Engine
4
‐
33
Inspect
Oil Line
Look for cracks or damage.
Relief Valve (1)
Spring (2)
Look for damage or wear.
Assembling the crankcase
Apply sealant (quick gasket) (1) to
the mating surfaces of both
halves. Use only a thin bead of
sealant.
Install the dowel pins (2).
Fit the left crankcase half onto the
right crankcase half. Tap lightly on
the case with a soft hammer.
Crankcase. Thoroughly wash the case
halves in a mild solvent.
Clean all the gasket surfaces and
crankcase mating surfaces thoroughly.
Look for cracks or damage.
Inspect oil delivery passages
Look for clogs, blow out with
compressed air.
Bearings.
Clean and lubricate. Check
operation. Check for
smoothness in operation.
Summary of Contents for Challenger 500
Page 1: ...SERVICE MANUAL Challenger 500 Challenger 700...
Page 50: ...500 UV Engine Specifications 2 10...
Page 51: ...500 UV Engine Specifications 2 1 1...
Page 52: ...500 UV Engine Specifications 2 12...
Page 53: ...500 UV Engine Specifications 2 13...
Page 209: ...Electrical 6 11 Ignition System Circuit Diagram 1 High tension coil 2 C D I 3 Magneto...
Page 213: ...Electrical 6 15 Electric Starting System...
Page 216: ...Electrical 6 18 Charging System...
Page 218: ...Electrical 6 20 Lighting System...
Page 219: ...Electrical 6 21 Signaling System...
Page 220: ...Electrical 6 22 Cooling System...
Page 221: ...Electrical 6 23 2WD 4WD Selecting System...
Page 244: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 10856 05 2015...