Cub Cadet Challenger 550 Service Manual Download Page 58

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2-17

Specifications

Item

Metric

Standard

Service Wear

Limit

Rear disc brake

Type

Dual Ventilated Hydraulic Disc

Disc outside diameter X

thickness

165 ×5.0mm

(6.50 × 0.20in)

Pad thickness inner

Pad thickness outer

5.6mm

(0.22in)

5.6mm

(0.22in)

1.5 mm

(0.06 in)

Master cylinder inside

diameter

17.4mm

(0.69in)

Caliper cylinder inside

diameter

32.0mm

(1.26in)

Brake fluid type

DOT 3

Summary of Contents for Challenger 550

Page 1: ...SERVICE MANUAL Challenger 550 750...

Page 2: ...ata 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 and...

Page 3: ...hapter 1 General Chapter 3 Periodic Maintenance and Adjustments Chapter 5 Chassis Chapter 7 Engine Management System Chapter 6 Electrical Diagram Chapter 8 Troubleshooting INDEX Chapter 2 Specificatio...

Page 4: ...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 Frozen Fasteners Remo...

Page 5: ...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 Inspection 5 6 Inspection 4 13 Installation 5 8 Instal...

Page 6: ...5 33 5 34 5 38 5 38 5 38 5 40 5 40 5 41 5 42 5 44 5 47 5 48 5 49 5 51 5 52 5 53 5 54 5 55 5 57 5 58 5 60 5 61 5 62 5 63 5 65 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: ...H Manufacturer UV below 750cc UV above 750 cc ZZ 550cc WZ 750cc 44 DOT Check Digits H 2017 Model Year J 2018 Model year K 2019 Model Year L 2020 Model Year M 2021 Model Year A Manufacturing Plant A B...

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: ...ver 17 Air filter case engine and air intake duct Rear brake fluid reservoir 18 Head turn signal lamp 19 Water cooler 20 Front turning lights 21 High low beam lights 22 2 4 WD 23 The front axle differ...

Page 10: ...Code 140 Clutch 1 5 Taper 0 150 Clutch 1 7 Taper 1 150 Clutch 1 7 Taper CARB Comp 2 Year Code Year Code Year Code Year Code Year Code 2010 A 2013 D 2016 G 2019 K 2011 B 2014 E 2017 H 2020 L 2012 C 201...

Page 11: ...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 12: ...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 13: ...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 14: ...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 equipment f...

Page 15: ...certain applications such as the rear axle on an UTV 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...

Page 16: ...nd 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 clip To install an E clip center it...

Page 17: ...g conditions Multi grade oils are identified by a W after the first number which indicates the low temperature viscosity Engine oils are most commonly mineral petroleum based but synthetic and semi sy...

Page 18: ...luble Local ordinances may restrict types of cleaning chemicals Refer to Safer in this chapter Use brake parts cleaner for brake system components Brake parts cleaner leaves no residue Electrical cont...

Page 19: ...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 20: ...ening 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 b...

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: ...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 23: ...eam 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 dra...

Page 24: ...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 25: ...ing 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...

Page 26: ...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 the measu...

Page 27: ...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 and75 100mm 3 4 in Micrometers that cover a wider range of measurements are available These use...

Page 28: ...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 29: ...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 30: ...st 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 ga...

Page 31: ...l indicator The gauge set shown in Figure 32 consists of a dial indicator handle and different length adapters anvils to fit the gauge to various bore sizes The bore gauge is used to measure bore size...

Page 32: ...needle 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...

Page 33: ...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 34: ...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 35: ...pply penetrating fluid as described the insert a screwdriver in the slot and rap the top of the screwdriver with a hammer This loosens the rust so the screw can be removed in the normal way If the scr...

Page 36: ...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 off th...

Page 37: ...rike 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 idea...

Page 38: ...earing race Figure44 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 insta...

Page 39: ...n 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 w...

Page 40: ...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 41: ...the coolant reserve tank and all tank lines 5 Cover the exhaust and intake opening 6 Apply a protective substance to the plastic and rubber components Make sure to follow the manufacturer s instructio...

Page 42: ...35cc Bore 102mm 4 015in Stroke 90mm 3 543in Compression Ratio 9 7 1 Single Cylinder 546cc Bore 91mm 3 582in Stroke 84mm 3 307in Compression Ratio 9 5 1 Starting Electric Lubrication Wet Sump Oil Type...

Page 43: ...iable Frame Type Steel Tube Frame Transmission 0 7 1 66 1 Toe In 0 10mm 0 0 39in L H N R P Tires Front Tubeless 25X8 12 Radial Brakes Front Dual Ventilated Hydraulic Disc Rear Dual Ventilated Hydrauli...

Page 44: ...creen digital Coolant Temp LCD screen Code Parking Brake LED Four Wheel Drive Light LCD Differential gear lock LCD screen Symbol display 750 UV Engine Specifications Item Metric Standard Service wear...

Page 45: ...01mm 1 1815in B 36 50 36 60mm 1 4370 1 4409in 36 40mm 1 4331in Camshaft Run out limit 0 03mm 0 0012in Cam Chain Number of links Adjustment Method 130 Automatic Rocker arm Inside diameter 12 000 12 018...

Page 46: ...0453 in 0 2341 in Stem Outside Diameter IN EX 5 975 5 990 mm 0 2352 0 2358 in 5 930mm 5 960 5 975 mm 0 2346 0 2352 in 0 2335 in Guide Inside Diameter IN 6 000 6 012 mm 0 2362 0 2367 in 6 050 MM EX 6...

Page 47: ...Length Valve Closed IN EX Compressed pressure Installed IN EX Tilt limit IN EX Direction of winding 32 63mm 1 28in 31 0mm 1 22in 36 46mm 1 44in 34 6mm 1 36in 27 5mm 1 08in 31 0mm 1 22in 100 0 115 7N...

Page 48: ...ston off set 1 0 mm 0 0394 in Off set direction Intake side Piston pin bore inside diameter 22 002 22 010 mm 0 8662 0 8665 in 22 045 mm 0 8679in Piston pin outside diameter 21 990 21 995 mm 0 8657 0 8...

Page 49: ...ce 0 03 0 07mm 0 0012 0 0028in 0 13 mm 0 0051 in Oil ring Dimensions B T 3 4 2 5mm 0 1339 0 0984in End gap installed 0 20 0 70 mm 0 0079 0 0276in Side clearance 0 06 0 15 mm 0 0024 0 0059in Crankshaft...

Page 50: ...ent Bore x stroke 546cm3 91 x 84 0mm 3 58 X 3 31i in Compression ratio 9 6 1 Starting system Electric starter Lubrication system Wet sump Engine Specifications Item Standard Limit Cylinder head Warp l...

Page 51: ...thod 124 Automatic Valve spring Inner spring Free length Outside spring Within spring Set length valve closed Outside spring Within spring Compressed pressure installed Outside spring Within spring IN...

Page 52: ...m EX 0 0890in 0 9 1 1mm 1 6mm C seat width IN 0 0354 0 0433in 0 9 1 1 mm 0 0630in 1 6mrn EX 0 0354 0 0433in 0 85 1 15mm 0 0630in D margin thickness IN 0 0335 0 0453in 0 85 1 315mm EX 0 0335 0 0453in 5...

Page 53: ...550 UV Engine Specifications 2 12...

Page 54: ...550 UV Engine Specifications 2 13...

Page 55: ...ection limit 0 06 mm 0 0024 in 0 06 mm 0 0024 in Shifter Shifter type Shift drum and guide bar Fuel Delivery Electronic Fuel Injection Oil pump Oil Filter Type Oil Pump Type Tip clearance Side clearan...

Page 56: ...pressure Radiator capacity including all routes Coolant reservoir capacity From low to full level 410mm 315mm 35mm 16 14in 12 40in 1 38in 107 9 137 3Kpa 15 35 19 53psi 2 5L 2 64 US qt 0 35L 0 20L 0 3...

Page 57: ...8 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 Type Dual Ventil...

Page 58: ...ilated Hydraulic Disc Disc outside diameter X thickness 165 5 0mm 6 50 0 20in Pad thickness inner Pad thickness outer 5 6mm 0 22in 5 6mm 0 22in 1 5 mm 1 5 mm 0 06 in 0 06 in Master cylinder inside dia...

Page 59: ...t Bolt 7mm 2 20 14 Rocker arm shaft stopper Bolt 6mm 2 10 7 2 Valve adjusting locknut 6mm 5 14 10 Engine oil drain bolt 14mm 1 30 22 Oil filter cartridge union bolt 20mm 1 63 4 6 Oil filter cartridge...

Page 60: ...tator lead holder Bolt 6mm 2 10 7 2 A C magneto cover Bolt 6mm 12 10 7 2 Starter clutch Bolt 8mm 3 30 22 Clutch carrier assembly Nut 22mm 1 160 115 stake Clutch housing assembly Bolt 6mm 9 10 7 2 Bear...

Page 61: ...olant reservoir Bolt 6mm 2 8 5 9 Radiator bracket and frame Bolt 6mm 4 8 5 9 Fuel pump Bolt 6mm 2 8 5 9 Fuel tank Bolt 8mm 2 22 16 Muffler stay Bolt 6mm 2 11 8 Muffler and exhaust pipe Bolt 8mm 1 20 1...

Page 62: ...60 44 Universal joint yoke and drive pinion gear 14mm 120 88 Differential motor and differential gear case cover 8mm 22 16 Differential gear case cover and differential gear case 8mm 22 16 Rear drivi...

Page 63: ...8mm 22 16 Front brake caliper bleed screw 6mm 8 5 9 Rear wheel and rear wheel hub 10mm 60 44 Rear wheel hub and constant velocity joint of half shaft 20mm 260 190 Rear brake hose and frame 6mm 8 5 9...

Page 64: ...a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warping tighten multi fastener assemblies in a...

Page 65: ...thium base grease 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 lithi...

Page 66: ...an 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 67: ...rrestor Check lug nuts Check battery condition Adjust front wheel toe in Change oil Check fuel line Replace fuel line Clean air filter element Check brake pedal Adjust parking brake Check brake light...

Page 68: ...hours Every 200 hours Every 300 hours Every 500 hours Every 3900 hours Every Year Every 2 years Every 4 years Check Exhaust System Check Wheel Bearings Check Engine Timing Change brake fluid Replace r...

Page 69: ...ly check the fluid level and add brake fluid as needed Replace oil seals inside master cylinder and calipers every 2yrs Replace Brake Hoses every 4y ears or if cracked or damaged Maintenance and Adjus...

Page 70: ...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 71: ...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 72: ...loss of performance 1 Start the engine and let it warm up for several minutes 2 Stop the engine and remove the sparkplug 3 Assemble the compression pressure tester and adapter screw into the spark pl...

Page 73: ...plug and lower the cargo bed Checking the engine oil level 1 Place the vehicle on a level surface 2 Remove the seat bottom and engine access panel 3 Unscrew the dipstick and check the oil level Oil le...

Page 74: ...se 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 of clean eng...

Page 75: ...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 specifica...

Page 76: ...t the filter element will affect carburetor tuning and possible engine damage Checking the Coolant Level Place the vehicle on a level surface Remove the hood cover Note Vehicle should not be warmed up...

Page 77: ...t 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 1 7 Drain the coolant...

Page 78: ...t lbs 14 Fill the radiator 15 Install the radiator 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 con...

Page 79: ...hen fluid begins to come out of the bleeder screw hole replace the bleeder screw 1 The bleeder screw can be accessed via the front right wheel well 3 Start the utility vehicle and let it idle 4 Remove...

Page 80: ...3 15 Periodic Maintenance Maintenance and Adjustment of the UV Checking the coolant temperature warning light Coolant temperature indicator light 1...

Page 81: ...ttom Engine Cover 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 for Pr...

Page 82: ...rrow facing the direction shown in figure below 3 Remove the bolts used to widen the gap on the secondary sheaves 4 Install the following Drive belt cover Engine Cover Seat bottom Cleaning the Spark A...

Page 83: ...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 UTV Adjusting the Parking Brake Free Play 1 Shift the drive select lever...

Page 84: ...adjustment nut 1 on the rear differential 2 Loosen the lock nut 1 and then tighten the bot 2 to adjust the parking brake Turn the bolt until it touches then back it of turn 3 If the vehicle can be hel...

Page 85: ...id immediately Do not mix different type of brake fluid Use Dot 3 brake fluid only as mixing can cause brake failure and expensive repairs CHECKING THE FRONT BRAKE PADS 1 Remove the front wheels 2 Che...

Page 86: ...G THE BRAKE HOSES AND BRAKE LINES 1 Remove Seat bottom and Engine Cover 2 Lift the hood up 3 Lift the cargo bed 4 Check the following for cracks wear or damage and if needed replace Front brake hoses...

Page 87: ...brake fluid to the reservoir 3 The Bleeding process must be performed in the following order starting with the right rear Note Always start with the caliper that is furthest from the master cylinder F...

Page 88: ...o the left to ensure the bleeder valve is fully closed 12 Technician 1 needs to inform Technician 2 that the bleeder valve is closed and to repeat the brake pedal pumping procedure 13 Repeat Steps 8 t...

Page 89: ...re 23 If fluid does not flow after five 5 attempts at the right front caliper close the bleeder valve and move to the left front caliper 24 Perform the brake bleeding procedure on the left front calip...

Page 90: ...of the brakes after bleeding the brakes ADJUSTING THE SELECT LEVER SHIFT ROD Neutral High Low Reverse Parking Select lever shift rod Warning The vehicle must be stopped and your foot off the accelera...

Page 91: ...ll the filler plug 23 Nm 2 3 m kg 17 ft lbs 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 92: ...the B measurement to find Tow 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...

Page 93: ...omplete A spanner wrench is included in the tool kit shipped with this utility vehicle 1 Using a spanner wrench loosen the upper lock nut 2 Adjust the pre load adjuster nut to the desired setting Turn...

Page 94: ...Periodic Maintenance 3 29...

Page 95: ...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 96: ...ommended tire combinations Tire wear limit a Front and rear 3 0 mm 0 12 in 2 Reference label on vehicle for correct tire inflation pressures Changing the Tail Brake Light Assembly All light assemblies...

Page 97: ...ing order should always start with the smallest diameter bolt working up to the largest diameter bolt in a cross pattern from outsideto inside 6 Bolt and nut tightening order should always start with...

Page 98: ...t box top panel 6 Engine wiring harness 7 Cross member 8 Bed assembly 9 Fuel Line 10 Coolant lines 11 Exhaust header 12 Shift cable Remove the parts in the order 1 listed For installation reverse the...

Page 99: ...ove the parts in the order listed 2 Copper washer 7 3 Oil Line 3 1 4 Oil Line 2 1 5 Spark plug 1 6 Tappet Cover Intake 1 7 Tappet Cover Exhaust 2 8 Timing Chain Tensioner Cap Bolt 1 9 Timing Chain Ten...

Page 100: ...ng 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 cover...

Page 101: ...thin screwdriver 1 until it stops With the screwdriver still inserted install the tensioner and a new gasket onto the block The up mark on the tensioner should face up Remove the screwdriver make sure...

Page 102: ...1 1 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 was...

Page 103: ...it 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 scra...

Page 104: ...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 sprocket N...

Page 105: ...d Valve springs Valve Keeper Qty 10 Remarks Remove the parts in the order listed 2 Valve spring collar 5 3 Intake valve spring 3 4 Exhaust valve spring 2 5 Intake valve 3 6 Exhaust valve 2 7 Valve ste...

Page 106: ...12mm Exhaust0 14mm Measure the margin thickness Both Intake and Exhaust 0 85 1 15 mm Measure valve stem run out Run out Limit 0 01 mm Whenever a valve is removed always replace the valve guide seal I...

Page 107: ...he 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 valv...

Page 108: ...ston Water Pump Qty Remarks Remove parts in the order outlet Hose listed 1 Cylinder Head Coolant inlet joint 1 2 Cylinder O ring 1 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Wrist pin clip 2 6 Wrist pin 1...

Page 109: ...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 110: ...l piston pin 2 through piston wall Rod piston wall Install piston pin clips 3 3 Cylinder O ring 10mmbolts 42Nm or 31 ft lbs 6mmbolts 10Nm or 7 ft lbs Install the cylinder with one hand while compressi...

Page 111: ...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 112: ...bolts for installation 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 s...

Page 113: ...lywheel onto the crankshaft 5 Securing flywheel On 2019 units install the M22 nut and torque to 160 Nm On Prior years slide the fan hub against the rotor Run a bolt in the end of the crankshaft and re...

Page 114: ...ll In the following order Air Shroud 1 Engine cooling fan Air Shroud 2 2 Torque to Shroud bolts to 10 Nm or 7 ft lbs 3 Torque fan to 7 Nm or 5 ft lbs 4 Note Be sure to include O ring and backing plate...

Page 115: ...ve the parts in the order oil pump gears listed 1 Nut Lock washer 1 1 2 Balancer driven oil pump drive gear 1 3 Chain 1 4 Straight key 1 5 Oil pump driven gear 1 6 Plate 1 7 Balancer drive gear 1 8 Sp...

Page 116: ...r wear 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 stiffness in links if necessary replace the timing...

Page 117: ...order listed Engine assembly 1 Drive Belt cover 1 2 Rubber gasket 1 3 Bearing Housing 1 4 Dowel pin 2 5 Primary sheave assembly 1 6 V belt 1 7 Primary fixed sheave 1 8 Secondary sheave assembly 1 9 Dr...

Page 118: ...Primary Sheave Remove the parts in the order listed 1 Primary pulley sheave cap 1 2 Primary pulley slider 4 3 Spacer 4 4 Primary pulley cam 1 5 Primary pulley weight 8 6 Collar 1 7 Oil seal 2 8 Primar...

Page 119: ...Sheave Qty Remarks Remove the parts in the order listed 1 Nut 1 2 Spring seat 1 3 Compression spring 1 4 Spring seat 1 5 Guide pin 4 6 Secondary sliding sheave 1 7 O ring 2 8 Secondary fixed sheave 1...

Page 120: ...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 121: ...ace of the primary sliding sheave Spacer Sliders 1 Primary pulley cam 2 3 Assembling the secondary sheave Apply assembly lube to The secondary sliding sheave 1 inner surface and oil seals The bearings...

Page 122: ...lbs Tighten the secondary sheave nut 2 100 Nm or 74 ft lbs Note Use the sheave holder 3 to hold the primary sheave Tighten in order Primary sheave nut then Secondary sheave nut Note Tightening the bol...

Page 123: ...arts in the order listed Primary and secondary sheaves 1 Clutch housing assembly 1 2 Gasket dowel pin 1 2 3 One way clutch bearing 1 4 Nut 1 Apply High strength red thread locker and stake nut to cran...

Page 124: ...emarks Disassembling the clutch housing Remove the parts in the order listed 1 Oil seal 1 2 Circlip 1 3 Bearing Housing 1 4 Circlip 1 5 Bearing 1 6 Circlip 1 7 Bearing 1 For installation reverse the o...

Page 125: ...ay 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 housi...

Page 126: ...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 127: ...C magneto rotor Primary and secondary sheaves 1 Clutch carrier assembly 1 1 Starter Motor O ring 2 Oil Filter O ring 1 3 Oil Line assembly O ring 1 2 4 Oil Line adapter O ring 1 1 5 Relief valve assem...

Page 128: ...case Remove the parts in the order listed 1 Shift lever cover gasket 1 1 2 Dowel pin 1 3 Shift lever 1 1 4 Shift lever 2 assembly 1 5 Right crankcase half 1 6 Dowel pin 1 7 Left crankcase half 1 8 Spa...

Page 129: ...Remarks Removing the crankcase bearings Remove the parts in the order listed Crankshaft and oil pump Transmission Middle drive driven shaft 1 O ring collar 1 1 2 Oil seal 1 3 Bearing retainer 1 For in...

Page 130: ...t crankcase half onto the 3 Spring 2 Look for damage or wear 4 Crankcase Thoroughly wash the case halves in a mild solvent Clean all the gasket surfaces and crankcase mating surfaces thoroughly Look f...

Page 131: ...ft Crankcase Right Crankcase Caution Before installing and torque is applied be sure to check that the transmission is functioning properly by rotating the shift drum manually in both directions Insta...

Page 132: ...the crankshaft and Oil Pump Crankcase separation Qty 1 1 Remarks Remove the parts in the order listed 2 Oil Strainer O ring 1 1 3 Oil pump assembly gasket 1 4 Balancer 1 5 Plate 1 For installation re...

Page 133: ...1 Part Name Disassembling the oil pump Rotor cover Qty 1 Remarks Remove the parts in the order listed 2 Pin 2 3 Shaft 1 4 Pin 1 5 Inner rotor 1 6 Outer rotor 1 For installation reverse the order 7 Oi...

Page 134: ...arance a Between the inner rotor 1 and the outer rotor 2 2 Side clearance b Between the outer rotor 2 and the pump housing 3 3 Body clearance c Between the outer rotor 2 and the pump housing 3 Tip cle...

Page 135: ...should be replaced whenever removed from the crankshaft Install Assemble the oil pump Inner rotor Outer rotor Oil pump shaft With the recommended lubricant Install the crankshaft and balancer Note Ho...

Page 136: ...the order listed Crankcase separation 1 Middle driven gear Low 1 wheel gear 2 Shift drum 1 3 Shift fork assembly 1 4 Short spring 1 5 Shift fork 1 1 6 Long spring 1 7 Shift fork 2 1 8 Guide bar 1 9 S...

Page 137: ...bly No Part Name Qty Remarks Disassembling the Drive axle Remove the parts in the order listed 1 Clutch dog 1 2 High wheel gear 1 3 Middle drive gear 1 4 Driven sprocket 1 For installation reverse the...

Page 138: ...ork 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 H...

Page 139: ...the shaft run out Use a truing stand and a dial gauge Shaft run out 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 t...

Page 140: ...shaft 1 Crankcase separation Qty Remarks Remove the parts in the order listed 1 2 Bearing Housing Middle drive gear 1 3 Nut 1 4 Middle drive pinion gear 1 5 Shim 1 6 Middle drive shaft 1 For installa...

Page 141: ...s Remove the parts in the order listed 1 Drive shaft coupling 2 Cir clip 2 3 Bearing 2 4 Universal joint 1 5 Universal joint yoke 1 6 Bearing housing O ring 1 1 7 Shim 1 8 Middle driven pinion gear 1...

Page 142: ...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 di...

Page 143: ...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 beari...

Page 144: ...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 145: ...excessive runout Inspect the brake calipers and brake levers for damage corrosion or deformity Check for brake rotor wear Has it exceeded the wear limit Check for brake pad wear Is the master cylinde...

Page 146: ...wheel sway during driving Check for damage to the steering knuckle bearing Check if the ball joint is damaged Check if the front wheel axle nut is loose or damaged Check the front wheel splines for d...

Page 147: ...fferential for wear or damage Check the gears of the rear gearbox for wear or damage Check the CV joint rubber boot for damage Check the Universal joint for damage or wear 12 Failure to shift into fou...

Page 148: ...sembly 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 TieL 200 2 11 Dust Boots 2 12 Flange Bolt 10mm X 30mm 4 13 Tie Rod end 2 14 Locknut...

Page 149: ...Wheel assembly No Part Name Qty Remarks Removing the steering Wheel assembly 1 Hex Socket Bolt 5mm X 16mm 6 2 Steering Wheel Cap 1 3 4 Horn Switch Steering Wheel 1 1 5 Flange nut 12mm X 1 25 1 6 Steer...

Page 150: ...ge or wear Inspect the steering wheel for damage or wear to the wheel covering This is a safety area and any damage or wear needs to be repaired immediately Warning This is a safety area and any damag...

Page 151: ...aft assembly 1 Checking and servicing the Universal joints on the steering shaft Bearing 1 Cir clip 2 Oil seal 3 Cross axis 4 Inspect for smooth operation Replace any parts with wear or damage 2 Inspe...

Page 152: ...ct the steering Joint Bolt M8 20 32 Nm 3 2m kg 23 ft lbs 3 Attach the steering Tube to the frame 7 Inspect the rack and pinion gear Check the splines on the end of the shaft for wear or damage Check t...

Page 153: ...um mark 2 Check the brake pedal front edge height to floorboard It should be set between 75 and 85mm If out of spec adjust to meet the required travel distance 3 Check for spongy feel of the pedal If...

Page 154: ...Removing the front Brake line attachment hardware Qty Remarks 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 155: ...Chassis 5 11 Front Disc Brakes No 1 Part Name Removing the brake discs Brake Caliper assembly Qty 1 Remarks 2 Brake Disc 1 3 Bolt 4 4 Axle housing 4 5 Bolt 4 6 Brake disc guard 1...

Page 156: ...12 Inspect the Front Brake Discs Inspect for galling or damage Measure brake disc runout Brake disc runout 0 10 mm 0 004 in Brake disc thickness 1 Wheel Hub 2 Rim 3 Brake disc minimum thickness 3 0 m...

Page 157: ...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 158: ...k 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 that...

Page 159: ...Removing the front brake caliper Remove the parts in the order listed Brake fluid 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake Pad holding bolt 2 5 Brake caliper mounting bolt 2 For install...

Page 160: ...marks Disassembling the front brake caliper Remove the parts in the order listed 1 Brake pad holding bolt 2 2 Brake pad 2 3 Pad spring 1 4 Brake caliper piston 1 5 Dust seal 2 6 Caliper Piston seal 2...

Page 161: ...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 162: ...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 DOT3 Brake Fluid 3 Bleed the air o...

Page 163: ...s 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 164: ...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 165: ...2 Hex Flange Nut 1 3 Parking arm 1 4 Parking Brake Plunger Assembly 1 5 Parking Cable Bracket 1 6 Tension Spring 1 7 Tension spring mounting plate 1 8 Lower Slide Shaft Rubber Cover 1 9 Lower Slide Sh...

Page 166: ...Part Name Qty 16 Piston 1 17 Cone Compression Spring 1 18 Inside Brake Pad 1 19 Pad Guide pin 2 20 Ball Bearing 3 21 Parking brake case bolt 2 22 Sliding shaft rubber cover 1 23 Mounting Bracket Bolts...

Page 167: ...ake 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 Ins...

Page 168: ...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 169: ...m kg 12 ft lbs Installing the Rear Brake Caliper 1 Install the brake caliper with the mounting bolts 40Nm 4 0m kg 29 ft lbs Brake hose 1 Copper washers Union bolt 2 48Nm 4 8m kg 35 ft lbs 2 Tighten th...

Page 170: ...n the order listed Brake Fluid Drain 1 Brake Fluid Reservoir cap 1 2 Brake Fluid Reservoir diaphragm 1 3 Brake Fluid Reservoir float 1 4 Union bolt 1 5 Copper washer 2 6 Brake hose 1 Disconnect 7 Brak...

Page 171: ...luid 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 lbs 2 Install the Brake line 19Nm 1 9 m kg 13 ft lbs 3...

Page 172: ...g support 1 3 Seating support 1 4 Cover battery 1 5 Cover engine 1 6 Cover battery box 1 7 Front panel footrest 1 8 Washer rubber 8 17 6 9 Side Pane l front left 1 10 Side Panel middle left 1 11 Side...

Page 173: ...cover 1 19 Washer rubber 1 20 Lock engine cover 1 21 Screw cross head self drilling ST3 9 13 8 22 Screw thread clip M6 2 43 23 Bolt hexagon socket M6 16 46 24 Bolt hexagon socket M6 20 4 25 Screw cro...

Page 174: ...is Front Wheel and Tire No 1 Part Name Removing the front wheel Front rim Qty 2 Remarks 2 Front tire 2 3 Nut M10 8 4 Wheel decoration cover 2 5 Nut M22 1 5 2 6 Front hub 2 7 cotter pin 3 2 50 2 8 Bolt...

Page 175: ...1 Chassis Rear wheel No Part Name Qty Remarks 1 Removing the rear wheel Rear rim 2 2 Rear tire 2 3 Rear hub 2 4 Bolt M10 30 4 5 Nut M10 8 6 Wheel decoration cover 2 7 Nut M22 1 5 2 8 Cotter pin 3 2 50...

Page 176: ...0 ft lb Installing the Wheel assembly 1 Install the wheel with the arrow on the tire pointing toward the front of the UTV 2 Install the tapered lug nuts Torque 55 Nm or 40 ft lbs Warning Wheels and ti...

Page 177: ...5 33 Chassis Transmission System Front Bridge No 1 Part Name Cir clip Qty 1 2 CV Joint 2 3 Cir clip 1 4 Cir clip 2 5 Boot band 2 6 Dust boot 2 7 Boot band 2 8 Joint shaft 1 9 Half axle assembly 1...

Page 178: ...e Front differential assy 1 2 Front differential case 1 3 Front differential case 1 4 Drive driven gears assy with rear differential status 1 5 Connection fork 1 6 Hexagon flange nut m14 1 5 1 7 O typ...

Page 179: ...12 Connection fork 1 13 Socket hexagon screw M8 10 1 14 Hexagon flange bolt M10 1 25 15 1 15 Clip D0 62 1 16 Pin 5 75 1 17 Transfer case assembly 1 18 Divide device connection 1 19 Rack 1 20 O ring 2...

Page 180: ...1 Remarks 24 Bearing 35 62 9 1 25 Rolling bearing 15 21 12 1 26 Screw 1 27 Copper washer 13 1 5 1 28 Hexagon flange nut M10 1 25 1 29 Shaft fork 6 30 Clamp 20 32 1 31 Universal joint 1 32 Clip D0 62 1...

Page 181: ...Cir clip 20 26 1 2 39 Spring 25 2 3 28 2 40 Hexagon flange bolt M8 28 6 41 Front dustproof rubber cover 19 38 50 2 front transmission shaft 42 Hexagon flange bolt M10 1 25 30 2 43 Hexagon flange bolt...

Page 182: ...niversal joint 1 Remove the Universal joint 2 Remove the cir clips 1 3 Place a pipe 2 Correct size to collect outside diameter of the bearing beneath the yoke 3 and press the bearing 4 into the pipe a...

Page 183: ...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 184: ...al 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 terminal 1 to rotate the pinion gear 2 until the paint mark...

Page 185: ...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 lbs 3 Install the front bridge differential onto the frame 2 Bolts 10mm X1...

Page 186: ...o Part Name Qty Remarks 1 Cir clip 2 2 Boot band 2 3 Boot band 2 4 Dust boot 2 5 Cir clip 1 6 Double off set joint assembly 1 7 Cir clip 1 8 Cir clip 1 9 Double off set joint assembly 1 10 Joint shaft...

Page 187: ...r reducer assy Qty 1 Remarks 2 Rear reducer case 1 3 Bearing 22 30 13 1 4 Bearing 55b M6720 55 67 20 1 5 Drive driven gears 1 6 Bearing 25 62 17 1 7 Mount bracket rear disk brake plate 1 8 Oil seal 61...

Page 188: ...acket rear brake caliper 1 14 Rear adjustment gasket 1 15 Hexagon bolt with washer 4 16 Socket hexagon screw M8 25 1 17 Rear adjustment gasket 1 18 Speed sensor comp 1 19 O ring gasket fuel injection...

Page 189: ...al 65 90 9 1 26 Bearing 16017C2 85 130 14 1 27 O ring 3 150 2 28 Adjustment gasket 1 29 Oil Seal 65 90 9 1 30 Fuel drain screw plug 1 31 Hexagon flange nut M10 1 25 25 1 32 Hexagon flange bolt M8 12 4...

Page 190: ...nge nut M10 1 25 2 40 Cir clip 20 26 1 1 41 Rear dust cover 20 5 48 30 1 42 Vent pipe rear reducer 1 43 Steel Wire Clamp 8 1 44 Clip 11 1 45 Spring 25 2 3 28 1 46 Hexagon flange bolt M10 1 25 120 2 47...

Page 191: ...Gearshift cable assy 1 3 Hexagon flange bolt M6 30 2 4 Gearshift arm 1 5 Reverse cable 1 6 Hexagon Flange Nut M8 2 7 Gearshift cable fix plate 1 8 Gearshift cable fix plate 1 9 Hexagon Flange Bolt M6...

Page 192: ...u must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjustment Select lever shift rod Make sure the shift lever is in the neutral position...

Page 193: ...rame welding kit front right 1 3 Bolt hexagon flange head M10 1 25 78 8 4 tube 10 3 23 50 8 5 Bushing 23 28 16 6 Nut lock M10 1 25 16 7 Shield CV basic 2 8 Hexagon flange bolt M6 16 8 9 Bolt hexagon f...

Page 194: ...ll kit right 17 Rod ball kit left 18 Buffer stabilizer bar 20 45 2 19 Strap buffer plated 2 20 Washer spring lock 8 4 21 Bolt hexagon flange head M8 20 4 22 A frame welding kit front left 1 23 A frame...

Page 195: ...n or 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...

Page 196: ...t hexagon flange head M10 1 25 78 8 4 bushing 23 28 8 5 tube 10 3 23 50 8 6 Nut lock M10 1 25 12 7 Stabilizer bar welding kit rear 1 8 Buffer stabilizer bar 20 45 2 9 Strap buffer plate 2 10 Bolt hexa...

Page 197: ...flange head M6 16 4 18 Bolt hexagon flange head M10 1 25 65 2 19 Washer spring 8 4 20 Bolt hexagon flange head M10 1 25 60 2 21 Nut lock M12 1 25 4 22 A frame welding kit rear right 1 23 A frame weldi...

Page 198: ...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 tem...

Page 199: ...1 5 Radiator fan assy 1 6 M shaped fixed pipe clamps 3 7 H shaped rubber washer 6 8 Hexagon flange bolt M6 20 2 9 Hexagon flange nut M6 2 10 Secondary water tank 1 11 Secondary water tank cover 1 12...

Page 200: ...g System No Part Name Qty Remarks 18 Hexagon flange bolt M6 16 2 19 Water pipe 1 30 Pressure proof rubber oil pipe 10 17 300 2 31 Metal oil pipe 1 32 Metal oil pipe 1 33 Screw hoop 12 20 6 34 Hexagon...

Page 201: ...t bleed bolts 5 Pour in new antifreeze mixture until the coolant flows out each bleed opening 6 Replace the bleed bolts 7 Add New coolant to the reservoir to be above the minimum level mark 8 Follow t...

Page 202: ...Bolt 6mm X65mm 1 4 Bolt 6mm X10mm 1 5 Water pipe 2 1 6 O ring 20 7 X2 6 1 7 Water pipe 3 1 8 Hose clamp 2 9 Cylinder inlet water joint 1 10 Bolt 6mm X20mm 2 11 O ring 33 4 X2 4 1 12 Water pipe 1 1 13...

Page 203: ...59 Chassis Water Pump No 18 Part Name Water pump housing cover Qty 1 19 Gasket 1 20 Cir clip 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...

Page 204: ...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 205: ...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 206: ...e 1 5 Safety belt assy 2 6 Hexagon socket head bolt M6 20 2 7 Hexagon flange step bolt M10 1 25 20 14 5 4 8 Hexagon flange bolt M10 1 25 20 2 9 Hexagon flange nut M10 1 25 4 10 Cross large plate head...

Page 207: ...marks 1 Removing the fuel tank Fuel tank assembly 1 2 Fuel tank 1 3 Cap gas tank 1 4 Cap fuel pump 1 5 Gasket pump 1 6 Fuel pump 1 7 Connector outlet fuel 1 8 Connector inlet fuel 1 9 Climp A 8 10 Lin...

Page 208: ...pling Qty 1 Remarks 13 Line fuel 0 05MPa 1 14 Hose heat insulation 1 15 Clip line brake 1 16 Bolt hexagon flange head M6 16 1 17 Fuel cleaner 1 18 Clamp tank 2 19 Bolt hexagon flange head M8 30 2 20 L...

Page 209: ...the pressure feed fuel hose 3 Connect a fuel pressure gauge 4 Turn the ignition switch to the run position Do not start the engine 5 Fuel Pressure should read 42 45 PSI 6 Turn the key to the off posi...

Page 210: ...itch 2 2 Radiator fan 3 Gear motor 4 Winch 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 Ignition coil 12 Gea...

Page 211: ...al 6 2 Electrical Components 1 Fuse Relay Box 2 Starter relay 3 Battery 4 Rectifier regulator 5 Speedometer 6 On Command four wheel drive switch and differential gear lock switch 7 Ignition switch com...

Page 212: ...vives 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 batt...

Page 213: ...ere 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 Installing a battery...

Page 214: ...p Using a Constant Voltage Charger Lead Acid Battery Yes No Set Charge time to a maximum of 20 hours Measure the open circuit voltage prior to charging Connect the charger and ammeter to the battery a...

Page 215: ...ng time determined by the open circuit voltage If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery Let the battery sit for 30 minutes then measure the op...

Page 216: ...r the hood cover on the right side of the vehicle 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 immediately ch...

Page 217: ...e switch 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 left T...

Page 218: ...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 219: ...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 220: ...6 11 Electrical Ignition System Circuit Diagram 1 High tension Coil 2 C D I 3 Magneto...

Page 221: ...es Main Ignition 2 Battery 3 Sparkplug 4 Ignition spark cap 5 Spark plug cap resistance 6 Ignition coil resistance 7 Main switch 8 Pickup coil resistance 9 Rotor pickup coil resistance 10 Wiring conne...

Page 222: ...d to White Blue terminal 4 Pickup coil resistance secondary 0 063 0 077 Ohms Meets specification Incorrect Replace the pickup coil stator assembly Replace the Spark Plug Cap Check the Ignition coil re...

Page 223: ...6 14 Electrical Incorrect Replace the C D I unit Repair wiring or replace connectors as necessary Check the wiring of the entire ignition circuit...

Page 224: ...6 15 Electrical Electric Starting System...

Page 225: ...If the size of jumper wire is too small the jumper could burn and or cause injury 4 Starter relay Connect Battery positive to Yellow Blue terminal 1 Connect Battery Negative to Blue Black terminal 2 C...

Page 226: ...starter motor Qty Remarks Remove the parts in the order 1 Starter motor lead 1 listed 2 Starter motor O ring 1 1 1 Disassembling the starter motor Bracket 1 1 2 Washer kit 1 3 Bracket 2 1 4 Shims 5 Br...

Page 227: ...6 18 Electrical Charging System...

Page 228: ...internal 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 tes...

Page 229: ...6 20 Electrical Lighting System...

Page 230: ...6 21 Electrical Signaling System...

Page 231: ...6 22 Electrical Cooling System...

Page 232: ...6 23 Electrical 2WD 4WD Selecting System...

Page 233: ...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 234: ...g 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 ex...

Page 235: ...injector Do not reuse injectorseal rings dip injector tips into lubricants cycle injectors repeatedly without fuel pressure pulse a high leak rate injector allow water into the fuel system contact or...

Page 236: ...charge ifan accidental attempt is made to start the engine Disconnect the electrical connector from the injector wiring harness Relieve fuel pressure Remove the retaining clip from the fuel injector R...

Page 237: ...Install the retaining clip after connecting the fuel line Tighten the injector mounting to the desired torque as mentioned in this manual Tighten the fuel line Re install the injector electrical conne...

Page 238: ...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 is an interac...

Page 239: ...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 240: ...l close to the spark plug and keep the plug wire short inlength 6 inches or less if possible Mount the coil away from any pickup type devices especially Crank Cam sensor and route wiring away from the...

Page 241: ...Step Action Yes 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 ru...

Page 242: ...Reverse the removal process Fill with at least 3 liters of fuel Install fuel filler cap Turn on the ignition key to prime the pump and fuel lines Fuel Leakage check procedure After performing any serv...

Page 243: ...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 Coolant Temp Sensor circuit High...

Page 244: ...tem 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 After...

Page 245: ...oing to the fuel tank 2 wires go to the back of the unit and 2 wires go to the front of the unit Find the white 2 pin connector that goes toward the throttle body and connect 12v Do you hear the pump...

Page 246: ...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 247: ...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 248: ...enting 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 escape past an open valve seat In this...

Page 249: ...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 cover Lock the engine as described in this p...

Page 250: ...r 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 Al...

Page 251: ...eter readings indicates a poor connection Find and 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...

Page 252: ...tor 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 of the voltage that was sent the remainder...

Page 253: ...i E I l I I t H L 1 I f fi I L JIr _ _IA_ _ II i B B I ll I I f l M l ii I I I I 1 i I MY2017 2018 Wiring...

Page 254: ...MY 2019 Forward Wiring...

Page 255: ...Form Number 769 12198_06...

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Cub Cadet Challenger 550, Service Manual

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Summary of Contents for Challenger 550

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