Huansong HS700UTV Brief

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Brief introduction to maintenance handbook of

The handbook is edited by Technical Center of Chongqing Huansong Industries (Group)

Co., Ltd., and is supplied to dealers and technicians as document of technique.

Mainly, the handbook gives methods to check, maintain and repair utility terrain

vehicles （UTV）, and supplies some relevant technique and performance data. Some

techniques and method inside may be used to check, maintain and repair other models of

UTV, although it is mainly for HS700UTV.

Please read the handbook through and fully understand it; otherwise, any improper

repairing and amounting would bring you problems, and accident may occur in your use.

Proper use and maintenance can guarantee UTV being driven safely, reduce its

malfunction, and help the vehicle remain its best performance.

The standards, performances and specifications mentioned in interpretation are

based on the sample in design, and they are subject to changes according to the

product's improvement without prior notice.

Third version , May, 2010

Published by Chongqing Huansong Industries (Group) Co., Ltd.

Chongqing Huansong Industries (Group) Co., Ltd holds the copy right.

No publishing and reprinting without permission.

FOREWORD

HS700/600/500UTV

Table of Contents

Troubleshooting

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Summary of Contents for Huansong HS700UTV

Page 1 Brief introduction to maintenance handbook of HS700/600/500UTV The handbook is edited by Technical Center of Chongqing Huansong Industries (Group) Co., Ltd., and is supplied to dealers and technicians as document of technique. Mainly, the handbook gives methods to check, maintain and repair utility terrain vehicles （UTV）, and supplies some relevant technique and performance data.
Page 2: Table Of Contents
CONTENT CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION……………………………………………………………………1 WATNINGS CAUTIONS AND NOTES……………………………………………………1 DESCRIPTION……………………………………………………………………………………2 IDENTIFICATION CODE……………………………………………………………………… 3 Frame No. ………………………………………………………………………………… 3 Engine No. ………………………………………………………………………………… 3 SAFETY ………………………………………………………………………………………… 4 Handing gasoline safely…………………………………………………………………… 5 Cleaning parts……………………………………………………………………………… 5 Warning labels……………………………………………………………………………… 6 SERIAL NUMBERS…………………………………………………………………………… 6 FASTENERS…………………………………………………………………………………… 6 Torque specifications ………………………………………………………………………...
Page 3 Wrenches ………………………………………………………………………………… 12 Adjustable wrenches …………………………………………………………………… 12 Socket wrenches, ratchets and handles ……………………………………………… 13 Impact drivers …………………………………………………………………………… 14 Allen wrenches…………………………………………………………………………… 14 Torque wrenches………………………………………………………………………… 14 Torque adapters ………………………………………………………………………… 15 Pliers……………………………………………………………………………………… 16 Snap ring pliers…………………………………………………………………………… 16 Hammers ………………………………………………………………………………… 17 Ignition grounding tool…………………………………………………………………… 17 PRECISION MEASURING TOOLS …………………………………………………………...
Page 4 Removal…………………………………………………………………………………… 28 Installation………………………………………………………………………………… 29 Interference fit …………………………………………………………………………… 29 Seal replacement………………………………………………………………………… 31 STORAGE……………………………………………………………………………………… 31 Storage area selection…………………………………………………………………… 31 Preparing the motorcycle for storage …………………………………………………… 32 Returning the UTV to service…………………………………………………… 32 TROVBLESHOOTING……………………………………………………………………… 33 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… 34 STARTING THE ENGINE ………………………………………………………………… 34 Engine is cold ……………………………………………………………………………...
Page 5 Poor high speed performance ………………………………………………………… 43 FUEL SYSTEM……………………………………………………………………………… 43 Rich mixture……………………………………………………………………………… 43 Lean mixture……………………………………………………………………………… 44 ENGINE………………………………………………………………………………………… 44 Engine smoke……………………………………………………………………………… 44 Black smoke ……………………………………………………………………………… 44 Blue smoke………………………………………………………………………………… 44 White smoke or steam…………………………………………………………………… 44 Low engine compression ………………………………………………………………… 45 High engine compression ……………………………………………………………… 45 Engine overheating (cooling system) …………………………………………………...
Page 6 Jumper wire……………………………………………………………………………… 54 TEST PROCEDURES………………………………………………………………………… 55 Voltage test……………………………………………………………………………… 55 Voltage drop test………………………………………………………………………… 55 Peak voltage test………………………………………………………………………… 56 Continuity test……………………………………………………………………………… 56 Testing for a short with a self-powered test light or ohmmeter……………………… 56 Testing for a short with a test light or voltmeter………………………………………… 57 BRAKE SYSTEM………………………………………………………………………………...
Page 7 HYDROGRAPHIC CHART…………………………………………………………………… 84 LUBRICATION OIL WAY…………………………………………………………………… 85 CHAPTER 3 MAINTENCE AND ADJUSTMENT OF THE UTV MAINTENANCE SCHEDULE……………………………………………………………… 86 ENGINE Adjusting the valve clearance…………………………………………………………… 88 Idle adjustment …………………………………………………………………………… 91 Adjusting the throttle cable……………………………………………………………… 91 Adjusting the starter cable……………………………………………………………… 92 Checking the spark plug ………………………………………………………………… 93 Checking the ignition timing………………………………………………………………...
Page 8 Changing the final gear oil……………………………………………………………… 116 Checking the differential gear oil……………………………………………………… 117 Changing the differential gear oil……………………………………………………… 117 Checking the constant velocity joint dust boots……………………………………… 118 Checking the steering system………………………………………………………… 119 Adjusting the toe-in …………………………………………………………………… 120 Adjusting the front shock absorbers………………………………………………… 121 Adjusting the rear shock absorbers ……………………………………………………...
Page 9 CRANKCASE Starter motorand oil filter……………………………………………………………… 177 Crankcase……………………………………………………………………………… 179 Crankcase bearings…………………………………………………………………… 180 CRANKSHAFT AND OIL PUMP Crankshaft and oil pump ……………………………………………………………184 Oil pump…………………………………………………………………………………185 TRANSMISSION Transmission…………………………………………………………………………… 188 Drive axle assembly…………………………………………………………………… 189 MIDDLE GEAR Middle drive shaft………………………………………………………………………… 193 Middle driven shaft ……………………………………………………………………… 194 CARBURETOR………………………………………………………………………………...
Page 10 Checking the front brake disc ………………………………………………………… 221 Front brake pads………………………………………………………………………… 222 Replacing the front brake pads………………………………………………………… 223 Front brake caliper……………………………………………………………………… 224 Disassembling the front brake calipers ……………………………………………… 226 Assembling the front brake calipers…………………………………………………… 227 Installing the front brake calipers …………………………………………………… 227 Rear brake disc …………………………………………………………………………...
Page 11 Checking the gear motor………………………………………………………………… 256 Assembling the universal joint……………………………………………………………257 Adjusting the differential gear lash……………………………………………………… 257 Assembling the differential gear …………………………………………………………258 Installing the front bridge parts………………………………………………………… 259 Rear bridge ……………………………………………………………………………… 260 REVERSE MECHANISM PARTS ……………………………………………………… 266 Adjusting reverse mechanism parts ………………………………………………… 268 Checking and service of reverse mechanism…………………………………………...
Page 12 Disassembling and checking ,service oil cooling system…………………………… 294 Installing oil cooling system…………………………………………………………… 295 CHAPTER 6 ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION ……………………………… 296 ELECTRICAL ……………………………………………………………………………… 297 ELECTRICAL COMPONENTS…………………………………………………………… 297 Checking the switch…………………………………………………………………… 299 Checking the switch continuity ……………………………………………………… 300 Checking the bulbs and bulb sockets ……………………………………...
Page 13 If the brake lights fail to come on …………………………………………………… 323 If the neutral lights fail to come on ………………………………………………… 324 If the parking brake indicator light fails to come on ………………………………… 325 If the reverse indicator light fails to come on ……………………………………… 326 If the coolant temperature warning …………………………………………………...
Page 14 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE/HARD STARTING………………………………………………… 363 Fuel system ……………………………………………………………………………… 363 Electrical system ………………………………………………………………………… 363 Compression system …………………………………………………………………… 364 POOR IDLE SPEED PERFORMANCE ………………………………………………… 365 Poor idle speed performance…………………………………………………………… 365 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… 365 Poor medium and high-speed performance………………………………………… 365 FAULTY GEAR SHIFTING…………………………………………………………………...
Page 15 SPECIFICATIONS…………………………………………………………………………… 373 Geberar specifications ………………………………………………………………… 373 Engine specifications ……………………………………………………………… 373 ENGINE REMOVAL………………………………………………………………………… 379 CYLINDER HEAD AND CYLINDER HEAD COVER…………………………………… 381 ROCKER ARMS AND CAMSHAFT……………………………………………………… 384 VALVES AND VALVE SPRINGS………………………………………………………… 388 CYLINDER AND PISTON………………………………………………………………… 393 HS700UTV/HS600UTV/HS500UTV WIRING DIAGRAM……………………………… 397 - 14 -...
Page 16: General Information
GENERAL INFORMATION GENERAL INFORMATION The text provides complete information on maintenance， tune-up repair and overhaul， Hundreds of photographs and illustrations created during the complete disassembly of utility terrain vehicles (UTV) guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time.
Page 17: Description
GENERAL INFORMATION DESCRIPTION 1. Headlights 2. Front shock absorber assembly Adjusting ring 3. Brake fluid reservoir 4. Air filter element (Engine and air intake duct) 5. V-belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9. Cargo bed 10.
Page 18: Identification Code
GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved in the lower right side of Figure. Engine No. Engine No. is carved on the right side of the Engine, Figure. - 3 -...
Page 19: Safety
GENERAL INFORMATION SAFETY Professional mechanics can work for years and never sustain a serous injury or mishap. Follow these guidelines and practice common sense to safely service the utility terrain venires Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide.
Page 20: Handing Gasoline Safely
GENERAL INFORMATION Handling Gasoline Safely Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. Because gasoline is used so often, many people forget it is hazardous. Only use gasoline as fuel for gasoline internal combustion engines. Keep in mind when working on the machine, gasoline is always present in the fuel tank, fuel line and carburetor.
Page 21: Warning Labels
GENERAL INFORMATION Warning Labels Most manufacturers attach information and warning labels to the UTV. These labels contain instructions that are important to personal safety when operating, servicing, transporting and storing the UTV. Refer to the owner’s manual for the description and location of labels. Order replacement labels from the manufacturer if they are missing or damaged.
Page 22: Washers
GENERAL INFORMATION Washers The two basic types of washers are flat washers and lock washers. Flat washers are simple discs with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose. Washers can be used as spacers and seals.
Page 23: Shop Supplies
GENERAL INFORMATION Remove and install snap rings with snap rings pliers. Refer to Basic Tools in this chapter In some applications. it may be necessary to replace snap rings after removing them Compress or expand snap rings only enough to install them.
Page 24: Greases
GENERAL INFORMATION Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide range of operating conditions. Multi-grade oils are identified by a W after the first number, which indicates the low-temperature viscosity. Engine oils are most commonly mineral (petroleum) based, but synthetic and semi-synthetic types are used more frequently.
Page 25: Gasket Sealant
GENERAL INFORMATION water-soluble. Local ordinances may types of cleaning chemicals. Refer to Safer in this chapter. Use brake parts cleaner to brake system components. Brake parts cleaner leaves no residue. Use electrical contact cleaner is a powerful solvent used to remove fuel deposits and varnish from fuel system components.
Page 26: Basic Tools
GENERAL INFORMATION BASIC TOOLS Most of the procedures in this manual can be carried out with basic hand tools and test equipment familiar to the home mechanic. Always use the correct tools for the job. Keep tools organized and clean. Store them in a tool chest with related tools organized together. Quality tools are essential.
Page 27: Wrenches
GENERAL INFORMATION NOTE Another way to prevent cam out and to increase the grip of a Phillips screwdriver is to apply valve grinding compound or permute screw ＆ socket Gripper onto screwdriver tip. After loosening/tightening the screw, clean the screw recess to prevent engine oil contamination.
Page 28: Socket Wrenches, Ratchets And Handles
GENERAL INFORMATION off the fastener. Because one jaw is adjustable and may become loose, this shortcoming is aggravated. Make certain the solid jaw is the one transmitting the force. Socket Wrenches, Ratchets and Handles Sockets that attach to a ratchet handle (Figure 7) are available with 6-point or 12-point openings (Figure 8) and different drive sizes.
Page 29: Impact Drivers
GENERAL INFORMATION Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers.
Page 30: Torque Adapters
GENERAL INFORMATION A torque wrench is a precision tool that must be properly cared for to remain accurate. Store torque wrenches in cases or separate padded drawers within a toolbox. Follow the manufacturer’s instructions for their care and calibration. Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench.
Page 31: Pliers
GENERAL INFORMATION grip. The effective length is the sum of L and A. Example: TA=20 ft.-lb. A=3in. L=14in. × =16.5 ft. - lb. In this example, the torque wrench would be set to the recalculated torque value (TW = 16.5 ft. –lb.).
Page 32: Hammers
GENERAL INFORMATION WARNING Snap rings can slip and fly off when removing and installing them. Also, the snap ring pliers tips may break. Always wear eye protection when using snap ring pliers. Hammers Various types of hammers are available to fit a number of applications. Use a ball-peen hammer to strike another tool, such as a punch or chisel.
Page 33: Feeler Gauge
GENERAL INFORMATION Precision measurements can vary according to the experience of the person performing the procedure. Accurate results are only possible if the mechanic possesses a feel for using the tool. Heavy-handed use of measuring tools produces less accurate results. Hold the tool gently by the fingertips to easily feel the point at which the tool contacts the object.
Page 34: Micrometers
GENERAL INFORMATION individual lines on the fixed scale equal 1 cm. The movable scale is marked in 0.05 mm (hundredth) increments. To obtain a reading, establish the first number by the location of the 0 line on the movable scale in relation to the first line to the left on the fixed scale. In this example, the number is 10 mm. To determine the next number, note which of the lines on the movable scale align with a mark on the fixed scale.
Page 35: Adjustment
GENERAL INFORMATION be any dirt or burrs between the tool and the measured object. Never force the micrometer to close around an object. Close the micrometer around the highest point so it can be removed with a slight drag. Adjustment Before using a micrometer, check its adjustment as follows: Clean the anvil and spindle faces.
Page 36: Standard Inch Micrometer
GENERAL INFORMATION micrometer. A 0-25 mm micrometer, for example, will have sleeve marks numbered 0 through 25 in 5 mm increments. This numbering sequence continues with larger micrometers. On all metric micrometers, each mark on the lower half of the sleeve equals 0.50 mm. The tapered end of the thimble has 50 lines marked around it.
Page 37: Telescoping And Small Bore Gauges
GENERAL INFORMATION visible. Each sleeve number equals 0.100 in. 2. Count the number of lines between the numbered sleeve mark and the edge of the thimble. Each sleeve mark equals 0.025 in. 3. Read the thimble mark that aligns with the sleeve line. Each thimble mark equals 0.01 in. NOTE If a thimble mark does not align exactly with the sleeve line, estimate the amount between the...
Page 38: Compression Gauge
GENERAL INFORMATION dimensions and movements. Measuring brake rotor runout is a typical use for a dial indicator. Dial indicators are available in various ranges and graduations and with three basic types of mounting bases: magnetic (B. Figure 31). Clamp, or screw-in stud.
Page 39: Electrical System Fundamentals
GENERAL INFORMATION Each time an analog ohmmeter is used or if the scale is changed, the ohmmeter must be calibrated. Digital ohmmeters do not require calibration. 1. Make sure the meter battery is in good condition. 2. Make sure the meter probes are in good condition. 3.
Page 40: Basic Service Methods
GENERAL INFORMATION BASIC SERVICE METHODS Most of the procedures in this manual are straightforward and can be performed by anyone reasonably competent with tools. However, consider personal capabilities carefully before attempting any operation involving major disassembly. 1. Front, in this manual, riders to the front of the UTV, The front of any component is the end closest to the front the UTV.
Page 41: Removing Frozen Fasteners
GENERAL INFORMATION If special tools are required, have them available before starting the procedure. When special tools are required, they are described at the beginning of the procedure Make diagrams of similar-appearing parts. For instance, crankcase bolts are often not the same lengths.
Page 42: Repairing Damaged Threads
GENERAL INFORMATION Repairing Damaged Threads Occasionally, threads are stripped through carelessness or impact damage. Often the threads can be repaired by running a tap (for internal threads on nuts) or die (for external threads on bolts) through the threads (Figure 37). To clean or repair spark plug threads, use a spark plug tap.
Page 43: Bearings
GENERAL INFORMATION wire brush Clean the inside of the hose thoroughly. Do not use any lubricant when installing the hose (new or old). The lubricant may allow the hose to come off the fitting, even with the clamp secure. Bearings Bearings are used in the engine and transmission assembly to reduce power loss, heat and noise resulting from friction.
Page 44: Installation
GENERAL INFORMATION the inner race will damage them. Always make sure the press arm (Figure 42) aligns with the center of the shaft. If the arm is not centered, it may damage the bearing and/or shaft. The moment the shaft is free of the bearing. It drops to the floor. Secure or hold the shaft to prevent it from falling.
Page 45 GENERAL INFORMATION installation. Note the following: Secure the shaft so it is ready for bearing installation. Clean all residues from the bearing surface of the shaft. Remove burrs with a file or sandpaper. Fill a suitable pot or beaker with clean mineral oil. Place a thermometer rated above 120℃(248°F) in the oil.
Page 46: Seal Replacement
GENERAL INFORMATION bearings in the housing. d. Before heating the bearing housing, place the new bearing in a freezer if possible. Chilling' a bearing slightly reduces its outside diameter while the heated bearing housing assembly is slightly larger due to heat expansion. This makes bearing installation easier. NOTE Always install bearings with the manufacturer’s mark or number facing outward.
Page 47: Preparing The Motorcycle For Storage
GENERAL INFORMATION to saltwater. 4. Consider the area’s risk of fire, theft or vandalism. Check with an insurer regarding UTV coverage while in storage. Preparing the Motorcycle for Storage The amount of preparation a motorcycle should undergo before storage depends on the expected length of non-use, storage area conditions and personal preference.
Page 48: Trovbleshooting
GENERAL INFORMATION TROVBLESHOOTING Diagnose electrical and mechanical problems by following an orderly procedure and remembering the basic operating requirements Define Symptoms Determine Which areas could exhibit these symptoms Test and analyze The suspect areas Is date The problem By following a systematic approach, the possibility of unnecessary parts replacement can be avoid, always start with the simple and most obvious checks when troubleshooting, This would include the engine stop switch, fuel quantity and condition, fuel vale position and spark plug cap tightness Proper maintenance as described in Chapter Three reduces the necessity for troubleshooting.
Page 49: Starting The Engine
GENERAL INFORMATION If one basic requirement is missing the engine will not run. STARTING THE ENGINE When experiencing engine-starting troubles, it is easy to work out of sequence and forget basic starting procedures. The following sections describe the recommended starting procedures. Engine is cold 1.
Page 50: Engine Cold With Air Temperature
GENERAL INFORMATION 2. Check that the chock knob is fully closed (pushed in). 3. Open the throttle fully and hold in this position. Then start the engine firmly through its entire stoke ten times to clear the engine. Close the throttle. 4.
Page 51: Engine Is Hot
GENERAL INFORMATION NOTE Do not race the engine during the warm-up period. The carburetor accelerator pump can overly richen the air/fuel mixture and cause the engine to stall. Engine is hot Shift the transmission into neutral. Turn the fuel valve on NOTE Do not open the throttle when starting the engine in Step 3.
Page 52: Engine Will Not Start
GENERAL INFORMATION If the engine starts, close the throttle and release the hot start lever. If the engine starts but idles roughly, vary the throttle position slightly until the engine idles and responds smoothly. If the engine still does not start, refer to Engine Will Not Start in this chapter. ENGINE WILL NOT START Identifying the Problem If the engine does not start, perform the following steps in order while remembering the Engine...
Page 53: Spark Test
GENERAL INFORMATION Perform the Spark Test in this section. If there is a strong spark, perform Step 7. If there is no spark or if the spark is very weak, refer to Ignition System Testing in Chapter Ten. If the fuel and ignition systems are working correctly, perform a leak down test (this chapter) and cylinder compression test.
Page 54: Starter Does Not Turn Over Or Turns Over Slowly
GENERAL INFORMATION evident between the spark tester or spark plug terminals. If there is a strong, blue spark, the ignition system is functioning properly, Check for one or more of the following possible malfunctions: a. Faulty fuel system component. b. Flooded engine. c.
Page 55: Engine Backfires, Cuts Out Or Misfires During Acceleration
GENERAL INFORMATION Engine Backfires, Cuts Out or Misfires During Acceleration A backfire occurs when fuel is burned or ignited in the exhaust system. A lean air/fuel mixture can cause these engine performance problems. Check for the following conditions: a. Incorrect float level adjustment. b.
Page 56: Engine Will Not Idle Or Idles Roughly
GENERAL INFORMATION Engine Will Not Idle or Idles Roughly 1. Clogged air filter element. 2. Poor fuel filter or fuel hose. 3. Faulty accelerator pump assembly. 4. Contaminated or stale fuel. 5. Incorrect carburetor adjustment. 6. Leaking head gasket. 7. Intake air leak. 8.
Page 57: Poor Idle Or Low Speed Performance
GENERAL INFORMATION normal Check for one or more of the following problems Low engine compression Worn spark plug Fouled spark plug Incorrect spark plug heat range Weak ignition coil Incorrect ignition timing Plugged carburetor passages Incorrect oil level (too high or too low) Contaminated oil Worn or damaged valve train assembly Engine overheating...
Page 58: Poor High Speed Performance
GENERAL INFORMATION Poor High Speed Performance Check ignition timing. If the ignition timing is correct. Perform Step 2. If the timing is incorrect. Perform the Peak Voltage Check the fuel system as described in this chapter Check the valve clearance as described. Note the following: If the valve clearance as correct.
Page 59: Lean Mixture
GENERAL INFORMATION Contaminated float valve seat Worn or damaged float valve and seat Leaking or damaged float Clogged carburetor jets Incorrect carburetor jetting Lean Mixture The following conditions can cause a lean air/fuel mixture: Intake air leak Float level too low Clogged fuel line, fuel filter or fuel shutoff valve Partially restricted fuel tank breather hose Plugged carburetor air vent hose...
Page 60: Low Engine Compression
GENERAL INFORMATION Large amounts of steam can also be caused by a cracked cylinder head or cylinder block surface that allows coolant to leak into the combustion chamber. Perform a Coolant System Pressure Test. Low Engine Compression Problems with the engine top end will affect engine performance. When the engine is suspect, perform the leak down procedure in this chapter and make a compression test .
Page 61: Engine Overheating (Engine)
GENERAL INFORMATION 1. Low coolant level. 2. Air in cooling system. 3. Clogged radiator, hose or engine coolant passages. 4. Worn or damaged radiator cap. 5. Damaged water pump. Engine Overheating (Engine) 1. Improper spark plug heat range. 2. Low oil level. 3.
Page 62: Englne Lubrication
GENERAL INFORMATION Consider the following when troubleshooting engine noises: 1. Knocking or pinging during acceleration can be caused by using a lower octane fuel than recommended. May also be caused by poor fuel. Pinging can also be caused by an incorrect spark plug heat range or carbon buildup in the combustion chamber.
Page 63: High Oil Pressure
GENERAL INFORMATION Clogged oil strainer screen. Clogged oil filter. Internal oil leakage. Oil relief valve stuck open. Incorrect type of engine oil. High Oil Pressure Oil relief valve stuck closed. Clogged oil filter. Clogged oil gallery or metering orifices. No Oil Pressure Low oil level.
Page 64 GENERAL INFORMATION When performing a leak down test, the engine is first set at TDC on its compression stroke so that all the valves are closed. When the combustion chamber is pressurized, very little air should escape. However, the difficulty in performing a leak down test on a single cylinder engine(especially on the engines described in this manual with low static engine compression) is in preventing the piston from moving as the combustion chamber starts to pressurize.
Page 65 GENERAL INFORMATION WARNING Do not attempt to lock the engine by trying to use a tool to hold the Allen bolt on the end of the crankshaft. Once the combustion chamber becomes pressurized, any crankshaft movement can throw the tool away from the engine under considerable force, attempting to hole the tool can cause serious injury.
Page 66: Electrical Testing
GENERAL INFORMATION c. Air leaking through both the intake and exhaust valves indicates the engine is not set at TDC on its compression stroke. Air leaking through the coolant filler neck indicates a leaking cylinder head gasket or a cracked cylinder head or cylinder liner. e.
Page 67: Intermittent Problems
GENERAL INFORMATION Intermittent Problems Intermittent problems are problems that do not occur all the time and can be difficult to locate. For example. When a problem only occurs when the UTV is ridden over rough roads (vibration) or in wet conditions (water penetration).
Page 68: Electrical Component Replacement
GENERAL INFORMATION Water—when this problem occurs in wet conditions, or in areas with high humidity, start and run the engine in a dry area. Then, with the engine running, spray water related problems repair themselves after the component becomes hot enough to dry itself. Electrical component replacement Most UTV dealerships and parts suppliers will not accept the return of any electrical part.
Page 69: Ohmmeter
GENERAL INFORMATION Ohmmeter An ohmmeter measures the resistance (in ohms) to current flow in a circuit or component. Like the self-powered test light, an ohmmeter contains its own power source and should not be connected to a live circuit. Ohmmeter may be analog type (needle scale) or digital type (LCD or LED readout). Both types of ohmmeter have a switch that allows the user to select different ranges of resistance for accurate readings.
Page 70: Test Procedures
GENERAL INFORMATION the motorcycle 4. When using a jumper wire always install an inline fuse/fuse holder (available at most auto supply stores or electronic supply stores) to the jumper wire. Never use a jumper wire across any load (a component that is connected and turned on). This would result in a direct short and will blow the fuse(s) TEST PROCEDURES Voltage test...
Page 71: Peak Voltage Test
GENERAL INFORMATION 2. Connect the voltmeter negative test lead to the electrical load (where the electricity is going). 3. If necessary, activate the component(s) in the circuit. For example. If checking the voltage in the starter circuit, it would be necessary to push the starter button. 4.
Page 72: Testing For A Short With A Test Light Or Voltmeter
GENERAL INFORMATION Connect the other test lead to a good ground (bare metal). Make sure the part used for a ground is not insulated with a rubber gasket or rubber grommet. With the self-powered test light or ohmmeter attached to the fuse terminal and ground, wiggle the wiring harness relating to the suspect circuit at various intervals.
Page 73: Brake Drag
GENERAL INFORMATION can also enter the system from loose or damaged hose fittings. Air in the hydraulic system causes a soft or spongy brake lever action. This condition is noticeable and reduces brake performance. When it is suspected that air has entered the hydraulic system, flush the brake system and bleed the brakes as described in Chapter Fifteen.
Page 74: Hard Brake Lever Or Pedal Operation
GENERAL INFORMATION Brake caliper not sliding correctly on slide pins. Sticking or damaged brake caliper pistons. Contaminated brake pads and disc. Plugged master cylinder port. Contaminated brake fluid and hydraulic passages. Restricted brake hose joint. Loose brake disc mounting bolts. Damaged or misaligned wheel.
Page 75: Leaking Brake Caliper
GENERAL INFORMATION Damaged or missing brake pad spring or pad retainer. Leaking Brake Caliper Damaged dust and piston seals. Damaged cylinder bore. Loose caliper body bolts. Loose banjo bolt. Damaged banjo bolt washers. Damaged banjo bolt threads in caliper body. Leaking Master Cylinder Damaged piston secondary seal.
Page 76: Specifications
SPECIFICATIONS SPECIFICATIONS HOW TO CONVERSION TABLE OF UNIT （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY...
Page 77: Geberar Specifications
SPECIFICATIONS GEBERAR SPECIFICATIONS Item Standard Dimensions : Overall length 3,010 mm（118.5 in） Overall width 1,460 mm（57.5 in） Overall height 1,940 mm（77.2 in） Seat height 818 mm（32.2 in） Wheelbase 1,890 mm（72.4 in） Minimum ground clearance 280 mm（11.0 in） Minimum turning radius 3,900 mm（154 in）...
Page 78 SPECIFICATIONS Item Standard Air filter Wet type element Fuel Unleaded gasoline only Type 30.0L（6.60 lmp gal, 7.93 US gal） Fuel tank capacity Carburetor Type/quantity PD42J-A / 1 Spark plug DPR8EA / 1 (NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Clutch type Wet ,centrifugal automatic Transmission...
Page 79 SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 185 mm (7.3 in) Rear wheel travel 185 mm (7.3 in) Electrical Ignition system C.D.I.
Page 80: Engine Specifications
SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) Cylinder 100.10 mm Bore size 100.005 ~ 100.055 mm (3.9410 in) Measuring point (3.9372 ~ 3.9392 in) ---- 50 mm (1.97 in) Camshaft Drive method Chain drive (Left) ---- Cam dimensions...
Page 81 SPECIFICATIONS Item Standard Limit Cam chain No. of links Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in) Arm-to-shaft clearance 0.009 ~ 0.042 mm ----...
Page 82 SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
Page 83 SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) ---- Measuring point “H” 2.5 mm (0.10 in) ---- Piston off-set 1.0 mm(0.0394 in)
Page 84 SPECIFICATIONS Item Standard Limit Oil ring ---- 2.5×3.4 mm (0.0984× 0 .1339 in) Dimensions (B×T) ---- 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) End gap (installed) ---- 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Side clearance Crankshaft 74.95 ~ 75.00 mm ---- Crank width “A”...
Page 85 SPECIFICATIONS Item Standard Limit Transmission Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter Shifter type Shift drum and guide bar ---- Air filter oil grade Engine oil ---- Carburetor ---- Mark KINZO...
Page 86: Chassis Specifications
SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 108 mm (4.25 in) ---- Spring free length 313 mm (12.32 in) ---- Spring fitting length 247.9 mm (9.76 in) ---- Spring rate 19.4 N/mm(1.94 kg/mm, 108.6 lb/in) ---- Stroke...
Page 87 SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.2 mm 1.5 mm (0.20 in) (0.06 in) Pad thickness outer 5.2 mm 1.5 mm (0.20 in) (0.06 in)
Page 88: Electrical Specifications
SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit Voltage 12 V ---- Ignition system Ignition timing (BTDC) 12°/ 1,500 r/min ---- Advancer type Digital type ---- C.D.I. Pickup coil resistance/color 459 ~ 561 Ωat 20 °C (68 °F)/ ---- Rotor rotation direction sensing coil White/Red –...
Page 89 SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) ---- 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, 27.5 ~ 36.0 oz)
Page 90: Tightening Torques
SPECIFICATIONS TIGHTENING TORQUES Engine tightening torques Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Cylinder head (exhaust pipe) Stud bolt Cylinder head cover Bolt —...
Page 91 SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Bolt Bolt Crankcase Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
Page 92 SPECIFICATIONS Tightening torque Thread Remarks Part to be tightened Part name Q’ty ft · lb m.kg size Left-hand Shift rod locknut (select lever unit) — threads Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) —...
Page 93: Chassis Tightening Torques
SPECIFICATIONS Chassis tightening torques Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm...
Page 94 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hub Front wheel hub and constant velocity joint of half 26.0 Stake shaft Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt...
Page 95 SPECIFICATIONS Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Support frame (enclosure) and frame Support frame (enclosure) and side frame (enclosure) Top frame (enclosure) and side frame (enclosure) Seat support and frame Footrest plate and frame - 80-...
Page 96: General Tightening Torque Specifications
SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 97: Lubrication Pionts And Lubricant Types
SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES Engine Lubrication points Lubricant Oil seal lips Bearings O-rings Piston, piston ring Piston pin Buffer boss and balancer drive gear Crankshaft seal and spacer Valve stem Valve stem end Rocker arm shaft Rocker arm Camshaft lobe and journal Oil pump assembly Oil filter cartridge O-ring...
Page 98: Chassis
SPECIFICATIONS CHASSIS Lubrication points Lubricant Lip of oil seal (full) Light lithium-base grease o-ring(full) Light lithium-base grease Steering shaft (upper end ,lower end) Light lithium-base grease Ball connection of steering pushing rod Light lithium-base grease Front wheel fork(ball-shaped joint) Light lithium-base grease Front wheel bearing Grease used for bearing Front &...
Page 99: Hydrographic Chart
SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure ：splash - 84-...
Page 100: Lubrication Oil Way
SPECIFICATIONS LUBRICATION OIL WAY Hydrographic chart ：Pressure ：splashing oil - 85-...
Page 101: Maintenance Schedule
MAINTENANCE AND ADJUSTMENT OF THE UTV MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. MAINTENANCE SCHEDULE EVERY INITAL Whichever...
Page 102 MAINTENANCE AND ADJUSTMENT OF THE UTV Whichever EVERY INITAL comes first month ITEM ROUTINE 1,200 2,400 2,400 4,800 (mi) (200) (750) (1,500) (1,500) (3,000) hours · Check condition. · Spark plug Adjust gap and clean. ○ ○ ○ ○ ○ ·...
Page 103: Engine
MAINTENANCE AND ADJUSTMENT OF THE UTV ENGINE Adjusting the valve clearance NOTE: ·The valve clearance must be adjusted when the engine is cool to the touch. ·Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke.
Page 104 MAINTENANCE AND ADJUSTMENT OF THE UTV ② Fan impeller ③ As manhole covers 3. calibration · Wrench to counterclockwise rotation crankshaft · According to the rotor turning counterclockwise, rotor turn to mark the dead spots ② of crank box, namely ① : the dead point position is compressed.
Page 105 MAINTENANCE AND ADJUSTMENT OF THE UTV Valve clearance (cold) Intake 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust 0.15 ~ 0.20 mm (0.0059 ~ 0.0079 in) 5. Adjust: valve clearance ① Lock nut ② Valve thickness gauge（gap Regulation） ③ Regulator ④...
Page 106: Idle Adjustment
MAINTENANCE AND ADJUSTMENT OF THE UTV IDLE ADJUSTMENT 1. Starting engines, thorough warm machine 2. Remove: ·Lift the cargo bed up. ·driver seat ·passenger seat ·console Refer to “SEATS ” in chapter 5. 3. Install ·Engine tachometer 4. Confirm speed ·Standard Engine Idle speed Engine idle speed 1,400 ±100 r/min...
Page 107: Adjusting The Starter Cable
MAINTENANCE AND ADJUSTMENT OF THE UTV ② External shaft cover ③ Throttle Cable Solenoid ④ Adjusting Screw ⑤ Throttle Valves ⑥ Throttle Cable 1. Remove following parts: ·driver seat ·passenger seat ·console 2. Remove: ·Throttle valve cover ② 3. Check: ·throttle cable Slack ⑥...
Page 108: Checking The Spark Plug
MAINTENANCE AND ADJUSTMENT OF THE UTV a. Disconnect the starter cable ① from the carburetor body. NOTE: Do not remove the starter plunger ② from the starter cable. b. Measure the starter plunger stroke distance of the starter (choke) knob ③ fully close to ○...
Page 109: Checking The Ignition Timing
MAINTENANCE AND ADJUSTMENT OF THE UTV is there, then check the pole clearance by thickness gauge. It is qualified if the pole clearance between 0.7mm. Otherwise it should be adjusted. Wear/damage Replace. ·insulator ② Abnormal color Replace. Normal color is a medium-to-light tan color. 5.
Page 110: Measuring The Compression Pressure
MAINTENANCE AND ADJUSTMENT OF THE UTV a. Warm up the engine and keep it at the specified speed Engine speed 1,400 ~ 1,500 r/min ○ b. Remove the timing plug c. Visually check the stationary pointer ① to verify it is within the required firing range ② indicated on the flywheel.
Page 111 MAINTENANCE AND ADJUSTMENT OF THE UTV 4. check standard value standard compression pressure data 1200Kpa (12kg/ cm )-1000r/min 5. read the highest data on the compression pressure meter ·Above the maximum pressure: Check the cylinder head, valve surfaces, and piston crown for carbon deposits. ·Below the minimum pressure: Check the accumulation carbon in the firebox...
Page 112: Checking The Engine Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV 18 Nm-20Nm (1.8 m · kg, 13 ft · lb) 5. Lower the cargo bed. CHECKING THE ENGINE OIL LEVEL 1. Place the vehicle on a level surface 2. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS”...
Page 113: Changing The Engine Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick. 6. Install: ·console ·passenger seat ·driver seat Refer to “SEATS”...
Page 114 MAINTENANCE AND ADJUSTMENT OF THE UTV · Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) 6. Install： ·engine oil drain bolt ① 7.
Page 115 MAINTENANCE AND ADJUSTMENT OF THE UTV cartridge and the oil pump for damage or leakage. Refer to “THE ENGINE” in chapter 4. d. Start the engine after solving the problem(s) and check the engine oil pressure again. e. Tighten the oil gallery bolt to specification. Oil gallery bolt 7 Nm (0.7 m ·...
Page 116: Chassis
MAINTENANCE AND ADJUSTMENT OF THE UTV CHASSIS CLEANING THE AIR FILTER NOTE: There is a check hose at the bottom of the ① air filter case. If dust and/or water collect in this hose, clean the air filter element and air filter case.
Page 117: Checking The Coolant Level
MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING Use a cleaning solvent which is designed to clean parts only. Never use gasoline or low flash point solvents as they may cause a fire or explosion. b. Squeeze the excess solvent out of the element and let it dry.
Page 118: Changing The Coolant
MAINTENANCE AND ADJUSTMENT OF THE UTV Add the recommended coolant to the proper level. CHANGING THE COOLANT 1. Remove: ·driver seat ·passenger seat ·console Lift the hood up.。 ·coolant reservoir cap ① ·Disconnect coolant reservoir hose ② ·Adding water instead of coolant lowers the antifreeze content of the coolant.
Page 119 MAINTENANCE AND ADJUSTMENT OF THE UTV cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, turn the radiator cap counterclockwise while pressing down on it and then remove it. 6.
Page 120 MAINTENANCE AND ADJUSTMENT OF THE UTV 13. Fill cooling (with specified amount recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors aluminum engines Mixing ratio 1 : 1 (antifreeze : water) Quantity total amount 2.5 L (2.20 Imp qt, 2.64 US qt) Coolant reservoir capacity 0.35 L (0.31 Imp qt, 0.37 US qt) NOTE:...
Page 121: Checking The Coolant Temperature Warning Light
MAINTENANCE AND ADJUSTMENT OF THE UTV 14. Install: ·air bleed bolt 9 Nm (0.9 m · kg, 6.5 ft · lb) ·radiator cap ·Fill coolant reservoir: (with the recommended coolant to the maximum level mark○ ·Install coolant reservoir cap: · Start the engine, warm it up for several minutes, and then turn it off.
Page 122: Checking The V-Belt
MAINTENANCE AND ADJUSTMENT OF THE UTV Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light Coolant temperature warning light does not come on. come on. Turn the main switch to “START” with the transmission in neutral position.
Page 123: Cleaning The Spark Arrester
MAINTENANCE AND ADJUSTMENT OF THE UTV ·Replace V-belt: Install the bolts ① into the secondary fixed sheave hold. NOTE: Tightening bolts ① will push secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. ·Remove the V-belt ①from the primary sheave and secondary sheave.
Page 124: Adjusting The Brake Pedal
MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING: · Select a well-ventilated area free of combustible materials. · Always let the exhaust system cool before performing this operation. · Do not start the engine when removing the tailpipe from the muffler. 3.
Page 125: Adjusting The Parking Brake
MAINTENANCE AND ADJUSTMENT OF THE UTV b. Turn brake rod ② in or out until the correct free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. c. Tighten the locknut to specification. Locknut 17 Nm (1.7 m ·...
Page 126: Checking The Brake Fluid Level
MAINTENANCE AND ADJUSTMENT OF THE UTV ·console ·passenger seat ·driver seat Refer to “SEATS” in chapter 5. CHECKING THE BRAKE FLUID LEVEL 1. Place the vehicle on a level surface. NOTE: When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal.
Page 127: Checking The Rear Brake Pads
MAINTENANCE AND ADJUSTMENT OF THE UTV Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 5. Brake pad wear limit ○ a 1.5 mm (0.06 in) 3. Operate the brake pedal. 4. Install: ·front wheels CHECKING THE REAR BRAKE PADS 1.
Page 128: Bleeding The Hydraulic Brake System
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Hold the vehicle in an upright position and apply the brake pedal. 5. Install: ·console ·passenger seat ·driver seat BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if: · The system has been disassembled. ·...
Page 129 MAINTENANCE AND ADJUSTMENT OF THE UTV Front □ Rear □ d. Place the other end of the hose into a container. e. Slowly apply the brake pedal several times. f. Push down on the pedal and hold it. g. Loosen the bleed screw and allow the pedal to travel towards its limit.
Page 130: Adjusting The Select Lever Shift Rod
MAINTENANCE AND ADJUSTMENT OF THE UTV ADJUSTING THE SELECT LEVER SHIFT ROD ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable WARNING Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged 1.
Page 131: Checking The Final Gear Oil Level
MAINTENANCE AND ADJUSTMENT OF THE UTV so that it does not rotate and turn the adjusting ○ ○ in direction a or b until the brake ② light comes on at the proper time. ○ Direction Brake light comes on sooner. ○...
Page 132: Checking The Differential Gear Oil
MAINTENANCE AND ADJUSTMENT OF THE UTV Periodic oil change 0.25 L (0.22 Imp qt) Total amount 0.28 L (0.25 Imp qt) WARNING Take care not to allow foreign material to enter the final gear case. ·Install: oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHECKING THE DIFFERENTIAL GEAR OIL 1.
Page 133: Checking The Constant Velocity Joint Dust Boots
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Check the gasket (drain plug). If it is damaged, replace it with new one. 6. Fill: ·differential gear case Periodic oil change 0.32 L (0.28 Imp qt, 0.34 US qt) Total amount 0.33 L (0.29 Imp qt, 0.35 US qt) NOTE: If gear oil is filled to the brim of the oil filler hole,...
Page 134: Checking The Steering System
MAINTENANCE AND ADJUSTMENT OF THE UTV □ Rear CHECKING THE STEERING SYSTEM 1. Check: Place the vehicle on a level surface. steering assembly bearings Try to the steering wheel up and down, and back and forth. Excessive play Replace the steering shaft assembly.
Page 135: Adjusting The Toe-In
MAINTENANCE AND ADJUSTMENT OF THE UTV ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Adjust. Out of specification Toe-in 0 ~ 10 mm (0.00 ~ 0.39 in) (with tires touching the ground) NOTE: Before measuring the toe-in, make sure that the tire pressure is correct.
Page 136: Adjusting The Front Shock Absorbers
MAINTENANCE AND ADJUSTMENT OF THE UTV c. The same number of turns should be given to both the right and left tie-rods until the ② specified toe-in is obtained. This is to keep the length of the rods the same. d.
Page 137: Checking The Tires
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight, operating conditions. 1. Adjust: • spring preload Turn the adjuster to increase ① or decrease the spring preload. CHECKING THE TIRES WARNING •...
Page 138 MAINTENANCE AND ADJUSTMENT OF THE UTV Fast inflation could cause the tire to burst. • MAXIMUM LOADING LIMIT a. Vehicle loading limit (total weight of cargo, operator, passenger and accessories, and tongue weight): 843kg b. Cargo bed: 150kg c. Trailer hitch: Pulling load (total weight of trailer and cargo): 100 kg Tongue weight (vertical weight on trailer...
Page 139: Checking The Wheels
MAINTENANCE AND ADJUSTMENT OF THE UTV WARNING It is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately. CHECKING THE WHEELS 1. Check: • Wheels ① Damage/bends Replace. NOTE: Always balance the wheel when a tire or wheel has been changed or replaced.
Page 140: Electrical
MAINTENANCE AND ADJUSTMENT OF THE UTV ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
Page 141 MAINTENANCE AND ADJUSTMENT OF THE UTV as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. • Therefore, take special care when charging the battery. NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Page 142 MAINTENANCE AND ADJUSTMENT OF THE UTV Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 ~ 30% 2. Charge: • battery(refer to the appropriate charging method illustration) . WARNING Do not quick charge a battery.
Page 143 MAINTENANCE AND ADJUSTMENT OF THE UTV (voltage) charger NOTE: • Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. • Set the charging voltage to 16 ~17 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.) Measure the open-circuit voltage...
Page 144 MAINTENANCE AND ADJUSTMENT OF THE UTV Charging method using a constant voltage charger NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Measure the open-circuit voltage Prior to charging. Connect a charger and ammeter to the battery and start charging.
Page 145: Checking The Fuses
MAINTENANCE AND ADJUSTMENT OF THE UTV NOTE: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads NOTE: First, connect the positive battery lead ①, and then the negative battery lead ②. •...
Page 146: Adjusting The Headlight Beam
MAINTENANCE AND ADJUSTMENT OF THE UTV related electrical devices. d. If the fuse immediately blows again, check the electrical circuit. Current Description Quantity rating Main 30 A Lighting 15 A system fuse Ignition 10 A Terminal 10 A (Auxiliary DC jack) 4WD(Four wheel drive) Signaling...
Page 147: Changing The Headlight Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV CHANGING THE HEADLIGHT BULB Remove: • Lift the hood up. • headlight bulb holder cover ① • headlight bulb holder (with bulb) ① • bulb NOTE: Remove the defective bulb by unhooking the headlight bulb holder tabs ② WARNING Keep flammable products and your hands away from the bulb while it is on, since it will...
Page 148: Changing The Tail/Brake Light Bulb
MAINTENANCE AND ADJUSTMENT OF THE UTV • headlight bulb holder (with bulb) • headlight bulb holder cover • Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel ① • tail/brake light bulb holder (with bulb) ② •...
Page 149: Engine
ENGINE ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air.
Page 150: Engine Removal
ENGINE ENGINE REMOVAL Part Name Remarks Removing carburetor and intake Remove the parts in the order listed. manifold. Carburetor Carburetor joint (intake manifold) Intake manifold Drain plug For installation, reverse the removal procedure. - 135-...
Page 151 ENGINE 1、NOTE • Removing the drain plug NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. 2、INSTALL • Install intake manifold • Install intake manifold bolt • Install carburetor joint • Install carburetor NOTE: When installed, don't make an object from the intake fell into the cabinet.
Page 152: Cylinder Head And Cylinder Head Cover
ENGINE CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head cover Remove the parts in the order listed. and cylinder head Union bolt Copper washer Oil delivery pipe 3 Oil delivery pipe 2 Spark plug Tappet cover (intake) Tappet cover (exhaust) Timing chain tensioner cap bolt Timing chain tensioner / gasket...
Page 153 ENGINE Part Name Remarks Thermo switch 1 For installation, reverse the removal procedure. - 138-...
Page 154 ENGINE 1、CHECK 1). Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2). Checking the cylinder head cover • cylinder head cover Cracks/damage Replace the cylinder head cover and cylinder head as a set. 3).
Page 155 ENGINE 5). Checking the cylinder head (1). Eliminate: • carbon deposits (from combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats (2). Check: • cylinder head Scratches/damage Replace the cylinder head cover and cylinder head as a set.
Page 156 ENGINE 2). Installing the cylinder head • cylinder head gasket • cylinder head • bolts (M9: 1 ~ 6, 38Nm) • bolts (M6: 7, 10Nm) NOTE: • Tighten the bolts in the proper sequence. • Follow the numerical order shown in the illustration.
Page 157: Rocker Arms And Camshaft
ENGINE ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Plug/O-ring Rocker arm shaft stopper Rocker arm shaft 2 Rocker arm 3 Rocker arm shaft3/O-ring Rocker arm 4 Rocker arm shaft1/O-ring Rocker arm 1 Rocker arm 2...
Page 158 ENGINE Part Name Remarks Decompress or cam guide plate Camshaft sprocket Camshaft Cylinder head Cylinder head gasket For installation, reverse the removal procedure. - 143-...
Page 159 ENGINE 1、CHECK 1). Checking the rocker arms • rocker arm lobes ① • valve adjusters ② Blue discoloration/pitting/scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked. b.
Page 160 ENGINE 2). Checking the camshaft • cam lobes Pitting/scratches/blue discoloration Replace • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3).
Page 161 ENGINE 2). Installing the camshaft • camshaft • camshaft sprocket a. Turn the crankshaft counterclockwise with a T-sleeve. b. Align the “I” mark ① on the rotor with the stationary pointer ② on the A.C. magneto cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (TDC).
Page 162 ENGINE 1NOTE: Insert a screwdriver into the timing chain tensioner hole and push the timing chain guide (intake side) inward. f. Remove the retaining wire. - 147-...
Page 163: Valves And Valve Springs
ENGINE VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve cotter Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat For installation, reverse the removal procedure.
Page 164 ENGINE 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
Page 165 ENGINE • valve stem runout Out of specification Replace. Runout limit 0.01 mm 1NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
Page 166 ENGINE 1NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Install the new valve guide using a valve guide remover ① and valve guide installer ②. b.
Page 167 ENGINE 1NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. d. Apply a fine lapping compound to the valve face and repeat the above steps. 1NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
Page 168 ENGINE To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve. - 153-...
Page 169: Cylinder And Piston
ENGINE CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Coolant inlet joint Cylinder/O-ring Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal procedure.
Page 170 ENGINE 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) 1NOTE: Check whether the piston and the piston groove is cracked and abraded.
Page 171 ENGINE • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. 1NOTE: Clean carbon from the piston ring grooves rings before measuring...
Page 172 ENGINE 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) 1NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.
Page 173: Engine Cooling Fan And A.c. Magneto
ENGINE ENGINE COOLING FAN AND A.C. MAGNETO Part Name Remarks Removing the engine cooling fan and Remove the parts in the order listed. A.C. magneto Drive belt cover Engine oil Coolant Water pump assembly Engine cooling fan air duct assembly Air shroud 1 Engine cooling fan Air shroud 2...
Page 174 ENGINE Part Name Remarks Pickup coil Stator assembly A.C. magneto rotor Woodruff key Starter wheel gear Washer Starter idle gear shaft Bearing Starter idle gear For installation, reverse the removal procedure. - 159-...
Page 175 ENGINE 1、CHECK 1). Checking the A.C. magneto • stator coil • pickup coil Damage Replace. 2). Checking the starter clutch • starter clutch ① Cracks/damage Replace. • starter clutch bolts ② Loose Replace with new ones, and clinch the end of the bolts. 1NOTE: •...
Page 176 ENGINE • starter idle gear teeth ① • starter wheel gear teeth ② Burrs/clips/roughness/wear Replace. • starter wheel gear (contacting surface) Damage/pitting/wear Replace. 3). Checking the engine cooling fan • engine cooling fan • air shroud 1 • air shroud 2 Cracks/damage Replace.
Page 177 ENGINE 1NOTE: Before installing the engine cooling fan pulley, do not forget to install the O-ring. • engine cooling fan ① (7Nm) 1NOTE: Install the bolts in the holes in the collar of the engine cooling fan. • air shroud ① (10Nm) •...
Page 178: Balancer Gears And Oil Pump Gears
ENGINE BALANCER GEARS AND OIL PUMP GEARS Part Name Remarks Removing the balancer gears and oil Remove the parts in the order listed. pump gears Nut/lock washer Balancer driven/oil pump drive gear Chain Straight key Oil pump driven gear Plate Balancer drive gear Spring Timing chain guide (intake side)
Page 179 ENGINE 1、CHECK 1) Checking the oil pump drive gear and oil pump driven gear • oil pump drive gear ① • oil pump driven gear ② Replace Cracks/wear/damage 2).Checking the balancer drive gear and balancer driven gear • balancer drive gear ① •...
Page 180 ENGINE • balancer driven gear 1NOTE: Align the punch mark (a) on the balancer drive gear with the punch mark (b) on the balancer driven gear. • lock washer(new replacement) • balancer driven gear nut ①(110Nm) 1NOTE: • Place an aluminum plate ② between the teeth of the balancer drive gear ③...
Page 181: Primary And Secondary Sheaves Primary And Secondary Sheaves
ENGINE PRIMARY AND SECONDARY SHEAVES Primary and secondary sheaves Part Name Remarks Removing the primary and secondary Remove the parts in the order listed. sheaves Engine assembly Drive belt cover Rubber gasket Bearing housing Dowel pin Primary sheave assembly V-belt Primary fixed sheave Secondary sheave assembly Drive belt case...
Page 182: Primary Sheave
ENGINE Primary sheave Part Name Remarks Disassembling the primary sheave Remove the parts in the order listed. Primary pulley sheave cap ① Primary pulley slider ② Spacer ③ Primary pulley cam ④ ⑤ Primary pulley weight Collar ⑥ Oil seal ⑦...
Page 183: Secondary Sheave
ENGINE Secondary sheave Part Name Remarks Disassembling the secondary Sheave Remove the parts in the order listed. ① Spring seat ② Compression spring ③ Spring seat ④ Guide pin ⑤ Secondary sliding sheave ⑥ O-ring ⑦ Secondary fixed sheave ⑧ Oil seal ⑨...
Page 184 ENGINE 1、Check 1). Checking the primary sheave • weight outside diameter (a) Out of specification Replace the weight. Weight outside diameter limit: 29.5 mm • primary pulley slider • primary sliding sheave splines Wear/cracks/damage Replace. • spacer • primary pulley cam Cracks/damage Replace.
Page 185 ENGINE 2、Measure • secondary sheave spring free length (a) Out of specification Replace the secondary sheave spring. 3、INSTALL 1). Assembling the primary sheave (1)Clean: • primary sliding sheave face ① • primary fixed sheave face ② • collar ③ • weights ④ •...
Page 186 ENGINE 2). Assembling the secondary sheave (1)Apply: • assembly lube (to the secondary sliding sheave ① inner surface and oil seals)。 • assembly lube (to the bearings, oil seals and inner surface of the secondary fixed sheave ②) (2)Install: • guide pins ① •...
Page 187 ENGINE 1NOTE: • Tightening the bolts ① will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen. • Install the V-belt so that its arrow faces the direction show in the illustration. (2)Tighten: •...
Page 188: Clutch
ENGINE CLUTCH Part Name Remarks Removing the clutch Remove the parts in the order listed. Primary and secondary sheaves Clutch housing assembly Gasket/dowel pin One-way clutch bearing Clutch carrier assembly For installation, reverse the removal procedure. - 173-...
Page 189 ENGINE Part Name Remarks Disassembling the clutch housing Remove the parts in the order listed. ① Oil seal ② Circlip ③ Bearing housing ④ Circlip ⑤ Bearing ⑥ Circlip ⑦ Bearing ⑧ Clutch housing For assembly, reverse the disassembly procedure. - 174-...
Page 190 ENGINE 1、CHECK 1). Checking the clutch • clutch housing ① Heat damage/wear/damage Replace. • one-way clutch bearing ② Chafing/wear/damage Replace. 1NOTE: • Replace the one-way clutch assembly and clutch housing as a set. • The one-way clutch bearing must be installed with the flange side facing in.
Page 191 ENGINE 3、INSTALL • clutch carrier assembly • nut ① 160Nm) 1NOTE: Use a universal clutch holder to hold the ② clutch carrier assembly. • Lock the threads with a drift punch. • one-way clutch bearing 1NOTE: The one-way clutch bearing should be installed in the clutch carrier assembly with the arrow mark (a) facing toward the clutch housing.
Page 192: Starter Motorand Oil Filter
ENGINE CRANKCASE Starter motorand oil filter Part Name Remarks Remove the starter motor, timing Remove the parts in the order listed. chain and oil filter A.C. magneto rotor Primary and secondary sheaves Clutch carrier assembly Starter motor/O-ring Oil filter cartridge/O-ring Oil pipe assembly/O-ring Oil pipe adapter/O-ring Relief valve assembly...
Page 193 ENGINE Part Name Remarks Reverse switch Oil filler cap Oil delivery pipe 1 For installation, reverse the removal procedure. - 178-...
Page 194: Crankcase
ENGINE Crankcase Part Name Remarks Separating the crankcase Remove the parts in the order listed. Shift lever cover/gasket Dowel pin Shift lever 1 Shift lever 2 assembly Right crankcase Dowel pin Left crankcase Spacer Crankshaft seal For installation, reverse the removal procedure.
Page 195: Crankcase Bearings
ENGINE Crankcase bearings Part Name Remarks Removing the crankcase bearings Remove the parts in the order listed. Crankshaft and oil pump Transmission Middle drive/driven shaft O-ring/collar Oil seal Bearing retainer Bearing For installation, reverse the removal procedure. - 180-...
Page 196 ENGINE 1、CHECK 1). Checking the oil delivery pipe • oil delivery pipe Cracks/damage Replace. Clogged Blow out with compressed air. 2). Checking the relief valve • relief valve ① • spring ② Damage/wear Replace the defective part(s). 3). Checking the crankcase (1) Thoroughly wash the case halves in a mild solvent.
Page 197 ENGINE 2、INSTALL 1). Assembling the crankcase (1) Apply: • sealant (Quick Gasket) ① (to the mating surfaces of both case halves) (2) Install: • dowel pins ② (3) Fit the left crankcase onto the right case. Tap lightly on the case with a soft hammer CAUTION: Before installing and torque the crankcase holding bolts, be sure to check whether the...
Page 198 ENGINE 2). Installing the shift levers • shift lever 2 assembly ① (14Nm) • shift lever 1 ② 1NOTE: When installing the shift lever 1, align the punch mark (a) on the shift lever 1 with the punch marks (b) on the shift lever 2. - 183-...
Page 199: Crankshaft And Oil Pump Crankshaft And Oil Pump
ENGINE CRANKSHAFT AND OIL PUMP Crankshaft and oil pump Part Name Remarks Removing the crankshaft and oil pump Remove the parts in the order listed. Crankcase separation Oil strainer/O-ring Oil pump assembly/gasket Balancer Plate Relief valve assembly Crankshaft For installation, reverse the removal procedure.
Page 200: Oil Pump
ENGINE Oil pump Part Name Remarks Disassembling the oil pump Remove the parts in the order listed. Rotor cover ① ② ③ Shaft ④ Inner rotor ⑤ Outer rotor ⑥ Oil pump housing ⑦ For assembly, reverse the disassembly procedure. - 185-...
Page 201 ENGINE 1、CHECK 1). Checking the oil pump • rotor housing • rotor cover Cracks/wear/damage Replace. • oil pump operation Unsmooth Repeat steps #1 and #2 or replace the defective parts. 2). Checking the oil strainer • oil strainer ① • O-ring ② Damage Replace.
Page 202 ENGINE Big end side clearance Limit: 1.0 mm (0.0394 in) • runout (b)(C) Out of specification Replace the crankshaft. Runout limit (b): 0.03 mm (C): 0.03 mm The crankshaft ① and the crank pin ② oil passages must be properly interconnected with a tolerance of less than 1 mm (0.04 in).
Page 203: Transmission Transmission
ENGINE TRANSMISSION Transmission Part Name Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Middle driven gear Low wheel gear Shift drum Shift fork assembly Short spring Shift fork 1 Long spring Shift fork 2 Guide bar Secondary shaft Drive axle assembly Chain...
Page 204: Drive Axle Assembly
ENGINE Drive axle assembly Part Name Remarks Disassembling the drive axle Remove the parts in the order listed. Clutch dog ① High wheel gear ② ③ Middle drive gear Driven sprocket ④ Drive axle ⑤ For assembly, reverse the disassembly procedure.
Page 205 ENGINE 1、CHECK 1). Checking the shift forks • shift fork follower ① • shift fork pawl ② Scoring/bends/wear/damage Replace. • guide bar Roll the guide bar on a flat surface. Bends Replace. ： WARNING Do not attempt to straighten a bent guide bar. •...
Page 206 ENGINE 3). Checking the high wheel gear and middle drive gear • gear teeth Blue discoloration/pitting/wear Replace. • mated dogs Rounded edges/cracks/missing portions Replace. • gear movement Unsmooth Repeat steps #1 or replace the defective parts. • circlip Bends/looseness/damage Replace. 4).
Page 207 ENGINE 3、INSTALL 1). Assembling the shift fork • guide bar ① • shift fork 2 ② • long spring ③ • shift fork 1 ④ • short spring ⑤ 2). Installing the transmission • chain ① • drive axle assembly ② •...
Page 208: Middle Gear Middle Drive Shaft
ENGINE MIDDLE GEAR Middle drive shaft Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Bearing housing Middle drive gear Middle drive pinion gear Shim Middle drive shaft Bearing retainer For assembly, reverse the disassembly procedure.
Page 209: Middle Driven Shaft
ENGINE Middle driven shaft Part Name Remarks Removing the middle drive shaft Remove the parts in the order listed. Crankcase separation Drive shaft coupling Circlip Bearing Universal joint Universal joint yoke Bearing housing/O-ring Shim Middle driven pinion gear Bearing retainer Bearing retainer - 194-...
Page 210 ENGINE Part Name Remarks Middle driven shaft For installation, reverse the removal procedure. - 195-...
Page 211 ENGINE 1、CHECK 1). Checking the pinion gears • gear teeth (drive pinion gear) ① • gear teeth (driven pinion gear) ② Pitting/galling/wear Replace. • O-ring Damage Replace. • bearings Pitting/damage Replace. • universal joint movement Roughness Replace universal joint. 2). Selecting the middle drive and driven gear shims When the drive and driven gear, bearing housing assembly and/or crankcase replaced,...
Page 212 ENGINE 3、INSTALL 1). Installing the middle driven shaft • bearing retainer ① Bearing retainer 80 Nm 1NOTE: Attach the ring nut wrench ② CAUTION: The middle driven shaft bearing retainer has left-handed threads. To tighten the retainer, turn it counterclockwise. •...
Page 213 ENGINE • universal joint yoke • washer • nut ① 1NOTE: Use the universal joint holder ② to hold the yoke. Universal joint yoke nut 150 Nm • universal joint. a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c.
Page 214 ENGINE • drive shaft coupling • washer • nut ①(97Nm) 1NOTE: Use the coupling gear/middle shaft tool ② to hold the drive shaft coupling. 2). Installing the middle drive shaft (1) Tighten: • middle drive pinion gear nut ① (145Nm) 1NOTE: Secure the middle drive shaft in the vise with a clean rag.
Page 215: Carburetor
ENGINE CARBURETOR Part Name Remarks Removing the carburetor Remove the parts in the order listed. Carburetor assembly Screw on upper cover Plunger spring Oil needle component Big diaphragm Plunger Diaphragm circlip Coasting enricher diaphragm Pilot air jet Drain screw Float chamber Float Needle valve set - 200-...
Page 216 ENGINE Part Name Remarks Main jet Needle jet Pilot jet Starter jet Carburetor heater Throttle stop screw For assembly, reverse the disassembly procedure. - 201-...
Page 217 ENGINE 1、CHECK 1). Checking the carburetor • carburetor body • float chamber Cracks/damage Replace • float ① • float tang ② Damage Replace. • needle valve seat ① • needle valve ② • O-ring ③ Contamination/wear/damage Replace as a set. 1NOTE: Always replace the needle valve and valve seat as a set.
Page 218 ENGINE • diaphragm (coasting enricher ) ① • spring ② • cover ③ Tears (diaphragm) /damage Replace. • jet needle ① • main jet ② • needle jet ③ • pilot air jet ④ • pilot jet ⑤ • starter jet ⑥ •...
Page 219 ENGINE c. If the float height is not within the specification, check the valve seat and needle valve. d. If either is worn, replace them both. e. If both are fine, adjust the float height by bending the float tang ① on the float. f.
Page 220: Malfunction Inspection
CHASSIS MALFUNCTION INSPECTION Appearance malfunction inspection Phenomenon Measure 1. Replace new plastic cover 2. Check whether installation supporter deformed, repairing Plastic cover damaged or re-painting is needed before replacing new plastic cover. 3. Re-paste decals and re-rivet warning labels 1. Replace new bumper. 2.
Page 221 CHASSIS Other system malfunction inspection Phenomenon Measure 1. Check whether steering wheel clip loosen or damaged. 2. Check whether steering column clip and clip seat loosen Steering wheel loosen, shift up or damaged. and down 3. Check whether steering column bottom end bearing damaged.
Page 222 CHASSIS Other system malfunction inspection Phenomenon Measure Front and rear axles arise 5. Check whether axle universal joint rubber boot damaged abnormal sound during drive or universal joint damaged 1. Check whether four wheel drive switch normal. 2. Check whether power divider damaged. Fail to shift into four-wheel-drive or lock differential.
Page 223: Direction System The Structure Of The Steering
CHASSIS DIRECTION SYSTEM THE STRUCTURE OF THE STEERING Part Name Remarks Removing the structure of the steering Steering machine parts Drive gear wheel Circlip Bearing Adjuster spring Pressure pad Circlip Oil seal Plastic locking tie L=200 Dust boots Flange bolt M10x30 M10×30 - 208-...
Page 224 CHASSIS Part Name Remarks Tie-rod end Tie-rod end locknut M10 Steering joint Flange bolt M8×20 Notch nut M12 Pin 3.2×32 Plastic locking tie - 209-...
Page 225: The Structure Of Steering Wheel Part
CHASSIS THE STRUCTURE OF STEERING WHEEL PART Part Name Remarks Removing steering wheel part Flange bolt M8x16 Steering shaft Steering wheel Washer Φ12.5 Flange nut M12x1.25 Wheel center cover - 210-...
Page 226: Diassembling The Parts Of The Steering Wheel
CHASSIS THE STRUCTURE OF STEERING WHEEL PART DIASSEMBLING THE PARTS OF THE STEERING WHEEL Remove: ·plastic center lid ① ·flange nut, washer ② ·steering wheel ③ a. Takes down the plastic center lid ① b. Takes down the steering wheel flange nut, the washer Attached figure ②...
Page 227: Diassembling The Steering Column Parts
CHASSIS • Flange nut ④ Inspect fastens nut of the steering wheel whether does have flaw and fissure , if it is, must replace. Check the internal spline between the steering wheel and steering column whether have damaged, if the attrition is serious, must replace the steering wheel.
Page 228: Checking And Service The Steering Column Parts
CHASSIS CHECKING AND SERVICE THE STEERING COLUMN PARTS 1. Check: • steering column tube ① • bearing ② • central axis of the steering shaft ③ • spline ④ • loosening ⑤ • rocky ledge ⑥ The central axis of the steering shaft whether flexible and moves.
Page 229: Checking And Service The Steering Drive Axle
CHASSIS STEERING DRIVE AXLE CHECKING AND SERVICE THE STEERING DRIVE AXLE • bearing ① • circlip ② • oil seal ③ • cross axis ④ • Inspect the cross gimbal turn agility with no stagnation. If does, dismantle and check the cross axis, bearing ,and the bearing hole on the cross gimbal fork whether have wear and corrosion, to instead the parts based on the check.
Page 230: Diassembling The Steering Machine Part
CHASSIS STEERING MACHINE PARTS DIASSEMBLING THE STEERING MACHINE PART 1. Loose the four piece of nut, dismantle the direction machine from the frame. 2. Loose the open-groove nut on the L/R turning steering knuckle, take down the steering tension rod from the steering knuckle. THE STRUCTURE OF THE STEERING 1.
Page 231: Reinstalls The Steering System Parts
CHASSIS 4. Check: • tie-rods Bends/damage Replace. 5. Check: ·steering joint Crack/distortion Replace. 6. Check: ·drive gear ·spline gear the drive of the gear whether agile. If it is not agile, dismantle the direction machine to see the drive gear and spline gear whether have wear,...
Page 232 CHASSIS pieces of locknut to connect the direction machine ball and the rod. Bolt M10×30 48 Nm (4.8m · kg,35 ft · lb) 40 Nm (4.0m · kg,29 ft · lb) 2. Connecting the steering transmission shaft and direction machine with one piece of flange bolt M8×20.
Page 233: Brake System
CHASSIS BRAKE SYSTEM PREPARATION FOR CHECKING BEFORE THE MAINTENANCE OF THE BRAKE SYSTEM Brake system is crucial to the life safety of the operator and therefore must be periodically in- spected and maintained. This vehicle uses the double return route hydraulic pressure disc brake system.
Page 234: Front Disk Brake Components
CHASSIS FRONT DISK BRAKE COMPONENTS Part Name Remarks Removingfront disk brake components Belt 3（L=150） Belt4（L=200） Belt 6（L=150） Bolt M6×30 Bolt M6×20 Disc brake pipe clip Flange bolt M6×20 Wire clip fixed plate Disk brake assembly - 219-...
Page 235: Front Brake Discs
CHASSIS FRONT BRAKE DISCS Remarks Part Name Removing the brake discs Brake caliper assembly Brake disc Bolt Turn join Bolt Brake disc guard - 220-...
Page 236: Checking The Front Brake Disc
CHASSIS CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Check the wheel runout. If wheel runout is within the limits, replace the brake disc. Brake disc maximum deflection 0.10 mm (0.004 in) •...
Page 237: Front Brake Pads
CHASSIS FRONT BRAKE PADS Part Name Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper mounting bolt Brake pad holding bolt Brake pad For installation, reverse the removal Pad spring procedure. - 222-...
Page 238: Replacing The Front Brake Pads
CHASSIS REPLACING THE FRONT BRAKE PADS 1NOTE: It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads. 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2.
Page 239: Front Brake Caliper
CHASSIS FRONT BRAKE CALIPER Part Name Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Union bolt Copper washer Brake hose Brake pad holding bolt Brake caliper mounting bolt Brake caliper assembly For installation, reverse the removal procedure.
Page 240 CHASSIS Part Name Remarks Disassembling the front brake caliper Remove the parts in the order listed. Brake pad holding bolt Brake pad Pad spring Brake caliper piston Dust seal Caliper piston seal Bleed screw For assembly, reverse the disassembly procedure. - 225-...
Page 241: Disassembling The Front Brake Calipers
CHASSIS DISASSEMBLING THE FRONT BRAKE CALIPERS 1. Remove: • brake caliper pistons • dust seals ① • caliper piston seals ② a. Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body. WARNING ：...
Page 242: Assembling The Front Brake Calipers
CHASSIS ASSEMBLING THE FRONT BRAKE CALIPERS WARNING ： • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Must use DOT4 Brake Fluid • Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled. 1.
Page 243 CHASSIS 1NOTE: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake caliper. WARNING ： Proper brake hose routing is essential to insure safe vehicle operation. 2. Fill: •...
Page 244: Rear Brake Disc
CHASSIS REAR BRAKE DISC Part Name Remarks Removing the rear brake disc Remove the parts in the order listed. Brake caliper assembly Final drive gear Rear brake disc For installation, reverse the removal procedure. - 229-...
Page 245: Checking The Rear Brake Disc
CHASSIS CHECKING THE REAR BRAKE DISC 1. Check: • brake disc Galling/damage Replace. 2. Measure: • brake disc deflection Out of specification Replace. Brake disc maximum deflection 0.10 mm (0.004 in) • brake disc thickness ○ Out of specification Replace. Brake disc minimum thickness 4.5 mm (0.18 in) - 230-...
Page 246: Rear Brake Caliper And Brake Pads
CHASSIS REAR BRAKE CALIPER AND BRAKE PADS Part Name Remarks Removing the rear brake caliper and brake pads Rear skid plate Brake fluid Parking brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting Bolt Parking brake lever assembly Union bolt Copper washer Brake hose...
Page 247 CHASSIS Part Name Remarks Brake caliper assembly Brake pad (piston side) Brake pad Insulator/pad shim Pad spring Brake caliper bracket Parking brake arm nut Parking brake arm Set bolt Parking brake arm shaft Parking brake case bolt Parking brake case Gasket Brake caliper piston - 232-...
Page 248 CHASSIS Part Name Remarks Dust seal Caliper piston seal Bleed screw - 233-...
Page 249: Replacing The Rear Brake Pads
CHASSIS REPLACING THE REAR BRAKE PADS 1. Measure: • brake pad wear limit ○ Out of specification Replace the brake pads as a set. Brake pad wear limit 1.5 mm (0.06 in) 2. Install: • brake pads • brake pad spring 1NOTE: Always install new brake pads, new brake pad shims, new insulators, and a new brake...
Page 250: Assembling The Rear Brake Caliper
CHASSIS • brake caliper cylinders ② Wear/scratches Replace the brake Caliper assembly. • brake caliper body ③ Cracks/damage Replace. • brake fluid delivery passage (brake caliper body) Blockage Blow out with compressed air. 1WARNING ： Replace the caliper piston seals and dust seals whenever the brake caliper is disassembled.
Page 251 CHASSIS 3. Install: • gasket ① • parking brake case ② • parking brake case bolts ③ 22Nm (2.2 m · kg,16 ft · lb) • O-ring ④ 4. Install: • parking brake arm shaft ① • parking brake arm ② •...
Page 252: Installing The Rear Brake Caliper
CHASSIS 5. Install: • brake pad (piston side) ① (with insulator and pad shim) 1NOTE: Align the projection a on the piston side of the brake pad with the groove in the brake caliper piston. 6. Install: • brake pad holding bolts 17Nm (1.7 m ·...
Page 253 CHASSIS Brake fluid level is below the “MIN” level line Add the recommended brake fluid to the proper level. 5. Adjust: • parking brake cable free play - 238-...
Page 254: Brake Master Cylinder
CHASSIS BRAKE MASTER CYLINDER Part Name Remarks Removing the brake master cylinder Remove the parts in the order listed. Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Brake fluid reservoir float Union bolt Copper washer Brake hose Disconnect.
Page 255: Checking The Master Cylinder
CHASSIS CHECKING THE MASTER CYLINDER 1. Check: • brake master cylinder ① Wear/scratches Replace the brake master cylinder assembly. • brake master cylinder body Cracks/damage Replace. • brake fluid delivery passage (brake master cylinder body) Blockage Blow out with compressed air. 2.
Page 256 CHASSIS • union bolt 27Nm (2.7 m · kg,19 ft · lb) 3. Fill: • brake fluid reservoir Must use DOT4 Brake Fluid 1NOTE: Brake fluid may damage painted surfaces or plastic parts. Always clean up spilled brake fluid immediately. 4.
Page 257: Footrest Assembly
CHASSIS FOOTREST ASSEMBLY Part Name Remarks Left footrest Screw M6×16 Footrest cover Sheathing paper Screw M6×20 Nut, spring M6 Right footrest Rubber Screw Rear brake bump, holder Flange bolt M8×12 Speedup footrest Washer Φ22×Φ15×2 Cotter clip - 242-...
Page 258 CHASSIS Part Name Remarks Spring Rear brake pedal Washer Φ22×Φ15×2 Cotter clip Spring Throttle cable Belt 7（L=200） Belt 4（L=150） Belt 3（L=200） Rubber of dust-proof Brake assembly Brake piece Handle, brake piece Screw Flange bolt M6×20 - 243-...
Page 259 CHASSIS Part Name Remarks Cable Clip 1 （L=150） Nut，choke cable Belt7 （L=200） Cable clip Flange bolt M6×10 Choke cable - 244-...
Page 260: Wheel And Tyre Parts
CHASSIS WHEEL AND TYRE PARTS FRONT WHEELS Remarks Part Name Removing the front wheel Front wheel rim Front wheel Valve cap Center cap 1WARNING ： Axle nut Securely support the vehicle so There is no danger of it falling over. Front wheel hub - 245-...
Page 261: Rear Wheels
CHASSIS REAR WHEELS Part Name Remarks Removing the rear wheel 1WARNING ： Securely support the vehicle so There is no danger of it falling over. Rear wheel Center cap Axle nut For installation, reverse the removal Rear wheel hub procedure. - 246-...
Page 262: Checking The Wheel Tyre
CHASSIS CHECKING THE WHEEL TYRE 1. Check: • wheel tyre 2. Measure: • wheel runout Over the specified limit Replace the wheel or check the wheel bearing play ① 3. Check: • wheel balance Out of balance Adjust. Wheel runout limit Radial ②: 2.0 mm (0.08 in) Lateral ③: 2.0 mm (0.08 in) 1WARNING...
Page 263: Installing The Wheel Tyre
CHASSIS INSTALLING THE WHEEL TYRE 1. Install: • wheel 1NOTE: The arrow mark ① on the tyre must point in the direction of rotation □ of the wheel. 2. Tighten: • wheel nuts ① The angle of the conical bores is 60° 1WARNING ：...
Page 264: Transmission System
CHASSIS TRANSMISSION SYSTEM Front Bridge Part Name Remarks Circlip Double off-set joint assembly Circlip Circlip Boot band Dust boot Boot band Joint shaft Half axle assembly - 249-...
Page 265 CHASSIS Part Name Remarks Removing the front bridge Transmission shaft part, front bridge Differential gear case Differential gear case cover Drive pinion gear Universal joint yoke Nut M14×1.25 O- ring Φ14×d=Φ7 Oil seal,Φ48×Φ65×9 Oil seal, front box input shaft Shim（0.1T） Shim（0.2T）...
Page 266 CHASSIS Part Name Remarks Bolt M8×25 Differential gear assembly Bolt M8×25 Bolt M8×10 Oil change bolt M10×16 Circlip Column pin Φ5×80 Gear motor Coulping shaft device Rack O- ring, divide moved=Φ2×Φ81 O- ring, front box cover d=Φ2.4×Φ140 Bearing 6007 RΦ35×Φ62×14 Bearing 6912Φ60×Φ85×13 - 251-...
Page 267 CHASSIS Part Name Remarks Bearing 16007 Φ35×Φ62×9 Bearing HK152112Φ15×Φ21×12 Bolt M14×15×10 Washer Φ14×2 Nut M10 Washer Φ10 Shaft fork 4 Universal joint Bolt M14X15 Block ring Hose Φ4.5×L=710 Clip pipe 1 Clamp Intermediate shaft - 252-...
Page 268 CHASSIS Part Name Remarks Circlip Cushion piece Spring D=Φ25×Φ2.3×28 Dustproof rubber Dustproof rubber Bolt M10×25 Washer Screw - 253-...
Page 269: Disassembling The Front Bridge
CHASSIS DISASSEMBLING THE FRONT BRIDGE 1. Take down the left and right front wheel parts. 2. Sequently remove the front disk brake clip, cotter pin, open-groove nut, cushion and front wheel hub. 3. Disassembly the left and right arm rocker and cross steering knuckle.
Page 270: Checking The Joints
CHASSIS CHECKING THE JOINTS 1.Check • Dust boots Cracks/damage Replace 2.Check • double off-set joint spline • ball joint spline • shaft spline Wear/damage Replace. • balls and ball races • inner surface of double off-set joint Pitting/wear/damage Replace. • Check whether the inner and outer ball cage of the left and right transmission shaft movement is Smooth, ceaseless.
Page 271: Checking The Gear Motor
CHASSIS • oil seals • O-rings Damage Replace. 2.Check: • drive shaft splines • universal joints • drive pinion gear splines Wear/damage Replace. • spring Fatigue Replace. Move the spring up and down. 3.Check: • front drive shaft Bends Replace. •...
Page 272: Assembling The Universal Joint
CHASSIS ASSEMBLING THE UNIVERSAL JOINT Install: • universal joint a. Install the opposite yoke into the universal joint. b. Apply wheel bearing grease to the bearings. c. Install the bearing ① onto the yoke. d. Press each bearing into the universal joint using a suitable socket.
Page 273: Assembling The Differential Gear
CHASSIS ASSEMBLING THE DIFFERENTIAL GEAR 1. Measure: • gear lash 2. Install : • gear motor a. Installed to the differential gear, to the right to put it into the 2WD mode. b. Connect two C size batteries to the gear motor terminal ①...
Page 274: Installing The Front Bridge Parts
CHASSIS INSTALLING THE FRONT BRIDGE PARTS 1. Put the left and right transmission shaft in the front bridge differential device. 2. Pour 0.32L SAE 80 API GL-4 the high quality gear grease into the front bridge differential device and screws tight the oil filler bolt.
Page 275: Rear Bridge
CHASSIS Rear Bridge Part Name Remarks Circlip Boot band Boot band Dust boot Circlip Double off-set joint assembly Circlip Circlip Double off-set joint assembly Joint shaft Half axle assembly - 260-...
Page 276 CHASSIS Part Name Remarks Speed reducer assembly Final gear case Bearing assembly Bearing HK556720Φ55×Φ67×20 Final drive pinion gear Bearing 6305Φ25×Φ62×17 Drive shaft coupling Oil seal Φ61×Φ35×9 Bearing 55BM6720Φ55×Φ67×20 O-ring Φ3.1×Φ63.8 Flat gasket Φ12×4×Φ30 Flange nut M12×1.25 Final drive pinion gear bearing housing rear adjustment gasket Ⅰ（0.1T）...
Page 277 CHASSIS Part Name Remarks rear adjustment gasketⅠ（0.2T） rear adjustment gasketⅠ（0.5T） Bolt M8×35 Washer Φ8.5 rear adjustment gasketⅡ （1.7T） rear adjustment gasketⅡ （1.8T） rear adjustment gasketⅡ （1.9T） rear adjustment gasketⅡ （2.0T） rear adjustment gasketⅡ （2.1T） Speed sensor assembly O-ring d=Φ2.3×Φ19.4 Vent rear speed-reducer Ring gear bearing housing Ring gear stopper M8 - 262-...
Page 278 CHASSIS Part Name Remarks Washer Φ8.5 Flange nut M8 Oil seal Φ65×Φ90×9 Bearing 16017Φ85×Φ130×14 O-ring d=Φ3.1×Φ150 Washer（0.1T） Washer（0.2T） Bolt M8×25 Washer Φ8.5 Bolt M10×1.25×25 Bolt M8x20 Washer Φ8.5 Spring Φ16.5×d=Φ2×30 Middle driving axes, rear bridge - 263-...
Page 279 CHASSIS Part Name Remarks Circlip d=20.5×δ=1 Connection cover, rear bridge middle driving axes Circlip d=17.5×δ=1 Self-lock flange nut Front dustproof cover 2,rear bridgeΦ23.5×Φ46×35 Rear dustproof cover 1,rear bridge Φ19×Φ40.7×30 Oil hose Φ4.5×1320 Oil hose clip Φ7.2×d=1 Washer Clip Clip Driven gear Boot band Flange bolt M10×1.25×125 - 264-...
Page 280 CHASSIS （ The service method of the rear bridge parts is as the same as the front bridge parts, please refer to the before-mentioned to operate.） 1NOTE: Apply lithium-soap-based grease to the bearing assembly and o-ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing.
Page 281: Reverse Mechanism Parts
CHASSIS REVERSE MECHANISM PARTS Part Name Remarks Gear assembled Lever sheath of gearshift Gearshift, dust-proof rubber Gearshift assembly Rod of gearshift Ball assembly, gearshift Pulling ball assembly, gearshift Washer Φ6 Bolt M8×12 Bolt M8×16 Plastic bolt Clip clamp Make water-pipe clip - 266-...
Page 282 CHASSIS Part Name Remarks Make water-pipe cap Nut M6 Nut M6(L) - 267-...
Page 283: Adjusting Reverse Mechanism Parts
CHASSIS ADJUSTING REVERSE MECHANISM PARTS ① Neutral ② High ③ Low ④ Reverse ⑤ Select lever shift rod ⑥ Shift control cable 1NOTE: Before shifting, you must stop the vehicle and take your foot off the accelerator pedal. Otherwise, the transmission may be damaged. 1.
Page 284 CHASSIS try again., if still not good to inform the special serviceman to service the reverse mechanism. 2. If the reverse mechanism appears lacks files, adjust the connecting nut on the striking fork to have contraposition then fasten the reverse mechanism again.
Page 285: Suspension
CHASSIS SUSPENSION Front Suspension and arm Part Name Remarks Upper left rocker assembly Front upper gimbal Elasticity block ring Upper right rocker assembly Front upper gimbal Block ring, shaft Front lower left rocker assembly Front lower right rocker assembly Middle bushing Flange bolt M10×70 - 270-...
Page 286 CHASSIS Part Name Remarks Locknut M10 x1.25 Washer Locknut M10x1.25 Pin 3.2x32 Front shocker absorber (left & right) Locknut M10x1.25 Flange bolt M10×1.25×52 Rocker baffle Flange nut M6 Flange bolt M6x12 Front upper gimbal - 271-...
Page 287: Disassembling, Service And Assembly The Supporting Rocker Parts
CHASSIS DISASSEMBLING, SERVICE AND ASSEMBLY THE SUPPORTING ROCKER PARTS 1. Disassembling and Service In the suspension, there is easy to appear the problem with bushing, cotter pin and shock absorber. • If the left and right rocker rocks fiercely, check the few aspect, whether the bushing of the rocker is crushed, the middle rubber separate is aging and chapped.
Page 288: Checking The Front Arms
CHASSIS To check whether put on the butter before fix, then fix the upper and lower rockers and L/R front shock absorber, etc . CHECKING THE FRONT ARMS 1. Check: • front arms Bends/damage Replace. 2. Check: • Middle bushing Wear/damage Replace.
Page 289: Installing The Front Arms And Front Shock Absorber
CHASSIS I NSTALLING THE FRONT ARMS AND FRONT SHOCK ABSORBER 1. Install: • front arms • front shock absorber a. Install the front upper arm ① and front lower arm ②. 1NOTE: • Lubricate the bolts ③with lithium-soap-based grease. • Be sure to position the bolts ③ so that the bolt head faces outward.
Page 290: Rear Suspension
CHASSIS Rear Suspension Part Name Remarks Rear shocker absorber (L.&R.) Flange bolt M12×1.25×70 Flange bolt M12×1.25×65 Nut M12x1.25 Stabilizer Left balling rod, balancing pole Right balling rod, balancing pole Locknut M8 Cushion rubber cover, rear balancing pole Board, balancing pole Flange bolt M8x16 cushion plate - 275-...
Page 291: Rear Arm Shaft
CHASSIS Rear arm shaft Part Name Remarks Rear upper swing arm assembly Rear lower right swing arm assembly Rear lower left swing arm assembly Tube, rear rocker Flange bolt M10×1.25×70 Locknut M10x1.25 Rear upper swing arm Gasket buffer cover rocker arm Rear lower right arm sheeting Rear lower left arm sheeting - 276-...
Page 292: Checking And Service Of Rear Suspension
CHASSIS Rear Suspension and arm CHECKING AND SERVICE OF REAR SUSPENSION 1. It is similar to the front suspension ,Check if there exists any distortion or crack on the install axis of the shock absorber in which case it must be replaced. 2.
Page 293: Installing The Rear Arms And Rear Shock Absorber
CHASSIS 1. Check: • shock absorber rod Bends/damage Replace the shock absorber assembly. • shock absorber assembly Oil leaks Replace the shock absorber assembly. • spring Move the spring up and down. Fatigue Replace the shock absorber assembly. INSTALLING THE REAR ARMS AND REAR SHOCK ABSORBER 1.
Page 294: Cooling System
CHASSIS COOLING SYSTEM RADIATOR Part Name Remarks Former left rubber hose Left metal hose After left rubber hose Right rubber hose Right metal hose Former right rubber hose Bolt clip Clip Bolt M6 Cooler, water-tank Radiator fan assembly Phillip screw M6×25 - 279-...
Page 295 CHASSIS Part Name Remarks Plain cushion Φ6 Nut clip M5 Water tank cap Oil cooler on the mounting bracket Oil cooler under mounting bracket radiator radiator cover Oil cooler Bolt M6×20 Plain cushion Φ6 Bolt M6×20 Plain cushion Φ6 Bush Water tank, rubber cushion - 280-...
Page 296 CHASSIS Part Name Remarks Standby water bottle Oil cooler shield Hose Clip Φ8 Overflow hose Φ7×Φ12 Clip Φ11 - 281-...
Page 297: Checking The Radiator
CHASSIS CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator Damage Repair or replace. 1NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • all rubber hose Cracks/damage Replace.
Page 298: Checking The Oil Cooler
CHASSIS the refrigerating fluid until the water level stop to change, then screw the exhaust nut, cover the water tank lid. The water tank inspection is finished. . 2. Check: • cooling system Leaks Repair or replace any faulty part. Recommended antifreeze: High quality ethylene glycol antifreeze containing...
Page 299: Water Pump
CHASSIS WATER PUMP 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Water pump assembly Bolt M6×45 Bolt M6×65 Bolt M6×10 Water pipe Ⅱ O-ring 20.7×2.6 Water pipe Ⅲ Water pipe clip Cylinder inlet water joint Bolt M6×20 O-ring 33.4×2.4...
Page 300 CHASSIS 10Nm (1.0m · kg,7.2 ft · lb) 12Nm (1.2m · kg,8.7 ft · lb) Part Name Remarks Pipe clip Ⅱ Save temperature Save temperature cover Bolt M6×20 Water pump housing cover Gasket Circlip Impeller assembly Water pump seal Oil seal Bearing Water pump housing O-ring...
Page 301: Disassembling The Water Pump
CHASSIS DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder ① • rubber damper ② 1NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal ① • Water pump housing② 1NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 302: Assembling The Water Pump
CHASSIS 2. Check: • water pump seal ① • oil seal ② • water pipe ③ Cracks/damage/wear Replace. • bearing ④ Rough movement Replace. 1NOTE: Apply lithium-soap-based grease to the oil seal and Apply engine oil to the bearing 3. Measure: •...
Page 303 CHASSIS 3. Install: • rubber damper ① • rubber damper holder ② 1NOTE: • Before installing the rubber damper, apply tap water or coolant onto its outer surface. • Make sure that the rubber damper and rubber damper holder are flush with the impeller.
Page 304: Seat
CHASSIS SEAT Part Name Remarks One-seat assembly Plate cushion Setting board , seat Flange bolt M8×30 Flange locknut M8×1.25 Flange bolt M8×30 Lock hook parts, seat Bolt M6×38 Nut M6 Locker, seat Air control switch seat Bushing, battery Bushing Φ10.5 Side armrest - 289-...
Page 305 CHASSIS Part Name Remarks Flange bolt M6×25 Pillow part Bolt M8×30 Nut M10×1.25 Bolt M10×25-Φ14×5 Flange locknut M10×1.25×20 Cover Locker Life belt assembly Accelerate nut M10×1.25 Special bolt M10×1.25×22 Special bolt M10×1.25×25 Washer Φ6 Cushion - 290-...
Page 306: Fuel Tank
CHASSIS OIL SYSTEM FUEL TANK 7Nm (0.7m · kg,5.1 ft · lb) 30Nm (3.0m · kg,22 ft · lb) Part Name Remarks Pump Bushing Tube Φ12 Inlet vitta Φ6×Φ9×210 Clip Φ10 Minus press bump, minus press pipe Ⅰ Clip Φ10 Flange bolt M6x20 Oil line Φ7×Φ11 Cannulation...
Page 307 CHASSIS 7Nm (0.7m · kg,5.1 ft · lb) 30Nm (3.0m · kg,22 ft · lb) Part Name Remarks Foam, shock absorber Foam, press board Flange bolt M8×25 Line clip Φ13 Tank Vitta connection O-type ring Flange screw M5x10 Fuel sensor Cushion Screw Fuel tank...
Page 308 CHASSIS 7Nm (0.7m · kg,5.1 ft · lb) 30Nm (3.0m · kg,22 ft · lb) Part Name Remarks Fuel pipe ,minus press bump Φ5.5×Φ12×70 Clip Φ12 Fuel tank insulation paperⅠ Small fuel tank Pump suction trigeminal tube Φ3 Fuel tank insulation paperⅡ Fuel tank insulation paperⅢ...
Page 309: Checking The Fuel Pump Operation
CHASSIS CHECKING THE FUEL PUMP OPERATION 1. Remove: • driver seat • passenger seat • console • right protector 2. Place a container under the end of the fuel hose ①. 3. Check: • fuel pump operation a. Suck on the end of the vacuum hose. 4.
Page 310: Installing Oil Cooling System
CHASSIS Oil Cooling System INSTALLING OIL COOLING SYSTEM 1. To take a pressure resistance inspection to the Cooling System after maintain, pressure is 0.3MPA. 2. After take the pressure resistance inspection, pass over 0.03MPA compressed air through the connecting oil cooler, steel oil pipe and Rubber Pipe for 3 minutes, do not leak.
Page 311: Electrical Components
ELECTRICAL COMPONENTS ELECTRICAL SYSTEM MALFUNCTION INSPECTION Phenomenon Measure 1、 Check whether switches normal. 2、 Check whether cables damaged. Abnormal lights 3、 Check whether lights damaged. 1、 Check whether four wheel drive switch normal. Fail to shift into 2、 Check whether power divider damaged. four-wheel-drive or lock differential.
Page 312: Electrical
ELECTRICAL COMPONENTS ELECTRICAL ELECTRICALCOMPONENTS 1. Thermo switch 2 2. Radiator fan 3.Gear motor 4.Brake light switch 5.Parking brake switch 6.Pickup coil/stator assembly 7.Speed sensor 8. Diode 1 9. Circuit breaker(radiator fan motor) 10.Thermo switch 1 11. Ignition coil 12. Gear position switch 13.Reverse switch - 297 -...
Page 313 ELECTRICAL COMPONENTS 1. Four-wheel drive relay 1 2. Four-wheel drive relay 2 3. Starter relay 4. Four-wheel drive relay 3 5. Differential gear lock indicator light relay 6. Four-wheel drive indicator light relay 7. Fuse box 8. C.D.I. unit 9. Battery 10.
Page 314: Checking The Switch
ELECTRICAL COMPONENTS CHECKING THE SWITCH CHECKING THE SWITCH Use a pocket tester to check the terminals for continuity. If the continuity is faulty at any point, replace the switch. 1NOTE: • Set the pocket tester to “0” before starting the test. •...
Page 315: Checking The Switch Continuity
ELECTRICAL COMPONENTS Checking the switch continuity Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals. Poor connection, no continuity Correct or replace. * The coupler locations are circled. 1. Fuse 2. Brake light switch 3.On-Command four-wheel drive switch and differential gear lock switch 4.Main switch 5.Light switch 6.Parking brake switch...
Page 316: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals Damage/wear Repair or replace the bulb, bulb socket or both. Improperly connected Properly connect. Incorrect continuity reading Repair or replace the bulb, bulb socket or both.
Page 317: Ignition System
ELECTRICAL COMPONENTS IGNITION SYSTEM CIRCUIT DIAGRAM - 302 -...
Page 318: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main, ignition) 7. Main switch 2. Battery 8. Pickup coil resistance 3. Spark plug 9. Rotor rotation direction detection coil 4. Ignition spark gap resistance 5.
Page 319 ELECTRICAL COMPONENTS 4. Ignition spark gap INCORRECT • Disconnect the spark plug cap from the spark plug. • Connect the pulse ignition spark checker or ignition checker ① as shown. Repair or replace the spark plug. ② Spark plug cap •...
Page 320 ELECTRICAL COMPONENTS Primary coil resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) • Connect the pocket tester (Ω × 1k) to the ignition coil. Tester (+) lead Orange lead terminal Tester (–) lead Spark plug lead • Check that the secondary coil has the specified resistance.
Page 321 ELECTRICAL COMPONENTS resistance 0.063 ~ 0.077 Ω at 20 °C (68 °F) (Red – White/Blue) OUT OF SPECIFICATION MEETS SPECIFICATION Replace the pickup coil/stator assembly. 10.Wiring connection POOR CONNECTION • Check the connections of the entire ignition system. Refer to “CIRCUIT DIAGRAM”. CORRECT Properly connect the ignition system.
Page 322: Electric Starting System
ELECTRICAL COMPONENTS ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ① Switch ② C.D.I ③ Relay ④ Motor ⑤ Battery - 307 -...
Page 323: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main, ignition, signaling system) 6. Gear position switch 2. Battery 7. Brake light switch 3. Starter motor 8. Diode 1 4. Starter relay 9. Wiring connection (the entire starting system) 5.
Page 324 ELECTRICAL COMPONENTS DOSE NOT TURN Repair or replace the starter motor. TURNS 4. Starter relay • Remove the starter relay from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the starter relay terminals. Battery (+) terminal Yellow/Blue terminal ①...
Page 325 ELECTRICAL COMPONENTS Tester (+) lead Yellow/Blue terminal ① Tester(–)lead Black/Yellow terminal ② Continuity Tester(+) lead Yellow/Blue terminal ① Tester (–) lead Blue/White terminal ③ 1NOTE: Tester (+)lead When you switch the tester’s positive and B lack/Yellow terminal ② negative probes, the readings in the left chart Tester (–) lead will be reversed.
Page 326: Starter Motor
ELECTRICAL COMPONENTS STARTER MOTOR Part Name Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. Disassembling the starter motor Remove the parts in the order listed. Bracket 1 ①...
Page 327: Checking The Starter Motor
ELECTRICAL COMPONENTS CHECKING THE STARTER MOTOR 1. Check: • commutator Dirty Clean it with #600 grit sandpaper. 2. Measure: • commutator diameter Out of specification Replace the starter motor. 3. Measure: • mica undercut ⓑ Out of specification Scrape the mica using a hacksaw blade.
Page 328: Assembling The Starter Motor
ELECTRICAL COMPONENTS ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 ① 1NOTE: Align the projection ⓐ on the brush seat 1 with the slot ⓑ on the yoke. 2. Install: • yoke • brackets 1NOTE: Align the match marks ⓐ on the yoke with the match marks ⓑ...
Page 329: Charging System
ELECTRICAL COMPONENTS CHARGING SYSTEM CIRCUIT DIAGRAM - 314 -...
Page 330: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING Procedure IF THE BATTERY IS NOT CHARGED: Check: 1. Fuse (main) 4. Charging coil resistance 2. Battery 5. Wiring connections(the entire charging system) 3. Charging voltage 1NOTE: Remove some parts before maintenance 1. Cushion Repair with following special toolings 1.
Page 331 ELECTRICAL COMPONENTS 4. Charging coil resistance • Disconnect the A.C. magneto coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the charging coils. Tester (+) lead White terminal ① Tester (–) lead White terminal ② Tester (+) lead White terminal ①...
Page 332: Lighting System
ELECTRICAL COMPONENTS LIGHTING SYSTEM CIRCUIT DIAGRAM - 317 -...
Page 333: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE HEADLIGHT AND/OR TAILLIGHT FAIL TO COME ON: Procedure Check 1. Fuses (main, lighting system) 4. Light switch 2. Battery 5. Wiring connections(the entire lighting system) 3. Main switch 1NOTE: • Remove following part(s) before troubleshooting: 1.
Page 334: Checking The Lighting System
ELECTRICAL COMPONENTS CHECKING THE LIGHTING SYSTEM 1. If the headlights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Voltage • Connect the pocket tester (DC 20 V) to the headlight couplers.
Page 335: If The Taillights Fail To Come On
ELECTRICAL COMPONENTS 2. If the taillights fail to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2) . Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light couplers.
Page 336: Signaling System
ELECTRICAL COMPONENTS SIGNALING SYSTEM CIRCUIT DIAGRAM - 321 -...
Page 337: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF A BRAKE LIGHT, AN INDICATOR LIGHT, OR THE WARNING LIGHT FAILS TO COME ON: Procedure Check: 1. Fuses (main, signaling system) 3. Main switch 2. Battery 4. Wiring connections (the entire signal system) 1NOTE: • Remove the following part(s) before troubleshooting: 1.
Page 338: Checking The Signal System
ELECTRICAL COMPONENTS CHECKING THE SIGNAL SYSTEM 1. If the brake lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Bake light switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 339: If The Neutral Lights Fail To Come On
ELECTRICAL COMPONENTS 2. If the neutral lights fail to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Gear position switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 340: If The Parking Brake Indicator Light Fails To Come On
ELECTRICAL COMPONENTS 3. If the parking brake indicator light fails to come on: (1). Bulb and bulb socket • Check the bulb and bulb socket for NO CONTINUITY continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Parking brake switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 341: If The Reverse Indicator Light Fails To Come On
ELECTRICAL COMPONENTS 4. If the reverse indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Reverse switch NO CONTINUITY Refer to “CHECKING THE SWITCH”.
Page 342: If The Coolant Temperature Warning
ELECTRICAL COMPONENTS 5. If the coolant temperature warning light does not come on when the main switch to “ON”, or if the coolant temperature warning light does not come on when the temperature is high (more than 117 ~ 123 °C (242.6 ~ 253.4 °F): (1).
Page 343 ELECTRICAL COMPONENTS (3). Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead White/Blue terminal ② • Turn the main switch to “ON”. OUT OF SPECIFICATION •...
Page 344: If The Differential Gear Lock Indicator Light Fails To Come On
ELECTRICAL COMPONENTS 6. If the differential gear lock indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). Differential gear lock indicator light relay •...
Page 345 ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead Black/Green terminal ② OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 346: If The Four-Wheel Drive Indicator Light Fails To Come On
ELECTRICAL COMPONENTS 7. If the four-wheel drive indicator light fails to come on: (1). Bulb and bulb socket NO CONTINUITY • Check the bulb and bulb socket for continuity. CONTINUITY Replace the bulb and/or bulb socket. (2). four-wheel drive indicator light relay •...
Page 347 ELECTRICAL COMPONENTS (4).Voltage • Connect the pocket tester (DC 20 V) to the indicator light assembly 1 coupler. Tester (+) lead Brown terminal ① Tester (–) lead White/Yellow terminal ② OUT OF SPECIFICATION • Turn the main switch to “ON”. •...
Page 348: Cooling System
ELECTRICAL COMPONENTS COOLING SYSTEM CIRCUIT DIAGRAM ① Temperature control switch ② fan motor ③ Battery ④ Circuit breaker ⑤ switch - 333 -...
Page 349: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FAN MOTOR DOES NOT MOVE: Procedure Check: 1. Fuse (main) 5. Thermo switch 3 2. Battery 6. Wiring connection(the entire cooling system) 3. Main switch 4. Radiator fan motor 1NOTE: • Remove the following part(s) before troubleshooting.
Page 350 ELECTRICAL COMPONENTS 4.Radiator fan motor • Disconnect the radiator fan motor coupler. • Connect the battery (12 V) as shown. Battery (+) lead Blue terminal ① Battery (–) lead Black terminal ② DOES NOT TURN • Check the operation of the radiator fan motor.
Page 351 ELECTRICAL COMPONENTS 5.Thermo switch 3 • Remove the thermo switch 3 from the radiator. • Connect the pocket tester (Ω × 1) to the thermo switch 3 ①. • Immerse the thermo switch 3 in coolant ②. • Check the thermo switch 3 for continuity. While heating the coolant use a thermometer ③...
Page 352: 2Wd/4Wd Selecting System
ELECTRICAL COMPONENTS 2WD/4WD SELECTING SYSTEM CIRCUIT DIAGRAM ① Transfer Switch ② Relay orchid orchid Blue Orchid green Orchid state gray Black green ③ Battery Red 1 red 1 Light black ④ Motors Lock Speedometer Blue Blue Yellow Blue Brown Black green red1 yellow1...
Page 353: Troubleshooting
ELECTRICAL COMPONENTS TROUBLESHOOTING IF THE FOUR-WHEEL DRIVE INDICATOR FAILS TO COME ON: Procedure Check: 1. Fuses (main, four-wheel drive) 7. On-Command four-wheel drive switch and 2. Battery differential gear lock switch 3. Main switch 8. Gear motor 4. Four-wheel drive relay 1 9.
Page 354 ELECTRICAL COMPONENTS 4. Four-wheel drive relay 1 • Remove the four-wheel drive relay 1 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 1 terminals. Tester (+) lead Black/Yellow terminal ①...
Page 355 ELECTRICAL COMPONENTS 6. Four-wheel drive relay 3 • Remove the four-wheel drive relay 3 from the wire harness. • Connect the pocket tester (Ω × 1) and the battery (12 V) to the four-wheel drive relay 3 terminals. Battery (+) terminal Brown/Red terminal ①...
Page 356 ELECTRICAL COMPONENTS Replace the gear motor. 9. Wiring connection • Check the connections of the entire 2WD/ 4WD selecting system. Refer to “CIRCUIT POOR CONNECTION DIAGRAM”. CORRECT Properly connect the 2WD/4WD selecting system. Replace the C.D.I. unit. - 341 -...
Page 357: Engine Management System
ENGINE MANAGEMENT SYSTEM INTRODUCTION EMS (Engine Management System) EMS is a self contained set of components including a custom built computer and sensors and actuators which control the operation of an engine by monitoring the engine speed, load and temperature and providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required.
Page 358: Layout Of Ems Components
ENGINE MANAGEMENT SYSTEM 6. Oxygen Sensor 7. Ignition Coil 8. Fuel Pump Module Layout of EMS Components Legend: Dotted line indicates inputs Solid line indicates outputs COMPONENTS OF EMS Electronic Control Unit 1．Description & Working Principle The ECU continuously monitors the operating conditions of the engine through the system sensors.
Page 359: Multec 3.5 Injectors
ENGINE MANAGEMENT SYSTEM ECU Handing ACTION REASON DO NOT: Place the ECU close to the exhaust High temperature might reduce the life of the pipe or Engine when removed ECU and also can damage the ECU Place the ECU close to or pour ECU is susceptible to water and liquids DO NOT: water, oil or any other liquids.
Page 360 ENGINE MANAGEMENT SYSTEM 2．Handling - DOs & DONTs 3.5 FUEL INJECTOR HANDLING ACTION REASON DO NOT: Re-use injector seal rings if at all Leakage. possible. If no other choice exists, take extra care in inspecting the seal rings for damage. DO NOT: Dip injector tips into lubricants.
Page 361 ENGINE MANAGEMENT SYSTEM Use proper lubricants on seal ring Avoid damage to seal ring during installation. surfaces to install injector in engine. Avoid contamination at seal. Minimize time between applying lubricant and inserting injector / rail. DO: Pulse (actuate) stuck closed or tip-leak To verify the injector failure suspected injector (Actuate consists of one pulse <5 sec duration at 9 to 15V).
Page 362 ENGINE MANAGEMENT SYSTEM • Remove the fuel line connection from the injector • Carefully clean debris from the interface surfaces. Do not damage seal mating surfaces. • Remove the injector from the manifold • Apply a light coating of a lubricant to both the upper and lower injector seal ring of the replacement injector.
Page 363: Throttle Body Assembly(With Stepper Motor)
ENGINE MANAGEMENT SYSTEM 5．Plugging Fuel deposits cause plugging resulting in flow shifts over the life of the injector. Fuel varnish or gumming, a type of injector deposit, is created when certain types of fuel are heated by high injector tip temperatures at soak (no fuel flow). Deposit build up in the director holes causes the flow shifts •...
Page 364 ENGINE MANAGEMENT SYSTEM 2．Handling – DOs and DONTs THROTTLE BODY ASSEMBLY HANDLING ACTION REASON DO: Use care during assembly of harness to throttle Avoid terminal damage. body. DO: Avoid any liquid contamination in the throttle Ensure proper operation. body area. DO: Unload and install units one at a time from Damage may be done to critical components.
Page 365: Engine Coolant Temperature Sensor
ENGINE MANAGEMENT SYSTEM • Remove air cleaner outlet hose and throttle body outlet hose 4．Cleaning Procedure If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and varnish that are present.
Page 366: Oxygen Sensor
ENGINE MANAGEMENT SYSTEM This sensor has two functions. The first is the intake manifold air temperature, it provides a resistance that varies as a function of temperature within prescribed tolerance limits. The second is the intake manifold air pressure; it provides a voltage varies as the intake air pressure.
Page 367 ENGINE MANAGEMENT SYSTEM DO NOT: Use a screw driver to asset in removing It is possible to damage a secondary lead in secondary boots from the secondary tower. Use such a manner that creates an electrical path to tools designed for secondary removal. outside the system permitting improper system operation misfire, or even possible personal injury if arcing occurs.
Page 368 ENGINE MANAGEMENT SYSTEM Install secondary leads before In the event the low voltage connection has connecting the primary leads. been made and the power applied, unwanted secondary output might occur possibly resulting in injury, damage the ignition component, and test equipment DO: Take care when working around the ignition The high voltage produced by the coil system.
Page 369 ENGINE MANAGEMENT SYSTEM DO: Spark plug wires(secondary leads) & primary - Spark plug wires carry very high voltage wiring: (30,000 volt). If the secondary lead loses its - must not contact sharp surface dielectric characteristics thru being nicked, cut , - must not be under tension between fixed points chaffed, then an arc thru to a near by ground - must be clear of moving parts (belts, fan, etc…)
Page 370: Fuel Pump Module
ENGINE MANAGEMENT SYSTEM Regap spark plugs exact -Too wide a gap could cause the plug to measurement specified by the engine misfire(higher required ignition voltage). manufacturer to keep the best fuel economy and -Too narrow of a gap could affect idle stability proper engine performance -A flat gauge can’t accurately measure the spark - Use round wire-type gauge for an accurate...
Page 371 ENGINE MANAGEMENT SYSTEM Pressure Regulator is a diaphragm type mechanical device. Fuel flow from filter enters in the inlet of pressure regulator. Pressure regulator regulates the fuel pressure at a set pressure by releasing the excessive fuel flow to fuel tank. 2．Service Procedure: Precautions: Before attempting any service on fuel system, following cautions should be always followed for...
Page 372 ENGINE MANAGEMENT SYSTEM Connect power supply 1. Check Fuel (battery) to fuel module. 1. Check electrical Pump Harness Make sure that enough fuel available in circuit from fuel integrity fuel tank to avoid fuel pump running module to ECU 2. Check Fuel dry.Is the fuel pump running 2.
Page 373 ENGINE MANAGEMENT SYSTEM • Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque: 3~4 Nm. Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow the tightening torque and tightening sequence instruction.Over torque and miss-sequence can cause unequal compression of gasket and leakage.
Page 374 ENGINE MANAGEMENT SYSTEM After making sure that engine is cold, relieve fuel pressure as follows. • Place vehicle gear in ‘Neutral’. • Disconnect fuel module electrical coupler from vehicle harness. • Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3 times of about 3 seconds each time to relieve fuel pressure in lines.
Page 375 ENGINE MANAGEMENT SYSTEM DO NOT: Use Fuel Module if the strainer Contamination enters fuel pump thru with excessive damage/ cut. damaged strainer damages the Fuel Pump DO NOT: Use Fuel Pump for draining duel Not intended function of fuel module. in fuel tank.
Page 376: Ems Fault Diagnosis
ENGINE MANAGEMENT SYSTEM EMS FAULT DIAGNOSIS EME Fault Diagnosis When fault comes up, the odometer's clock will turn into a number， which is a fault code, find out the cause with this numbe;press clock button,then it will turn back to clock mode, and five second later,the fault code will show again.
Page 377 ENGINE MANAGEMENT SYSTEM 0562 System Voltage Low KsDGDM_SysVoltLow System Voltage 0563 System Voltage High KsDGDM_SysVoltHigh 0650 MIL Circuit Malfunction KsDGDM_MIL_Circuit 1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer 1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High 0137 O2S 2 Circuit Low Voltage KsDGDM_O2_2_ShortLow Oxygen Sensor 2 0138 O2S 2 Circuit High Voltage...
Page 378: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING 1NOTE: The following trouble, not including all possible troubles, is a help for trouble guide. Please refer to relevent contents for the inspection, adjustment and replacement of part. STARTING FAILURE/HARD STARTING FUEL SYSTEM 1、No oil 2、Fuel filter is clogged Fuel tank 3、Fuel filter net is clogged 4、Breather tube is clogged...
Page 379: Compression System
TROUBLESHOOTING 3、Woodruff key is bad 1、Main switch is bad 2、The engine is off and switch is inefficient Switches and wires 3、Wires is broken or shortened 6、Faulty gear position switch 7、Faulty brake light switch 1、Faulty starter motor Starter motor 2、Faulty starter relay 3、Faulty starter clutch Battery Faulty battery...
Page 380: Poor Idle Speed Performance
TROUBLESHOOTING POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE 1、Improperly returned starter plunger 2、Loose pilot jet 3、Clogged pilot jet 4、Clogged pilot air jet Carburetor 5、Improperly adjusted idle speed (throttle stop screw) 6、Improper throttle cable play 7、Flooded carburetor 1、Faulty spark plug 2、Faulty C.D.I.
Page 381: Jumps Out Of Gear
TROUBLESHOOTING Shift guide Shift guide JUMPS OUT OF GEAR Shift forks Worn shift fork Improper thrust play Shift drum Worn shift drum groove Transmission Worn gear dog OVERHEATING OVERHEATING 1、Improper spark plug gap Ignition system 2、Improper spark plug heat range 3、Faulty C.D.I.
Page 382: Faulty Brake
TROUBLESHOOTING FAULTY BRAKE POOR BRAKING EFFECT 1、Worn brake pads 2、Worn disc 3、Air in brake fluid 4、Leaking brake fluid 5、Faulty master cylinder kit cup Disc brake 6、Faulty caliper kit sea 7、Loose union bolt 8、Broken brake hose and pipe 9、Oily or greasy disc/brake pads 10、Improper brake fluid level SHOCK ABSORBER MALFUNCTION MALFUNCTION...
Page 383: Lighting System
TROUBLESHOOTING Damaged frame LIGHTING SYSTEM HEAD LIGHT IS OUT OF WORK 1、Improper bulb 2、Too many electric accessories 3、Hard charging( broken stator coil and/or faulty Head light is out of work rectifier/regulator) 4、Incorrect connection 5、Improperly grounded 6、Bulb life expired BULB BURNT OUT 1、Improper bulb 2、Faulty battery 3、Faulty rectifier/regulator...
Page 384: Hs600Utv Supplementary
TROUBLESHOOTING SERVICE MANUAL SUPPLE MENTARY HS600UTV - 369 -...
Page 385: Hs600Utv Service Manual
HS600UTV SERVICE MANUAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Engine : Engine type Liquid cooled 4-stroke, Water cool Cylinder arrangement Forward-inclined single cylinder Displacement 608cm Bore×stroke 96×84.0mm（3.78×3.31in） Compression ratio 8.5:1 Starting system Electric starter Lubrication system Wet sump Carburetor Type/quantity PD42J-A / 1 ENGINE SPECIFICATIONS Item Standard...
Page 386 HS600UTV SERVICE MANUAL Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 95.95 ~ 95.97 mm ---- (3.7756 ~ 3.7783 in) ---- Measuring point “H” 10 mm (0.3937 in) ---- 1.0 mm(0.0394 in) Piston off-set...
Page 387: Hs500Utv Service Manual
HS500UTV SERVICE MANUAL SERVICE MANUAL SUPPLE MENTARY HS500UTV - 372 -...
Page 388: Specifications
HS500UTV SERVICE MANUAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Engine : Engine type Liquid cooled 4-stroke, Water cool Cylinder arrangement Forward-inclined single cylinder Displacement 471cm Bore×stroke 84.5×84.0mm（3.33×3.31in） Compression ratio 9.4:1 Starting system Electric starter Wet sump Lubrication system Carburetor Type/quantity PD36J / 1 ENGINE SPECIFICATIONS Item Standard...
Page 389 HS500UTV SERVICE MANUAL Intake “A” 32.30~32.20 mm (1.271 ~ 1.268in) “B” 40.88 ~ 40.78 mm (1.6094 ~ 1.6055in) Exhaust “A” 32.30 ~ 32.20 mm (1.272 ~ 1.268 in) “B” 40.95 ~ 40.85 mm (1.6122~ 1.6083 in) Camshaft runout limit Cam chain No.
Page 390 HS500UTV SERVICE MANUAL Direction of winding (top view) Clockwise Clockwise Valve dimensions head diameter face width seat width margin thickness ---- “A” head diameter 39.9 ~ 40.1 mm (1.5709~ 1.5787 in) 33.9 ~ 33.98 mm ---- (1.3346 ~ 1.3378in) “B” face width 2.25 mm (0.0900 in) ---- 2.26 mm...
Page 391 HS500UTV SERVICE MANUAL Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 84.45 ~ 84.47 mm ---- (3.3248 ~ 3.3256 in) ---- Measuring point “H” 15mm (0.59in) ---- Piston off-set 0.5mm(0.0197in)
Page 392 HS500UTV SERVICE MANUAL Piston rings Top ring Type Barrel ---- Dimensions (B× T ) 1.0 ×3.0mm ---- (0.03937× 0.1181in) End gap (installed) 0.30 ~ 0.45 mm 0.70 mm (0.0118 ~ 0.0177 in) (0.0276 in) Side clearance (installed) 0.04 ~ 0.08 mm 0.13 mm (0.0016 ~ 0.0031 in) (0.0051 in)
Page 393 HS500UTV SERVICE MANUAL Item Standard Limit Oil ring ---- Dimensions (B×T) 2.0×2.85 mm ---- (0.0787× 0 .1122in) End gap (installed) 0.20 ~ 0.70 mm ---- (0.0079 ~ 0.0276 in) Side clearance 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Carburetor KINZO ---- Mark...
Page 394: Engine Removal
HS500UTV SERVICE MANUAL ENGINE REMOVAL Part Name Remarks Removing carburetor and intake Remove the parts in the order listed. manifold. Carburetor Intake manifold Drain plug For installation, reverse the removal procedure. - 379-...
Page 395 HS500UTV SERVICE MANUAL 1、NOTE • Removing the drain plug 1NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. 2、INSTALL • Install intake manifold • Install intake manifold bolt • Install carburetor joint • Install carburetor 1NOTE: When installed, don't make an object from the intake fell into the cabinet.
Page 396: Cylinder Head And Cylinder Head Cover
HS500UTV SERVICE MANUAL CYLINDER HEAD AND CYLINDER HEAD COVER Part Name Remarks Removing the cylinder head cover Remove the parts in the order listed. and cylinder head Spark plug Tappet cover (intake) Tappet cover (exhaust) Timing chain tensioner cap bolt Timing chain tensioner / gasket Left cover of cylinder head Dowel pin...
Page 397 HS500UTV SERVICE MANUAL 1、CHECK 1). Checking the valve clearance • Valve clearance Refer “ADJUSTING VALVE CLEARANCE” in chapter 3. 2). Checking the tappet covers • tappet cover ① Cracks/damage Replace. • O-rings ② 1NOTE: When installing, new replacement washer and apply wheel bearing grease LS. 3).
Page 398 HS500UTV SERVICE MANUAL Mineral deposits/rust Eliminate. 2、INSTALL 1). Installing the cylinder head • cylinder head • washers • bolts 1NOTE: • Tighten the bolts in the proper sequence. • timing chain guide (exhaust side) • timing chain tensioner a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.
Page 399: Rocker Arms And Camshaft
HS500UTV SERVICE MANUAL ROCKER ARMS AND CAMSHAFT Part Name Remarks Removing the rocker arms and Remove the parts in the order listed. camshaft Cylinder head cover Rocker arm shaft 1/O-ring Rocker arm 1 Rocker arm shaft 2/O-ring Rocker arm 2 Locknut Valve adjuster Decompress or cam guide plate...
Page 400 HS500UTV SERVICE MANUAL 1、CHECK 1). Checking the rocker arms • rocker arm lobes ① • valve adjusters ② Blue discoloration / pitting / scratches Replace. • rocker arms • rocker arm shafts Damage/wear Replace. a. Check whether the rocker arm is worn out, or damaged and whether the oil hole is blocked.
Page 401 HS500UTV SERVICE MANUAL 2). Checking the camshaft • cam lobes Pitting/scratches/blue discoloration Replace • camshaft journal Wear/damage Replace • Measure the external diameter of camshaft journal with micrometer. Out of specification Replace. • small holes on camshaft sprocket • rotor “I” mark Out of alignment 3).
Page 402 HS500UTV SERVICE MANUAL 2). Installing the camshaft • camshaft • camshaft sprocket a. Turn the crankshaft counterclockwise with a T-sleeve. b. Align the “I” mark ① on the rotor with the stationary pointer ② on the A.C. magneto cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (TDC).
Page 403: Valves And Valve Springs
HS500UTV SERVICE MANUAL VALVES AND VALVE SPRINGS Part Name Remarks moving the valves and valve springs Remove the parts in the order listed. Cylinder head cover Valve cotter Valve spring retainer Valve stem seal Intake valve with inner spring Intake valve with outer spring Exhaust valve with inner spring Exhaust valve with outer spring Valve spring seat...
Page 404 HS500UTV SERVICE MANUAL 1、CHECK • valve sealing Leakage at the valve seat Check the valve face, valve seat and valve seat width. a. Pour a clean solvent ① into the intake and exhaust ports. b. Check that the valve seals properly. There should be no leakage at the valve seat ②.
Page 405 HS500UTV SERVICE MANUAL • valve stem runout Out of specification Replace. Runout limit 0.01 mm 1NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. • The valve seat surface width Out of specification Reface the valve seat.
Page 406 HS500UTV SERVICE MANUAL 2). Remove: • valve guide 1NOTE: To ease guide removal, installation and to maintain correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. 3). Lap: • valve face • valve seat 1NOTE: After reface the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.
Page 407 HS500UTV SERVICE MANUAL e. Install the valve into the cylinder head. g. Press the valve through the valve guide and onto the valve seat to make a clear pattern. h. Measure the valve seat width again. If the valve seat width is out of specification, reface and relapse the valve seat.
Page 408: Cylinder And Piston
HS500UTV SERVICE MANUAL CYLINDER AND PISTON Part Name Remarks Removing the cylinder and piston Remove the parts in the order listed. Water pump outlet hose Cylinder head Coolant inlet joint Cylinder/O-ring Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set For installation, reverse the removal...
Page 409 HS500UTV SERVICE MANUAL 1、CHECK 1).Checking the cylinder and piston • cylinder and piston walls Vertical scratches Rebore or replace the cylinder and the piston. 2).Checking the piston rings • piston ring (Insert in cylinder piston ring will be ① ,and measure the end gap.) 1NOTE: Check whether the piston and the piston...
Page 410 HS500UTV SERVICE MANUAL • ring end gap Out of specification Replace. Repairing limit value Top ring/2nd ring:0.5mm • ring side clearance Use a thickness gauge. Out of specification Replace the piston and rings as a set. 1NOTE: Clean carbon from the piston ring grooves rings before measuring...
Page 411 HS500UTV SERVICE MANUAL 3、INSTALL: 1). Installing the piston • piston rings (onto the piston) 1NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil.

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