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Aeon Crossland X4 400 2012 Service Manual

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2012 CROSSLAND X4 400
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Aeon Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.
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  • Page 1 FOREWORD This service manual is designed primarily for use by certified Aeon Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

  • Page 2: Understanding Manual Safety Labels And Directions

    UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 GENERAL INFORMATION MAINTENANCE CVT SYSTEM ENGINE 4X4 TRANSMISSION FUEL SYSTEM AND CARBURETOR FINAL DRIVE BODY / STEERING / BRAKES ELECTRICAL...

  • Page 4: General Information

    GENERAL INFORMATION CHAPTER 1 MODEL INFORMATION ............. 1-2 .

  • Page 5: Model Information

    GENERAL INFORMATION MODEL INFORMATION VIN IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The frame can be found under front cab on the right side of Engine serial number local under rear seat stamped on the rear of frame. crankcase beneath exhaust pipe. The vehicle identification number (VIN) and engine serial number are important for identification purposes.
  • Page 6 GENERAL INFORMATION CROSLAND 4X 400 Model---AT77-69E Model number---RF3AU7710CT???????? Engine Model---V69S...

  • Page 7: General Specification

    GENERAL INFORMATION GENERAL SPECIFICATION SPECIFICATIONS MODEL: CROSSLAND 4X 400 ENGINE DRIVE SYSTEM Type Gear Box Oil capacity 1200 CC/ 80w90 4 Stroke, Single horizontal camshaft Displacement 346.4 CC Gear Oil type 80w90 Cooling Liquid cooled Transmission type CVT with H/L/N/R Bore and stroke 82 mm *65.6 mm Forward gear ratio...

  • Page 8: Coversion Table

    GENERAL INFORMATION COVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm = kg-m in. lbs x .0115 x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 9: Glossary Of Terms

    GENERAL INFORMATION GLOSSARY OF TERMS ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters.
  • Page 10 GENERAL INFORMATION Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system.

  • Page 11: Table Of Contents

    MAINTENANCE CHAPTER 2 PERIODIC MAINTENANCE CHART ........... .2-3 PERIODIC MAINTENANCE OVERVIEW .
  • Page 12 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ..........2.20 BATTERY MAINTENANCE .

  • Page 13: Periodic Maintenance Chart

    AEON dealer. ◆ = SEVERE USE ITEM -- See Above NOTE: Inspection may reveal the need for replacement parts. Always use genuine Aeon parts. Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or death.
  • Page 14 Perform a break-in oil change at 25 hours, Clean filter at every oil change; ◆ Oil pre-filter screen 1000 ■ Perform these procedures more often for vehicles subjected to severe use. ◆ Have an authorized AEON dealer perform these services.

  • Page 15: 50 - 300 Hour Maintenance Interval

    ◆ Brake fluid 100H 1500 Inspect periodically; adjust when ■ Toe adjustment parts are replaced. Headlight Aim Adjust as needed ■ Perform these procedures more often for vehicles subjected to severe use. ◆ Have an authorized Aeon dealer perform these services.

  • Page 16: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLA INSPECTION AND MAINTENANCE PRE-RIDE / DAILY INSPECTION • Throttle - check for free operation Perform the following pre-ride inspection daily, and when • Headlight / Taillight / Brake light - check operation of all servicing the vehicle at each scheduled maintenance. indicator lights and switches •...
  • Page 17 MAINTENANCE MAINTENANCE QUICK CHART (FRONT / REAR)

  • Page 18: Maintenance Quick Reference

    MAINTENANCE MAINTENANCE QUICK REFERENCE Item Comment Method Frequency Engine oil OW-50 Synthetic Check level or Check during pre-ride inspection change 20W-40 Semi-Synthetic change oil oil every 30 hours or 6 months. Transmission SAE80W-90 Gear Check level or Inspect periodically and change Lubricant change lube.

  • Page 19: Recoil Starter And Operation

    MAINTENANCE RE-COIL OIL STARTER AND OPERATION Throttle Free Play Adjustment If the battery becomes too weak to start the engine, use the Inspection re-coil starter to start the engine until the battery is serviced. 1. Place the transmission in the N position. 2.

  • Page 20: Idle Speed Adjustment

    MAINTENANCE FUEL SYSTEM AND AIR INTAKE Vent Lines 1. Check fuel tank, front gear case, and rear gear case and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. 2. Be sure vent lines are routed properly and secured with cable ties.

  • Page 21: Fuel Filter

    MAINTENANCE FUEL FILTER 3. Inspect the drained fuel for water or sediment. The fuel filter should be replaced in accordance with the 4. Tighten drain screw. “Periodic Maintenance Chart” or whenever sediment is 5. Check for fuel leaks. visible in the filter. 6.

  • Page 22: Air Box Sediment Tube

    MAINTENANCE AIR BOX SEDIMENT TUBE Periodically check the air box sediment tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube. 4. Apply commercially available foam filter oil to the foam filter. 5. Inspect the filter support screen and clean away any oil or sediments in the air box.

  • Page 23: Engine And Transmission Oil Location

    MAINTENANCE ENGNIE ENGINE AND TRANSMISSION OIL LOCATION 4. Check to see that the oil level is in the ’normal’ range. The OIL LEVEL level should be, at minimum, halfway between to the top of the To Check The Oil Level: viewing area.

  • Page 24: Engine Oil And Filter Service

    MAINTENANCE NOTE: The sealing surfaces on the drain plug and Recommended Engine oil: crankcase should be clean and free of burrs, nicks Synthetic, 0W-40 Above 0°C (32°F) or scratches. Semi-Synthetic 20W-40 Below 0°C (32°F) ENGINE OIL AND FILTER SERVICE 9. Reassemble the pre-filter screen and spring to the pre-filter The single cylinder engine is a wet-sump engine, meaning the plug.

  • Page 25: Engine Mounts Location

    MAINTENANCE 5. When clearance is correct, hold adjuster screw and tighten 2. Remove spark plug and rotate engine to TDC on the locknut securely. compression stroke. There are 2 places align TDC, One locates 6. Re-check the valve clearance. in engine oil filling cap of upper right crankcase, another locate 7.

  • Page 26: Transmission, Final Drive And Trasfer Gear

    MAINTENANCE TRANSMISSION, FINAL DRIVE AND TRANSFER GEAR TRANSMISSION LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. Remember to: • Verify the vehicle is level before proceeding. • Verify the vent hose is routed properly and is not obstructed. •...

  • Page 27: Front Differential Lubrication

    MAINTENANCE Transfer Gear case Drain Plug: 19 Nm (14 ft. lbs.) Transfer Case Lubricant: 100 ml (3 oz.)/ 80W90 FRONT DIFFERENTIAL LUBRICATION Follow instructions to check / change transmission fluid. Follow instructions to check / change transmission fluid. Transfer gear case lubricant check/ change procedure which Transfer gear case lubricant check/ change procedure which same as transmission.

  • Page 28: Cvt Drying

    MAINTENANCE COOLING SYSTEM CVT DRYING COOLING SYSTEM OVERVIEW NOTE: If operating the vehicle through water, be sure The engine coolant level is controlled, or maintained, by the to check the CVT and other components for water recovery system. The recovery system components are the ingestion.

  • Page 29: Coolant Strength / Type

    MAINTENANCE With the engine at operating temperature, the coolant level • Do not use tap water, straight antifreeze, or straight water in the should be between the upper and lower marks on the coolant system. Tap water contains minerals and impurities, which build recovery bottle.

  • Page 30: Electrical And Ignition System

    MAINTENANCE ELECTRICAL AND IGNITION SYSTEM BATTERY MAINTENANCE Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one-tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.

  • Page 31: Battery Off Seasonstorage

    MAINTENANCE Battery Cleaning CAUTION Keep the battery terminals and connections free of corrosion. Always wear safety glasses, rubber protective If cleaning is necessary, remove the corrosion with a stiff wire gloves and appropriate clothing when working with brush. Wash with a solution of one-tablespoon baking soda batteries.

  • Page 32: Battery Charging (Sealed Battery)

    MAINTENANCE BATTERY CHARGING (SEALED BATTERY) BATTERY INSPECTION The sealed battery is already filled with electrolyte and has When installing a new battery, make sure it's fully charged been sealed at the factory. Never pry the sealing strip off or prior to its initial use. Using a new battery that has not been add any type of fluid to this battery.

  • Page 33: Fuses / Fuse Holder Location

    MAINTENANCE FUSES / FUSE HOLDER LOCATION A 15 Amp fuse protects the main electrical system, a 30 Amp fuse protects ignition system and a 10 Amp fuse protects the headlight and taillight. See illustrations for fuse locations. 1. It locates under the seat and in storage box. 2.

  • Page 34: Engine/ Frame Ground

    Replace the tie-rod end, if tie rod end has any vertical Due to the critical nature of the procedures outlined play. in this chapter, an authorized Aeon Dealer performs The steering component repair and adjustment. Only a qualified technician should replace worn or damaged steering parts.

  • Page 35: Toe Alignment Inspection

    MAINTENANCE 1. Elevate front end of ATV so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

  • Page 36: Toe Adjustment

    MAINTENANCE TOE ADJUSTMENT • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both ends of the tie rod. Tie Rod Jam Nut Torque: • Shorten or lengthen the tie rod until alignment is as required to 16-19 Nm (12-14 ft.

  • Page 37: Rear Suspension Spring Preload Adjustment

    MAINTENANCE REAR SUSPENSION SPRING PRELOAD NOTE: ADJUSTMENT The spring preload of the rear shock absorber can be adjusted to suit the rider’s preference, weight, and The rear spring preload can be adjusted. To make preload the riding conditions. adjustments, rotate the adjustment cam clockwise to decrease spring tension or counter-clockwise to increase spring tension.

  • Page 38: Brake System

    MAINTENANCE BRAKE SYSTEM BRAKE FLUID INSPECTION Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only. Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.
  • Page 39 MAINTENANCE Foot Brake Adjustment 1. Repeat step 1~5 for parking caliper cable adjusting. 1. Position the vehicle on a level surface. 2. Shift the transmission into neutral (if applicable). 3. Elevate the vehicle by placing a suitable stand under the frame.

  • Page 40: Brake Pad/ Disc Inspection

    MAINTENANCE WHEELS AND TIRES Brake Pad / Disc Inspection WHEELS 1. Check the brake pads for wear, damage, or looseness. Inspect all wheels for run out or damage. Check wheel bolts 2. Inspect the brake pad wear surface for excessive wear. and ensure they are tight.

  • Page 41: Wheel Installation - Front / Rear

    MAINTENANCE Wheel Installation - Front / Rear Tire Pressure Inspection (PSI - Cold) Front Rear 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be 5 psi (35 kPa) 5 psi (35 kPa) sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
  • Page 42 CVT SYSTEM CHAPTER 3 CVT SYSTEM OVERVIEW ............. .3-2 CVT MAINTENANCE / INSPECTION .

  • Page 43: Cvt System Overview

    (initial vehicle movement), clutch up shift forces applied to it from the drive belt, while at the same time and backshift. During the development of an Aeon ATV, the reacting to the torque at the transmission input shaft. If the CVT system is matched first to the engine power curve;...

  • Page 44: Cvt System Drying

    CVT SYSTEM CVT SYSTEM DRYING NOTE: If operating the ATV through water, be sure to check the CVT cover and other ATV components for water ingestion. The ATV should be checked immediately. Refer to Owner’s Manual for Safe Riding Tips. 1.

  • Page 45: Cvt Exploded View

    CVT SYSTEM CVT EXPLODED VIEW...

  • Page 46: Cvt Overheating/Diagnosis

    Repeat several times as required. During this procedure, the throttle should not be held at the full position. CVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. A certified AEON technician should perform Inspection/repair of clutch components.

  • Page 47: Drive Clutch Removal

    CVT SYSTEM DRIVE CLUTCH REMOVAL Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Position the vehicle on a level surface. Use the parking brake. 2. Remove seat, storage box and LH plastic panel to gain access to the outer clutch cover.
  • Page 48 CVT SYSTEM 8. Remove outer sheave from crankshaft. 7. Remove belt. 8. Use two hands to hold the cam plate and the primary sliding sheave together when removing the primary sliding sheave and the cam plate assembly. This prevents the roller weights from falling out of the assembly.

  • Page 49: Driven Clutch Removal

    CVT SYSTEM DRIVEN CLUTCH DRIVEN CLUTCH REMOVAL 2. Remove the nut by pincer and air wrench. NOTE: This assembly utilizes a torque limiting system to prevent transmission damage. Use care removing the clutch assembly, as the torque limiting components become free and could fall apart. Mark or note parts during disassembly.

  • Page 50: Driven Clutch Service

    CVT SYSTEM DRIVEN CLUTCH SERVICE DRIVEN CLUTCH DISASSEMBLY AND INSPECTION Driven Clutch Friction Pad Service Limit: 2 mm (0.078”) 1. Inspect the condition of the clutch drum. Measure the inside Driven Clutch Hub I. D.: diameter of the cover at 90 degree intervals using a caliper. Service Limit: 153 ﹢0.2 mm Inspect the condition and diameter of the drum lining.

  • Page 51: Driven Clutch Assembly

    CVT SYSTEM 2. Have an assistant available for final assembly. Install the compression spring. Place the friction pad assembly over the spring and compress the driven assembly together with both hands. With the assembly compressed and the threads exposed, have an assistant thread a new retaining nut onto the shaft.

  • Page 52: Cvt Belt Inspection

    CVT SYSTEM CVT BELT INSPECTION Inspect the surface of the drive belt for uneven wear or grease deposits. Using a caliper, measure the width of the belt. The service limit of the belt is 24 mm. If the width of the belt is less Do not allow grease to contact the V-belt and the than the service limit, or if the belt is worn, glazed or secondary sheave assembly.

  • Page 53: Drive Clutch Service

    CVT SYSTEM DRIVE CLUTCH SERVICE DRIVE CLUTCH DISASSEMBLY AND 5. Inspect belt-contacting surface of both sheave for wear or INSPECTION damage. 1. Remove outer drive clutch sheave and drive belt. Note parts assembly order. 2. Slide sheave and cam plate off crankshaft as an assembly. NOTE: When removing primary sliding sheave and cam plate assembly, hold cam plate and sliding sheave together.
  • Page 54 ENGINE CHAPTER 4 ENGINE ILLUSTRATION ............. . .4-3 ENGINE EXPLODED VIEWS .
  • Page 55 ENGINE PISTON RING INSTALLED GAP ..............4-28 ALTERATOR/ STSTER/ OIL PUMP EXPLODED VIEW .

  • Page 56: Engine Illustration

    ENGINE ENGINE ILLUSTRATION ENGINE EXPLODED VIEW...
  • Page 57 ENGINE...

  • Page 58: Cooling System Exploded View

    ENGINE COOLING SYSTEM EXPLODED VIEW...

  • Page 59: Oil Folw Diagram

    ENGINE OIL FLOW DIAGRAM...

  • Page 60: Cooling System

    ENGINE COOLING SYSTEM SPECIFICATIONS CONDITION SPECIFICATION Thermostat Open 65° C Thermostat Full Open 80° C System Capacity 1200CC Fan Switch “On” 75° C/ 85° C (Two type) Pressure Cap Relief 0.9 Bar COOLANT CIRCULATION Recommended Coolant A) From radiator to coolant pump. Use only high quality antifreeze/coolant mixed with distilled B).

  • Page 61: Radiator

    ENGINE RADIATOR 1. Suspend the thermostat in a container filled with water. 1. Apply compressed air to the rear of the radiator. 2. Slowly heat the water. 2. Straighten any flattened fins with a thin, flathead screwdriver. 3. Place a thermometer in the water. 4.

  • Page 62: Fan Switch

    ENGINE FAN SWITCH WATER PUMP Removal 1. The fan switch is located at right of radiator. 1. Remove water pump tube. 2. Take off water pump bolts. 3. Tap water pump lightly with a plastic hammer in reinforced areas only until loose. FAN STARTING TEMPERATURE PRINT LOCATION.

  • Page 63: Air Drain Procedure

    ENGINE AIR DRAIN PROCEDURE 3. Remove recovery bottle cap and fill bottle to the full line. 4. Slightly loosen the bleed hose (bypass hose) to let air drain. 5. Push back and tight the bleed hose. Always wear safety glasses and proper shop clothing when performing the procedures in this manual.

  • Page 64: Overheat Trouble Shooting

    ENGINE OVERHEAT TROUBLE SHOOTING • Low coolant level • Air in cooling system • Wrong type/mix of coolant • Faulty pressure cap or system leaks • Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage) •...

  • Page 65: Piston

    ENGINE PISTON The following components require engine removal ASSEMBLY IDENTIFICATION for service: The piston has an identification mark for piston settle 1. Cam Chain and Sprockets placement. 2. Cylinder Head Note the directional and identification marks when viewing the 3. Cylinder pistons from the top.

  • Page 66: Engine Installation

    ENGINE Front engine mount Transmission ◎ Inspect transmission operation and adjust linkage if necessary. Exhaust ◎ Replace exhaust gaskets. Seal connections if desired with high temp sealant. ◎ After running the engine, verify all bolted exhaust connections are tight and in good condition. Engine Mount Torque ◎...

  • Page 67: Top-End Disassembly

    ENGINE TOP END DISASSEMBLY Oil Flow Test 4. Align single (TDC) mark on flywheel with in the inspection hole, and the cam sprocket holes (horizontal) aligned with the gasket surface line. Oil temperature can cause serious injury and damage. Wear the proper safety gear when performing these procedures.

  • Page 68: Cam Chain Tensioner Inspection

    ENGINE CAMSHAFT/SPROCKET REMOVAL AND INSPECTION 7. Using a cross screwdriver, turn the tensioner clockwise to retract the plunger. The plunger should move smoothly in and NOTE: Orientation of the components is important for reassembly. Mark all components before out of the tensioner body. 8.

  • Page 69: Rocker Arm/Shaft Disassembly And Inspection

    ENGINE ROCKER ARM/SHAFT DISASSEMBLY AND 3. Check de-compressor movement smooth on camshaft. INSPECTION 4. Inspect cam lobes surface, Replace it if has pitting, scratches or blue discoloration. 1. Remove rocker arm shaft and rocker arm from cylinder 5. Measure both intake and exhaust cam lobes length. Replace head.

  • Page 70: Cylinder Head Removal

    ENGINE CYLINDER HEAD REMOVAL 4. Check the two contact areas on the rocker arms. Replace them if has signs of abnormal wear. NOTE: Cam chain and tensioner must be removed. 5. Inspect the surface of the rocker arm shafts. Replace it if has If no crankshaft service is being performed, secure blue discoloration, pitting or scratches.

  • Page 71: Cylinder Head Inspection

    ENGINE CAUTION CYLINDER HEAD INSPECTION 1. Thoroughly clean cylinder head surface to remove all traces Tap only in reinforced areas or on thick parts of of gasket material and carbon. cylinder head casting to avoid damaging casting. 10. Remove cylinder head gasket and 2-dowel pins. Use care not to damage sealing surface.

  • Page 72: Combustion Chamber Inspection

    ENGINE COMBUSTION CHAMBER INSPECTION Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Inspect the combustion chamber for cracks and/or damage from foreign debris. CYLINDER HEAD DISASSEMBLY Wear eye protection or a face shield during cylinder 4.

  • Page 73: Valve Inspection

    ENGINE 5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). VALVE SPRING VERTICALITY Replace if excessive wear is evident. Service Limit: 1.6mm NOTE: Replace seals whenever the cylinder head is disassembled.

  • Page 74: Valve Seat Reconditioning

    ENGINE NOTE: Be sure to measure each guide and valve Follow the manufacturers instructions provided with the valve combination individually. seat cutters in the Valve Seat Reconditioning Kit. Abrasive 8. Replace valve and/or guide if clearance is excessive. stone seat reconditioning equipment can also be used. Keep NOTE: If valve guides are replaced, valve seats must valves in order with their respective seat.
  • Page 75 ENGINE ◎ If the indicated seat contact is at the top edge of the valve If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be face and contacts the margin area(B) it is too high on the valve face.

  • Page 76: Cylinder Head Assembly

    ENGINE CYLINDER HEAD ASSEMBLY 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Lapping is not required with an interference angle. Wear eye protection during assembly. NOTE: Assemble the valves one at a time to maintain proper order.

  • Page 77: Valve Sealing Test

    ENGINE BOTTOM END AISASSEMBLY 6. Place retainer on spring and install valve spring compressor. 2. Pour a small amount of cleaning solvent into each port and Compress spring only enough to allow split keeper installation check for leakage around each valve. to prevent loss of spring tension.

  • Page 78: Cam Chain Follower/ Tensioner Blades

    ENGINE CAM CHAIN FOLLOWER /TENSIONER BLADES 1. Remove bolt securing tensioner blade to crankcase A *Using a piston ring plier: Carefully expand ring and lift it off the piston. 2. Remove blades and inspect for cracks, wear, or damage. PISTON REMOVAL Do not expand the ring more than the amount 1.

  • Page 79: Cylinder Hone Selection/Honing Procedure

    ENGINE CYLINDER TAPER Limit: 0.05mm Max. CYLINDER OUT OF ROUND Limit: 0.05mm Max. CYLINDER HONE SELECTION/HONING PROCEDURE A hone, which will straighten as well as remove material from the cylinder, is very important. Using a CYLINDER WARP: common spring loaded glaze breaker for honing is 0.05 mm MAX not advised.

  • Page 80: Piston Inspection

    ENGINE ◎ After honing has been completed, inspect cylinder for 2. Subtract this measurement from the maximum cylinder thinning or peeling. measurement obtained earlier. IMPORTANT: Clean the Cylinder After Honing PISTON TO CYLINDER CLEARANCE It is very important that the cylinder be thoroughly cleaned Std: 0.02-0.05 mm after honing to remove all grit material.

  • Page 81: Piston Ring Installed Gap

    ENGINE PISTON RING INSTALLED GAP 5. Measure connecting rod small end ID. Replace crankshaft if out-of-round. 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown. 6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge.

  • Page 82: Alterator/ Stster/ Oil Pump Exploded View

    ENGINE ALTERATOR/ STATER/ OIL PUMP EXPLODED VIEW NOTE: The CVT system, starter motor, starter drive, flywheel, stator, oil pump and transmission can be serviced with the engine in the frame. 4-29...

  • Page 83: Sterterdrive Gear Removal/ Inspection

    ENGINE STARTER DRIVE GEAR REMOVAL/ INSPECTION 1. Remove water pump tube. 2. Take off water pump bolts. 3. Tap water pump lightly with a plastic hammer in reinforced areas only until loose. 8. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.

  • Page 84: Flwheel/ One-Way Clutch Removal/ Inspection

    ENGINE 3. Remove flywheel. 3. Inspect the bearing surfaces and drive teeth for signs of CAUTION wear or gouging. Replace the one-way clutch as an assembly if it is not working properly. Do not hammer or strike the tool while attached to 4.

  • Page 85: Oil Pump Drive Sprocket Removal/ Inspection

    ENGINE 7. Inspect idle gear and starter wheel teeth. Replace it if has any burrs, clips, roughness or worn. 8. Inspect the starter wheel contact surface. Replace it if has too much worn, pitting or damaged. 3. Remove pump chain drive sprocket circlip and chain from pump drive shaft and crankshaft.

  • Page 86: Oil Pump Removal

    ENGINE OIL PUMP REMOVAL CRANKCASE SEPARATION AND CAM CHAIN REMOVAL NOTE: Oil pump is not a serviceable assembly. NOTE: Stator housing, flywheel and gears have are previously removed for this procedure. Use care during the removal process to avoid damage to the cam chain.

  • Page 87: Crankshaft Removal

    ENGINE CRANKSHAFT / CAM & OIL CHAIN / 3. Watch the gap along the crankcase mating surface and SPROCKET INSPECTION separate the crankcase evenly. 4. Once the crankshaft bearing is free from the case, the 1. Inspect the crankshaft main bearings and cam and oil pump crankshaft and cam chain can be removed by hand for service.

  • Page 88: Crankcase/ Bearing Inspection

    ENGINE CRANKCASE / BEARING INSPECTION NOTE: Removal and installation of new seals is recommended anytime the crankcase is disassembled. 1. Inspect the bearings in the crankcase. NOTE: Due to extremely close tolerances and minimal side wear, the bearing must be inspected visually and by feel.

  • Page 89: Engine Reassembly

    ENGINE ENGINE REASSEMBLY CRANKSHAFT AND CAM/ OIL CHAIN NOTE: Use care not to damage the crankshaft end. INSTALLATION Lubricate all bearings with clean engine oil before assembly. 1. Support the crankcase on blocks. The balance shaft flat must square with crankshaft 2.

  • Page 90: Oil Pump And Chain Installation

    ENGINE 5. Install 4 flange bolts (circled) from the right side crankcase. 3. Beware the oil pump cover arrow must align with point. NOTE: Use care not to damage the crankshaft end. OIL PUMP COVER SCREW TORQUE: CRANKCASE BOLT TORQUE: 8 Nm 20 Nm (15ft.

  • Page 91: Piston Ring Installation

    ENGINE PISTON RING INSTALLATION 5. Install chain on oil pump and crankshaft sprocket then place oil pump sprocket into oil pump shaft. NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston.

  • Page 92: Piston Installation

    ENGINE PISTON INSTALLATION 4. Install the other cir-clip with the gap facing up or down. CAUTION: Do not re-use cir-clips. Cir-clips become (See Caution with Step 3 above). Push the piston pin in both deformed during the removal process. Do not directions to make sure the clips are properly seated in the compress the new clip more than necessary to groove.

  • Page 93: Cylinder Head And Camshaft Installation

    ENGINE CYLINDER HEAD AND CAMSHAFT 3. Install the cam chain guide and dowel pins into the cylinder. INSTALLATION Verify the bottom end is seated properly in the crankcase. NOTE: Clean the gasket surfaces on the cylinder 4. Pull the cam chain through the cylinder chain room and secure with mechanic’s wire.
  • Page 94 ENGINE 4. Install cylinder head bottom mount nut. 6. Insert cam into cylinder head. 7. Install exhaust side rocker shaft and rocker arm. 5. Install cylinder head nuts and torque to specification. CYLINDER HEAD NUT TORQUE: 22~25Nm (16~18ft-lb) 4-41...
  • Page 95 ENGINE 8. Install intake side rocker shaft and rocker arm. 9. Install 2 dowel pins onto cylinder head. 15. Install de-compressor into camshaft. 10. Ensure the piston locate At TDC (top die center). 11. Pull cam chain fully up then install cam sprocket into camshaft.

  • Page 96: Cam Chain Tensioner Installation

    ENGINE 18. Install rocker and cam sprocket cover then torque bolts to specification. TENSIONER BOLT TORQUE: 19. Connect coolant hose with cylinder and coolant pump. 10 Nm (7.4 ft. lbs.) 3. Install the tensioner cap. Torque cap to specification. TENSIONER CAP TORQUE: 10 Nm (7.4 ft.
  • Page 97 ENGINE CAMSHAFT TIMING - METHOD 1 Method 1 - Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) 4-44...
  • Page 98 ENGINE CAMSHAFT TIMING - METHOD 2 Method 2 - Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) Cam Timing (View through timing inspection hole) Position crankshaft at TDC 4-45...

  • Page 99: Intake Valve Clearance Adjustment

    ENGINE INTAKE VALVE CLEARANCE ADJUSTMENT FLYWHEEL INSTALLATION 1. Verify cam lobes are pointed down. 1. Install flywheel key, flywheel washer, and nut. 2. Insert a 0.1mm feeler gauge between end of intake valve Torque flywheel nut to specification. stem and adjuster screw. 3.

  • Page 100: Stator Housing Installtion

    ENGINE TROUBLESHOOTING STATOR HOUSING INSTALLATION SPARK PLUG FOULING ◎ Spark plug cap loose or faulty ◎ Choke cable adjustment or plunger/cable sticking NOTE: The stator, flywheel, starter drive, and stator ◎ Foreign material on choke plunger seat or plunger can be serviced with the engine in the frame. ◎...

  • Page 101: Engine Does Not Turn Over

    ENGINE ENGINE TURNS OVER BUT FAILS TO PISTON FAILURE - SCORING START ◎ Lack of lubrication ◎ No fuel ◎ Dirt entering engine through cracks in air filter or ducts ◎ Dirt in fuel line or filter ◎ Engine oil dirty or contaminated ◎...
  • Page 102 TRANSMISSION CHAPTER 5 TRANSMISSION SYSTEM ..............5-2 TRANSMISSION EXPLODED VIEW .

  • Page 103: Transmission Exploded View

    TRANSMISSION TRANSMISSION SYSTEM TRANSMISSION EXPLODED VIEW SHIFT LEVER 2. Disconnect cable from shifter. Removal 3. Remove the gearshift selector out of mounting bracket and 1. Pry the shift lever cover using a suitable tool and remove the away from frame. screw.

  • Page 104: Shift Cable Inspection / Adjustment

    TRANSMISSION TRANSMISSION MAINTENANCE 4.Remove shift cable from shift selector. 6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount. 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted.
  • Page 105 TRANSMISSION 7. Remove the jam nut from the left side of the swing arm pivot. 4. Remove rear shock upper mount bolt. 8. Remove the swing arm pivot bolts from both sides of the swing arm. Support the front of the swing arm during removal. 5.

  • Page 106: Transfer Case Disassembly

    TRANSMISSION TRANSFER CASE DISASSEMBLY IMPORTANT: Shift housing repairs are not possible without performing transfer case disassembly. Read and understand all instructions before beginning disassembly. 1. Drain the transfer oil from transfer case. 5. Remove the front transfer gear from transfer case. 2.
  • Page 107 TRANSMISSION NOTE: Record the number and thickness of shims for 9. Note timing of shift shaft before removing. The center tooth on reassembly. shift shaft is positioned between the two dots on the drum teeth. 10. Remove the shift shaft by pulling straight outward. 11.

  • Page 108: Transmission Disassembly

    TRANSMISSION TRANSMISSION DISASSEMBLY Note: Do not lose these two washers. 1. Remove the cover screws. 2. Remove cover or with output shaft. Push or tap on shift shaft to keep it in the case. 7. If input drive shaft or gear requires service, remove driven clutch as outlined in CVT Chapter.

  • Page 109: Transmission Inspection

    TRANSMISSION TRANSMISSION INSPECTION MAIN SHAFT REMOVAL AND INSPECTION NOTE: Always wear the appropriate protective gear and use caution when operating a press. 1. Inspect sliding gear dogs (D) and dog slots in the mating gears DRIVE SHAFT REMOVAL AND INSPECTION (E) for wear or damage.

  • Page 110: Count Shaft Inspection

    TRANSMISSION Removal 4. Remove low speed gear components from main shaft. 1. Remove the snap ring from high-speed spur gear side of main shaft. 2. Remove forward spur gear and dog components until next snap ring. Snap ring pressure can cause rings and pliers to eject suddenly.

  • Page 111: Shift Drum Removal And Inspection

    TRANSMISSION OUTPUT SHAFT INSPECTION 3. Remove the snap ring from low speed side of drum shaft. 1. Inspect the shaft and gears visually without excessive wear or crack. Replace any damaged as an assembly. 4. Remove all components from drum shaft as below. SHIFT DRUM REMOVAL AND INSPECTION Spring pressure can cause components to eject suddenly.

  • Page 112: Transmission Reassembly

    TRANSMISSION TRANSMISSION REASSEMBLY 2. Inspect the count gear visually without excessive wear or crack. 3. Install #8 spring and #7 washer into shaft. Replace any damaged as an assembly. 4. Push the washer and spring very hard then install #6 retainer into shaft groove to maintain the spring.

  • Page 113: Transmission Gear Reassembly

    TRANSMISSION TRANSMISSION GEAR REASSEMBLY 6. Install #4 spring into shaft. NOTE: Lubricate all bearings with clean transmission oil before assembly. Clean the gasket surfaces on the crankcase and transmission cover. Remove all traces of old gasket material and apply a new base gasket. 1.
  • Page 114 TRANSMISSION 5. Use caution when installing the gear position indicator spring 8. Install the output shaft. and pin located in the end of the drum shaft. 6. Insert shift fork into main shaft dog and drum then install fork shaft. 8.

  • Page 115: Low Speed

    TRANSMISSION 12. Check transmission operation before final assembly, and after 11. Install detent ball, spring, o-ring and bolt. installing detent cover. LOW SPEED 12. Install the shift cover then fastens bolts to 10Nm. Connect both shift cable and adjust porosity position. HIGH SPEED 13.
  • Page 116 TRANSMISSION 17. Install the transfer case cover then tighten all bolt to 12Nm. Transmission cover Bolt Torque: 12 Nm (8.8, ft. lbs.) 16. Apply Lubricant to transmission from detent case cover filler 17. Install front transfer gears onto transfer case. and transfer case to its filler.

  • Page 117: Troubleshooting

    TRANSMISSION TROUBLESHOOTING Gear Will Not Engage • Shift arm indexed incorrectly • Shift cables loosened • Shift cables broken • CVT Belt broken • Internal trans gear damage • Shift fork broken or bent • Shift shaft broken • Loose fasteners on selector box •...
  • Page 118 FUEL AND CARBURETOR CHAPTER 6 CARBURETION SYSTEM ..............6-2 CARBURETOR FUNCTION .

  • Page 119: Fuel And Carburetor

    FUEL AND CARBURETOR CARBURETOR SYSTEM CARBURETOR FUNCTION Carburetor Component Function System Main Main Main Gasoline is extremely flammable and explosive Components Function Affect under certain conditions. Float System Inlet Pipe, Needle Maintains All systems; all Always stop the engine and refuel outdoors or in a Level Control) and Seat, Float specified fuel...

  • Page 120: Carburetion Specifications

    FUEL AND CARBURETOR CARBURETION SPECIFICATIONS OPERATION OVERVIEW The engine of a vehicle is operated under a wide range of CROSSLAND 4x4 KEIHIN conditions, from idling with the throttle valve remaining almost closed, to full load or maximum output with the throttle CVK AK4 BWGH Type valve fully opened.

  • Page 121: Carburetor Operation

    FUEL AND CARBURETOR CARBURETOR OPERATION HIGH ALTITUDE OPERATION NOTE: It is strongly recommended that Carbon Clean be added regularly as directed to the fuel systems. The CROSSLAND 400 4X4 has been tested to 4,000 M above Carbon Clean stabilizes the fuel, preventing clogging sea level to assure satisfactory performance.
  • Page 122 FUEL AND CARBURETOR The CV carburetor has two throttles, the cable operated butterfly (1) and the vacuum operated plugs (2). The butterfly controls the idle mixture strength from the passage (13) that can be adjusted by screw (12). Idle mixture composition is determined by the idle jet (11) and the air jet (16).

  • Page 123: Float System

    FUEL AND CARBURETOR FLOAT SYSTEM The float system is designed to maintain a constant height of gasoline during operation. When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level, the floats rise. When the buoyancy of the float and the fuel pressure of the fuel pump balance, the needle valve seals the orifice in the needle seat, preventing further fuel delivery, and the level of fuel in the bowl remains...

  • Page 124: Float Height Adjustment

    FUEL AND CARBURETOR FUEL LEVEL TEST FLOAT HEIGHT ADJUSTMENT A fuel level test can be performed if the drain hose fitting is 1. Hold the carburetor in an upside down position. accessible. Be sure to re-attach the bowl drain hose after 2.

  • Page 125: Carburetor Jetting

    FUEL AND CARBURETOR CARBURETOR JETTING Pilot Jet IMPORTANT: The following guidelines must be From idling to low speeds, the fuel supply is metered by the followed when establishing a main jet setting: pilot jet. There are several air bleed openings in the sides of the 1.

  • Page 126: Air / Fuel Mixtrue Ratio

    FUEL AND CARBURETOR Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point. At that time the tapered portion of the needle begins to move out of the jet, affecting fuel flow as the opening enlarges.

  • Page 127: Throttle Opening Vs Fuel Flow

    FUEL AND CARBURETOR THROTTLE OPENING VS FUEL FLOW Throttle valves are numbered 1.0, 1.5, 2.0, etc., according to In a full throttle condition the cross-sectioned area between the the size of the cutaway. The higher the number, the leaner the jet needle and the needle jet is larger than the cross-sectioned gasoline/air mixture.

  • Page 128: Idle And Low Speed Circuit

    FUEL AND CARBURETOR IDLE AND LOW SPEED CIRCUIT MIDRANGE SLIDE POSITION AND FUEL DISCHARGE At idle with the throttle plate closed and the air stream cut off, idle speed is maintained by fuel metered through the slow jet. As the throttle plate is opening, airflow increases through the Air from the slow air jet mixes with the fuel and is delivered to carburetor and the pressure drop in the venture near the needle the port at the vacuum side of the throttle plate.

  • Page 129: High Speed Circuit Slide Position And Fuel Discharge

    FUEL AND CARBURETOR HIGH SPEED CIRCUIT SLIDE POSITION AND ACCELERATIVE PUMP SYSTEM FUEL DISCHARGE The accelerator pump used sudden throttle openings (rapid As the throttle plate is opening, the pressure difference accelerations) to quickly inject fuel into carburetor venturi to between the chambers above and below the diaphragm provide extra fuel for smooth acceleration.

  • Page 130: Fuel Delivery

    FUEL AND CARBURETOR FUEL DELIVERY VENT SYSTEM The throttle opening chart below demonstrates component The fuel tank vent supplies atmospheric pressure to the fuel in relationship to fuel flow versus throttle valve opening. the tank. The vent must be free of debris and restrictions to The pilot system’s main function is that of a low speed jet.

  • Page 131: Carburetor Cleaning

    FUEL AND CARBURETOR CARBURETOR CLEANING Carburetor cleaners can be extremely caustic. Extended periods of soaking can loosen the adhesive sealer on the passage drill-way plugs. Do not soak rubber or plastic components (such as the vacuum slide diaphragm, needle seat screen, or O-Rings in caustic cleaning solutions.
  • Page 132 FUEL AND CARBURETOR FUEL TANK OPERATION 6-15...

  • Page 133: Fuel Tank Removal

    FUEL AND CARBURETOR FUEL TANK REMOVAL 1. Refer chapter 8 to remove front of cab and plastic plate. 2. Place a shop rag or towel underneath the tank and remove fuel line, fuel valve and filter from the tank. 3. Completely drain fuel from fuel tank. 4.

  • Page 134: Air Cleaner System

    FUEL AND CARBURETOR AIR CLEANER SYSTEM DUAL INTAKE REMOVAL 2. Disconnect manifold vacuum hose “B” and remove dual 1.Remove and disconnect intake pipe from cylinder and dual intake filter box fastener bolt “A”. . intake. 3. Remove complete dual intake assembly. 4.

  • Page 135: Air Cleaner Removal

    FUEL AND CARBURETOR AIR CLEANER REMOVAL 5. Apply commercially available foam filter oil to the foam 1.Remove strap from carburetor snorkel and oil separator filter. hoses from head cover. 6. Reinstall the foam filter, foam and air box cover. Secure the clips.

  • Page 136: Troubleshooting

    FUEL AND CARBURETOR TROUBLE SHOOTING FUEL STARVATION / LEAN MIXTURE POOR ILDE Symptoms: Hard start or no start, bog, backfire, popping Idle Too High through intake / exhaust, hesitation, detonation, low power, • Idle adjusted improperly / air mixture screw damaged spark plug erosion, engine runs hot, surging, high idle, idle •...
  • Page 137 FINAL DRIVE CHAPTER 7 GENERAL INFORMATION ..............7-2 TORQUE SPECIFICATIONS .

  • Page 138: Final Drive

    FINAL DRIVE GENERAL INFORMATION / FRONT KNUCKLE TORQUE SPECIFICATIONS FRONT KNUCKLE INSPECTION / REMOVAL Final Drive Fasteners 1. Elevate front of vehicle and safely support machine under the frame area. Fastener Torque Front Wheel Lug Nut 55 Nm (40 ft. lbs) Front Hub Castle Nut 200 Nm (145 ft.
  • Page 139 FINAL DRIVE 2. Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement. The tire should rotate smoothly without binding or rough spots. 7. Remove the front wheel hub assembly. 3. Remove the (4) wheel nuts and remove the front wheel. 8.

  • Page 140: Bearing Replacement

    FINAL DRIVE NOTE: Due to extremely close tolerances and 7. Wipe the knuckle clean of any excess compound and install minimal wear, the bearings must be inspected the snap ring. visually, and by feel. While rotating bearings by hand, FRONT KNUCKLE INSTALLATION inspect for rough spots, discoloration, or corrosion.
  • Page 141 FINAL DRIVE 8. Install the steering tie rod end onto the front knuckle and torque fastener to 40 Nm (30 ft. lbs.). 6. Install brake caliper mounting bolts and torque to 30 Nm (22 ft. lbs.). Tie Rod End Fastener Torque: 40 Nm (30 ft.

  • Page 142: Front Drive Shaft

    FINAL DRIVE FRONT DRIVE SHAFT DRIVE SHAFT / CV JOINT HANDLING TIPS 11. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. Care should be exercised during drive shaft removal or when servicing CV joints.
  • Page 143 FINAL DRIVE NOTE: If the vehicle has been operated with a 7. Before installing the new boot, remove all grease from the damaged boot, the CV joint grease may be boot area and shaft. contaminated. Inspect the grease carefully for NOTE: It is very important to use the correct type and contamination and clean the joint thoroughly if quantity of grease by using the grease contained in...

  • Page 144: Drive Shaft Installation

    FINAL DRIVE FRONT GEAR CASE / PROPSHAFT SERVICE DRIVE SHAFT INSTALLATION 9. Install the steering tie rod end onto the front knuckle and 1. Install new spring ring on drive shaft. Apply an anti-seize torque fastener to 40 Nm (30 ft. lbs.). compound to splines.
  • Page 145 FINAL DRIVE...

  • Page 146: Front Gearcase Disassembly / Inspection

    FINAL DRIVE 11. Remove the front gear case mount bolts, nuts and remove the front gear case from frame and prop shaft. FRONT GEAR CASE DISASSEMBLY / Always wear eye protection. INSPECTION NOTE: If yoke or bearing is removed, cross bearing 1.

  • Page 147: Gearcase Installation

    FINAL DRIVE 2. Apply bearing grease to the bearings. 4. Connect the gear motor wire harness. 3. Install the bearing onto yoke. 5. Install both front drive shafts into the front gear case. 6. Add the proper lubricant to the front gear case. Front Gear case Recommend Oil: SAE 80w/90 Gear Oil Front Gear case capacity:...

  • Page 148: Swing Arm

    FINAL DRIVE SWING ARM / GEAR CASE REAR HUB REMOVAL 3. Elevate rear of vehicle and safely support machine under the 1. Remove the hub nut cover. Remove the cotter key from the frame area. hub nut. 2. Slightly loosen the hub nut and the four-wheel nuts. 4.

  • Page 149: Swing Arm Removal

    FINAL DRIVE 2. Remove the jam nut from the left side of the swing arm pivot. 2. Remove rear shocks. 3. Remove the swing arm pivot bolts from both sides of the swing arm. Support the front of the swing arm during removal. 4.

  • Page 150: Gear Case Disassembly

    FINAL DRIVE GEAR CASE DISASSEMBLY 1. Remove the four nuts that secure the brake disc adapter assembly to the tube assembly. Pull the brake disc assembly from the axle tube. 4. Remove the gear case from the swing arm assembly. 2.
  • Page 151 FINAL DRIVE 6. Remove the side gear case cover. 9. Inspect and replace the inner bearing and seal if needed. 7. Remove the bevel gear from the housing. 10.Remove the pinion shaft seal to gain access to the pinion gear holding nut. Use the Rear Gear case Input Shaft Collar Tool to remove the pinion holding nut.

  • Page 152: Shimming Procedure

    FINAL DRIVE REAR SWING ARM ASSEMBLY 5. Install the shims and bevel gear into the gear case housing. 1. Replace all seals and O--rings during re--assembly. Turn the drive gear shaft (pinion) to feel for gear backlash. 2. Install the pinion shaft into the gear case. Install the pinion holding nut and torque to 100 Nm (74 ft-lb.).
  • Page 153 FINAL DRIVE 9. With reasonable backlash achieved, shims should now be 12. Install the gasket and gear case cover (D). placed on the outside of the bevel gear. 13. Apply Loctitet 242 to the cover bolts. Place the two larger cover bolts (I) in the correct cover holes during assembly.
  • Page 154 FINAL DRIVE 17. Install the assembled gear case into the swing arm. 19. Install the axle into the left axle tube through the gear case. If necessary, rotate the shaft for the axle to feed through the gear case. 18. Apply Loctitet 242 to the bolts. Install the eight bolts that secure the swing arm to the gear case to 55 Nm (40 ft-lb.).

  • Page 155: Rear Axle Run-Out Inspection

    FINAL DRIVE REAR AXLE RUN-OUT INSPECTION 1. Park the vehicle on a flat surface and apply the parking brake. 2. Place a jack under the rear gear case and raise until the rear wheels are off the ground. 3. Strap the vehicle securely to the ground so that the machine is held solid and will not wiggle.
  • Page 156 BODY / STEERING / BRAKE CHAPTER 8 GENERAL INFORMATION ............. .8-3 TORQUE SPECIFICATIONS .
  • Page 157 BODY / STEERING / BRAKE FRONT CALIPER / DISC SERVICE ........... . .7-20 CALIPER REMOVAL .

  • Page 158: General Information

    BODY / STEERING / BRAKE GENERAL INFORMATION TORQUE SPECIFICATIONS Fastener Torque Suspension Fasteners Front LH / RH Upper 42 Nm (31 ft. lbs.) A-Arm Bolt Front LH / RH Lower 42 Nm (31 ft. lbs.) A-Arm Bolt Tie Rod End Jam Nut 50 Nm (37 ft.

  • Page 159: Cab And Panel

    BODY / STEERING / BRAKE CAB AND PANEL...

  • Page 160: Seat Removal

    BODY / STEERING / BRAKE SEAT REMOVAL 1. Use a property rod to support seat. 4. Remove both feet well from front and rear cabs. 2. Remove hinge and seat assembly away from storage box. 5. Remove the 8 screws attaching front and rear cabs to the CAB AND PANEL REMOVAL footwalls on each side.

  • Page 161: Rear Cab Removal

    BODY / STEERING / BRAKE 2. Disconnect power supplier wires against with main harness. 7. There are 2 bolts locate under front rack and recovery tank. Completely remove the front cab from body. 3. Disconnect both front indicator plugs. REAR CAB REMOVAL 1.

  • Page 162: Front Bumper Removal / Installation

    BODY / STEERING / BRAKE 3. Disconnect the taillight harness. Remove the 2 bolts attaching the rear cabs then take off taillight. 4. Torque mounting bolts to 10 Nm (90 in. lbs.). Front Bumper Mount Bolt Torque 4. Remove the 5 bolts fasten the rear cab then take off rear cab. 10 Nm (90 in.

  • Page 163: Handlebar

    BODY / STEERING / BRAKE HANDLEBAR HANDLEBAR REMOVAL / INSTALLATION 2. Remove right of throttle lever housing and master cylinder. 1. Push the buckle when removing the rear brake switch out of the brake lever. 3. The “UP” mark should face up on the master cylinder clamp while master cylinder installation.

  • Page 164: Steering

    BODY / STEERING / BRAKE STEERING 5. Remove both handlebar upper clamps. 6. Remove handlebar from lower clamps. 9. Install the front block bolts first and evenly tighten the bolts down. Evenly torque the 2 front bolts to 15--18 Nm (11--13 ft.lbs).

  • Page 165: Steering Shaft Inspection

    BODY / STEERING / BRAKE STEERING SHAFT INSPECTION To Flame Treat The Decal Area: Inspect steering shaft, replace it if has bent 1. Pass the flame of a propane torch back and forth quickly Do not attempt to straight a bent steering shaft; this may over the area where the decal is to be applied until the surface dangerously weaken the shaft.

  • Page 166: Brake System

    BODY / STEERING / BRAKE BRAKE SYSTEM GENERAL SPECIFICATION Front Brake Disc Item Standard Service Limit Brake Pad Thickness 7.6 mm (0.298”) 4.3 mm (0.17”) Brake Disc Thickness 4mm (0.16”) 3.5mm (0.14”) Brake Disc Thickness Variance Between 0.05mm (0.002”) Measurements Brake Disc Run out 0.25mm (0.01”) Rear Brake Disc...

  • Page 167: Brake System Service Note

    BODY / STEERING / BRAKE ◎ Inspect caliper piston seals for foreign material that could BRAKE SYSTEM SERVICE NOTE Disc brake systems are lightweight, low maintenance, and prevent caliper pistons from returning freely. ◎ Perform a brake burnishing procedure after installing new perform well in the conditions ATVs routinely encounter.

  • Page 168: Brake System Operation

    BODY / STEERING / BRAKE BRAKE SYSTEM OPERATION The front brake system is hydraulically actuated. The foot brake system is hydraulically actuated. When the right front brake lever (master cylinder) is When the right foot brake lever (master cylinder) is applied, the two front brake calipers are active and applied, the two front brake calipers and a rear under pressure.
  • Page 169 BODY / STEERING / BRAKE The brake system consists of the following components or assemblies: brake lever; master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line. When the hand activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake system.

  • Page 170: Front Brake

    BODY / STEERING / BRAKE FRONT BRAKE 8-15...

  • Page 171: Master Cylinder

    BODY / STEERING / BRAKE MASTER CYLINDER Installation Removal 1. Reverse Steps 1-5 for master cylinder installation. Locate the master cylinder above the LH front tire in the 2. After installing the foot brake check pedal free play. Pedal wheel well area. free play should not exceed .090”...
  • Page 172 BODY / STEERING / BRAKE BRAKE BLEEDING / FLUID CHANGE PROCEDURE NOTE: When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. Always wear safety glasses during these 5. Have an assistant slowly pump brake lever until pressure procedures.

  • Page 173: Pad Removal

    BODY / STEERING / BRAKE 10. Add brake fluid to MAX level inside reservoir. Master Cylinder Fluid Level: Between the MIN and MAX line shown on the reservoir. 11. Install master cylinder reservoir cover. 12. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve.

  • Page 174: Pad Assembly / Installation

    BODY / STEERING / BRAKE 4. Slowly pump the brake pedal until pressure has been built up. Maintain at least1.3 cm (1/2") of brake fluid in the reservoir to prevent air from entering the brake system. 5. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

  • Page 175: Caliper Removal

    BODY / STEERING / BRAKE FRONT CALIPER / DISC SERVICE CALIPER REMOVAL Replace disc if worn beyond service limit. 1. Elevate and safely support the front of the vehicle. 2. Remove the (4) wheel nuts and the front wheel. Use care when supporting vehicle so that it does not tip or fall.

  • Page 176: Rear Brake

    BODY / STEERING / BRAKE REAR BRAKE Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the rear wheel. 3. Loosen pad set screw 2-3 turns. 4.

  • Page 177: Pad Inspection

    BODY / STEERING / BRAKE PARKING BRAKE PAD INSPECTION Slowly pump the brake pedal until pressure has been built up. 1. Clean the caliper with brake cleaner or alcohol. Maintain at least1.3 cm (1/2") of brake fluid in the reservoir to 2.

  • Page 178: Pad Inspection

    BODY / STEERING / BRAKE 4. Remove the two caliper mounting bolts and lift caliper off 7. Remove the inner brake pad. the brake disc. Pad Inspection 5. Turn swing arm counterclockwise to end. 1. Clean the caliper with brake cleaner or alcohol. 6.

  • Page 179: Brake Burnishing Procedure

    BODY / STEERING / BRAKE If the brake pads are contaminated with grease, oil, or liquid soaked do not use the pads, use only new clean pads. 2.Install caliper and torque mounting bolts to specification. Rear Caliper Mount Bolt Torque: 2.

  • Page 180: Rear Caliper / Disc Service

    BODY / STEERING / BRAKE REAR CALIPER / DISC SERVICE CALIPER REMOVAL 1. Elevate and safely support the rear of the vehicle. 5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. Use care when supporting vehicle so that it does not tip or fall.

  • Page 181: Rear Brake Disc Inspection

    BODY / STEERING / BRAKE 6. Remove the two caliper mounting bolts and removes the 2. Use a micrometer and measure the disc thickness at eight caliper. different points around the pad contact surface. Replace disc if worn beyond service limit. 7.

  • Page 182: Disc Replacement

    BODY / STEERING / BRAKE DISC REPLACEMENT FOOT BRAKE REMOVAL 1. Remove rear brake and parking caliper (see “REAR AND PARKING CALIPER SERVICE”). Note: The foot brake system is hydraulically 2. Remove left wheel hub cotter pin, castle nut and washers. actuated.

  • Page 183: Foot Brake Fluid Filling / Bleeding

    BODY / STEERING / BRAKE 2. Remove the cotter pin from foot brake lever and foot brake 5. Remove foot brake lever and other components, arrange master cylinder. them order. FOOT BRAKE FLUID FILLING / BLEEDING 1. Remove cover, and diaphragm from reservoir. 3.

  • Page 184: Troubleshooting

    BODY / STEERING / BRAKE 4. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 5. Slowly pump foot brake lever until pressure builds and holds.
  • Page 185 ELECTRICAL CHAPTER 9 GENERAL INFORMATION ............9-3 ELECTRICAL SYSTEM SERVICE NOTES .
  • Page 186 ELECTRICAL STARTER REASSEMBLY ................9-16 STARTER RELAY .

  • Page 187: General Information

    ELECTRICAL GENERAL INFORMATION ELECTRICAL SYSTEM SERVICE NOTE WIRES COLOR LETTER LIST Reference the following notes when diagnosing electrical Letter Color Letter Color problems. Black Blue/ White Black/ Green Blue/Yellow • Refer to wiring diagram for stator and electrical Black Orange component resistance specifications.

  • Page 188: Switch Service

    ELECTRICAL SWITCH SERVICE CHECK THE CONNECTION Check the connectors for stains, rust, moisture, etc. 7. Perform steps 1 to 3 when checking the wire harness continuity. 1.Disconnect connector. 8. As a quick remedy, use a contact revitalizer available at 2.Check connector moisture. Dry each terminal with an air most part stores.

  • Page 189: Check A Switch Shown In The Manual

    ELECTRICAL CHECK A SWITCH SHOWN IN THE MANUAL HEADLIGHT SWITCH The terminal connections for switches (main switch, handlebar Headlight switch include light and beam switch which local on switch, engine stop switch, light switch, etc.) are shown in a handlebar by left side. chart similar to the one on the right.

  • Page 190: Hazard Switch

    ELECTRICAL HAZARD SWITCH 1. When the hazard switch is pushed to the “ ” position, there should be continuity between the (Br/W, L/R & DB) wires. SPEEDOMETER / ODOMETER 2. When the hazard switch is pushed to the “ ” position, there should no continuity between any of the wires.

  • Page 191: Transmission Switch

    ELECTRICAL TRANSMISSION SWITCH Switch Removal/Test 1. Remove the CVT cover. The indicator switch will be visible between the drive and driven clutch. Refer to Chapter 3 for CVT cover removal and install. 2. Remove the screws that retain the indicator switch. 3.

  • Page 192: Switch Installatiom

    ELECTRICAL BRAKE LIGHT SWITCH 7. Finally shift the transmission into “low speed” and test for continuity between the W/R wires and ground. Foot brake pedal lever utilizes an electrical brake switch that 8. Inspect the shift indicator contacts, shift drum, pin and spring. sends voltage to activate the brake light.

  • Page 193: Bulb Inspection

    ELECTRICAL Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 2.Inspect bulb for continuity with the multi-meter, If discontinuity 2. Bulb C is used for turn signal and brake/tail lights and can be Replace the bulb.

  • Page 194: Ignition System

    ELECTRICAL IGNITION SYSTEM RPM LIMITER SPECIFICATIONS NOTE: The ATV is limited through the CDI box located on the bulkhead under the front cab. In forward gear, the CDI reads the RPM’s from the stator. The CDI acts as a limiter when the peak RPM is met.

  • Page 195: Spark Plug Type And Gap

    ELECTRICAL NOTE: Use only the recommended fuse capacity, as 6. If out of specification or no spark, inspect spark plug cap use of a higher amperage fuse to correct blown—fuse resistance. situations could lead to electrical component ◎ SPARK PLUG CAP RESISTANCE damage.

  • Page 196: Main Switch

    ELECTRICAL 4. If stator pick up coil resistance reading overdue specified, replace completely stator. Pickup coil resistance: 103 ~ 110Ω at 20 °C (68 °F) ◎ STATOR COIL 1. Resistance Value of Each Stator Leg Measure the resistance value of each of the three-stator legs: 5.

  • Page 197: Voltage Drop Test

    ELECTRICAL STARTING SYSTEM VOLTAGE DROP TEST STARTING CIRCUIT OPERATION The Voltage Drop Test is used to test for bad connections. The starting circuit on this model consists of the starter motor, When performing the test, you are testing the amount of starter relay, brake light switch, and C.D.I.

  • Page 198: Starter Motor

    ELECTRICAL STARTER MOTOR DISASSEMBLY If battery less than 11.8V inspect regulator and stator, recharge or replace the battery. NOTE: Use only electrical contact cleaner to clean ◎ STARTER MOTOR starter motor parts. Other solvents may leave a The starter motor is a complete service part. If it is determined residue or damage internal parts and insulation.

  • Page 199: Starter Brush Inspection / Replacement

    ELECTRICAL STARTER BRUSH INSPECTION / 2. Using a digital multi-tester, measure the resistance between REPLACEMENT each of the communicator segments. The reading should be 1. Release the brush coil spring away. 3 ohms or less. 2. Push the armature out of case. Armature coil resistance Continuity Less 3Ωat 20 °C (68 °F) 3.

  • Page 200: Starter Reassembly

    ELECTRICAL ◎ MAIN SWITCH 7. Inspect the permanent magnets in starter housing. Make sure they are not cracked or separated from housing. Refer to “KEY/MAIN SWITCH” at above. If main switch isn’t continuity, replace the main switch. CAUTION ◎ TRANSMISSION SWITCH Use care when handling the starter housing.

  • Page 201: Charging System

    ELECTRICAL CHARGING SYSTEM IF THE BATTERY IS NOT CHARGED FOLLOWING PROCEDURE TO CHECKING. ◎ MAIN FUSE 1. The main fuse box is located under seat. ◎ CURRENT DRAW - KEY OFF Do not connect or disconnect the battery cable or ammeter with the engine running.

  • Page 202: Alternator Output Test (Ac Amp)

    ELECTRICAL Current Draw - Key Off: 10. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. Maximum of .02 DCA (20 mA) ◎ ALTERNATOR OUTPUT TEST (AC AMP) 1. The “break even” point of the charging system is the point at This test measures AC amperage from the alternator.

  • Page 203: Sealed Low Maintenance Battery

    ELECTRICAL BATTERY CHECK 1. Check the date label on the side of the battery to calculate when to check voltage. The battery should be checked every 3 months. 2. Check the voltage with a voltmeter or multi-meter. A fully charged battery should be 12.8 V or higher. 3.

  • Page 204: Sealed Low Maintenancebattery Charging

    ELECTRICAL SEALED LOW MAINTENANCE BATTERY NEVER attempt to add electrolyte or water to a Low INSPECTION/ REMOVAL Maintenance battery. Doing so will damage the case and The battery is located under left of dump box. shorten the life of the battery. Refer to the Battery Maintenance Video (PN 9917987) for proper instruction on servicing Low Maintenance batteries.

  • Page 205: Sealed Low Maintenance Battery Ocv Open Circuit Voltage Test

    ELECTRICAL Following are three tests, which can easily be made on a A battery may indicate a full charge condition in the OCV test battery to determine its condition: OCV Test, Specific Gravity and the specific gravity test, but still may not have the storage Test and Load Test.

  • Page 206: Sealed Low Maintenance Battery Charging Procedure

    ELECTRICAL Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Point -80℃ (-75℉) 1.265 Battery electrolyte is poisonous. It contains sulfuric -37℃ (-35℉) 1.225 acid. Serious burns can result from contact with -27℃ (-17℉) 1.200 skin, eyes or clothing. Antidote: -15℃ (+5℉) 1.150 External: Flush with water.

  • Page 207: Battery Terminals/ Terminal Bolts

    ELECTRICAL 5. Charge battery at 1/10 of its amp/hour rating. Examples: 1/10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4 amp; 1/10 of 18 amp battery = 1.8 amp Refill using only distilled water. Tap water contains (recommended charging rates).

  • Page 208: Conventional Battery Ocv-Open Circuit Voltage Test

    ELECTRICAL OPEN CIRCUIT VOLTAGE CONVENTIONAL BATTERY OCV - OPEN State of charge Conventional Low Maintenance CIRCUIT VOLTAGE TEST Lead-acid Type Battery voltage should be checked with a digital 100% 12.60V 12.70V Multi-tester. Readings of 12.6 volts or less require further 75% Charged 12.40V 12.50V...

  • Page 209: Conventional Battery Off-Season Storage

    ELECTRICAL CONVENTIONAL BATTERY OFF SEASON 3. Install battery in vehicle with positive terminal toward the STORAGE front. Coat threads of battery bolt with a corrosion resistant To prevent battery damage during extended periods of dielectric grease. 4. Connect battery cables. non-use, the following basic battery maintenance items must be performed: ◎...

  • Page 210: Light System

    ELECTRICAL LIGHT SYSTEM IF THE HEADLIGHT AND TAILLIGHT FAIL TO COME 4. Turn the main switch” on” and beam switch on” ”. ON, FOLLOWING PROCEDURE TO CHECKING. ◎ Fuse Connect probe (+) into ”L: terminal and probe (-) into “B” Check the fuse (main, light system) continuity.

  • Page 211: Radiator Fan Motor

    ELECTRICAL COOLING SYSTEM 4. Turn the main switch” on” and step foot brake pedal. 3. Check the operation of the radiator fan motor. If the fan Connect probe (+) into “G/Y” and probe (-) into “B”. does not run, replace it. ◎...
  • Page 212 ELECTRICAL Step: Heating Water temperature Continuity Less than 75 ± 3 °C (167 ± 5.4 °F) More than 75 ± 3 °C (167 ± 5.4 °F) Step: Cooling Water temperature Continuity More than 68 °C (154.4 °F) Less than 68 °C (154.4 °F) Handle the thermo switch with special care.
  • Page 213 ELECTRICAL 9-29...

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