6
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CHAPTER 3
MAINTENCE AND ADJUSTMENT OF THE UTV
MAINTENANCE SCHEDULE……………………………………………………………… 82
ENGINE
Adjusting the valve clearance…………………………………………………………… 84
Checking the spark plug ………………………………………………………………… 87
Checking the ignition timing……………………………………………………………… 88
Measuring the compression pressure………………………………………………… 89
Checking the engine oil level …………………………………………………………… 90
Changing the engine oil ………………………………………………………………… 91
CHASSIS
Cleaning the air filter………………………………………………………………… 93
Checking the coolant level …………………………………………………………… 94
Changing the coolant…………………………………………………………………… 95
Checking the coolant temperature warning light …………………………………… 98
Checking the v-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 brake pipes ………………………………………… 104
Bleeding the hydraulic brake system ………………………………………………… 104
Adjusting the select lever shift rod …………………………………………………… 106
Adjusting the brake light switch …………………………………………………… 106
Checking the final gear oil level…………………………………………………… 107
Changing the final gear oil…………………………………………………… 107
Checking the differential gear oil…………………………………………………… 108
Checking the constant velocity joint dust boots……………………………………… 109
Checking the steering system………………………………………………………… 110
Adjusting the toe-in …………………………………………………………………… 111
Adjusting the front and rear shock absorbers………………………………………… 112
Checking the tires ……………………………………………………………………… 114
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Checking the wheels…………………………………………………………………… 115
Checking and lubricating the cables ………………………………………………… 116
ELECTRICAL
Checking and charging the battery…………………………………………………… 117
Checking the fuses …………………………………………………………………… 123
Changing the headlight bulb………………………………………………………… 125
Changing the tail/brake light bulb …………………………………………………… 126
CHAPTER 4
ENGINE
ENGINE NOTE……………………………………………………………………………… 128
ENGINE REMOVAL………………………………………………………………………… 129
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 WATER PUMP…………………………………………………152
PRIMARY AND SECONDARY SHEAVES…………………………………………………155
CRANKCASE COVER AND OIL PUMP……………………………………………………159
CRAKCASE AND MIDDLE DRIVEN SHAFT………………………………………………163
GEARCASE SHIFT LEVER AND OIL PUMP……………………………………………171
GEARCASE TRANSMISSION………………………………………………………………175
CHAPTER 5
CHASSIS
MALFUNCTION INSPECTION…………………………………………………………… 181
PANEL AND CARGO BED
Front panel………………………………………………………………………………… 184
