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Hsun HS700UTV Maintenance Handbook

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Brief introduction to maintenance handbook of HS700UTV
The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to
dealers and technicians as document of technique.
Mainly, the handbook gives methods to check, maintain and repair UTV, and supplies
some relevant technique and performance data. Some techniques and method inside may
be used to check, maintain and repair other models of UTV, although it is mainly for
HS700UTV.
Please read the handbook through and fully understand it; otherwise, any improper
repairing and amounting would bring you problems, and accident may occur in your use.
Proper use and maintenance can guarantee UTV being driven safely, reduce its
malfunction, and help the vehicle remain its best performance.
The standards, performances and specifications mentioned in interpretation are based
on the sample in design, and they are subject to changes according to the product's
improvement without prior notice.
Brief introduction to maintenance handbook of HS700UTV
second version , June,2009
Published by Chongqing Hsun Industries (Group) Ltd
Chongqing Hsun Industries (Group) Ltd holds the copy right.
No publishing and reprinting without permission.
FOREWORD

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Summary of Contents for Hsun HS700UTV

  • Page 1 FOREWORD Brief introduction to maintenance handbook of HS700UTV The handbook is edited by Chongqing Hsun Industries (Group) Ltd, and is supplied to dealers and technicians as document of technique. Mainly, the handbook gives methods to check, maintain and repair UTV, and supplies some relevant technique and performance data.

  • Page 2: Table Of Contents

    CONTENT DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION CODE ………………………………………………………………… Frame No. ……………………………………………………………………………… Engine No. ……………………………………………………………………………… CHAPTER 1 GENERAL INFORMATION MANUAL ORGANIZATION………………………………………………………………… WATNINGS ,CAUTIONS AND NOTES…………………………………………………… SAFETY ……………………………………………………………………………………… 1-3 Handing gasoline safely ……………………………………………………………… Cleaning parts…………………………………………………………………………… Warning labels…………………………………………………………………………… SERIAL NUMBERS………………………………………………………………………… FASTENERS………………………………………………………………………………… Torque specifications…………………………………………………………………… Self-locking fasteners…………………………………………………………………...
  • Page 3 Socket wrenches, ratchets and handles…………………………………………… 1-13 Impact drivers…………………………………………………………………………… 1-14 Allen wrenches………………………………………………………………………… 1-14 Torque wrenches………………………………………………………………………… 1-14 Torque adapters………………………………………………………………………… 1-15 Pliers……………………………………………………………………………………… 1-16 Snap ring pliers………………………………………………………………………… 1-16 Hammers………………………………………………………………………………… 1-16 Ignition grounding tool………………………………………………………………… 1-17 PRECISION MEASURING TOOLS……………………………………………………… 1-17 Feeler gauge…………………………………………………………………………… 1-18 Calipers…………………………………………………………………………………… 1-18 Micrometers……………………………………………………………………………… 1-19 Adjustment………………………………………………………………………………...
  • Page 4 Preparing the Motorcycle for Storage………………………………………………… 1-31 Returning the Motorcycle to Service…………………………………………………… 1-32 1-33 CHAPTER TWO TROVBLESHOOTING………………………………………………… 1-34 ENGINE PRINCIPLES AND OPERATING REQUIREMENTS………………………… STARTING THE ENGINE ………………………………………………………………… 1-34 Engine is cold …………………………………………………………………………… 1-34 Engine is warm…………………………………………………………………………… 1-34 Starting the engine after a fall or after the engine stalls……………………………… 1-35 Flooded engine……………………………………………………………………………...
  • Page 5 Low engine compression……………………………………………………………… 1-45 High engine compression……………………………………………………………… 1-46 Engine overheating (Cooling System) ……………………………………………… 1-46 Engine overheating (Engine) ………………………………………………………… 1-46 Preignition………………………………………………………………………………… 1-47 Detonation………………………………………………………………………………… 1-47 Power Loss Engine Noises……………………………………………………………… 1-47 ENGLNE LUBRICATION…………………………………………………………………… 1-48 High Oil Consumption or Excessive ……………………………………………………… 1-48 Exhaust smoke…………………………………………………………………………… 1-48 1-48 Low oil pressure…………………………………………………………………………...
  • Page 6 1-58 Soft or Spongy Brake Lever or Pedal………………………………………………… 1-60 Brake drag……………………………………………………………………………… 1-60 Hard Brake Lever or Pedal Operation………………………………………………… 1-60 Hard Brake Lever or Pedal Operation………………………………………………… 1-61 Brake Squeal or Chatter………………………………………………………………… 1-61 Leaking brake caliper…………………………………………………………………… 1-61 Leaking master cylinder………………………………………………………………… CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT………………………………………...
  • Page 7 Adjusting the starter cable …………………………………………………………… 3-7 Checking the spark plug……………………………………………………………… Checking the ignition timing ………………………………………………………… Measuring the compression pressure ……………………………………………… 3-10 Checking the engine oil level ……………………………………………………… 3-11 Changing the engine oil ……………………………………………………………… 3-12 CHASSIS Cleaning the air filter ………………………………………………………………… 3-15 Checking the coolant level ……………………………………………………………...
  • Page 8 …………………………………………………………… 3-43 Changing the headlight bulb ………………………………………………………… 3-44 Changing the tail/brake light bulb CHAPTER 4 ENGINE ENGINE NOTE …………………………………………………………………………… ENGINE REMOVAL………………………………………………………………………… 4-2 CYLINDER HEAD AND CYLINDER HEAD COVER ………………………………… ROCKER ARMS AND CAMSHAFT …………………………………………………… 4-10 VALVES AND VALVE SPRINGS ……………………………………………………… 4-16 CYLINDER AND PISTON…………………………………………………………………...
  • Page 9 DIRECTION SYSTEM The structure of the steering…………………………………………………………… The structure of steering wheel part…………………………………………………… 5-6 Diassembling the parts of the steering wheel ………………………………………… The structure of steering wheel part …………………………………………………… 5-8 Diassembling the steering column parts……………………………………………… Checking and service the steering column parts …………………………………… 5-10 Steering drive axle ………………………………………………………………………...
  • Page 10 Checking the joints……………………………………………………………………… 5-55 Checking the differential gear ………………………………………………………… 5-56 Installing the front bridge parts………………………………………………………… 5-57 Rear bridge ……………………………………………………………………………… 5-58 REVERSE MECHANISM PARTS ……………………………………………………… 5-64 Adjusting reverse mechanism parts ………………………………………………… 5-67 Checking and service of reverse mechanism………………………………………… 5-67 SUSPENSION……………………………………………………………………………… 5-68 Front Suspension and arm ……………………………………………………………...
  • Page 11 CHECKING THE SWITCH ……………………………………………………………… Checking the switch…………………………………………………………………… Checking the switch continuity ……………………………………………………… CHECKING THE BULBS AND BULB SOCKETS …………………………………… IGNITION SYSTEM ……………………………………………………………………… TROUBLESHOOTING …………………………………………………………………… ELECTRIC STARTING SYSTEM ……………………………………………………… 6-11 CIRCUIT DIAGRAM ……………………………………………………………………… 6-11 TROUBLESHOOTING …………………………………………………………………… 6-12 STARTER MOTOR ……………………………………………………………………… 6-15 Checking the starter motor ……………………………………………………………...
  • Page 12 CHAPTER 7 TROUBLESHOOTING STARTING FAILURE/HARD STARTING………………………………………………… 7-1 Fuel system ……………………………………………………………………………… Electrical system ………………………………………………………………………… 7-1 Compression system …………………………………………………………………… POOR IDLE SPEED PERFORMANCE ………………………………………………… Poor idle speed performance…………………………………………………………… POOR MEDIUM AND HIGH-SPEED PERFORMANCE ……………………………… Poor medium and high-speed performance…………………………………………… 7-3 FAULTY GEAR SHIFTING………………………………………………………………… Shift lever does not move ………………………………………………………………...

  • Page 13: Description And Machine Identification

    GENERAL INFORMATION DESCRIPTION AND MACHINE IDENTIFICATION 1. Headlights 2. Front shock absorber assembly adjusting ring 3. Brake fluid reservoir 4. Air filter element (engine and air intake duct) 5. V-belt case 6. Driver seat 7. Driver seat belt 8. Spark plug 9.

  • Page 14: Identification Code

    GENERAL INFORMATION IDENTIFICATION CODE Frame No. Frame No. is carved in the lower right side of Figure. Engine No. Engine NO. is carved on the right side of the engine, Figure.

  • Page 15: Manual Organization

    GENERAL INFORMATION CHAPTER ONE GENERAL INFORMATION The text provides complete information on maintenance，tune-up repair and overhaul，Hundreds of photographs and illustrations created during the complete disassembly of UTV guide the reader through every job，All procedures are in step-by-step format and designed for the reader who may be working on the UTV for the first time MANUAL ORGANIZATION A shop manual is a tool and, as in all Clymer manuals, the chapters are thump tabbed for easy...

  • Page 16: Handing Gasoline Safely

    GENERAL INFORMATION Do not operate the utility terrain venires in an enclosed area venires The exhaust gasses contain carbon monoxide. an odorless, colorless and tasteless poisonous gas. Carbon monoxide levels build quickly in small enclosed areas and can cause unconsciousness and death in a short time. Make sure to properly ventilate the work area or operate the UTV side Never use gasoline or any extremely flammable liquid to clean parts.

  • Page 17: Cleaning Parts

    GENERAL INFORMATION sparks or where someone is smoking .Gasoline vapor is heavier than air, it collects in low areas and is more easily ignited than liquid gasoline. Allow the engine to cool completely before working on any fuel system component. Do not store gasoline in glass containers.

  • Page 18: Serial Numbers

    GENERAL INFORMATION SERIAL NUMBERS Serial and identification numbers are stamped on various locations on the frame, engine and carburetor body. Record these numbers in the Quick Reference Data section in the front of the manual. Have these numbers available when ordering parts. FASTENERS Proper fastener selection and installation is important to ensure the motorcycle operates as designed and can be serviced efficiently.

  • Page 19: Washers

    GENERAL INFORMATION Washers The two basic types of washers are flat washers and lock washers. Flat washers are simple discs with a hole to fit a screw or bolt. Lock washers are used to prevent a fastener from working loose. Washers can be used as spacers and seals.

  • Page 20: Shop Supplies

    GENERAL INFORMATION into place Observe the following when installing snap rings: Remove and install snap rings with snap rings pliers. Refer to Basic Tools in this chapter In some applications. it may be necessary to replace snap rings after removing them Compress or expand snap rings only enough to install them.

  • Page 21: Greases

    GENERAL INFORMATION Viscosity is an indication of the oil’s thickness. Thin oils have a lower number while thick oil have a higher number. Engine oils fall into the 5-to50-weight range for single-grade oils. Most manufactures recommend multi-grade oil. These oils perform efficiently across a wide range of operating conditions.

  • Page 22: Cleaners Degreasers And Solvents

    GENERAL INFORMATION Cleaners, Degreasers and Solvents Many chemicals are available to remove oil, grease and other residue from the motorcycle UTV. Before using cleaning solvents, consider how they will be used and disposed of , particularly if they are not water-soluble. Local ordinances may types of cleaning chemicals. Refer to Safer in this chapter. Use brake parts cleaner to brake system components.

  • Page 23: Basic Tools

    GENERAL INFORMATION fastener to work loose from vibration or hear expansion and contraction. Some thread locking compound sparingly. Excess fluid can run into adjoining parts. CAUTION Thread locking compounds are anaerobic and will stress, crack and attack most plastics. Use caution when using These products in areas where there are plastic components.

  • Page 24: Wrenches

    GENERAL INFORMATION specifications. Poor quality or damaged Phillips screwdrivers can back out (cam out) and round over the screw head. In addition. Weak or soft screw materials can make removal difficult. The best type of screwdriver to use on Phillips screw is the ACR Phillips II screwdriver, patented by the horizontal anti-cam out ribs found on the driving faces or flutes of the screwdriver’s tip (figure 4).

  • Page 25: Adjustable Wrenches

    GENERAL INFORMATION open-end on the other. This combination makes it a convenient tool. Adjustable wrenches An adjustable wrench or Crescent wrench (Figure 6) can fit nearly any nut or bolt head that has clear access around its entire perimeter. An adjustable wrench is best used as a backup wrench to keep a large nut or bolt from turning while the other end is being loosened or tightened with a box-end or socket wrench.

  • Page 26: Impact Drivers

    GENERAL INFORMATION most convenient tool for fastener removal and installation Impact Drivers An impact driver provides extra force for removing fasteners by converting the impact of a hammer into a turning motion. This makes it possible to remove stubborn fasteners without damaging them. Impact drivers and interchangeable bits (Figure 10) are available from most tool suppliers.

  • Page 27: Torque Adapters

    GENERAL INFORMATION torque wrenches in cases or separate padded drawers within a toolbox. Follow the manufacturer’s instructions for their care and calibration. Torque Adapters Torque adapters or extensions extend or reduce the reach of a torque wrench. The torque adapter shown in (Figure 13) is used to tighten a fastener that cannot be reached because of the size of the torque wrench head, drive, and socket.

  • Page 28: Pliers

    GENERAL INFORMATION Pliers Pliers come in a wide range of types and sizes. Pliers are useful for holding, cutting, bending, and crimping. Do not use them to turn fasteners. Figure 15 and Figure 16 show several types of useful pliers. Each design has a specialized function.

  • Page 29: Ignition Grounding Tool

    GENERAL INFORMATION condition and the handle is not cracked. Select the correct hammer for the job and make sure to strike the object squarely. Do not use the handle or the side of the hammer to strike an object. Ignition Grounding Tool Some test procedures require turning the engine over without starting it.

  • Page 30: Feeler Gauge

    GENERAL INFORMATION Feeler Gauge Use feeler or thickness gauges (Figure19) for measuring the distance between two surfaces. A feeler gauge set consists of an assortment of steel strips of graduated thickness. Each blade is marked with its thickness. Blades can be of various lengths and angles for different procedures.

  • Page 31: Micrometers

    GENERAL INFORMATION Micrometers A micrometer is an instrument designed for linear measurement using the decimal divisions of the inch or meter (Figure 22). While there are many types and styles of micrometers, most of the DECIMAL PLACE VALUES* Indicates 1/10 (one tenth of an inch or millimeter) 0.01 Indicates 1/100 (one one-hundredth of...

  • Page 32: Care

    GENERAL INFORMATION b. If the adjustment is correct, the 0 mark on the thimble will align exactly with the 0 mark on the sleeve line. If the marks do not align, the micrometer is out of adjustment. c. Follow the manufacturer’s instructions to adjust the micrometer. 2B.

  • Page 33: Standard Inch Micrometer

    GENERAL INFORMATION 1. Read the upper half of the sleeve line and count the number of lines visible. Each upper line equals 1mm. 2. See if the half –millimeter line is visible on the lower sleeve line. If so, add 0.50mm to the reading in Step 1.

  • Page 34: Telescoping And Small Bore Gauges

    GENERAL INFORMATION Telescoping and Small Bore Gauges Use telescoping gauges (Figure 28) and small bore gauges (Figure 29) to measure bores. Neither gauge has a scale for direct readings. Use an outside micrometer to determine the reading. To use a telescoping gauge, select the correct size gauge for the bore.

  • Page 35: Compression Gauge

    GENERAL INFORMATION Compression Gauge A compression gauge (Figure 33) measures combustion chamber (cylinder) pressure, usually in psi or kg/ cm . The gauge adapter is either inserted or screwed into the spark plug hole to obtain the reading. Disable the engine so it does not start and hold the throttle in the wide-open position when performing a compression test An engine that does not have adequate compression cannot be properly tuned.

  • Page 36: Voltage

    GENERAL INFORMATION Voltage Voltage is the electrical potential or pressure in an electrical circuit and is expressed in volts. The more pressure (voltage) in a circuit the more work can be performed. Direct current (DC) voltage means the electricity flows in one direction. All circuits powered by a battery are DC circuits.
  • Page 37 GENERAL INFORMATION memory alone. 5. Protect finished surfaces from physical damage or corrosion. Keep gasoline and other chemicals off painted surfaces. 6. Use penetrating oil on frozen or tight bolts. Avoid using heat where possible. Heat can warp, melt or affect the temper of parts. Heat also damages the finish of paint and plastics. 7.

  • Page 38: Removing Frozen Fasteners

    GENERAL INFORMATION Removing Frozen Fasteners If a fastener cannot be removed, several methods may be used to loosen it. First, apply a penetrating fluid. Apply it liberally and let it penetrate for 10-15 minutes. Rap the fastener several times with a small hammer. Do not hit it hard enough to cause damage. Reapply the penetrating fluid if necessary.

  • Page 39: Stud Removal/Installation

    GENERAL INFORMATION Stud Removal/Installation A stud removal tool (Figure 38) is available from most tool suppliers. This tool makes the removal and installation of studs easier. If one is not available, thread two must onto the stud and tighten them against each other.

  • Page 40: Removal

    GENERAL INFORMATION mark or number facing outward. Removal While bearing are normally removed only when damaged, there may be times when it is necessary to remove a bearing that is in good condition. However, improper bearing removal will damage the bearing and possibly the shaft or case.

  • Page 41: Interference Fit

    GENERAL INFORMATION to the inner bearing race (Figure 44). 2. When installing a bearing as described in Step 1, some type of driver is required. Never strike the bearing directly with a hammer or it will damage the bearing. When installing a bearing, use a piece of pipe or a driver with a diameter that matches the bearing inner race.
  • Page 42 GENERAL INFORMATION 2. Follow this step when installing a bearing in a housing. Bearings are general installed in a housing with a slight interference fit Driving the bearing into the housing using normal methods may damage the housing or cause bearing damage. Instead, heat the housing before the bearing is installed.

  • Page 43: Seal Replacement

    GENERAL INFORMATION Seal Replacement Seals (Figure 47) contain oil, water, grease or combustion gasses in a housing or shaft. Improperly removing a seal can damage the housing or shaft. Improperly installing the seal can damage the seat. Note the following: 1.
  • Page 44 GENERAL INFORMATION 2. Lubricate the drive chain. 3. Start the engine and allow it to reach operating temperature. Drain the engine oil regardless of the riding time since the last service. Fill the engine with the recommended type of oil. 4.

  • Page 45: Chapter Two Trovbleshooting

    GENERAL INFORMATION CHAPTER TWO TROVBLESHOOTING Diagnose electrical and mechanical problems by following an orderly procedure and remembering the basic operating requirements → Define Symptoms ↓ → Determine Which areas could exhibit these symptoms ↓ Test and analyze → The suspect areas ↓...

  • Page 46: Engine Principles And Operating Requirements

    GENERAL INFORMATION ENGINE PRINCIPLES AND OPERATING REQUIREMENTS An engine needs three basics to run properly: Correct air/fuel mixture Compression Engine runs A spark at the right time If one basic requirement is missing the engine will not run. STARTING THE ENGINE When experiencing engine-starting troubles, it is easy to work out of sequence and forget basic starting procedures.

  • Page 47: Starting The Engine After A Fall Or After The Engine Stalls

    GENERAL INFORMATION Starting the engine after a fall or after the engine stalls 1. Shift the transmission into neutral. 2. Release the hot start lever as the engine starts. 3. If the engine fails to start, refer to Flooded Engine in this section. Flooded engine If the engine fails to start after several attempts, it is probably flooded.

  • Page 48: Cold Engine With Air Temperature Below 10℃(50°F)

    GENERAL INFORMATION Cold engine with air temperature below 10℃(50°F) 1. Shift the transmission into neutral. 2. Turn the fuel valve on 3. If the temperature is below 32°F (0℃), open the throttle two or three times to allow the accelerator pump to feed additional fuel to the engine.

  • Page 49: Flooded Engine

    GENERAL INFORMATION 4. If the engine fails to start, refer to Flooded Engine in this section. Flooded engine If the engine fails to start after several attempts, it is probably flooded. This situation occurs when too much fuel is drawn into the engine and the spark plug fails to ignite it. The smell of gasoline is often evident when the engine is flooded.

  • Page 50: Spark Test

    GENERAL INFORMATION NOTE A cracked or damaged direct ignition coil or spark plug cap and cable can cause intermittent problems that are difficult to diagnose. If the engine occasionally misfires or cuts out, use a spray bottle to wet the direct ignition coil or plug cap and plug cable while the engine is running.

  • Page 51: Starter Does Not Turn Over Or Turns Over Slowly

    GENERAL INFORMATION WARNING Mount the spark tester or spark plug away from the spark plug hole in the cylinder. If the engine is flooded, do not perform this test. The spark tester can ignite fuel ejected through the spark plug hole. 5.

  • Page 52: Engine Backfires, Cuts Out Or Misfires During Acceleration

    GENERAL INFORMATION 6. Incorrect float level adjustment. 7. Plugged carburetor jets. NOTE If a warm or hot engine will start with the choke on, or if a cold engine starts and runs until the choke is turned off. The pilot jet is probably plugged. 8.

  • Page 53: Poor Fuel Mileage

    GENERAL INFORMATION If the engine backfires when the throttle is released, check the following: 1. Lean carburetor pilot system. 2. Loose exhaust pipe-to-cylinder head connection. 3. Faulty ignition system component. 4. Check the following engine components: a. Broken valve springs. b.
  • Page 54 GENERAL INFORMATION 2. Test ride the UTV and accelerate quickly from first to second gear. If the engine speed in-creased according to throttle position. Perform Step 3. If the engine speed did not increase. Check CVT a. Warped clutch plates/discs b.

  • Page 55: Poor Idle Or Low Speed Performance

    GENERAL INFORMATION Poor Idle or Low Speed Performance Check for an incorrect pilot screw adjustment Check for damaged or loose intake pipe and air filter housing hose clamps. These conditions will cause an air leak Perform the spark test in this chapter. Note the following: a.

  • Page 56: Rich Mixture

    GENERAL INFORMATION lighter parts of the fuel have evaporated. Depending on the condition of the fuel. a no-start condition can result c. If there is an excessive amount of fuel on the plug. Check for a clogged air filter or flooded carburetor.

  • Page 57: Blue Smoke

    GENERAL INFORMATION Blue smoke Blue smoke indicates that the engine is burning oil in the combustion chamber as it leaks past worn valve stem seals and piston rings. Excessive oil consumption is another indicator of an engine that is burning oil. Perform a compression test to isolate the problem. White smoke or steam It is normal to see white smoke or steam from the exhaust after first starting the engine in cold weather.

  • Page 58: Engine Overheating (Cooling System)

    GENERAL INFORMATION Engine Overheating (Cooling System) WARNING Do not remove the radiator cap, coolant drain plug or disconnect any coolant hose immediately after or during engine operation. Scalding fluid and steam may be blown out under pressure and cause serious injury. When the engine has been operated, the coolant is very hot and under pressure.

  • Page 59: Detonation

    GENERAL INFORMATION Detonation Detonation is the violent explosion of fuel in the combustion chamber before the proper time of ignition. Using low octane gasoline is a common cause of detonation. Even when using a high octane gasoline, detonation can still occur. Other causes are over-advanced ignition timing, lean air/fuel mixture at or near full throttle, inadequate engine cooling, or the excessive accumulation of carbon deposits in the combustion chamber.

  • Page 60: Englne Lubrication

    GENERAL INFORMATION Excessive valve clearance. Worn or damaged camshaft. Damaged camshaft. Worn or damaged valve train components. Damaged valve lifter bore(s). f. Valve sticking in guide. Broken valve spring. Low oil pressure. i. Clogged cylinder oil hole or oil passage. ENGLNE LUBRICATION An improperly operating engine lubrication system quickly leads to engine seizure.

  • Page 61: No Oil Pressure

    GENERAL INFORMATION No Oil Pressure 1. Low oil level. 2. Oil relief valve stuck closed. 3. Damaged oil pump. 4. Incorrect oil pump installation. 5. Internal oil leak. Oil Level Too Low 1. Oil level not maintained at correct level 2.
  • Page 62 GENERAL INFORMATION 1. Support the UTV on a work stand with the rear wheel off the ground. 2. Remove the air filter assembly Open and secure the throttle so it is at its wide-open position. 3. Remove the spark plug. 4.
  • Page 63 GENERAL INFORMATION Turn the drive sprocket by hand and shift the transmission into top gear with the shift pedal. Mount a holding tool or equivalent onto the drive sprocket. Use a wooden block and clamp to hold the holding tool so it cannot move when the combustion chamber becomes pressurized. Check that the TDC marks are still aligned as described in Step7, If not, turn the crankshaft as required, then relock the holding tool in position.

  • Page 64: Electrical Testing

    GENERAL INFORMATION ELECTRICAL TESTING This section describes basic electrical testing and test equipment use. Preliminary Checks and Precautions Refer to the color wiring diagrams at the end of the manual for component and connector identification, Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground.

  • Page 65: Electrical Component Replacement

    GENERAL INFORMATION connector c. A change in meter readings indicates a poor connection. Fine and repair the problem or replace the part. Check for wires with cracked or broken insulation NOTE An analog ohmmeter is useful when making this type of test. Slight needle movements are apparent when indicating a loose connection Heat –...

  • Page 66: Test Equipment

    GENERAL INFORMATION specification, especially resistance. A number of variables can affect test results dramatically. These include: the testing meter’s internal circuitry, ambient temperature and conditions under which the machine has been operated. All instructions and specifications have been for accuracy: however. Successful test results depend to a great degree upon individual accuracy.

  • Page 67: Ohmmeter

    GENERAL INFORMATION ohmmeter have a switch that allows the user to select different ranges of resistance for accurate readings. The analog ohmmeter also has a set-adjust control which is used to zero or calibrate the meter (digital ohmmeters do not require calibration). An ohmmeter is used by connecting its test leads to the terminals or leads of the circuit or component to be tested.

  • Page 68: Test Procedures

    GENERAL INFORMATION will blow the fuse(s) Test Procedures Voltage test Unless otherwise specified. Make all voltage tests with the electrical connectors still connected. Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing.

  • Page 69: Peak Voltage Test

    GENERAL INFORMATION a. The voltmeter should indicate 0 volts. If there is a drop of 0.5 volts or more. There is a problem within the circuit. A voltage drop reading of 12 volts indicates an open in the circuit. b. A voltage drop of 1 or more volts indicates that a circuit has excessive resistance. c.

  • Page 70: Testing For A Short With A Test Light Or Voltmeter

    GENERAL INFORMATION 5. With the self-powered test light or ohmmeter attached to the fuse terminal and ground, wiggle the wiring harness relating to the suspect circuit at various intervals. Start next to the fuse terminals and work away from the fuse terminal. Watch the self-powered test light or ohmmeter while progressing along the harness.

  • Page 71: Brake Drag

    GENERAL INFORMATION 2. Low brake fluid level. WARNING As the brake pads wear, the brake fluid level in the master cylinder reservoir drops. Whenever adding brake fluid to the reservoir, visually check the brake pads for wear. If it does not appear that there is an increase in pad wear, check the brake hoses, lines and banjo bolts for leaks.

  • Page 72: Hard Brake Lever Or Pedal Operation

    GENERAL INFORMATION 9. Damaged or misaligned wheel. 10. Incorrect wheel alignment. 11. Incorrectly installed brake caliper. 12. Damaged front or rear wheel. Hard Brake Lever or Pedal Operation When applying the brakes and there is sufficient brake performance but the operation of brake lever feels excessively hard, check for the following possible causes: 1.

  • Page 73: Leaking Master Cylinder

    GENERAL INFORMATION 1. Damaged dust and piston seals. 2. Damaged cylinder bore. 3. Loose caliper body bolts. 4. Loose banjo bolt. 5. Damaged banjo bolt washers. 6. Damaged banjo bolt threads in caliper body. Leaking Master Cylinder 1. Damaged piston secondary seal. 2.

  • Page 74: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS 1. How to use conversion table of unit （1）How to use conversion table All the specified documents in this manual are taken SI and Metric as unit. With the following conversion table, metric unit could be conversed into imperial unit. Sample: METRIC MULTIPLY...
  • Page 75 GENERAL SPECIFICATIONS 2. General specifications Item Standard Dimensions : Overall length 3,010 mm（118.5 in） Overall width 1,460 mm（57.5 in） Overall height 1,940 mm（77.2 in） Seat height 818 mm（32.2 in） Wheelbase 1,890 mm（72.4 in） Minimum ground clearance 280 mm（11.0 in） Minimum turning radius 3,900 mm（154 in）...
  • Page 76 GENERAL SPECIFICATIONS Item Standard Wet type element Air filter Fuel Unleaded gasoline only Type 30.0L（6.60 lmp gal, 7.93 US gal） Fuel tank capacity Carburetor Type/quantity PD42J-A / 1 Spark plug DPR8EA / 1(NGK) Type/manufacturer 0.8-0.9 mm（0.031-0.035 in） Spark plug gap Wet ,centrifugal automatic Clutch type Transmission...
  • Page 77 GENERAL SPECIFICATIONS Item Standard Suspension Front suspension Double wishbone Rear suspension Double wishbone Shock absorber Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/oil damper Wheel travel Front wheel travel 185 mm (7.3 in) Rear wheel travel 185 mm (7.3 in) Electrical Ignition system C.D.I.

  • Page 78: Engine Specifications

    GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Cylinder head Warp limit ---- 0.03 mm (0.0012 in) 100.10 mm Cylinder Bore size 100.005 ~ 100.055 mm (3.9410 in) Measuring point (3.9372 ~ 3.9392 in) ---- 50 mm (1.97 in) Camshaft Drive method Chain drive (Left) ---- Cam dimensions...
  • Page 79 GENERAL SPECIFICATIONS Item Standard Limit Cam chain Cam chain adjustment method Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) Shaft outside diameter 11.976 ~ 11.991 mm ---- (0.4715 ~ 0.4721 in) Arm-to-shaft clearance 0.009 ~ 0.042 mm ----...
  • Page 80 GENERAL SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 ~ 0.037 mm 0.08 mm (0.0004 ~ 0.0015 in) (0.0031 in) 0.025 ~ 0.052 mm 0.10 mm (0.0010 ~ 0.0020 in) (0.0039 in) Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm ---- (0.0354 ~ 0.0433 in)
  • Page 81 GENERAL SPECIFICATIONS Item Standard Limit Piston Piston to cylinder clearance 0.050 ~ 0.070 mm 0.15 mm (0.0020 ~ 0.0028 in) (0.0059 in) Piston size “D” 99.945 ~ 99.995 mm ---- (3.9348 ~ 3.9368 in) ---- 2.5 mm (0.10 in) Measuring point “H” ---- 1.0 mm(0.0394 in) Piston off-set...
  • Page 82 GENERAL SPECIFICATIONS Item Standard Limit Oil ring ---- 2.5×3.4 mm (0.0984× 0 .1339 in) Dimensions (B×T) ---- 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) End gap (installed) ---- 0.06 ~ 0.15 mm (0.0024 ~ 0.0059 in) Side clearance Crankshaft 74.95 ~ 75.00 mm ---- Crank width “A”...
  • Page 83 GENERAL SPECIFICATIONS Item Standard Limit Transmission Main axle deflection limit ---- 0.06 mm (0.0024 in) Drive axle deflection limit ---- 0.06 mm (0.0024 in) Shifter Shifter type Shift drum and guide bar ---- Engine oil ---- Air filter oil grade Carburetor ---- Mark...
  • Page 84 GENERAL SPECIFICATIONS Height 238 mm (9.37 in) ---- Thickness 24 mm (0.94 in) ---- Radiator cap opening pressure 107.9 ~ 137.3 kPa ---- (1.079~1.373 kg/cm2, 15.35~19.53 psi) Radiator capacity 2.5 L (2.20 Imp qt, 2.64 US qt) ---- (including all routes) Coolant reservoir Capacity 0.35 L (0.31 Imp qt, 0.37 US qt)

  • Page 85: Chassis Specifications

    GENERAL SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Steering system Type Rack and pinion ---- Front suspension Shock absorber travel 108 mm (4.25 in) ---- Spring free length 313 mm (12.32 in) ---- Spring fitting length 247.9 mm (9.76 in) ---- Spring rate 19.4 N/mm(1.94 kg/mm, 108.6 lb/in) ----...
  • Page 86 GENERAL SPECIFICATIONS Item Standard Limit Front disc brake Type Dual ---- Disc outside diameter × thickness 200 × 3.5 mm (7.87 × 0.14 in) ---- Pad thickness inner 5.2 mm 1.5 mm (0.20 in) (0.06 in) Pad thickness outer 5.2 mm 1.5 mm (0.20 in) (0.06 in)

  • Page 87: Electrical Specifications

    GENERAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit 12 V ---- Voltage Ignition system Ignition timing (BTDC) 12°/ 1,500 r/min ---- (BTDC) ---- Advancer type Digital type C.D.I. Pickup coil resistance/color 459 ~ 561 Ωat 20 °C (68 °F)/ ---- Rotor rotation direction sensing coil White/Red –...
  • Page 88 GENERAL SPECIFICATIONS Item Standard Limit Electric starter system Type Constant mesh type ---- Starter motor Output 0.8 kW ---- Armature coil resistance 0.025 ~ 0.035 Ωat 20 °C (68 °F) ---- Brush overall length 12.5 mm (0.49 in) ---- 5 mm(0.20 in) Spring force 7.65 ~ 10.01 N (780 ~ 1,021 g, 27.5 ~ 36.0 oz)

  • Page 89: Tightening Torques

    GENERAL SPECIFICATIONS TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Cylinder head Bolt Bolt Spark plug — Stud bolt Cylinder head (exhaust pipe) Cylinder head cover Bolt Tappet cover (exhaust) —...
  • Page 90 GENERAL SPECIFICATIONS Thread Tightening torque Part to be tightened Part name Q’ty Remarks size m · kg ft · lb Crankcase Bolt Bolt Bolt Bearing housing (clutch housing Bolt assembly) Bolt Air duct assembly 1 bracket Oil seal (engine cooling fan pulley) Bolt Retainer Drive belt case...
  • Page 91 GENERAL SPECIFICATIONS Shift rod locknut (select lever unit) Left-hand — threads Thread Q’ty Remarks Part to be tightened Part name size ft · lb m.kg Shift rod locknut (shift arm side) — Select lever unit Bolt Plug (right crankcase) — Water pump assembly Bolt Water pump housing cover...

  • Page 92: Chassis Tightening Torques

    GENERAL SPECIFICATIONS CHASSIS TIGHTENING TORQUES Thread Tightening torque Part to be tightened Remarks size m · kg ft · lb Rubber connecting bracket 1(or 2) and frame Engine and Rubber connecting bracket 2 (front) Engine and Rubber connecting bracket 1 (rear) Rear upper arm and frame Rear lower arm and frame Rear knuckle and rear upper arm...
  • Page 93 GENERAL SPECIFICATIONS Seat belt and frame Seat belt and ceiling (enclosure) 7/16 Front wheel and front wheel hu Front wheel hub and constant velocity joint of half shaft 26.0 Stake Steering knuckle and brake disc guard Front brake caliper and front wheel steering knuckle Front brake hose union bolt Front brake hose holder and steering knuckle Front brake hose holder and front upper arm...

  • Page 94: General Tightening Torque Specifications

    GENERAL SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 95: Lubrication Pionts And Lubricant Types

    GENERAL SPECIFICATIONS LUBRICATION PIONTS AND LUBRICANT TYPES ENGINE Lubrication points Lubricant Oil seal lips Bearings O-rings Piston, piston ring Piston pin Buffer boss and balancer drive gear Crankshaft seal and spacer Valve stem Valve stem end Rocker arm shaft Rocker arm Camshaft lobe and journal Oil pump assembly Oil filter cartridge O-ring...

  • Page 96: Hydrographic Chart

    GENERAL SPECIFICATIONS HYDROGRAPHIC CHART Hydrographic chart ：Pressure ：splash 2-23...

  • Page 97: Lubrication Oil Way

    GENERAL SPECIFICATIONS LUBRICATION OIL WAY 2-24...

  • Page 98: Maintence And Adjustment Of The Utv

    MAINTENCE AND ADJUSTMENT OF THE UTV Note: The correct maintenance and adjustment are necessary to ensure vehicle and normal driving The repair personnel should be familiar with the contents of this article. Maintenance schedule EVERY INITAL Whichever month ITEM ROUTINE comes first 1,200 2,400...
  • Page 99 · Check operation. Rear brake* ○ ○ ○ ○ ○ · Adjust if necessary. · Select lever safety Check operation. ○ ○ ○ · system cable Adjust if necessary. · Check operation. V-belt* ○ ○ ○ ○ · Check for cracks or damage. ·...

  • Page 100: Engine

    ENGINE ADJUSTING THE VALVE CLEARANCE Note: ·The valve clearance must be adjusted when the engine is cool to the touch. · Adjust the valve clearance when the piston is at the Top Dead Center TDC) on the compression stroke. · Remove: ·driver seat ·passenger seat ·console...
  • Page 101 3. calibration · Wrench to counterclockwise rotation crankshaft 2. According to the rotor turning counterclockwise, rotor turn to mark the dead spots② of crank box, namely ①: the dead point position is compressed. 4. Check: ·valve clearance ·Beyond the standard → Adjust. Valve clearance (cold) Intake 0.10 ~ 0.15 mm...

  • Page 102: Idle Adjustment

    14（1.4kg.m） Measuring clearance rules with the valve · clearance. · If the gap beyond the standard value, repeat the above steps until the correct gap. 6. Install all removed parts According to remove the reverse order for installation ① Engine fan components ②...

  • Page 103: Adjusting The Throttle Cable

    Note Don't lock screw too tight Turning in Idle speed becomes higher. Turning out Idle speed becomes lower. 6. sever: ·Tachometer 7. Lower the cargo bed. 8. Install: · console · passenger seat ·driver seat ADJUSTING THE THROTTLE CABLE Note Throttle cable free play should be adjusted properly before adjusting the engine idle speed.

  • Page 104: Adjusting The Starter Cable

    Note After adjustment throttle pressure on the accelerator cable several times, ensuring the throttle ③ , then close completely loosen the accelerator pedal . 5. Install: · console · passenger seat · driver seat ADJUSTING THE STARTER CABLE 1. Remove: ·...

  • Page 105: Checking The Spark Plug

    3. Install: ·console ·passenger seat ·driver seat CHECKING THE SPARK PLUG 1. Lift the cargo bed up. 2. Remove: pull out the spark plug cap ① and remove the spark plug by sleeve 3. Check: ·spark plug type Incorrect → Replace. Standard spark plug DPR8EA-9/NGK 4.

  • Page 106: Checking The Ignition Timing

    CHECKING THE IGNITION TIMING Note Engine idle speed and throttle cable free play should be adjusted properly before checking the ignition timing. 1. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the cargo bed up. 3.

  • Page 107: Measuring The Compression Pressure

    9. Lower the cargo bed. 10. Install: ·console ·passenger seat ·driver seat Refer to “SEATS” in chapter 5. MEASURING THE COMPRESSION PRESSURE Note Insufficient compression pressure will result in a loss of performance. 1. Start the engine and let it warm up for several minutes.

  • Page 108: Checking The Engine Oil Level

    (11.5 kg/cm2, 163.57 psi) Maximum: 1,480 Kpa (14.8 kg/cm2, 210.50 psi) ·Crank over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide-open until the compression reading on the gauge stabilizes. Note When cranking the engine, ground the spark plug lead to prevent sparking.

  • Page 109: Changing The Engine Oil

    4. Start the engine and let it warm up for several 5. Stop the engine and check the oil level again. Note Wait a few minutes until the oil settles before checking the oil level. Note Never remove the dipstick just after high speed operation because the heated oil could spurt out.
  • Page 110 with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m · kg, 12 ft · lb) 6. Install： ·engine oil drain bolt ① 7. Fill: ·Before the oil is put into the crankcase, please cleanout oil filter and make it in good working condition, then assemble.
  • Page 111 Oil gallery bolt 7 Nm (0.7 m · kg, 5.1 ft · lb) 12. Install: ·console ·passenger seat ·driver seat Refer to “SEATS” in chapter 5. 3-14...

  • Page 112: Cleaning The Air Filter

    CLEANING THE AIR FILTER NOTE There is a check hose at the bottom of the air filter ① case. If dust and/or water collects in this hose, clean the air filter element and air filter case. 1. Remove: ·driver seat ·passenger seat ·console ·air filter case cover ①...

  • Page 113: Checking The Coolant Level

    4. Install: ·air filter element ·air filter case cover Note To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case. console ·passenger seat ·driver seat CHECKING THE COOLANT LEVEL 1. Place the vehicle on a level surface. 2.
  • Page 114 used if distilled water is not available. 2. Drain: ·coolant (from the coolant reservoir) 3. Connect: ·coolant reservoir hose 4. Remove: ·coolant drain bolt (water pump) (along with the ① copper washer) 5. Remove: ·radiator cap ① WARNING: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot.
  • Page 115 9. Check: ·copper washer ① ·coolant drain bolt ② Damage → Replace. 10. Install: ·coolant drain bolt (water pump) T R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 11. Connect: ·water pump inlet hose ·coolant outlet hose 12.

  • Page 116: Checking The Coolant Temperature Warning Light

    Note： Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. Use only distilled water. However, soft water may be used if distilled water is not available.

  • Page 117: Checking The V-Belt

    Coolant temperature warning light checking method Turn the main switch “ON”. Coolant temperature warning light does Coolant temperature warning not come on. light comes on Turn the main switch to “START” with the transmission in neutral position. Coolant temperature warning Coolant temperature light come on momentarily.

  • Page 118: Cleaning The Spark Arrester

    Out of specification → Replace. V-belt width 33.2 mm (1.31 in) <Limit:> 29.9 mm (1.18 in) ·Replace V-belt: Install the bolts 1(90101-06016) into the secondary fixed sheave hold. Note: Tightening the bolts 1 will push the secondary sliding sheave away, causing the gap between the secondary fixed and sliding sheaves to widen.

  • Page 119: Adjusting The Brake Pedal

    performing this operation.。 · Do not start the engine when removing the tailpipe from the muffler. 3. Remove: ·Remove the bolts . ① ·Remove the tailpipe ② by pulling it out of the muffler. 4. Install： ·Insert the tailpipe into the muffler and align the bolt ②...

  • Page 120: Adjusting The Parking Brake

    ADJUSTING THE PARKING BRAKE 1. Shift the drive select lever into low gear “L”. . 2. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter5. 3. Check: ·parking brake cable free play ○ a Out of specification → Adjust.。 Parking brake cable free play 2 ~ 3 mm (0.079 ~ 0.118 in) 4.

  • Page 121: Checking The Front Brake Pads

    NOTE： Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. WARNING: · Use only the designed quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. ·Refill with the same type of brake fluid: mixing fluids may result in a harmful chemical reaction and lead to poor performance.

  • Page 122: Checking The Brake Hoses And Brake Pipes

    CHECKING THE BRAKE HOSES AND BRAKE PIPES 1. Remove: ·driver seat ·passenger seat ·console Refer to “SEATS” in chapter 5. 2. Lift the hood up. 3. Lift the cargo bed. 4. Check: ·front brake hoses① ·rear brake pipes ② ·rear brake hoses ③ Cracks/wear/damage →...

  • Page 123: Adjusting The Select Lever Shift Rod

    d. Place the other end of the hose into a container. e. Slowly apply the brake pedal several times. f. Push down on the pedal and hold it. g. Loosen the bleed screw and allow the pedal to travel towards its limit. h.

  • Page 124: Adjusting The Brake Light Switch

    b. Loosen both locknuts ① WARNING: The select lever shift rod locknut (select lever side) has left-handed threads. To loosen the locknut, turn it clockwise. c. Tighten the locknuts ① ADJUSTING THE BRAKE LIGHT SWITCH Note: ·The brake light switch is operated by movement of the brake pedal.

  • Page 125: Changing The Final Gear Oil

    WARNING: Take care not allow foreign material to enter the final gear case. 4. Install: ·oil filler plug 23 N.m (2.3 m · kg, 17 ft · lb) CHANGING THE FINAL GEAR OIL 1. Place the vehicle on a level surface. 2.

  • Page 126: Changing The Differential Gear Oil

    ·oil filler plug 23 Nm (2.3 m · kg, 17 ft · lb) CHANGING THE DIFFERENTIAL GEAR OIL 1. Place the vehicle on a level surface. 2. Place a receptacle under the differential gear case. 3. Remove: ·oil filler plug① 4.

  • Page 127: Checking The Constant Velocity Joint Dust Boots

    CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1. Check: • dust boots ① Damage → Replace. Refer to “FRONT CONSTANT VELOCITY JOINTS, DIFFERENTIAL GEAR AND DRIVE SHAFT” in chapter 5. Front Rear CHECKING THE STEERING SYSTEM 1. Check: Place the vehicle on a level surface. steering assembly bearings Try to the steering wheel up and down, and back and forth.

  • Page 128: Adjusting The Toe-In

    ADJUSTING THE TOE-IN 1. Place the vehicle on a level surface. 2. Measure: • toe-in Out of specification → Adjust. Toe-in 0 ~ 10 mm (0.00 ~ 0.39 in) (with tires touching the ground) Note: Before measuring the toe-in, make sure that the tire pressure is correct.

  • Page 129: Adjusting The Front Shock Absorbers

    Locknut (rod end) 40 Nm (4.0 m · kg, 29 ft · lb) ADJUSTING THE FRONT SHOCK ABSORBERS WARNING: Always adjust both shock absorber spring preload to the same setting. Uneven adjustment can cause poor handling and loss of stability. Note: The spring preload of the shock absorbers can be adjusted to suit the operator’s preference, weight,...

  • Page 130: Checking The Tires

    CHECKING THE TIRES WARNING: • TIRE CHARACTERISTICS a.Tire characteristics influence the handling of vehicle’s. If other tire combinations are used, they adversely affect your vehicle’s handling characteristics and are therefore not recommended. manufactur Type Size Fron Rawhide WANDA 25 × 8-12 Rawhide Rear WANDA...

  • Page 131: Checking The Wheels

    →Adjust. NOTE: • The tire pressure gauge ① is included as standard equipment. • If dust or the like is stuck to this gauge, it will not provide the correct readings. Therefore, take two measurements of the tire’s pressure and use the second reading.

  • Page 132: Checking And Lubricating The Cables

    WARNING: • Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim. CHECKING AND LUBRICATING THE CABLES WARNING: A damaged cable sheath may cause corrosion and interfere with the cable movement.

  • Page 133: Electrical

    ELECTRICAL CHECKING AND CHARGING THE BATTERY WARNING: Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. •...
  • Page 134 NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1.
  • Page 135 • battery(refer to the appropriate charging method illustration) • WARNING: Do not quick charge a battery. NOTE: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
  • Page 136 Note: • Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. • Set the charging voltage to 16 ~17 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.) Measure the open-circuit voltage prior to charging.
  • Page 137 Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. s the amperage higher than the standard charging amperage written on the battery? Charge battery until This type of battery charger cannot charging voltage reaches 15 V.

  • Page 138: Checking The Fuses

    Note: Constant amperage chargers are not suitable for charging MF batteries. 3. Install: • battery • Connect: battery leads Note: First, connect the positive battery lead ①, and then the negative battery lead ②. • Check: battery terminals Dirt → Clean with a wire brush. Loose connection →...
  • Page 139 • battery case cover 2. Check: • fuses a. Connect the pocket tester to the fuse and check it for continuity. 。 Note: Set the tester to the “Ω × 1” position. b. If the tester indicates“∞”, replace the fuse. 3.

  • Page 140: Adjusting The Headlight Beam

    damage to the electrical system, a malfunction of the lighting and ignition systems and could possibly cause a fire. 4. Install: • battery case cover 5. Close the hood. ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • headlight beam (vertically) • turn the adjuster in or out.
  • Page 141 • headlight bulb holder (with bulb) • headlight bulb holder cover • Close the hood. CHANGING THE TAIL/BRAKE LIGHT BULB 1. Remove: • cargo bed panel ① • tail/brake light bulb holder (with bulb) ① • bulb Note: Turn the bulb holder counterclockwise and remove the defective bulb.

  • Page 142: Cylinder Head

    CYLINDER HEAD ENGINE ENGINE NOTE 1．Make sure the components, oil, adhesive, sealant are from the company or recommended. 2．Original removal oil seal，gasket, O-ring, piston ring can not be re-assemblied again, make sure all these parts are new. 3．Pay attention to keep dismantled parts orderly, make sure their original positions for reassembling. 4．Prevent dismantled parts damaged, clean before measure and assembly, remove the oil with compressed air.
  • Page 143 CYLINDER HEAD ENGINE REMOVAL Name part Remarks Removing carburetor and intake Remove the parts in the order listed. manifold. Carburetor Carburetor joint (intake manifold) Intake manifold Drain plug For installation, reverse the removal procedure.
  • Page 144 CYLINDER HEAD NOTE • Removing the drain plug NOTE: Before remove drain plug, please prepare vessel for containing oil and cotton yarn. INSTALL • Install intake manifold • Install intake manifold bolt • Install carburetor joint • Install carburetor NOTE: When installed, don't make an object from the intake fell into the cabinet.
  • Page 145 CYLINDER HEAD CYLINDER HEAD AND CYLINDER HEAD COVER Name part Remarks Removing the cylinder head cover Remove the parts in the order listed. and cylinder head Union bolt Copper washer Oil delivery pipe 3 Oil delivery pipe 2 Spark plug Tappet cover (intake) Tappet cover (exhaust) Timing chain tensioner cap bolt...
  • Page 146 CYLINDER HEAD Name part Remarks Thermo switch 1 For installation, reverse the removal procedure.
  • Page 147 CYLINDER HEAD CHECK 1、Checking the valve clearance • Valve clearance Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 2、Checking the cylinder head cover • cylinder head cover Cracks/damage→ Replace the cylinder head cover and cylinder head as a set. 3、Checking the tappet covers •...
  • Page 148 CYLINDER HEAD 5、Checking the cylinder head 1). Eliminate: • carbon deposits (from the combustion chamber) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats 2). Check: •...
  • Page 149 CYLINDER HEAD INSTALL 1、Installing the cylinder head cover • cylinder head cover • washers ① • bolts ②(Allen wrench M5 , 8-12 Nm) NOTE: Tighten the cylinder head cover bolts in stages, using a crisscross pattern. 2、Installing the cylinder head •...
  • Page 150 CYLINDER HEAD c. With the screwdriver still inserted into the timing chain tensioner, install the timing chain tensioner and gasket onto the cylinder block. Then, tighten the timing chain tensioner bolts to the specified torque. WARNING Always use a new gasket. NOTE: The “UP”...

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