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THE CYLINDER HEAD ASSEMBLY (1/3)

40050140

VALVE SPRING WASHER

5.

SC050121291

HEXAGON SOCKET SCREW

4.

40070031

SEALING BALL

3.

40056002

VALVE STEM SEAL

2.

40058011

CYLINDER HEAD ASSY.

1.

PART NO.

PART NAME

NO.

Please clean up correlative parts and lubricate with 10W/40 oil
1.Knock the 2 balls (2) into cylinder head (1)
2.Paste the screw (4) with LT272 , tighten to cylinder head with 5Nm
3.Install the washer (5) on the valve spring seat
4.knock valve stem seal (6) into valve guide , keep distance between

the bottom of seal and the top of cylinder head within 12.7

±

0.5 mm

2

5

3

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Summary of Contents for Gladiator

Page 1: ...GLADIATOR QUADRIFT SERVICE MANUAL ...

Page 2: ...Ⅰ Power train Control System Introduction P1 Ⅱ 500cc EFI Engine Service Manual P20 Ⅲ GLADIATOR QUADRIFT Chassis Service Manual P80 Ⅳ Special Tools P141 TOPIC ...

Page 3: ...rication System Engine Breather System CVT System Start System Injection System Emission Control System Cylinder Head Block EMS System Electricity wiring Circuit Power train Control System Introduction P2 P3 P4 P5 P6 P7 P8 P9 P10 P19 ...

Page 4: ...otor Dismantle Cam Shaft Dismantle Chain Dismantle Cylinder Head Dismantle Balancer Dismantle The Oil Pump Dismantle The Driveshaft Dismantle The Oil Main Circuit Dismantle The Cylinder Block Dismantle The Transmission Gear Dismantle The Oil Release Valve Dismantle The Crankshaft Dismantle The Piston Dismantle 500cc EFI Engine Service Manual P21 P22 P22 P23 P23 P24 P26 P27 P28 P29 P31 P32 P33 P34 ...

Page 5: ...aft Assembly The Lay Shaft Assembly The Rear Driveshaft Assembly The Cylinder Head Assembly The Water Pump Assembly The Shift Drum And Fork Assembly The Transmission Gear Assembly The Gear Idle Gear Assembly The Crankcase And Cylinder Block Assembly The Bearing And Crankshaft Assembly P45 P47 P48 P49 P50 P52 P53 P56 P57 P58 P60 P61 P65 ...

Page 6: ...L BATTERY REMOVAL DIRECTION INDICATION LIGHTER FLASHER REMOVAL FUSE BOX REMOVAL RELAYS REMOVAL REAR RACK REMOVAL REAR COVER REMOVAL LHS RHS FOOT REST COVERS REMOVAL PROTECTOR REMOVAL AIR FILTER BOX REMOVAL FUEL TANK REMOVAL EXHAUST PIPE REMOVAL FRONT REAR WHEEL REMOVAL FRONT PROPELLER SHAFT REMOVAL Chassis Service Manual P81 P81 P83 P84 P85 P87 P87 P88 P89 P92 P94 P94 P95 P96 P97 P100 P101 P103 P1...

Page 7: ...VAL REAR LHS RHS BRAKE CALIPER REMOVAL REAR LHS RHS HUB REMOVAL REAR LHS RHS SHOCK ABSORBER REMOVAL REAR LHS RHS A ARM ASSY REMOVAL REAR DIFFERENTIAL REMOVAL ECU REMOVAL RADIATOR REMOVAL INSTRUMENT REMOVAL FRONT BRAKE PAD REMOVAL REAR BRAKE PAD REMOVAL FOOT BRAKE PADDLE REMOVAL Chassis Service Manual P115 P118 P119 P120 P121 P124 P126 P127 P128 P129 P131 P133 P134 P136 P137 P138 P139 ...

Page 8: ...Power Power Train Control Train Control Introduction Introduction 1 ...

Page 9: ...gle Cylinder SOHC 4 Valve Displacement 497 Bore x Stroke 90 x 78 mm Compression Radio 10 0 Power 15kW 5000rpm homologation Max Power 30kW 7000rpm Torque 40Nm 5500rpm Max rev 7500rpm Transmission CVT V belt Emission 2002 51 EC Weight 67kg 2 ...

Page 10: ... Balancer Crankshaft Con Rod Cylinder Piston Liner Crankshaft Camshaft Release Valve Lubrication Wet Sump Oil Pump Rotor Type Oil Filter Paper Type Oil Type 10W40 SJ Oil Volume 3 0 L 3 5 L Replace Filter Pressure Release 4 5 kg cm2 Pressure S W 0 2 kg cm2 Oil Inlet Oil Return Left Side Right Side 3 ...

Page 11: ...Engine Breather System Engine Oil Exhaust Side Intake Side Air Box Air Filter Breather Hose Piston Con Rod Crankshaft Blow by gas Blow by Gas Spec 10 L min 4 ...

Page 12: ... Belt Type DAYCO P N Off Road 5324 On Road 5324 CVT Drive Wheel Tightening Torque 40 45Nm Driven Wheel Tightening Torque 120Nm Ratio Min Max 0 316 1 581 Engine Speed Limit 7500rpm CVT Belt Drive Wheel Driven Wheel 5 ...

Page 13: ...ecification CECTEK Type 40196007 Output 0 7 kW Operation Voltage 12 V Temperature Range 10 120 Starter Circuit Diagram Rewind Starter Handler Starter Spin Nose Ring Gear Starter GND Battery GND GND Key S W Relay Starter S W 6 ...

Page 14: ...ntake Valve Throttle Body ASM Idle Air Control Valve IACV Intake Air Intake Port Fuel Injection Air Flow Temperature air temp coolant temp IACV or TPS MAP RPM ECU To calculate air flow and necessary fuel flow Injector Fuel injection control 7 ...

Page 15: ...ssion relational part ECU Throttle Body ASM Injector Spark Plug Ignition Coil ASM O2 Sensor Catalyst Catalyst 100 cells in2 Volume 116 Emission Updated 2002 51 EC Catalyst Throttle Body ASM Injector Ignition Coil ASM O2 Sensor 8 ...

Page 16: ... Cylinder Head ASM Aluminum Alloy AC4B T6 SOHC Chain Drive 4 Valves Spark Plug Champion PRG7C Cylinder Block ASM Liner Material FC250 Aluminum Alloy ADC12 Intake Valve 2 Exhaust Valve Spark Plug Cast in Liner Spark Plug 9 ...

Page 17: ...EMS System Block Diagram Pin Assignment 10 ...

Page 18: ...duction ECU Type MC21 1030 Assembly Electrical Characteristic Operation Voltage Range 9 16V Storage Temperature Range 40 70 Operation Current 500mA ECU Type MC21 1030 ECU Pin 28 Map Sensor Connector ECU Connector 11 ...

Page 19: ...tor Part Introduction Identification Code 28140652 Injector holes 4ea Circuit Diagram Measurement Resistance 12 0 0 6Ω ECU Injector Pin 28 MPR Main Power Relay Identification Code 28140652 ECU Pin 28 MPR 12 ...

Page 20: ...Throttle Body ASM Throttle Body Throttle Position Sensor TPS Idle Air Control Valve IACV Step Motor 13 ...

Page 21: ...ntroduction TPS Circuit Diagram Step Motor Circuit Diagram Measurement ECU Pin 21 GND TPS Resistance 1 2 kΩ TPS Step Motor ECU ECU Pin6 5V GND 5V GND ECU Pin 21 ECU Pin 33 Pin 24 Pin 24 Pin 25 Pin 34 Pin 33 Pin 34 Pin 25 Pin 21 Pin 6 14 ...

Page 22: ...Characteristic Voltage 12V Vcc Pitch Angle 65 10 Roll Angle 20 20 Temperature 10 60 Circuit Diagram Assembly Bolt M4 2ea Tighten Torque 1 5 2 5Nm Measurement Vcc OUTPUT 3 9 kΩ Vcc GND OUTPUT Top View Left View Rollove r Sensor ECU Vcc 12V GND OUTPUT Pin 11 15 ...

Page 23: ...Fuel Pressure 250 10 kpa Feed Fuel Rate 30 6 L hr Min Circuit Diagram Measurement Full Stop 4 10 Ω Empty Stop 93 100 Ω Fuel Level Fuel Filter Fuel Connector Sensor Sensor Pump Pump Fuel Pump ECU 12V GND meter Rela y GND END S W Pump Pump Sensor Sensor Pin 1 meter Pin24 16 ...

Page 24: ...ntroduction Sensor Characteristic Voltage 12V Vcc Temperature 10 60 Circuit Diagram Assembly Bolt M6 2ea Tighten Torque 10 2Nm Measurement Primary 2 9 Ω 10 Secondary 15 kΩ 10 Coil Primary Secondary ECU Pin 27 12 V PBT Black PBT Black Spark Side GND 17 ...

Page 25: ...Part Introduction Electric Characteristic Voltage 12V Output 16V 1500rpm Circuit Diagram Rectifier Crank Sensor Rectifier Connector Crank Sensor Connector Crank Sensor RTV GVB GND Vehicle GND RTA GVB CNKP CNKN 18 ...

Page 26: ...19 ...

Page 27: ...SERVICE MANUAL FOR 500cc EFI ENGINE 20 ...

Page 28: ...technician can disassembly the CECTEK RSGA 500 EFI ENGINE Improper disassembly may damage the engine CECTEK can not provide the warranty to the engine which has not been properly disassembled and assembled by trained and certificated technician Remove the CVT cover CVT COVER DISMANTLE The CVT cover 21 ...

Page 29: ... the driven pulley then removal the belt The belt Reinstall the installer must can read the printed word on the belt Loosen the driven pulley bolt then remove the driven pulley CVT BELT DISMANTLE CVT DRIVEN PULLEY DISMANTLE The Driven pulley 22 ...

Page 30: ...Loosen the driving pulley bolt Screw the CVT Puller by air wrench to remove the drive pulley Loosen the rewind starter bolt 5 CVT DRIVING PULLEY DISMANTLE REWIND STARTER DISMANTLE The drive pulley 23 ...

Page 31: ...e timing Use the Rewind Starter Stooper clockwise rotate crankshaft then check chain timing TIMING CHECK before dismantle engine must be check the chain timing Loosen the cam cover bolts 4 then remove the cam cover The rewind starter 24 ...

Page 32: ...When ALT mark correct then check cylinder head sprocket have six pieces counter from cylinder head six pieces ALT rotor mark meet the accessory cover mark 25 ...

Page 33: ...the accessory cover bolt 11 Raise the accessory cover by screwdriver from the prominence of case ACCESSORY COVER DISMANTLE When remove the accessory cover be care the spin nose antithrust spring and washer 26 ...

Page 34: ...Loosen the discompressor mechanism bolt by open wrench Pull out the discompressor mechanism START PRESSURE RELEASE MECHANISM DISMANTLE The discompressor mechanism and notice the spring 27 ...

Page 35: ...y air wrench The socket deep 85mm Screw Crankshaft Protector to end on crankshaft ALTERNATOR ROTOR DISMANTLE Screw the ALT Puller to end on ALT rotor Screw the CVT Puller on ALT Puller by air wrench then remove the ALT rotor 28 ...

Page 36: ... the spring and O ring Loosen the tensioner bolts 2 then remove the tensioner CAM SHAFT DISMANTLE Loosen the cam sprocket bolts 2 then remove the cam sprocket Loosen the cam antitrust plate Bolt then remove the plate cover spring O ring 29 ...

Page 37: ...Pull out intake and exhaust rock arm shaft by magnet Pull out the cam shaft The rock arms and cam trust plate The cam shaft 30 ...

Page 38: ...Loosen the chain guide bolt then remove the chain Notice the bosh The chain CHAIN DISMANTLE 31 ...

Page 39: ...Loosen the cylinder head bolts 4 Remove the cylinder head and notice the lock pins Remove the gasket and chain guide The cylinder head gasket and chain guide CYLINDER HEAD DISMANTLE pin guide gasket 32 ...

Page 40: ...r bolts 8 Raise the balancer cover by screwdriver from the prominence of case Loosen the water pump idle pulley bolt and unclip the oil pump gear clip The oil pump gear The water pump idle gear BALANCER DISMANTLE clip bolt 33 ...

Page 41: ...Loosen the balancer bolts by use screwdriver stop the balancer The balancer Loosen the oil pump bolts 3 and unclip the oil pump gear clip The oil pump and back plate THE OIL PUMP DISMANTLE 34 ...

Page 42: ...e the spin nose and washer Loosen the front driveshaft yoke bolts then remove the yoke Loosen the front driveshaft seal cover bolt 3 then remove the cover THE DRIVESHAFT DISMANTLE The yoke The seal cover 35 ...

Page 43: ...the front driveshaft and remove the 4WD gear Remove the rear driveshaft yoke and seal cover same procedure of front driveshaft Loosen the starter bolts 2 then remove the starter Loosen the front driveshaft yoke bolts then remove the yoke The 4WD gear 36 ...

Page 44: ...Loosen the shift drum cover bolts 7 Loosen the shift drum antitrust plate Loosen the oil filiter cover Remove the oil filter THE OIL MAIN CIRCUIT DISMANTLE 37 ...

Page 45: ...osen the main circuit bolt then remove the main circuit The main circuit Remove the rear driveshaft yoke and seal cover Reversal the engine and loosen the oil sump bolts 12 THE CYLINDER BLOCK DISMANTLE 38 ...

Page 46: ...e scraper and hammer to open the oil sump The oil sump When reinstall must clean the surface of the oil sump Raise the crankcase by screwdriver from the prominence of case Loosen the crankcase bolts 12 39 ...

Page 47: ...The crankcase When reinstall must clean the surface of the crankcase Remove the main shaft Remove the rear shaft Remove the layshaft THE TRANSMISSION GEAR DISMANTLE 40 ...

Page 48: ...n reinstall must clean the surface of the crankcase Loosen the shift fork bolt then pull out the shift fork shaft and remove the fork Loosen the shift position rotor bolt then remove the parking shaft plate The shift fork 41 ...

Page 49: ...t plate Pull out the shift drum from the cylinder block Loosen the oil release valve bolt then remove the oil release valve by magnet The shift drum THE OIL RELEASE VALVE DISMANTLE THE PARTS ONLY APPLY THE VEHICLE HAVE GEAR PARKING FUNCTION 42 ...

Page 50: ...l release valve Loosen the connecting rod bolts 2 The cylinder block When reinstall must clean the surface of the crankcase Remove the connecting rod cap then remove the crankshaft THE CRANKSHAFT DISMANTLE 43 ...

Page 51: ...Pull out the piston Must clean the carbon on piston Piston ring inspection The second ring top side Loosen the speed sensor bolt then remove the speed sensor THE PISTON DISMANTLE 44 ...

Page 52: ... THE PISTON AND CONNECTION ROD ASSEMBLY 1 Before assembly must confirm if the piston 4 5 is matching the category of liner 2 A category piston only can be installed on A category liner 3 A category piston only can be installed on B category liner 40096015 PISTON RING OIL CONTROL 8 40096014 PISTON RING SECOND 7 40096013 PISTON RING TOP 6 40096012 PISTON B 5 40096011 PISTON A 4 40090027 CLIP 3 40090...

Page 53: ... side mark R is same side of piston 8 Install one clip 3 into the piston clip groove firmly 9 Install pin 2 into pin groove 10 Install the clip 3 into the other side groove to stop the pin 2 11 Then sequentially install parts 8 7 6 the crevice position of each ring as figure A shows 12 The opening of ring 8 of spacer shall be upward as figure B shows A 46 ...

Page 54: ...river 3 into balancer reference to figure A 3 Clip the E ring 4 check the retain E ring install into the groove of balancer shaft THE BALANCER ASSEMBLY 40128004 BALANCER SHAFT ASSY 4 40130083 PIN 3 40150030 GEAR 37T 2 RES009 RETAIN E RING 1 PART NO PART NAME NO 47 ...

Page 55: ...y of crankshaft 3 Install cam chain sprocket 4 into crankshaft 1 be shall install long side into gear side of crankshaft reference to figure A 4 Screw nut 5 to crankshaft 1 tighten torque 250Nm THE BALANCER ASSEMBLY 40110024 NUT M30 5 41010004 PCAM CHAIN SPROCKET 4 40120018 GEAR 36T 3 40110108 KEY 2 40110023 CRANKSHAFT 1 PART NO PART NAME NO 48 ...

Page 56: ... 2 into main shaft 1 be shall bearing of ring side install to main shaft of gear side 2 Install spacer 3 into main shaft then install seal 4 into spacer 3 3 Install a C ring 5 into main shaft of groove then put a washer 6 into main shaft 4 Install needle bearing 7 and high gear 8 into main shaft be shall install high gear of raised side into main shaft of gear side 5 Install a washer 6 into main s...

Page 57: ...gear and bearing please lubricate with 10W 40 oil 1 Install bearing 2 into lay shaft 1 be shall install bearing of long side into bevel gear side 2 Install needle bearing 3 into lay shaft then install low gear 4 into lay shaft be shall install low gear 4 of plane into bevel gear side 3 Install retain C ring 5 into lay shaft of groove 4 Install high gear 6 into lay shaft be shall install high gear ...

Page 58: ...lay shaft then put a washer 7 into lay shaft be shall install reversal gear 9 of groove side into bevel gear side 7 Install retain C ring 10 into lay shaft of groove 8 Measure and calculate gear back clearance then choose and install adjusting washer 11 9 Install bearing 12 into lay shaft 10 Install washer 13 and screw flat head screw 14 into lay shaft tighten torque 9Nm 51 ...

Page 59: ...he bolt 5 with washer 4 on the shaft 1 the tighten torque 20Nm 4 Install the washer 6 which thickness shall be measured in advance into shaft 1 then press the bearing 7 into shaft 1 finally intsall the O ring 8 46050025 O RING 8 DGB6305 BEARING 7 46050009 19 WASHER 6 BFH080251094 BOLT 5 46050007 WASHER 4 46050023 GEAR 3 DGB6205 BEARING 2 46058001 DRIVE SHAFT ASSY 1 PART NO PART NAME NO 52 ...

Page 60: ... PART NO PART NAME NO Please clean up correlative parts and lubricate with 10W 40 oil 1 Knock the 2 balls 2 into cylinder head 1 2 Paste the screw 4 with LT272 tighten to cylinder head with 5Nm 3 Install the washer 5 on the valve spring seat 4 knock valve stem seal 6 into valve guide keep distance between the bottom of seal and the top of cylinder head within 12 7 0 5 mm 2 53 ...

Page 61: ...NAME NO Please clean up correlative parts and lubricate with 10W 40 oil 1 Install valve spring 3 x4 on the valve spring washer 2 Install cotter 5 x2 on the spring cap 4 4pcs 3 Install assembled spring cap 3 on the spring with jig press it into the valve stems until a clear clik sound was heard 4 check the cap is firmly installed on the stem with jig 54 ...

Page 62: ... cam bore 2 Install intake rocker 2 on the cam shaft the rocker face toward intake side 3 Install exhaust rocker 3 on the cam shaft the rocker face toward exhaust side 4 Install shaft roecker assy 4 x2 through intake rocker 2 and exhaust rocker 3 5 Install the screw 6 through plate 5 and tighten to 9Nm attention for the bottom of plate shall be clipped onto the groove of cam shaft 6 Adjust the int...

Page 63: ...al 2 on water pump shaft 3 and check the shaft have 12 1mm between macanicla seal and water pump shaft 40070064 CAP 8 40130063 GEAR 35T 7 40130083 PIN 6 40130077 WASHER 5 40130071 PROPELLER 4 40130075 SHAFT 3 40136011 MACHANICLA SEAL 2 40010053 ACCESSORY COVER 1 PART NO PART NAME NO RCS012 RETAIN C RING 9 56 ...

Page 64: ...70005 PARKING BREAK SHAFT 5 46070002 SHIFT FORK LAY SHIFT 4 46070001 SHIFT FORK MAIN SHAFT 3 46070013 SHAFT SHIFT FORK 2 46078002 SHIFT DRUM ASSY 1 PART NO PART NAME NO 46070014 SPRING BLADE 10 46070015 SHIFT LOCATING SPRING 9 RCS010 RETAIN C RING 11 57 THE PARTS ONLY APPLY THE VEHICLE HAVE GEAR PARKING FUNCTION ...

Page 65: ...Shift locating rotor install position Install fork shift by plastic hammer and all parts lubricate Install lay shaft to cylinder block Then push it to position THE TRANSMISSION GEAR ASSEMBLY 58 ...

Page 66: ...shaft to cylinder block then push it to position Install main shaft and push the needle bearing to position Lubricate oil release valve and install valve spring guide into cylinder block Then screw the bolt Torque 10Nm 59 ...

Page 67: ...EMBLY 46030011 WASHER 5 46030006 REVERSE GEAR 27T 4 46030032 NEEDLE BEARING 3 46030027 O RING 2 46030009 SHAFT 1 PART NO PART NAME NO Please clean up correlative parts and lubricate with 10W 40 oil RCH020 RETAIN C RING 6 60 ...

Page 68: ...001 609 MAIN BEARING GREEN 4 888 4001 608 MAIN BEARING NO COLOR 3 888 4001 607 MAIN BEARING BLACK 2 40018014 CRANKCASE 1 PART NO PART NAME NO No groove bearing for low crankcase The crankshaft mark position have 3 marks EX A 2 B CVT side ALT side 61 ...

Page 69: ... 1 CVT side ALT side N No color G Green B Black Choose bearing color and install to crankcase EX cylinder block mark is 1 A 1 crankcase mark is A 2 B so we choose ALT side bearing color is No color 1 A 1 A 1 A 2 B and CVT side bearing color is Green 1 B 1 A 1 A 2 B up and low bearing install the same color 62 ...

Page 70: ... 8 40096024 BEARING YELLOW 7 40096025 BEARING BLACK 6 40098013 CONROD ASSY 5 888 4001 615 MAIN BEARING GREEN 4 888 4001 614 MAIN BEARING NO COLOR 3 888 4001 613 MAIN BEARING BLACK 2 40018014 CYLINDER BLOCK 1 PART NO PART NAME NO Groove bearing for cylinder block 63 ...

Page 71: ...or and install to connecting rod EX connecting rod mark is A crankcase mark is A 2 B so we choose the bearing color is blue A 2 A A 2 B up and low bearing install the same color Y Yellow BL Blue B Black B Y Y BL The connecting rod mark position EX A 64 ...

Page 72: ...e all bearing Install crankshaft THE BEARING AND CRANKSHAFT ASSEMBLY Lubricate all rotation position Before screw the two bolts be lubricate connecting rod bolts Torque 20Nm 90 90 screw the two bolts equally 65 ...

Page 73: ...se Assembly Glue on cylinder block according figure A and glue diameter about 1mm Install crankcase to cylinder block Keep away the main gallery Figure A Glue Path Main Gallery Lay the glue diameter about 1mm 66 ...

Page 74: ...Lubricate the bolt and washer then screw it Torque 35Nm 90 screw the bolts equally Install the cylinder block bolts The tighten torque 35Nm Install shift drum antithrust plate Torque 10Nm 67 ...

Page 75: ...ly Glue on shift drum cover Glue diameter about 1mm Install the shift drum cover The bolts torque 10Nm Reverse the engine then screw the cylinder bolt The bolts torque 20Nm Install the main circuit The bolt torque 20Nm 68 ...

Page 76: ...balancer Install balancer gear then check crankshaft gear mark to balancer half of gear position Lay the Bolt Glue on the bolt then install the balancer plate The bolts torque 20Nm Lubricate the oil pump and rotor 69 ...

Page 77: ...The bolts torque 10Nm Install the oil pimp gear then clip the E clip Install the water pump idle gear then tighten the bolt The bolts torque 10Nm Install the chain guide Torque 10Nm 70 ...

Page 78: ...Install the chain guide into cylinder block and notice the lock position Install the cylinder head gasket and lock pins Install the cylinder head Lubricate the cylinder head bolts and washer 71 ...

Page 79: ...inder bolts Torque 35Nm 90 90 screw the four bolts equally The M6 bolts torque 10Nm Lubricate cam shaft Install the cam shaft into cylinder head Lubricate the rock arms and shafts then install into cylinder head 72 ...

Page 80: ... sprocket mark must correct to blue mark of chain When crank sprocket mark correct then check cylinder head sprocket have six pieces counter from cylinder head six pieces five gears crankshaft sprocket mark Check the crankshaft gear mark and balancer mark the mark 73 ...

Page 81: ...Lay Bolt Glue on discompressor bolt then screw it Torque 5Nm Install the thermostat Torque 10Nm Install the tensioner and screw the bolts then put the spring and screw the cover The bolts torque 10Nm The cover torque 10Nm 74 ...

Page 82: ...lug Torque 10 12Nm Lubricate the spin nose and then install into cylinder block Install the fly wheel assy and ALT rotor then screw the nut Torque 200Nm Install the cylinder head cover then screw the bolts Torque 10Nm 75 ...

Page 83: ...sary cover Glue diameter about 1mm Install accessary cover then screw the bolts The bolts torque 10Nm Install the drive shaft seal cover then screw the bolts The bolts torque 10Nm Check 4WD gear groove correct to low crankcase groove 76 ...

Page 84: ... Glue diameter about 1mm Install balancer cover then screw the bolts The bolts torque 10Nm Lay the Case Assembly Glue on oil sump cover Glue diameter about 2mm Lay the Bolt Glue on drive yoke bolt then install drive yoke The bolts torque 20Nm 77 ...

Page 85: ...e bolt The bolts torque 120Nm Install the driven pulley then screw the bolt The bolts torque 45Nm Screw the Belt Removal Tool to end to open the driven pulley then install the belt Install oil sump then screw the bolts The bolts torque 10Nm 78 ...

Page 86: ...Install the CVT cover then screw the bolts The bolts torque 10Nm The engine assembly complete Then rotate driven pulley check the belt on position 79 ...

Page 87: ...SERVICE MANUAL FOR GLADIATOR QUADRIFT CHASSIS 80 ...

Page 88: ...left position 2 Push the key and turn it to SEAT OPEN position 3 Then you will hear the latch release sound Click 4 Lift the seat up and draw the seat backward to remove the seat INSTRUMENT COVER REMOVAL 1 Remove the 2 screws on the upper instrument covers ...

Page 89: ...ment cover 3 Remove the 4 screws on the rear instrument covers 4 The screws may fall into the chassis be careful in catching the screws 5 Lift the rear instrument cover up and remove the seal between the instrument and the cover 6 Put the seal back on the instrument to prevent the part missing ...

Page 90: ...ering handle to the dead left position 2 Remove the screw latch on the right forward corner of saddle upper cover 3 Remove the screw latch on the left forward corner of saddle upper cover 4 Remove the two screws on the rear of saddle upper cover ...

Page 91: ...ove the cover SIDE SADDLE COVERS REMOVAL LHS RHS are in same process 1 Must remove the upper saddle cover before removing side saddle cover 2 Remove the frame fastening screw 3 When install torque 10Nm 4 Remove the rear latch screw 5 Remove the front loser latch screw ...

Page 92: ...backward direction 1 8 Slightly lift the cover up and pull the cover upward direction 2 for removing the cover FRONT BUMPER COVER REMOVAL Reversely perform the below process to install 1 Remove the upper two screws on the cover 2 When install torque 10Nm 1 2 ...

Page 93: ...86 3 Remove the RHS screw on the cover 4 When install torque 10Nm 5 Remove the LHS screw on the cover 6 When install torque 10Nm 7 Pull the cover forward to remove the cover from bumper ...

Page 94: ...nto the latch hole Press the latch to release the panel 2 Slide the panel out under the front rack 3 Note for ATV Quadrift 500 EFI There is not rack above the maintenance access panel You can direct lift up the panel KEY POSITION COVER REMOVAL Reversely perform the below process to install 1 Remove the key out ...

Page 95: ...om the key hub It could be easier that using you finger as a stop then drawing the cover out 4 Keep the cover face up to prevent the scratch on the marks FRONT RACK REMOVAL Reversely perform the below process to install 1 Loosen the two bolts under the RHS front cover but not remove them 2 When install torque 10Nm 2 1 ...

Page 96: ...Remove the two bolts under the LHS front cover 4 When install torque 10Nm 5 Remove the front rack FRONT COVER REMOVAL Reversely perform the below process to install 1 Remove 12V accessory plug connector 3 4 ...

Page 97: ...connectors 3 The connectors are latched pull the latch outward and disconnect the connectors 4 Remove the RHS 3 front cover latch screws and LHS 3 front cover latch screws 5 Remove the RHS front mask cover bolt above the bumper direction headligh 1 2 3 ...

Page 98: ...he LHS front mask cover bolt above the bumper 7 Pull the foot brake fluid reservoir out from the cover 8 Release the foot brake fluid reservoir latch 9 Pull the foot brake fluid reservoir tube out from the latch gap ...

Page 99: ...f the front cover 11 Pull the cove up and make sure and make sure there are no connected wires and tubes 12 Separate the cover and frame BATTERY REMOVAL Reversely perform the below process to install 1 Pull the rubber strip of battery out from the hook ...

Page 100: ...93 2 Remove the strip form the other hook 3 Remove the Negative pole screw of harness 4 Remove the Positive pole screw of harness 5 Pull the battery out form the chamber ...

Page 101: ...connector out form the flasher 2 Pull the rubber mount form the cover 3 Remove the flasher form the rubber mount FUSE BOX REMOVAL Reversely perform the below process to install The function and the Amp limit of each fuse are described as the lable on the fuse box 1 Press down the latches on the both side of fuse box cover 2 Lift the cover up ...

Page 102: ...Remove the Front mounting screw 4 Remove the rear mounting screw RELAYS REMOVAL Reversely perform the below process to install 1 Press down the relay connector latch 2 Remove the connector out form the relay ...

Page 103: ...ecifications Relay 7 is the main switch relay REAR RACK REMOVAL Reversely perform the below process to install 1 Remove 2 RHS bolts under the rear cover 2 When install torque 10Nm 3 Remove 2 LHS bolts under the rear cover 4 When install torque 10Nm 5 Lift the rear rack up to remove 1 2 3 7 4 5 6 ...

Page 104: ...versely perform the below process to install 1 Remove the RHS tail lights connector 2 Remove the LHS tail lights connector 3 Cut the RHS LHS taillight harness strip 4 Remove the latch screws between rear cover and rear fender ...

Page 105: ...ve the LHS screw on the license plate frame under rear cover 6 Remove the RHS screw on the license plate frame under rear cover 7 Remove the LHS screw near the taillight 8 Remove the RHS screw near the taillight ...

Page 106: ...99 9 Remove the fuel tank cap 10 Install the fuel tank back but under the cover 11 Pull the harness out form the rear cover 12 Remove the rear cover ...

Page 107: ...m the below process to install 1 Remove the screw on the passenger foot rest mount cover 2 Remove the passenger foot rest chamber mount cover 3 Remove the 5 bolts on the foot rest cover 4 When install torque 10Nm 5 Lift the foot rest cover up to remove it ...

Page 108: ...0Nm 3 Remove the 2 bolts on the LHS and RHS of rear bottom protector 4 Pull the rear bottom protector down to remove it 5 When install torque 10Nm MIDDLE BOTTOM PROTECTOR REMOVAL Reversely perform the below process to install 1 Remove the 6 bolts on the middle bottom protector 2 Pull the middle bottom protector down to remove it 3 When install torque 10Nm 1 2 3 4 5 6 ...

Page 109: ...ely perform the below process to install 1 Remove the 2 bolts on the A arm protector then remove the protector 2 When install torque 10Nm FRONT LHS RHS A ARM PROTECTOR REMOVAL Reversely perform the below process to install 1 Remove the 2 bolts on the A arm protector then remove the protector 2 Remove the bolt on the front side of rear A arm protector then remove the rear A arm protector 3 When ins...

Page 110: ...AL Reversely perform the below process to install 1 Remove the 2 bolts on the from seat clamp 2 When install torque 10Nm 3 Remove the seat clamp 4 Release the air filter upper cover latches 5 Remove the air filter upper cover ...

Page 111: ...er by clean lining to prevent foreign object 7 Remove the bolt in the front side of air filter box 8 Remove the LHS bolt on the lower air filter box 9 Remove the RHS bolt on the lower air filter box 10 When install torque 10Nm ...

Page 112: ...Reinstall the upper air filter box 12 Press the latch down and disconnect harness form the IAT sensor connector 13 Release the clamp between throttle body and inlet 14 Release the clamp on engine blow by tube ...

Page 113: ...106 15 Remove engine blow by tube 16 Cover the engine blow by outlet by tape 17 Turn the air filter box counterclockwise along the engine center datum 18 Lift the air filter box up to remove it ...

Page 114: ...body inlet by tape FUEL TANK REMOVAL 1 Disconnect the fuel pump power harness connector 2 Press the latch on the both side of fuel line connector to remove fuel line from fuel pump outlet 3 Cover the fuel line connector by tape ...

Page 115: ...p outlet by tape 5 Release the CVT ventilation outlet tube clamp 6 Press the CVT ventilation outlet rubber adapter to remove the CVT ventilation outlet tube 7 Remove the CVT ventilation outlet tube from the fuel tank protector ...

Page 116: ...109 8 Pull the CVT ventilation outlet tube out form the frame 9 Cover the CVT cover outlet by tape 10 Remove RHS front fuel tank mounting bolt 11 Remove RHS rear fuel tank mounting bolt ...

Page 117: ...ng bolt 13 When install torque 10Nm 14 Slightly lift the LHS of fuel tank up and push the RHS of fuel tank down 15 Slightly rotate the fuel tank along the center datum of ATV and pull the tank out from the frame 16 Remove the fuel tank ...

Page 118: ... spilled on the frame EXHAUST PIPE REMOVAL 1 Release the exhaust pipe clamp bolt 2 Release the font bolt of muffler mounting but not remove 3 When install torque 20Nm 4 Remove the rear bolt of muffler mounting but not remove ...

Page 119: ...the mounting bolts 6 Slightly rotate the muffler and pull it back to remove the muffler 7 Press the connector latch and disconnect the O2 sensor harness connector 8 Hold the front exhaust pipe and remove the mounting nut on the cylinder head ...

Page 120: ...ipe gasket is complete without crack damage or break FRONT REAR WHEEL REMOVAL 1 Release the wheel nut by the sequences as the mark 1 2 3 4 2 Remove the wheel nut to remove the wheel from the hub 3 When install torque 60Nm 1 2 3 4 ...

Page 121: ...OVAL 1 Remove the cutter pin on the hub nut 2 Remove the hub nut 3 When install torque 100Nm 4 Remove the 4 bolts on the front engine output shaft coupling 5 When install torque 25Nm 6 Remove the front propeller universal coupling ...

Page 122: ...l propeller shaft coupling and then remove the propeller shaft REAR PROPELLER SHAFT REMOVAL 1 Remove the cutter pin on the hub nut 2 Remove the hub nut 3 When install torque 100Nm 4 Remove the 4 bolts on the rear engine output shaft coupling ...

Page 123: ...t coupling 6 Remove 4 bolts on the differential propeller shaft coupling 7 When install torque 25Nm 8 Slide the propeller shaft out form the differential input coupling LHS RHS STEERING LINK REMOVAL 1 Turn the steering to get the best access of ball joint nut ...

Page 124: ...cutter pin on the ball joint mounting nut 3 When install torque 30Nm 4 Remove the ball joint mounting nut 5 When install torque 30Nm 6 Remove the nut and washer 7 Remove the ball joint form knuckle by ball joint puller ...

Page 125: ...tter pin form the ball joint nut on the steering column plate 10 Remove the ball joint nut on the steering column plate 11 When install torque 30Nm FRONT LHS RHS BRAKE CALIPER REMOVAL 1 Remove the 2 caliper mounting bolts 2 When install torque 25Nm ...

Page 126: ...9 3 Release brake tube clamp 4 Remove the brake caliper FRONT LHS RHS SHOCK ABSORBER REMOVAL 1 Hang the front upper A arm by rope 2 Remove the shock upper mounting bolt and nut 3 When install torque 40Nm ...

Page 127: ...move the shock lower mounting bolt and nut 5 When install torque 40Nm 6 Remove the shock absorber FRONT LHS RHS HUB REMOVAL 1 Hang the front upper A arm by rope 2 Remove the hub nut 3 When install torque 100Nm ...

Page 128: ... 5 Use the hub CV joint bolt as the support to pull the hub out with the brake disk FRONT LHS RHS A ARM ASSY REMOVAL 1 Remove the cutter pin on lower A arm knuckle ball joint bolt 2 Remove the nuts and washers 3 When install torque 30Nm ...

Page 129: ...move the front knuckle from the lower A arm 5 Remove the cutter pin on the upper A arm ball joint bolt 6 Remove the nut and washer on the upper A arm ball joint bolt 7 When install torque 30Nm 8 Remove the knuckle form the upper A arm ...

Page 130: ...er A arm mounting bolt and washer 10 Remove the upper A arm 11 Remove the lower A arm front mounting bolt and nut 12 When install torque 40Nm 13 Remove the lower A arm rear mounting bolt and nut 14 When install torque 40Nm ...

Page 131: ... Drain the differential oil 2 Re add 325 20c c Recommend oil type PENNZOIL 4096 80W 90 GL 5 3 Hold the drive shaft and tug the drive shaft horizontally 4 Cover the differential by tape 5 Disconnect the differential lock motor harness ...

Page 132: ...ounting bolts 7 When install torque 40Nm 8 Remove the rear differential mounting bolts 9 When install torque 40Nm 10 Lift the differential up from the mounting bracket 11 Rotate the differential vertically and horizontally by 90 degree 1 2 ...

Page 133: ...differential out from the frame 13 Remove the differential REAR LHS RHS BRAKE CALIPER REMOVAL 1 Remove the 2 brake caliper mounting bolts 2 When install torque 25Nm 3 Release the brake tube clamp and remove the caliper ...

Page 134: ...127 REAR LHS RHS HUB REMOVAL 1 Hang the rear A arm by rope 2 Remove the hub nut 3 When install torque 100Nm 4 Remove hub nut and washer 5 use the hub bolt as a support to pull the hub with disk out ...

Page 135: ...by rope 2 Remove the shock absorber upper mounting bolt and nut 3 When install torque 40Nm 4 Remove the shock absorber lower mounting bolt and nut 5 When install torque 40Nm 6 The nut of rear RHS shock upper mounting should be put toward front of ATV Nut F R ...

Page 136: ... of ATV REAR LHS RHS A ARM ASSY REMOVAL 1 Remove the knuckle upper mounting bolt and nut 2 When install torque 40Nm 3 Remove the knuckle lower mounting bolt and nut 4 When install torque 40Nm 5 Remove the A arm upper mounting bolt and nut 6 When install torque 40Nm Nut R F ...

Page 137: ...r upper A arm Assy 8 Remove the lower A arm front mounting bolt and nut 9 When install torque 40Nm 10 Remove the rear lower A arm after mounting bolt and nut 11 When install torque 40Nm 12 Remove the rear lower A arm assy ...

Page 138: ...L 1 Drain the differential oil 2 Re add 325 20c c Recommend oil type PENNZOIL 4096 80W 90 GL 5 3 Hold the drive shaft and tug the drive shaft horizontally 4 Cover the differential by tape Rear Differential Removal and Installation ...

Page 139: ...e rear differential lock harness 2 Remove the rear mounting bolt and nut 3 When install torque 40Nm 4 Remove the front mounting bolt and nut 5 When install torque 40Nm 6 Lift the differential up from the mounting bracket ...

Page 140: ...tate differential along the center datum of ATV 8 Pull the differential backward to remove it from frame ECU REMOVAL 1 Remove the MAP tube from the ECU 2 Press the connector latch down and pull the harness down ...

Page 141: ...134 3 Remove the ECU harness connector 4 Remove rear ECU mounting bolts 5 When install torque 10Nm 6 Remove front ECU mounting bolts RADIATOR REMOVAL 1 Release the lower radiator outlet tube clamp ...

Page 142: ...135 2 Remove the lower radiator outlet tube 3 drain all of the coolant 4 Disconnect the coolant temperature sensor connector 5 Remove the radiator cap mounting bolt ...

Page 143: ...6 Remove the 4 radiator mounting bolts 7 When install torque 40Nm 8 Pull the radiator forward to remove it INSTRUMENT REMOVAL 1 Press the connector latch down 2 Pull the harness connector down to remove it ...

Page 144: ...137 3 Remove the two mounting bolts to remove the instrument FRONT BRAKE PAD REMOVAL 1 Remove the 2 front brake pad mounting 2 Push the brake pad piston to retract position 3 Pull the brake pad 1 out 1 ...

Page 145: ...138 4 Remove the brake pad 1 5 Remove the brake pad 2 6 Inspect the brake pads REAR BRAKE PAD REMOVAL 1 Push the caliper bracket to retract the piston 1 2 1 2 ...

Page 146: ... 2 Push the caliper bracket to retract the piston 3 Remove the brake pads FOOT BRAKE PADDLE REMOVAL 1 Remove the cutter pin on the foot brake cylinder link pin 2 Remove the foot brake cylinder link pin 1 2 ...

Page 147: ...140 3 Remove the foot brake paddle hub screw 4 When install torque 10Nm 5 Remove the brake switch spring 6 Push the cylinder piston back 7 Pull the paddle backward to remove it ...

Page 148: ...SPECIAL TOOLS 141 ...

Page 149: ...OL NUMBER NAME TOOL PHOTO 991000001 EMS DIAGNOSTIC KIT ASSY Include 991000002 991000003 991000004 991000002 EMS DIAGNOSTIC SOFTWARE 991000003 EMS DIAGNOSTIC CABLE 991000004 EMS DIAGNOSTIC USB ADAPTOR 142 ...

Page 150: ...MBER NAME TOOL PHOTO 991000005 REMOVER ALTERNATOR ROTOR ASSY Include 991000006 991000007 991000008 991000006 CRANKSHAFT PROTECTOR 991000007 HOLDER ALTERNATOR REMOVER 991000008 PULLER CVT ALTERNATOR M12 1 5 143 ...

Page 151: ... SPANNER FUEL RETAINER 992000002 REWIND STARTER STOPPER 888 4002 653 B1 CASE ASSEMBLY GLUE 1207F Brand ThreeBond Type 1207F Liquid Gasket Black Silicone Type Volume 333ml 888 4002 670 B BOLT GLUE T272 Brand Loctie Type 272 Volume 250ml 144 ...

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