Chassis
5
‐
37
Disassembling the Front Bridge
1. Remove the left and right front
wheels.
2. Remove the front disc brake clip,
cotter pin, open-groove nut,
cushion and front wheel hub.
3. Disassemble the left and right
rocker arm and cross steering
knuckle.
4. Disassemble the differential.
5. Remove the front bridge from the
frame.
6. Remove the oil from the differential.
7. Pull out the left and right
transmission shaft from the
differential.
Disassembling the Universal joint
1. Remove the universal joint
2. Remove the circlips (1)
3. Place a pipe (2) of the correct size
to collect outside diameter of the
bearing beneath the yoke (3), and
press the bearing (4) into the pipe
as shown.
4. Repeat the process for the opposite
side.
5. Remove the yoke.
Removing the Differential Gear
Assembly
1. Remove the differential gear
assembly
Checking the CV Joints
1. Inspect the dust boots
Look for cracks, splits or damage.
2. Inspect the double off-set spline,
ball joint spline, and shaft spline.
Look for wear or damage.
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...