Crossfire 1000GTR Maintenance Handbook Download

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CHASSIS

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No.

Part Name

Qty

Remarks

Rubber bush

15 Knob

Mounting seat assy, accelerator pedal

Accelerator pedal welding assy

Spring

Air filter intake tube joint 76× 63×42.3

20 Clamp

70- 90

Air filter intake tube

Inner right mud-guard plate

Inner left mud-guard plate

Right footrest protector

Left footrest protector

Battery mounting plate

Rear brake plate wielding part

CHASSIS

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CHECKING THE BRAKE PEDAL

①

Brake pedal

②

Free travel

Inspect the brake pedals for free clearance and

smooth operation.

Adjust if incorrect measurement is found.

Summary of Contents for 1000GTR

Page 1: ...UTV HS800UTV 5 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 mainte...

Page 2: ......

Page 3: ...ly 4 Cleaning parts 5 Warning labels 5 SERIAL NUMBERS 6 FASTENERS 6 Torque specifications 6 Self locking fasteners 6 Washers 6 Cotter pins 7 Snap rings and E clips 7 SHOP SUPPLIES 8 Lubricants and Flu...

Page 4: ...eeler gauge 16 Calipers 17 Micrometers 18 Adjustment 18 Care 19 Metric micrometer 19 Standard inch micrometer 20 Telescoping and small bore gauges 21 Dial Indicator 21 Compression gauge 22 Multimeter...

Page 5: ...engine 33 ENGINE WILL NOT START 34 Identifying the problem 34 Spark test 35 The starter cannot work repeatedly or can only work slowly 36 POOR ENGINE PERFORMANCE 36 The engine starts slowly or diffic...

Page 6: ...4 HIGH OIL CONSUMPTION OR EXCESSIVE 44 Exhaust smoke 44 Low oil pressure 44 High oil pressure 44 No oil pressure 44 Oil level too low 44 Oil contamination 45 CYLINDER LEAK DOWN TEST 45 ELECTRICAL TEST...

Page 7: ...iper 55 Leaking master cylinder 55 CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT 57 How to use conversion table 57 Definition of unit 57 GEBERAR SPECIFICATIONS 58 ENGINE SPECIFICATIONS...

Page 8: ...belt 99 Cleaning the spark arrester 100 Adjusting the brake pedal 101 Checking the brake fluid level 102 Checking the front brake pads 103 Checking the rear brake pads 103 Checking the brake hoses and...

Page 9: ...9 CYLINDER HEAD AND CYLINDER HEAD COVER 131 ROCKER ARMS VALES AND CAMSHAFT 136 VALVES AND VALVE SPRINGS 139 CYLINDER AND PISTON 144 ENGINE LEFT CRANKCASE COVER AND A C MAGNETO 148 STARTER MOTOR AND WA...

Page 10: ...PARTS 226 Front wheels 226 Rear wheels 227 TRANSMISSION SYSTEM 231 C V axle front axle 231 Front bridge 232 C V axle rear axle 237 Rear bridge reducer 238 SHIFT OPERATING SYSTEM 245 SUSPENSION 248 Fro...

Page 11: ...oting 283 STARTER MOTOR 285 CHARGING SYSTEM 286 Circuit diagram 286 Troubleshooting 287 LIGHTING SYSTEM 288 Circuit diagram 288 Troubleshooting 289 Checking the lighting system 290 SIGNALING SYSTEM 29...

Page 12: ...coil 314 Fuel pump module 318 EMS FAULT DIAGNOSIS EME fault diagnosis 324 Fault code list 324 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE HARD STARTING 326 Fuel system 326 Electrical system 326 Compre...

Page 13: ...ght is out of work 330 Bulb burnt out 331 Error display of meter 331 CHAPTER 9 WIRING DIAGRAM WIRING DIAGRAM 332 WIRING EFI DIAGRAM 333 IGNITION SYSTEM CIRCUIT DIAGRAM 334 ELECTRIC STARTING SYSTEM CIR...

Page 14: ......

Page 15: ...he first time WARNINGS CAUTIONS AND NOTES The terms WARNING CAUTION and NOTE have specific meaning in this manual WARNING emphasizes areas where injury or even death could result from negligence Mecha...

Page 16: ...ning lights 13 Rear bumper assy 14 Muffler 15 Rear wheel 16 Engine 17 Passenger seat belt 18 Fuel tank cap 19 Ignition switch 20 Passenger handrail 21 Front wheel 22 Front shock absorber 23 Water and...

Page 17: ...3 GENERAL INFORMATION 3 IDENTIFICATION CODE Frame No Frame No is carved on the right side of front main frame Engine No Engine NO Is carved on the right side of the engine Figure...

Page 18: ...drilling grinding hammering compressed air and chemicals 11 Wear the correct clothing for the job Tie up or cover long hair so it does not get caught in moving equipment 12 Do not carry sharp tools in...

Page 19: ...in the home garage Many types of chemical cleaners and solvents are available for shop use Most are poisonous and extremely flammable To prevent chemical exposure vapor buildup fire and serious injury...

Page 20: ...various subassemblies are not installed and tightened correctly Fasteners that are improperly installed or work loose can cause extensive damage it is essential to use an accurate torque wrench as de...

Page 21: ...secure parts within housing bores In some applications in addition to securing the component s snap rings of varying thicknesses also determine endplay These are usually called selective snap rings Th...

Page 22: ...oil satisfies The classifications are MA high friction applications and MB low frication applications NOTE Refer to Engine Oil and Filter in Chapter Three for further information on API SAE classifica...

Page 23: ...most common from of antifreeze Check the UTV Manufacturer s recommendations when selecting antifreeze Most require one specifically designed for aluminum engines There types of antifreeze have additiv...

Page 24: ...carried out with basic hand tools and test equipment familiar to the home mechanic Always use the correct tools for the job Keep tools organized and clean Store them in a tool chest with related tool...

Page 25: ...ound on the driving faces or flutes of the screwdriver s tip figure 4 ACR Phillips II screwdrivers were designed as part of a manufacturing drive system to be used with ACR Phillips II screws but they...

Page 26: ...ontact the fastener at only two points which makes them more subject to slipping off the fastener Because one jaw is adjustable and may become loose this shortcoming is aggravated Make certain the sol...

Page 27: ...ible to remove stubborn fasteners without damaging them Impact drivers and interchangeable bits Figure 10 are available from most tool suppliers When using a socket with an impact driver Make sure the...

Page 28: ...cause of the size of the torque wrench head drive and socket If a torque adapter changes the effective lever length Figure 14 the torque reading on the wrench will not equal the actual torque applied...

Page 29: ...s are needed to cut wire and can be used to remove cotter pins Use needle nose pliers to hold or bend small objects Locking pliers Figure 16 sometimes called Vise Grips are used to hold objects very t...

Page 30: ...G TOOLS The ability to accurately measure components is essential to perform many of the procedures described in this manual Equipment is manufactured to close tolerances and obtaining consistently ac...

Page 31: ...iquid crystal display LCD to show the measurement Properly maintain the measuring surfaces of the caliper There must not be any dirt or burrs between the tool and the object being measured Never force...

Page 32: ...djust care for and read the measurements of various types of outside micrometers For accurate results properly maintain the measuring surfaces of the micrometer There cannot be any dirt or burrs betwe...

Page 33: ...sure the spindle and anvil faces do not contact each other or another object If they do temperature changes and corrosion may damage the contact faces 3 Do not clean a micrometer with compressed air D...

Page 34: ...0 025 in increments Every fourth sleeve mark is numbered 1 2 3 4 5 6 7 8 9 These numbers indicate 0 100 0 200 0 300 and so on The tapered end of the thimble has 25 lines marked around it Each mark eq...

Page 35: ...bore Do not over tighten the gauge because there is no built in release Excessive tightening can damage the bore surface and damage the tool Remove the gauge and measure the outside dimension Figure...

Page 36: ...if using a meter not recommended by the manufacturer Such requirements are noted when applicable Ohmmeter analog calibration Each time an analog ohmmeter is used or if the scale is changed the ohmmet...

Page 37: ...t current to operate in a battery powered system Resistance Resistance is the opposition to the flow of electricity within a circuit or component and is measured in ohms Resistance causes a reduction...

Page 38: ...als 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 plast...

Page 39: ...all out during assembly Do not apply grease to electrical or brake components Removing Frozen Fasteners If a fastener cannot be removed several methods may be used to loosen it First apply a penetrati...

Page 40: ...Figure 40 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 41: ...ctions as a guideline NOTE Unless otherwise specified install bearings with the manufacturer s mark or number facing outward Removal While bearing are normally removed only when damaged there may be t...

Page 42: ...shaft and into the housing at the same time a tight fit is required for both outer and inner bearing races In this situation install a spacer underneath the driver tool so that pressure is applied eve...

Page 43: ...zle and evaporate immediately the temperature is correct Heat only one housing at a time CAUTION Do not heat the housing with a propane or acetylene torch Never bring a flame into contact with the bea...

Page 44: ...ce Storage Area Selection When selecting a storage area consider the following 1 The storage area must be dry A heated area is best but not necessary It should be insulated to minimize extreme tempera...

Page 45: ...the intake and exhaust openings 2 Service the air filter as described in Chapter Three 3 Inspect the cooling system Check the drain plug and hose connections for leaks 4 Refill the fuel tank Turn the...

Page 46: ...ark 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 sta...

Page 47: ...the volume of oil when in idle speed automatically Countermeasure When start the engine run 2 to 3 minutes in idle speed If it can t run normally in idle turn off the engine and restart it repeatedly...

Page 48: ...icient amount of fuel to start the engine 4 If there is sufficient fuel in the fuel tank remove the spark plug immediately after attempting to start the engine The plug s insulator should be wet indic...

Page 49: ...ly CAUTION After removing the direct ignition coil or spark plug cap and before removing the spark plug in Step 1 clean the area around the spark plug with compressed air Dirt that falls into the cyli...

Page 50: ...justment 3 The fuel tank connection hose is clogged 4 The fuel hose is clogged or the oil filter is clogged 5 The injector is clogged NOTE If a warm or hot engine will start with the choke on or if a...

Page 51: ...the following 1 Lean throttle 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 Stuck or...

Page 52: ...rease Check for one or more of the following problems a Clogged air filter b Restricted fuel flow c Pinched fuel tank breather hose Figure 9 d Clogged or damaged silencer or muffler NOTE A clogged exh...

Page 53: ...correct Perform the Peak Voltage 2 Check the fuel system as described in this chapter 3 Check the valve clearance as described Note the following a If the valve clearance as correct Perform Step 4 b I...

Page 54: ...ion can result c If there is too much fuel on the end of the spark plug go to check whether there is overflow at the air filter or the ducting damper Rich Mixture The following conditions can cause a...

Page 55: ...er mixes with the oil in the crankcase sludge is produced Sludge can eventually cause engine damage as it circulates through the lubrication system and blocks off oil passages Large amounts of steam c...

Page 56: ...chamber 6 Dragging brake s 7 Slipping clutch The Ignition Advance Angle Is Too Large Preignition is the premature burning of fuel and is caused by hot spots in the combustion chamber Glowing deposits...

Page 57: ...stion chamber 2 Slapping or rattling noises at low speed or during acceleration May be caused by excessive piston to cylinder wall clearance piston slap NOTE Piston slap is easier to detect when the e...

Page 58: ...il High Oil Pressure 1 The lubrication oil pressure valve is stuck and closed 2 Clogged oil filter 3 Clogged oil gallery or metering orifices No Oil Pressure 1 Low oil level 2 The lubrication oil pres...

Page 59: ...ure it will be necessary to lock the engine at TDC on its compression stroke and then perform the leak down test Follow the manufacturer s directions along with the follow the manufacturer s direction...

Page 60: ...hand and shift the transmission into top gear with the shift pedal b 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...

Page 61: ...ground or switch If the other circuits work properly and the shared wiring is good the cause must be in the wiring used only by the suspect circuit If all related circuits are faulty at the same time...

Page 62: ...ng an open circuit Other heat related problem occur when a component creates its own heat as it starts to fail or go bad a Troubleshoot the problem to help isolate the problem or area b To check a con...

Page 63: ...any given circuit The voltmeter unlike the test light also indicates how much voltage is present at each test point When using a voltmeter attach the positive lead to the component or wire to be check...

Page 64: ...umper wire is a simple way to bypass a potential problem and isolate it to a particular point in a circuit If a faulty circuit works properly with a jumper wire installed an open exists between the tw...

Page 65: ...Note the voltage reading The reading should be within I volt of battery voltage If the voltage is less There is a problem in the circuit Voltage drop test The wires Cables Connectors and switches in...

Page 66: ...wires or components within the circuit A circuit with an open On the other hand has no continuity This type of test can be performed with a self powered test light or an ohmmeter An ohmmeter gives the...

Page 67: ...ately When replacing or refilling the brake fluid use only DOT 4 brake fluid from a closed container Always check the brake operation before riding the motorcycle Soft or Spongy Brake Lever or Pedal O...

Page 68: ...4 Brake caliper not sliding correctly on slide pins 15 Sticking master cylinder piston assembly 16 Sticking brake caliper pistons Brake Drag When the brakes drag the brake pads are not capable of movi...

Page 69: ...Warped brake disc 5 Loose brake disc mounting bolts 6 Brake caliper not sliding correctly on slide pins 7 Mismatched brake pads 8 Damaged wheel bearings Brake Squeal or Chatter 1 Contaminated brake pa...

Page 70: ...56 GENERAL INFORMATION 56 4 Loose banjo bolt washers 5 Damaged banjo bolt washers 6 Damaged banjo bolt threads in master cylinder body 7 Loose or damaged reservoir cap...

Page 71: ...14 0 6214 3 281 1 094 0 3937 0 03937 mph mi ft yd in in Volume capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Others kg mm kg cm2 Cent...

Page 72: ...tank 690kg 1 521 lb Engine Model Engine type Cylinder arrangement Displacement Bore stroke Compression ratio Starting system Lubrication system HS2V91MY 1 for HS1000UTV HS2V91MX 1 for HS900UTV HS2V91...

Page 73: ...leaded gasoline only 28L 6 16 lmp gal 7 40 US gal Throttle Type quantity D54A 1 for HS1000UTV and HS900UTV D46 1 1 for HS800UTV 5 Spark plug Type manufacturer Spark plug gap DCPR7E 1 NGK 0 6 0 7 mm 0...

Page 74: ...A arm type Independent Dual A arm type Coil spring airbag damping Coil spring airbag damping 235mm 9 25 in 235mm 9 25 in Electrical Ignition system Generator system Battery type Battery capacity EFI A...

Page 75: ...03 mm 0 0012 in Cylinder Bore size Measuring point 91 016 91 030mm 3 544 3 584 in 50 mm 1 97 in Camshaft Drive method Cam dimensions Intake A B Exhaust A B Camshaft runout limit 25 95 26 05mm 1 022 1...

Page 76: ...0047in 0 12 0 15 mm 0 0047 0 0059 in Valve dimensions head diameter face width seat width margin thickness A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem out...

Page 77: ...0 08 mm 0 0031 in 0 10 mm 0 0039 in 0 01 mm 0 0004 in Valve spring Inner spring Free length IN EX Set length valve closed IN EX Compressed pressure installed IN EX Tilt limit IN EX Direction of windi...

Page 78: ...09 in 4 0 mm 0 15 in 0 5mm 0 0394 in Intake side 20 007 20 013mm 0 8664 0 8667in 21 99 21 995 mm 0 8657 0 8659 in 0 15 mm 0 0059 in Piston rings Top ring Type Dimensions B T End gap installed Side cle...

Page 79: ...79 0 0276 in 0 06 0 15 mm 0 0024 0 0059 in Crankshaft Crank width A Runout limit C1 C2 Big end side clearance D Big end radial clearance E 90 45 90 55mm 3 561 3 565in 0 4 0 6 mm 0 0157 0 0236 in 0 041...

Page 80: ...65 Kpa 0 65 kg cm2 9 2 psi at 1 500 r min Cylinder head Water pump Type Reduction ratio Single suction centrifugal pump 15 15 1 0 Shaft drive Middle gear backlash Final gear backlash Differential gear...

Page 81: ...Stroke 120mm 4 72in 272mm 10 71in 224mm 8 82in 48 03 N mm 4 90 kg mm 70 74N mm 7 22kg mm 35 94 1 mm 1 38 3 70in 94 1 120mm 3 70 4 72in Front wheel Type Rim size Rim material Rim runout limit radial la...

Page 82: ...side diameter Brake fluid type Dual 260 5 mm 10 24 0 20 in 9 0 mm 0 35 in 9 0 mm 0 35 in 19 0mm 0 75in 25 0mm 0 98in DOT 4 Rear disc brake Type Disc outside diameter thickness Pad thickness inner Pad...

Page 83: ...ce 4 5 5 0 k Oxygen sensor type 25325359 Charging system Nominal output Charging coil resistance color 14 V 40 A at 4 500 r min 0 32 0 43 at 20 68 F White White White Rectifier regulator Regulator typ...

Page 84: ...unning rpm 2 950 r min Electric starter system Type Starter motor Output Armature coil resistance Brush overall length Starter relay Amperage rating Coil winding resistance Constant mesh type 0 8 kW 0...

Page 85: ...Oil pump assembly Oil cooler inlet pipe 1 oil cooler outlet pipe 1 Oil cooler inlet pipe 1 oil cooler outlet pipe 1 clamp Oil cooler inlet pipe 2 oil cooler outlet pipe 2 clamp Intake manifold Intake...

Page 86: ...12 10 1 0 7 2 Starter clutch Bolt M8 3 30 3 0 22 Clutch carrier assembly Nut M22 1 160 16 0 115 Stake Clutch housing assembly Bolt M6 9 10 1 0 7 2 Bearing retainer middle drive shaft Screw M8 4 29 2 9...

Page 87: ...diator bracket and frame Bolt M6 4 7 0 7 5 1 Fuel pump Bolt M6 2 7 0 7 5 1 Fuel tank Bolt M8 2 30 3 0 22 Muffler stay Bolt M6 2 11 1 1 8 0 Muffler and exhaust pipe Bolt M8 1 20 2 0 14 Muffler bracket...

Page 88: ...8 13 1 3 9 4 Differential gear case cover and differential gear case M8 25 2 5 18 Rear driving axle gear case and frame M10 70 7 0 51 Rear driving axle gear case filler plug M20 23 2 3 17 Rear driving...

Page 89: ...and constant velocity joint of half shaft M20 260 26 0 190 Stake Rear brake hose and frame M6 7 0 7 5 1 Brake pipe and brake master cylinder M10 19 1 9 13 Pedal holder assembly and frame M8 16 1 6 11...

Page 90: ...ighten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require cle...

Page 91: ...artridge O ring Apply lithium soap based grease Starter idle gear shaft Apply molybdenum disulfide grease Starter wheel gear Apply engine oil Clutch housing assembly shaft end Apply lithium soap based...

Page 92: ...oint of front brake cable Light lithium base grease Front brake lever axle and rear brake lever axle Light lithium base grease Adjusting nut and pin of front brake cable Light lithium base grease Adju...

Page 93: ...7 SPECIFICATIONS 79 HYDROGRAPHIC CHART Hydrographic chart Pressure...

Page 94: ...8 SPECIFICATIONS 80 LUBRICATION OIL WAY LUBRICATION OIL WAY Pressure splashing oil...

Page 95: ...8 SPECIFICATIONS 81 Engine gearbox lubrication oil path circuit Gearbox lubrication oil path circuit Pressure splashing oil...

Page 96: ...filter element clean Replace if necessary Every20 40hours More often in wet of dusty areas Front brake Check operation fluid leakage Correct if necessary Rear brake Check operation Adjust if necessar...

Page 97: ...Engine oil filter cartridge Replace Final gear oil Check oil level oil leakage Replace Differential gear oil Lights and switches Check operation Adjust headlight beams NOTE Recommended brake fluid DO...

Page 98: ...just the valve clearance when the piston is at the Top Dead Center TDC on the compression stroke Remove driver seat passenger seat console 1 Remove following parts spark plug cylinder cover Crankshaft...

Page 99: ...ake 0 08 0 12 mm 0 0031 0 0047 in Exhaust 0 12 0 16 mm 0 0047 0 0063 in 4 calibration adjusting tools A Spin the crank when the rotoflex s scale shows 1 it is cylinder 1 s timing spin the crank counte...

Page 100: ...t adjusting tool until the proper clearance is obtained in order to avoid adjuster rotating along fix the lock nut after finishing Fixed nut 14 Nm 1 4 m kgf 10 ft lbs Measuring clear Measure the clear...

Page 101: ...e clearance by thickness gauge It is qualified if the pole clearance is between 0 8 to 0 9mm Otherwise it should be adjusted Wear damage Replace insulator Abnormal color Replace Normal color is a medi...

Page 102: ...ual starting mechanism name 5 Check Engine tachometer a worm up the engine at specified speed Engine speed 1 400 1 500 r min b Remove Ignition signal sensor c Visually check the stationary pointer to...

Page 103: ...E standard value standard compression pressure data 1200Kpa 12kg c 1000r min 5 read the highest data on the compression pressure meter Above the maximum pressure Check the cylinder head valve surfaces...

Page 104: ...m 20Nm 1 8 m kg 13 ft lb 5 Lower the cargo bed CHECKING THE ENGINE OIL LEVEL 1 Place the vehicle on a level surface 2 Remove driver seat passenger seat console Refer to SEATS in chapter 5 3 Check engi...

Page 105: ...ace 1 Start the engine and let it warm up for several minutes 2 Stop the engine and place an oil pan under the engine 3 Remove driver seat passenger seat console 4 Remove dismount the following parts...

Page 106: ...vel when the vehicle is placed on flat ground Oil level of gearbox Periodic oil change The oil capacity after the engine is disassembled and reassembled 2L The oil should be put into the engine for af...

Page 107: ...filter element assembly air filter element NOTE Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine damage Addi...

Page 108: ...eeze out the excess oil NOTE The element should be wet but not dripping 4 Install air filter element air filter case cover NOTE To prevent air leaks make sure that the sealing surface of the element m...

Page 109: ...reservoir cap Disconnect coolant reservoir hose 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 ant...

Page 110: ...or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap c...

Page 111: ...shes in your eyes thoroughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce v...

Page 112: ...led water is not available 14 Install air bleed bolt 9 Nm 0 9 m kg 6 5 ft lb radiator cap Fill coolant reservoir Install coolant reservoir cap Start the engine warm it up for several minutes and then...

Page 113: ...Coolant temperature warning light checking method Turn the main switch ON Coolant temperature warning light does not come on Coolant temperature warning light come on Turn the main switch to START wi...

Page 114: ...sheave and secondary sheave Install the V belt NOTE Install the V belt so that its arrow faces the direction shown in the illustration Remove the bolts 2 Install drive belt cover driver seat CLEANING...

Page 115: ...pipe into the muffler and align the bolt holes Insert the bolt 1 and tighten it Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blo...

Page 116: ...n checking the brake fluid level make sure that the top of the brake fluid reservoir top is horizontal 2 Lift the hood up 3 Check brake fluid level Fluid level is under MIN line Fill up NOTE Brake flu...

Page 117: ...pads Wear indicator groove a almost disappeared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 5 Brake pad wear limit a 1 5 mm 0 06 in 3 Operate the brake pedal 4 Install f...

Page 118: ...pedal 4 Install driver seat BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake f...

Page 119: ...ease the pedal i Repeat steps e to h until all the air bubbles have disappeared from the fluid j Tighten the bleed screw Front brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb Rear brake caliper blee...

Page 120: ...ure the select lever is in NEUTRAL b Loosen both locknuts WARNING The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Tighten the loc...

Page 121: ...1 Place the vehicle on a level surface 2 Remove oil filler plug 3 Check oil level Oil level should be up to the brim of the hole Oil level low Add oil to the proper level Recommended oil SAE 80 API G...

Page 122: ...OIL 1 Place the vehicle on a level surface 2 Remove oil filler plug 3 Check oil level Oil level should be up to the brim of hole Oil level low Add oil to proper level WARNING Take care not allow forei...

Page 123: ...gear oil is filled to the brim of the oil filler hole oil may start leaking from the differential gear case breather hose Therefore check the quantity of the oil not its level WARNING Take care not to...

Page 124: ...ace the sliding bearing Refer to section Steering system of chapter 5 Check tie rod ends Ball pin unit of steering tension rod Rotate the steering bar leftward and or rightward Then roate from left to...

Page 125: ...he between two marks d Rotate the front tires 180 until the marks are exactly opposite one another e Measure distance B between the marks f Calculate the toe in using the formula given below Toe in B...

Page 126: ...Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a HSUN dealer for any service The s...

Page 127: ...n tighten it to the specified torque Rebound damping force Turn the rebound damping force adjusting screw in direction S to increase the rebound damping force and thereby harden the damping and in dir...

Page 128: ...ed they can adversely affect your vehicle s handling characteristics and are therefore not recommended i e Type Front 6PR 27 9 14 Rear 6PR 27 11 14 T a Recommended tire cold pressure Front 140Kpa 20ps...

Page 129: ...ressure may adversely affect the handling of this vehicle and may cause loss of control Maintain proper tire pressures et tire pressures when the tires are cold Tire pressures must be e ual in both fr...

Page 130: ...ING THE CABLES WARNING A dama ed cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace a dama ed cable as soon as possible 1 Check cable shea...

Page 131: ...hen char in or handlin batteries keep batteries and electrolyte out of reach of children Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury first aid in case of...

Page 132: ...t 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 t...

Page 133: ...caps o not use a high rate batter charger since it forces a high a perage current into the batter uic l an can cause batter o erheating an batter plate a age f it is i possible to regulate the chargin...

Page 134: ...g it ot batteries can explode s sho n in the follo ing illustration the open circuit oltage of an batter stabili es about inutes after charging has been co plete herefore ait inutes after charging is...

Page 135: ...standard charging amperage after 5 minutes replace the battery Adjust the voltage to obtain the standard charging amperage Set the timer to the charging time determined by the open circuit voltage If...

Page 136: ...r than the standard charging amperage written on the battery Charge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage char...

Page 137: ...ck attery terminals Dirt Clean with a wire rush oose connection Connect properly u ricate attery terminals Install attery case co er Close the hoo CHECKING THE FUSES NOTE Always turn off the main swit...

Page 138: ...ent rating Quantity Lighting system fuse 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC jack 10 A 1 4WD Four wheel drive 5A 1 Signaling system fuse 10 A 1 Backup fuse 10 A 1 Reserve 15 A 1 Reserve 10 A...

Page 139: ...ed Turning out Headlight beam lowered CHANGING THE HEADLIGHT BULB Remo e ift the hoo up hea light ul hol er co er hea light ul hol er with ul ul NOTE Remove the defective bulb by unhooking the headlig...

Page 140: ...a cloth moistened with alcohol or lacquer thinner hea light ul hol er with ul hea light ul hol er co er Close the hoo CHANGING THE TAIL BRAKE LIGHT BULB Remo e Rear panel rear position lamp an stop l...

Page 141: ...touching the glass part of the bulb Keep it free from oil otherwise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clea...

Page 142: ...e specified torque Opposite order is for removing bolts and nuts 6 Make sure sealing bolt with the sealant must be replaced 7 Make sure to use new bearing when remove assembly set up by pressure 8 Det...

Page 143: ...sket 1PK N862C 4 intake pipe 2 2 Intake pipe 2 3 Flange bolt M8 40 4 4 Clamp 40 60 4 5 Intake pipe joint 1 6 Three way intake pipe 1 7 Inlet temperature pressure sensor 28086011 1 8 TMAP pressure plat...

Page 144: ...3 ENGINE 130 No Part Name Qty Remarks 13 Oil Pipe 8 14 80 2 14 Three way pipe copper 1 15 Oil Pipe clip 14 8 4 16 Damper D54A 1 For installation reverse the removal procedure...

Page 145: ...r head Remove the parts in the order listed 1 Thermostat cover 2 2 Thermostat 1 3 Cylinder water outlet connector 1 4 Washer 1 5 O ring 2 6 Cylinder head cover 2 7 Cylinder cover pad 2 8 Spark plug 2...

Page 146: ...32 ENGINE 132 No Part Name Qty Remarks 13 Timing chain tensioner gasket 2 14 Dowel pin 4 15 Timing chain guide exhaust side 2 For installation reverse the removal procedure...

Page 147: ...r head as a set 3 Checking the tappet co ers Cylin er hea co er Cracks damage Replace Cylin er co er pa NOTE When installing new replacement washer and apply wheel bearing grease LS 4 Removing the scr...

Page 148: ...ng the cylinder head cylin er hea gasket cylin er hea olts M 3 Nm olts M Nm NOTE ighten the bolts in the proper se uence ollo the nu erical or er sho n in the illustration ighten the bolts in t o stag...

Page 149: ...ING Always use a new gasket NOTE The UP mark on the timing chain tensioner should face up Timing chain tensioner bolt 10 Nm d Remove the screwdriver make sure that the timing chain tensioner rod relea...

Page 150: ...the parts in the order listed camshaft Cylinder head cover 1 Rocker arm shaft 4 2 Wave washer 8 3 Rocker arm exhaust 2 4 Rocker arm intake 2 5 Valve adjuster 8 6 Locknut 8 7 Camshaft sprocket 2 8 Cam...

Page 151: ...iameter of the rocker arm holes Out of specification Replace Rocker arm inside diameter repairing limit value 12 05mm Check the surface of the rocker arm shafts orn pitting scratches Replace e Measure...

Page 152: ...hecking the camshaft sprocket camshaft sprocket ear amage Replace the camshaft sprocket an timing chain as a set a of a tooth Correct Timing chain procket Checking the ecompression system ecompression...

Page 153: ...he valves and valve springs Remove the parts in the order listed Cylinder head cover Valve lock clip Valve spring retainer Intake valve spring Exhaust valve spring Intake valve Exhaust valve Valve ste...

Page 154: ...larger than the o y of the stem Replace al e seats Pitting wear Reface the al e seat 2 MEASURE Measure The al es surface wi th Repairing limit value 2 0mm stem to gui e clearance Stem to guide clearan...

Page 155: ...tall the al e into the cylin er hea Press the al e through the al e gui e an onto the al e seat to make a clear pattern c Measure the al e seat wi th here the al e seat an al e face ma e contact luein...

Page 156: ...is to wide or narrow or cracked grind it to ensure impermeability 3 Lap al e face al e seat NOTE After reface the valve seat or replacing the valve and valve guide the valve seat and valve face should...

Page 157: ...attern h Measure the valve seat width again If the valve seat width is out of specification reface and relapse the valve seat 3 INSTALL 1 Apply moly enum isulfi e oil onto the valve stem and valve ste...

Page 158: ...emoving the cylinder and piston Remove the parts in the order listed Water pump outlet hose Pin 14 16 Gasket cylinder body Cylinder body assy Gasket cylinder head Piston ring set Piston Piston circlip...

Page 159: ...n groove is cracked and abraded 3 Checking the piston pin piston pin Blue discoloration grooves Replace then check the lubrication system 2 MEASURE At the top the mi le and the bottom of the piston st...

Page 160: ...e measuring the side clearance Side clearance Standard Limit Top ring 0 04 0 08mm 0 13mm 2nd ring 0 03 0 07mm 0 13mm piston pin to piston clearance a Measure the piston pin outsi e iameter Measure the...

Page 161: ...ngine oil onto the piston pin piston rings an piston e sure that the arro ar a on the piston points to the e haust si e of the engine efore installing the piston pin clip co er the cran case ith a cle...

Page 162: ...the parts in the order listed Engine oil Water pump assembly 1 Left crankcase cover 1 2 Inspection port cover O ring 1 1 3 Crankcase location sensor O ring 1 1 4 Plug oil level gauge O ring 1 1 5 A C...

Page 163: ...4 ENGINE 149 No Part Name Qty Remarks 12 Starter idle gear 1 13 Starter idle gear shaft 1 For installation reverse the removal procedure...

Page 164: ...tall the starter wheel gear onto the starter clutch an hol the starter clutch Turn the starter wheel gear counterclockwise to check that the starter clutch an wheel gear engage If the starter clutch a...

Page 165: ...ins A C magneto rotor NOTE efore installing the rotor clean the outsi e of the cran shaft an the insi e of the rotor fter installing the rotor chec that the rotor rotates s oothl f not reinstall the e...

Page 166: ...the order listed 1 Hexagonal socket head plugnpt1 8 1 2 Oil plug M10 1 25 12 crankcase 1 3 Oil filter 1 4 O ring 61 5 2 4 1 5 Oil filter cover 1 6 Flange bolt M6 20 3 7 Pressure sensor 1 8 Pressure li...

Page 167: ...1 16 Middle gear 1 17 Water pump assy 1 18 Straight pin 4 16 1 19 Water pump double gear 1 20 Bearing HK1010 1 21 Flange bolt M6 65 1 22 Aluminum Washer 6 12 1 5 1 23 Flange bolt M6 35 2 24 Starting m...

Page 168: ...g the relief valve spring Pressure imiting Plunger pring Aluminum asher ollow Bolt Damage wear Replace the defective part s 4 Checking the oil filter cartridge Oil filter cartri ge Damage Replace Cont...

Page 169: ...heaves Remove the parts in the order listed Engine assembly 1 Clutch cover assy 1 2 Flange Bolt M6 28 9 3 Gasket clutch cover 1 4 Double sided toothed belt91 SA 29 5 945 31 2 26 14 6 1 5 Bolt M12 140...

Page 170: ...ry clutch 1 12 Clutch cover seat assy 1 13 Flange bolt M6 22 9 14 O ring 56 75 3 53 1 15 O ring 50 4 1 16 Self lock nut M6 2 17 Spring Washer 6 9 18 Gum cover 1 19 Clutch cover plug 1 20 Flange bolt M...

Page 171: ...easure secon ary shea e spring free length a Out of specification Replace the secon ary sheave spring 3 INSTALL Assem ling the primary shea e Clean primary sli ing shea e primary fi e shea e primary s...

Page 172: ...ves 1 Install secon ary shea e assem ly elt primary shea e assem ly NOTE ightening the bolts ill push the secon ar sli ing shea e a a causing the gap bet een the secon ar fi e an sli ing shea es to i...

Page 173: ...moving the crankcase cover and oil pump Remove the parts in the order listed Crankcase separation 1 Crankshaft cover 1 2 Gasket 1 3 Dowel pin 2 4 Crankcase exhaust pipe 1 5 Crankcase block 1 6 Oil sea...

Page 174: ...1 2 12 Oil pump housing 1 13 Oil pump gear 1 14 Water pump gear circlip 1 1 15 Shaft pin 1 1 16 Water pump gear washer 1 1 17 Oil pump middle gear 1 18 Shaft 1 19 Bearing 1 20 Fuel and air separator a...

Page 175: ...6 ENGINE 161 No Part Name Qty Remarks 24 Valve piece 1 25 Chain plate 1 26 Timing chain guide secondly cylinder 1 27 Timing chain 1 28 Right crankcase 1 For assembly reverse the disassembly procedure...

Page 176: ...as a set timing chain gui es ear amage Replace 2 MEASURE Measure the oil pump tip clearance a etween the inner rotor an the out rotor si e clearance etween the outer rotor an the pump housing o y clea...

Page 177: ...e shaft Remove the parts in the order listed Crankcase separation 1 solid pin 6 12 1 2 right crankcase assy 1 3 bolt M10 1 25 25 1 4 Washer 10 32 5 2 5 o ring 25 2 4 1 6 shaft sleeve 1 7 shaft sleeve...

Page 178: ...2 1 14 Bearing 6906 1 15 O ring 51 2 4 1 16 Oil seal 30 47 7 1 17 Flange bolt M6 20 3 18 4 WD shift sleeve 1 19 Transmission shaft spring 1 20 Bearing 6206 1 21 Y output shaft 1 1 22 Adjusting Washer...

Page 179: ...olt M8 25 4 28 O ring 25 2 4 1 29 Y Shaft bush 25 32 14 5 1 30 Bush 25 32 18 1 31 U joint A 22 1 32 Washer 10 32 5 2 33 Bolt M10 1 25 25 1 34 Cross U joint 22 1 35 Clip 22 4 36 U joint A 22 1 37 U joi...

Page 180: ...case mating surfaces thoroughly 3 heck crankcase Cracks amage Replace oil eli ery passages Clogge Blow out with compresse air 2 MEASURE Measure the crankshaft crank wi th A Out of specification Replac...

Page 181: ...Before installing and torque the crankcase holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions 4 Tighten crankcase o...

Page 182: ...each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place a Press each eari...

Page 183: ...spee sensor to hol the mi le ri en gear c Attach the gear lash measurement tool an ial gauge a mm in Measure the gear lash while rotating the output shaft ack an forth NOTE Measure the gear lash at 4...

Page 184: ...easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place a Press each earing into the uni ersal oint usi...

Page 185: ...case separation 1 Inner hexangular screw M8 45 1 2 Inner hexangular screw M8 40 3 3 Spring Washer 8 4 4 Flange bolt M6 45 1 5 Flange bolt M6 35 4 6 Bracket clutch cover seat 1 7 Flange bolt M6 16 2 8...

Page 186: ...5 Steel ball S 9 5 1 16 Gearshift drum assy 1 17 Circlip 12 2 18 Fork shaft seat 2 19 Fork shaft 12 111 2 1 20 H spring 1 21 H shift fork 1 22 R l shift fork 1 23 R l spring 1 24 Fork shaft seat 2 25...

Page 187: ...shift assembly 1 30 Drive segment gear gear shift 1 31 Flange bolt M6 20 1 32 Pin 8 12 1 33 Fan driven gear combination 34 Pin 10 16 2 35 Oil pump assy Gear Box 1 36 Nut M10 1 25 1 37 Stud bolt M10 1...

Page 188: ...74 ENGINE 174 No Part Name Qty Remarks 42 O ring 18 3 5 1 43 Gear box 1 44 Exhaust pipe nozzle 1 For assembly reverse the disassembly procedure...

Page 189: ...se transmission Remove the parts in the order listed Gear case separation 1 Gear case cover 1 2 Bearing 6305 1 3 Bearing plate 1 4 Cross recessed countersunk head screw 3 5 Main shaft 1 6 Pin 2 18 1 7...

Page 190: ...Bearing 6403 1 13 Washer 17 34 2 2 1 14 R driven gear 1 15 Washer 25 4 33 1 1 16 H driven gear 1 17 L driven gear 1 18 Needle bearing 25 29 9 6 2 19 Counter shaft 1 20 Needle bearing 15 28 2 1 21 Was...

Page 191: ...t 12 56 1 26 Bracket clutch cover seat 1 27 Flange bolt M6 35 4 28 Flange bolt M6 45 1 29 Bush 25 32 18 1 30 O ring 25 2 4 1 31 Oil seal 32 47 7 1 32 Inner hexangular screw M8 40 3 33 Spring washer 8...

Page 192: ...place gui e ar Roll the gui e ar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar shift fork mo ement on the gui e ar Unsmooth operation Replace the shift fork an...

Page 193: ...pump operation Unsmooth Repeat steps 1 and 2 or replace the efecti e parts 2 Measure 1 Measure the oil pump tip clearance a between the inner rotor and the out rotor si e clearance between the outer r...

Page 194: ...rt spring Installing the shift le ers shift le er assem ly 14Nm shift le er NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever...

Page 195: ...brake clamp assembly parts deformed 2 Brake performance degressive 1 Check whether disc plates abrasion exceeded limits 2 Check whether brake shoe of clamp abrasion exceeded limits or polluted by fri...

Page 196: ...ring knuckle bearing damaged 2 Check whether king pin ball joint damaged 3 Check whether front wheel and axle locknut loosen or damaged 4 Check whether front wheel hub inner spline and front wheel axl...

Page 197: ...ber boot damaged or universal joint damaged 8 Fail to shift into four wheel drive or lock differential 1 Check whether four wheel drive switch normal 2 Check whether power divider damaged 3 Check whet...

Page 198: ...D CARGO BED Front Panel No Part Name Qty Remarks Removing the front panel 1 Headlight cover 1 2 Front board 1 3 Left fender front cover 1 4 Right fender front cover 1 5 Screw M6 16 50 8 Rubber ring 2...

Page 199: ...Remarks 10 Steering wheel cover left 1 11 Dashboard 1 12 Screw thread clip M6 2 28 13 Dashboard cover 4 14 Sundry box 1 15 Dashboard operation 1 16 Switch cable 1 17 Switch cable 1 18 Cover glove box...

Page 200: ...86 CHASSIS 186 No Part Name Qty Remarks 20 Plastic jaw 2 21 Self tapping screw cross pan headed ST4 8 13 4 22 Self tapping screw cross pan headed ST3 6 10 4...

Page 201: ...HOOD Remove switch Hood Release To open the hood pull up the switch to release the latch and open the hood CAUTION Never open operator s seat while the engine is running Support hood with the other h...

Page 202: ...Screw thread clip M6 2 16 2 Screw M6 16 30 3 Clutch intake pipe cover right 1 4 Clutch intake pipe cover left 1 5 Clutch intake pipe dustproof mesh 2 6 Right side board assy carrier 2 7 Left side boar...

Page 203: ...emarks Removing the side cover parts 1 Screw thread clip M6 2 24 2 Socket hexagon screw M6 16 35 3 Hexagon flange bolt M8 20 2 4 Parking system 1 5 Anti dust rubber parking system 1 6 Cotter pin 2 32...

Page 204: ...ide board seat 1 10 Gear shift cover 1 11 Side protective plate right 1 12 Side protective plate left 1 13 Protective plate R 1 14 Protective plate L 1 15 Side decoration plate right 1 16 Side decorat...

Page 205: ...ing the cargo bed 1 Screw Thread clip M6 2 17 2 Socket hexagon screw M6 16 15 3 Cross plate head tapping screw ST3 9 13 6 4 Knob 3 5 Rubber bush 3 6 Rear cargo box cover 1 7 Cargo bed 1 8 Cross large...

Page 206: ...CHASSIS 192 No Part Name Qty Remarks 10 Clamp 118 140 1 11 Seat rear protective plate right 1 12 Seat rear protective plate 1 13 Seat rear protective plate left 1 14 Cross large plate head screw M6 16...

Page 207: ...ing the head shed frame 1 Rear part shed assy 1 2 Hexagon flange bolt M10 1 25 20 10 3 Shed support rear section left 1 4 Shed support rear section right 1 5 Screw M10 1 25 25 16 6 Hexagon flange nut...

Page 208: ...ront segment of roof rod left 1 11 Safety belt locker 2 12 Protective net right 1 13 Protective net left 1 14 Hexagon flange nut M10 1 25 25 2 15 Right shoulder protector assy right 1 16 Left shoulder...

Page 209: ...5 CHASSIS 195 No Part Name Qty Remarks 19 Spring cushion 10 16 20 Waved seal 2 21 Waved seal 2 22 Shed cross bar 1...

Page 210: ...t Name Qty Remarks Removing the steering wheel 1 Steering wheel comp 1 2 Steering wheel cap 1 3 Socket hexagon plain head screws M6 16 6 4 Lower cover 1 5 Horn 1 6 Steering pole cover 1 7 Clamp 1 8 Be...

Page 211: ...lange bolt M6 16 4 13 Gas spring assy 1 14 Pin shaft I 1 15 Cotter pin 5 1 2 16 Steering pipe bracket 1 17 Hexagon flange bolt M10 1 25 16 3 18 Bolts M6 10 10 20 5 2 19 Hexagon flange Nut M10 1 25 2 2...

Page 212: ...8 CHASSIS 198 No Part Name Qty Remarks 23 Steering wheel cover right 1 24 Steering wheel cover left 1 25 Socket hexagon screw M6 12 2 26 Cross small plate head tapping screw ST3 9 13 3...

Page 213: ...rks Removing the steering mechanism 1 Steering mechanism comp 1 2 Bolt M8 1 25 20 2 3 Bolt M8 1 25 80 2 4 Rubber boot 2 5 Clamp 2 6 Steel clamp 15 2 7 Hexagonal nut M12 2 8 Ball Joint 2 9 Hexagon nut...

Page 214: ...l rocky le ge re erse turning clearance crack reak Replace loose play A ust the steering wheel to rotate whether nim le o not ha e stagnation A ust the tor ue of the steering wheel whether o iously in...

Page 215: ...some problems in the check it should be service immediately to ensure the normal work of the steering system DIASSEMBLING THE STEERING COLUMN PARTS Remove ront co er connection co ers part steering w...

Page 216: ...r is wear out if so instea the central a is 3 Check The spline in the two en s of the central a is whether ha e wear if ose instea the central a is 4 Check The steering shaft tu e an wel ing line of t...

Page 217: ...egra ation Replace NOTE When replace the dust boots of the ball must enter 1 2 volume in lithium grease in to the dust boots 2 Check Ball oint steering mechanism turning rocky le ge ree play Replace t...

Page 218: ...herwise please adjust the screw to meet required travel distance 1 Inspect the brake pedal does maintain the certain counter tension When checks disk brake plate the saved liquid in the oil cup will p...

Page 219: ...y Remarks Removing brake components 1 Front brake pad 2 2 Front right brake oil pipe 1 3 Front left brake oil pipe 1 4 Rear disk brake main tube 1 5 Rear brake pipe left 1 6 Rear brake pipe right 1 7...

Page 220: ...22 8 11 Outer brake pad assy 1 12 Outer brake pad assy 1 13 Front brake caliper right 1 14 Front brake caliper left 1 15 Hexagon flange bolt M6 16 15 16 Cable clip 15 17 Nut M8 1 18 Hexagon flange bol...

Page 221: ...flange bolt M10 1 25 30 2 23 Inner brake pad assy 1 24 Outter brake pad assy 1 25 Parking brake assy 1 26 Outer brake pad assy 2 27 Outer brake pad assy 1 28 Rear brake caliper right 1 29 Rear brake...

Page 222: ...f specification Check the wheel runout If wheel runout is within the limits replace the rake isc Brake disc maximum deflection 0 10 mm 0 004 in rake isc thickness wheel hu wheel tyre Out of specificat...

Page 223: ...in 3 Install rake pa s rake pa spring NOTE Always install new brake pads and brake pad spring as a set a Connect a suita le hose tightly to the rake caliper lee no le Put the other en of this hose int...

Page 224: ...n disassembly and reassembly may cause serious in ury and even death eplace dama ed brake caliper f only replace the brake caliper of one side please check carefully whether the brakin force of ri ht...

Page 225: ...well and distort 2 Check rake caliper pistons Scratches rust wear Replace the brake caliper assembly rake caliper cylin ers Wear scratches Replace the brake caliper assembly rake caliper o y Cracks da...

Page 226: ...DOT4 Brake Fluid eplace the caliper piston seals and dust seal whenever a brake caliper is disassembled 1 Install caliper piston seals ust seals 2 Install rake caliper pistons INSTALLING THE FRONT BR...

Page 227: ...per brake hose routing is essential to insure safe vehicle operation 2 Fill rake reser oir Must use DOT4 Brake Fluid NOTE Brake fluid may damage painted surfaces or plastic parts Always clean up spill...

Page 228: ...2 4 CHASSIS 214 The service method of the rear brake caliper is as the same as the front brake caliper please refer to the before mentioned to operate...

Page 229: ...1 Check parking isc Galling amage Replace Measure parking isc eflection Out of specification Replace Parking disc maximum deflection 0 10 mm 0 004 in parking isc thickness Out of specification Replac...

Page 230: ...m 0 04 in 3 Install rake pa s pa spring NOTE Always install new brake pads new brake pad shims new insulators and a new brake pad spring as a set 4 Check rake flui le el minimum le el mark houl the fl...

Page 231: ...ase check carefully whether the brakin force of ri ht and left are balance and e ual 1 Remove rake caliper piston ust seal caliper piston seal a Turn the rake caliper piston counterclockwise to remo e...

Page 232: ...uld be cleaned and lubricated with new brake fluid only before installation Must use DOT4 Brake Fluid eplace the caliper piston seal and dust seal whenever a brake caliper is disassembled Install cali...

Page 233: ...le for the parking brake arm shaft has multiple threads If the punch mark on the parking brake arm shaft is not between the alignment marks when the parking brake arm shaft is screwed in completely re...

Page 234: ...BRAKE CALIPER 1 Install rake caliper assem ly rake caliper mounting olts 40Nm 4 0m kg 29 ft lb rake hose copper washers union olt 48Nm 4 8m kg 35 ft lb NOTE Tighten the union bolt while holding the b...

Page 235: ...o y Cracks amage Replace rake flui eli ery passage rake master cylin er o y Blockage Blow out with compresse air Check rake master cylin er kit cratches wear amage Replace as a set 3 Check rake flui r...

Page 236: ...m 1 9 m kg 13 ft lb washer plate rake hose union olt 27Nm 2 7 m kg 19 ft lb 3 ill rake flui reser oir Must use DOT4 Brake Fluid NOTE Brake fluid may damage painted surfaces or plastic parts Always cle...

Page 237: ...M6 2 30 2 Socket hexagon screw M6 12 20 3 Socket hexagon plain head screws M6 20 4 4 Bolt M12 1 25 55 1 5 Bush 12 18 32 1 6 Spring 2 12 5 53 1 7 Shock absorbtion rubber 1 9 Hexagon flange nut M12 1 25...

Page 238: ...lerator pedal welding assy 1 18 Spring 1 19 Air filter intake tube joint 76 63 42 3 1 20 Clamp 70 90 1 21 Air filter intake tube 1 22 Inner right mud guard plate 1 23 Inner left mud guard plate 1 24 R...

Page 239: ...225 CHASSIS 225 CHECKING THE BRAKE PEDAL Brake pedal Free travel Inspect the brake pedals for free clearance and smooth operation Adjust if incorrect measurement is found...

Page 240: ...y Remarks Removing the front wheel 1 Front wheel rim 2 2 Front tyre 2 3 Cycle valve 2 4 Nut M10 8 5 Wheel decoration cover 2 6 Cotter 3 2 50 2 WARNING Securely support the vehicle so There is no dange...

Page 241: ...Removing the rear wheel 1 Rear wheel rim 2 2 Rear tyre 2 3 Cycle valve 2 4 Rear hub 2 5 Bolt M10 30 8 WARNING Securely support the vehicle so There is no danger of it falling over 6 Nut M10 8 7 Wheel...

Page 242: ...ay 3 Check wheel alance Out of alance A ust Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in WARNING The profile depth falls below 3mm Please replace the tyre immediately tire wear limi...

Page 243: ...ft lb INSTALLING THE WHEEL TYRE 1 Install wheel NOTE The arrow mark on the tyre must point in the direction of rotation A of the wheel Tighten wheel nuts WARNING Tapered wheel nuts are used for both...

Page 244: ...an profile epth Insufficient tyre pressure can result in not only intensifie wearing of the tyre ut also insta ility uring the course of operating the ehicle such as har turning E cessi e tyre pressu...

Page 245: ...arks Removing the C V axle front axle L R 1 Circlip 2 2 Double off set assembly 4 3 Circlip 4 4 Ball bearing 4 5 Circlip 4 6 Hoop A dust P shed 4 7 Outer rubber dust P cover 2 8 Adjustable clamp 4 9 C...

Page 246: ...ifferential case 1 2 Front differential case 1 3 Fuel Drain screw plug 2 4 O seal 2 2 16 4 2 5 Master accessory gear 1 6 Differentail assy 1 7 Ventilate pipe 1 8 Oil Pipe clip 8 1 9 Clip 72 1 10 Hexag...

Page 247: ...circle transfer case 1 18 O seal 2 2 16 4 1 19 Hexagon flange bolt M8 25 8 20 Speed sensor comp 1 21 Joint cross shaft 2 22 Connection fork 1 23 Connection fork 1 24 Transfer case assembly 1 25 Seal r...

Page 248: ...rsal oint a Remo e the circlips Place the uni ersal oint in a press c ith a suita le iameter pipe en eath the yoke press the earing into the pipe as shown Repeat the steps for the opposite earing e re...

Page 249: ...o ement is mooth ceaseless If it is stagnation an o ious ecoming less loosen replace it Disassem e the left an right transmission shaft cleaning an assem le it again NOTE 1 The dustproof rubber wrap o...

Page 250: ...aring into the uni ersal oint using a suita le socket CAUTION Check each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all t...

Page 251: ...xle L R 1 Circlip 2 2 Adjustable clamp 4 3 Hoop A dust P shed 4 4 Inner rubber dust proof 2 5 Circlip 4 6 Double off set joint assembly 2 7 Double off set joint assembly 2 8 Circlip 4 9 Ball bearing 4...

Page 252: ...t Name Qty Remarks Removing the rear bridge reducer 1 Rear differential housing 1 2 Rear differential housing 1 3 Oli seal 52 35 7 2 4 Bearing 32008E 1 5 Rear adjustment gasket 1 6 Rear adjustment gas...

Page 253: ...Qty Remarks 9 Driven gear connecting plate 1 10 Adjustment gasket 2 11 Bearing 32010E 1 12 Bearing seat 1 13 Metal bushing 1 14 Drain O ring 1 15 Fuel drain screw plug 1 16 Welding combination of shi...

Page 254: ...rt Name Qty Remarks 18 Fix bracket 1 19 Returning spring 2 20 Sleeve of shift fork 1 21 Fork pin 1 22 Bolt M10 1 25 20 8 23 Oil filling plug 1 24 Oil filling o ring 1 25 Spring pin 4 28 1 26 Hexagon f...

Page 255: ...arks 27 Oil filling o ring 1 28 Drive gear pin 1 29 Drive gear 2 30 Rear adjustment gasket 2 31 Driven gear rear differential 1 32 Rear adjustment gasket 3 33 Rear differential housing 1 34 Adjust bus...

Page 256: ...Name Qty Remarks 36 Adjust bushing 1 37 Bearing 32206E 2 38 O ring 1 39 Mount bracket rear disk brake plate 1 40 Rear differential drive gear 1 41 Washer 12 30 4 1 42 Spring 1 43 Magnetic valve 1 44...

Page 257: ...43 CHASSIS 243 No Part Name Qty Remarks 45 Steel clamp 1 46 Hexagon flange Nut M12 1 25 25 1 47 Rubber bush 1 48 Connecting bush 1 49 Braking plate 1 50 Spring 2 3 28 20 1 51 Hexagon flange bolt M8 16...

Page 258: ...is as the same as the front bridge parts please refer to the before mentioned to operate NOTE Apply lithium soap based grease to the bearing assembly and o ring and bearing and driven gear and oil se...

Page 259: ...ift operating system 1 Gear shifter assembly 1 2 Gear shift knob 1 3 Hexagon flange self lock nuts 1 4 Gear shift boot 1 5 Clamp 1 6 Gearshift assy 1 7 Hexagon flange self lock nut M6 2 8 Gear shift r...

Page 260: ...fore shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjust elect le er shift ro a Make sure the select lever is in NEUTRAL...

Page 261: ...3 Remove the gear shift mechanism and check whether the linking rod is cracked If so it should be changed 4 Check whether the bouncing spring of gear shift mechanism is intense enough 5 Check whether...

Page 262: ...HASSIS 248 SUSPENSION Front Swing Arm No Part Name Qty Remarks Removing the front swing arm 1 Hexagon bolt M10 1 25 57 2 2 Hexagon bolt M10 1 25 55 2 3 Hexagon flange Nut M10 1 25 4 4 Front shock abso...

Page 263: ...s Removing the front suspension 1 Spring washer d0 32 4 2 Right front upper swing arm 1 3 Left front upper swing arm 1 4 Right front lower swing arm 1 5 Left front lower swing arm 1 6 Rear right suspe...

Page 264: ...oint B 2 10 Bolt M10 1 25 80 8 11 Bush 10 23 50 8 12 Nylon bush 16 13 Hexagon flange Nut M10 1 25 10 14 Hexagon flange bolt M10 1 25 45 2 15 Hexagon Nut M12 1 25 2 16 Cotter pin 2 32 2 17 Spring washe...

Page 265: ...shock absorber and maintain method whether it can returns to the position under the pressure and the torsional spring is rupture If it is rupture or nearly to rupture instead the shock absorber wheth...

Page 266: ...STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check Mi le ushing Wear damage Replace 3 Check all oints Damage pit...

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Summary of Contents for 1000GTR

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Crossfire 1000GTR, Maintenance Handbook

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Summary of Contents for 1000GTR

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