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Crossfire E10 Service Manual
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Crossfire E10 Service Manual

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CROSSFIRE
E10 / E10 CREW
SERVICE MANUAL

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Summary of Contents for Crossfire E10

  • Page 1 CROSSFIRE E10 / E10 CREW SERVICE MANUAL...
  • Page 2 CROSSFIRE E10 / E10 CREW SERVICE MANUAL WARNING: BEFORE OPERATING THIS VEHICLE, The parts of different types/ variants/ THE OWNER AND EACH OPERATOR versions maybe un-interchangeable, MUST HAVE READ AND HAVE even some parts have almost same AN UNDERSTANDING OF ALL THE appearance.
  • Page 3 NOTICE This manual was produced by the Crossfire Motorcycles primarily for use by Crossfire Motorcycles dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that...

  • Page 4: Table Of Contents

    CONTENTS CHAPTER1 ……………………………………………………….General Information CHAPTER2 ………………………………………….……………………Maintenance CHAPTER3…………………………………………..…………………………Chassis CHAPTER4………………………………………………….……………….Final Drive CHAPTER5………………………………………………………………………Brakes CHAPTER6………………………………………………….….……………..Electrical...
  • Page 5 Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
  • Page 6 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 1.1 IMPORTANT INFORMATION 1.2 V.I.N AND MOTOR SERIAL NUMBER 1.3 VEHICLE DIMENSIONS...
  • Page 7 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “...
  • Page 8 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL Replace distorted circlips. When installing a circlip ① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives. See sectional view. ④Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector.
  • Page 9 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
  • Page 10 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL V.I.N AND ENGINE SERIAL NUMBER The vehicle identification number ① is stamped into the left side of the rear frame tube. The engine serial number ② is stamped into left side of engine crankcase. CHAPTER 1 GENERAL PAGE.
  • Page 11 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL VEHICLE DIMENSIONS CHAPTER 1 GENERAL PAGE. 1- 6...
  • Page 12 CHAPTER 1 GENERAL INFORMATION SERVICE MANUAL NOTES CHAPTER 1 GENERAL PAGE. 1- 7...

  • Page 13: Chapter2

    CHAPTER 2 MAINTENANCE SERVICE MANUAL CHAPTER 2 MAINTENANCE The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 2.1 PERIODIC MAINTENANCE 2.
  • Page 14 CHAPTER 2 MAINTENANCE SERVICE MANUAL 2.1 PERIODIC MAINTENANCE CAUTION Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer.  More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 15 CHAPTER 2 MAINTENANCE SERVICE MANUAL grease to connector when replaced Tail / Indicator Lamp Check operation daily; apply dielectric Daily Daily Inspection grease to socket when replaced Transmission 20 hrs Monthly Inspect monthly; change annually  Level Brake Pad Wear 10 hrs Monthly Inspect periodically...
  • Page 16 CHAPTER 2 MAINTENANCE SERVICE MANUAL 7. Tie Rods Grease Grease Semi-annually  Inspect, Locate fittings and 8. Ball Joints Grease Grease, or replace it if Semi-annually  necessary 9. Prop Shaft ＆ Shaft Grease Locate fitting and Grease Semi-annually  Yoke, Spline Joint Ensure reliable connection Monthly...
  • Page 17 CHAPTER 2 MAINTENANCE SERVICE MANUAL LUBRICATION RECOMMENDATIONS NOTE: 1.More often under severe use, such as wet or dusty conditions. 2.Grease: Light weight lithium-soap grease. 3.Grease M：Molybdenum disulfide (MoS ) grease (water resistant). 4.When suspension action becomes stiff or after washing. 1.
  • Page 18 CHAPTER 2 MAINTENANCE SERVICE MANUAL 2.2 TOE ALIGNMENT METHOD: STRAIGHTEDGE OR STRING Be sure the steering wheel in a straight ahead position. NOTE: String should just touch side surface of rear tire on each side of the UTV. The recommended toe alignment is 1/8”to 1/4”(3 to 6mm) toe out.
  • Page 19 CHAPTER 2 MAINTENANCE SERVICE MANUAL 2.3 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level on reservoir.
  • Page 20 CHAPTER 2 MAINTENANCE SERVICE MANUAL lever and attempt to move the UTV. 2. If the rear wheels are locked, it is adjusted properly. 3. If the wheels are not locked, it must be adjusted. To adjust (set up) the mechanical parking brake, use the following procedure Note: The adjusting on the caliper is for the wear out of the pads.
  • Page 21 CHAPTER 2 MAINTENANCE SERVICE MANUAL 2.4 SUSPENSION SPRING RPELOAD ADJUSTMENT Operator weight and vehicle loading affect suspen ents. Adjust as sion spring preload requirem sary. neces FRONT SUSPENSION Compress and release front suspension. Damping should be smooth throughout the range of travel.
  • Page 22 CHAPTER 2 MAINTENANCE SERVICE MANUAL brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward rotation. 2. Install the wheel nuts and tighten them by hand. 3.
  • Page 23 CHAPTER 2 MAINTENANCE SERVICE MANUAL 2.7 FRAME , NUTS, BOLTS, FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. PAGE.
  • Page 24 CHAPTER 2 MAINTENANCE SERVICE MANUAL NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 12...
  • Page 25 CHAPTER 3 CHASSIS SERVICE MANUAL CHAPTER 3 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 3.1 FRONT A-A RM REPLACEMENT 3.2 REAR A-A RM REPLACEMENT 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION...
  • Page 26 CHAPTER 3 CHASSIS SERVICE MANUAL 3.1 FRONT A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud.
  • Page 27 CHAPTER 3 CHASSIS SERVICE MANUAL 3.2 REAR A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the wheel nuts and wheel. NOTE: To ease the removal of the spindle bolt, remove the hub cap and loosen the spindle bolts before removing the wheel.
  • Page 28 CHAPTER 3 CHASSIS SERVICE MANUAL 5. Loosen two bolts that secure the rear knuckle to the A-arm. Remove the rear knuckle assembly by sliding it off of the axle. 6. Remove the bolt that secures the shock absorber to the lower A-arm. 7.

  • Page 29: Chapter3

    CHAPTER 3 CHASSIS SERVICE MANUAL 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the rear wheel to gain access to the stabilizer bar, each side. 3. Remove the stabilizer bar nut from the lower A-arm, each side.
  • Page 30 CHAPTER 3 CHASSIS SERVICE MANUAL 5. Remove the stabilizer from the frame. 6. Inspect the stabilizer bar. Inspect the bushings and replace if needed. 7. Inspect the stabilizer joint and replace if needed. 8. Reverse the procedure for installation. Torque the stabilizer bolts to 23 ft.lbs (32 Nm).
  • Page 31 CHAPTER 3 CHASSIS SERVICE MANUAL 1. Hold strut rod with wrench and remove top nut. 2. Compress spring. 3. Remove all strut pivot assembly. 4. Remove coil spring and collapse strut body. 5. Remove two pinch bolts from strut body. 6.
  • Page 32 CHAPTER 3 CHASSIS SERVICE MANUAL Torque screw s to 8 ft.lbs. (11 Nm). 10. Install A-arm on ball joint cup and torque castle nut to 25 ft. lbs. (35 Nm ). 11. Reinstall cotter pin with open ends toward rear of machine.
  • Page 33 CHAPTER 3 CHASSIS SERVICE MANUAL 3.6 STEERING ASSEMBLY 1. Remove the bolt and nuts that fixed the plastic sleeve. 2. With the steering wheel cover bolts removed, remove the steering wheel cover and steering wheel and horn switch. 3. With the steering wheel holder nut / spring washer / flat washer removed, remove the steering wheel holder and plastic sleeve.
  • Page 34 CHAPTER 3 CHASSIS SERVICE MANUAL NOTES CHAPTER 3 CHASSIS PAGE. 3- 10...

  • Page 35: Chapter4

    CHAPTER 4 FINAL DRIVE SERVICE MANUAL CHAPTER 4 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each CUV model for spare parts information and service. 4.1 WHEEL, HUB, AND SPINDLE TORQUE TABLE 4.2 FRONT HUB EXPLODED VIEW 4.3 FRONT HUB REMOVAL/INSPECTION...
  • Page 36 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 4.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 59 Ft.Lbs 66 N.m Front W heel Nuts 59 Ft.Lbs 66 N.m Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 N.m Rear Hub Retaining Nut 101 Ft.Lbs 137 N.m...
  • Page 37 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 3. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots. 4. Remove wheel nuts and wheel. 5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
  • Page 38 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 6. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 7. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (25 N.m) CAUTION: New bolts have a pre-applied locking agent which is destroyed bolts upon removal.
  • Page 39 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 4.6 REAR HUB EXPLODED VIEW 4.7 REAR HUB AND KNUCKLE REMOVAL/ INSPECTION 1. Elevate rear end and safely support machine under main frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service...
  • Page 40 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 6. Remove the upper and lower control arm bolts. 7. Slide the rear hub and knuckle from the rear drive shaft. 8. Inspect the rear hub and knuckle assembly by hand for smoothness and side to side movement, replace as needed.
  • Page 41 CHAPTER 4 FINAL DRIVE SERVICE MANUAL 3. Inspect the shaft splines and cv boots for any damage. 4.10 REAR DRIVE SHAFT INSTALLATION 1. Install a new circlip onto the rear drive shaft. Apply Anti-Seize Compound onto the rear driveshaft splines (both ends). 2.
  • Page 42 CHAPTER 4 FINAL DRIVE SERVICE MANUAL NOTES CHAPTER 4 FINAL DRIVE. 4-...
  • Page 43 CHAPTER 5 BRAKES SERVICE MANUAL CHAPTER 5 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. NOTE: Also See Chapter 2 for Maintenance Information.
  • Page 44 CHAPTER 5 BRAKES SERVICE MANUAL 5.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness Brake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ .051m m Between Measurements Brake Disc Runout 0.005 "/ .127mm Rear Brake Caliper...
  • Page 45 CHAPTER 5 BRAKES SERVICE MANUAL  Adjust foot brake after pad service.  Test for brake drag after any brake system service and investigate cause if brake drag is evident.  Make sure caliper moves freely on guide pins (where applicable) . ...
  • Page 46 CHAPTER 5 BRAKES SERVICE MANUAL 1. Clean reservoir cover thoroughly. 2. Remove cover from reservoir. 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. 4. Add brake fluid between the MIN line and MAX line of reservoir.

  • Page 47: Chapter5

    CHAPTER 5 BRAKES SERVICE MANUAL 5.6 PARKING BRAKE AND BRAKE LINE INSPECTION 1. Inspect the spring on the parking brake lever assembly. Brake Line 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3.
  • Page 48 CHAPTER 5 BRAKES SERVICE MANUAL 5.7 PARKING BRAKE ADJUSTMENT Parking Brake Inspection 1. Push the parking brake up with your hand. 2. After 7 to 9 clicks of lever travel, the vehicle should not roll while parked. 3. If the vehicle moves, adjustment is necessary. 4.
  • Page 49 CHAPTER 5 BRAKES SERVICE MANUAL 4. Measure the thickness of the caliper parking brake pads. Replace pads if worn beyond the service limit. Service Limit 3/64"(1 mm) The Procedure of Pads Replacement 1. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed.
  • Page 50 CHAPTER 5 BRAKES SERVICE MANUAL 5.9 FRONT PADS REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support front of CUV safely. CAUTION: Be care when supporting vehicle so that it does not tip or fall.
  • Page 51 CHAPTER 5 BRAKES SERVICE MANUAL REMOVAL / REPLACEMENT 5.10 FRONT DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator.
  • Page 52 CHAPTER 5 BRAKES SERVICE MANUAL 5.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION CAUTION: The caliper is a non-serviceable Component, it must be replaced as an assembly. Brake Hose NOTE: If any special service needed, contact the CUV manufacture via the agent for the parts and special instruction.
  • Page 53 CHAPTER 5 BRAKES SERVICE MANUAL from brake hose. 3. After the fluid has drained into the container, remove the caliper mounting bolts and remove caliper. 4. Remove brake pads as described above. 5. Inspect surface of caliper for nicks, scratches or damage and replace if necessary. 6.
  • Page 54 CHAPTER 5 BRAKES SERVICE MANUAL NOTES CHAPTER 5 BRAKES PAGE. 5- 12...

  • Page 55: Chapter6

    CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL CHAPTER 6 ELECTRICAL HEADLIGHT ADJUSTMENT BATTERY LIGHTING SYSTEM CHARGING SYSTEM METER TROUBLESHOOTING WIRING DIAGRAM CHAPTER 6 FINAL DRIVE. 6-...
  • Page 56 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 6.1HEADLIGHT ADJUSTMENT HEADLIGHT ADJUSTMENT 1. The headlight beam can be adjusted vertically. 2. Place the vehicle on a level surface with the headlight approximately 33in(10m) from a wall. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
  • Page 57 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 6.2 BATTERY 6.2.1 Lead acid battery Battery capacity：DC 72V 140Ah (6×12V) Battery connection NOTE: Tighten the cable terminal. Poor contact of battery terminal may result in burnout of terminal. : Keep the sharp drop switch disconnected (pressed) during wiring. ：Connect the two ends of a single cable before connecting the next one.
  • Page 58 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 6.2.2 Lithium battery Battery Type: LiFePO4 Battery Battery capacity：76.8V 150Ah NOTE: Tighten the cable terminal. Poor contact of battery terminal may result in burnout of terminal. NOTE: Please turn off the battery switch before connecting the battery. CHAPTER 6 FINAL DRIVE.
  • Page 59 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL Battery Maintenance： After running out of battery, it should be charged in a timely manner and kept charged once three month when the vehicle is idle! 1. Check if the battery wiring is loose, poor cable contact can cause a fire. 2.
  • Page 60 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 6.3 Vehicle travel system Emergency stop switch： CHAPTER 6 ELECTRICAL CTRICAL PAGE 6-...
  • Page 61 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL NOTE: When a vehicle is in danger, the user should press the emergency stop switch atthe first time. The vehicle will not be able to drive or charge after pressing the emergencystop switch When the emergency stop switch is in normal working state, the terminals A and B are connected. Motor controller：...
  • Page 62 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL Accelerator pedal： Working principle： The motor controller outputs 12V power to the accelerator pedal； The rotation of the accelerator pedal generates different voltage signals to the controller； The voltage signal is between 0 and 5V, as shown in the following figure； The switch signal of the accelerator pedal is a safety insurance item.
  • Page 63 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL LIGHTING SYSTEM Tail/Brake Tail/Brake Light Light Tail/Brake Tail/Brake Light Light Parking Parking switch switch Head Head Light Light Head Head Light Light Meter Meter Gr/G Rear Rear license license plate plate light light DC-DC DC-DC Battery Battery...
  • Page 64 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL TROUBLESHOOTING Procedure Check: 1. Fuse 4.Lights switch 2. Battery 5.Diatance light switch 3. Main switch 6. Wiring connection (entire lighting system) 1.fuse refer “CHECKING SWITCHES” NO CONTINUITY section Replace the fuse 2. Battery and DC-DC Check the input and output of DC-DC INCORRECT...
  • Page 65 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL switch POOR CONNECTIONS 6.Wiring connection Check the connection of the entire lighting system correct 7.check the condition of each of the lighting system’s circuits Refer to “LIGHTING SYSTEM CHECK” LIGHT SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on NO CONTINUITY 1.Blub and bulb socket CHECK SWITCHES...
  • Page 66 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 1. the taillight fails to come on 1. Bulb and bulb socket NO CONTINUITY CHECK SWITCHES Replace the bulb and /or bulb socket CONTINUITY 2. Voltage Connect the pocket tester (DC20V) to the LED Blub socket connector.
  • Page 67 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL CHARGING SYSTEM Connecting positive and negative poles of battery pack (Red Wire Connecting Positive Pole) 1、Charging interface 2、Charger socket 3、Charger body 4、Charging display lamp 5、Battery temperature sensor CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 13...
  • Page 68 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL Indicator lamp Charging capacity < 80% flashing interval of red light 1s； Charging capacity > 80% yellow light flashing interval 1s； Charge = 100% green light always on Charging driving protection: When the charger is charging, the internal switch of the charger will disconnect the line from the key switch to the motor controller, ensuring that it cannot be driven while charging.
  • Page 69 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL METER 1. Headlight switch indicator 11. Function buttons1 2. Seat belt warning 12. Left Turn Indicator 3. Headlight switch indicator 13. Electricity Gauge 4. 2WD-4WD indicator 14. Reverse indicator 5. Rear differential lock indicator 15.
  • Page 70 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL Key function: Caution: Electric fuel injection failure alarm indicator should be lit, when open the key switch but did not start the engine, to prompt the alarm function is normal. After the engine starting, the lamp shall be put out, otherwise the efi system is faulty.
  • Page 71 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL P0026 BMS communication failure Motor controller power reduced by 50% P0027 SOC too low Motor controller power reduced by 50% P0028 The voltage difference of the battery cell is Motor controller power reduced large by 50% P0029 Large temperature difference between...
  • Page 72 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL TROUBLESHOOTING The instrument has a fault code. Please search for the fault based on the fault code. This chapter explains some common faults that cannot display fault codes. Fault 1: There is one direction (forward or backward) that cannot work Measure: Check the shifter plug;...
  • Page 73 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL 6.7 WIRING DIAGR CHAPTER 6 ELECTRICAL CTRICAL PAGE 6- 19...
  • Page 74 CHAPTER 6 ELECTRICAL CUV SERVICE MANUAL NOTES CHAPTER 7 ELECTRICAL CTRICAL PAGE 7- 20...

This manual is also suitable for:

E10 crew