Cub Cadet Challenger 500 Page 242 Service Manual Download

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Alternator

Horn

Blue/

Green
Brown/

White
Blue/

Red

Brown/

Black

Brown/

Red

Black/

Yellow

Gray

Pink

Black

Brown/

Red

Red/

Green

K1= 2/4 WD Relay

K2= Auxillary Start Relay

K3= Differential Lock Relay

K4=

K5= Fuel Pump Relay

K6= Gear Start Relay

K7=

Purple

Red/

White

Black

White/

Blue

Green/

White

Red/

Brown

Brown/

Yellow

Gray

Rotational Speed Signal

Red/

Yellow

Blue Green Yellow Dark

Brown

Gray

Dark

Green

Pink

Green/

Red

Blue/

Red

Blue/

Green

Light

Blue

Blue/

Black

Green/

Red

Gray

Blue/

Red

Black

Yellow Button

Red Button

Yellow Button

No Press

Press

No Press

Press

4WD

2WD

4WD

Lock

Blue/ Green

Brown/

Red

Brown/

Black

Brown/

White

Pink

Blue/

Black

Gray

Blue/ Red

Black/

Yellow

Blue/

Black

Purple

Blue/

White
Brown/

Red

Brown/

Red

Brown

Pink

Black

Red

Purple

Brown/

Blue

Brown

Brown/ Red

Brown/

Blue

Pink

Red/ Yellow

Red/ White

Blue/

White

Red/

Green

Red/

White

Red

Brown/

Blue

Red/

Yellow
Brown/

Blue

Brown/

Blue

Brown/ Blue

Red

Key Switch

Battery

Starter

Motor

Parking

Switch

Brake

Switch

Radiator Fan

Motor

Engine Inner

Gearshift Switch

EPS

Motor

EPS

Controller

Diode 10A

Fuel Pump

Module

Speed

Sensor

Right Rear

Turning

Light

Right Front

Turning

Light

License

light

Left Rear

Turning

Light

Left Front

Turning

Light

Head

Lights

Trailer Plug

Safety

Belt

Lock

Light Switch

Voltage Regulator

White

Red

Black

Red

30A

12V-30Ah

Gray

Brown

Red

Green/ Black

White

Brown/ Red

Red/

Black

Blue

Blue/ Red

Yellow

Blue/

White

Yellow/

Blue

Starter

Solenoid

Diodes

EPS Fault Signal

Green/ Black

Purple

Dark Brown

Speed Signal

White

Left Turn

Light

Right Turn

Light

Dark Green

Low Gear

Light

Hi Gear

Light

Neutral

Light

Reverse

Light

White/ Red

Blue/ White

Light Blue

Green/ White

Blue/ Red

Brake

Light

4WD

Lock

Emergency

Light

Position

Light

High Beam

Light

4WD

Light

Safety Belt

Light

Yellow

Blue

Green/ Red

White/ Black

Black/ Red

White/

Blue

Red/ Brown

Brown/ Yellow

Water Temperature Light (Alert)

Yellow

Blue

Green

Blue

Green

Dark Green

Dark Brown

Blue

Yellow

Black/ Red

Blue/

Black

Light Blue

Green/ Red

White/ Black

Green/ White

White/ Red

Blue/ White

Black/

Yellow

Brown/

Black

Light

Blue

Black

Purple

Red/ White

Gray

White/ Blue

Green/ White

Red/ Brown

4WD / Differential Switch

Pink

Brown/ Yellow

Blue/ Green
Brown/ Black

Blue/ Red
Black/ Yellow
Green/ White

White/ Blue
Brown/ Yellow
Red/ Brown

Purple

Brown

Red/ White

Purple
Pink

Yellow

Green/ White

White/ Blue

Brown/ Yellow

Red/ Brown

Yellow

Green

Dark Green

Blue

Dark Brown

Gray

Blue

Yellow

Blue

Dark Green

Brown/

Yellow

Red/

Brown

Brown/ White

Red

Dark Brown

Blue

Beams

Tail

Lights

Tail

Lights

Dash Screen

12V O

utlet

Front

Differential

Brown/

Red

Pink

Red

Brown/ Blue

Blue/ White

Pink

Black

Blue/ Black

Brown/ Red

Brown/ Black

ECU Plug

Flasher/

Alarm

Black

Green/ Yellow

Green/

Yellow

Black

Red/

White

Relay Key

Fuel Level Signal

Speed Signal

Water Temperature Light (Alert)

Rotational Speed Signal

Fault Signal

Gray

Water

Temp

Switch

Black

Wire Colors Listed In Black Font (#4 Regular) Above Wire Or To The Right Of Wire.

Wire Function Listed In Red Font (#5 Semi Bold) Above Wire.

(

) The EPS (Power Assist Steering) Is Optional On The CX500 & CX700.

(

) The Power Assist Steering Is Standard On The CX700 Crew.

(

) The ECU Plug Connects To The Main Harness Plug Of The EFI Harness.

(

) The Alternator Wire Lead Connects To The Main Wire Harness.

(

) The Color Of This Wire Could Either Be

Red/ Blue

Red/ Green

(

) The Fuel Pump Module Includes The Fuel Level Sensor.

NOTES:

Blue/ Red

White/ Blue

Water Temperature Light (Alert)

Pink

Black

Blue

Black

Starter

Relay

NOTE

(

)

NOTE

(

)

NOTE

(

)

Main Harness

Altn. Harness

Open

White White White

White/

Black

Red/ Blue
Red/ Blue

Red/ Blue

Black

Orange/ Red

Blue

Safety

Belt

Lock

Blue
Blue

White

Blue/ Red

Pink

Light Blue/ Red

Green/ Black

ain Harness

F1= Meter/ECU Energize (5A)

F2= Brake Light / Turning Light (10A)

F3= EPS’s ECU (10A)

F4= Auxillary DC Jack 2/4WD (15A)

F5= Meter / ECU Switch (15A)

F6= Headlights (15A)

Fuse Key

Main Harness

Black

Gray

Main Harness

Green/ Red

Blue

Black

Main

Harness

Black

Blue/ Red

Relay

Assembly / Fuse Box

Black

Red/ Green

Yellow/ Red

Black

Diodes

White/

Black

Dark

Green

Brown

Green/

Red

Blue

Yellow

Red/

White

Purple

Blue/

Red

Orange/

Red

Green/

White

Light

Blue

Blue/

White

White/

Red

White

Brown

Blue

Yellow

Purple

Blue/

Red

Light

Blue

Blue/

White

White/

Red

White

Main Harness 16 Pin Connector

Dash Harness 16 Pin Connector

Red

Orange

Green

Blue/

Yellow

Yellow/

Red

Blue/

Green

Black

Yellow

Black/

Red

Pink

White/

Black

Red/

Brown

Yellow/

Black

Brown/

White

Yellow/

Green

Yellow/

White

Green/

Red

Black

Open

Dash Harness 12 Pin Connector

Main Harness 12 Pin Connector

Black/

Red

Open

White/

Black

Red/

Brown

Brown/

Yellow

Green/

Black

Green/

Yellow

White/

Blue

Black

Open

Dash Screen Connectors

Black

Everything Within The

Yellow Background Is

Part Of The EPS

Brown/ Blue

Light Blue

Black

Blue/ Black

Located Inside

Main Harness

Brown

Function

Main Harness

Switch Harness

Light

Blue

Blue/

Green

Blue/

Black

Open

Blue/

Red

Gray

Main Harness

Pink

Black

Red

Main

Harness
Switch

Harness

Red/

Yellow

Blue

Green Yellow Dark

Brown

Gray

Dark

Green

Pink

Green/

Red

Func

tion

ain Harness

Blue/ Black

Black

ain

Harness

Blue/ White

Blue/ Black

Red

Black

Brown/ Blue

ain Harness

Black

NOTE (D)

Located Inside

Main Harness

Located Inside

Main Harness

Eng

ine I

nner

earshif

t S

wit

Par

king S

wit

Star

ter S

olenoid

Nega

tiv

e / Gr

ound

Saf

y B

elt

Saf

y B

elt

12V Outlet

Main

Harness

Horn

Main

Harness

Main

Harness

Star

ter R

ela

Red/ White

Brown/ Blue

Winch

Controller

Plug

Red

Blue

Black

Green

Black

Red

Green

Black

Red

Winch Solenoid

NOTE

(

)

MAIN HARNESS PART NUMBER

34100-115N-0100

Black

Red

White

Red

Green

Pink

Red/ Yellow

Main Harness

EPS Controller Harness

Brown

Black

Motor Harness

Controller Harness

Green
White
Black
Red

Light Blue
Blue/ Red

(D)

White

Green/ Black

Everything Within The

Purple Background Is

Part Of The Winch

Summary of Contents for Challenger 500

Page 1: ...SERVICE MANUAL Challenger 500 Challenger 700...

Page 2: ...ce data Please read the handbook through and fully understand it otherwise any improper repairing could cause problems and or an accident may occur Proper use and maintenance will reduce malfunctions...

Page 3: ...roubleshooting Wiring Diagram Chapter 6 Electrical Chapter 7 Engine Management System Chapter 4 Engine Chapter 5 Chassis Chapter 2 Specifications Chapter 3 Periodic Maintenance and Adjustments I ndex...

Page 4: ...8 1 9 1 10 1 11 1 11 1 11 1 12 1 13 1 14 1 15 1 15 1 16 1 17 1 17 1 18 1 19 1 20 1 20 1 21 1 22 1 23 1 24 Electrical System Fundamentals Voltage Resistance Amperage Basic Service Methods Removing Fro...

Page 5: ...ction 4 7 Chapter 5 Installation 4 8 Valves and Valve springs 4 9 Inspection 5 1 Inspection 4 10 Steering System 5 4 Installation 4 11 Steering Wheel Assembly 5 5 Cylinder and Piston 4 12 Disassembly...

Page 6: ...5 33 5 34 5 37 5 37 5 38 5 39 5 39 5 40 5 41 5 42 5 45 5 46 5 47 5 49 5 50 5 51 5 52 5 53 5 55 5 56 5 58 5 59 5 60 5 62 5 66 6 1 6 3 6 4 6 6 6 7 6 8 6 9 6 10 6 11 6 12 6 15 Brake Master Cylinder Insp...

Page 7: ...MH Manufacturer UV below 750 cc UV above 750 cc SZ TZ 500cc YZ 700cc 44 DOT Check Digits A 2010 Model Year B 2011 Model year C 2012 Model Year D 2013 Model Year E 2014 Model Year A Manufacturing Plan...

Page 8: ...on the UV for the first time Warnings Cautions and Notes The terms Warning Caution and Note have specific meanings in this manual Warning Emphasizes areas where injury or even death could result from...

Page 9: ...go bed 10 Tail brake lights 11 Rear shock absorber adjusting ring 12 Cargo bed release lever 13 Spark arrester 14 Passenger seat belt 15 Passenger seat 16 Oil filter 17 Engine oil dipstick 18 Battery...

Page 10: ...ion 1 3 Identification Code Vehicle Identification Number Vehicle Identification number is stamped in the lower right side of the frame Engine Number Engine number is printed on a white tag on top of...

Page 11: ...s 8 When replacing fasteners make sure the new fasteners are the same size and strength as the original ones 9 Keep your work area clean and organized 10 Wear eye protection anytime the safety of the...

Page 12: ...until they can be properly disposed of or washed 7 Do not pour water onto a gasoline fire Water spreads the fire and makes it more difficult to put out Use a class B BC or ABC fire extinguisher to ex...

Page 13: ...numbers available when ordering parts Fasteners Proper fastener selection and installation is important to ensure the UV operates as designed and can be serviced efficiently The choice of original equ...

Page 14: ...ertain applications such as the rear axle on an UV or motorcycle the fastener must be secured in this way For these applications a cotter pin and castellated slotted nut is used To use a cotter pin fi...

Page 15: ...ear eye protection when removing and installing snap rings E clips are used when it is not practical to use a snap ring Remove E clips with a flat blade screwdriver by prying between the shaft and E c...

Page 16: ...he first number which indicates the low temperature viscosity Engine oils are most commonly mineral petroleum based but synthetic and semi synthetic types are used more frequently When selecting engin...

Page 17: ...luble Local ordinances may restrict types of cleaning chemicals Refer to Safety in this chapter Use brake parts cleaner for brake system components Brake parts cleaner leaves no residue Electrical con...

Page 18: ...to use Quality tools are a good investment Some of the procedures in this manual specify special tools In many cases the tools is illustrated in use Those with a large tool kit may be able to perform...

Page 19: ...sening or tightening the screw clean the screw recess to prevent engine oil contamination Wrenches Open end box end and combination wrenches Figure 5 are available in a variety of types and sizes The...

Page 20: ...e socket Sockets combined with any number of drivers make them the most convenient tool for fastener removal and installation Impact Drivers An impact driver provides extra force for removing fastener...

Page 21: ...ket Wrenches Ratchets and Handles Sockets that attach to a ratchet handle Figure 7 are available with 6 point or 12 point openings Figure 8 and different drive sizes The drive size indicates the size...

Page 22: ...beam the dial indicator and the audible click Figure 12 A torque wrench is a precision tool that must be properly cared for to remain accurate Store torque wrenches in their case or separate padded d...

Page 23: ...ng from holding two parts together to gripping the end of a broken stud Use caution when using locking pliers as the sharp jaws will damage the objects they hold Snap Ring Pliers Snap ring pliers are...

Page 24: ...ion Measuring 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 con...

Page 25: ...onvenient reading Vernier calipers have marked scales that must be compared to determine the measurement The digital caliper uses a liquid crystal display LCD to show the measurement Properly maintain...

Page 26: ...a part that it can measure The usual sizes Figure 23 are 0 25mm 0 1 in 25 50 mm 1 2 in 50 75 mm 2 3 in and 75 100mm 3 4 in Micrometers that cover a wider range of measurements are available These use...

Page 27: ...s do not align the micrometer is out of adjustment Follow the manufacturer s instructions to adjust the micrometer Care Micrometers are precision instruments They must be used and maintained with grea...

Page 28: ...ith the sleeve line Each thimble mark equals 0 01mm Add the readings from steps 1 3 Standard Inch Micrometer The standard inch micrometer Figure 26 is accurate to one thousandth of an inch or 0 001 Th...

Page 29: ...ost and carefully insert the gauge into the bore Carefully move the gauge in the bore to make sure it is centered Tighten the knurled end of the gauge to hold the movable post in position Remove the g...

Page 30: ...ure 33 measures combustion chamber cylinder pressure usually in PSI or kg 2 cm The gauge adapter is either A cylinder bore gauge is similar to a dial indicator The gauge set shown in Figure 32 consist...

Page 31: ...edle must align with the 0 mark to obtain accurate measurements 4 If necessary rotate the meter ohms adjust knob until the needle and 0 mark align Electrical System Fundamentals A thorough study of th...

Page 32: ...he amount of current within a circuit Current is the actual flow of electricity The higher the current the more work can be performed up to a given point If the current flow exceeds the circuit it wil...

Page 33: ...mbly 12 Some operations require using a hydraulic press If a press is not available have these operations performed by a shop equipped with the necessary equipment Do not use makeshift equipment that...

Page 34: ...ply penetrating fluid as described the insert a screwdriver in the slot and tap the top of the screwdriver with a hammer This loosens the rust so the screw can be removed in the normal way If the scre...

Page 35: ...the fitting of any corrosion or rubber hose material with a wire brush Clean the inside of the hose thoroughly Do not use any lubricant when installing the hose Lubricant may allow the hose to come of...

Page 36: ...trike the hammer directly against the shaft Instead use a brass or aluminum rod between the hammer and shaft Figure 41 and make sure to support both bearing races with wooden blocks as shown 3 The ide...

Page 37: ...ce Figure 44 3 When installing a bearing use a piece of pipe or a driver with a diameter that matches the bearing inner race Figure 45 shows the correct way to use a driver and hammer to install a bea...

Page 38: ...on Do not heat the housing with a propane or acetylene torch Never bring a flame into contact with the bearing or housing The direct heat will destroy the case will cause hardening of the bearing and...

Page 39: ...rely into the housing until it is to the correct depth or flush as noted during removal Never install a seal by hitting against the seal with a hammer Storage Several months of non use can cause a gen...

Page 40: ...in the coolant in the coolant reserve tank and all tank lines 6 Cover the exhaust and intake opening 7 Apply a protective substance to the plastic and rubber components Make sure to follow the manufac...

Page 41: ...ype or Grade Engine Oil API Service SG or higher Final Gear oil SAE 80 API GL 4 Hypoid Gear oil or 80W90 Gear oil Differential Gear oil SAE 80 API GL 5 Hypoid Gear oil or 80W90 Gear oil Type Liquid Co...

Page 42: ...Transmission L H N R Chassis Frame Type Steel Tube Frame Toe In 0 10mm 0 0 39 in Tires Front Tubeless 25X8 12 Radial Rear Tubeless 25X10 12 Radial Tire Air Pressure Max 10 psi Cold Brakes Front Dual...

Page 43: ...Krypton Bulb 12V10w Neutral Reverse LED Coolant Temp LED Parking Brake LED Four Wheel Drive Light LED Differential gear lock LED 700 UV Engine Specifications Item Metric Standard Service wear Limit C...

Page 44: ...01 mm 1 1815 in B 36 50 36 60 mm 1 4370 1 4409 in 36 40 mm 1 4331 in Camshaft Runout limit 03 mm 0 0012 in Cam Chain Number of links Adjustment Method 126 Automatic Rocker arm Inside diameter 12 000 1...

Page 45: ...453 in 0 2341 in Stem Outside Diameter IN EX 5 975 5 990 mm 0 2352 0 2358 in 5 930 mm 5 960 5 975 mm 0 2346 0 2352 in 0 2335 in Guide Inside Diameter 6 000 6 012 mm 0 2362 0 2367 in 6 050 MM IN EX 6 0...

Page 46: ...gth Valve Closed IN EX Compressed pressure Installed IN EX Tilt limit IN EX Direction of winding 32 63 mm 1 28 in 31 0 mm 1 22in 36 46 mm 1 44 in 34 6 mm 1 36 in 27 5 mm 1 08 in 31 0 mm 1 22 in 100 0...

Page 47: ...ton off set 1 0 mm 0 0394 in Off set direction Intake side Piston pin bore inside diameter 22 004 22 015 mm 0 8663 0 8667 in 22 045 mm 0 8679 in Piston pin outside diameter 21 991 22 000 mm 0 8658 0 8...

Page 48: ...0 03 0 07 mm 0 0012 0 0028 in 0 13 mm 0 0051 in Oil ring Dimensions B T 2 5 3 4 mm 0 0984 0 1339 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Side clearance 0 06 0 15 mm 0 0024 0 0059 in Cranks...

Page 49: ...ool Engine type Cylinder arrangement Forward inclined single cylinder Displacement 471cm3 Borexstroke 84 5X84 0mm 3 33X3 31in Compression ratio 9 4 1 Startingsystem E l ectri c starter Lubri cation sy...

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 54: ...mm 0 06 mm 0 0024 in 0 0024 in Shifter Shifter type Shift drum and guide bar Air filter oil grade Engine Oil Fuel Delivery Electronic Fuel Injection Oil pump Oil Filter Type Oil Pump Type Tip clearanc...

Page 55: ...ll routes Coolant reservoir capacity From low to full level 380 mm 14 96 in 238 mm 9 37 in 24 mm 0 94 in 107 9 137 3 Kpa 15 35 19 53 psi 2 5 L 2 64 US qt 0 35 L 0 37 US qt 0 20 L 0 21 US qt Steering s...

Page 56: ...m 0 08 in 0 08 in Brake lever and brake pedal Accelerator pedal free play Brake pedal free play Parking brake cable free play 0 mm 0 mm 2 3 mm 0 0 in 0 0 in 0 079 0 118 in Front disc brake Dual Ventil...

Page 57: ...draulic Disc 1 5 mm 1 5 mm 0 06 in 0 06 in Type Disc outside diameter X thickness 165 5 0 mm 6 50 0 20 in Pad thickness inner Pad thickness outer 5 6 mm 5 6mm 0 22 in 0 22 in Master cylinder inside di...

Page 58: ...lt 7 mm 2 20 14 Rocker arm shaft stopper Bolt 6 mm 2 10 7 2 Valve adjusting locknut 6 mm 5 14 10 Engine oil drain bolt 14 mm 1 30 22 Oil filter cartridge union bolt 20 mm 1 63 4 6 Oil filter cartridge...

Page 59: ...m 2 10 7 2 A C magneto cover Bolt 6 mm 12 10 7 2 Starter clutch Bolt 8 mm 3 30 22 Clutch carrier assembly Nut 22 mm 1 160 115 stake Clutch housing assembly Bolt 6 mm 9 10 7 2 Bearing Retainer middle d...

Page 60: ...t reservoir Bolt 6 mm 2 7 5 1 Radiator bracket and frame Bolt 6 mm 4 7 5 1 Fuel pump Bolt 6 mm 2 7 5 1 Fuel tank Bolt 8 mm 2 30 22 Muffler stay Bolt 6 mm 2 11 8 Muffler and exhaust pipe Bolt 8 mm 1 20...

Page 61: ...0 7 2 Universal joint yoke and drive pinion gear 14 mm 62 45 Differential motor and differential gear case cover 8 mm 13 9 4 Differential gear case cover and differential gear case 8 mm 25 18 Rear dri...

Page 62: ...ub 8 mm 30 22 Front brake caliper bleed screw 6 mm 6 4 3 Rear wheel and rear wheel hub 10 mm 55 40 Rear wheel hub and constant velocity joint of half shaft 20 mm 260 190 Rear brake hose and frame 6 mm...

Page 63: ...a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a...

Page 64: ...ase Joint 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...

Page 65: ...n Replace if necessary Every 20 40 hours More often if in dusty or wet environments Axle Boots Check Operation Replace if Damaged X X X X X Crankcase Breather System Check Breather Hose for Cracks or...

Page 66: ...just if Necessary X X X Cooling System Check for coolant leaks Repair if Necessary Replace coolant every 24 months X X X X X Accelerator Pedal Check Operation and Free Play X X X X X Drive Shaft U Joi...

Page 67: ...the fluid level and add brake fluid as needed Replace oil seals inside master cylinder and calipers every 2 years Replace Brake Hoses every 4 years or if cracked or damaged Maintenance and Adjustments...

Page 68: ...rclockwise until the timing mark for TDC is aligned in the window 2 Remove the cooling fan 1 Fan cover 2 Fan impeller 3 Timing plug cover Note When aligning the timing mark for TDC there should be cle...

Page 69: ...the adjuster steady lock down the locknut 4 Note The adjuster cannot move or your adjustment will not be correct 5 It is always a good idea to rotate the crankshaft 2 full revolutions and recheck your...

Page 70: ...a loss of performance 1 Start the engine and let it warm up for several minutes 2 Stop the engine and remove the spark plug 3 Assemble the compression pressure tester and adapter and screw it into the...

Page 71: ...cargo bed Checking the engine oil level 1 Place the vehicle on a level surface 2 Remove the driver s seat passenger s seat center console and heat shield 3 Unscrew the dipstick and check the oil leve...

Page 72: ...m the crankcase 6 It is always recommended to change the oil filter when doing an oil change Remove the oil filter With an oil filter wrench Lubricate the O ring of the new oil filter with a thin coat...

Page 73: ...engine oil passages the oil filter and the oil pump for damage or leakage Start the engine after solving the problem s and check the engine oil pressure again Tighten the oil galley bolt to specificat...

Page 74: ...damp but not soaked or dripping Install Air filter element Air filter case cover Console Passenger s seat Driver s seat Note Never operate the engine with the air filter element removed This will all...

Page 75: ...p 1 2 Disconnect coolant reservoir hose 2 3 Drain coolant from the reservoir 4 Reconnect coolant reservoir hose 5 Remove the coolant drain bolt 1 along with the copper washer 6 Remove the radiator cap...

Page 76: ...or cap 16 Fill the coolant reservoir with the recommended coolant to the max level mark a Note Adding water instead of coolant lowers the antifreeze content of the coolant 17 Install coolant reservoir...

Page 77: ...Passenger s seat Console Drive belt cover 2 Check the V belt for cracks wear scaling or chipping Replace if necessary 3 Check for oil or grease inside V belt housing If found see cleaning instructions...

Page 78: ...facing the direction shown in figure 3 Remove the bolts used to widen the gap on the secondary sheaves 4 Install the following Drive belt cover Console Passenger s seat Driver s seat Cleaning the Spa...

Page 79: ...cylinder Tighten the locknut to correct torque 3 Make sure there is no drag on the front or rear wheels when trying to move the UV Adjusting the Parking Brake 1 Shift the drive select lever into Low...

Page 80: ...hen the brake pads wear indicator grooves a have almost disappeared replace the brake pads as a set 5 Install the console passenger s seat and driver s seat Checking the Brake fluid Level 1 Place the...

Page 81: ...n very low The brake operation has been faulty 1 Locate the brake fluid reservoir 2 Add the proper brake fluid to the reservoir 3 Install the diaphragm Be careful not to spill any fluid or allow the r...

Page 82: ...ing to prevent damage to the transmission 1 Adjustment of the shift lever rod Make sure the select lever is in the neutral position Loosen both locknuts 1 Adjust the rod Tighten the locknuts Adjusting...

Page 83: ...all the filler plug 23 Nm 2 3 m kg 17 ft lb Changing the Final Gear Oil 1 Place the vehicle on a level surface 2 Place a container under the final gear case to collect the drained oil 1 Install the dr...

Page 84: ...rement to find toe in measurement Adjust by the following Mark both tie rods ends This reference point will be needed during adjustment Loosen the locknut tie rod end 1 on each tie rod The same number...

Page 85: ...ystem Check the steering wheel for excessive play up or down and side to side Check the tie rod ends Inspect for vertical play if any then replace the tie rod end in question Replacement is found in C...

Page 86: ...eplace with manufacturer recommended tire combinations Tire wear limit a Front and rear 3 0 mm 0 12 in 2 Check tire air pressure Minimum tire pressure 9 psi Maximum tire pressure 22 psi Note These are...

Page 87: ...der cover Close the hood Changing the Tail Brake Light Bulb Remove Cargo bed panel 1 Install New bulb into the tail brake light bulb holder Tail brake light bulb holder with bulb Cargo bed panel Tail...

Page 88: ...ning order should always start with the smallest diameter bolt working up to the largest diameter bolt in a cross pattern from outside to inside 6 Bolt and nut tightening order should always start wit...

Page 89: ...ke assembly Fig 1 Drain Plug Fig 2 Qty Remarks Remove the parts in the order 1 listed For installation reverse the order listed After removal of the intake system cover the opening so that no foreign...

Page 90: ...per washer 3 Oil Line 3 4 Oil Line 2 5 Spark plug 6 Tappet Cover Intake 7 Tappet Cover Exhaust 8 Timing Chain Tensioner Cap Bolt 9 Timing Chain Tensioner Gasket 10 Timing Chain Guide Exhaust Side 11 T...

Page 91: ...ing or scratching the spark plug threads or valve seats Look for cracks or damage Look at the cylinder head water jackets clean out any mineral deposits or rust 3 Inspect the Tappet covers Tappet cove...

Page 92: ...the illustration in 2 stages Timing chain guide exhaust side Timing chain tensioner Lightly press the timing chain tensioner rod into the housing by hand While pressing wind it clockwise with a thin s...

Page 93: ...2 Rocker arm shaft stopper 2 3 Rocker arm shaft 2 1 4 Rocker arm 3 1 5 Rocker arm shaft 3 O ring 1 1 6 Rocker arm 4 1 7 Rocker arm shaft 1 O ring 1 1 8 Rocker arm 1 1 9 Rocker arm 2 1 10 Wave washer...

Page 94: ...t 11 96mm Subtract the rocker arm shaft outer diameter from the rocker arm inside diameter to determine the clearance Clearance limit 0 05mm Inspect the Camshaft Cam Lobes look for discoloration scrat...

Page 95: ...ad Center Caution Do not turn the crankshaft during the camshaft installation Temporarily install the camshaft sprocket on the camshaft Do not install the bolts Install the timing chain on the sprocke...

Page 96: ...Valves and Valve springs 1 Valve keeper 2 Valve spring collar 3 Intake valve spring 4 Exhaust valve spring 5 Intake valve 6 Exhaust valve 7 Valve stem seal 8 Valve spring seat Remove the parts in the...

Page 97: ...0 12mm Exhaust 0 14mm Measure the margin thickness Both Intake and Exhaust 0 85 1 15 mm Measure valve stem runout Runout Limit 0 01 mm Whenever a valve is removed always replace the valve guide seal I...

Page 98: ...the face of the valve Turn the valve until the valve face and the valve seat are evenly polished Clean off all of the lapping compound and install a new valve guide seal Install valve spring seats val...

Page 99: ...inder and piston Water Pump outlet Hose Cylinder Head 1 Coolant inlet joint 2 Cylinder O ring 3 Cylinder gasket 4 Dowel pin 5 Wrist pin clip 6 Wrist pin 7 Piston 8 Piston ring set 1 1 1 1 2 2 1 1 1 Re...

Page 100: ...der and measure with a feeler gauge Top ring 2nd ring limit 0 5mm 3 Measure piston outer diameter at 10 mm above the skirt Piston to cylinder clearance limit 0 15mm 4 Measure piston ring side clearanc...

Page 101: ...piston pin 2 through piston wall rod piston wall Install piston pin clips 3 3 Cylinder O ring 10mm bolts 42Nm or 31 ft lbs 6mm bolts 10Nm or 7 ft lbs Install the cylinder with one hand while compress...

Page 102: ...g fan air duct assembly 1 2 Air shroud 1 1 3 Engine cooling fan 1 4 Air shroud 2 1 5 A C Magneto coupler 2 6 Engine cooling fan pulley base 1 7 A C Magneto cover gasket 1 1 8 Dowel pin 2 9 Stator lead...

Page 103: ...on Install the starter wheel gear onto the starter clutch and hold the starter clutch Note Install the starter wheel gear with the groove a facing the A C Magneto rotor Turn the starter wheel gear cou...

Page 104: ...C Magneto cover use a long rod to hold the A C Magneto rotor in position from the outside This will make assembly easier Be careful not to damage the oil seal Apply Note Install the air shroud 1 10 Nm...

Page 105: ...pump gears 1 Nut Lock washer 2 Balancer driven oil pump drive gear 3 Chain 4 Straight key 5 Oil pump driven gear 6 Plate 7 Balancer drive gear 8 Spring 9 Pin 10 Timing chain guide intake side 11 Timin...

Page 106: ...r if it is necessary to replace either one replace them both as a set Note Balancer driven gear Timing chain Timing chain guides Look for cracks and stiffness in the links If necessary replace the tim...

Page 107: ...aves Engine assembly 1 Drive Belt cover 2 Rubber gasket 3 Bearing Housing 4 Dowel pin 5 Primary sheave assembly 6 V belt 7 Primary fixed sheave 8 Secondary sheave assembly 9 Drive belt case 10 Rubber...

Page 108: ...Primary Sheave 1 Primary pulley sheave cap 2 Primary pulley slider 3 Spacer 4 Primary pulley cam 5 Primary pulley weight 6 Collar 7 Oil seal 8 Primary sliding sheave 9 O ring Remove the parts in the o...

Page 109: ...he Secondary Sheave 1 Nut 2 Spring seat 3 Compression spring 4 Spring seat 5 Guide pin 6 Secondary sliding sheave 7 O ring 8 Secondary fixed sheave 9 Oil seal 10 Oil seal Remove the parts in the order...

Page 110: ...k for cracks or damage Primary sliding sheave Primary fixed sheave Look for cracks or damage 2 Inspect the Secondary sheave Secondary fixed sheave Secondary sliding sheave Look for smooth operation sc...

Page 111: ...ing sheave Spacer Sliders 1 Primary pulley cam 2 Primary sliding sheave cap 3 Nm or 25 in lbs 3 Assembling the secondary Sheave Apply assembly lube to The secondary sliding sheave 1 inner surface and...

Page 112: ...ents Chapter 3 will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Install the V belt with the arrow facing the direction in the illust...

Page 113: ...Removing the clutch Primary and secondary sheaves 1 Clutch housing assembly 2 Gasket dowel pin 3 One way clutch bearing 4 Nut 5 Clutch carrier assembly 1 1 2 1 1 1 Remove the parts in the order liste...

Page 114: ...emarks Disassembling the clutch housing 1 Oil seal 2 Circlip 3 Bearing housing 4 Circlip 5 Bearing 6 Circlip 7 Bearing 8 Clutch housing Remove the parts in the order listed 1 1 1 1 1 1 1 For installat...

Page 115: ...e way clutch bearing Install the one way clutch bearing and clutch carrier assembly to the clutch housing and hold the clutch carrier assembly When turning the clutch housing clockwise A the clutch ho...

Page 116: ...Dowel pins Gasket Clutch housing assembly 10 Nm or 7 ft lbs Tighten the bolts in stages using a cross pattern After tightening check the operation of the clutch housing assembly that it rotates counte...

Page 117: ...C magneto rotor Primary and secondary sheaves Clutch carrier assembly 1 Starter Motor O ring 2 Oil Filter O ring 3 Oil Line assembly O ring 4 Oil Line adapter O ring 5 Relief valve assembly 6 Speed se...

Page 118: ...case Remove the parts in the order listed 1 Shift lever cover gasket 2 Dowel pin 3 Shift lever 1 4 Shift lever 2 assembly 5 Right crankcase half 6 Dowel pin 7 Left crankcase half 8 Spacer 9 Crankshaft...

Page 119: ...Remarks Removing the crankcase bearings Crankshaft and oil pump Transmission Middle drive driven shaft 1 O ring collar 2 Oil seal 3 Bearing retainer 4 Bearing 1 1 1 1 9 Remove the parts in the order l...

Page 120: ...all 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 gask...

Page 121: ...t Crankcase Right Crankcase Installing the shift levers Shift lever 2 assembly 1 14 Nm or 10 ft lbs Shift lever 1 2 Note When installing the shift lever 1 align the punch mark a on the shift lever 1 w...

Page 122: ...s Removing the Crankshaft and Oil Pump Remove the parts in the order listed 1 Crankcase separation 2 Oil Strainer O ring 3 Oil pump assembly gasket 4 Balancer 5 Plate 6 Relief valve assembly Crankshaf...

Page 123: ...Part Name Qty Remarks Disassembling the Oil Pump 1 Rotor cover 2 Pin 3 Shaft 4 Pin 5 Inner rotor 6 Outer rotor 7 Oil Pump housing Remove the parts in the order listed 1 2 1 1 1 1 For installation rev...

Page 124: ...ween the outer rotor 2 and the pump housing 3 Body clearance c between the outer rotor 2 and the pump housing 3 Tip clearance Limit 0 23 mm Side clearance Limit 0 17 mm Body clearance Limit 0 24 mm Me...

Page 125: ...hould be replaced whenever removed from the crankshaft Install Assemble the oil pump Inner rotor outer rotor and oil pump shaft with the recommended lubricant Install the crankshaft and balancer Note...

Page 126: ...the order listed Crankcase separation Middle driven gear 1 Low wheel gear 2 Shift drum 3 Shift fork assembly 4 Short spring 5 Shift fork 1 6 Long spring 7 Shift fork 2 8 Guide bar 9 Secondary shaft 1...

Page 127: ...bly No Part Name Qty Remarks Disassembling the Drive Axle 1 Clutch dog 2 High wheel gear 3 Middle drive gear 4 Driven sprocket 5 Drive axle Remove the parts in the order listed 1 1 1 1 For installatio...

Page 128: ...movement on the guide bar Look for smooth movement If replacement is necessary replace as a set Springs Look for cracks or damage Shift drum Inspect the grooves Look for scratches wear or damage High...

Page 129: ...the shaft runout Use a truing stand and a dial gauge Shaft runout limit 0 06 mm Install Assembling the shift fork Guide bar 1 Shift fork 2 Long Spring 3 Shift fork 4 Short Spring 5 Installing the tra...

Page 130: ...s Removing the Middle Drive Shaft Crankcase separation 1 Bearing housing 2 Middle drive gear 3 Nut 4 Middle drive pinion gear 5 Shim 6 Middle drive shaft 7 Bearing retainer Remove the parts in the ord...

Page 131: ...the order listed Crankcase separation 1 Drive shaft coupling 2 Circlip 3 Bearing 4 Universal joint 5 Universal joint yoke 6 Bearing housing O ring 7 Shim 8 Middle driven pinion gear 9 Bearing retainer...

Page 132: ...0 3 mm Measure gear lash Temporarily install the left crankcase half Wrap a rag around a screwdriver and insert it into the right crankcase speed sensor hole to hold the middle driven gear Attach a d...

Page 133: ...yoke nut 150 Nm or 110 ft lbs Universal joint Install the opposite yoke onto the universal joint Apply wheel bearing grease to the bearings Install the bearing 1 onto the yoke Caution Check each bear...

Page 134: ...t 1 Note Use the coupling gear middle shaft tool 2 to hold the drive shaft coupling Nut Torque 97 Nm or 71 ft lbs Install the middle drive shaft Tighten the middle pinion gear nut 1 to 145 Nm or 107 f...

Page 135: ...on the Mechanical Compression Release gear to be parallel to the sealing sur face of the cylinder head Figure A If the MCR bump is not visible as in Figure B the timing is 180 degrees off The MCR bump...

Page 136: ...ake calipers and brake levers for damage corrosion or deformity 2 Loss of Brake performance Check for brake rotor wear Has it exceeded the wear limit Check for brake pad wear Is the master cylinder lo...

Page 137: ...driving Check for damage to the steering knuckle bearing Check if the king pin ball joint is damaged Check if the front wheel axle nut is loose or damaged Check the front wheel splines for damage or w...

Page 138: ...ntial for wear or damage Check the gears of the rear gearbox for wear or damage Check the universal joint rubber boot for damage Check the universal joint for damage or wear 12 Failure to shift into f...

Page 139: ...embly 1 2 Pinion 1 3 Circlip 1 4 Bearing 1 5 Adjuster 1 6 Spring 1 7 Pressure pad 1 8 Circlip 1 9 Oil seal 1 10 Zip tie L 200 2 11 Dust Boots 2 12 Flange bolt 10mm X 30mm 4 13 Tie rod end 2 14 Locknut...

Page 140: ...Steering Wheel assembly No Part Name Qty Remarks Removing the Steering Wheel Assembly 1 Flange bolt 8mm X 16mm 4 2 Steering shaft 1 3 Steering wheel 1 4 Washer 1 5 Flange nut 12mm X 1 25 1 6 Plastic c...

Page 141: ...is a safety area and any damage or wear needs to be repaired immediately Warning This is a safety area and any damage or wear needs to be repaired immediately Do not let vehicle leave without proper...

Page 142: ...aft assembly 1 Checking and servicing the Universal joints on the steering shaft Bearing 1 Circlip 2 Oil seal 3 Cross axis 4 Inspect for smooth operation Replace any parts with wear or damage 2 Inspec...

Page 143: ...g wheel nut torque 48 Nm 4 8m kg 35 ft lb The Brake System The brake system is crucial to the life of the operator and passengers and therefore must be periodically inspected and maintained This vehic...

Page 144: ...brake disc 1 for thickness 2 Brake discs wear as well as brake pads therefore a periodic inspection may reveal scoring or wear to a disc Replacement is necessary if this is found 5 Check the brake li...

Page 145: ...Qty Remarks Removing the Front Brake Line Attachment Hardware 1 Belt 3 L 150 2 2 Belt 4 L 200 4 3 Belt 6 L 150 4 4 Bolt 6mm X 30mm 1 5 Bolt 6mm X 20mm 1 6 Disc brake line clip 3 7 Flange bolt 6mm X 20...

Page 146: ...Chassis 5 11 Front Disc Brakes No 1 2 3 4 5 6 Part Name Removing the Brake Discs Brake caliper assembly Brake disc Bolt Axle housing Bolt Brake disc guard Qty Remarks 1 1 4 4 4 1...

Page 147: ...Inspect for galling or damage Measure brake disc deflection in 4 spots approximately 90 degrees from each other Brake disc maximum deflection 0 10 mm 0 004 in Brake disc thickness 1 Wheel hub 2 Rim 3...

Page 148: ...Pads No Part Name Qty Remarks Removing the Front Brake Pads 1 Brake caliper mounting bolt 2 Brake pad holding bolt 3 Brake pad 4 Pad spring Remove parts in the order listed 2 2 2 For installation rev...

Page 149: ...ck into the caliper Watch the brake fluid level in the reservoir so you don t overflow the reservoir After the pads have been installed be sure to fill the reservoir with the proper brake fluid so tha...

Page 150: ...ving the Front Brake Caliper Brake fluid Union bolt Copper washer Brake hose Brake pad holding bolt Qty Remarks Remove the parts in the order listed 1 2 1 2 5 Brake caliper mounting bolt 6 Brake calip...

Page 151: ...embling the Front Brake Caliper Qty Remarks Remove the parts in the order listed 1 Brake pad holding bolt 2 Brake pad 3 Pad spring 4 Brake caliper piston 5 Dust seal 6 Caliper piston seal 7 Bleed scre...

Page 152: ...dure injury can occur when the piston is expelled from the caliper 2 Remove the dust seals 1 and caliper piston seals 2 All internal brake components should be cleaned with new brake fluid only Do not...

Page 153: ...s 2 Union bolt 3 Note When installing the brake hose be sure that the brake fitting touches the stop a on the brake caliper 2 Fill the brake fluid reservoir Must use DOT 3 Brake Fluid 3 Bleed the air...

Page 154: ...9 Rear Brake Disc No Part Name Qty Remarks Removing the Rear Brake Disc Brake caliper assembly Final drive gear 1 Rear brake disc 1 Remove the parts in the order listed For installation reverse the or...

Page 155: ...ear Brake Disc 1 Inspect the disc Look for galling or damage 2 Measure the rear brake disc deflection Brake disc maximum deflection 0 10 mm 0 004 in 3 Measure the brake disc thickness a Brake disc min...

Page 156: ...te Brake fluid Parking Brake switch coupler Spring Parking brake cable Parking brake lever assembly mounting bolt Parking brake lever assembly Union bolt Copper washer Brake hose Brake caliper mountin...

Page 157: ...Brake caliper bracket 1 17 Parking brake arm nut 1 18 Parking brake arm 1 19 Set bolt 1 20 Parking brake arm shaft 1 21 Parking brake case bolt 2 22 Parking brake case 1 23 Gasket 1 24 Brake caliper...

Page 158: ...ke caliper piston counterclockwise to remove it Warning All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 2 Insp...

Page 159: ...unterclockwise completely so that the punch mark a on the parking Align an end b of the groove in the brake piston with the punch mark c on the caliper body 3 Install the gasket 1 the parking brake ca...

Page 160: ...7 m kg 12 ft lb Installing the Rear Brake Caliper 1 Install the brake caliper with the mounting bolts 40Nm 4 0m kg 29 ft lb Brake hose 1 Copper washers Union bolt 2 48Nm 4 8m kg 35 ft lb 2 Tighten the...

Page 161: ...emarks Remove the parts in the order listed Drain 1 Brake fluid reservoir cap 2 Brake fluid reservoir diaphragm brake 3 Fluid reservoir float 4 Union bolt 5 Copper washer 6 Brake hose 7 Brake line 8 B...

Page 162: ...fluid reservoir diaphragm 2 Look for cracks or damage Installing the Brake Master Cylinder 1 Install the brake master cylinder 16Nm 1 6 m kg 11 ft lb 2 Install the brake line 19Nm 1 9 m kg 13 ft lb 3...

Page 163: ...paper 1 5 Sheathing film 1 6 Self locking flange nut 6mm 2 7 Clip 6mm 9 8 Right footrest cover 1 9 Dust guard plate 1 10 Screw 6mm X 16mm 11 11 Brake pedal mount 1 12 Flange bolt 8mm x 16mm 2 13 Accel...

Page 164: ...ver assembly 1 22 Micro switch 1 23 Screw 4mm X 12mm 1 24 Parking brake dust cover 1 25 Parking brake cable 1 26 Flange bolt 6mm X 16mm 1 27 Cable clip 2 28 Choke cable 1 29 Anchor 4 30 Brake pedal mu...

Page 165: ...Chassis 5 30 Front Wheel and Tire No Part Name Qty Removing the Front Wheel 1 Rim 2 2 Tire 2 3 Valve cap 2 4 Nut 8 5 Center cap 2 6 Axle nut 2 7 Front wheel hub 2...

Page 166: ...Chassis 5 31 Rear wheel No Part Name Qty Removing the rear wheel 1 Rear wheel 2 2 Center cap 2 3 Axle nut 2 4 Rear wheel hub 2...

Page 167: ...0 ft lb Installing the Wheel Assembly 1 Install the wheel with the arrow on the tire pointing toward the front of the UV 2 Install the tapered lug nuts Torque 55 Nm or 40 ft lbs Warning Wheels and tir...

Page 168: ...Chassis 5 33 Transmission System Front Bridge No Part Name Qty 1 Circlip 1 2 CV joint 2 3 Circlip 1 4 Circlip 2 5 Boot band 2 6 Dust boot 2 7 Boot band 2 8 Joint shaft 1 9 Half axle assembly 1...

Page 169: ...al gear case cover 1 4 Drive pinion gear 1 5 Universal joint yoke 1 6 Nut 14mm X 1 25 1 7 O ring 1 8 Oil seal 1 9 Oil seal front box input shaft 2 10 Shim 0 1T 1 Shim 0 2T 1 Shim 0 5T 1 11 Bolt 8mm X...

Page 170: ...ack 1 21 O ring 2 X 81 1 22 O ring 2 4 X 140 4 23 Bearing 6007 1 24 Bearing 6912 1 25 Bearing 16007 1 26 Bearing 152112 1 27 Bolt M14X15X10 1 28 Washer 14 X 2 1 29 Nut 10mm 1 30 Washer 10 2 31 Shaft f...

Page 171: ...Chassis 5 36 No Part Name Qty 37 Clamp 2 38 Intermediate shaft 2 39 Circlip 2 40 Cushion 1 41 Spring 25 X 2 3 X 28 1 42 Dust boot 1 43 Dust boot 1 44 Bolt 10mm X 25mm 1 45 Washer 2 46 Screw 2...

Page 172: ...ansmission 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 be...

Page 173: ...g or damage 3 Inspect the oil seals and O rings Look for damage 4 Inspect the drive shaft splines universal joints and the drive pinion gear splines Look for wear or damage 5 Inspect the spring Look f...

Page 174: ...o the grooves in each bearing Assembly of the Differential Gear 1 Slide the differential gear all the way to the right to put it into the 2 WD mode 2 Connect two C size batteries to the gear motor ter...

Page 175: ...n shafts into the front bridge differential 2 Fill with 0 32L 80w90 gear lube and tighten the filler bolt 23 Nm 2 3m kg 17 ft lb 3 Install the front bridge differential onto the frame 2 Bolts 10mm X 1...

Page 176: ...No Part Name Qty Remarks 1 Circlip 2 2 Boot band 2 3 Boot band 2 4 Dust boot 2 5 Circlip 1 6 Double off set joint assembly 1 7 Circlip 1 8 Circlip 1 9 Double off set joint assembly 1 10 Joint shaft 1...

Page 177: ...ve pinion gear 1 6 Bearing 6305 1 7 Drive shaft coupling 1 8 Oil seal 61 X 35 X 9 1 9 Bearing 65BM6720 1 10 O ring 3 1 X 63 8 1 11 Flat gasket 12 X 4 X 30 1 12 Flange nut 12mm X 1 25 1 13 Pinion gear...

Page 178: ...20 Vent rear speed reducer 1 21 Ring gear bearing housing 1 22 Ring gear stopper 8mm 1 23 Washer 8 5 4 24 Flange nut 8mm 2 25 Oil seal 65 X 90 X 9 2 26 Bearing 16017 1 27 O ring 3 1 X 150 2 28 Washer...

Page 179: ...r bridge 1 36 Circlip 2 37 Cover 1 38 Circlip 1 39 Self locking flange nut 1 40 Dust cover 2 1 41 Dust cover 1 1 42 Oil line 1 43 Oil line clip 1 44 Washer 1 45 Clip 1 46 Clip 1 47 Driven gear 1 48 Bo...

Page 180: ...Lever sheath of gearshift 1 3 Gearshift dust boot 1 4 Gearshift assembly 1 5 Gearshift rod 1 6 Heim joint 1 7 Lever 1 8 Washer 1 9 Bolt 8mm X 12mm 1 10 Bolt 8mm X 16mm 3 11 Plastic bolt 1 12 Clip cla...

Page 181: ...Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjustment Make sure the shift lever is in the neutral position Loos...

Page 182: ...pper ball joint 1 3 Elasticity block ring 1 4 Upper right A arm 1 5 Front upper ball joint 1 6 Block ring shaft 1 7 Front lower left A arm 1 8 Front lower right A arm 1 9 Middle bushing 8 10 Flange bo...

Page 183: ...No 15 16 17 18 19 20 21 Part Name Front shock absorber left and right Locknut 10mm X 1 25 Flange bolt 10mm X 1 25 X 52 Rocker baffle Flange nut 6mm Flange bolt 6mm X 12mm Front upper ball joint Qty 2...

Page 184: ...r damage 2 Inspect the shock absorber body Look for oil leaks 3 Inspect the spring Look for fatigue Installing the front A arms and shock absorbers 1 Install both the upper arm 1 and the lower arm 2 N...

Page 185: ...ber left and right 2 2 Flange bolt 12mm X 1 25 X 70 2 3 Flange bolt 12mm X 1 25 X 65 2 4 Nut 12mm X 1 25 4 5 Stabilizer 1 6 Left idler arm 1 7 Right idler arm 1 8 Locknut 8mm 4 9 Rubber isolator 2 10...

Page 186: ...er A arm assembly 1 2 Rear Lower right A arm assembly 1 3 Rear Lower left A arm assembly 1 4 Bushing 8 5 Flange bolt 10mm X 1 25 X 70 8 6 Locknut 10mm X 1 25 8 7 Rear upper A arm 1 8 Bushing gasket 16...

Page 187: ...Inspect the shock absorber body Look for oil leaks Inspect the spring Look for cracks or fatigue Installing the Rear A Arms and Shock Absorbers 1 Install the rear upper arm 1 and rear lower arm 2 temp...

Page 188: ...e After left rubber hose Right rubber hose Right metal hose Formed right rubber hose Bolt clip Clip Bolt 6mm Radiator assembly Radiator fan assembly Phillips screw 6mm X 25 Quad seal Nut clip 5mm Radi...

Page 189: ...diator 1 19 Radiator cover 3 20 Oil cooler 1 21 Bolt 6mm X 20mm 4 22 Quad seal 4 23 Bolt 6mm X 20mm 2 24 Quad seal 2 25 Bushing 2 26 Grommet 2 27 Radiator fill reservoir 1 28 Oil cooler shield 1 29 Ho...

Page 190: ...the drain plug and top off the radiator with the new coolant 7 Add new coolant to the reservoir to be above the minimum level mark 8 Shut the UV off and allow the unit to cool off 9 After unit has coo...

Page 191: ...p assembly Bolt 6mm X 45mm Bolt 6mm X 65mm Bolt 6mm X 10mm Water pipe 2 O ring 20 7 X 2 6 Water pipe 3 Hose clamp Cylinder inlet water joint Bolt 6mm X 20mm O ring 33 4 X 2 4 Water pipe 1 Clamp Pipe c...

Page 192: ...Chassis 5 57 No Part Name Qty 18 Water pump housing cover 1 19 Gasket 1 20 Circlip 1 21 Impeller assembly 1 22 Water pump seal 1 23 Oil seal 1 24 Bearing 1 25 Water pump housing 1 26 O ring 1...

Page 193: ...rom the water pump housing 3 by tapping them out from the outside of the water pump housing Inspecting the Water pump 1 Inspect the water pump housing cover 1 the water pump housing 2 the impeller 3 t...

Page 194: ...on 2 Install the water pump seal 1 into the housing 2 using a mechanical seal installer 3 and water pump seal installer 4 Do not lubricate this seal with oil or grease Use the special tool 3 Install t...

Page 195: ...4 Flange bolt 8mm X 30mm 8 5 Flange locknut 8mm X 1 25 8 6 Flange bolt 8mm X 30mm 1 7 Seat latch 2 8 Bolt 6mm X 38mm 4 9 Nut 6mm 4 10 Seat latch stud 2 11 Grommet 1 4 12 Grommet 2 4 13 Bushing 10 5 2...

Page 196: ...Seat No Part Name Qty 18 Nut 10mm X 1 25 1 19 Bolt 2 20 Flange locknut 2 21 Cover 2 22 Seat belt latch 2 23 Seat belt 2 24 Nut 2 25 Bolt 10mm X 1 25 X 22mm 2 26 Bolt 10mm X 1 25 X 25mm 2 27 Washer 6...

Page 197: ...e Fuel tank Insulation paper Shock absorber cushion Binder plate Fuel pump cover Rubber tube Fuel outlet plug Clip 10 Clip Three way pipe High pressure pipe Fuel pipe Fuel pump assembly fuel inlet plu...

Page 198: ...r 2 Place a container under the end of the fuel hose 1 3 Turn the ignition switch to the run position Do not start the engine 4 Fuel should start running out the hose 5 Turn the key to the off positio...

Page 199: ...itch 2 2 Radiator fan 3 Gear motor 4 Brake light switch 5 Parking brake switch 6 Pickup coil stator assembly 7 Speed sensor 8 Diode 1 9 Circuit breaker radiator fan motor 10 Thermo switch 1 11 Ignitio...

Page 200: ...rive relay 3 5 Differential gear lock indicator light relay 6 Four wheel drive indicator light relay 7 Fuse box 8 C D I unit 9 Battery 10 Regulator Rectifier 11 Indicator light assembly 1 12 Indicator...

Page 201: ...ives The typical lifespan of a lead acid battery is 1 to 2 years but if maintained with a battery tender they can survive longer Maintenance Free Battery The maintenance free battery is a sealed batte...

Page 202: ...burns and or permanent eye damage First Aid in Case of Bodily Contact Skin Wash thoroughly with water Eyes Flush with water for 15 minutes and seek immediate medical attention When installing a batter...

Page 203: ...tart charging Make sure the setting is at 1 10 the amp hour rating of the battery This is typically 2 amp 12 Volts Charge the battery until the charging amperage drops all the way down usually 1 amp T...

Page 204: ...e open circuit voltage Monitor the amperage for 3 5 minutes Is the standard charging amperage exceeded Adjust the voltage to obtain the standard charging amperage Adjust the charging voltage to 20 25...

Page 205: ...box Inside the centralized relay box on the fire wall After testing and replacement of the fuse turn on the main switch to energize and check the circuit that was affected If the fuse blows immediate...

Page 206: ...tch for continuity Turn the switch on and off a few times when checking it The terminal connections for switches main switch light switch etc are shown in a chart similar to the one on the right This...

Page 207: ...between lead terminals Poor connection no continuity correct or replace The coupler locations are circled 1 Fuse 2 Brake light switch 3 On Command four wheel drive switch and differential gear lock sw...

Page 208: ...lb socket for damage or wear proper connections and also for continuity between the terminals Caution Avoid touching the glass part of the bulb as the oils in your skin transfer to the bulb This cause...

Page 209: ...Electrical 6 11 Ignition System Circuit Diagram 1 High tension coil 2 C D I 3 Magneto...

Page 210: ...lug cap resistance 6 Ignition coil resistance 7 Main switch 8 Pickup coil resistance 9 Rotor pickup coil resistance 10 Wiring connections the entire Ignition circuit No Continuity Continuity Incorrect...

Page 211: ...il Replace the main switch Test the main switch for continuity Out of Specification Both Tests meet specification correct Incorrect Test the A C magneto coupling resistance Connect multimeter as shown...

Page 212: ...Electrical 6 14 Check the wiring of the entire ignition circuit Repair wiring or replace connectors as necessary incorrect Replace the C D I unit...

Page 213: ...Electrical 6 15 Electric Starting System...

Page 214: ...ack terminal 2 Connect the multimeter positive lead to the red terminal 3 Connect the multimeter negative lead to the black terminal 4 Check for continuity 5 Main switch for continuity 6 Gear position...

Page 215: ...Removing the starter motor 1 Remove the parts in the order Starter motor lead listed 2 Starter motor O ring 1 1 Disassembling the starter motor 1 Bracket 1 1 2 Washer kit 1 3 Bracket 2 1 4 Shims 5 Br...

Page 216: ...Electrical 6 18 Charging System...

Page 217: ...ernal short 2nd test in ohms 1 white wire to 2 white wire 2 white wire to 3 white wire 3 white wire to 1 white wire We should have continuity or small numbers 0 32 0 43 ohms Now perform the 2nd test a...

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 222: ...ine speed load and temperature then providing the ignition spark at the right time for the prevailing conditions and metering the fuel to the engine in the exact quantity required Typical Components o...

Page 223: ...conditions The ECU also provides diagnosis when system malfunctions occur Handling This is the electrical brain for the UV Because of this it requires special handling Do not subject this unit to exce...

Page 224: ...fuel injector Do not reuse injector seal rings dip injector tips into lubricants cycle injectors repeatedly without fuel pressure pulse a high leak rate injector allow water into the fuel system cont...

Page 225: ...r wiring harness Relieve fuel pressure Remove the retaining clip from the fuel injector Remove the fuel line connection from the injector Carefully clean debris from the interface surfaces Do not dama...

Page 226: ...tall the retaining clip after connecting the fuel line Tighten the injector mounting to the desired torque as mentioned in the manufacturer manual Tighten the fuel line Re install the injector electri...

Page 227: ...to injector Start and idle the vehicle for an additional 2 minutes to ensure the residual injector cleaner is flushed from system Throttle Body Assembly with stepper motor The Throttle Body Assembly i...

Page 228: ...rticles Throttle Body Installation Reverse the removal procedure for installation noting the following Adjust accelerator cable play Check to ensure that all removed parts are back in place Precaution...

Page 229: ...to the spark plug and keep the plug wire short in length 6 inches or less if possible Mount the coil away from any pickup type devices especially the crank cam sensor and route wiring away from these...

Page 230: ...es No 1 Switch on ignition key Fuel pump primes for 3 seconds when the ignition key is ON Check for fuel pump running noise for 3 seconds after ignition key is ON Do you hear the pump running Go to st...

Page 231: ...everse the removal process Fill with at least 3 liters of fuel Install the fuel filler cap Turn on the ignition key to prime the pump and fuel lines Fuel Leakage Check Procedure After performing any s...

Page 232: ...ke Air Temperature Sensor IAT 0113 IAT circuit high voltage IAT short high Coolant Temperature Sensor 0117 Coolant temp sensor circuit low voltage Coolant short low Coolant Temperature Sensor 0118 Coo...

Page 233: ...system is working correctly Perform this test on the engine when it is both cold and hot if possible If the test results are positive for each test the ignition system is working correctly Caution Af...

Page 234: ...ng to the fuel tank Two wires go to the back of the unit and two wires go to the front of the unit Find the white 2 pin connector that goes towards the throttle body and connect 12v Do you hear the pu...

Page 235: ...coolant hose immediately after or during engine operation Scalding fluid and steam may be blown out under pressure and cause serious injury When the engine has been operated the coolant is very hot an...

Page 236: ...ossibility of more extensive damage Use a mechanic s stethoscope to isolate the location Determining the exact cause of a noise can be difficult If this is the case consult with a professional mechani...

Page 237: ...tic engine compression is in preventing the piston from moving as the combustion chamber starts to pressurize Any piston movement will force the crankshaft to turn away from TDC and allow air to escap...

Page 238: ...shaft movement can throw the tool away from the engine under considerable force attempting to hold the tool can cause serious injury Engine damage may also occur to the crankshaft or right crankcase c...

Page 239: ...component and connector identification Use the wiring diagrams to determine how the circuit should work by tracing the current paths from the power source through the circuit components to ground Als...

Page 240: ...repair the problem or replace the part Check for wires with cracked or broken insulation Heat This is another common problem with connectors or plugs that have loose or poor connections As these conn...

Page 241: ...V The ECU controls all the electrical and motor systems on the UV It sends out voltage to the sensors which use the voltage to measure something In their processing of the measurement they use up some...

Page 242: ...Gray Water Temp Switch Black Wire Colors Listed In Black Font 4 Regular Above Wire Or To The Right Of Wire Wire Function Listed In Red Font 5 Semi Bold Above Wire A The EPS Power Assist Steering Is O...

Page 243: ...ow Black White Black Orange Black Red Blue Gray Green Black Red Blue Yellow Black Green Black Red Black Red Blue Brown Black Light Green Green Black Green Black Purple White Black Black White Blue Gre...

Page 244: ...MTD Products Inc Product Training and Education Department FORM NUMBER 769 10856 05 2015...

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Cub Cadet Challenger 500, Service Manual

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Summary of Contents for Challenger 500

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