ODES UTV Desertcross 1000cc-3 Maintenance Manual
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ODES UTV Desertcross 1000cc-3 Maintenance Manual

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UTV Desertcross 1000cc-3
Maintenance Manual
Shandong ODES Industry Co. Ltd.
Any copy or without written permission or authorization is prohibited to use
the manual (version 2, May 2020).
All rights reserved

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жорж
April 25, 2025

на скорости глохнет на 35кмч и вовь заводится на 30кмч и так циклично

1
1 comments:
Mr. Anderson
May 12, 2025

The ODES UTV Desertcross 1000cc-3 may stall at 35 km/h and restart at 30 km/h due to contamination or malfunction in the CVT (Continuously Variable Transmission) system. Specifically, possible causes include:

- Water, dirt, or oil contamination in the CVT area
- Damaged drive or driven pulley components
- Incorrect drive or driven pulley spring tension (too stiff or too smooth)

These issues can affect engine RPM and power transmission, leading to stalling at higher speeds. Cleaning the CVT system and replacing damaged or worn parts may resolve the issue.

This answer is automatically generated

-1
Владимир
May 28, 2025

Коробка не включает соответствующие скорости на паркинге едит в перед

0
1 comments:
Mr. Anderson
May 28, 2025

The ODES UTV Desertcross 1000cc-3 may not engage the correct gears in park and move forward due to the following possible causes:

1. Incorrect shifter cable adjustment – The shifter cable may need to be adjusted.
2. Gearbox position sensor (GBPS) issues – Damaged wires or a faulty sensor can cause incorrect gear engagement.
3. Damaged or worn shifting fork or sleeve – These components should be inspected by removing the actuator.
4. Defective actuator – The actuator may need to be tested and replaced if faulty.
5. Low oil level in the gearbox – This can cause unusual noise or vibrations and affect gear engagement.

Each of these issues should be checked and repaired as needed.

This answer is automatically generated

0
Сергей
May 17, 2025

Может ли стоять хруст в коробке передач, из-за вариатора

0
1 comments:
Mr. Anderson
May 22, 2025

Yes. A grinding noise in the transmission of the ODES UTV Desertcross 1000cc-3 can be caused by variator-related issues such as worn or damaged sliding sheave pulley components, worn or damaged driven pulley cam, or malfunctioning one-way clutch. These parts are part of the CVT system (variator), and damage or malfunction can cause unusual noises.

This answer is automatically generated

0
Вадим
April 6, 2025

Как правильно поменять ремень вариаотора?

0
1 comments:
Mr. Anderson
April 6, 2025

To properly replace the variator belt on an ODES UTV Desertcross 1000cc-3, follow these steps:

1. Remove the variator cover and gasket.
2. Remove the old belt.
3. Block the drive pulley using a pulley holding tool.
4. Mark the sliding sheave and governor cup for correct reinstallation.
5. Unscrew and remove the drive pulley screw (right-hand thread), conical spring washer, and thrust washer.
6. Install the new belt with the arrow printed on the belt pointing toward the front of the vehicle (viewed from the top) to ensure proper rotation direction.
7. Reinstall the drive pulley, thrust washer, and other components.
8. Install the variator cover gasket.
9. Install the center top screw first, then tighten the remaining screws following the specified sequence.

This answer is automatically generated

0
Михаил
February 28, 2025

Как правельно выстовить метки зажигания

0
1 comments:
Mr. Anderson
February 28, 2025

To correctly set the ignition timing marks on the ODES UTV Desertcross 1000cc-3:

1. Align Piston No. 1 to TDC Ignition:
- Confirm that the printed marks on the camshaft timing gear are parallel with the cylinder head base in the lowest position.
- Check that Mark "1" on the magneto flywheel aligns with the notch on the magneto cover.
- Ensure the crankshaft position sensor is correctly located.

2. Use the Crankshaft TDC Position Tool:
- Install the crankshaft TDC position tool to lock the crankshaft in position.

3. Set Piston No. 2 to TDC Ignition:
- Follow the procedure described under "CRANKSHAFT TIMING PISTON NO. 2."

4. Adjust for Piston No. 1:
- Remove the crankshaft TDC position tool.
- Turn the crankshaft 280° counterclockwise to set piston No. 1 (front) to TDC ignition.

These steps ensure the correct ignition timing for the engine.

This answer is automatically generated

0
Роман
July 20, 2025

Перегорает предохранитель на бензонасос багги десерт кросс 1000 сс3

User image 687d4c4a812b8
0
Роман
July 20, 2025

Перегорает предохранитель на бензонасос багги десерт кросс 100 сс 3

0
Вячеслав
June 25, 2025

Добрый день! Не включается АКПП на багги AODES LTSTRT GROSS 1000.

0
Helen
June 4, 2025

Сгорел стартер, не можем его вытащить. Крепление стартера открутили, но вытянуть не получается так как упирается в кожух там где временная передача. Как правильно снять стартер? Там два штифта (левый, правый) куда одевает ремень, правый снял - все нормально, левый часть снял, а там с левой стороны ещё круг алюминевый. Как снять этот круг, чтоб снять пластиковые кожух для дальнейшего снятия стартера? Подскажите пожалуйста, как правильно снять стартер?

0
Сергей
March 31, 2025

С чего подходит левый передний наружный ШРУС?

0

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Summary of Contents for ODES UTV Desertcross 1000cc-3

  • Page 1 UTV Desertcross 1000cc-3 Maintenance Manual Shandong ODES Industry Co. Ltd. Any copy or without written permission or authorization is prohibited to use the manual (version 2, May 2020). All rights reserved...
  • Page 2 Foreword GROUP INDEX This manual contains such content as introductions on overhaul, maintenance, overhauling program, dismantling, GENERAL INFORMATION assembling, troubleshooting and service data of UTV1000-7 PERIODIC MAINTENANCE This manual will help you know the vehicle better so that you can assure your customers of fast and reliable service.
  • Page 3 1.GENERAL INFORMATION 1. GENERAL INFORMATION PRECAUTIONS........1-1 TECHNICAL SPECIFICATIONS....1-3 TIGHTENING TORQUE......1-6 PRECAUTIONS Do not make engine under operation at a closed place or place with poor ventilation for a long time. If engine stops operation, please do not touch it or silencer to avoid burning. Due to high corrosive, battery fluid (dilute sulfuric acid) may cause burns to skin and eyes.
  • Page 4 1.GENERAL INFORMATION 16. Check whether rubber parts are aged. If necessary, replace them. Keep rubber parts far away from grease. 17. If necessary, special tools can be used. 18. Rotate inside and outside races of bearing to ensure flexibility of balls. If axial or radial resistance is too large, please replace it.
  • Page 5 1.GENERAL INFORMATION TECHNICAL SPECIFICATIONS Item Parameter Dimensions UTV1000-7 Overall length 3339mm(131.457in) Overall width 1782mm(70.157in) Overall height 1935mm(76.18in) Seat height 517mm(20.354in) Wheelbase 2322mm(91.417in) Ground clearance 318mm(12.52in) Engine Type Two-cylinder, 4-stroke,SOHC, water cooling Number of valves 8(mechanical adjustment) Cylinder diameter 91 mm(3.583in) Piston stroke 75 mm(2.953in) Compression ratio...
  • Page 6 1.GENERAL INFORMATION Rocker arm bore diameter 12 .036to 12.050mm(0.4739in to 0.4744in) Service limit 12.060mm(0.4748in) Rocker arm shaft diameter 12.00 to 12.018mm(0.4724in to 0.473in) Service limit 11.990mm(0.472in) Piston measurement 90.950 to 90.966mm(3.5807in 3.5813in) Service limit 90.850mm(3.576in) Size “A” Cylinder measurement 91.955 to 91.003mm(3.6203in to 3.5830in) Size “B”...
  • Page 7 1.GENERAL INFORMATION Brakes System Front and rear unified Type Front Dual disc brake Type Rear Dual disc brake New disk thickness 5.0mm(0.197in)(Front) 5.0mm(0.197in)(Rear) Minimum disk thickness 5.0mm(0.197in)(Front) 5.0mm(0.197in)(Rear) Maximum disk warpage 0.2mm(0.0079in) Operation Foot operation Suspension and shock absorber Front suspension Double wishbone Rear suspension Double wishbone...
  • 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 Water temperature sensor 16(11.8) Oil pressure switch 12.5(9.2) Adjusting nut of valve clearance 12(8.9) Main pulley bolt 100(73.8) Driven pulley bolt 60(44.3） Magneto flywheel bolt 150(110.7) Magneto stator bolt 12.5(9.2) One way bolt 30(22.1) Engine oil drain plug 20(14.76) Gearbox oil drain plug 20(14.76)

  • Page 10: Table Of Contents

    2.PERIODIC MAINTENANCE 2. PERIODIC MAINTENANCE MAINTENANCE SCHEDULE · · · · · · · · · · · · 2-1 AIR CLEANER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3 VALVE CLEARANCE ·...

  • Page 11: Periodic Maintenance

    2.PERIODIC MAINTENANCE ● Check fuel hose for cracks or damage.. ● Replacement fuel hose every 48 months Fuel line* ● Replacement fuel filter every 24 months ● Replace (Check oil level every month) . Engine oil ● Replace. Engine oil filter ●...
  • 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. If vehicle is used in dusty area, inspect more frequently than specified in MAINTENANCE SCHEDULE.

  • Page 13: Valve Clearance

    2.PERIODIC MAINTENANCE VALVE CLEARANCE Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification,if necessary. Valve clearance is to be checked when the engine is cold.The intake and exhaust valves must be checked an adjusted when the piston is at TOP-DEAD –CENTER(TDC) on the compression stroke.
  • Page 14 2.PERIODIC MAINTENANCE Valve clearance of cylinder 2 Use a 14 mm Allen key to turn crankshaft until piston 2, rear is at TDC ignition. When rear piston is at TDC ignition, marks on magneto flywheel “2” and on the magneto cover are aligned.
  • Page 15 2.PERIODIC MAINTENANCE Valve clearance of cylinder 1 Using a 14 mm Allen key, turn crankshaft 280 ° counterclockwise. 1. Allen key 14mm 2. Turn crankshaft 280° counterclockwise Until marks on magneto flywheel “1” and magneto cover are aligned. 1. Mark “1” on magneto flywheel 2.
  • Page 16 2.PERIODIC MAINTENANCE Insert the feeler gauge between the valve stem end and adjusting screw on the rocker arm to check the clearance. If the valve clearance is out of specification, adjust valves as follows. Valve clearance 0.06 to 0.10mm Intake (0.00236 to 0.00394 inches) 0.11 to 0.15mm Exhaust...

  • Page 17: Throttle Cable Play

    2.PERIODIC MAINTENANCE Spark plug heat range Check the spark plug heat range by observing the electrode color. If the electrode of the spark plug is appearing wet or dark color, replace the spark plug with a hotter type one. If it is white or appearing glazed, replace the spark plug with a colder type one.
  • Page 18 2.PERIODIC MAINTENANCE ENGINE OIL Oil level verification Strictly follow this procedure, otherwise wrong oil level may be indicated. Ensure vehicle is on a level surface. The engine must be cold. CAUTION If just stop engine,Wait at least half hours to allow oil to flow down to crankcase then check oil level.
  • Page 19 2.PERIODIC MAINTENANCE Ensure vehicle is on a level surface. Start engine and let idle for a few minutes. Stop engine. Wait a few minutes to allow oil to flow down to crankcase. Lift the rear cargo bed. Remove dipstick. Raise the vehicle, support it securely. Place a drain pan under the engine drain plug area.

  • Page 20: Front Differential Oil

    2.PERIODIC MAINTENANCE CAUTION In order to expand service life of vehicle, please use grade SJ standard engine oil conforming to API with its 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...
  • Page 21 2.PERIODIC MAINTENANCE Clean the drain plug area. Place an oil pan under the front reducer case,and then drain oil completely by removing Drain Plug the drain plug. Tighten the drain plug to 20 N.m(14.76Lbf.lt). Pour the specified oil(GL-4-90) about 150~180mL by syringe through the oil level check plug hole until the oil over flows.

  • Page 22: Steering System

    2.PERIODIC MAINTENANCE STEERING SYSTEM Park vehicle at flat ground and hold steering wheel for wobbling to up, down, left and right.Check whether there is loosing. In case of wobbling, tighten nut or dismantle steering column for further inspection. Park vehicle at flat ground and turn steering wheel left or right slowly to see whether it can be turned flexibly.

  • Page 23: Gear Shift

    2.PERIODIC MAINTENANCE 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.
  • Page 24 2.PERIODIC MAINTENANCE COOLING SYSTEM To prevent rust formation or freezing condition, always replenish the system with the premixed coolant or with 50% antifreeze and 50% water. Do not use tap water, straight antifreeze or straight water in the system. Tap water contains minerals and impurities which build up in the system.
  • Page 25 2.PERIODIC MAINTENANCE Unscrew bleed screws on top of Bleed thermostat housing.Both cylinders must be screw bled. Unscrew bleed bolt on top of raditor. Fill up the radiator with coolant, when the coolant comes out by the thermostat housing hole, install the bleed screws with its gasket ring and torque to 10 N.m(7.38Lbf.ft).

  • Page 26: Wheels

    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 27 2.PERIODIC MAINTENANCE ENGINE COMPRESSION PRESSURE The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on results of a compression test. Before measuring cylinder pressure, ensure installation and tightening of cylinder cap bolt with designated torque and reasonable clearance of valve.
  • Page 28 2.PERIODIC MAINTENANCE ENGINE OIL PRESSURE Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. The engine oil pressure test should be done with a warm engine 90℃ and the recommended oil. Lift the rear cargo bed.
  • Page 29 2.PERIODIC MAINTENANCE Grease fitting location of front suspension arms. Grease fitting location of rear suspension arms. Lubricate rear knuckles with lithium-soap based grease. There are two grease fittings on each rear knuckle. 2- 21...
  • Page 31 3. ENGINE 3. ENGINE COMPONENTS.....3-1 TIMING CHAIN..........3-65 COOLING SYSTEM....3-10 BOTTOM END..........3-75 MAGNETO SYSTEM....3-28 CONTINUOUSLY VARIABLE......3-95 TOP END........3-39 GEARBOX AND4X4 COUPLING UNIT...3-102 COMPONENTS...
  • Page 32 3. ENGINE ENGINE LUBRICATION CIRCUIT 1. Camshaft bearings 2. 0il pressure switch 3. 0il filter 4. 0il pressure regulator valve 5. 0il strainer 6. 0il pump 7. Crankshaft main bearings 8. Crankshaft support bearing 9. Connecting rod' bearings...

  • Page 33: Engine Oil

    3. ENGINE -Refill engine with recommended engine oil Refer INSPECTION to OIL LEVEL VERIFICATION in the PERIODIC MAINTENANCE PROCEDURES subsection. ENGINE OIL PRESSURE -Check for high oil consumption ,refer to HIGH NOTE : The engine oil pressure test should be OIL CONSUMPTION in the TROUBLESHOOT Done with a warm engine100°...
  • Page 34 3. ENGINE HIGH OIL CONSUMPTION 1. Leaking breather oil seal. -Check if the oil seal of the breather is brittle, hard or damaged. Refer to BOTTOM END subsection. 2. Valve stem seals worn or damaged. -Replace valve stem seals. 3. Worn piston rings(blue exhaust smoke). -Replace piston rings.
  • Page 35 3. ENGINE Oil Pressure Switch Access If resistance values are incorrect, replace the oil Refer to BODY and remove: pressure switch. - Upper console If the values are correct, check wiring. Oil Pressure Switch Removal - Lower console - RH lateral console panel Unplug the oil pressure switch connector.
  • Page 36 3. ENGINE Oil Pressure Regulator Removal Remove plug screw and pull oil pressure regulator out. 1. Oil pump Oil Pump Removal 1. Plug screw Remove the PT0 cover. Refer to PTO COVER in 2. Gasket ring the BOTTOM END subsection. 3.
  • Page 37 3. ENGINE 1. Retaining screws 2. Oil pump cover 1. Oil pump bore 2. Outer rotor 3. Remove oil pump shaft with needle pin and 3. Oil pump shaft inner rotor. 4. Needle pin 4. Remove outer rotor. 5. Inner rotor Check inner rotor for corrosion pin holes or other damages.
  • Page 38 3. ENGINE 1. Outer rotor 2. Inner rotor OIL PUMP COVER- MEASUREMENT "B″ A. 0.25mm (.0098in) Substract measurement ''B" from measurement "A" If clearance of inner and outer rotors exceeds the to obtain axial clearance. Tolerance, replace oil pump rotors. Ensure to also check oil pump cover.
  • Page 39 3. ENGINE ENGINE OIL STRAINER REED VALVE Oil Strainer Location The engine is equipped with a reed valve which The engine oil strainer is located between both prevents accumulation of larger oil quantities in crankcase halves. the crankcase. The reed valve is fitted into the Oil Strainer Removal crankcase.
  • Page 40 3. ENGINE COOLING SYSTEM RADIATOR 1000R Engine...
  • Page 41 3. ENGINE WATER PUMP 1000R Engine...
  • Page 42 3. ENGINE Thermostat Removal GENERAL NOTICE Never start engine without coolant. 800R Models Some engine parts such as the rotary seal on 1. Install a hose pincher on both radiator hoses the water pump shaft can be damaged. REQUIRED TOOL LARGE HOSE PINCHER PROCEDURES (P/N 520 032 500)
  • Page 43 3. ENGINE 1000 Models THERMOSTAT OPENING TEMPERATURE MODELS STARTS TO OPEN FULLY OPEN 1. Install a hose pincher on both radiator hoses 800R 65° C(149° F) 75° C(167° F) 1000 65° C(149° F) 88° C(190° F) REQUIRED TOOL LARGE HOSE PINCHER Replace thermostat if it does not begin to open at (P/N 520 032 500) specified temperature.
  • Page 44 3. ENGINE NOTE :Turning steering to LH stop or removing LH front wheel assembly provides greater access for radiator removal. 9. Carefu1ly remove radiator through LH wheel well. Radiator Installation 1. For installation, reverse the removal procedure however, pay attention to the following details. 2.
  • Page 45 3. ENGINE RADIATOR COOLING FAN 4. Fill radiator with the recommended coolant. Radiator Cooling Fan Operation Refer PERIODIC MAINTENANCE PROCEDUTE subsection. The ECM controls the radiator cooling fan via the Bleed cooling system, refer inputs of the coolant temperature sensor (CTS) and MAINTENANCE PROCEDUTE subsection.

  • Page 46: Engine

    3. ENGINE ENGINE INTAKE COOLING CHECK ENGINE MESSAGE IN LIMP HOME TEMPERATURE TEMPERATURE LIGHT MULTIFUNCTION MODE GAUGE — — — — 88° C(190° F) Turns ON — — — — 85° C(185° F) Turn OFF — — — — 96° C(205° F) Turns ON —...

  • Page 47: Cooling System

    3. ENGINE COOLING FAN TROUBLESH00TING CHART WATER PUMP HOUSING YES→ Is fan working? Everything Water Pump Housing Location 1t is located on the engine MAG side (RH side of YES→ Check "Relay driver Replace fuse Is engine). fuse(5A) fan working? Water Pump Housing Access fuse (30A).
  • Page 48 3. ENGINE Check impeller for cracks or other damage. Re- place impeller if damaged. Water Pump Impeller Installation The installation is the opposite of the removal procedure. NOTICE Be careful not to damage impeller fins during installation. WATER PUMP SHAFT AND SEALS TYPICAL 1.
  • Page 49 3. ENGINE 7. Inner part of rotary seal 1. Small chisel 4. Use 2 screwdrivers and carefully remove the outer part of the rotary seal. TYPICAL – INNER PARTS OF ROTARY SEAL REMOVED 3. Carefully bend down the outer part of rotary seal lip using a smal1 chisel.
  • Page 50 3. ENGINE 5. Thoroughly remove carefully sealing residue and burr of rotary seal using a scraper. NOTICE Be careful not to damage water pump shaft. 1. Pull on screws to remove seal 8. Check water pump shaft axial play. lf not adequate, engine must be disassembled to replace the water pump shaft.
  • Page 51 3. ENGINE OIL SEAL INSTALLATION 1. Rotary seal 5. Ensure that the oi1 seal is properly seated in 2. M8 robust flat washer (P/N 420 227 935) water pump cavity. 3. M8×1.25 nut (P/N 233 281 414) 11. Remove M8 nut. NOTE: The robust M8 flat washer remains on water pump shaft.
  • Page 52 3. ENGINE SEAL PUSHER INSTALLTION ROTARY SEAL PUSHER PLATE ASSEMBLY 1. Seal pus1lerai1gneol with pusher bolt 1. 4×tubes (70mm(2.75in) length) 12.5 lighten the pusher bolt by hand until it stops 2. 4×screws M6×85 3. Plane surface on pus1ler bolt against the sea1 pusher. 13.
  • Page 53 3. ENGINE 1. Water pump shaft WATER PUMP SHAFT PROPERYL ADJUSTED WISH 2. Crankcase MAG side ROTARY SEAL NOTICE The water pump shaft must be properly 3. Remove outer part of rotary seal. adjusted with rotary seal. The water pump shaft must move freely while REQUIED TOOL BLAND HOLE PULLER KIT pushing it toward the crankcase.
  • Page 54 3. ENGINE 1.Handle 2. Pusher When installing the oil seal on the pusher, make sure the sealing lip points outwards. Push NEW oil seal in place. 1. Oil seal 2. Machined surface for rotary seal 1. Oil seal SEAL REMOVAL-FROM INSIDE 2.
  • Page 55 3. ENGINE REQUIED TOOL WATER PUMP GEARS SEAL PUSHER (P/N 529035766) Water Pump Gears Identification 7. Surface where rotary seal is pushed by tool 1. Water pump shaft 2. Water pump gear Water Pump Shaft Assembly 3. Water pump intermediate drive gear 4.
  • Page 56 3. ENGINE CRANKCASE MAG SIDE CRANKCASE PTO SIDE 1. Water pump gear 1. Water pump Intermediate drive gear 2. Needle pin 2. Circlip 3. Thrust Washer 3. Water pump intermediate shaft Water Pump Intermediate Drive Gear 4. Crankcase PTO side Remove clrclip retaining...
  • Page 57 3. ENGINE - Needle pin Install NEW circlip to retain water pump - Water pump gear. intermediate drive gear. NOTICE Never use the circlip a second time. NOTICE A missing thrust washer will cause a Always install a NEW one. leaking rotary seal.

  • Page 58: Magneto System

    3. ENGINE MAGNETO SYSTEM...
  • Page 59 3. ENGINE Magneto Cover Inspection and PROCEDURES MAGNETO COVER Cleaning Magneto Cover Access Check magneto cover for cracks or other damage. Remove fuel tank, refer to FUEL TANK AND Replace if necessary. FUEL PUMP NOTE: Clean all metal components in a Magneto Cover Removal nonferrous metal cleaner.
  • Page 60 3. ENGINE TYPICAL TIGHTENING SEQUENCE 3. If any reading is out of specification, replace stator. MANGENTO COVER SCREW 4. Re-plug connectors properly. Tightening 10N.m±1N.m Stator Static Test: Insulation （89lbf.in±9lbf.in） torque 1. Disconnect the stator connector from the voltage regulator/rectifier. Refill engine with recommended oi1. 2.
  • Page 61 3. ENGINE 3. If there is a resistance or continuity, the stator coils and/or the wiring is shorted to ground and needs to be repaired or replaced. 4. Re-plug connectors properly. Stator Dynamic Test: AC Voltage Output Disconnect stator connector voltage regulator/rectifier.
  • Page 62 3. ENGINE HOLDING STRIP SCREWS NOTE: Use grease to place protector on crank- Service product LOCTITE243 shaft end prior to screw on the magneto puller. (BLUE) (P/N293 800 060) Tightening torque 4N· m± 0.5N· m (35lbf· in±4lbf· in) STATOR RETAINING SCREWS Tightening torque 11N·...
  • Page 63 3. ENGINE Rotor Installation Rotate starter double gear counterclockwise to For installation, reverse the removal procedure. align intermediate gear teeth with sprag clutch However, pay attention to the following. gear. Use PULLEY FLANGE CLEANER (P/N413 711 809) to clean following: - Crank shaft taper - Oil passage in crank shaft taper - Thread in crankshaft...
  • Page 64 3. ENGINE Remove sprag clutch housing screws and sprag on threads of sprag clutch housing screws. clutch housing. Install screws but do not torque yet. Apply engine oil on sprag clutch and sprag clutch gear needle bearing. 1. Sprag clutch housing screws 2.
  • Page 65 3. ENGINE Starter Drive Gear Removal Remove MAGENTO COVER. See procedure in this subsection. Remove location pins, starter double gear and intermediate gear. 1. Rotor 2. Spfag clutch gear Sprag Clutch Gear Inspection Inspect gear, especially teeth and sprag clutch Collar, for wear and other damage.
  • Page 66 3. ENGINE INTAKE MANIFOLD...
  • Page 67 3. ENGINE 2. Release fuel pressure by running engine until it PROCEDURES runs out of gas. PLENUM BRACKET 3. Disconnect the fuel hoses at the fuel injectors , Plenum Bracket Installation refer to ELECTRON FUEL INJECTION (EFI). △CAUTION The fuel hose may still be under On Cylinder1, install the plenum bracket using the appropriate mounting holes.
  • Page 68 3. ENGINE Intake Manifold Installation The installation is the reverse of the removal procedure. However, attention followin9. Tighten intake manifold retaining screws to specified torque one cylinder at a time. INTAKE MANIFOLD RETAINING SCREWS Tightening torque 20N·m±2.5N·m (15lbf· ft 士 2 lbf· ft) Tighten elbow retaining screws to specification.

  • Page 69: Top End

    3. ENGINE TOP END CYLINDER HEAD NO.1...
  • Page 70 3. ENGINE CYLINDER HEAD NO.2...
  • Page 71 3. ENGINE CYLINDER AND PISTONS...
  • Page 72 3. ENGINE △WARING GENERAL Always respect this order disassembly; disconnect BLACK Special reference are made in the text for cable first. procedures which are different for cylinder no. 1 and cylinder no. 2. Remove radiator cap. △WARING To prevent burning yourself only remove radiator wearing appropriate safety equipment.
  • Page 73 3. ENGINE First Procedure Turn the drive pulley. Second Procedure 1. Remove plug screw with 0-ring from magneto cover. 2. Use a14 mm Allen key and turn crankshaft. NOTICE Turn only clockwise to avoid loosening of magneto flywheel Allen screw. Set the piston to precisely ignition TDC.
  • Page 74 3. ENGINE REQIRED TOOL Set needle of measuring gauge to zero. TDCDIAL NOTE: All testers have specific instructions on INFICATOR gauge operation and required pressure. (P/N 414 104 700) Install gauge adapter into previously cleaned spark plug hole. Supply combustion chamber with air pressure. 1.
  • Page 75 3. ENGINE - Air escaping into crankcase area means excessively worn cylinder and/or broken piston rings. -Air/oil escaping from crankcase means damaged gasket and/or loosened screws(refer to BOTTOM END subsection). NOTE: For all the checkpoints mentioned above, see the appropriate engine section to diagnose and repair the engine.
  • Page 76 3. ENGINE 1. Camshaft retaining plate 2. Pan head screw 1. Rocker arm (exhaust side) 3. Cylinder head' 2. Rocker arm (intake side ) 3. Thrust washers Remove rocker arm shafts NOTICE Pay attention not to lose thrust washers or drop them into the timing chain compartment. 1.
  • Page 77 3. ENGINE ROCKER ARM SHAFT DIAMETER 12.00mm to12.018mm (.4724in to.4731 in) SERVICE LIMIT 11.990mm(.472in) Any area worn excessively will require parts replacement. Rocker Arm Installation 1. Rocker arm (exhaust side) NOTE: Use the same procedure for exhaust and 2. Roller intake rocker arm.
  • Page 78 3. ENGINE CAMSHAFT NOTE: The engine is equipped with two different camshafts. 1. Camshaft retaining plate 2. Pan head screw 3. Cylinder head Remove rocker arms (see ROCKER ARM in this 1. Intake cam subsection). 2. Exhaust cam Remove the camshaft. 3.
  • Page 79 3. ENGINE A. Camshaft lobe (exhaust valves) B. Camshaft lobe (intake valves) C. Camshaft journal (timing chain side) A. Camshaft lobe (exhaust valves) D. Camshaft journal (spark plug side) B. Camshaft lobe (intake valves) C. Camshaft journal (timing chain side) CAMSHAFT LOBE (EXHAUST) D.
  • Page 80 3. ENGINE NOTE: Before removing cylinder head, blow out remaining coolant by air pressure. During cylinder head removal, the remaining coolant in cylinder head could overflow into the engine and a little quantity of coolant could drop into the engine. In this case, the engine oil will be contaminated.
  • Page 81 3. ENGINE 1. Cylinder head A. Cam shaft bearing (timing chain side) 2. Timing chain B. Cam shaft bearing (spark plug side) 3. Chain guide (fixed) CAMSHAFT BEARING 4. Cylinder head l gasket (TIMING CHAIN SIDE) 35.000 mm Cylinder Head Inspection to35.025mm Inspect timing chain guide (fixed) for wear, cracks (1.378in to1.3789in)
  • Page 82 3. ENGINE TIGHTENCE SEQUENCE-M10 CYLINDER HEAD TYPICAL SCREWS 1. Timing chain guide (tensioner side) mounted in M10 CYLINDER HEAD SCREWS crankcase Tightening torque 20N· m±1N· m 2. Timing chain guide (fixed) between cylinder ,and (step1) (15lbf· ft± 1 lbf· ft) cylinder head M10 CYLINDER HEAD SCREWS Install a NEW cylinder head gasket.
  • Page 83 3. ENGINE VALVE SPRINGS Valve Spring Removal Refer to following procedures in this subsection to remove: - CAMSHAFT - CYLINDER Compress valve spring. REQUIRED TOOL VALVE SPRING COMPRESSOR (P/N529 035 724) VALVE SPRING 1. Valve spring compressor clamp COMPRESSOR 2. Valve spring compressor cup CUP (P/N529 035 764) 3.
  • Page 84 3. ENGINE VA LVES Valve Removal Remove valve spring, see VALVE SPRING in this subsection. Push valve stem, then pull valves (intake and exhaust) out of valve guide. A. Valve spring length VALVE SPRING FREE LENGTH 40.81 mm(1.607in) SERVICE LIMIT 39.00 mm(1 535in) Replace valve springs if not within specifications.
  • Page 85 3. ENGINE VALVE STEM DIAMETER Valve Stem Seal EXHAUST VALVE 4.956mm to4.970 mm Always install NEW seals whenever valves are (.1951 in to.1957in) removed. SERVICE LIMIT 4.930mm(.1941 in) Valve INTAKE VALVE Inspect valve surface, check for abnormal stem 4.966mm to4.980 mm wear and bending.
  • Page 86 3. ENGINE If valve seat contact width is too wide or has dark VALVE GUIDES spots, replace the cylinder head. Valve Guide Inspection Always replace valve stem seals whenever valve guides are removed. Measure valve guide in three places using a small bore gauge.
  • Page 87 3. ENGINE Clean the valve guide bore before reinstalling the valve guide into cylinder head. Install valve guide. REQUIED TOOL VALVE GUIDE INSTALLER 1. Valve seat 2. Valve face (contact surface to valve seat) 3. Turn valve while pushing against cylinder head A.
  • Page 88 3. ENGINE Cylinder Inspection Check cylinder for cracks, scoring and wear ridges on the top and bottom of the cylinder. If so, replace cylinder. Cylinder Taper Measure cylinder bore at3 recommended positions. A. Perpendicular to crankshaft axis B. Parallel to crankshaft axis CYLINDER OUT 0F ROUND NEW (MAXIMUM) 0.015mm(.0006in)
  • Page 89 3. ENGINE 1. Piston circlip NOTE: The removal of both piston circlips is not necessary to remove piston pin. Push piston pin out of piston. 1. Piston ring compressor tool 2. Piston 3. Cylinder NOTICE Chain guide has to be fixed between cylinder and cylinder head.
  • Page 90 3. ENGINE 1. Measuring perpendicularly (90° ) to piston pin A. 8mrn (375in) 1. Use the micrometer to set the cylinder bore The measured dimension should be as described in gauge the following tables. If not, replace piston. 2. Dial bore gauge PISTON MEASUREMENT 90.950 mm to90.966mm (3.5807in to3.5813in)
  • Page 91 3. ENGINE Connecting Rod/Piston Pin Clearance CONNECTING ROD SMALL END DIAMETER 800R Using synthetic abrasive woven, clean piston pin 20.010 mm to20.020 mm from deposits . (.7878in to.7882in) Inspect piston pin for scoring, cracking or other SERVICE LIMIT 20.060 mm(.7898 in) damages.
  • Page 92 3. ENGINE 1. Circlip 2. Sleeve 3. Assembly jig from piston clip installer 1. Piston of cylinder 1 Push taper side of assembly jig until circlip reaches 2. Mark on piston must show to intake side of middle of sleeve. cylinder 1 Align sleeve with piston pin axis and push 3.
  • Page 93 3. ENGINE 1. Piston 2. Feeler gauge Ring End Gap CORRECT POSITION OF THE PISTON CIRCLIP RING/PISTON GR00VE CLEARANCE UPPER COMPRESSION RING PISTON RINGS 0.20 mm to 0.40 mm (.008in to.016in) Ring Removal SERVICE LIMIT 0.60 mm(.024in) Remove the piston (see PISTON in this LOWER COMPRESSION RING subsection).
  • Page 94 3. ENGINE 1. Upper compression ring 2. Lower compression ring 3. 0il scraper ring NOTICE Ensure that top and second rings are not interchanged. Check that rings rotate smoothly after installation. Space the piston ring end gaps120° apart and do not align the gaps with the piston pin bore or the thrust side axis.

  • Page 95: Timing Chain

    3. ENGINE TIMING CHAIN...
  • Page 96 3. ENGINE GENERAL IMPORTANT: Note position parts disassembly. This may help to find the root cause of a problem. A component that is not replaced should be reinstalled in the same position as originally mounted. TROUBLESHAOOTONG UNUSUAL ENGINE NOISE OR VIBRATION IMPROPER VALVE CLEARANCE...
  • Page 97 3. ENGINE Timing Chain Tensioner Installation 1. For installation, reverse the removal procedure. However, pay attention to the following. NOTE: Before installing the chain tensioner make sure, that the camshaft timing gear can be moved back and forth. 1. Chain tensioner plug 2.
  • Page 98 3. ENGINE 7. Then compress the spring and screw the plug in. Camshaft Timing Gear Installation NOTE: To avoid overstressed timing chain, the For installation, reverse the removal procedure. plug must engage into threads within the first full Pay attention to the following details. turn.
  • Page 99 3. ENGINE 4. Set camshaft to TDC ignition position by 7. Install and tighten camshaft timing gear aligning the camshaft flange flat spot with the tool retaining screws to specified torque. lever. NOTE: In addition, to ensure proper camshaft timing, press camshaft adjustment tool lever downwards.
  • Page 100 3. ENGINE 1. Plug 2. O-ring 1. Allen key74mm 4. Remove the crankshaft position sensor (CPS), 5.1 The rear piston is at TDC when it's index mark on the magneto flywheel is aligned with notch in the magneto cover. 1. CPS 2.
  • Page 101 3. ENGINE TYPICAL – PISTON AT TDC IGNTION CYLINDER 1 AT TDC IGNTION 1. Mark “1” on magneto flywheel 1. Printed marks on camshaft timing gear 2. Cylinder head base 2. Notch on magneto cover 3. Location of crankshaft position sensor 6.
  • Page 102 3. ENGINE REQUIED TOOL CRANKSHAFT TDC POSITION TOOL NOTE: Make sure to match the teeth on the crankshaft TDC position tool with the magneto rotor. 1. Magneto cover 2. TDC position tool TIMING CHAIN The engine is equipped with two timing chains. - MAG side timing chain is located behind the magneto cover.
  • Page 103 3. ENGINE 1. Timing chain 1. Timing chain 2. Lower timing chain guide 2. Lower timing chain guide 3. Timing chain guide (tensioner side) 3. Timing chain guide (tensioner side) Carefully pull the timing chain sideward and down NOTE: Mark the operating direction of the timing from the crankcase.
  • Page 104 3. ENGINE Refer to TIMING CHAIN in this subsection Timing Chain Guide Inspection (Tensioner Side) Check timing chain guide for wear, cracks or de- forming. Replace if necessary. Timing Chain Guide Inspection 1. Timing chain (Tensioner Side) If chain is excessively worn or damaged, replace it The installation is the reverse of the removal as a set (camshaft timing gear and timing chain).

  • Page 105: Bottom End

    3. ENGINE BOTTOM END ENGINE DRIVE SHAFT...
  • Page 106 3. ENGINE CRANKCASE AND PTO COVER...
  • Page 107 3. ENGINE CRANKSHAFT...
  • Page 108 3. ENGINE GENERAL IMPORTANT: Note position parts disassembly. This may help to find the root cause of a problem. A component that is not replaced should be reinsta1led in the same position as originally mounted. PROCEDURES ENGINE DRIVE SHAFT NOTE: The engine drive shaft transmits the power from the gearbox to the front differentia1 and is 1.
  • Page 109 3. ENGINE 1. Bearing cover 2. Drive shaft bearing Do not apply in excess as it will spread out inside Check drive shaft for cracks, bend, pitting or other crankcase. visible damages. NOTE: It is recommended to apply this specific sealant as described here to get a uniform Check drive shaft splines for wear or damages.
  • Page 110 3. ENGINE REQUIED 10N·m 士 1 N·m Tightening torque (89lbf· in 士 9lbf· in) Front Bearing Cover Installation 1. Bearing cover 2. Oil seal 5. Install drive shaft oil seal using the following FRONT OF ENGINE 1. Water pump cover 2.
  • Page 111 3. ENGINE 1. Bearing cover 1. O-ring 2. O-ring 2. Bearing cover 4. Install drive shaft oil seal using the fo1lowing 6. Reinstall remaining parts in the reverse order of tool. removal. PTO COVER OIL SEAL To replace oil seal it is not necessary to remove engine from vehicle.
  • Page 112 3. ENGINE PTO Oil Seal Installation The installation is the reverse of the removal procedure. Pay attention to the following details. NOTICE Oil seal must be installed with sealing lip toward the engine. Push oil seal in place. REQUIED PTO COVER OIL SEAL 1.
  • Page 113 3. ENGINE PLAIN BEARING TOOL PLAIN BEARING REMOVER / UNSTALLER The PT0 cover has to be supported from below with suitable support with straight surface, in order to prevent damage of the sea11ng surface. 1. Oil breather bore 2. Surface of sealing sleeve Check plain bearings for scorings or other damages.
  • Page 114 3. ENGINE 1. Mark position of oil bore on PTO cover 2. Mark position of oil bore on plain bearing remove/installer Carefully press-in the plain bearings in the same direction as during disassembly, from the outside towards the inside. Support PT0 cover with TIGHTENING SEQUENCE suitable support with straight surface, in order to PTO COVER SCREW...
  • Page 115 3. ENGINE 1. Breather gear 2. Intermediate gear 1. Thrust washer 3. Water pump drive gear 2. Water pump drive gear 4. Oil pump drive gear 3. Needle pin Drive Gears Removal Drive Gears Inspection Remove PT0 cover (refer to IC)70 C0 産用. Intermediate Gear/0il Pump Drive Gear/Water Withdraw intermediate gear and breather gear.
  • Page 116 3. ENGINE - Water pump housing. CRAN KCASE 11. Refer to LUBRICATION SYSTEM subsection Crankcase Disassembly to remove following parts: Refer PEROIDIC MAINTENANCE -Oil filter PROCEDURES subsection and: -Oil cooler 1.1 Drain cooling system. -Oil pump drive gear. 1.2 Drain engine oil. NOTE: Oil pump removal from crankcase is not 1.3 Drain gearbox oil.
  • Page 117 3. ENGINE 1. Engine oil strainer NOTE: During disassembly, do not damage the 2. Retaining plate sealing surfaces of the crankcase halves. 3. Screws Pull crankshaft out of crankcase. Remove the water pump intermediate shaft. Crankcase Cleaning △WARNING Use safety goggles to avoid eye injuries Clean crankcase using a part cleaner.
  • Page 118 3. ENGINE 1. Plain Bearing 2. Oil bore PUSH PLAIN BEARING OUTSIDE A. Measure plain bearing inside diameter 1. Crankcase half 2. plain bearing remover/installer MAIN BEARING INSIDE 3. Crankcase support sleeve DIAMETER(PTO/MAG) SERVICE 42.100 mm(1 6575in) Plain Bearing Installation (Main) LIMIT NOTICE Unless otherwise instructed, never use hammer to install plain bearings.
  • Page 119 3. ENGINE 1. Partition 1. Oil bore position marked on plain bearing 2. Oil bore remover/installer 3. Crankcase half PTO (inside) 2. Plain bearing oil bore 3. Oil bore position marked on crankcase Crankcase Assembly The assembly of crankcase is essentially the re- NOTICE Misalignment of the plain bearing and verse of removal procedure.
  • Page 120 3. ENGINE 3. Crankshaft position sensor. CRANKCASE SCREWS Tightening torque- 10N· m±1N· m (89lbf· in 士 9lbf· in) -Tightening torque- 25N· m±3N· m (18lbf· ft±2 lbf·ft) CRANK SHAFT 1. Crankshaft pisition sensor 2. Screw 4. Plug screw and discard sealing ring 1.
  • Page 121 3. ENGINE Gradually insert the tool in the crankshaft groove. Make sure that the tool tip enters the groove and does not jam on the crankshaft balancer surface. Crankshaft Removal Refer to CRANKCASE Crankshaft Inspection NOTE: Check each bearing journal of crankshaft for scoring, scuffing, cracks or other signs of wear.
  • Page 122 3. ENGINE 1. Connecting rod screws Measure crankpin . Compare to inside diameter of connecting rod big end. 1. Crank shaft 2. Connecting rods 3. Feeler gauge CONNECTING ROD BIG END AXIAL PLAV 0.200 mm to 0.500 800R ENGINE (.008in to.02in) SERVICE 0.600 mm(.024in) LIMIT...
  • Page 123 3. ENGINE Carry out the tightening procedure described in 2. Crankshaft area for MAG plain bearing CRANKSHAFT ASSEMBLY in this subsection. A. Connecting rod, big end plain bearing CONNECTING ROD BIG END RADIAL 800R 40.100mm(1.5787in) ENGINES SERVICE 1. Micrometer LIMIT 1000 42.100mm(1.6575in) 2.
  • Page 124 3. ENGINE 1. Half plain bearing of connecting rod big end 2. Split surface of the connecting rod 1. Micrometer 3. Nose of plain bearing in line with connecting 2. Crankshaft journal (PTO support bearing) rod groove CRANKSHAFT JOURNAL DIAMETER Oil the plain bearing surface of the connecting rod (PTO COVER BEARING) and crank pin before installation.
  • Page 125 3. ENGINE 1. Connecting rod small ends 2. Connecting rod offset 3. Connecting rod screws CONNECTING RODS SCREWS TIGHTENING 1. Angle torque wrench SEQUENCE Tighten to1/2 of specified torque 800R Engine: Tighten to30N· m±2N· m NOTE: NEW connecting rods can be installed (22lbf·ft 士...
  • Page 126 3. ENGINE 1. Crankcase half MAG side 2. Connecting rod cylinder 1 3. Connecting rod cylinder 2...

  • Page 127: Continuously Variable

    3. ENGINE CONTINUOUSLY VARIABLE TRANSMISSION Never touch CVT while engine is running. never drive vehicle when variator cover is removed. Subcomponent installation and assembly tolerances require strict adherence to procedures detailed. Never use any type of impact wrench at drive pulley removal and installation. The clutch assembly is a precisely balanced unit.
  • Page 128 3. ENGINE INSPECTION Inspect belt for cracks, fraying or abnormal wear. Replace if necessary. Drive belt width Service limit 30.00mm(1.181 in) Installation For installation, reverse the removal procedure. Pay attention to following details. 1. Word printed on belt 2. Drive pulley (front) 3.
  • Page 129 3. ENGINE Block drive pulley with the pulley holding tool. 1. Pulley holding tool 2. Torque wrench When the drive pulley is blocked, mark sliding sheave and governor cup to ensure correct reinstallation. Unscrew the drive pulley screw (right hand thread), then remove it as well as the conical spring washer and thrust washer.
  • Page 130 3. ENGINE parts for Never substitute conical spring washer and/ or screw with jobber ones. Always use genuine this particular case. Install thrust washer with its concave side towards drive pulley then install drive pulley screw. To torque the drive pulley screw, block the drive pulley. Refer at the beginning of this section. When the drive pulley is blocked, torque screw to 100N.m.
  • Page 131 3. ENGINE Inspection Driven pulley should be inspected annually for wear or damages. Check sliding and fixed sheave for cracks and sliding contact surface for excessive wear. Replace sliding sheave if necessary. Check sliding sheave bushings for cracks, scratch and for free movement when assembled to sliding sheave.

  • Page 132: Gearbox And4X4 Coupling Unit

    3. ENGINE GEARBOX AND4X4 COUPLING UNIT GEARBOX COMPONENTS AND 4×4 COUPING MECHANISISM...
  • Page 134 3. ENGINE GENEAL 1. Defective gearbox position sensor (GBPS) GEARBOX OVERVIEW -Perform a gearbox position sensor test. -Damaged wires .Repair as required. GEAR(S) IS (ARE) HARD TO SHIFT 1. Incorrect shifter cable adjustment. -Adjust shifter cable (refer to SHIFTER CABLE in SHIFTER subsection. 4 WHEEL DRIVEINDICATION FAILS 1.
  • Page 135 3. ENGINE (KEY ON) PIN A PIN C Battery (RED (BLACK/GREEN voltage wire) wire) If voltage is not as specified, test positive and ground separately. VSS Signal Test 1. Lift rear of vehicle so that rear wheels are off the ground. 2.
  • Page 136 3. ENGINE VSS Removal 1. Connect vehicle to the latest applicable Remove screw retaining the VSS version Of B.U.D.S. software, refer to COMMUNICATION TOOL AND B.U.D.S. subsection. NOTE: Ignition key must stay 0N during the reset procedure. If the key is turned off, the procedure must be carried out again.
  • Page 137 3. ENGINE MULITIMETER VOLITAGE If an error occurred or the GBPS is not PROBE within the allowed range while resetting, POSITIONS the ECM will generate a fault code and PIN1 and PIN3 of will not accept the setting. 5. If a fault message is displayed, follow GBPS connector 5 volts the instructions in the message(s).
  • Page 138 3. ENGINE 4WDINDICATOR SWITCH If resistance is out of specification, check wires and connectors. Repair and reset 4WDlndicator Switch Access To reach the4WD indicator switch, remove the fault codes. fo1lowing parts: If resistance is good and the other tests _ Passenger seat succeeded, replace the GBPS and reset - RH lateral console panel fault codes.
  • Page 139 3. ENGINE ACTUATOR Actuator Access To access the actuator, remove the fol1owing parts: - Passenger seat - RH lateral console panel - Fuel tank cowl. Remove screws securing fuel tank and move tank on passenger's floor without disconnecting hoses and connector from fuel pump. Actuator Test Check if the2WD/4WD selector works properly.
  • Page 140 3. ENGINE If the front propeller shaft turns, the actuator is not installed correctly. Remove actuator and reinstall it. Place ignition switch to 0N position and select the 2WD position. Turn front wheel again. The front propeller shaft should turn easily. If the front propeller shaft does not turn, the actuator is not installed correctly.
  • Page 141 3. ENGINE HANDLE (P/N420877 650) NOTICE Oil seal must be installed with sealing lip toward gearbox. hift Drum Shaft Oil Seal To replace the shift drum shaft oil seal, remove the GBPS (GEARBOX POSITION SENSIR). See procedure in this subsection. Use a suitable tube with the proper diameter to install the oil seal.
  • Page 142 3. ENGINE GEAR BOX Gearbox Removal Remove engine from vehicle. Refer to ENGINE REMOVAL AND INSTALLATUON for the procedure. Refer COUNTINOUSLY VARIABLE TRANSMISSION (CVT) subsection to remove following parts: - CVT cover - Drive and driven pulleys 1. Marked areas for removal - CVT air guide.
  • Page 143 3. ENGINE POSITION FOR SOFT HAMMER RH SIDE OF ENGINE 1. Nut M8 Pull gearbox to separate it from engine. Gearbox Disassembly NOTE: During gearbox disassembly, inspect the condition of each part closely. Gearbox Left Cover Set gearbox to NEUTRAL position. Unscrew all bolts retaining the gearbox left cover.
  • Page 144 3. ENGINE Insert a flat screwdriver in the slot of index lever. Turn screwdriver clockwise and remove index washer. 1. Bearing pin 2. Reverse intermediate gear 3. Needle bearing 4. Thrust washers Remove shift fork shaft. 1. Index lever Disengage shift forks from shift drum 2.
  • Page 145 3. ENGINE 1. Snap ring 2. Free pinion (HIGH range gear) 1. Main shaft assembly 3. Free pinion (LOW range gear) 2. Shift fork 4. Needle bearings 5. Main shaft assembly Remove shifting sleeve (HIGH range gear) and shift fork. Remove from main shaft assembly: - Snap ring (discard) - Shifting sleeve (LOW/REVERSE range gear)
  • Page 146 3. ENGINE 1. Shift shaft assembly 1. 5 Screws M8x55 Remove screw retaining shifting 2. 2 Screws M6x85 intermediate gear. 3. 2 Screws M6x55 4. 8 Screws M6x35 To remove cover, use2 big screwdrivers 1. Screw 2. Washer 3. Intermediate gear 4.
  • Page 147 3. ENGINE 1. Output shaft 2. 4×4 coupling sleeve 1. Shift fork shaft 3. Soft hammer 2. Shift fork 3. Shift drum Remove set screw, coupling fork shaft and coupling fork from right cover. Remove shift drum and thrust washer. 1.
  • Page 148 3. ENGINE 1. Ball bearing countershaft 2. Right cover 1. Counter shaft 2. Distance sleeve 3. O-ring Gearbox Bearings If necessary heat housing up to100° C(212° F) before removing ball bearings. △WARNING Clean oil, outside and inside, from housing before heating. NOTICE Always support gearbox housings 1.
  • Page 149 3. ENGINE Gearbox Inspection Always verify for the fol1owing when inspecting gearbox components: - Gear teeth damage - Worn or scoured bearing surfaces - Rounded engagement dogs and slots - Worn shift fork engagement groove - Worn splines on shafts and shifting sleeves. Bearings Check if ball bearings turn freely and smoothly.
  • Page 150 3. ENGINE 1. Bearing pin A. Outer diameter A. Bearing journal MAG side BEARING PIN OUTER DIAMETER B. Free pinion bearing 24.987mm to25.000mm C .Bearing journal CVT side (.984in to.984in) SERVICE 24.977 mm(.9833 in) MAIN SHAFT LIMIT FREE PINION BEARING 24.987mm to25.000 mm Check countershaft bearing journals for wear.
  • Page 151 3. ENGINE Output Shaft Check output shaft and its gear for cracks, bend, pitting or other visible damages. Check output shaft splines for wear or other damages. Check if the output shaft bearings turn freely and smoothly. Replace oil seal if brittle, hard or damaged. 4×4 Coupling Sleeve 1.
  • Page 153 4. COOLING SYSTEM 4. COOLING SYSTEM FAULT OVERHAULING · · · · · · · · · · · · · · · · · · · · · · 4-1 COOLING SYSTEM TEST · · · · · · · · · · · · · · · · · · · 4-2 THERMOSTAT ·...
  • Page 154 4. COOLING SYSTEM COOLING SYSTEM TEST WARNING To avoid potential burns, do not remove the radiator cap or loosen the cooling drain plug if the engine is hot. Open the upper cover of engine hood and remove the radiator cap. Install the test cap and a small hose pincher on overflow hose.
  • Page 155 4. COOLING SYSTEM THERMOSTAT The thermostat is a single action type. The thermostat is located on the top of cylinder head, on intake side. Remove:  thermostat housing screws pull thermostat cover 1. Thermostat cover 2. Screws  thermostat with gasket out of the hole. Thermostat test To check thermostat, put in water and heat water.
  • Page 156 4. COOLING SYSTEM Remove the connector of temperature controller on the radiator and the radiator water outlet hose B. Remove the fill hose C and the top mounting bolt D on the left side. Temperature controller Unplug the connectors of cooling fan. Connector of fan Pull out upward the radiator from the lower mounting holes on the frame, remove the...
  • Page 157 4. COOLING SYSTEM COOLANT TANK The coolant expands as the temperature (up to 100-110℃) and pressure rise in the system. If the limiting system working pressure cap is reached 110kPa, the pressure relief valve in the pressure cap is lifted from its seat and allows coolant to flow through the overflow hose into the overflow coolant tank.
  • Page 158 4. COOLING SYSTEM...
  • Page 159 4. COOLING SYSTEM WATER PUMP HOUSING ! WARNING It is located on the engine MAG side. To avoid potential burns, do not remove the radiator cap or loosen Water pump housing removal the cooling drain plug if the engine is hot . Drain cooling system.
  • Page 160 4. COOLING SYSTEM WATER PUMP SHAFT AND SEALS Shaft/Seal removal NOTE: It is not required to split crankcase to replace the water pump shaft and seals, but engine removal is necessary. Drain engine oil. Remove engine from vehicle. Refer to ENGINE REMOVAL section.
  • Page 161 4. COOLING SYSTEM Using 2 screwdrivers, pry out inner part of the rotary seal. To remove outer part of rotary seal, use an expander from puller kit. Install expander snugly against outer part and pull rotary seal out. Remove inner oil seal. 1.
  • Page 162 4. COOLING SYSTEM Apply MOLYKOTE inside lips oil seal when installing the oil seal on the pusher, make sure sealing lip points outside. Push inner oil seal in place. 1. Inner oil seal 2. Installer handle with oil seal pusher Slide water pump shaft with the new rotary seal into crankcase.
  • Page 163 5.FUEL SYSTEM 5. FUEL SYSTEM FUEL PRESSURE TEST · · · · · · · · · · · · · · · · · · · · · · 5-2 FUEL FILTER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-2 FUEL PUMP ·...
  • Page 164 5.FUEL SYSTEM FUEL PRESSURE TEST The pressure test will show the available pressure at the fuel pump outlet. It validates the pressure regulator, the fuel pump and leaks in the system. Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts.
  • Page 165 5.FUEL SYSTEM 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 166 5.FUEL SYSTEM Installation Install fuel sensor to fuel tank. Connect connector and hose. Turn on fuel supply switch, and check whether functions of fuel meter is normal or not. Fuel leakage is not allowed. FUEL TANK Fuel tank draining Never perform this operation when the engine and/or the exhaust system is/are hot. Never sue a hose pincher on injection system high pressure hoses.
  • Page 167 5.FUEL SYSTEM Pull front side of the fuel tank upward, continue lifting movement until you can remove the fuel tank completely. Fuel tank inspection Inspect fuel tank for any damage or cracks which may result in fuel leaks. If so replace tank with a new one.
  • Page 169 6.DRIVE TRAIN 6. DRIVE TRAIN FRONT DRIVE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-1 REAR DRIVE ·...

  • Page 170: Drive Train

    6.DRIVE TRAIN FRONT PROPELLER SHAFT Removal Place vehicle on PARK position and select 4WD. Remove left and right seats, gear shift handle and engine shield. Unscrew propeller shaft bolt on engine side. the right front Loosen wheel nut. Raise the front of vehicle, support it securely on jack stands.

  • Page 171: Front Wheel Hub

    6.DRIVE TRAIN FRONT WHEEL HUB Removal Raise the front of vehicle, support it securely on jack stands and remove front wheel. Remove cotter pin, castellated nut and belleville washer. Remove the caliper from knuckle. Pull the wheel hub to remove it. Inspection Check wheel hub for cracks or other damages.

  • Page 172: Front Drive Shaft

    6.DRIVE TRAIN FRONT DRIVE SHAFT Removal Remove the appropriate wheel hub. Remove the guard plate of brake caliper Remove the fixing clip of brake hose on the knuckle. Remove the shock absorber. Remove the ball joint of tie rod from the steering knuckle.

  • Page 173: Front Differential

    6.DRIVE TRAIN Check if the bearing in knuckle move freely and smoothly. If not, replace them. Installation Apply grease to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove. Insert the other end of drive shaft in the knuckle and install the knuckle to the lower suspension arm.
  • Page 174 6.DRIVE TRAIN Remove lower differential bolts. Remove the front differential. Inspection Inspect the gear case, case cover, bearing, oil seals and dust seal for wear or damage. If any damage or wear is found, replace the oil seal or dust seal with a new one. Check back lash and drag torque.

  • Page 175: Rear Drive

    6.DRIVE TRAIN REAR DRIVE REAR WHEEL HUB Removal 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. the rear wheel. Remove Remove cotter pin, castellated nut and belleville washer.

  • Page 176: Rear Drive Shaft

    6.DRIVE TRAIN Remove the caliper from knuckle. Pull the wheel hub to remove it. 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.
  • Page 177 6.DRIVE TRAIN Check the ring at teh end of drive shaft. If wear is apparent, replace the wear ring. Check if the bearing in kunckle move freely and smoothly. If not, replace them. Installation Apply grease to the splines and insert the end of drive shaft in differential and pull joint a little to make sure that the stop ring is locked in differential side gear groove.
  • Page 178 6.DRIVE TRAIN REAR PROPELLER SHAFT Removal Place vehicle on PARK position and select 4WD. Loosen the left rear wheel nut. Install a jack stand under the frame to lift the rear of vehicle off the ground until the shock absorber is fully extended. the left rear wheel.

  • Page 179: Rear Differential

    6.DRIVE TRAIN REAR DIFFERENTIAL Remove Clean the drain plug area.Place an oil pan under the front reducer case,and then drain oil completely by removing the drain plug. Raise rear of vehicle, support it securely on jack stands and remove rear wheels. On both sides, remove the drive shafts.

  • Page 180: Tires And Wheels

    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 design on the same axle. Front and rear tire pairs must be the identical model and manufacturer.
  • Page 181 6.DRIVE TRAIN CAUTION When installing each tire, make sure the arrow on the tire points in the direction of rotation. Also make sure the outer side of the wheel rim is facing outward. Inflate the tire to seat the tire bead. Check the rim line cast on the tire side walls.
  • Page 183 7. STEERING SYSTEM 7. STEERING SYSTEM ADJUSTMENT...........7-2 TROUBLESHOOTING........7-3...
  • Page 184 7. STEERING SYSTEM ADJUSTMENT ALIGNING THE WHEELS 1. Place vehicle on a level surface. 2. Inflate tires to recommended pressure. 3. Find rack and pinion center to center as follows: 3.1 Calculate the total steering wheel rota-tions from side to side. 3.2 Position the steering wheel at half the total rotations.
  • Page 185 7. STEERING SYSTEM TROUBLESHOOTING 1. STEERING COLUMN 1.1 Remove the backboard (Middle) 、 Backboard (Side) and Column Shroud 1.2 Remove screws on each side of the steering support. 1.3 Remove steering column from vehicle. Inspecting：Check steering shaft for wear, cracks or bending.Ensure universal joints are not worn and move freely；...
  • Page 187 7.STEERING SYSTEM 3. Redirector Assembly 3.1 Remove the cover 3.2 Remove steering booster body retaining bolts 3.3 Remove the retaining bolts of Redirector Assembly 3.4 Remove the tie Rod Inspecting：Check Internal spline for wear, cracks or bending.Ensure universal joints are not worn and move freely，Whether there is a rotation gap Replace if necessary Installing：The installation is the reverse of the removal pro-cedure...
  • Page 189 8. BRAKES SYSTEM 8. SUSPENSION SYSTEM FRONT SUSPENSION · · · · · · · · · · · · · · · · · · · · · · · · 8-1 REAR SUSPENSION · · · · · · · · · · · · · · · · · · · · · · · · · · 8-4 REMOVAL AND DISASSEMBLY ·...

  • Page 190: Removal And Disassembly

    8. BRAKES SYSTEM REMOVAL AND DISASSEMBLY Loosen wheel nut of the appropriate. Install a jack stand under the frame to lift the front of vehicle off the ground until shock absorber is fully extended then. wheels, brake caliper and hub remove steering knuckle from ball cage tie rod. Remove INSPECTION Shock absorber...

  • Page 191: Lower Suspension Arm

    8. BRAKES SYSTEM Lower Suspension Arm Inspect the suspension arm and for damage or distortion. If any damages or distortion are found, replace the suspension arm with a new one. Move suspension arm from side to side. There should be no noticeable loose. Replace bushing if necessary.

  • Page 192: Rear Suspension

    8. BRAKES SYSTEM REAR SUSPENSION The procedure explained below is the same for the RH and LH sides unless otherwise noted. 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.

  • Page 193: Inspection

    8. BRAKES SYSTEM wheels, brake caliper and hub Remove remove steering knuckle from ball cage tie rod INSPECTION Shock absorber Inspect the shock absorber for oil leakage or damage, inspect the bushing for wear or damage. If any damage are found, replace the rear shock absorber with a new one.

  • Page 194: Lower Suspension Arm

    8. BRAKES SYSTEM Lower Suspension Arm Inspect the suspension arm and for damage or distortion. If any damages or distortion are found, replace the suspension arm with a new one. Move suspension arm from side to side. There should be no noticeable loose. Replace bushing if necessary.
  • Page 195 8. BRAKES SYSTEM 9. BRAKES SYSTEM NOTICE............9-2 BRAKE FLUID REPLACMENT......9-3 BRAKE PADS REPLACMENT......9-4...
  • Page 196 8. BRAKES SYSTEM NOTICE： 1. This brake system is filled with an ethylene glycol based DOT4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids； 2. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or which has been stored for a long periods of time；...
  • Page 197 8. BRAKES SYSTEM BRAKE FLUID REPLACMENT 1. Place the vehicle horizontally，Four wheels off the ground，Remove the tire 2. Remove the oil cap from the oil pump，Use a needle to pump out the old brake fluid， pump in fresh brake fluid. 3.
  • Page 198 8. BRAKES SYSTEM NOTION： 1. Exhaust Valve Locking Torque 6N.M. 2. Four calipers operation, priority after the wheel operation, in accordance with the principle from far and near. 3. Brake system oil drainage at the same time, pay attention to supplement the oil storage pump, to ensure that there is visible oil.
  • Page 199 9. BRAKES SYSTEM . When replacing brake pad, replace the whole set, otherwise the braking performance will be adversely affected. (5). After changing the brake pad, press the brake pedal several times to check whether the brake is normal, and then check whether there is any change in the amount of brake fluid.
  • Page 201 10. ELECTRICAL SYSTEM 10. ELECTRICAL SYSTEM WIRING ...........10-1 STARTING SYSTEM........10-8 IGNITION SYSTEM........10-10 CHARGING SYSTEM......10-12 Warning ‹ Bulb will be very hot after turning on headlamp. Please do not touch it immediately after its off. In operation, bulb needs to be cooled. ‹...
  • Page 202 10. ELECTRICAL SYSTEM Removal/installation of main fuse 1、Remove battery negative connection. 2、Remove the main fuse box cover. 3、Disassemble in the order specified in the table。 4、 Installation sequence is opposite to disassembly sequence。 Remove/install fuse box 1、Remove battery anode connection。 2、Remove self-tapping nail for fixing fuse box。...
  • Page 203 10. ELECTRICAL SYSTEM exterior lighting system Removal and Installation of Front Combined Headlamps 1、Remove the positive and negative connection of battery。 2、Open front hood。 3、Remove （1 bolt , 2 bolt , 3 headlamp bracket , 4 headlamp;） 4、install vice versa pay attention to：...
  • Page 204 10. ELECTRICAL SYSTEM Removal and Installation of Top Lamps 1、Remove the positive and negative connection of battery。 2、Disconnect the positive power supply connected to the top lamp。 3、Disassemble (1, bolt ;2, top lamp) in the sequence shown in the diagram 4、The order of installation is contrary to the order of disassembly Removal and Installation of Top Lamp Control Switch 1、Open hood cover。...
  • Page 205 10. ELECTRICAL SYSTEM Removal and Installation of Electric Top 1、Box raised。 1、Disconnect the electric ceiling。 2、Disassemble (1, open pin ;2, upper fixed pin ;3, open pin ; 4, lower fixed pin ;5, electric top) in sequence as shown. 3、The resistance value of electric top resistor can be detected by using ohmmeter.
  • Page 206 10. ELECTRICAL SYSTEM 1、To adjust the speed, speed, metric, English system, M "and S","M" keys to adjust the mileage, clock, interval mileage, interval working time. 2、A left steering light 12 V positive is effective; the left steering light flashes at the same frequency when the vehicle turns on。...
  • Page 207 10. ELECTRICAL SYSTEM number through the change of pulse frequency. 13、The speed signal comes from the K-signal of ECU; 14、Gear signal, gear signal from gear controller voltage signal (L, h, N, R, P) 15、Engine fault indicator lamp, after engine operation fault alarm indicator lamp extinguished, engine operation this indicator lamp is still on, engine operation may not be normal, can use the old, fault diagnostic instrument to detect the fault code of the engine, fault code refers to the self -diagnosis...
  • Page 208 10. ELECTRICAL SYSTEM P0202 Injector 2 Circuit Malfunction KsDGDM_INJ_CYL_B_Fault P0230 Fuel Pump Relay (FPR) FPR Coil Circuit Low Voltage or KsDGDM_FPP_CircuitShortL Open P0232 FPR Coil Circuit High Voltage KsDGDM_FPP_CircuitShort High P0336 Crankshaft Position CKP Sensor Noisy Signal KsDGDM_CrankNoisySignal Sensor (CKP) P0337 CKP Sensor No Signal KsDGDM_CrankNoSignal...
  • Page 209 10. ELECTRICAL SYSTEM STARTING SYSTEM Starter motor Brush Check the brush on the brush holder whether it is worn abnormal, cracked or not smooth. Worn, cracked, or not smooth: → Replace...
  • Page 210 10. ELECTRICAL SYSTEM 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. If there is concave, scrape off insulator B, so that the distance with A is d.
  • Page 211 10. 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 The multimeter is set to 1x10Ω.
  • Page 212 10. ELECTRICAL SYSTEM IGNITION SYSTEM Ignition coil Primary peak voltage of ignition coil Remove the spark plug cap as shown in the right figure. Install the new spark plug to the cap. The cylinder is connected to grounding. Connect the multimeter and the peak voltage adapter as follows: +Probe: Green wire or grounding wire -Probe: Black / yellow wire...
  • Page 213 10. ELECTRICAL SYSTEM Note: Do not touch the test probes or spark plug, in case of electric shock. If the voltage is lower than the standard value, check the ignition coil and coupling coil. Resistance of ignition coil Disconnect the ignition coil wires and spark plug cap.
  • Page 214 10. ELECTRICAL SYSTEM CHARGING SYSTEM Resistance of generator coil Measure the resistance between three wires; If the resistance is not within the specified value, replace the stator coil. Check the generator core whether it is insulated. Install multimeter 1×10Ω. Resistance of generator coil: 0.9-1.5Ω (color: yellow) Insulation resistance ∞Ω...
  • Page 215 10. 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 multimeter reading is lower than 1.4V, replace the multimeter battery.
  • Page 217 11. TROUBLESHOOTING 11. TROUBLESHOOTING ELECTRICAL SYSTEM......11-1 COOLING SYSTEM......11-1 MAGNETO SYSTEM......11-2 LUBRICATION........11-3 CYLINDER AND HEAD......11-4 CRANKSHAFT........11-5 GEARBOX..........11-5 COUPLING UNIT........11-6 CVT............11-6 ENGINE GENERAL......11-9 FAULT CODES........11-13 ELECTRICAL SYSTEM Symptom: NO SPARK OR POOR SPARK Refer to ignition system. Symptom: STARTER DOES NOT TURN Refer to starting system.
  • Page 218 11. TROUBLESHOOTING Check temperature sensor for electrical/mechanical failure.  Temperature sensor defective. Replace. Check thermostat.  Thermostat defective (does not open when engine gets hot). Replace (refer to cooling system). Check leak indicator hole (in crankcase MAG side-water pump housing area) if coolant leaks.
  • Page 219 11. TROUBLESHOOTING LUBRICATION Symptom: LOW OR NO OIL PRESSURE/HIGH OIL CONSUMPTION Check oil level and search for leakage on crankcase and/or sealing parts.  Crankcase is leaking due to damage. Rebuild engine with new crankcase and gasket parts. Use recommended oil (refer to technical specifications). ...
  • Page 220 11. TROUBLESHOOTING 10. Check engine oil strainer in crankcase.  Oil strainer is clogged due to contamination. Clean or replace strainer and diagnose causes. Replace possible damaged parts (refer to bottom end). Symptom: OIL CONTAMINATION (white appearance) 1. Check leak indicator hole (in crankcase MAG side-water pump housing area) if water and oil leaks.
  • Page 221 11. TROUBLESHOOTING CRANKSHAFT Symptom: UNUSUAL ENGINE NOISE AND/OR VIBRATION 1. Check noise coming from crankshaft area..  Crankshaft plain bearings are damaged. Replace crankshaft plain bearings.  Connecting rod plain bearings are damaged. Replace connecting rod plain bearings.  Magneto rotor got loose. Replace damaged components and retighten rotor retaining screw with recommended torque (refer to MAGNETO SYSTEM).
  • Page 222 11. TROUBLESHOOTING COUPLING UNIT Symptom: 4 WHEEL DRIVE INDICATION FAILS 1. Check contact screw on gear housing right side for damage and/or wear.  Shifting indicator switch pin is worn and/or damaged. Replace shifting indicator switch.  Contact is corroded and/or contact screw for wiring harness got loose. Clean contact surface and retighten contact screw with recommended torque.
  • Page 223 11. TROUBLESHOOTING Check valve adjustment.  Intake and/or exhaust valves are not adjusted correctly. Adjust valves. Check engine condition.  Low engine compression. Check ignition condition.  Faulty spark plug. Install new spark plug(s). 10. Check differentials operation.  Vehicle on Neutral is hard to move. Repair or replace defective part(s). Symptom: ENGINE MAXIMUM RPM IS TOO HIGH AND VEHICLE TOP SPEED IS NOT REACHED.
  • Page 224 11. TROUBLESHOOTING Check cam and driven pulley fixed sheave for wear.  Cam and/or drive pulley fixed sheave out of wear limit and/or damaged. Replace damaged part(s). Check torque gear fixed in driven pulley sliding sheave for wear.  Torque gear out of wear limit and/or damaged. Replace torque gear). Check for foreign particles in CVT area (stones, dirt, etc.).
  • Page 225 11. TROUBLESHOOTING Symptom: BELT WORN EXCESSIVELY IN TOP WIDTH. Check drive belt width.  Considerable wear. Replace belt if narrower than specified (refer to CONTINUOUSLY VARIABLE TRANSMISSION (CVT) OR TECHNICAL SPECIFICATIONS)。 Check driver belt identification number.  Wrong type of belt. Replace belt with an appropriate drive belt. Check for localized belt wear caused by belt slippage.
  • Page 226 11. TROUBLESHOOTING 9. Check encoder wheel.  Bent tooth. Refer to MAGNETO SYSTEM. 10. Check engine compression.  Insufficient engine compression. Replace defective part(s). Symptom: ENGINE DOES NOT START 1. Electrical problem.  Determine if the electrical system works correctly (fuse(s), battery, wiring harness, etc.).
  • Page 227 11. TROUBLESHOOTING Piston seizure.  Spark plugs heat range is too hot. Install spark plugs with appropriate heat range (refer to TECHNICAL SPECIFICATIONS).  Compression ratio is too high. Install genuine parts.  Poor oil quality. Use recommended oil.  Leaks at air intake manifold (engine gets too lean). Retighten screws or replace air intake manifold gasket.
  • Page 228 11. TROUBLESHOOTING Symptom: ENGINE BACKFIRES Check spark plugs.  Carbon accumulation caused by defective spark plugs. Replace spark plugs. 2. Check leakage on intake manifold.  Air leak on intake system. Retighten screws and/or replace intake manifold gasket. 3. Check exhaust air leaking. ...
  • Page 229 11. TROUBLESHOOTING Symptom: HIGH ENGINE OPERATING TEMPERATURE Check if cooling system shows any failure (see COOLING SYSTEM).  System is leaking. Repair and/or replace damaged part(s). Check function of lubrication system (see LUBRICATION SYSTEM).  Lubrication is not working properly. Repair and/or replace damaged part(s). Check condition and heat range of spark plugs.
  • Page 230 11. TROUBLESHOOTING P0232 Fuel pump is existing short circuit power supply P0336 Signal of crankshaft position sensor is disturbed P0337 No signal of crankshaft position sensor P0351 Ignition coil of cylinder 1 is damaged P0352 Ignition coil of cylinder 2 is damaged P0505 Air bypass valve is damaged P0562...

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