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Nebula TAURUS 200 Service Maintenance Manual

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TAURUS 200
SERVICE MANUAL

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  • Page 1 TAURUS 200 SERVICE MANUAL...
  • Page 2 NOTICE This manual was produced by the NUBULA Group primarily for use by NUBULA 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 anyone who uses this book to perform maintenance and repairs on NUBULA vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
  • Page 3 CONTENTS CHAPTER1 ……………………………………………………….General Information CHAPTER2 ………………………………………….……………………Maintenance CHAPTER3…………………………………….……….….…………………….Engine CHAPTER4…………………………………………..…………………………Chassis CHAPTER5………………………………………………….……………….Final Drive CHAPTER6………………………………………………………………………Brakes CHAPTER7………………………………………………….….……………..Electrical...
  • Page 4 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 5: Chapter 1 General Information

    CHAPTER 1 GENERALINFORMATION 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 ENG INE SERIAL NUMB ER 1.3 VEHICLE DIMENSIONS...
  • Page 6 CHAPTER 1 GENERALINFORMATION 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 ”mated ”through normal wear.

  • Page 7: Checking Of Connections

    CHAPTER 1 GENERALINFORMATION 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 8: How To Use The Conversion Table

    CHAPTER 1 GENERALINFORMATION SERVICE MANUAL CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result Torque...
  • Page 9 CHAPTER 1 GENERALINFORMATION 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 10: Vehicle Dimensions

    CHAPTER 1 GENERALINFORMATION SERVICE MANUAL VEHICLE DIMENSIONS Note. The on-road equipments (rear view mirror, turn lights, etc.) are not Standard Equipment for USA. CHAPTER 1 GENERAL PAGE. 1- 6...

  • Page 11: Chapter 2 Maintenance

    CHAPTER 2 MAINTENANCE SERVICE MANUA 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 MAI NTENANCE 2.2 THROTTLE PEDAL INSPECTION 2.3 CHOKE ADJUS TMETN 2.4 FUEL SYSTEM...

  • Page 12: Periodic Maintenance Schedule

    CHAPTER 2 MAINTENANCE SERVICE MANUA 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart DL ：Due to the nature of the adjustments marked with a DL on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
  • Page 13 CHAPTER 2 MAINTENANCE SERVICE MANUA Tail lamp inspection Daily apply dielectric grease to socket when replaced ▲ Air Filter-Main Element Weekly Replace if necessary ▲ Transmission Oil Level Monthly change annually Battery Terminals Monthly Battery fluid level Monthly Brake pad wear Monthly ▲...
  • Page 14 CHAPTER 2 MAINTENANCE SERVICE MANUA ▲ Steering 50 hrs 6 months T if necessary ▲ Front Suspension 50 hrs 6 months T if necessary ▲ Rear Suspension 50 hrs 6 months T if necessary Spark Plug 100 hrs 12 months R if necessary Ignition Timing 100 hrs...
  • Page 15 CHAPTER 2 MAINTENANCE SERVICE MANUA are replaced Headlight Aim As Required Adjust if necessary ▲ Ball joint (A arm- strut) 10 hrs monthly I, (for damage, wear, and play) R. Replace if necessary LUBRICANT AND FLUID Item Lube Rec Method Frequency 1.Engine Oil SAE 15W/40 SE...
  • Page 16 CHAPTER 2 MAINTENANCE SERVICE MANUA CHAPTER 2 MAINTENANCE PAGE. 2-...

  • Page 17: Lubrication Recommendations

    CHAPTER 2 MAINTENANCE SERVICE MANUA 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. 5.Hours are based on 10 mph(16km/h) average.

  • Page 18: Fuel System

    CHAPTER 2 MAINTENANCE SERVICE MANUA 2.3 CHOKE ADJUSTMETN If the choke knob does not stay out when pulled, adjust the choke tension by tightening (clockwise) the chock cable boot until the choke slider freely but stays out when pulled. If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing 2.4 FUEL SYSTEM Gasoline is extremely flammable and explosive under certain conditions.

  • Page 19: Toe Alignment

    CHAPTER 2 MAINTENANCE SERVICE MANUA VENT LINES AND ROLL OVER VALVE 1. Check fuel tank, oil tank, carburetor, battery and transmission vent lines for signs of wear, deterioration, damage of leakage. Replace every two years. 2. Be sure vent lines are routed properly and secured with cable ties.

  • Page 20: Brake Pad Inspection

    CHAPTER 2 MAINTENANCE SERVICE MANUA Always pay attention to tie rods assembly, Both ends must screw in same and enough threads length. 2.6 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.

  • Page 21: Adjusting The Brake Pedal

    CHAPTER 2 MAINTENANCE SERVICE MANUA HOSE/FITTING INSPECTION Check braking system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. ADJUSTING THE BRAKE PEDAL Check the brake pedal free play. Free play should be 8 –...

  • Page 22: Front Suspension

    CHAPTER 2 MAINTENANCE SERVICE MANUA 8. Field test for parking. It must be capable of holding the laden UTV stationary on an 18% up and down gradient. A temporary adjusting can also be done to the brake cable on the parking lever side by turn the adjuster (nut) directly.

  • Page 23: Wheel Removal

    CHAPTER 2 MAINTENANCE SERVICE MANUA 2.8 WHEELS Inspect all wheels for runout of damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL REMOVAL 1. Stop the engine, place the transmission in gear and lock the parking brake.

  • Page 24: Tire Tread Depth

    CHAPTER 2 MAINTENANCE SERVICE MANUA  Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Tire Pressure  Improper tire inflation may affect UTV maneuverability. front rear  When replacing a tire always use original equipment size and 70kPa/10PSI 100kPa/14 type and replace in pairs.
  • Page 25 CHAPTER 2 MAINTENANCE SERVICE MANUA NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 15...

  • Page 26: Preparation For Removal Procedures

    CHAPTER 3 ENGINE SERVICE MANUAL CHAPTER 3 ENGINE 3.1PREPARATION FOR REMOVAL PROCEDURES 3.2REPLACEMENT PARTS 3.2.1Gaskets, oil seals and o-rings 3.2.2Bearings and oil seals 3.3PERIODIC INSPECTION AND ADJUSTMENT 3.3.1Air filter 3.3.2Spark plug 3.3.3Valve clearance adjustment 3.3.4Transmission oil inspection 3.3.5Crankcase oil inspection 3.4ENGINE REMOVAL AND INSTALLATION 3.4.1Cylinder head 3.4.2Cylinder body, piston and piston ring...

  • Page 27: Replacement Parts

    CHAPTER 3 ENGINE SERVICE MANUAL 3.1 PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dust and dirt before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. During machine disassembly, clean all parts and place them in the order of disassembly, which will speed up assembly and allow for the correct installation of all parts.
  • Page 28 CHAPTER 3 ENGINE SERVICE MANUAL 3.3 PERIODIC INSPECTION AND ADJUSTMENT 3.3.1 Air filter 1. Remove air filter case cover and 7 fixing screws. 2. Remove 2 filter element fixing screws to check the element for dirt or damage. If so, replace. NOTE: As the air filter element is paper-made and contains engine oil, it is not proper to clean it with air.
  • Page 29 CHAPTER 3 ENGINE SERVICE MANUAL 2. Rotate cooling fan to set the mark on camshaft sprocket in Top Dead Center position, that is, to align the timing line on the rotor with the mark on the crankcase. NOTE: Since crankshaft equipped with decompression,...
  • Page 30 CHAPTER 3 ENGINE SERVICE MANUAL 3.3.4 Transmission oil inspection 1. Remove the oil level plug. 2. Wipe the oil on the plug and insert it into the filler hole without screwing. The oil level should reach the fourth mark. 3. When replacing the oil, remove transmission case drain plug located on the front cover and drain the oil..

  • Page 31: Installation

    CHAPTER 3 ENGINE SERVICE MANUAL 3.4 ENGINE REMOVAL AND INSTALLATION 3.4.1 Cylinder head A. Camshaft removal 1. Remove cylinder head cover 2. Remove camshaft chain pensioner screw and then O-ring. 3. Lock camshaft chain pensioner by turning it clockwise. 4. Rotate fan to have the mark on the camshaft chain in an upward position, which is TDC of engine compression stroke.
  • Page 32 CHAPTER 3 ENGINE SERVICE MANUAL 6. Loosen 2 nuts (B) 、Loosen 4 nuts （A), Remove camshaft holder and pins 7. Remove camshaft. 8. Check for intake and exhaust cam damage. Replace when intake valve ： below 25.75mm exhaust valve ： below 25.41mm. 9.
  • Page 33 CHAPTER 3 ENGINE SERVICE MANUAL 2. Check camshaft holder, rocker arms and rocker arm shafts for abnormal wear and tear. 3. Measure the inside diameter of rocker arm shaft hole in camshaft holder. Limit: 10.10mm. 4. Measure the inside diameter of rocker arm hole.
  • Page 34 CHAPTER 3 ENGINE SERVICE MANUAL 5. Remove dowel pin, cylinder head gasket and take out chain guide. 6. Remove the gasket on cylinder surface. NOTE: Make sure the contact cylinder surfaces are not scratched. Make no other objects fall into the crankcase. NOTE: The cylinder head gasket must not be reused.
  • Page 35 CHAPTER 3 ENGINE SERVICE MANUAL 15. Eliminate carbon deposits from valve seat. NOTE: Be sure not to scratch the valve seat contact face. 16. Measure valve guide inside diameter. Limit: Intake： 5.08mm exhaust ：5.10mm Install cylinder head in the reverse order of removal.
  • Page 36 CHAPTER 3 ENGINE SERVICE MANUAL Remove piston ring. Eliminate the carbon deposits from the piston ring grooves and rings. NOTE: Be sure to keep the piston ring undamaged. Position piston ring. Measure the gap between piston ring and ring groove. Limit: first ring：...
  • Page 37 CHAPTER 3 ENGINE SERVICE MANUAL 8. Measure piston outside diameter from an angle of 90º to piston pin bore, in a position some 9mm from piston bottom. 9. Check cylinder inside surface for scratches wear. Measure cylinder inside diameter from and angle of 90º to piston pin and in upper, middle and lower three positions.
  • Page 38 CHAPTER 3 ENGINE SERVICE MANUAL Take out V-belt. Check belt for cracks, wear, scaling or chipping. Measure V-belt width. limit ：19.0mm, Remove sliding sheave. Remove movable cams. Remove clutch weights. CHAPTER 3C ENGINE PAGE. - 13 -...
  • Page 39 CHAPTER 3 ENGINE SERVICE MANUAL Check weights wear. 10. Measure weight outside diameter. Limit ： 17.44mm 11. Measure sliding sheave inside diameter Limit ：24.06mm. 12. Check collar wear. Measure collar outside diameter. Limit ：23.94mm,replace. 13. Remove clutch. 14. Check clutch disk wear. Limit ：125.5mm CHAPTER 3C ENGINE PAGE.
  • Page 40 CHAPTER 3 ENGINE SERVICE MANUAL 15. Check spacer wear. Measure its thickness. Limit ：1.5mm 16. Remove clutch assembly. 17. Remove clutch locknut. 18. Take out secondary fixed sheave and sliding sheave. 19. Measure compression spring free length. Limit: 163mm CHAPTER 3C ENGINE PAGE.
  • Page 41 CHAPTER 3 ENGINE SERVICE MANUAL 20. Check secondary sliding sheave wear. Measure its shaft inside diameter. Limit ：34.06m 21. Check secondary fixed sheave wear. Measure its shaft diameter. Limit ： 33.94mm Install them in the reverse order of removal. NOTE: Never smear grease to the V-belt, secondary sheave and clutch.
  • Page 42 CHAPTER 3 ENGINE SERVICE MANUAL 3.4.4Transmission 3.4.4.1 Transmission Disassembly Remove transmission case drain plug located on the front cover and drain the oil. 2. Remove transmission case fixing bolts. 3. Knock the input shaft carefully with a soft face hammer to separate the transmission case from...
  • Page 43 CHAPTER 3 ENGINE SERVICE MANUAL 4. Prior to reinstalling the transmission make sure the mating surfaces are clean and dry, and shafts are fully seated in transmission case. Apply silicon glue to mating surfaces. 5. Reinstall left crankcase and torque bolts in a cross pattern in 3 step to 14.5 ft.lbs.
  • Page 44 CHAPTER 3 ENGINE SERVICE MANUAL 3.4.5 Crankcase and crankshaft 1. Remove chain guide fixing bolt to take out chain. 2. Remove driven gear from crankshaft and inspect gear for wear. CHAPTER 3C ENGINE PAGE. - 19 -...
  • Page 45 CHAPTER 3 ENGINE SERVICE MANUAL 3. Remove crankcase fixing bolts and separate the left crankcase from the right one. 4. Remove gasket fitting pin. 5. Take out crankshaft and timing chain. 6. Clean gasket on crankcase contact face . NOTE: Make sure the contact faces are not scratched to avoid oil leakage.
  • Page 46 CHAPTER 3 ENGINE SERVICE MANUAL 7. Remove oil seal from crankcase. Inspect oil seal for wear. 8. Measure connecting rod big end side clearance. Limit ：0.55mm. 9. Measure big end crankpin diametral clearance. limit ：0.55mm 10. Measure small end orifice inside diameter. limit ：...
  • Page 47 CHAPTER 3 ENGINE SERVICE MANUAL 2. Remove 4 fixing bolts to take out fan. Inspect fan for blade aging and cracks. If so, replace. 3. Remove magneto flywheel locknut. 4. Take out magneto rotor using the flywheel puller. Inspect magneto flywheel tapered orifice and key way for wear, scratches and cracks.
  • Page 48 CHAPTER 3 ENGINE SERVICE MANUAL 3.4.7 Electric starter 1. Remove starter clutch. 2. Remove idler gear and idle gear shaft. 3. When turning the starter wheel gear counterclockwise, it should turn freely. When turning the starter wheel gear clockwise, it should be engaged. 4.
  • Page 49 CHAPTER 3 ENGINE SERVICE MANUAL 10. Measure idle gear shaft orifice inside diameter. Limit ：10.05mm 11. Measure idle gear shaft outside diameter. Limit ：9.94mm Install them in the reverse order of removal. 3.4.8 Oil pump 1. Remove bolts to dismount right crankcase cover.
  • Page 50 CHAPTER 3 ENGINE SERVICE MANUAL Inspect oil pump inner and outer rotors for abnormal wear. If so, replace the oil pump assembly. 7. Fasten pump with screws after assembling. Install oil pump in the reverse order of removal. NOTE: Be sure to point the arrow on the oil pump to the direction of crankshaft in installation and infuse some oil into the pump beforehand.
  • Page 51 CHAPTER 3 ENGINE SERVICE MANUAL 2. Remove fuel hose and air pressure tube. 3. Remove throttle cable locknut to take out throttle cable. Loosen inlet-valve seat screw and air filter fixing screw to remove carburetor. NOTE: Make sure the fuel in the fuel bowl is drained before the carburetor removal lest the cylinder head be sprinkled with the fuel, which is likely to bring about a fire.
  • Page 52 CHAPTER 3 ENGINE SERVICE MANUAL 3.6 TIGHTENING TORQUES OF ENGINE MAIN FASTENERS Description Thread size Tightening torque (N•m) Cylinder head bolt Oil filter screen cover bolt Exhaust pipe nut Camshaft seat nut Valve adjuster lock nut Cam chain tensioner bolt Transmission case drain bolt Clutch drive plate nut Clutch driven disk nut...

  • Page 53: Ignition System

    CHAPTER 3 ENGINE SERVICE MANUAL 3.7 IGNITION SYSTEM 3.7.1 INSTALLATION INFORMATION OPERATING POINTS ● Check ignition system in accordance with the troubleshooting procedure in section 3.11.2 ● As the ignition system has an electric automatic spark control in CDI unit, there is no need for spark advance angle adjustment.

  • Page 54: Cdi Inspection

    CHAPTER 3 ENGINE SERVICE MANUAL ● Poor CDI ground ● Faulty pickup coil ● Poor high tension lead terminal connection ● Faulty CDI unit High Tension Voltage Normal but No Spark ● Faulty spark plug ● Faulty spark plug cap No High Tension Voltage ●...
  • Page 55 CHAPTER 3 ENGINE SERVICE MANUAL Test the primary coil resistance, the standard value of which should be 0.1-1.0Ω. Test the secondary coil resistance from spark plug cap negative terminals, the standard value of which should be 7-9kΩ(with cap) and cap). 3-4kΩ(without Coil test using after market spark tester.
  • Page 56 CHAPTER 3 ENGINE SERVICE MANUAL Since CDI is used, there is no need to adjust the timing advance. If the spark advance is abnormal, inspect CDI, pickup coil or magneto. Replace if necessary. Remove timing lid. After the engine is warmed up, check the spark advance angle by the spark timing lamp.
  • Page 57 CHAPTER 4 CHASSIS SERVICE MANUAL CHAPTER 4 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. 4.1 FRONT A-ARM REPLACEMENT 4.2 REAR A-ARM REPLACEMENT 4.3 REAR STABILIZER BAR REMOVA L/INSTALLATION...
  • Page 58 CHAPTER 4 CHASSIS SERVICE MANUAL 4.1 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 59 CHAPTER 4 CHASSIS SERVICE MANUAL Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. 4.2 REAR A-ARM REPLACEMENT CHAPTER 4 CHASSIS PAGE. 4-...
  • Page 60 CHAPTER 4 CHASSIS SERVICE MANUAL 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 61 CHAPTER 4 CHASSIS SERVICE MANUAL 7. Loosen the bolt that secure the A-arm to frame by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper A-arm. 8. Examine the A-arm bushing and A-arm shaft. Replace if worn.
  • Page 62 CHAPTER 4 CHASSIS SERVICE MANUAL 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 63 CHAPTER 4 CHASSIS SERVICE MANUAL 8. Reverse the procedure for installation.Torque the stabilizer bolts to 23 ft.lbs (32 Nm). 4.4 FRONT STRUT REPLACEMENT 1. Hold strut rod with wrench and remove top nut. 2. Compress spring. 3. Remove upper strut pivot assembly. 4.
  • Page 64 CHAPTER 4 CHASSIS SERVICE MANUAL 7. Install front shock cartridge until bottomed in strut casting. 8. Install pinch bolts with clamp(s). Torque pinch bolts to 15ft.lbs.(21Nm). 9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully.
  • Page 65 CHAPTER 4 CHASSIS SERVICE MANUAL 4.6 BOX REMOVAL/INSTALLATION Box Removal 1. Disconnect the license light coupler. 2. Lift the box into the dump position. 3. Remove the box shock pin from the frame (both sides). 4. Remove the shocks from the shock brackets. Let the shocks fully extend.
  • Page 66 CHAPTER 4 CHASSIS SERVICE MANUAL 4.7 STEERING ASSEMBLY REMOVAL/INSTALLATION 1. With the steering wheel cover bolts removed, remove the steering wheel cover and the steering wheel. 2. With the steering wheel holder nut removed, remove the steering wheel holder. 3. Remove the steering column bolts. 4.

  • Page 67: Chapter 5 Final Drive

    CHAPTER 5 FINAL DRIVE SERVICE MANUAL CHAPTER 5 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. 5.1 W HEEL, HUB , AND SPINDLE TORQUE TABLE 5.2 FRONT HUB EXPLODED VIEW 5.3 FRONT HUB REMOVAL/INSPECTION...

  • Page 68: Wh E E L , H U B , And Spindle Torque Table

    CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 59 Ft.Lbs 66 Nm Front W heel Nuts 59 Ft.Lbs 66 Nm Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 Nm Rear Hub Retaining Nut 101 Ft.Lbs 137 Nm...

  • Page 69: Front Hub Installation

    CHAPTER 5 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 70 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 7. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) CAUTION: New bolts have a pre-applied locking agent which is destroyed bolts upon removal.

  • Page 71: Rear Hub Exploded View

    CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.6 REAR HUB EXPLODED VIEW 5.7 RE AR HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate rear end and safely support machine under main frame area. C AUTIO N: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service...

  • Page 72: Re Ar Drive Shaft Rem Oval

    CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.8 RE AR HUB AND KNUCKLE INSTALL ATION 1. Start the rear hub and knuckle assembly onto the drive shaft. 2. Align the bottom of knuckle and lower control arm. Secure with the lower control arm bolt. 3.

  • Page 73: Re Ar Drive Shaft Install Ation

    CHAPTER 5 FINAL DRIVE SERVICE MANUAL 5.10 RE AR DRIVE SHAFT INSTALL ATION 1. Install a new circlip onto the rear drive shaft. Apply Anti-Seize Compound onto the rear driveshaft splines (both ends). 2. Reinstall the rear driveshaft into the rear gearcase.
  • Page 74 CHAPTER 5 FINAL DRIVE SERVICE MANUAL 7. Lower the vehicle. Torque the spindle retaining nut to 101 ft.lbs. (137 Nm). Install a new cotter key and the hub cap. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) CHAPTER 5 FINAL DRIVE.

  • Page 75: Chapter 6 Brakes

    CHAPTER 6 BRAKES SERVICE MANUAL CHAPTER 6 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 76: Specifications

    CHAPTER 6 BRAKES SERVICE MANUAL 6.1 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 "/ 0.051m m Between Measurements Brake Disc Run out 0.005 "/0 .127mm Rear Brake Caliper...

  • Page 77: Brake Bleeding-Fluid Change

    CHAPTER 6 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 78 CHAPTER 6 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 up to the indicated MAX level on the reservoir.
  • Page 79 CHAPTER 6 BRAKES SERVICE MANUAL Master Cylinder Fluid Level Between the MIN line and the MAX line of reservoir. 12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve.

  • Page 80: Parking Brake Adjustment

    CHAPTER 6 BRAKES SERVICE MANUAL 1. Inspect the spring on the parking brake lever assembly. 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3. Inspect the brake lines and brake line connections for possible leaks or loose lines. 6.7 PARKING BRAKE ADJUSTMENT Parking Brake Inspection 1.
  • Page 81 CHAPTER 6 BRAKES SERVICE MANUAL will not roate. 5. Back the adjustment bolt (B) out 1/4 turn. 6. Tighten the jam nut (A) while holding the adjustment nut (B) in place. 6.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads.
  • Page 82 CHAPTER 6 BRAKES SERVICE MANUAL 6.9 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set REMOVAL 1. Elevate and support front of CUV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 83 CHAPTER 6 BRAKES SERVICE MANUAL INSPECTION Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Service Limit 0.3/64"(1 mm) INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots.
  • Page 84 CHAPTER 6 BRAKES SERVICE MANUAL 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New 0.150-0.164" (3.810 - 4.166 mm) Service Limit 0.140"...
  • Page 85 CHAPTER 6 BRAKES SERVICE MANUAL 1. Remove wheel, remove caliper from the strut. 2. Loosen and remove brake hose to caliper. Place a container under caliper to catch fluid draining. INSPECTION Inspect caliper body for nicks, scratches or worn. Replace caliper as an assembly if any problem exists.
  • Page 86 CHAPTER 6 BRAKES SERVICE MANUAL damage brake line. Support caliper so as not to kink or bend brake line. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed. NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
  • Page 87 CHAPTER 6 BRAKES SERVICE MANUAL Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 1. Safely support the rear of the machine. 2. Use a wrench to remove the brake line. Place a container to catch brake fluid draining from brake lines.

  • Page 88: Removal/ Replacement

    CHAPTER 6 BRAKES SERVICE MANUAL micrometer and a dial indicator. Replace disc if worn beyond service limit. Brake Disc Thickness New 0.150-0.164" (3.810 - 4.166 mm) Service Limit 0.140" / 3.556 mm Brake Disc Thickness Variance Service Limit 0.002 " (0.051 mm) difference between measurements 3.

  • Page 89: Chapter 7 Electrical

    CHAPTER 7 ELECTRICAL SERVICE MANUAL CHAPTER 7 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY IGNITION SYSTEM CHARGING SYSTEM ELECTRICS STARTING SYSTEM LIGHTING SYSTEM REVERSE LIMIT SYSTEM GEAR POSITION INDICATOR SWITCH TEST SPEEDOMETER SYSTEM 7.10 MAIN SWITCH 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR 7.12 WIRING DIAGRAM CHAPTER 7 ELECTRICAL PAGE.7-...

  • Page 90: Headlight Adjustment

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.1 PARTS INSPECTION AND SERVICE A HEADLIGHT ADJUSTMENT 1. Use bulb 12V 35W/35W. 2. Remove the black sheath, turning the socket counterclockwise and take it out. Turning the bulb counterclockwise and Remove it from the socket. 3.
  • Page 91 CHAPTER 7 ELECTRICAL SERVICE MANUAL TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recommended lamp. 3. Reinstall the lens cover removed in step 1. 4.

  • Page 92: Battery Testing

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 93 CHAPTER 7 ELECTRICAL SERVICE MANUAL Load test CAUTION: Remove spark plug high tension leads and connect securely to engine ground before proceeding. NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly. A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage capacity necessary to properly function in the electrical system.

  • Page 94: Ignition System Troubleshooting

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.3 IGNITION SYSTEM IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark  Spark plug gap incorrect  Fouled spark plug  Faulty spark plug cap or poor connection to high tension lead  Related wiring loose, disconnected, shorted, or corroded Emergency switch faulty ...

  • Page 95: Circuit Diagram

    CHAPTER 7 ELECTRICAL SERVICE MANUAL CIRCUIT DIAGRAM CHAPTER 7 ELECTRICAL PAGE.7-...
  • Page 96 CHAPTER 7 ELECTRICAL SERVICE MANUAL IF THE IGNITION SYSTEM FAILS TO OPERATE Procedure Check: 1. Fuse (Main) 7.Pickup coil resistance 2. Battery 8.Main switch 3. Spark plug 9.Engine stop switch 4. lgnition spark gap 10.Wiring connection 5. Spark plug cap resistance (entire ignition system) 6.
  • Page 97 CHAPTER 7 ELECTRICAL SERVICE MANUAL Turn the main switch to "ON". Check the ignition spark gap . MEETS SPECIFICATION Check the spark by pushing the ignition switch, and increase the The ignition system is not faulty. spark gap until a misfire occurs. Minimum spark gap: 6mm (0.24 in) OUT OF...
  • Page 98 CHAPTER 7 ELECTRICAL SERVICE MANUAL Tester (+) lead Light Green Terminal 6. Ignition coil resistance Tester (- ) lead Black Terminal Disconnect the ignition coil connector from wire harness. Connect the pocket tester to the ignition coil.  Check if the primary coil has the specified resistance or inductance.
  • Page 99 CHAPTER 7 ELECTRICAL SERVICE MANUAL 7. Pickup coil resistance  Disconnect the pickup coil coupler from the wire harness. Connect the pocket tester (Ω 100) to the pickup coil coupler. Tester (+) lead → BI/Y Terminal Tester (- ) lead→ engine ground ...
  • Page 100 CHAPTER 7 ELECTRICAL SERVICE MANUAL CHECK SWITCHES Replace the Emergency switch. CONTINIUTY 10.Wiring connection Check the connection of the entire ignition system Refer to ―CIRCUIT DIAGRAM‖. POOR CONNECTIONS Correct CORRECT Replace the igniter unit. CHAPTER 7 ELECTRICAL PAGE.7- 12...

  • Page 101: Charging System Circuit Diagram

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM CURRENT DRAW KEY OFF CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to light bulbs . Connect an ammeter in series with the negative battery cable. Check for current draw with the key off, if the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated.
  • Page 102 CHAPTER 7 ELECTRICAL SERVICE MANUAL CHARGING SYSTEM Procedure Check: 1. Fuse (Main) 4.Stator coil resistance 2. Battery 5.Wiring system (entire charging system) 3.Charging voltage 1. fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to "BATTERY TESTING" Clean battery terminals Recharge or replace the battery 3.Charging voltage...
  • Page 103 CHAPTER 7 ELECTRICAL SERVICE MANUAL 4. Starter coil resistance Remove the A.C. magneto coupler from wire harness Connect the pocket tester (ΩX1) the starter coil Tester (+) lead – starter motor terminal Tester (-) lead –engine ground OUT OF SPECITICATION Measure the stator coil resistance Stator coil resistance 0.5-0.8Ω（20℃）...
  • Page 104 CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.5 ELECTRICS STARTING SYSTEM D I A G R A M CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 105 CHAPTER 7 ELECTRICAL SERVICE MANUAL TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE Procedure Check: 6. Engine stop switch 1. Fuse (Main) 7. front/rear brake switch 2. Battery 8. wiring connection (entire starting system) 3. starter motor 4. starter relay 5.
  • Page 106 CHAPTER 7 ELECTRICAL SERVICE MANUAL WARNING 4.Starter relay A wire used as a jumper lead Disconnect the relay unit coupler from must have the equivalent the wire harness. capacity as that of the battery Connect the pocket tester (Ωx1) and lead or more, otherwise it battery (12V) to the relay unit coupler may burn.
  • Page 107 CHAPTER 7 ELECTRICAL SERVICE MANUAL 8. Wiring connection POOR CONNECTION Check the connections of the entire starting system. Refer to ―CIRCUIT DIAGRAM Correct CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...

  • Page 108: Lighting System

    CHAPTER 7 ELECTRICAL SERVICE MANUAL LIGHTING SYSTEM FOR USA MODEL CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 109 CHAPTER 7 ELECTRICAL SERVICE MANUAL FOR EUROPE MODEL CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 110 CHAPTER 7 ELECTRICAL SERVICE MANUAL TROUBLESHOOTING Procedure Check: 1. Fuse (Main) 4.Lights switch 2. Battery 5.Distance light switch 3. Main switch 6. Wiring connection (entire lighting system) 1.fuse NO CONTINUITY Replace the fuse 2. Battery Check the battery condition. INCORRECT Refer to ―BATTERY INSPECTION‖...
  • Page 111 CHAPTER 7 ELECTRICAL SERVICE MANUAL POOR CONNECTIONS 6.Wiring connection Check the connection of the entire lighting system correct 7.check the condition of each lighting system. Refer to ―LIGHTING SYSTEM CHECK‖ LIGHT SYSTEM CHECK 1. If the headlight fail to come on NO CONTINUITY 1.Blub and bulb socket CHECK SWITCHES...
  • Page 112 CHAPTER 7 ELECTRICAL SERVICE MANUAL 2. 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 bulb socket connector. Tester (+) lead →...
  • Page 113 CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.7 REVERSE LIMIT SYSTEM The limit set for the speed limiter by the manufacturer is 20 km/h, which can be reset in accordance with the user’s practice. Turning the adjusting bolt clockwise is to increase the speed, while counterclockwise decrease it.
  • Page 114 CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.8 GEAR POSITION INDICATOR SWITCH TEST CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 115 CHAPTER 7 ELECTRICAL SERVICE MANUAL Switch schematic CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 116 CHAPTER 7 ELECTRICAL SERVICE MANUAL SPEEDMETER SYSTEM OPERATION OF SPPED SENSOR Speed Sensor is on the rear axle Operation Instructions of Electric Dial Meter and Speed Sensor/ Operation Instructions of LCD Meter and Speed Sensor Hall Sensor is a new type sensor used to measure speed, angle, revolution and length, etc by means of voltage pulse signals converted from sensing gear ratio of black metal gear or gear rack.
  • Page 117 CHAPTER 7 ELECTRICAL SERVICE MANUAL Operation Instructions of the Meter assembly 1. Turn indicator light 7、8. The odometer 2. High beam indicator light 9. low voltage indicator 3. Seatbelt light 10. Fuel gauge Indicator 4. Reverse indicator light 11. Electric Dial Meter 5.

  • Page 118: Main Switch

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.10 MAIN SWITCH CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...

  • Page 119: Fuel Gauge/ Fuel Level Sensor

    CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.11 FUEL GAUGE/ FUEL LEVEL SENSOR Removal Turn the main switch to“OFF”. bolts Disconnect the fuel level sensor from wire harness. Remove the four bolts, washer, spring washers and fuel level sensor from the fuel tank. Installation Install the sensor into the fuel tank .(refer to the right photo)

  • Page 120: Float Position

    CHAPTER 7 ELECTRICAL SERVICE MANUAL When shows that there are only two segments, segments should blink. With the fuel level sensor float at the top (FULL) position, turn the main switch to “ON” and check the fuel gauge. All segments up to segment “F”should come on.
  • Page 121 CHAPTER 7 ELECTRICAL SERVICE MANUAL Circuit of the fuel level CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...
  • Page 122 CHAPTER 7 ELECTRICAL SERVICE MANUAL 7.12 WIRING DIAGR CHAPTER 7 ELECTRICAL CTRICAL PAGE 7...

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