Summary of Contents for Odes Industry UTV170-10
- Page 1 UTV170-10 Maintenance Manual Shandong Odes Industry Co.,Ltd Any copy or without written permission or authorization of Odes Industry is prohibited to use the manual (version 1, May 2020). All rights reserved...
- Page 2 GENERAL INFORMATION dismantling, assembling, troubleshooting and service data of UTV170-10 This manual will help you know the vehicle beter so PERIODIC MAINTENANCE that you can assure your customers of fast and reliable service. ENGINE This manual hass been prepareed on the basis of the latest specifications at the time of publication.If...
- Page 3 1.GENERAL INFORMATION 1. GENERAL INFORMATION PRECAUTIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-1 TECHNICAL SPECIFICATIONS ·...
- Page 4 1.GENERAL INFORMATION If bearing cannot be clamped tightly in pressing into machine or axle, please replace bearing. 19. Please install a side dust proof bearing at correct direction. In installation of open or double-face dust proof bearing, pay attention to that marks of manufacturer shall be outward. 20.
- Page 5 1.GENERAL INFORMATION TECHNICAL SPECIFICATIONS Item Parameter Dimensions Overall length 2895mm Overall width 1290mm Overall height 1870mm Seat height 780mm Wheelbase 1840mm Ground clearance 181mm Engine Single cylinder, 4 stroke, forced air cooling Type Number of valves 1(mechanical adjustment) Cylinder diameter 61 mm Piston stroke 57.8 mm...
- Page 6 1.GENERAL INFORMATION Size “B” φ61mm—φ61.01mm Size “A” Cylinder measurement Size “B” 0.03mm—0.05mm Clearance of cylinder - piston Service limit 0.090mm Piston ring type 0.10mm—0.25mm Piston ring end gap New 1st 0.20mm—0.35mm New 2nd 0.15mm—0.6mm New 3rd 1st 0.4 mm；2nd0.6 mm；3rd0.8 mm All service limit 0.03-0.07 mm Piston/ring groove clearance...
- Page 7 1.GENERAL INFORMATION 82 to 97KPa Pressure AT 24× 8-12 (Rim 12× 6) Size Front AT 24× 8-12 (Rim 12× 6) Size Rear Brakes Front and rear unified System Pincer disc brake Type Front Pincer disc brake Type Rear 3.7mm(Front) 4mm(Rear) New disk thickness 3.2mm(Front) 3.5mm(Rear) Minimum disk thickness...
- Page 8 1.GENERAL INFORMATION TIGHTENING TORQUE Locking devices ( e.g.: locking tabs, elastic stop nuts ,self-locking fasteners ,etc.) must be installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be renewed. In order to avoid a poor assembling, tighten screws, bolts or nuts in accordance with the following recommended torque value: Torque (N·...
- Page 9 1.GENERAL INFORMATION As for important tightening torques , please refer to following standards. Installation location Specifications (mm) Torque N.m(lbf.ft) 70(51.6) Fastening bolt of engine 70(51.6) Fastening nut of suspension arm Bolt of rear shock absorber 80(59) Bolt of front shock absorber 80(59) 80(59) Fastening nut of wheel rim...
- Page 10 2.PERIODIC MAINTENANCE 2. PERIODIC MAINTENANCE MAINTENANCE SCHEDULE · · · · · · · · · · · · · · · · · · · · · · 2-1 AIR CLEANER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3 THROTTLE CABLE PLAY ·...
- Page 11 2.PERIODIC MAINTENANCE leakage. ●Brake fluid needs to be above the lowest position. ●Correct if necessary. Replace pads/disk if worn to the limit. ●Check operation and free play. Accelerator pedal* ●Check balance/damage/ run out Wheels* ●Repair if necessary. ●Check bearing assemblies for looseness or Wheel bearings* damage..
- Page 12 2.PERIODIC MAINTENANCE AIR CLEANER In case of driving in dusty environment, air filter shall be cleaned regularly. It is of great possibility to accelerate wear to engine if there is not filtering element or worn filtering element is used. So, please keep air filter under good conditions all the time.
- Page 13 2.PERIODIC MAINTENANCE Remove bolt and filter element Blow low pressure compressed air on filter element to clean it. Properly reinstall removed parts in the reverse order of their removal. pay attention to the seal gasket of air filter housing is not skew. CAUTION 1.If liquid /deposits are found, squeeze and dry the foam filter.
- Page 14 2.PERIODIC MAINTENANCE THROTTLE CABLE PLAY Before starting the engine, check the gas pedal to be sure it is operating correctly. Make sure the gas pedal fully returns to the idle position as soon as it is released. Check the free play and adjust if needed. Press the throttle to make sure it moves smoothly without sticking and snaps back automatically when it is released Check to see that the gas pedal operates correctly.
- Page 15 2.PERIODIC MAINTENANCE Replace engine oil Prior to change the oil, ensure vehicle is on a level surface. Oil and oil filter must be replaced at the same time. Oil change and oil filter replacement should be done with a warm engine. WARNING The engine oil can be very hot.
- Page 16 2.PERIODIC MAINTENANCE CAUTION In order to expand service life of vehicle, please use grade SJ standard engine oil conforming to with viscosity indication being SAE10W/40. If viscosity of engine does not reach SAE 10W/40, make corresponding selection according to drawing Replace gearbox oil Prior to change the gearbox oil, ensure vehicle is on a level surface, should be done with a warm engine.
- Page 17 2.PERIODIC MAINTENANCE CAUTION BRAKING SYSTEM Check to see if any brake fluid is leaking out of the pipe joints or the brake fluid reservoir. Apply the brakes firmly for one minute. If there is any leakage, have the vehicle inspected by an authorized dealer. Test the brakes at slow speed after starting out to make sure they are working properly.
- Page 18 2.PERIODIC MAINTENANCE Parking brake adjustment Pull the parking brake lever dowon to engage the parking brake. To release the unit, press button on of parking lever then push the parking lever to the bottom. The free play is 15～20mm, the travel is 7 teeth. If necessary, slacken the cable by loosening the locknut and screwing the adjuster on the brake holder.
- Page 19 2.PERIODIC MAINTENANCE WHEELS Lift wheels up at horizontal position and ensure no load to each wheel. Shake wheels to left and right to see whether their connecting parts are installed tightly and check whether they can be swung. No adequate tightening: → tightening Swing: →...
- Page 20 2.PERIODIC MAINTENANCE SUSPENSION SYSTEM Lubricate both suspension arms with lithium-soap based grease. There are two grease fittings on each suspension arm. Check operation and for leakage. Grease fitting location of front suspension arms. Lubricate the chain with lubricating oil. CHAIN MAINTENANCE The new chain is too long or extended after use, it is difficult to adjust, the chain link can be removed according to the situation, but it must be an even number.
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Page 21: Table Of Contents
3.ENGINE 3. ENGINE REMOVING THE CYLINDER HEAD · · · · · · · · · · · · · 3-1 CHECKING THE CYLINDER HEAD · · · · · · · · · · · · · · 3-2 CHECK THE TIMING CHAIN TENSIONER ·... -
Page 22: Check The Timing Chain Tensioner
3.ENGINE 2.Remove： Remove the bolts of the cylinder head head“1-4” 3.Loosen: · Timing chain tensioner cap bolt. 4.Remove : · Timing chain tensioner (along with the gasket) · Camshaft sprocket · Timing chain To prevent the timing chain from falling into the crankcase， fasten it with a wire. - Page 23 3.ENGINE INSTALLING THE CYLINDER HEAD 1.Install： · Dowel pins · Cylinder head O-ring 2.Install： Cylinder head 3.Install： ·Cylinder head top cover“1” · Washers · Cylinder head nuts · Cylinder head bolts · Cylinder bolts 4.Tighten： · Cylinder bolt · Cylinder head bolts ·...
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Page 24: Rocker Arm Shafts
3.ENGINE REMOVE THE ROCK ARMS AND CAMSHAFT 1.Loosen： ·Locknuts“1” ·Valve clearance adjusting screws“2” 2.Remove： · Intake rocker arm shaft · Intake rocker arm · Exhaust rocker arm shaft · Exhaust rocker arm 3.Remove： · Camshaft Screw an 5mm bolt “1”into the threaded of the rocker arm shaft，and then pull out the shaft. CHECK THE CAMSHAFT 1.Check：... -
Page 25: Removing The Piston
3.ENGINE REMOVING THE PISTON 1.Remove： ·Piston pin clips“1” ·Piston pin“2” ·Piston“3” NOTICE Do not use a hammer to drive the piston pin out. · Before removing the piston pin clips，cover the crankcase opening with a clear rag to prevent the piston pin clips from falling into the crankcase. - Page 26 3.ENGINE 2.Install： ·Piston“1” ·Piston pin“2” ·Piston pin clips“3” · Apply engine oil to the pin ·Make sure the mark“a”on the pistons towards the intake side of the cylinder. Before installing the piston pin clips，cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase.
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Page 27: Installing The Cdi Magneto Rotor
3.ENGINE 3.Remove： ·CDI magneto rotor“1” · Woodruff key NOTICE To protect the end of the crankshaft，place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft. Use the flywheel puller“2”. Make sure the flywheel puller is centered over the CDI magneto rotor. -
Page 28: Assembling The Oil Pump
3.ENGINE ASSEMBLING THE OIL PUMP 1.Lubricate： · Oil pump inner rotor · Oil pump outer rotor · Oil pump shaft 2.Install： ·Oil pump housing“1” ·Oil pump outer rotor“2” ·Oil pump inner rotor“3” ·Oil pump shaft“4” ·Oil pump housing cover“5” 3.Install： ·Pin“6”... -
Page 29: Removing The Primary Sheave
3.ENGINE REMOVING THE PRIMARY SHEAVE 1.Remove： ·Primary fixed sheave nut“1” · Washer ·Primary fixed sheave“2” · CDI magneto rotor cover While holding the CDI magneto rotor“3”with the rotor holding tool，loosen the primary fixed sheave nut“1” REMOVING THE SECONDARY SHAEAVE 1.Remove： ·Clutch housing nut“1”... -
Page 30: Check The Bearings
3.ENGINE 2.Check： · Timing chain guide（intake side） Damage/wear→Replace CHECKING THE CRANKSHAFT 1.Measure： · Crankshaft runout Out of specification→Replace the crankshaft assembly. Turn the crankshaft slowly. Runout limit：0.04mm 2.Measure · Crankshaft width Out of specification→Replace the crankshaft 3.Check · Crankshaft sprocket Damage/wear→Replace the crankshaft. -
Page 31: Removing The Transmission
3.ENGINE After installing the left crankcase，make sure that the timing chain is securely meshed with the crankshaft sprocket. 7.Tighten： “ · Crankcase bolts Thoroughly wipe off any sealant that protrudes from between the left crankcase and the right crankcase. ” ·... -
Page 32: Assembling The Main Axle
3.ENGINE ASSEMBLING THE MAIN AXLE 1.Install： · Primary driven gear ·Washer“1” ·Circlip“2” Be sure the circlip sharp-edgde corner “a”is positioned opposite side to the washer and gear. 2.Install： · Clutch dog Install the clutch dog“1”so that the recessed portion“a”of the clutch dog faces the recesses“b”in the primary driven gear“2”. - Page 33 4.COOLING SYSTEM 4. COOLING SYSTEM FAULT OVERHAULING · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-1 FAULT OVERHAULING Check whether soil of fins is blocked or damaged. Correct curved fins。 Use water and compressed air to clean soil.
- Page 34 5.FUELSYSTEM 5. FUEL SYSTEM FUEL PRESSURE TEST · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2 FUEL FILTER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2 FUEL PUMP ·...
- Page 35 5.FUELSYSTEM on injection system high pressure hoses. Replace any damage or deteriorated fuel lines. When the repair is completed, ensure that all hoses are connected and secured. Always perform the fuel pressure test if any component has been removed. A pressure test must be done before turning the ignition key to ON and setting the engine stop switch to RUN.
- Page 36 5.FUELSYSTEM FUEL PUMP Fuel pump electrical test. When turning ignition key ON, the fuel pump should run for 5 seconds to build up the fuel pressure in the system. If the pump does not work, disconnect the connector from the fuel pump. Install a temporary connector to the fuel pump connector.
- Page 37 6. DRIVE TRAIN 6. DRIVE TRAIN FRONT WHEEL HUB · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1 REAR WHEEL HUB · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1 REAR DRIVE SHAFT ·...
- Page 38 6. DRIVE TRAIN Inspection Check wheel hub for cracks or other damages. Check inner splines and wheel rim bolts for wear or other damages. If any damage is detected on wheel hub, replace it with a new one. REAR DRIVE SHAFT Removal Remove the appropriate wheel hub.
- Page 39 6. DRIVE TRAIN TIRES AND WHEELS When the tires are replaced, never install a bias tire with a redial tire. such a combination could create handling and/or stability problems. Dot mix tires of different size and/or de-sign on the same axle. Front and rear tire pairs must be the identical model and manufacturer.
- Page 40 6. DRIVE TRAIN Inflate the tire to seat the tire bead. Check the rim line cast on the tire side walls. It must be equidistant from the wheel rim all the way around. If the distance between the rim line and the wheel rim varies this indicates that the bead is not properly seated.
- Page 41 7. STEERING SYSTEM 7. STEERING SYSTEM STEERING ALIGNMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-2 Inspect the tie rod for distortion or damage. If any damage are found, replace the tie rod with a new one. Inspect the tie ends for smooth movement.
- Page 42 7. STEERING SYSTEM Tie rod installation For the installation, reverse the removal procedure. Tighten tie rod lock nuts finger tight. Install tie rod on steering knuckle.. Torque tie rod retaining nut to 60N.m. Install new cotter pins. Both ends of cotter pins must be folded around nut.
- Page 43 8. SUSPENSION SYSTEM 8. SUSPENSION SYSTEM FRONT SUSPENSION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 8-1 REMOVAL AND DISASSEMBLY ·...
- Page 44 8. SUSPENSION SYSTEM Extend and compress the piston several times over its entire stroke. Check that it moves smoothly and with uniform resistance with rod up. Any of the following conditions will denote a defective shock: A skip or hang up when reversing stroke at mid-travel.
- Page 45 8. SUSPENSION SYSTEM REAR SUSPENSION During assembly or installation, use the torque values and service products as in the torque table REMOVAL AND DISASSEMBLY Loosen wheel nut of the appropriate. Install a jack stand under the frame to lift the rear of vehicle off the ground until the shock absorber is fully extended. wheels, brake caliper and hub Remove remove steering knuckle from ball cage tie rod...
- Page 46 9. BRAKES SYSTEM 9. BRAKES SYSTEM BRAKE FLUID REPLACMENT · · · · · · · · · · · · · · · · · · · · 9-2 BRAKE PADS REPLACMENT · · · · · · · · · · · · · · · · · · · · · · 9-3 BRAKE DISC ·...
- Page 47 9. BRAKES SYSTEM BRAKE FLUID REPLACMENT Place the vehicle on a level surface. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Remove the dust cap of air bleeder valve. Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle.
- Page 48 9. BRAKES SYSTEM BRAKE PADS REPLACMENT Remove the wheel. Remove the brake caliper mounting bolt and brake pads mounting pins. Remove the brake pads. Make sure that pad spring is in position. Install the new brake pads. Install pad pins by pushing in the pads against pad spring to align pad slots in the pads and caliper body.
- Page 49 9. BRAKES SYSTEM Reassembly and remounting Reassemble snd remount the brake disc in the reverse order of removal and disassembly. Pay attention to the following points: Install the disc to the wheel hub with the punching letters on the disc showed up. Make sure that the disc is clean and free of any greasy matter.
- Page 50 9. BRAKES SYSTEM Test Disconnect switch connectors. Check switch operation as follows. SWITCH POSITION RESISTANCE Firmly pushed 0.2Ωmax Released Infinite If switch is defective, replace with a new one. If switch tests good, check wiring harness. Remove Disconnect switch connectors. Drain brake system.
- Page 51 10.CHASSIS 10. CHASSIS EXHAUST SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-1 SILENCER INSPECTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-1 REAR SEAT ·...
- Page 52 10.CHASSIS REAR SEAT WARNING Be careful not to operate when the engine is running or the silencer is at high temperature Disassemble /install procedures 1、Keep the vehicle on a level surface.. 2、Remove the connecting bolts between the rear seat and the frame. Disassemble the cargo box handle spring, cargo box gas spring, cargo box support sleeve, etc.
- Page 53 10.CHASSIS CAR ROOF HANDRAIL The limit spring and steel ball in handrail will be caused certain wear and tear if the car drove on the rough road for a long time, so the handrails should be inspected regularly in the following manner. Disassemble /install procedures 1、Keep the vehicle in a horizontal plane.
- Page 54 10.CHASSIS SEAT The seat will be wear and tear if in the sun for a long time and open it too often 。 1、Open the seat and check whether have cracks and serious wear for the following parts, if so, please replace it with a new one in time （1）Seat hinges （2）Seat rubber pads 2.Check whether have cracks and breakage for the seat and backrest leather,...
- Page 55 10.CHASSIS CAR FRAME WARNING Be careful not to operate when the engine is running or the silencer is at high temperature Car frame chassis base The chassis base will be damaged by the sundry objects on the ground if the car drove on the rough road for a long time 1、Keep the vehicle in a horizontal plane.
- Page 56 11.ELECTRICAL SYSTEM 11. ELECTRICAL SYSTEM CHARGING SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11-1 RESISTAMCE OF GENERATOR COIL ·...
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Page 57: Starting System
11.ELECTRICAL SYSTEM REGULATOR RECTIFIER Measure the resistance between terminals with multimeter. If the resistance is not within the range of specified values, replace the regulator / rectifier. NOTE: If the probe is not connected and the multi meter reading is lower than 1.4V, replace the multi meter battery. -
Page 58: Brush Brush
11.ELECTRICAL SYSTEM BRUSH BRUSH Check the brush on the brush holder whether it is worn abnormal, cracked or not smooth. Worn, cracked, or not smooth: → Replace RECTIFIER Check the rectifier whether it is discolored, abnormal wear or concave. Abnormal wear or damage: → Replace If the rectifier is discolored, grind it with sanding paper, then wipe it with a clean fabric. -
Page 59: Auxiliary Starter Relay
11.ELECTRICAL SYSTEM AUXILIARY STARTER RELAY Apply 12V voltage between the positive and negative terminals of the starter relay. Test the connection between A and B with the multimeter. If the starter relay clicks and is connected, the starter relay is OK. When there is no voltage of 12V, they are not connected, the starter relay is OK. -
Page 60: Lgnition System
11.ELECTRICAL SYSTEM has a DC capacitor igniter and a high voltage ignition coil, which can raise the voltage of the battery from 12V to more than 15000V, which also can be transported to the spark plug by high-voltage wire to generate spark discharge. - Page 61 11.ELECTRICAL SYSTEM Repeat the steps above for several times. Measure the maximal value of the primary peak voltage. Set the multi meter at the AC voltage position. Primary peak voltage of ignition coil: ≥150V NOTE: Do not touch the test probes or spark plug, in case of electric shock.
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Page 62: Indicator Light
11.ELECTRICAL SYSTEM INDICATOR LIGHT The above picture is the indicator light function and interface definition of the instrument. Check the indicator lights with the following steps Each signal indicator has different signals, the following table is the signal information.According to the corresponding information in the table, check with the multi meter. - Page 63 11.ELECTRICAL SYSTEM When the battery is not in use for more than one month, remove the positive and negative electrodes and charge the battery every 2-3 months.Before the first time use or when the battery voltage is below 12.75V,please charge the battery.
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Page 64: Relay And Fuse
11.ELECTRICAL SYSTEM RELAY AND FUSE Functional definition of relays and fuses. Check fuse first whatever any system doesn’t work. AND three spare fuses for reserve. Open the seat, remove the suitcase, remove the cover of fuses box. Check the fuse and relay. NOTE：... -
Page 65: Switches
11.ELECTRICAL SYSTEM Unplug the connector and remove the self-tapping nail with screwdriver. Each lamp is fixed with 3 self-tapping nails.And the self-tapping nail specification is ST3.5×12. NOTE: Pay attention to distinguish between left and right when reinstalling. Combined rear taillights Includes position lights, brake lights, turn lights. - Page 66 12. TROUBLESHOOTING 12. TROUBLESHOOTING ELECTRICAL SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12-1 COOLING SYSTEM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 12-1 MAGNETO SYSTEM ·...
- Page 67 12. TROUBLESHOOTING 4. Check wiring harness for cracks or other damages. harness shows electrical failure and/or other damages. Replace/repair wiring harness. LUBRICATION Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION 1. Check oil level and search for leakage on crankcase and/or sealing parts. ...
- Page 68 12. TROUBLESHOOTING Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION 1. Check noise coming from cylinder head area. Improper valve clearance adjustment. Readjust valve clearance and/or replace defective part(s). Faulty chain tensioner. Replace spring and/or mechanism. Chain guide worn out. Replace chain guide. ...
- Page 69 12. TROUBLESHOOTING CVT one way clutch is worn out or damaged. Replace defective part(s) (refer to CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)). Check if friction washer at one way clutch is worn. Replace friction washer (refer to CONTINUOUSLY VARBRIABLE TRANSMISSION (CVT)). 4.
- Page 70 12. TROUBLESHOOTING one-way clutch. Spring sleeve(s) inside one-way clutch is (are) worn out. Replace both sleeves and springs and lubricate inside of one-way clutch. Spring(s) inside one-way clutch is (are) worn out. Replace both pins and springs and lubricate inside of one-way clutch.
- Page 71 12. TROUBLESHOOTING 2. Check drive belt identification number. Excessive belt speed. Using unspecified type of belt. Replace belt with proper type of belt. 3. Check if pulley sheaves are clean. Oil on pulley surfaces. Clean pulley surfaces with fine emery cloth and wipe clean using pulley flange cleaner and a cloth.
- Page 72 12. TROUBLESHOOTING Replace. 6. Check fuel level in fuel tank and fuel pressure. Low or no fuel pressure. Replace defective part(s) refer to FUEL TANK AND FUEL PUMP. 7. Check CAPS (camshaft position sensor). Defective sensor/wiring. Refer to ENGINE MANAGEMENT. Symptom: ENGINE SUDDENLY TURNS OFF 1.
- Page 73 12. TROUBLESHOOTING part(s). Check engine ground. Poor engine ground. Clean. Symptom: ENGINE DOES NOT OFFER MAXIMUM POWER AND/OR DOES NOT REACH MAXIMUM OPERATING RPM Check spark plugs condition and/or gap. Fouled spark plugs or wrong spark plug gap. Readjust gap and clean spark plugs or replace.