Crossfire 1000GTR Manuals

Manuals and User Guides for Crossfire 1000GTR. We have 1 Crossfire 1000GTR manual available for free PDF download: Maintenance Handbook

Crossfire 1000GTR Maintenance Handbook (266 pages)

Brand: Crossfire | Category: Offroad Vehicle | Size: 5 MB

Table of Contents
3
General Information
15
Watnings , Cautions and Notes
15
Description
16
Identification Code
17
Frame no
17
Engine no
17
Safety
18
Handing Gasoline Safely
18
Cleaning Parts
19
Warning Labels
19
Serial Numbers
20
Fasteners
20
Torque Specifications
20
Self-Locking Fasteners
20
Washers
20
Cotter Pins
21
Snap Rings and E-Clips
21
Shop Supplies
22
Lubricants and Fluids
22
Engine Oils
22
Greases
22
Brake Fluid
23
Coolant
23
Cleaners, Degreasers and Solvents
23
Gasket Sealant
23
Gasket Remover
24
Thread Locking Compound
24
Basic Tools
24
Screwdrivers
25
Wrenches
25
Adjustable Wrenches
26
Socket Wrenches, Ratchets and Handles
26
Impact Drivers
27
Allen Wrenches
27
Torque Wrenches
27
Torque Adapters
28
Pliers
29
Snap Ring Pliers
29
Hammers
30
Ignition Grounding Tool
30
Precision Measuring Tools
30
Feeler Gauge
31
Calipers
31
Micrometers
32
Adjustment
32
Care
33
Metric Micrometer
33
Standard Inch Micrometer
34
Telescoping and Small Bore Gauges
35
Dial Indicator
35
Compression Gauge
36
Multimeter
36
Cltp-On Ammeter
36
Magneto Puller
37
Electrical System Fundamentals
37
Voltage
37
Resistance
37
Amperage
37
Basic Service Methods
38
Removing Frozen Fasteners
39
Removing Broken Fasteners
39
Repairing Damaged Threads
40
Stud Removal/Installation
40
Removing Hoses
40
Bearings
41
Removal
41
Installation
42
Interference Fit
42
Seal Replacement
44
Storage
44
Storage Area Selection
44
Preparing the Motorcycle for Storage
44
Returning the UTV to Service
45
Trovbleshooting
45
Engine Principles and Operating Requirements
46
Starting the Engine
46
Engine Is Cold
47
Engine Is Warm
47
Flooded Engine
47
Engine will Not Start
48
Identifying the Problem
48
Spark Test
49
The Starter Cannot Work Repeatedly or Can Only Work Slowly
50
Poor Engine Performance
50
The Engine Starts Slowly or Difficultly
50
Engine Backfires, Cuts out or Misfires During Acceleration
50
The Engine Is Not Idling or Cannot Idle Stably
51
Poor Fuel Mileage
51
Engine will Not Idle or Idles Roughly
51
Low Engine Power
51
Poor Idle or Low Speed Performance
53
Poor High Speed Performance
53
Fuel System
53
Rich Mixture
54
Lean Mixture
54
Engine
54
Engine Smoke
54
Black Smoke
54
Blue Smoke
54
White Smoke or Steam
55
Low Engine Compression
55
High Engine Compression
55
Engine Overheating (Cooling System)
55
Engine Overheating (Engine)
56
The Ignition Advance Angle Is too Large
56
Detonation
56
Power Loss
56
Engine Noises
57
Englne Lubrication
57
High Oil Consumption or Excessive
58
Exhaust Smoke
58
Low Oil Pressure
58
High Oil Pressure
58
No Oil Pressure
58
Oil Level too Low
58
Oil Contamination
59
Cylinder Leak down Test
59
Electrical Testing
61
Preliminary Checks and Precautions
61
Intermittent Problems
62
Electrical Component Replacement
63
Test Equipment
63
Ammeter
63
Self-Powered Test Light
63
Ohmmeter
63
Jumper Wire
64
Test Procedures
65
Voltage Test
65
Voltage Drop Test
65
Peak Voltage Test
66
Continuity Test
66
Testing for a Short with a Self-Powered Test Light or Ohmmeter
66
Testing for a Short with a Test Light or Voltmeter
67
Brake System
67
Soft or Spongy Brake Lever or Pedal
67
Brake Drag
68
Hard Brake Lever or Pedal Operation
69
Brake Grabs
69
Brake Squeal or Chatter
69
Leaking Brake Caliper
69
Leaking Master Cylinder
69
Specifications
71
How to Use Conversion Table of Unit
71
How to Use Conversion Table
71
Definition of Unit
71
Geberar Specifications
72
Engine Specifications
75
Chassis Specifications
81
Electrical Specifications
83
Tightening Torques
85
Engine Tightening Torques
85
Chassis Tightening Torques
88
General Tightening Torque Specifications
90
Lubrication Pionts and Lubricant Types
91
Engine
91
Chassis
92
Hydrographic Chart
93
Lubrication Oil Way
94
Maintence and Adjustment of the Utv
96
Maintenance Schedule
96
Engine
98
Adjusting the Valve Clearance
98
Checking the Spark Plug
101
Checking the Ignition Timing
102
Measuring the Compression Pressure
103
Checking the Engine Oil Level
104
Changing the Engine Oil
105
Chassis
107
Cleaning the Air Filter
107
Checking the Coolant Level
108
Changing the Coolant
109
Checking the Coolant Temperature Warning Light
112
Checking the V-Belt
113
Cleaning the Spark Arrester
114
Adjusting the Brake Pedal
115
Checking the Brake Fluid Level
116
Checking the Front Brake Pads
117
Checking the Rear Brake Pads
117
Checking the Brake Hoses and Brake Pipes
118
Bleeding the Hydraulic Brake System
118
Adjusting the Select Lever Shift Rod
120
Adjusting the Brake Light Switch
120
Checking the Final Gear Oil Level
121
Changing the Final Gear Oil
121
Checking the Differential Gear Oil
122
Checking the Constant Velocity Joint Dust Boots
123
Checking the Steering System
124
Adjusting the Toe-In
125
Adjusting the Front and Rear Shock Absorbers
126
Checking the Tires
128
Checking the Wheels
129
Checking and Lubricating the Cables
130
Electrical
131
Checking and Charging the Battery
131
Checking the Fuses
137
Changing the Headlight Bulb
139
Changing the Tail/Brake Light Bulb
140
Engine
142
Engine Note
142
Engine Removal
143
Cylinder Head and Cylinder Head Cover
145
Rocker Arms Vales and Camshaft
150
Valves and Valve Springs
153
Cylinder and Piston
158
Engine Left Crankcase Cover and A.C. Magneto
162
Starter Motor and Water Pump
166
Primary and Secondary Sheaves
169
Crankcase Cover and Oil Pump
173
Crakcase and Middle Driven Shaft
177
Gearcase Shift Lever and Oil Pump
185
Gearcase Transmission
189
Malfunction Inspection
195
PANEL and CARGO BED Front Panel
198
Side Cover
202
Side Cover Parts
203
Cargo Bed
205
Head Shed Frame
207
DIRECTION SYSTEM Steering Wheel Part
210
Steering Mechanism Part
213
Brake System
218
Disk Brake Components
219
Footrest Part
237
Wheel and Tyre Parts
240
Front Wheels
240
Rear Wheels
241
Transmission System
245
C.V Axle, Front Axle
245
Front Bridge
246
C.V Axle, Rear Axle
251
Rear Bridge Reducer
252
Shift Operating System
259
Suspension
262
Front Swing Arm
262
Front Suspension
263

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