven gear shims When the drive and driven gear, bearing housing assembly and/or crankcase replaced,...
- Page 200 3、INSTALL 1). Installing the middle driven shaft • bearing retainer ① Bearing retainer 80 Nm 1NOTE: Attach the ring nut wrench ② CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer, turn it counterclockwise. • bearing retainer ① a.
- Page 201 • universal joint yoke • washer • nut ① 1NOTE: Use the universal joint holder ② to hold the yoke. Universal joint yoke nut 150 Nm • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c.
- Page 202 • drive shaft coupling • washer • nut ①(97Nm) 1NOTE: Use the coupling gear/middle shaft tool ② to hold the drive shaft coupling. 2). Installing the middle drive shaft (1) Tighten: • middle drive pinion gear nut ① (145Nm) 1NOTE: Secure the middle drive shaft in the vise with a clean rag.
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Page 203: Chassis
CHASSIS MALFUNCTION INSPECTION Appearance malfunction inspection Phenomenon Measure 1. Replace new plastic cover. 2. Check whether installation supporter deformed, repairing Plastic cover damaged or re-painting is needed before replacing new plastic cover. 3. Re-paste decals and re-rivet warning labels. 1. Replace new bumper. 2. - Page 204 CHASSIS 4. Check whether front wheel and front wheel axle nut loosen or damaged. Off tracking by braking at 5. Check whether front wheel hub inner spline and front high-speed wheel axle outer spline worn or loosen. 6. Check whether rubber cushion connected to front suspension rocker and frame damaged.
- Page 205 CHASSIS Phenomenon Measure 1. Check whether front and rear axles splines damaged. 2. Check whether gears of front gearbox and differential over worn. Front and rear axles arise abnormal sound during drive 3. Check whether rear gearbox gears over worn. 4.
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Page 206: Direction System
CHASSIS DIRECTION SYSTEM THE STEERING WHEEL PARTS (EPA TYPE) Part Name Remarks Removing the steering wheel parts Steering mechanism comp Driving gear Steering wheel comp Spring washer -8 Up cover for steering wheel Middle cover for steering wheel Socket hexagon screw M6×16 Clip Φ16 Decoration cover for steering wheel - 196-... - Page 207 CHASSIS Part Name Remarks Clip Rubber dust cover Hexagon flange bolt M10×1.25×35 Ball joint, steering mechanism Hexagonal nut M12 Steering drive axle Hexagon flange bolt M8×30 Steering column Hexagon flange bolt M8×25 Hexagon nut M12×1.25 Cotter pin 2×25 Steering wheel body - 197-...
- Page 208 CHASSIS Part Name Remarks Hexagon flange nut M12×1.25 Decoration cover for steering column Down cover for steering wheel Washer Φ10×Φ20×2 Spring washer -10 Washer Φ8×Φ16×1.6 Washer Φ15×Φ28×2 Cross small plate head tapping screw ST3.6×10 - 198-...
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Page 209: The Steering Wheel Parts (E-Mark Type)
CHASSIS THE STEERING WHEEL PARTS (E-mark TYPE) Part Name Remarks Removing the steering wheel parts Steering mechanism comp Driving gear Steering wheel comp Spring washer -8 Upper cover, steering wheel Middle cover, steering wheel Socket hexagon screw M6×16 Clip Φ16 Decoration cover, steering wheel - 199-... - Page 210 CHASSIS Part Name Remarks Clip Rubber dust cover Hexagon flange bolt M10×1.25×35 Ball joint, steering mechanism Hexagonal nut M12 Steering drive axle Hexagon flange bolt M8×30 Steering column Hexagon flange bolt M8×25 Hexagon nut M12×1.25 Cotter pin 2×25 Steering wheel body - 200-...
- Page 211 CHASSIS Part Name Remarks Hexagon flange nut M5 Screw M5×12 Ignition switch Hexagon flange nut M12×1.25 Washer Φ5 Small washer d=5 Screw Light switch assy Cross big plate head screw M5×16 Cross plate head tapping screw ST4.8×13 Upper cover, ignition switch - 201-...
- Page 212 CHASSIS Part Name Remarks Lower cover, ignition switch Tapping Clamp F4.2 Washer Φ5×Φ15×1.2 Decoration cover, steering column Rubber cushion, ignition switch cover Lower cover, steering wheel Washer Φ10×Φ20×2 Spring washer -10 Washer Φ8×Φ16×1.6 Washer Φ15×Φ28×2 Cross small plate head tapping screw ST3.6×10 - 202-...
- Page 213 CHASSIS THE STRUCTURE OF STEERING WHEEL PART DIASSEMBLING THE PARTS OF THE STEERING WHEEL Remove: ·plastic center lid ① ·flange nut, washer ② ·steering wheel ③ a. Takes down the plastic center lid ① b. Takes down the steering wheel flange nut, the washer Attached figure ②...
- Page 214 CHASSIS • Flange nut ④ Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering wheel.
- Page 215 CHASSIS CHECKING AND SERVICE THE STEERING COLUMN PARTS 1. Check: • steering column tube ① • bearing ② • central axis of the steering shaft ③ • spline ④ • loosening ⑤ • rocky ledge ⑥ The central axis of the steering shaft whether flexible and moves.
- Page 216 CHASSIS STEERING MACHINE PARTS DIASSEMBLING THE STEERING MACHINE PART 1. Check: • pressure pad ① • dust boots ② Wear/damage Replace. Damage/degradation Replace 1NOTE: When replace the dust boots of the ball , must enter 1/2 volume in lithium grease in to the dust boots.
- Page 217 CHASSIS 6. Check: Whether the inspection gear drive reverse gap does surpass the rating, If it does, adjust the gap and the bolt . If cannot reduce the gap through the adjustment, instead the drive gear and spline gear. WARNING Do not use the welding to repair the steering joint.
- Page 218 CHASSIS Bolt M8×16 24 Nm (2.4m · kg,17 ft · lb) 4. Use one piece of flange self-lock nut M12×1.25 fix the steering wheel on the steering column tube, then cover the direction column plastic center lid. Steering wheel tight of force 48 Nm(4.8m ·...
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Page 219: Brake System
CHASSIS BRAKE SYSTEM PREPARATION FOR CHECKING BEFORE THE MAINTENANCE OF THE BRAKE SYSTEM Brake system is crucial to the life safety of the operator and therefore must be periodically in- spected and maintained. This vehicle uses the double return route hydraulic pressure disc brake system. -
Page 220: Disk Brake Components
CHASSIS DISK BRAKE COMPONENTS Part Name Remarks Removing disk brake components Front brake hose Rear brake hose Hexagon flange bolt M6×25 Hexagon flange bolt M6×12 Oil pipe clip, front disc brake Clip, oil pipe Rear right brake caliper Rear left brake caliper Rear right brake plate Rear left brake plate Hexagon step bolt M8×20... - Page 221 CHASSIS Part Name Remarks Front brake pad Cooper seal Strainer bolt Cooper seal Rear right Brake Hose Rear left Brake Hose - 211-...
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Page 222: Front And Rear Brake Discs
CHASSIS FRONT AND REAR BRAKE DISCS Remarks Part Name Removing the brake discs Brake caliper assembly Brake disc Bolt Turn join Bolt Brake disc guard - 212-... - Page 223 CHASSIS CHECKING THE FRONT AND REAR BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
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Page 224: Front And Rear Brake Pads
CHASSIS FRONT AND REAR BRAKE PADS Part Name Remarks Removing the brake pads Remove the parts in the order listed. Brake caliper mounting bolt Brake pad holding bolt Brake pad For installation, reverse the removal Pad spring procedure. - 214-... - Page 225 CHASSIS REPLACING THE FRONT AND REAR BRAKE PADS 1NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set.
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Page 226: Front And Rear Brake Caliper
CHASSIS FRONT AND REAR BRAKE CALIPER Part Name Remarks Removing the brake caliper Remove the parts in the order listed. Brake fluid Union bolt Copper washer Brake hose Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly For installation, reverse the removal procedure. - Page 227 CHASSIS Part Name Remarks Disassembling the brake caliper Remove the parts in the order listed. Brake pad holding bolt Brake pad Pad spring Brake caliper piston Dust seal Caliper piston seal Bleed screw For assembly, reverse the disassembly procedure. - 217-...
- Page 228 CHASSIS DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS WARNING: • Brake caliper is one of the most important security components. Disassembly and maintenance must have a rich experience in technology and complete tool. •Wrong disassembly and reassembly may cause serious injury and even death. Replace damaged brake caliper.
- Page 229 CHASSIS assembly. • brake caliper body ③ Cracks/damage Replace. • brake fluid delivery passage (brake caliper body) Blockage Blow out with compressed air. WARNING ： Replace the caliper piston seals and dust seals whenever brake caliper disassembled. ASSEMBLING FRONT REAR BRAKE CALIPERS WARNING ：...
- Page 230 CHASSIS INSTALLING THE FRONT AND REAR BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1. Install: • brake caliper assembly • brake caliper mounting bolts 48Nm (4.8m · kg,35 ft · lb) • brake hose ① •...
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Page 231: Parking Brake Disc
CHASSIS PARKING BRAKE DISC Part Name Remarks Removing the parking brake disc Remove the parts in the order listed. Brake caliper assembly Final drive gear Parking brake disc For installation, reverse the removal procedure. - 221-... - Page 232 CHASSIS CHECKING THE PARKING BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Replace. Brake disc maximum deflection 0.10 mm (0.004 in) • brake disc thickness ○ Out of specification Replace. Brake disc minimum thickness 4.5 mm (0.18 in) - 222-...
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Page 233: Parking Brake Caliper And Brake Pads
CHASSIS PARKING BRAKE CALIPER AND BRAKE PADS Part Name Remarks Removing the parking brake caliper and brake pads parking skid plate Brake fluid Parking brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting Bolt Parking brake lever assembly Union bolt Copper washer Brake hose... - Page 234 CHASSIS Part Name Remarks Brake caliper assembly Brake pad (piston side) Brake pad Insulator/pad shim Pad spring Brake caliper bracket Parking brake arm nut Parking brake arm Set bolt Parking brake arm shaft Parking brake case bolt Parking brake case Gasket Brake caliper piston - 224-...
- Page 235 CHASSIS Part Name Remarks Dust seal Caliper piston seal Bleed screw - 225-...
- Page 236 CHASSIS REPLACING THE PARKING BRAKE PADS 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring 1NOTE: Always install new brake pads, new brake pad shims, new insulators, and a new brake...
- Page 237 CHASSIS b. Remove the dust seal and caliper piston seal. 1WARNING ： All internal brake components should be cleaned in new brake fluid only. Do not use solvents as they will cause seals to swell and distort. 1. Check: • brake caliper pistons ① Scratches/rust/wear Replace the brake caliper assembly.
- Page 238 CHASSIS 2. Install: • brake caliper piston Turn the brake caliper piston clockwise until section a of the brake caliper piston is level with the surface of the brake caliper body. 1NOTE: Align an end ○ of the groove in the brake caliper piston with the punch mark ○...
- Page 239 CHASSIS c. Install the parking brake arm to the parking brake arm shaft so that the punch mark ⓒ on the parking brake arm is aligned with the punch mark ⓐon the parking brake arm shaft. d. Turn the parking brake arm until it contacts the pin ⓓ.
- Page 240 CHASSIS Must use DOT4 Brake Fluid 1NOTE: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. 3. Air bleed: • brake system 4. Check: • brake fluid level Brake fluid level is below the “MIN” level Add the recommended brake fluid to line the proper level.
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Page 241: Brake Master Cylinder
CHASSIS BRAKE MASTER CYLINDER Part Name Remarks Removing the brake master cylinder Brake fluid Brake master cylinder Hexagon flange bolt M6×16 Hexagon flange bolt M6×20 Oil pipe hoop Connecting fork Split pin Pin, connecting fork - 231-... - Page 242 CHASSIS CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder ① Wear/scratches Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air. ...
- Page 243 CHASSIS • union bolt 27Nm (2.7 m · kg,19 ft · lb) 3. Fill: • brake fluid reservoir Must use DOT4 Brake Fluid 1NOTE: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. 4.
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Page 244: Footrest Assembly
CHASSIS FOOTREST ASSEMBLY Part Name Remarks Removing the footrest Left footrest protector Cross large plate head screw M5×16 Axle cover Insulation paper Ⅲ Lamp switch, rear break Hexagon flange self-lock nuts M6 Nut Clip M6 Right footrest protector Dustproof plate, brake pedal Cross large plate head screw M6×16 Rear brake pump bracket assy Hexagon flange bolt M8×16... - Page 245 CHASSIS Part Name Remarks Washer Φ15×Φ22×1.5 Washer Φ12×1 Spring Φ2×Φ12.5×47 Welding, parking pedal Spring Φ2×φ12.5×52 Throttle cable Washer Φ5×Φ10×1.0 Parking system Parking sensor Screw M4×12 Spring Φ1.2×Φ7×28 Parking brake cable Hexagon flange bolt M6×16 Clip for cable - 235-...
- Page 246 CHASSIS Part Name Remarks Expansion bolt(plastic) Mudguard for brake pump Hexagon flange bolt M8×20 Clamp Ⅳ （L=370） Clamp Ⅴ（L=200） Clamp Ⅲ （L=300） Push ties Cross large plate head screw M6×20 - 236-...
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Page 247: Wheel And Tyre Parts
CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Part Name Remarks Removing the front wheel Front rim Front tyre Nut M10 Wheel decoration cover Ⅳ Nut M22×1.5 1WARNING ： Front hub Securely support the vehicle so There is no danger of it falling over. cotter pin 3.2×50 Bolt M10×30 - 237-... -
Page 248: Rear Wheels
CHASSIS REAR WHEELS Part Name Remarks Removing the rear wheel Rear rim Rear tyre Rear hub Bolt M10×30 Nut M10 1WARNING ： Wheel decoration cover Ⅳ Securely support the vehicle so There is no danger of it falling over. Nut M22×1.5 Cotter pin 3.2×50 - 238-... - Page 249 CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play ① 3. Check: • wheel balance Out of balance Adjust. Wheel runout limit Radial ②: 2.0 mm (0.08 in) Lateral ③: 2.0 mm (0.08 in) 1WARNING...
- Page 250 CHASSIS INSTALLING THE WHEEL TYRE 1. Install: • wheel 1NOTE: The arrow mark ① on the tyre must point in the direction of rotation □ of the wheel. 2. Tighten: • wheel nuts ① The angle of the conical bores is 60° 1WARNING ：...
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Page 251: Transmission System
CHASSIS TRANSMISSION SYSTEM Front Axle Part Name Remarks Circlip Double off-set joint assembly Circlip Circlip Hoop A, dust P shed Φ80 Outer rubber dust-P cover (C-1610) Hoop B, dust P shed Φ32 Joint shaft Inner rubber dust-p cover (C-1605) Front left C.V axle Front right C.V axle - 241-... -
Page 252: Front Bridge
CHASSIS Front Bridge Part Name Remarks Removing the front bridge Front Differential Comp Hexagon Flange Bolt M10×1.25×150 HexagonFlangeSelf-LockNutsM12×1.25 Hexagon Flange Bolt M10×1.25×70 Connection Fork C Universal Joint C-Type Ring,Crossing Front Differential Case Front Differential Case Cover Oil Seal Φ24×Φ38×8, Output Shaft Hexagon Flange Bolt M10×1.25×16 - 242-... - Page 253 CHASSIS Part Name Remarks Hexagon Bolt M14×1.25×10 Rubber Washer O-Ringφ140×Φ2.65 Front Adjustment Gasket Ⅰ φ 50 × Φ 61.5 Bearingφ35×Φ62×14 Drive Gears,Front Axle Front Adjustment Gasket Ii Front Adjustment Gasket Iii Bevel Gear Transfer Gear Hexagon Bolt M10×1.25×16 Washer10 - 243-...
- Page 254 CHASSIS Part Name Remarks Bearingφ60×Φ85×13 Front Adjustment Gasket Iv Connecting Sleeve Divide Device Connection Bearing Φ35×Φ62×9 Hexagon Flange Bolt M8×25 Bushing Φ5×75 Inner Hexagon Half-Round Screw M8×10 Vent pipe Clamp C NeedlebearingΦ15×Φ21×12 BearingΦ35×Φ62×14 - 244-...
- Page 255 CHASSIS Part Name Remarks O-Ringd0=62 OilsealΦ48×Φ65×9,Drive Gears,Front Axle O-RingΦ140×Φ2.4 Hexagon Flange Self-Lock Nuts M14×1.25 Connection Fork E Shift Fork Rack O-RingΦ80×Φ1.8 Transfer Case Assembly Hexagon Socket Head Bolt M8×20 Washer 8 Air Tap,Front Axle Driven Gears, Front Axle Spring holding hoop - 245-...
- Page 256 CHASSIS DISASSEMBLING THE FRONT BRIDGE 1. Take down the left and right front wheel parts. 2. Sequently remove the front disk brake clip, cotter pin, open-groove nut, cushion and front wheel hub. 3. Disassembly the left and right arm rocker and cross steering knuckle.
- Page 257 CHASSIS CHECKING THE JOINTS 1.Check • Dust boots Cracks/damage Replace 2.Check • double off-set joint spline • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set joint Pitting/wear/damage Replace. • Check whether the inner and outer ball cage of the left and right transmission shaft movement is Smooth, ceaseless.
- Page 258 CHASSIS • oil seals • O-rings Damage Replace. 2.Check: • drive shaft splines • universal joints • drive pinion gear splines Wear/damage Replace. • spring Fatigue Replace. Move the spring up and down. 3.Check: • front drive shaft Bends Replace. •...
- Page 259 CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
- Page 260 CHASSIS ASSEMBLING THE DIFFERENTIAL GEAR 1. Measure: • gear lash 2. Install : • gear motor a. Installed to the differential gear, to the right to put it into the 2WD mode. b. Connect two C size batteries to the gear motor terminal ①...
- Page 261 CHASSIS INSTALLING THE FRONT BRIDGE PARTS 1. Put the left and right transmission shaft in the front bridge differential device. 2. Pour 0.32L SAE 80 API GL-4 the high quality gear grease into the front bridge differential device and screws tight the oil filler bolt.
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Page 262: Rear Axle
CHASSIS Rear Axle Part Name Remarks Removing the rear axle Circlip Double off-set joint assembly Hoop A, dust P shed Φ80 Inner rubber dust-P cover (C-1520) Hoop B, dust P shed Φ32 Double off-set joint assembly Inner rubber dust-p cover (C-1605) Half axle assembly Rear left C.V axle Rear right C.V axle... -
Page 263: Rear Bridge
CHASSIS Rear Bridge Part Name Remarks Removing the rear bridge Rear reducer assy Rear Transmission Shaft K Hexagon Flange Bolt M10×1.25×120 Hexagon Flange Self-Lock Nuts M10x1.25 Connection Fork F Universal Joint Circlip D0=22 Hexagon Flange Self-Lock Nuts M12×1.25 Washer,Drive Gears Connection Fork G Oil Seal Φ61×Φ35×9, Input Shaft Hexagon Flange Bolt M8×35... - Page 264 CHASSIS Part Name Remarks Washer 8 Mountbracket, Brake Rear Adjustment GasketⅠ O-Ringφ71×Φ2.65 Bearingφ25×Φ62×17. Sleeve Drive Gears,Rear Axle Needle Bearinghk223013 Hexagon Flange Bolt M10×1.25×16 Rubber Washer, Fueldrainscrew Rear Axle Case Rear Differential Case Cover O-Ringφ65×Φ90×9 - 254-...
- Page 265 CHASSIS Part Name Remarks Speed Sensor Assy O-RingΦ18×Φ2.65 Air Tap,Rear Axle Clamp C Vent pipe Needlebearinghk556720 Rear Adjustment GasketⅡ Driven Gears,Rear Axle Rear Adjustment GasketⅢ BearingΦ85×Φ130×14 O-Ring Φ3.1×Φ150 Copper Gasket Φ8.2Χ1 Inner Hexagon Half-Round Screw M8×45 - 255-...
- Page 266 CHASSIS Part Name Remarks Hexagon Flange Self-Lock Nuts M8 Hexagon Flange Bolt M8×25 Hexagon Flange Bolt M10×1.25×25 Rear Drive Shaft Assy Circlip Φ25 Washer Φ31.5×Φ25×1,Drive Shaft Pressure Spring, Drive Shaft Rubbercover，Drive Shaft Rubber Washer, Driving Gear Bushing, Drive Shaft Sring holding hoop - 256-...
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Page 267: Reverse Mechanism Parts
CHASSIS REVERSE MECHANISM PARTS Part Name Remarks Removing reverse mechanism Gear Shifter Assembly Hexagon Flange BoltM8×45 Hexagon Flange Nut M8 Gearshift arm Hexagon Flange BoltM6×20 Spring Washer-8 Gear Shift Rod I Hexagon Flange Locked Nut M6 steering lever I,Gearshift Shift steering arm installation I Nylon BushingΦ12×Φ15.5 Hexagon Flange Bolt M6×16 - 257-... - Page 268 CHASSIS Part Name Remarks Spacing Cable Assy D, Reverse Gear Gear Shift Rod II Steering Arm II,Gear shifting Gear Shift Rod III Gearshift arm - 258-...
- Page 269 CHASSIS ADJUSTING REVERSE MECHANISM PARTS ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable 1NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. 1.
- Page 270 CHASSIS try again., if still not good to inform the special serviceman to service the reverse mechanism. 2. If the reverse mechanism appears lacks files, adjust the connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again.
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Page 271: Suspension
CHASSIS SUSPENSION Front Suspension and arm Part Name Remarks Removing front suspension and arm Left front upper swing arm Joint A，suspension Circlip D0=30 Right front upper swing arm Left front lower swing arm Right front lower swing arm Middle rubber tube, swing arm Hexagon flange bolt M10×1.25×70 - 261-... - Page 272 CHASSIS Part Name Remarks Hexagon flange nut M10×1.25 Dust cover B Hexagon nut M12×1.25 Cotter Pin 2.5×30 Front shock absorber Hexagon flange bolt M10×1.25×50 Protective board, swing arm Screw thread clip M6×5 Cross big plate head screw M6×12 Tie-rod, front anti-roll bar Hexagon flange bolt M10×1.25×45 - 262-...
- Page 273 CHASSIS Part Name Remarks "U" type rubber bush Φ21-40 Press block, rear anti-roll bar Hexagon flange bolt M8×22 Front anti-roll bar Spring washer -8 Hexagon flange bolt M10×1.25×75 Dust proof rubber boot Washer Φ13×Φ24×2 Spring washer -12 Washer Φ8×Φ16×1.6 Hexagon flange lock nut M8 - 263-...
- Page 274 CHASSIS DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and Service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. • If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
- Page 275 CHASSIS To check whether put on the butter before fix, then fix the upper and lower rockers and L/R front shock absorber, etc . CHECKING THE FRONT ARMS 1. Check: • front arms Bends/damage Replace. 2. Check: • Middle bushing Wear/damage Replace.
- Page 276 CHASSIS I NSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber a. Install the front upper arm ① and front lower arm ②. NOTE: • Lubricate the bolts ③with lithium-soap-based grease. • Be sure to position the bolts ③ so that the bolt head faces outward.
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Page 277: Rear Suspension
CHASSIS Rear Suspension Part Name Remarks Removing the rear suspension Rear shock absorber Hexagon flange bolt M12×1.25×70 Hexagon flange bolt M12×1.25×65 Hexagon flange nut M12×1.25 Rear anti-roll bar Left tie-rod, anti-roll bar Right tie-rod, anti-roll bar Hexagon flange nut M10×1.25 "U"... - Page 278 CHASSIS Part Name Remarks Spring washer -8 Washer Φ8×Φ16×1.6 Washer Φ10×Φ20×2 - 268-...
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Page 279: Rear Arm Shaft
CHASSIS Rear arm shaft Part Name Remarks Removing the rear arm shaft Rear right upper swing arm Rear left lower swing arm Rear right lower swing arm Middle rubber tube, swing arm Hexagon flange bolt M10×1.25×70 Hexagon flange nut M10×1.25 Rear left upper swing arm Dust cover B Protective board, rear right lower swing arm... - Page 280 CHASSIS Part Name Remarks Cross large plate head screw M6×16 Nut clip M6 - 270-...
- Page 281 CHASSIS Rear Suspension and arm CHECKING AND SERVICE OF REAR SUSPENSION 1. It is similar to the front suspension ,Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2.
- Page 282 CHASSIS CHECKING THE REAR SHOCK ABSORBER 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue Replace the shock absorber assembly.
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Page 283: Cooling System
CHASSIS COOLING SYSTEM RADIATOR 1 Part Name Remarks Removing the radiator 1 water inlet Ⅰ Screw Clip D Clip Ⅱ, Water Pipe Hexagon Flange Bolt M6×16 Metal Water Pipe I water inlet Ⅱ Exhalent siphon Ⅰ Cooler Fan Assy Radiator Support I Radiator Support Ⅱ... - Page 284 CHASSIS Part Name Remarks Water Tank Cover Water Temperature Sensor Secondary water tank cover Exhalent siphon for auxiliary kettle Flexible Clamp D BushΦ6.5×Φ22×6.5 Elastic hoop C water inlet for auxiliary kettle Radiator Cover Second Water Tank Cooling water tank component water inlet Ⅱ...
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Page 285: Radiator 2
CHASSIS RADIATOR 2 Part Name Remarks Removing the radiator 2 Oil cooler cover Weding Oil Cooler Assy lubricating oil cooler Locking Hoop For Screw A rubber fuel line Ⅰ Cross Large Plate Head Screw M6×12 fixing pipe clamp(M type) fixing pipe clamp(M type) Hexagon Flange Nut M6 Metal Oil Pipe Ⅲ... - Page 286 CHASSIS Part Name Remarks Pressureproof Rubber Oil PipeⅠ fuel line rubber Metal Oil PipeII Metal Oil PipeI pressureproof Rubber Pipeline IV pressureproof Rubber Pipeline V - 276-...
- Page 287 CHASSIS CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • all rubber hose Cracks/damage Replace.
- Page 288 CHASSIS the refrigerating fluid until the water level stop to change, then screw the exhaust nut, cover the water tank lid. The water tank inspection is finished. . 2. Check: • cooling system Leaks Repair or replace any faulty part. Recommended antifreeze: High quality ethylene glycol antifreeze containing...
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Page 289: Water Pump
CHASSIS WATER PUMP 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Water pump assembly Bolt M6×45 Bolt M6×65 Bolt M6×10 Water pipe Ⅱ O-ring 20.7×2.6 Water pipe Ⅲ Water pipe clip Cylinder inlet water joint Bolt M6×20 O-ring 33.4×2.4... - Page 290 CHASSIS 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Pipe clip Ⅱ Save temperature Save temperature cover Bolt M6×20 Water pump housing cover Gasket Circlip Impeller assembly Water pump seal Oil seal Bearing Water pump housing O-ring...
- Page 291 CHASSIS DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder ① • rubber damper ② NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal ① • Water pump housing ② NOTE: Tap out the water pump seal from the inside of the water pump housing.
- Page 292 CHASSIS 2. Check: • water pump seal ① • oil seal ② • water pipe ③ Cracks/damage/wear Replace. • bearing ④ Rough movement Replace. NOTE: Apply lithium-soap-based grease to the oil seal and Apply engine oil to the bearing 3. Measure: •...
- Page 293 CHASSIS 3. Install: • rubber damper ① • rubber damper holder ② NOTE: • Before installing the rubber damper, apply tap water or coolant onto its outer surface. • Make sure that the rubber damper and rubber damper holder are flush with the impeller.
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Page 294: Seat
CHASSIS SEAT Part Name Remarks Removing the seat Seat assy Safety belt placing plate Seat mounting board Hexagon flange bolt M8×30 Hexagon flange Nut M8 Seat locker Hexagon flange bolt M6×40 Hexagon flange Nut M6 Locker bracket, seat Rubber cushion Φ30-3 Rubber cushion Φ24-15 - 284-... - Page 295 CHASSIS Part Name Remarks Side armrest Hexagon flange bolt M6×25 Head rest Washer Φ8×Φ28×1.5 Hexagon flange nut M10×1.25 Hexagon flange step bolt M10×1.25×20-Φ14×5 Hexagon flange bolt M10×1.25×20 Washer Φ10×Φ25×3 Safety belt buckle Safety belt assy (3-point type) Washer Φ6×Φ18×1.6 Washer Φ8.5×Φ22×1.2 Hexagon flange step bolt M10×1.25×15-Φ14×5 Collar bush Φ8×Φ25×Φ36×7 - 285-...
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Page 296: Oil System
CHASSIS OIL SYSTEM FUEL TANK Part Name Remarks Removing the fuel tank Fuel Tank Assy. Oil Pump Plug Oil pump gland Breather pipe,fuel tank Fuel outlet Plug Spring Clamp E Pressure Clamp A Triplet Joint Fuel Pipe High Pressure Fuel PipeⅠ - 286-... - Page 297 CHASSIS Part Name Remarks High Pressure Fuel Pipe II φ8×φ14×885 Fuel Pump Fuel Inlet Plug Fuel tank switch cap Seal Gasket B For Fuel Pump Hoop Spring Connecting Cable, Oil Pump Fuel tank I Hexagon Flange Bolt M8×20 - 287-...
- Page 298 CHASSIS DISASSEMBLING OIL COOLING SYSTEM Except the Cooling System of the engine, this UTV is also equip the oil Cooling System. Disassembly, Inspection and Assembly of Oil Cooling System 1. Disassemble the oil cooler. 2. Disassemble the connecting steel oil pipe 3.
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Page 299: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Measure Phenomenon 1、 Check whether switches normal. 2、 Check whether cables damaged. Abnormal lights 3、 Check whether lights damaged. 1、 Check whether four wheel drive switch normal. Fail shift into four-wheel-drive 2、 Check whether front bridge differential mechanical conversion agency lock differential. -
Page 300: Electrical
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICALCOMPONENTS(bucket seat) 1. Thermo switch 2 2. Radiator fan 3.Gear motor 4. Windlass 5.Parking brake switch 6.Pickup coil/stator assembly 7.Speed sensor 8. Diode 1 9. Circuit breaker(radiator fan motor) 10.Thermo switch 1 11. Ignition coil 12. Gear position switch 13.Reverse switch 14.ECU unit 15. - Page 301 ELECTRICAL COMPONENTS 1. Relay assy 2. Starter relay 3. Battery 4. Rectifier/regulator 5. Speedmeter 6. On-Command four-wheel drive switch and differential gear lock switch 7. Ignition switch components 8. Light switch - 291 -...
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Page 302: Checking The Switch
ELECTRICAL COMPONENTS CHECKING THE SWITCH CHECKING THE SWITCH Use multimeter to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. 1NOTE: • Set the multimeter to “0” before starting the test. • The multimeter should be set to the “Ω × 1” range when testing the switch for continuity. -
Page 303: Checking The Switch Continuity(Bucket)
ELECTRICAL COMPONENTS Checking the switch continuity(bucket) Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. 1. Fuse 2. Brake light switch 3.On-Command four-wheel drive switch and differential gear lock switch 4.Main switch 5.Light switch 6.Parking brake switch... -
Page 304: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both. -
Page 305: Ignition System
ELECTRICAL COMPONENTS IGNITION SYSTEM CIRCUIT DIAGRAM（ ） see 353 page TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 7. Main switch 2. Battery 8. Pickup coil resistance 3. Spark plug 9. - Page 306 ELECTRICAL COMPONENTS 4. Ignition spark gap INCORRECT • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker ① as shown. Repair or replace the spark plug. ② Spark plug cap •...
- Page 307 ELECTRICAL COMPONENTS . resistance Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead Orange lead terminal Tester (–) lead Spark plug lead •...
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Page 308: Electric Starting System
ELECTRICAL COMPONENTS 9.Wiring connection • Check the connections of the entire ignition POOR CONNECTION system. Refer to “CIRCUIT DIAGRAM”. CORRECT Replace the ECU unit Properly connect the ignition system. ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM （ ） see348 page - 298 -... -
Page 309: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING 6. Gear position switch STARTER MOTOR FAILS 7. Brake light switch OPERATE: 8. Diode 1 9. Wiring connection (the entire starting system) Procedure NOTE: Check: • Remove following part(s) before 1. Fuses (main, ignition, signaling system) troubleshooting: 2. - Page 310 ELECTRICAL COMPONENTS 4. Starter relay Repair or replace the starter motor. • Remove the starter relay from the wire Small testers and battery and (12V) and start harness. relay terminal connection • Connect the pocket tester (Ω × 1) and the Check continuity of the start relay battery (12 V) to the starter relay terminals.
- Page 311 ELECTRICAL COMPONENTS NOTE: ㈠ When you switch the tester’s positive and negative probes, the readings in the left chart will be reversed. ㈡ Connect multimeter positive to Red/Bule white terminal (1) Connect multimeter negative to Yellow/Bule terminal (2) NOTE: ㈡ When you switch the tester’s positive and negative probes, the readings in the left chart will be reversed.
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Page 312: Starter Motor
ELECTRICAL COMPONENTS STARTER MOTOR Part Name Remarks Remove the parts in the order listed Removing the starter motor Flange bolt Starter motor assy. - 302 -... -
Page 313: Charging System
ELECTRICAL COMPONENTS CHARGING SYSTEM CIRCUIT DIAGRAM - 303 -... -
Page 314: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage NOTE: Remove some parts before maintenance 1. Cushion 1. Fuse (main) Repair with following special toolings Refer to “CHECKING THE SWITCH”. -
Page 315: Lighting System
ELECTRICAL COMPONENTS • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. Tester (+) lead White terminal ① Tester (–) lead White terminal ② Tester (+) lead White terminal ① Tester (–) lead White terminal ③... -
Page 316: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check 1. Fuses (main, lighting system) 4. Light switch 2. Battery 5. Wiring connections(the entire lighting system) 3. Main switch NOTE: • Remove following part(s) before troubleshooting: 1. -
Page 317: Checking The Lighting System
ELECTRICAL COMPONENTS CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers. -
Page 318: Signaling System
ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2) . Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light couplers. -
Page 319: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING 3. Main switch IF A BRAKE LIGHT, AN INDICATOR LIGHT, 4. Wiring connections (the entire signal system) OR THE WARNING LIGHT FAILS TO COME NOTE: • Remove the following part(s) before Procedure troubleshooting: Check: 1. Console 1. Fuses (main, signaling system) 2. -
Page 320: Checking The Signal System
ELECTRICAL COMPONENTS CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Bake light switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. - Page 321 ELECTRICAL COMPONENTS 2. If L, H, N, R, light is not bright (1). Gear position switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the gear position switch (2). Wire connection NO CONTINUITY Check the main beam connected to the gear switch connector is strong Repair the main beam connection with gear CONNECTION IS FIRM...
- Page 322 ELECTRICAL COMPONENTS 3. If the parking brake indicator light fails to come on: (1). Brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the parking brake switch (2). Voltage Set the multimeter to DC12V, test the brake lamp voltage at both ends Yellow3 power meter pens ①...
- Page 323 ELECTRICAL COMPONENTS 4. If the reverse indicator light fails to come on: (1). Directional signal switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the Reverse switch (2). Voltage Set the multimeter to DC12V, test the direction lamp voltage at both ends Dark/Brown power meter pens ①...
- Page 324 ELECTRICAL COMPONENTS 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F): (1).
- Page 325 ELECTRICAL COMPONENTS 6. If the four-wheel drive and front bridge differential lock indicator light fails to come on ： (1). Check the driver combination switch and front axle differential switch NO CONTINUITY Refer to “CHECKING THE SWITCH”. CONTINUITY Replace the to drive the combination switch. (2).
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Page 326: Cooling System
ELECTRICAL COMPONENTS COOLING SYSTEM CIRCUIT DIAGRAM - 316 -... -
Page 327: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure 5. Thermo switch 3 Check: 6. Wiring connection(the entire cooling system) 1. Fuse (main) 2. Battery NOTE: 3. Main switch • Remove following part(s) before 4. Radiator fan motor troubleshooting. - Page 328 ELECTRICAL COMPONENTS 4.Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead Brown terminal ① Battery (–) lead Blue/Red terminal ② DOES NOT TURN Replace the radiator fan motor. •...
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Page 329: 2Wd/4Wd Selecting System
ELECTRICAL COMPONENTS WARNING ： Handle the thermo switch 3 with special care. Never subject it to a strong shock or allow it to be dropped. Should it be dropped, it must be replaced. BAD CONDITION Thermo switch 3 28 Nm (2.8 m · kg, 20 ft · lb) GOOD CONDITION Replace the thermo switch 3 6. -
Page 330: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING 1. Check if the 2/4WD switch is working. a. Turn on the switch, put the gear to position N; keep front and rear wheel off the ground , and then roll the front wheel to see if the rear wheel is moving together with it or if it is rotatable. b. -
Page 331: Engine Management System
ENGINE MANAGEMENT SYSTEM INTRODUCTION EMS (Engine Management System) EMS is a self contained set of components including a custom built computer and sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature and providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required. -
Page 332: Layout Of Ems Components
ENGINE MANAGEMENT SYSTEM Layout of EMS Components Legend: Dotted line indicates inputs Solid line indicates outputs COMPONENTS OF EMS Electronic Control Unit 1．Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors. It also provides the necessary computation, adaptability, and output control in order to minimize the tailpipe emissions and fuel consumption, while optimizing vehicle drivability for all operating conditions. -
Page 333: Multec 3.5 Injectors
ENGINE MANAGEMENT SYSTEM 2．Handling – DOs & DONTs ECU Handing ACTION REASON DO NOT: Place the ECU close to the exhaust High temperature might reduce the life of the pipe or Engine when removed ECU and also can damage the ECU Place the ECU close to or pour ECU is susceptible to water and liquids DO NOT:... - Page 334 ENGINE MANAGEMENT SYSTEM 2．Handling - DOs & DONTs 3.5 FUEL INJECTOR HANDLING ACTION REASON DO NOT: Re-use injector seal rings if at all Leakage. possible. If no other choice exists, take extra care in inspecting the seal rings for damage. DO NOT: Dip injector tips into lubricants.
- Page 335 ENGINE MANAGEMENT SYSTEM Use proper lubricants on seal ring Avoid damage to seal ring during installation. surfaces to install injector in engine. Avoid contamination at seal. Minimize time between applying lubricant and inserting injector / rail. DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure suspected injector (Actuate consists of one pulse <5 sec duration at 9 to 15V).
- Page 336 ENGINE MANAGEMENT SYSTEM Remove the fuel line connection from the injector Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces. Remove the injector from the manifold Apply a light coating of a lubricant to both the upper and lower injector seal ring of the replacement injector.
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Page 337: Throttle Body Assembly(With Stepper Motor)
ENGINE MANAGEMENT SYSTEM 5．Plugging Fuel deposits cause plugging resulting in flow shifts over the life of the injector. Fuel varnish or gumming, a type of injector deposit, is created when certain types of fuel are heated by high injector tip temperatures at soak (no fuel flow). Deposit build up in the director holes causes the flow shifts ... - Page 338 ENGINE MANAGEMENT SYSTEM 2．Handling – DOs and DONTs THROTTLE BODY ASSEMBLY HANDLING ACTION REASON DO: Use care during assembly of harness to throttle Avoid terminal damage. body. DO: Avoid any liquid contamination in the throttle Ensure proper operation. body area. DO: Unload and install units one at a time from Damage may be done to critical components.
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Page 339: Engine Coolant Temperature Sensor
ENGINE MANAGEMENT SYSTEM 4．Cleaning Procedure If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and varnish that are present. -
Page 340: Oxygen Sensor
ENGINE MANAGEMENT SYSTEM 2．Sample Cleaning When necessary the samples may be cleaned in isopropyl alcohol or gasoline for one minute with mating connectors in place and then air-dried Oxygen Sensor 1．Description and Working Principle This sensor is a device for monitoring the residual oxygen in the exhaust of an internal combustion engine. - Page 341 ENGINE MANAGEMENT SYSTEM 3．DOs and DONTs Ignition Coil Handing Action Reason DO NOT: Install the low voltage connectors with This might cause an unwanted secondary firing, the power applied possibly leading to personal injury DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in secondary boots from the secondary tower.
- Page 342 ENGINE MANAGEMENT SYSTEM DO NOT: Use high impact tools to apply the spark Damage to the coil tower, secondary boot, or plug boot to the ignition secondary towers. mating connection surfaces might occur. Installation of the high voltage secondary leads by hand is preferred.
- Page 343 ENGINE MANAGEMENT SYSTEM DO: Ignition secondary leads should not be Voltage spikes can be transmitted from the routed with the ignition primary harness or any secondary cables into other leads which are in other electrical harness. close. This could create a component performance degradation or failure condition DO: Spark plug wires(secondary leads) &...
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Page 344: Fuel Pump Module
ENGINE MANAGEMENT SYSTEM deposits, clean with wire brush, taking care to injure the electrode or the insulator tip Regap spark plugs exact -Too wide a gap could cause the plug to measurement specified by the engine misfire(higher required ignition voltage). manufacturer to keep the best fuel economy and -Too narrow of a gap could affect idle stability proper engine performance... - Page 345 ENGINE MANAGEMENT SYSTEM Fuel Pump When power is supplied to fuel pump, motor in pump assembly rotates the impeller. Impeller in turn draws the fuel from strainer and pumps the flow to generate the system pressure. Pressure Regulator Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the inlet of pressure regulator.
- Page 346 ENGINE MANAGEMENT SYSTEM Connect power supply 1. Check Fuel (battery) to fuel module. 1. Check electrical Pump Harness Make sure that enough fuel available in circuit from fuel integrity fuel tank to avoid fuel pump running module to ECU 2. Check Fuel dry.Is the fuel pump running 2.
- Page 347 ENGINE MANAGEMENT SYSTEM Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque: 3~4 Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow the tightening torque and tightening sequence instruction.Over torque and miss-sequence can cause unequal compression of gasket and leakage.
- Page 348 ENGINE MANAGEMENT SYSTEM Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3 times of about 3 seconds each time to relieve fuel pressure in lines. Fuel Connections are now safe for servicing.
- Page 349 ENGINE MANAGEMENT SYSTEM DO NOT: Use Fuel Pump for draining duel Not intended function of fuel module. in fuel tank. DO NOT: Use module mounting bolts for Affects fuel module sealing. mounting other components. DO NOT: Damage fuel pump harness Damaged terminals will cause intermittent/ while servicing fuel module.
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Page 350: Ems Fault Diagnosis
ENGINE MANAGEMENT SYSTEM EMS FAULT DIAGNOSIS EME Fault Diagnosis When fault comes up, the odometer's clock will turn into a number， which is a fault code, find out the cause with this numbe;press clock button,then it will turn back to clock mode, and five second later,the fault code will show again. - Page 351 ENGINE MANAGEMENT SYSTEM 0562 System Voltage Low KsDGDM_SysVoltLow System Voltage 0563 System Voltage High KsDGDM_SysVoltHigh 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer 1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow Oxygen Sensor 2 0138 O2S 2 Circuit High Voltage...
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Page 352: Troubleshooting
TROUBLESHOOTING NOTE: The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to relevent contents for the inspection, adjustment and replacement of part. STARTING FAILURE/HARD STARTING FUEL SYSTEM 1、No oil 2、Fuel filter is clogged Fuel tank 3、Fuel pump filter net is clogged 4、Breather tube is clogged... -
Page 353: Compression System
TROUBLESHOOTING 1、Faulty starter motor 2、Faulty starter relay Starter motor 3、Faulty overrunning clutch in engine 4、Broken main switch 5、Broken main fuse 1、Low battery voltage Battery 2、Faulty battery COMPRESSION SYSTEM 1、Loose spark plug 2、Loose cylinder head or cylinder Cylinder and cylinder head 3、Broken cylinder head gasket 4、Broken cylinder gasket 5、Worn, damaged or seized cylinder... -
Page 354: Poor Medium And High-Speed Performance
TROUBLESHOOTING 1、Faulty ignition plug Electrical system 2、The performace of speed sensor become poor 3、Faulty ignition coil Valve train Improperly adjusted valve clearance Air filter Clogged air filter element POOR MEDIUM AND HIGH-SPEED PERFORMANCE POOR MEDIUM AND HIGH-SPEED PERFORMANCE 1、 Broken ECU 2、... -
Page 355: Engine Overheating
TROUBLESHOOTING ENGINE OVERHEATING OVERHEATING 1、Improper spark plug gap Ignition system 2、Improper spark plug heat range 1、Improper fuel level Fuel system 2、Clogged air filter element Compression system Heavy carbon deposit 1、Improper oil level 2、Improper oil viscosity Engine oil 3、Inferior oil quality Brake Brake drag 1、Low coolant level... -
Page 356: Shock Absorber Malfunction
TROUBLESHOOTING SHOCK ABSORBER MALFUNCTION Loss of damping function 1、Bent or damaged damper rod Shock absorber 2、Damaged oil seal lip 3、Fatigued shock absorber spring UNSTABLE HANDLING UNSTABLE HANDLING Steering column Improperly installed or bent 1、Incorrect toe-in 2、Bent steering shaft Steering 3、Improperly installed steering shaft 4、Damaged bearing 5、Bent tie-rods 1、Uneven tire pressures on both sides... -
Page 357: Bulb Burnt Out
TROUBLESHOOTING BULB BURNT OUT 1、Improper bulb 2、Faulty battery 3、Faulty rectifier/regulator Bulb burnt out 4、Improperly grounded 5、Faulty main and/or lights switch 6、Bulb life expired ERROR DISPLAY OF METER 1、 Then sensor on rear axle is damaged or polluted by iron powder Wrong Speed 2、...
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Questions and answers
What Antifreeze should be used in the Hisun Sector 750
The recommended antifreeze for the Hisun Motors HS750UTV-2 is high-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines.
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what type of coolant do I use on this utv
The recommended coolant for the Hisun Motors HS750UTV-2 is antifreeze mixed with distilled water. If distilled water is not available, soft water may be used. Different types of antifreeze should not be mixed.
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