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Ezgo 1600xd, Repair Manual

The Ezgo 1600xd Repair Manual is a comprehensive guide for maintaining and servicing your vehicle. This manual covers everything from basic maintenance to advanced repairs, ensuring your 1600xd is always in top condition. Download the manual for free from manualshive.com and keep your vehicle running smoothly.

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4

-2

SUUV-W00  

Apr. 2011

SAFETY

 FIRST

GENERAL

ENGINE

CVT

TRANSMISSION 

CHASSIS

REAR AXLE

BRAKE

FRONT AXLE

STEERING

HYDRAULIC 

ELECTRIC

INDEX

1.2 TIGHTENING TORQUE

Position

Specifi cation

Tightening torque

CVT drive pulley mounting bolt

-

54.0 Nm

5.5 kgf-m

40.0 lb-ft

CVT driven pulley mounting bolt

M8

24.5 Nm

2.5 kgf-m

18.0 lb-ft

Applied position

Purpose

Specifi cation

Mating surface of CVT cover and fl ywheel 

installation plate to engine 

Prevention of water entry

Three Bond 1206D or equivalent

CVT drive/driven pulley mounting bolt 

Prevention of looseness

LOCTITE #242 or equivalent

1.3  SEALANT AND ADHESIVE

1. SPECIFICATIONS

1.1 GENERAL SPECIFICATIONS

Item

Specifi cation

Type

Constant variable, belt

Pulley speed reduction ratio (drive : driven)

0.68 :  1

Belt width

Specifi cation

29  mm  (1.142  in.)

Allowable limit

24  mm  (0.945  in.)

Distance between center of two pulleys (Shaft distance)

327.15  mm  (12.8799  in.)

Drive pulley 

Centrifugal force reactive type variable pulley 

Driven pulley 

Spring compression type variable pulley

CVT - SPECIFICATIONS

UTV(EZGO향)_04_CVT.indd   2

UTV(EZGO향)_04_CVT.indd   2

2011-04-04   오후 3:45:33

2011-04-04   오후 3:45:33

Summary of Contents for 1600xd

Page 1: ...ISSUED APRIL 2011 1600xd 4x4 repair manual 619728...

Page 2: ......

Page 3: ...formation in this manual is based on the latest product information available at the time of publication Therefore some of the information in this manual may differ from the machine you have We have a...

Page 4: ......

Page 5: ...CHAPTER 3 ENGINE CHAPTER 5 TRANSMISSION CHAPTER 6 CHASSIS CHAPTER 7 REAR AXLE CHAPTER 8 BRAKE CHAPTER 10 STEERING CHAPTER 9 FRONT AXLE CHAPTER 11 HYDRAULIC SYSTEM CHAPTER 4 CVT CHAPTER 12 ELECTRIC SY...

Page 6: ......

Page 7: ...k area clean 1 3 2 3 Safety instructions when preparing tractor 1 4 2 4 Fire 1 4 2 5 Cautions when handling the battery 1 5 2 6 Cautions for high pressure hoses 1 5 2 7 Use of appropriate tools and eq...

Page 8: ...pection to prevent any injury 1 1 ALERT SYMBOLS The meanings of the safety alert symbols used in this manual are as follows A REMARK Broaden your knowledge with additionally supplied service informati...

Page 9: ...for your working envi ronment Never wear loose fitting clothing or a tie which can be caught by rotating part According to the statistics most accidents occurred with rotating parts are due to this i...

Page 10: ...if necessary 2 4 FIRE S76W011A Never smoke or allow flames or sparks in your work area when maintaining the fuel system S76W012A Keep flames or sparks away from the fuel container spray paint etc and...

Page 11: ...t the battery warm up to ambient temperature 16 C 60 F be fore charging Keep sparks and flames match lighter away from the battery The battery can explode due to hy drogen gasses inside the case Never...

Page 12: ...proper use of lock can cause a seri ous accident Check the buttons and operating direction of the hoist before using it Improper operation can cause a serious accident Do not use wooden blocks or bric...

Page 13: ...6W026A Do not open the radiator cap when the radiator is hot Hot coolant or steam can be surged leading to a serious scald S76W027A Check the surface temperature of the container be fore draining the...

Page 14: ...nd you could be charged in violation of regulations S76W031A Do not weld or apply heat to the tire rim or disc The tire can explode due to the rapidly increased pres sure in the tire Check tires for i...

Page 15: ...the existing part with a new one attach the same safety decal to the new part Otherwise the customer s safety will be threatened If a decal is damaged or detached attach the same decal to the part The...

Page 16: ...SMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 Part No U3215 85081 6 Part No U3215 85071 4 Part No T2615 54112 1 Part No U3215 85011 5 Part No U3215 85101 3 Part No T4...

Page 17: ...IS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 8 Part No U3215 85091 12 Part No U3215 85111 11 Part No U3215 85041 9 Part No U3215 85021 10 Part No U3215 85031 14 Part No U3215 85061...

Page 18: ...IS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 17 Part No U3215 85161 16 Part No U3215 85131 WR DYRLG SHUVRQDO LQMXU IURP ORVV RI VWHHULQJ FRQWURO Gr qrw orfn gliihuhqwldo ru wxuq zlw...

Page 19: ...e 2 8 6 4 Driving speed 2 9 7 MAINTENANCE 2 10 7 1 Maintenance schedule chart 2 10 7 2 Lubrication and replenishment 2 12 8 TIRE MAINTENANCE 2 13 8 1 Specified inflation pressure 2 13 8 2 Tightening t...

Page 20: ...vel light Hazard warning lamp 4WD Four Wheel Drive API American Petroleum Institute HI LO High speed Low speed RH LH Right Hand side and Left Hand side Determined based on driving direction ROPS Roll...

Page 21: ...umber assignment standard Model This vehicle serial number 1 is located on the struc ture frame where the battery is installed UUVO201A Year of manufacturing Example 2 2002 3 2003 D 2004 E 2005 F 2006...

Page 22: ...nsmission serial number It is marked on the side of the bleeding pipe on top of the transmission case Rear axle case serial number It is marked on the right side of the mating surface of the rear axle...

Page 23: ...ECTRIC INDEX 4 DIMENSIONS C E1 B D A E2 F C E1 B D A E2 F mm inch DESCRIPTION REMARKS A Overall length 2 852 112 3 B Overall width 1 543 60 7 C Overall height 1 940 76 4 D Wheel base 1 940 76 4 E Trea...

Page 24: ...l 3 2 0 85 Engine coolant U S gal 6 3 1 66 Transmission case U S gal 0 9 0 24 Front axle case U S gal 0 5 0 13 Rear axle case U S gal 0 8 0 2 Drive train Type Belt CVT Transmission Forward 2 High Low...

Page 25: ...R 6305R T2610 22661 6204 20x24x13 T2305 25241 T2305 25241 25x29x13 6204 6205 6204 25x29x13 K5400 1457 1 31T 19 HEX 25x30x13 6205 6304 K5400 1457 1 T8101 75520 38430 2155 1 34150 2156 1 K5400 1457 1 03...

Page 26: ...43861 32207J T4520 43011 4T 32009X 10 10 10 37 37 37 20 20 20 RII RQ 12 12 12 UUVW106A 6 2 GEAR ARRANGEMENT OF REAR AXLE 6 3 GEAR ARRANGEMENT OF FRONT AXLE UUVW107A 14T 12T 34T 8T 6005 6005 38440 442...

Page 27: ...gh 2800 rpm x 1 0 68 x 31 30 x 46 52 x 10 31 x 10 37 328 rpm 328 x 0 635 x x 60 1000 40 3 Reverse 2800 rpm x 1 0 68 x 17 26 x 46 52 x 10 31 x 10 37 207 rpm 207 x 0 635 x x 60 1000 25 Calculation of dr...

Page 28: ...10 Coolant Replace 11 Cooling system radiator grill coolant hose cooling fan Check 12 CVT belt Check Replace 13 CVT pulley and system Check 14 Gearbox and front rear axle oil Check Replace 15 Hydraul...

Page 29: ...conditions than in normal conditions 2 Every year or every 5 times of cleaning whichever comes first 3 Replace only if necessary The items listed above marked are registered as emission related critic...

Page 30: ...3 2 0 85 U S gal Engine oil API Service Classification CC or CD SAE 15W 40 4 Transmission case 0 9 0 24 U S gal SAE gear oil No 90 or DAEDONG UTF55 Shell DONAX TD Exxonmobil Mobilfluid 423 or 424 BP...

Page 31: ...PRESSURE Tires Front Rear Size Inflation pressure Size Inflation pressure Standard 25 x 10 12 6PR 0 84 kg cm 82 7 Kpa 12 psi 25 x 11 12 6PR 1 27 kg cm 124 Kpa 18 psi Items Tightening torque Front Whee...

Page 32: ...20 2 17 7 20 5 1 8 2 1 13 1 15 1 29 5 34 3 3 0 3 5 21 7 25 3 M10 10 mm 0 39 in 39 3 45 1 4 0 4 6 29 0 33 2 31 4 34 3 3 2 3 5 23 2 25 3 48 1 55 8 4 9 5 7 35 5 41 2 39 3 44 1 4 0 4 5 29 0 32 5 60 9 70 6...

Page 33: ...E GR 5 SAE GR 5 Nm kgf m lb ft Nm kgf m lb ft 5 16 23 1 27 8 2 35 2 84 17 0 20 5 32 5 39 3 3 31 4 01 24 0 29 0 3 8 47 5 57 0 4 84 5 82 35 0 42 0 61 0 73 2 6 22 7 47 45 0 54 0 1 2 108 5 130 2 11 07 13...

Page 34: ...on the head of bolt with number or punching 2 4T Full thread set screw 3 7T Partial thread bolt 5 7T Full thread set screw 6 9T Partial thread bolt Hardness and thread No Spring washer Pitch M5 M6 M8...

Page 35: ...ardness is not usually indicated 52 4T Regular Type 3 74 4T Fine Type 2 72 4T Fine Type 3 14 4T Regular Type 2 12 4T Regular Type 3 56 6T Regular Type 2 18 4T Fine Type 2 16 4T Fine Type 3 76 6T Fine...

Page 36: ...G ASSEMBLY F F F S76W111A In order to prevent displacement of a snap ring as semble its rounded area R against the opponent part as seen in the picture below S76W112A Since a spring pin can be displac...

Page 37: ...g Capacity bar x 14 504 psi t x 0 9842 UK ton x 0 2640 U S gal psi x 0 0690 bar UK ton x 1 016 t U S gal x 3 7850 Temperature t x 1 1023 US ton gal x 1 2010 U S gal C C x 1 8 32 F US ton x 0 9072 t U...

Page 38: ...MEMO...

Page 39: ...valves 3 13 3 1 9 Timing gears 3 14 3 1 10 Flywheel 3 14 3 1 11 MLS cylinder head gasket 3 15 3 2 Lubrication system 3 16 3 2 1 Engine oil flow 3 17 3 2 2 Relief valve 3 18 3 2 4 Oil pressure switch...

Page 40: ...heel deflection and crankshaft end play check 3 50 5 14 Oil pump check 3 50 6 DISASSEMBLY SERVICE AND ASSEMBLY 3 52 6 1 Engine removal 3 52 6 2 Engine component disassembly and assembly 3 58 6 2 1 Cyl...

Page 41: ...s Number of cylinders Engine model code assignment standard ENGINE EPA PLATE UUVW203A This aluminum plate is riveted on the engine cylinder head cover This provides the information such as model numbe...

Page 42: ...1 SAFETY FIRST GENERAL ENGINE CVT TRANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX ENGINE SPECIFICATIONS 2 SPECIFICATIONS 2 1 ENGINE DIMENSIONS mm in UUVW204A 564 22 2...

Page 43: ...timing BTDC 18 Fuel injection pump type CTD Pump Injection pressure 145 Kgf cm 2 062 psi Engine oil capacity 3 2 0 84 U S gal Engine oil specification SAE 15W 40 CD or higher of API grade Coolant cap...

Page 44: ...Value Allowable Limit Item Valve seat width Valve seat angle intake exhaust O D of valve stems intake exhaust I D of valve guides intake exhaust Clearance between valve stems and guides Valve recessi...

Page 45: ...mm 0 0059 0 0118 in 0 30 0 45 mm 0 0118 0 0177 in 0 20 0 35 mm 0 0079 0 0138 in 0 04 0 08 mm 0 0016 0 0031 in 0 02 0 06 mm 0 0008 0 0024 in 1 25 mm 0 0492 in 1 25 mm 0 0492 in 1 25 mm 0 0492 in Top r...

Page 46: ...crankshaft bearing 2 Clearance between crankshaft journals and bearing 1 Clearance between crankshaft journals and bearing 2 O D of crankpins I D of crankpin bearings Clearance between crankpins and b...

Page 47: ...5 kgf cm2 36 64 psi More than 49 kPa 0 5 kgf cm2 7 11 psi 0 11 0 15 mm 0 0043 0 0059 in 0 07 0 15 mm 0 0028 0 0059 in 0 105 0 150 mm 0 00413 0 00591 in Item Allowable Limit 245 kPa 2 5 kgf cm2 36 psi...

Page 48: ...ut 29 4 34 3 3 0 3 5 21 7 25 3 Oil switch Bis 1 4 1 9 0 14 0 20 1 0 1 4 Taper screw 14 7 19 6 1 5 2 0 10 8 14 5 Fuel supply limit cap nut 27 5 34 3 2 8 3 5 20 3 25 3 Idle limit fixing nut 13 7 15 7 1...

Page 49: ...and raises the power of the engine Deformation of the cylinder head by heat exhaust air is reduced because inlet ports are arranged alternately The combustion chamber is of DAEDONG s select circular...

Page 50: ...g and thrust bearings are plated with special raised alloy wear resistance Piston circumference has special elliptic shape in consideration of expansion due to heat The piston head is flat formed and...

Page 51: ...f carbon steel and cam sections are covered and tempered to provide greater wear resistance The rocker arm assembly includes the rocker arms arm brackets and arm shafts and converts the movement of th...

Page 52: ...the crankshaft gear either with 6 the one on the idle gear or 5 the idle gear with camshaft gear 3 idle gear 5 or with injection pump gear 1 The flywheel is installed on the rear end of the crankshaft...

Page 53: ...a triple layered steel structure complemented with non asbestos gasket features The top clearance variation is minimized and the thermal load is reduced while increasing durability When disassembling...

Page 54: ...RICATION SYSTEM ENGINE STRUCTURE AND FUNCTION A Oil sump screen B Oil pump 1 Inlet hole 2 Outlet hole C Oil filter cartridge and relief valve 3 To rocker arm shaft and cam shaft 4 To crankshaft 5 Reli...

Page 55: ...allend No 3Connectingrod ssmallend journal bearing No 1 main bearing Main oil gallery Idle gear Crank shaft gear Pressurized Splash flow Oil pump gear Relief valve Oil fiter Oil pan Strainer Oil pump...

Page 56: ...side to prevent the lack of lubrication oil in the engine If the oil filter element is clogged the by pass valve opens and lets the oil pass to each part of the engine without passing through the filt...

Page 57: ...ads is changed from inlet to outlet At D the space decreases and suctioned oil is discharged from the outlet port ENGINE STRUCTURE AND FUNCTION 1 Radiator 4 Cylinder block 2 Suction fan 5 Cylinder hea...

Page 58: ...entering by a special mechanical seal The thermostat is wax pellet type which controls the flow of the cooling water to the radiator to keep the proper temperature The case has a seat 1 and the pelle...

Page 59: ...The pressure type cap is installed on the radiator which prevents the pressure difference between the inside and the outside of the radiator from deforming the radiator A At high pressure higher than...

Page 60: ...ive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes 7 and returns to the fuel tank ENGINE STRUCTURE AND FUNCTION 2 5 3 1 7 4 8 6 9 UUVW2F1A Loosen the ble...

Page 61: ...6W234A 1 Suction valve 5 Chamber 2 Push rod 6 Diaphragm 3 Tappet 7 Fuel camshaft 4 Discharge valve The diaphragm 6 is linked to the tappet 3 with the push rod 2 The tappet is reciprocated by the eccen...

Page 62: ...el delivered 1 Delivery chamber 4 Feed hole 2 Plunger 5 Fuel chamber 3 Delivery valve 6 Control groove a Before delivery As the plunger 2 lowers fuel is drawn into the delivery chamber 1 through the f...

Page 63: ...aligned with the lengthwise slot When the plunger is pushed up the feed hole is closed by the plunger The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until...

Page 64: ...essure overcomes the counterforce of nozzle valve spring 3 the pressure pushes up the needle valve 7 constantly and then the proper amount of fuel is injected into the swirling air inside the combusti...

Page 65: ...ac cording to changes in the load The engine employs an all speed governor which controls centrifugal force of the steel balls 13 weight produced by rotation of the fuel camshaft 9 and tension of the...

Page 66: ...Steel ball 7 Governor lever 8 Idle spring 9 Start spring 10 Idle shaft 11 Governor sleeve 12 Fork lever 2 13 Fork lever 1 14 Fuel limit bolt 15 Torque spring As shown in the above figure the steel bal...

Page 67: ...d by the driver the stable speed is maintained F WHEN STOPPED When the key switch is moved to the OFF position the stop solenoid power is cut off to release the electromag net Therefore the stop pin c...

Page 68: ...e gas pass through a series of holes on the inner tube and fiberglass wool of muffler UUVW2F7A A Inlet air 1 Outlet port B To inlet manifold 2 Inlet port C Heavier dust 3 Air cleaner element 4 Body 5...

Page 69: ...e manifold 7 Bleeding pipe 8 Intake valve 9 Cylinder head 10 Cylinder head cover 11 Oil baffle plate 12 Bleeding pipe connec tion The PCV system is a system that prevents air pollution by returning th...

Page 70: ...ngine oil Use the specified fuel Tighten nut Adjust Clean or replace Repair or replace Repair or replace Repair or replace Replace head gasket tighten cylinder head bolts glow plug and nozzle holder R...

Page 71: ...en fuel injection Insufficient nozzle injection Compression pressure leak Adjust Repair or replace Repair or replace the fuel injection pump Repair or replace the nozzle Replace head gasket check tigh...

Page 72: ...nozzle holder hole and measure the pressure again JUDGMENT If the pressure raises after applying oil check the cyl inder wall and piston rings If the pressure still low check the top clearance valve c...

Page 73: ...TC on the side of the fly wheel is aligned with the reference mark on top of the rear plate of the flywheel Then turn the flywheel clockwise for approx 30 3 4 Remove the fuel in the nozzle holder wit...

Page 74: ...Diameter of flywheel Flywheel circumference for 1 Amount of shims to adjust 1 BTDC 18 270 mm 10 6 in 2 35 mm 0 093 in 0 1 mm 0 004 in BTDC Before Top Dead Center 1 Remove the oil pressure switch and i...

Page 75: ...en Check if any bubble can be seen in the overflow hose on the bottom of the reservoir tank around 5 minutes later If any bubble keep coming remove the engine cyl inder head to check the head gasket f...

Page 76: ...he valves marked with in the table below with a feeler gauge Item Valve clearance Factory spec 0 15 mm 0 006 in 196W253B A 196W254B A Cooling fan Fly wheel 3 2 1 Cooling fan IN EX IN EX IN EX Fly whee...

Page 77: ...limit 63 N 31 mm 6 4 kgf 31 mm 14 1 lbs 1 22 in Free length Specified value 35 1 35 6 mm 1 382 1 402 in Allowable limit 34 8 mm 1 37 in Place the spring on a spring compression tester and compress to...

Page 78: ...lace the cylinder head 1 2 3 Allowable limit 0 05 mm 0 0019 in Measure the rocker arm shaft O D with an outside micrometer Measure the rocker arm I D with an inside microm eter If the clearance exceed...

Page 79: ...value exceeds the allowable limit re place the valve and check the valve seat 1 2 3 4 Valve recess Specified value 0 9 1 1 mm 0 035 0 043 in Allowable limit 1 3 mm 0 051 in S76W270A 5 9 3 CYLINDER BOR...

Page 80: ...20 013 mm 0 7874 0 7879 in Allowable limit 20 03 mm 0 7886 in S76W273A 5 10 2 CLEARANCE BETWEEN PISTON PIN AND BUSHING Clearance between piston pin and bushing Specified value 0 014 0 038 mm 0 00055 0...

Page 81: ...learance Second ring compressionring Specified value 0 085 0 112 mm 0 0033 0 0044 in Oil ring Specified value 0 020 0 055 mm 0 0008 0 0022 in S76W277A Place the piston ring to be measured on the top f...

Page 82: ...the intermediate journal Measure the eccentricity half of the measured value while turning the crankshaft on the V blocks If the eccentricity exceeds the allowable limit re place the crankshaft 1 2 3...

Page 83: ...81A Oil clearance Specified value 0 034 0 092mm 0 0013 0 0036 in Allowable limit 0 20 mm 0 0079 in Journal O D Specified value 43 934 43 950 mm 1 7297 1 7303 in Metal 2 I D Specified value 43 984 44 0...

Page 84: ...e mark on the crank shaft gear with idle gear idle gear with camshaft gear and idle gear with fuel camshaft gear UUVW214A 5 12TIMING GEAR 5 12 1 TIMING GEAR SETTING 5 12 2 TIMING GEAR BACKLASH UUVW215...

Page 85: ...2 and camshaft stopper 3 If the clearance exceeds the allowable limit replace the camshaft stopper 3 1 2 3 Side clearance Specified value 0 07 0 22 mm 0 028 0 078 in Allowable limit 0 3 mm 0 0118 in T...

Page 86: ...llowable limit 0 1 mm 0 004 in Shaft O D Specified value 23 967 23 980 mm 0 9436 0 9441 in Bushing I D Specified value 24 000 24 021 mm 0 9449 0 9457 in S76W290A S76W291A Measure the O D of the camsha...

Page 87: ...dicator with its tip on the intermediate journal Measure the eccentricity half of the measured value while turning the camshaft on the V blocks If the eccentricity exceeds the allowable limit re place...

Page 88: ...he allowable limit replace the pump 1 2 3 S76W297A S76W298A S76W299A Set a dial indicator with its tip on the rear friction face of the flywheel near the edge Turn the flywheel to measure the deflecti...

Page 89: ...n the rotor and assemble the pump Disassemble the pump and measure the amount of the flatness with a scale to get the clearance If the clearance exceeds the allowable limit replace the pump 1 2 3 END...

Page 90: ...rking brake 1 UUVW224A UUVW223A Unscrew the four battery cover mounting screws M6 1 remove the side cover and disconnect the negative battery cable 2 UUVW225A UUVW226A Unscrew the four lower screen mo...

Page 91: ...brake cover 6 UUVW230A Unscrew the nine main floor assembly mounting screws M6 1 to remove the main floor assembly 7 UUVW231A UUVW232A Unscrew the six seat frame assembly mounting bolts M10 1 two air...

Page 92: ...to remove the heat shield Then unscrew the four muffler pipe mounting bolts M8 and two muffler pipe mounting nuts M10 2 and disconnect the spring to remove the muffler pipe 10mm 14mm UUVW235A 11 Unscr...

Page 93: ...mounting bolt 2 and fit the remov al tool into the CVT drive pulley bolt hole Then turn the tool to remove the CVT drive pulley 3 and belt and pull out the CVT driven pulley 4 using a lever CVT drive...

Page 94: ...Unscrew the four engine mounting bracket mount ing bolts M10 1 as well as the two front mounting rubber mounting bolts M12 2 and ground wiring mounting bolt 3 Then disconnect the ground wir ing 4 14m...

Page 95: ...linder block drain plug apply sealant to the thread of the plug IMPORTANT Loosen the bleeding screw 2 on the engine cool ant flange cover Then add the coolant through the radiator filler hole until th...

Page 96: ...injection nozzle holder connection to disconnect the high pressure pipe 2 in order 4 Nut tightening torque 24 5 34 3 Nm 2 5 3 5 kgf m 18 1 25 3 lb ft Undo and remove the PCV hose band 1 and un screw...

Page 97: ...them 90 degrees further in the same order Finally tighten them 70 degrees further Therefore theboltsshouldbetightenedevenlyin3steps When using the angle wrench install it to the head bolt and set the...

Page 98: ...IC INDEX 6 2 2 FUEL INJECTION PUMP Unscrew and pull out the idle adjusting screw shaft 1 1 UUVW263A UUVW264A Unscrew the two injection pump mounting bolts M8 1 and two nuts M8 2 to remove the injectio...

Page 99: ...nut tightening torque 23 5 27 4 Nm 2 4 2 8 kgf m 17 3 20 2 lb ft 4 1 Apply the liquid gasket Three bond 1215 1104 or equivalent on the pump installation surface of the cylinder block 2 Install the sh...

Page 100: ...ENGINE DISASSEMBLY SERVICE AND ASSEMBLY UUVW2A3A UUVW2A4A When installing the governor spring make sure that the governor spring 2 1 is installed on the inside of the governor spring 1 2 2 Be careful...

Page 101: ...bolts M6 1 and remove the gear case using the 10 mm socket wrench and T type socket wrench If necessary re move the relief valve 2 and engine oil filter 3 2 UUVW274A UUVW275A Unscrew the two fuel supp...

Page 102: ...o remove the fork lever 2 Then unscrew the two stopper mounting bolts M6 3 to remove the stopper 4 10mm 4 UUVW277A UUVW278A Pull out the fuel camshaft assembly 1 as one unit 5 ENGINE DISASSEMBLY SERVI...

Page 103: ...unting bolts M6 3 Then remove the idle gear shaft oil pump gear and oil pump in order 14mm 10mm 1 UUVW282A Unscrew the 18 oil pan mounting bolts M6 1 to remove the oil pan 10mm 2 Idle gear shaft mount...

Page 104: ...der to install them into their original positions later 1 UUVW286A Unscrew the five flywheel mounting bolts M10 1 and pull the flywheel to remove it 14mm 2 ENGINE DISASSEMBLY SERVICE AND ASSEMBLY DISA...

Page 105: ...ASSEMBLY Tap the crankshaft from its gear side with a rubber hammer to push out the crankshaft assembly to the flywheel side 5 UUVW291A Unscrew the main bearing case bolts 1 1 and remove the bearing c...

Page 106: ...ft When installing the main bearing case cover make sure that the mark UP on it faces the upper side Also tighten its outer bolts first and then its inner bolts 2 UUVW293A UUVW294A Flywheel bolt tight...

Page 107: ...tion Make sure that the mark caved on the big end of the connecting rod and the arrow mark on the piston face the same direction during installation IMPORTANT Apply oil onto the connecting rod cover b...

Page 108: ...r arm assembly And then adjust the valve clearance Refer to 5 7 1 Intake and exhaust valves clearance adjustment 1 2 UUVW298A To tighten the rocker arm support bolt the groove on the rocker arm shaft...

Page 109: ...eal 1 Install in the reverse order of removal When installing the valve apply oil to the valve stem and install in the cylinder head Lubricate the valve and its related parts after instal lation 4 5 6...

Page 110: ...l After heating the piston to approx 80 100 C lubri cate and assemble it with the connecting rod 1 2 3 4 5 S76W2O8A Install the top ring with its manufacturer mark Y to the top of the piston 6 Piston...

Page 111: ...ith the bottom portion Install the connecting rod with the piston so that it faces the injection pump along with the arrow mark B on the piston 9 6 3 5 THERMOSTAT UUVW2A5A Remove the two thermostat co...

Page 112: ...the measurements are not within the factory specifications replace the thermostat 1 2 3 T46W2F2A 6 3 6 WATER PUMP UUVW2A7A UUVW2A8A Unscrew the four water pump case nuts M6 1 tightened to the gear cas...

Page 113: ...tighten them with a hand until they are not screwed in Then tighten them with a torque wrench in several steps Main bearing case bolt 1 Specified torque 20 0 24 0 Nm 2 0 2 4 kgf m 15 0 17 0 lb ft 6 Al...

Page 114: ...out the key 6 and remove the 6305 bearing 7 and 6305Z bearing 8 Install in the reverse order of removal When installing the injection pump gear heat it to approx 80 C 176 F and fit it to the camshaft...

Page 115: ...2 to remove the rocker arm shaft assembly 3 Then pull out the push rods in order 6 UUVW2B3A Disconnect the intake hose 1 PCV valve hose 2 overflow hose 3 and fuel hose 4 Then unscrew the cylinder hea...

Page 116: ...ve clearance after installing the rocker arm assembly See 5 7 1 Clearance adjustment For the cylinder head bolt installation refer to 6 2 1 Cylinder head CAUTION UUVW2B7A Pull out the cylinder head ga...

Page 117: ...bottom of the engine oil pan to drain the engine oil Open the radiator drain cock to drain the coolant See 6 1 Engine removal 2 3 ENGINE DISASSEMBLY SERVICE AND ASSEMBLY UUVW2C1A Unscrew the fuel tank...

Page 118: ...e and 10 mm spanner to remove the cooling fan retainer alternator and fan belt 8 UUVW2C5A Undo the coolant hose band to disconnect the coolant hose 1 Then disconnect the engine stop solenoid connector...

Page 119: ...ng the gear case gasket apply Three Bon 1215 or equivalent to the both mating surfaces of the gasket before installation For the oil seal or O ring apply a small amount of grease or oil to its mating...

Page 120: ...1 E010 CYLINDER BLOCK COMPONENTS 1 TOTAL CYLINDER BLOCK ASSY 2 PLUG 3 PLUG 4 PLUG 5 PLUG 6 PLUG 7 STRAIGHT PIN 8 PIN STRAIGHT 9 PIN 10 PIN PIPE 11 O RING 12 COVER 13 GASKET 14 BOLT 15 PLUG 16 PUMP OI...

Page 121: ...R AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 2 E020 OIL PAN COMPONENTS 1 OIL PAN ASSY 2 PLUG 3 WASHER SEAL 4 GASKET OIL PAN 5 BOLT 6 FILTER1 OIL 7 O RING 8 F...

Page 122: ...C ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 3 E030 CYLINDER HEAD COMPONENTS 1 TOTAL CYLINDER HEAD ASSY 2 CAP SEALING 3 PLUG 4 PLUG 5 GUIDE INLET VALVE 6 GUIDE EXHAUST VALVE 7 COMBUSTION CHAMBER 8 B...

Page 123: ...LVE ASSY 16 BODY 17 SPRING 18 SEAT VALVE 19 STEEL BALL 20 O RING 21 SUPPORT OIL FILTER 22 PLUG 23 O RING 24 STUD 25 BOLT 26 STUD 27 STUD 28 BOLT 29 BOLT 30 NUT 31 WASHER SPRING 32 NUT 33 WASHER SPRING...

Page 124: ...5 E050 MAIN BEARING CASE COMPONENTS 1 BEARING CASE ASSY 2 BOLT BEARING CASE1 3 METAL CRANKSHAFT 4 GASKET BEARING 5 COVER BEARING CASE 6 GASKET COVER 7 BOLT FLANGE 8 BOLT FLANGE 9 SEAL OIL 10 MAIN BEA...

Page 125: ...EXPLODED VIEW 7 6 E080 VALVE ROCKER ARM COMPONENTS 1 VALVE INLET 2 VALVE EXHAUST 3 SPRING VALVE 4 RETAINER VALVE SPRING 5 COLLET VALVE SPRING 6 SEAL VALVE STEM 7 ROCKER ARM ALL ASSY 8 SHAFT ROCKER ARM...

Page 126: ...STEERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 7 E090 CYLINDER HEAD COVER COMPONENTS 1 CYLINDER HEAD COVER ASSY 2 COVER CYLINDER HEAD 3 CONNECTOR AIR BREATHER 4 PLUG OIL FILLER 5 O RI...

Page 127: ...E STEERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 8 E100 CAMSHAFT COMPONENTS 1 TAPPET 2 ROD PUSH 3 CAMSHAFT ASSY 4 GEAR CAMSHAFT 5 KEY 6 STOPPER CAMSHAFT 7 CIR CLIP EXTERNAL 8 BOLT 9 G...

Page 128: ...INE EXPLODED VIEW 7 9 E110 PISTON CRANK SHAFT COMPONENTS 1 PISTON PIN ASSY 2 PISTON 3 PIN PISTON 4 RING PISTON ASSY 5 TOP RING 6 RING 2 PISTON 7 PISTON OIL RING ASSY 8 CIR CLIP 9 CON ROD ASSEMBLY 10 B...

Page 129: ...ASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 10 E120 FLYWHEEL COMPONENTS 1 FLYWHEEL ASSY 2 GEAR RING 3 BOLT 4 PLATE REAR END 5 STUD 6 NUT 7 WASHER S...

Page 130: ...RIC INDEX ENGINE ENGINE EXPLODED VIEW 7 11 E130 NOZZLE HOLDER COMPONENTS 1 HOLDER NOZZLE 1 ASSY 2 GASKET 3 HEAT SHIELD 4 GASKET 5 TUBE1 INJECTION 6 TUBE2 INJECTION 7 TUBE3 INJECTION 8 CLAMP1 TUBE 9 CL...

Page 131: ...N PUMP 6 BOLT 7 STUD 8 WASHER SPRING 9 NUT 10 HOSE FUEL 11 SHAFT CAM 12 BEARING BALL 13 KEY 14 CIR CLIP EXTERNAL 15 GOVERNOR SLEEVE ASSY 16 BEARING 6004C3 17 SNAP RING 18 STOPPER FUEL CAMSHAFT 19 BOLT...

Page 132: ...INDEX ENGINE ENGINE EXPLODED VIEW 7 13 E150 SPEED CONTROL PLATE COMPONENTS 1 ADJUSTING BOLT 2 NUT 3 GASKET 4 NUT CAP 5 SNAP RING 6 CAP 7 LEVER SPEED CONTROL 8 PLATE SPEED CONTROL 9 GASKET SPEED CONTRO...

Page 133: ...3 BUSH 4 IDLE ADJUSTMENT BODY 5 IDEL ADJUSTING BOLT 6 SPRING IDLE 7 NUT 8 O RING 9 PACKING 10 CAP 11 COVER ENGINE STOP LEVER 12 GASKET SPEED CONTROLPLATE 13 BOLT FLANGE 14 ENGINE STOPSOLENOIDE GUIDE 1...

Page 134: ...GINE CVT TRANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 15 E170 GOVERNOR COMPONENTS 1 GOVERNOR LEVER ASSY 2 LEVER ASSY 3 BOLT 4 SPRING1...

Page 135: ...GINE ENGINE EXPLODED VIEW 7 16 E190 WATER HOSE COMPONENTS 1 FLANGE WATER 2 WATER FLANGE GASKET 3 BOLT 4 STUD 5 NUT FLANGE 6 HOSE WATER RETURN 7 HOSE WATER PUMP 8 BAND 9 THERMOSTAT ASSY 10 GASKET 11 BO...

Page 136: ...EX ENGINE ENGINE EXPLODED VIEW 7 17 E200 DYNAMO COMPONENTS 1 ALTERNATOR ASSY 2 SUPPORT2 ANTERNATOR 3 SUPPORT3 ALTERNATOR 4 SPACER 5 BOLT FLANGE 6 BOLT FLANGE 7 BOLT 8 WASHER PLAIN 9 COOLING FAN 10 WAS...

Page 137: ...EERING HYDRAULIC ELECTRIC INDEX ENGINE ENGINE EXPLODED VIEW 7 18 E220 MAINFOLD COMPONENTS 1 MANIFOLD INLET 2 BOLT SCREW 3 CONNECTOR AIR BREATHER 4 GASKET INLET MANIFOLD 5 BOLT 6 BOLT 7 BOLT 8 MANIFOLD...

Page 138: ...MEMO...

Page 139: ...e of cooling system for CVT 4 7 3 TROUBLESHOOTING 4 8 4 INSPECTION AND ADJUSTMENT 4 9 4 1 Adjusting distance between shafts for pulleys 4 9 4 2 Check and replacement for CVT belt 4 10 5 DISASSEMBLY SE...

Page 140: ...tion plate to engine Prevention of water entry Three Bond 1206D or equivalent CVT drive driven pulley mounting bolt Prevention of looseness LOCTITE 242 or equivalent 1 3 SEALANT AND ADHESIVE 1 SPECIFI...

Page 141: ...PLE 2 1 STRUCTURE OF CVT CONTINUOUSLY VARIABLE TRANSMISSION CVT driven pulley Transmission 6204R 52T 31T 10T 46T 26T 15T 17T 31T 03014 50820 K5400 1457 1 34150 2156 1 38430 2155 1 6305R 6305R T2610 22...

Page 142: ...ntact diameter against the belt is increased as the centrifugal force is increased by the engine RPM increase The driven pulley is installed to the input shaft of the transmission and its effective di...

Page 143: ...endulum B1 of the driving pulley moves out ward further the flanges on both sides become closer to each other and then the contact point of the belt and flange moves toward the circumference of the pu...

Page 144: ...er hand the effective diam eter of the driven pulley is increased as the free length of the belt is increased by reduction in the effective diameter of the driving pulley As a result the more the load...

Page 145: ...iction between the belt and pulley As the centrifugal fan rotates and draws air this air moves toward the end of the fan blades i e toward the circumference of the fan Then the negative pressure is ge...

Page 146: ...e in CVT clutch cover Clogged CVT filter Foreign material accumulated on CVT drive pulley cover fan blades Check clean or replace the CVT filter Clean the area around the fan blades of the CVT drive p...

Page 147: ...during the inspection of the CVT or installation of the engine or gear box perform the fol lowing procedures to measure the distance between shafts and offset value for the engine flywheel and gear bo...

Page 148: ...buttons 1 and 2 for wear Replace them as necessary 2 Measure the width of the CVT belt 1 Replace it with a new one if it has been used for more than 800 hours or its width is 1 in 25mm or less For re...

Page 149: ...2 UUVW235A Unscrew the battery mounting nuts 1 to remove the battery 4 Unscrew the heat shield mounting bolts 1 M6 4 EA to remove the heat shield Then unscrew the muffler pipe mounting bolts M8 4 EA a...

Page 150: ...T drive pulley mounting bolt tightening torque 54 Nm 5 5 kgf m 40 lb ft CVT driven pulley mounting bolt tightening torque 24 5 Nm 2 5 kgf m 18 0 lb ft Unscrew the CVT drive pulley mounting bolt 1 and...

Page 151: ...the both shafts 3 UUVW455A Tighten the mounting bolts for the gear box and en gine bracket as well as the 8 inner cover mounting bolts Then remove the shafts offset jig The jig should be removed easil...

Page 152: ...24 5 Nm 2 5 kgf m 18 0 lb ft 7 Install the outer CVT cover and tighten its mounting bolt 8 Make sure that all mounting bolts for the engine and CVT are installed properly When installing the internal...

Page 153: ...LEY ASSEMBLY COMPONENTS DISASSEMBLY AND ASSEMBLY UUVW343A UUVW344A Fix the shaft A of fixing pulley assembly and turn the spider assembly part B to remove and then remove the spider assembly 1 sliding...

Page 154: ...sembly make sure to set its thrusting part faces downward The left and right covers 2 should be installed with their protrusive area contacting with the slot on the lower side of the spider body UUVW3...

Page 155: ...l direction gradu ally by turns Apply the adhesive equivalent LOCTITE 271 to the following screw thread 1 2 After disassembling the lock nut of centrifugal lever you should replace it with new one to...

Page 156: ...RAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX CVT COMPONENTS COMPONENTS 1 CVT PRIMARY 2 CVT SECONDARY 3 BELT DRIVE 4 BOLT 5 ARM CAM 6 SPIDER KIT 7 FRICTION SPRING 8 FAN 9 SCREW 10 SCREW SET 11 BUT...

Page 157: ...13 12 18 10 15 7 6 13 13 18 11 4 4 1 9 2 17 16 14 3 4 4 4 5 8 2 UUVW353A 6 2 U0287A CLUTCH COVER 1 ADAPTOR CVT DRIVE 2 BOLT FLANGE 3 CLUTCH COVER ASSY INNER 4 BOLT FLANGE 5 BOLT 6 WASHER PLAIN 7 WASHE...

Page 158: ...MEMO...

Page 159: ...ar 5 9 4 2 Tooth contact of spiral bevel gear 5 10 4 3 Air gap of vehicle speed sensor 5 11 4 4 Shift cable length 5 12 4 5 Front wheel drive cable length 5 12 5 DISASSEMBLY SERVICE AND ASSEMBLY 5 13...

Page 160: ...front and rear wheels on high speed forward driving REMARK Rear wheel rotating ratio 31 30 x 46 52 x 10 31 x 10 37 0 079695 Front wheel rotating ratio 31 30 x 46 52 x 22 19 x 10 31 x 8 34 0 080336 It...

Page 161: ...Prevention of looseness LOCTITE 242 or equivalent Mating surface of transmission case and cover Prevention of oil leakage Three Bond 1206D or equivalent Mating surface of transmission case and front...

Page 162: ...25x30x17 10T 22T 19T 52T 31T 19 HEX 25x30x13 6205 6304 K5400 1457 1 T8101 75520 38430 2155 1 34150 2156 1 K5400 1457 1 03014 50820 6204 6305R T2610 22661 6305 34150 2156 1 6205 T8101 75520 6205 Forwa...

Page 163: ...shaft 2 For reverse driving as the 17 sprocket of the shaft 1 and the 26 sprocket of the shaft 2 are connected by the silence chain the rotating di rection of the shaft 2 becomes reverse to the one w...

Page 164: ...oove of the shift drum As the shift drum rotates the fork pin fixed to the groove of the shift drum moves left or right and the fork slides on the fork rod to shift the gear The detent disc 11 is inst...

Page 165: ...he rear axle drive shaft the 19 sprocket 6 of the front axle drive shaft 5 slides on the needle bearing and no power is delivered before the front wheel drive is activated When the front wheel drive l...

Page 166: ...damaged parts Abnormal noise Insufficient oil Improper gear backlash Worn gear Worn bearing Improper gear engagement Damaged silence chain Add oil Adjust the backlash or replace the related part Repla...

Page 167: ...andard backlash on the gear teeth contacted 0 2 0 3 mm 0 0079 0 0118 in Back lash on the spline 0 04 0 07 mm 0 0016 0 0028 in 1 2 3 4 If the 31 bevel gear should be moved to adjust the backlash adjust...

Page 168: ...The contact area should be over 35 of the entire teeth area and the center of the contact mark should be close to the center of the pinion in height Also the center of the contact mark should be loca...

Page 169: ...g gear toward the pinion and pull out the pinion from the ring gear if necessary to maintain the backlash Then measure the backlash T46W822A D TIP CONTACT 4 3 AIR GAP OF VEHICLE SPEED SENSOR During as...

Page 170: ...he transmis sion case side pull the cable gently to fit it into the mounting bracket and then adjust the cable length so that the lever can be moved to each gear posi tion freely Then tighten the moun...

Page 171: ...2 first 3 Pull out the parking brake cable connecting snap pin 3 and unscrew the caliper mounting bolts 4 M10 2 EA using the 14 mm socket wrench to disconnect the cable and separate the caliper assemb...

Page 172: ...BLY AND ASSEMBLY UUVW415A UUVW416A Set the transmission case assembly in a stable place and undo the drain plug 1 with the 22 mm socket wrench to drain the transmission fluid 1 UUVW417A UUVW418A Unscr...

Page 173: ...emove the ball bearing 1 from the spiral bevel pinion shaft on the transmission cover side to re move the 52 gear 2 3 UUVW446A On the transmission case cover side pull the drive shaft 1 driven shaft 2...

Page 174: ...ing 2 clutch dog 3 spring 4 clutch dog 5 snap ring 6 thrust collar 7 30 gear 8 needle bearing 9 driven shaft 10 and ball bearing 11 in order 7 Disconnect the shift guide lever 1 and pull out the fork...

Page 175: ...d direction UUVW451A CAUTION UUVW450A The 31 gear 2 cannot be removed from the drive shaft assembly it is shrink fitted with heat REMARK Remove the ball bearings 1 from the drive shaft assembly on bot...

Page 176: ...nt wheel drive cover mounting bolts 1 M8 8 EA using the 12 mm socket wrench to remove the front wheel drive cover 1 UUVW423A Remove the front wheel drive shaft and rear wheel drive shaft together whil...

Page 177: ...shims 2 on the case side in a safe place When assembling the shaft make sure to insert the shims in the cover in the ball bearing mounting area CAUTION When assembling the rear wheel drive shaft fit t...

Page 178: ...HYDRAULIC ELECTRIC INDEX UUVW428A UUVW429A When assembling the front wheel drive shaft tap in the ball bearing 1 to the splined side Then fit the fork 2 needle bearing 3 needle bearing 3 19 sprocket...

Page 179: ...ightening torque 7 8 15 7 Nm 0 8 1 6 kgf m 5 8 11 5 lb ft When installing the ball bearing holder mounting screws apply LOCTITE 242 or equivalent to their threads in advance CAUTION UUVW435A Remove th...

Page 180: ...ver mounting bolts 1 M6 5 EA and shift lever mounting nut 2 M8 1 EA using the 10 mm and 12 mm spanners and socket wrenches to remove the shift cover 1 UUVW437A Remove the shift disc 1 spacer 2 16 gear...

Page 181: ...he shaft make sure to align the serration alignment section UUVW443A UUVW442A UUVW445A UUVW444A IMPORTANT When reassembling these components insert the 16 gear 1 to the shift guide lever and set the 3...

Page 182: ...A When necessary remove the shift arm 6 and front wheel drive lock fork 7 by unscrewing the front wheel drive lever mounting nut 1 M10 1 EA removing the shift arm 2 and spring 3 and then pulling out t...

Page 183: ...ON COMPONENTS 6 COMPONENTS 6 1 U120A TRANSMISSION CASE COMPONENTS 1 TRANMISSION ASSY 2 MISSION CASE 3 COVER TRANSMISSION CASE 4 BOLT 5 PIN STRAIGHT 6 COVER FRONT AXLE DRIVE 7 BOLT 8 PIN STRAIGHT 9 COV...

Page 184: ...EAR 31 4 BEARING BALL 5 BEARING BALL 6 OIL SEAL 25 47 10 5 7 SILENT CHAIN 36 8 SHAFT 9 26T SPROCKET 10 BEARING NEEDLE 11 COLLAR THRUST 12 SNAP RING 13 CLUTCH DOG 14 CLUTCH DOG 15 COLLAR THRUST 16 GEAR...

Page 185: ...AL BEVEL GEARASSEMBLY 2 SHAFT 10 BEVEL PINION 3 BEVEL GEAR 31 4 SHIM 5 SHIM 6 SHIM 7 BEARING BALL 8 SHIM 0 1 9 SHIM 0 2 10 COLLAR 11 RING SNAP 12 WINNOW BEARING HOLDER 13 GEAR 52 14 SCREW 15 BEARING B...

Page 186: ...6 BOLT 17 SHIM 0 2 18 SHIM 0 3 19 BEARING BALL 20 SHAFT REAR DRIVE 21 22T SPROCKET 22 CIR CLIP EXTERNAL 23 COLLAR 24 BEARING BALL 25 SHIM 0 1 26 SHIM 0 2 27 SHIM 0 3 28 OIL SEAL 25 47 10 29 SILENT CHA...

Page 187: ...L ENGINE CVT TRANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX TRANSMISSION COMPONENTS 6 5 U160A PROPELLER SHAFT COMPONENTS 1 PROPELLER SHAFT ASSY FR 2 PIN SPRING 3 PRO...

Page 188: ...MEMO...

Page 189: ...ing brake cable 6 5 2 2 5 Accelerator pedal cable 6 6 3 DISASSEMBLY SERVICEANDASSEMBLY 6 6 3 1 Cargo bed removal 6 6 3 2 Seat and fender removal 6 7 3 3 Hood panel floor and radiator removal 6 9 3 4 H...

Page 190: ...IC INDEX 1 SPECIFICATIONS 1 1 TIRE Item Standard Specification Standard tire inflation pressure Front 25 x 10 12 6PR 12 psi 0 84 kgf cm 82 7 kPa Rear 25 x 11 12 6PR 18 psi 1 26 kgf cm 124 0 kPa Wheel...

Page 191: ...RAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 INSPECTION AND ADJUSTMENT 2 1 INSTALLATION DIRECTION OF FRONT REAR TIRES CHASSIS INSPECTION AND ADJUSTMENT UUVW501A Rear wheel outer direction Rear...

Page 192: ...ON CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 2 ROUTES FOR VARIOUS CABLES 2 2 1 DIFFERENTIAL LOCK CABLE 2 2 2 SHIFT SELECTOR CABLE CHASSIS INSPECTION AND ADJUSTMENT UUVW510...

Page 193: ...AL ENGINE CVT TRANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 2 3 FRONT WHEEL DRIVE CABLE 2 2 4 PARKING BRAKE CABLE CHASSIS INSPECTION AND ADJUSTMENT UUVW518B UUVW5...

Page 194: ...ULIC ELECTRIC INDEX 2 2 5 ACCELERATOR PEDAL CABLE 3 DISASSEMBLY SERVICE AND ASSEMBLY 3 1 CARGO BED REMOVAL UUVW524A UUVW527B UUVW531A UUVW530A UUVW2G6A UUVW528A Park the vehicle on level ground apply...

Page 195: ...it and injure yourself The cargo bed should be removed using a hoist or crane CAUTION Lift the cargo bed and remove the mounting pins 1 from both sides Then pull out the cargo bed support pole connect...

Page 196: ...D ASSEMBLY UUVW535A UUVW536A Unscrew the left and right cover mounting screws 1 for the middle fender to remove the covers 2 Remove the battery cover and disconnect the neg ative battery cable 1 3 UUV...

Page 197: ...the steering wheel cover and unscrew the mounting nut 1 to remove the steering wheel The unscrew the grip mounting screws to remove the grips 2 for the shift levers Steering wheel mounting nut tighten...

Page 198: ...pull out the rod connecting pin 2 Then remove the brake pedal 3 through the hole UUVW548A 6 Unscrew the accelerator pedal mounting bolt 1 to re move the accelerator pedal assembly UUVW550A UUVW549A 7...

Page 199: ...drain cock 1 to drain the coolant Then disconnect the coolant hose and electric motor connector and unscrew the radiator mounting bolts 2 to remove the radiator assembly 10 Assemble in the reverse or...

Page 200: ...to the speed control lever bracket pulling it gently with the speed control lever not pulled up and tighten the adjusting nut to secure it IMPORTANT Unscrew the accelerator lever mounting double nut a...

Page 201: ...LIC ELECTRIC INDEX 4 COMPONENTS 4 1 U030A ACCELERATOR PEDAL COMPONENTS UUVW554A 1 ARM ASSY ACCEL PEDAL 2 FOOT ACCEL PEDAL 3 PIN HEAD 4 PIN SNAP 5 WASHER PLAIN 6 SPRING ACCEL PEDAL 7 BRKT ACCEL PEDAL M...

Page 202: ...17 15 13 22 20 21 11 12 24 1 4 2 UUVW574A 1 HOOD ASSY GREEN 2 HOOD GREEN 3 HOOD HINGE LH ASSY 4 HOOD HINGE RH ASSY 5 TAPPING SCREW 6 GRILL ASSY 7 EMBLEM 8 PLATE RUBBER 9 PLATE FIXED 10 TAPPING SCREW...

Page 203: ...19 17 19 20 21 14 19 11 UUVW575A 1 STRUCTURE ASSY 2 STEERING COVER ASSY 3 BOLT 4 NUT FLANGE 5 BOLT FLANGE 6 COVER COOLING FAN 7 SCREW BLACK 8 HEAT PROTECTOR BRKT 9 SCREW BLACK 10 STAY ROD BRKT 11 NUT...

Page 204: ...ABLE ASSY 14 CLAMP 15 BOLT FLANGE 16 WASHER PLAIN 17 PIN SNAP 18 SELECTOR SHIFT LEVER ASSY 19 NUT 20 4WD LEVER ASSY 21 GRIP 22 BOLT SCREW 23 TUBE LOCK LEVER 24 SPRING ROD 25 PIN HEAD 26 BUSH 27 4WD CA...

Page 205: ...8 10 18 19 15 19 19 18 18 18 19 6 UUVW576A COMPONENTS 1 FENDER FR LH 2 FENDER FR RH 3 FENDER MIDDLE OUTER LH 4 COVER BATTERY 5 SCREW 6 NUT SPRING 7 FENDER MIDDLE OUTER RH 8 PANEL WHEEL WELL LH 9 PANEL...

Page 206: ...ENGINE MOUNTING FRONT BRACKET ASSY 8 DAMPER ROLL MOUNTING 9 BOLT 10 DAMPER ASS Y ENG MOUNTING 11 BUSH 12 BOLT 13 WASHER 14 FLANGE NUT 15 TM MOUNTING BRACKET ASSY FR 16 WASHER BOLT 17 BRACKET TM MOUNT...

Page 207: ...1 2 10 10 10 17 4 6 14 15 5 UUVW577A COMPONENTS 1 DECK ASSY BLACK 2 DECK UNDER BUMPER 3 TAILGATE ASSY BLACK 4 TAILGATEHINGEBRACKET BLACK 5 BOLT WASHER 6 STOP ROPE 7 REAMER BOLT WASHER 8 PIN SPLIT 9 PI...

Page 208: ...RING HYDRAULIC ELECTRIC INDEX 4 8 U1000A GAS CYLINDER 4 5 10 7 8 6 6 9 8 3 3 12 13 11 1 UUVW578A COMPONENTS 1 BRKT GAS SPRING 2 BOLT FLANGE 3 NUT 4 BRACKET STOPPER 5 BOLT FLANGE 6 COLLAR GAS SPRING 7...

Page 209: ...IC INDEX 4 9 U0225A ROPS 5 2 3 4 5 4 6 7 6 7 5 4 4 1 3 5 9 14 8 9 8 9 9 12 11 10 10 11 15 15 14 15 12 14 13 13 UUVW579A COMPONENTS 1 FRAME FRONT ASSY 2 REAR FRAME ASSY 3 FRAME MIDDLE 4 BOLT 5 FLANGE N...

Page 210: ...STEERING HYDRAULIC ELECTRIC INDEX 4 10 U0811A SEAT 3 10 10 10 3 2 1 7 6 9 5 8 9 6 11 11 A A A A 4 8 5 UUVW580A COMPONENTS 1 SEAT CUSHION ASSY 2 SEAT BACK ASSY 3 FLANGE BOLT 4 SEAT BELT ASSY 3PT 5 BUC...

Page 211: ...erential system assembly 7 9 4 2 Differential lock cable length 7 14 5 DISASSEMBLY SERVICE AND ASSEMBLY 7 14 5 1 Rear axle case removal Rear axle disassembly 7 14 5 2 Rear axle case disassembly and as...

Page 212: ...g torque Rear wheel Flange nut M10 39 2 45 1 Nm 4 0 4 6 kgf m 28 8 33 1 lb ft Rear axle case mounting section Bolt M8 17 6 20 6 Nm 1 8 2 1 kgf m 13 0 15 1 lb ft Rear suspension upper lower strut secti...

Page 213: ...F REAR AXLE SECTION 1 10 spiral bevel pinion 2 Rear wheel drive shaft assembly RH 3 Rear differential assembly 4 37 spiral bevel gear 5 Rear wheel drive shaft assembly LH 6 Differential shift UUVW601A...

Page 214: ...457 1 34150 2156 1 38430 2155 1 6305R 6305R T2610 22661 6204 20x24x13 T2305 25241 T2305 25241 25x29x13 6204 6205 6204 25x29x13 30T 34T K5400 1457 1 25x30x17 10T 22T 19T 52T 31T 19 HEX 25x30x13 6205 63...

Page 215: ...ifferential lock ON 1 6 3 5 6 4 2 UUVW602A REAR AXLE STRUCTURE AND FUNCTION As power is transferred through the rear propeller shaft from the transmission case this power drives the 37 spiral bevel ge...

Page 216: ...ad ro tates with very high speed and the side gear 6 with comparatively high load does not rotate at all In other words it is not possible to escape the pit since the wheel on ice with no friction rot...

Page 217: ...clutch on the differential case cover 5 se curely As the differential case 6 and the drive shaft 7 on one side rotate at the same speed by dog clutch the drive shaft on the other side rotates at the s...

Page 218: ...ck the differential lock links differential lock lever and shift for deformation or breakage and ad just or replace them if necessary Creaking noise from tires while driving Loose wheel nut Check the...

Page 219: ...1 2 UUVW605A 3 Set the lever type dial gauge as shown in the figure and set the sensor to contact with the splined sec tion of the 10 spiral bevel pinion lightly 4 Measure the backlash of the 10 spir...

Page 220: ...ing torque R Radius or bevel pinion spline REMARK 6 The total amount of the shims in the section 1 and 2 should never be changed Shim type 0 1 mm 0 0039 in 0 2 mm 0 0079 in 0 4 mm 0 0157 in 0 8 mm 0 0...

Page 221: ...h 1 2 The pre load of the taper roller bearing that supports the spiral bevel pinion shaft can be adjusted by tightening its mounting nut Refer to the diagram in this chapter The standard pre load is...

Page 222: ...ring gear side increase the amount of shims B to push the ring gear 2 away from the pinion 1 and increase the amount of shims C so that the backlash is maintained Then measure the backlash T85W615A R...

Page 223: ...m 0 76898 078980 in Differential pinion shaft O D 19 959 19 980 mm 0 78579 0 78661 in Standard clearance 0 06 0 102 mm 0 00236 0 00402 in Allowable clearance 0 25 mm 0 00984 in CLEARANCE CHECK UUVW614...

Page 224: ...ction E 40 mm 1 575 in To adjust the set length for the section F set the dif ferential lever in the UNLOCK position on the rear axle case side pull the cable gently to fit it into the mounting bracke...

Page 225: ...Nm 4 0 4 6 kgf m 28 8 33 1 lb ft Unscrew the rear wheel mounting nuts M10 10 EA using the 14 mm socket wrench and place a hydraulic stand under the frame for support Then lift the frame off the ground...

Page 226: ...ersal joint to sep arate the rear axle case assembly 9 UUVW623A The splined end of the CV joint is equipped with the inner extensible snap ring When removing the CV joint apply impact to the CV joint...

Page 227: ...3 UUVW629A Bolt M8 tightening torque 17 6 20 6 Nm 1 8 2 1 kgf m 13 0 15 1 lb ft UUVW627A UUVW628A Unscrew the rear axle case mounting bracket bolts 1 M10 13 EA using the 14 mm socket wrench to remove...

Page 228: ...lking nut and unscrew the caulking nut 2 Then tap the spiral bevel pinion shaft from outside the case inward to remove the bevel pinion shaft If necessary remove the taper roller bearing When reassemb...

Page 229: ...e and rear axle case cover keep the adjusting shims 1 in a safe place so that they can be fitted back in their original con dition 7 Assemble in the reverse order of disassembly 8 REAR AXLE DISASSEMBL...

Page 230: ...1 UUVW638A Pull out the spring pins 1 from the differential case and tap the differential pinion shaft 2 to remove the differential pinions 3 differential pinion wash ers 4 and differential pinion sha...

Page 231: ...out a spring pin hole Then pass the differential pinion shaft 2 through and install the differential pinion 3 differ ential pinion for the other side and differential pinion washer in order 2 REAR AXL...

Page 232: ...372 or equivalent to the bolt threads and tighten them diagonally in sev eral steps to the specified torque 5 Mounting bolt M10 tightening torque 48 55 9 Nm 4 9 5 7 kgf m 35 4 41 2 lb ft If necessary...

Page 233: ...JOINT BOOT REPLACEMENT REAR AXLE DISASSEMBLY SERVICE AND ASSEMBLY UUVW651A When installing the rear axle drive shafts to the rear axle case be careful not to switch their original installation positio...

Page 234: ...he snap ring Then fit the ball into the hole push it in along the housing groove and fit the stop ring 5 6 REAR AXLE DISASSEMBLY SERVICE AND ASSEMBLY During assembly fill the rear axle drive shaft hou...

Page 235: ...n the differential case side and then remove the two boots When installing the CV joint the larger opening of the bearing cup should be inserted into the housing first REAR AXLE DISASSEMBLY SERVICE AN...

Page 236: ...m 15 1 18 0 lb ft 68 Nm 6 8 kgf m 49 0 lb ft 4 5 6 SUSPENSION ASSEMBLY REMOVAL Unscrew the strut mounting bolts 1 M8 2 EA with the 14 mm and 12 mm spanners and remove the strut assembly 1 UUVW660A UUV...

Page 237: ...r mounting bolts 1 to remove the brake caliper 2 2 UUVW666A Pull out the rear axle cover 1 and remove the split pin and slotted nut to remove the hub 2 and brake disc 3 assembly 3 UUVW669A Pull out th...

Page 238: ...and unscrew the brake disc mounting bolts 2 to remove the brake disc 4 UUVW673A Loosen the left and right mounting bolts 1 M8 4 EA for the stabilizer 5 UUVW674A Pull the propeller shaft toward the rea...

Page 239: ...sassembly When assembling the components tighten the brake disc mounting bolts first to install the disc Then fit the spring pin to secure the propeller shaft 7 8 UUVW675A When installing a new propel...

Page 240: ...AKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX REAR AXLE COMPONENTS 6 COMPONENTS 6 1 U200A REAR AXLE DRIVE SHAFT UUVW676A 1 DRIVE SHAFT ASSY RR LH 2 BOOT REPAIR KIT FRT O B W GREASE 3 BOOT REPAIR KI...

Page 241: ...BEVEL 15 GEAR 37 BEVEL 16 COVER DIFFERENTIAL CASE 17 CASE DIFFERENTIAL 18 GEAR DIFF SIDE 19 OIL SEAL 30 75 12 20 WASHER DIFF 3 21 WASHER DIFF 22 WASHER DIFF 23 PINION 24 WASHER 25 SHAFT PINION 26 PIN...

Page 242: ...ON CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX REAR AXLE COMPONENTS 6 3 U680A REAR DIFFERENTIAL UUVW678A 7 7 7 7 1 REAR DIFF BRACKET ASSY RH 2 OIL SEAL 38 54 9 5 3 REAR DIFF B...

Page 243: ...BUMP STOPPER 6 SPRG SEAT LWR FR 7 BUSHING RR SHK ABS 8 BUSHING LWR_RR SHK ABS 9 REAMER BOLT SUS LWR REAR M8 10 REAMER BOLT SUS UPR REAR M8 11 NUT 12 WASHER PLAIN 13 WASHER PLAIN 14 WASHER SPRING 15 A...

Page 244: ...MEMO...

Page 245: ...s 8 7 4 4 Brake lamp switch installation clearance optional 8 7 4 5 Parking brake wire installation length adjustment 8 8 4 6 Brake pedal free play 8 8 5 DISASSEMBLY SERVICE AND ASSEMBLY 8 9 5 1 Rear...

Page 246: ...em Specification Remarks Brake type Hydraulically operated pedal type caliper disc Brake pedal free play 15 20 mm 0 59 0 79 in Allowable min brake disc thickness 3 5 mm 0 318 in Specification for new...

Page 247: ...r cylinder rod 2 pushes the master cylinder piston to deliver the brake fluid in the slave cylinder to each wheels This brake fluid flows to the fitting tee 3 through the brake tubes for the front rea...

Page 248: ...e The cam lever and bracket 4 are equipped with the steel ball pockets and the steel ball is seated in center in a normal state as shown in the figure A When the parking brake lever is pulled up and t...

Page 249: ...tube Replace the part Replace the part Check and replace the tube line Insufficient braking force Improperly adjusted brake free play Excessively worn brake disc or plate Damaged brake fluid tube Adj...

Page 250: ...unevenly scratched or split If an abnormal condition is found replace it with a new one IMPORTANT Measure the thickness of the parking brake disc with the same procedure Standard disc thickness 4 0 mm...

Page 251: ...m 1 Item Standard Brake lamp switch clearance A 0 1 mm 0 0 039 in UUVW705A Measure the clearance of the parking brake caliper with vernier calipers Standard clearance 4 8 mm 0 189 in or higher Standar...

Page 252: ...free play of the brake pedal can be adjusted by adjusting the installation length of the brake master cylinder rod Initial rod installation length A 128 mm 5 04 in 2 UUVW711A Connect the parking brake...

Page 253: ...normal bolt mounting holes Make sure to check the bolt hole size during installation IMPORTANT Mounting bolt M8 tightening torque 24 0 Nm 2 5 kgf m 18 0 lb ft Unscrew the brake caliper mounting bolts...

Page 254: ...move the mounting screws 2 using the 6 mm hex wrench 4 UUVW724A Remove the brake pad 1 by pressing it down 5 UUVW725A If necessary pull out the guide forward and remove the spring 6 UUVW726A For assem...

Page 255: ...27A Specified torque 16 0 21 0 Nm 1 6 2 1 kgf m 11 8 15 4 lb ft IMPORTANT 5 2 FRONT WHEEL BRAKE REMOVAL BRAKE PAD AND DISC REPLACEMENT Remove the axle cap 1 Then remove the ball joint bolt mounting sp...

Page 256: ...rew 1 and tap the brake fluid res ervoir upward to remove it 2 BRAKE DISASSEMBLY SERVICE AND ASSEMBLY UUVW731A Pull out the brake fluid cylinder snap ring 1 re move the piston 1 and 2 and unscrew the...

Page 257: ...0 Nm 1 6 2 1 kgf m 11 8 15 4 lb ft IMPORTANT Piston stroke 30 1 mm 1 18 0 039 in REMARK 5 4 BLEEDING BRAKE LINE UUVW714A Replenish the brake fluid reservoir with fluid up to the MAX level 1 UUVW715A R...

Page 258: ...and close the cap 1 Bleed the front and rear brakes with the same proce dures 4 5 Make sure that the brake fluid level in the brake fluid reservoir does not fall below the MIN line during bleeding the...

Page 259: ...SSEMBLY PARKING BRAKE PAD REPLACEMENT UUVW757A BRAKE DISASSEMBLY SERVICE AND ASSEMBLY Unscrew the parking brake caliper mounting nuts 1 M10 2 EA to remove the bracket 2 ball 3 cam lever 4 support plat...

Page 260: ...BRAKE DISASSEMBLY SERVICE AND ASSEMBLY The clearance of the brake pad should be over 4 8 mm 0 189 in UUVW705A IMPORTANT Fit the other pad 1 to the bolts and place the sup port plates 2 as a figure UUV...

Page 261: ...RRIER ASSY DIFF 16 SPRING PAD 17 BOLT 18 NUT 19 BOLT UNION 20 WASHER 21 BOOT KIT 22 CARRIER ASSY DIFF 23 BREATHER 24 CAP BREATHER 25 WASHER BOLT 26 HUB ASSY FR 27 BOLT M10x1 25 HUB 28 DISC BRAKE FRT 2...

Page 262: ...HYDRAULIC ELECTRIC INDEX 6 2 U0431A PARKING BRAKE 7 6 4 5 8 2 3 9 11 12 10 1 UUVW763A COMPONENTS 1 PARKING BRAKE ASSY 2 BOLT WASHER 3 CABLE ASSY PARKING 4 JOINT PIN 5 PIN SNAP 6 CLAMP 7 BOLT FLANGE 8...

Page 263: ...check 9 12 4 6 1 Differential pinion and differential pinion shaft 9 12 4 6 2 Differential case spiral bevel gear and differential side gear 9 13 5 DISASSEMBLY SERVICE AND ASSEMBLY 9 13 5 1 CV joint r...

Page 264: ...cifications Remarks Oil SAE gear oil 90 or DAEDONG UTF55 Exxon Mobil fluid 423 424 BP Tractran UTH Shell DONAX TD Grease NLGL grade No 2 or equivalent Lower section of hub strut Front axle case oil ca...

Page 265: ...Nm 2 1 kgf m 15 1 lb ft Knuckle mounting bolt M8 25 0 Nm 2 5 kgf m 18 0 lb ft Lower arm mounting nut M10 41 0 Nm 4 1 kgf m 29 5 lb ft Lower knuckle ball joint mounting nut slotted M10 35 0 Nm 3 5 kgf...

Page 266: ...2T 31T 10T 46T 26T 15T 17T 31T 03014 50820 K5400 1457 1 34150 2156 1 38430 2155 1 6305R 6305R T2610 22661 6204 20x24x13 T2305 25241 T2305 25241 25x29x13 6204 6205 6204 25x29x13 30T 34T K5400 1457 1 25...

Page 267: ...34 spiral bevel gear 3 Front differential case 4 Differential pinion shaft 5 Differential pinion 6 Differential side gear 7 CV joint As the power is transferred from the transmission through the fron...

Page 268: ...l bevel gear ring gear and one axle to each other When the vehicle is driven or cornering on a normal paved road the turning speed difference between the ring gear and axle is not immense and the fric...

Page 269: ...il Replace the damaged part Replace the damaged part Adjust the backlash Adjust the pre load Replace CV joint Oil leaked from front dif ferential case Excessive oil Damaged O rings Clogged overflow pi...

Page 270: ...09 0 12 kgf m R 0 0098 m F 9 2 12 2 kgf 20 3 26 9 lbs UUVW804A 4 2 TURNING TORQUE OF 8 BEVEL PINION SHAFT 4 INSPECTION AND ADJUSTMENT 4 1 TOE IN ADJUSTMENT A B UUVW873A Park the vehicle on level grou...

Page 271: ...side gears Size of adjusting shim 0 8 mm 0 031 in 1 0 mm 0 039 in Standard shim 1 2 mm 0 047 in 3 Standard backlash 0 15 0 25 mm 0 0059 0 0098 in The pre load of the taper roller bearing that support...

Page 272: ...in 18 2 mm 0 7165 in 5 Measure the contact area if the shim or collar has been adjusted This procedure can be skipped if it is not necessary to adjust the shim 3 Adjust the shims 2 and 3 if the 34 sp...

Page 273: ...n front shim 4 of pinion shaft gear side Decrease in rear shim 5 Increase in ring gear shim 2 Decrease in ring gear shim 3 A TOE CONTACT T46W819A Ring gear 34 Spiral bevel gear Remove the 8 bevel pini...

Page 274: ...6299 0 6306 in Standard clearance 0 016 0 052 mm 0 00063 0 00204 in Allowable clearance 0 25 mm 0 00984 in C DEEP CONTACT T46W821A If the contact mark is deep into the ring gear teeth push the ring ge...

Page 275: ...d level ground stop the en gine and apply the parking brake Then drain the front axle case oil 1 UUVW815A Place a hydraulic jack under the front frame and un screw the front wheel mounting nuts 1 M10...

Page 276: ...tie rod end and lower arm 5 When installing the tie rod end mounting bolt tighten the slotted nut to the specified torque and then tighten it further until the split pin hole is aligned with the nut g...

Page 277: ...12 mm socket wrench and pull the front axle drive shaft to remove it as an assembly 7 UUVW823A 5 2 CV JOINT BOOT REPLACEMENT Remove the O ring 1 and snap ring 2 from the front axle drive shaft assembl...

Page 278: ...mage the oil seal If a new bearing holder is used apply grease to its mating surface for the O ring and oil seal IMPORTANT During installation make sure that the larger opening of the CV joint 3 cup i...

Page 279: ...NT AXLE DISASSEMBLY SERVICE AND ASSEMBLY During assembly set the spring length A of the front strut assembly to be 328 3 mm 12 9 0 12 in Tighten each tightening section to the specified torque when as...

Page 280: ...pring pin 1 and disconnect the propeller shaft 6 UUVW836A Unscrew the front axle case mounting bolts 1 M10 4 EA and disconnect the bleeding hose Then re move the front differential case assembly by li...

Page 281: ...original state during assembly 2 UUVW839A Unscrew the front differential case mounting bolts 1 M10 7 EA with the 14 mm socket wrench 1 Bolt specified torque 39 2 44 1 Nm 4 0 4 5 kgf m 28 8 32 4 lb ft...

Page 282: ...1 M8 6 EA with the 12 mm socket wrench and remove the spiral bevel gear 2 and differential case 3 by tap ping them with a rubber hammer 3 FRONT AXLE DISASSEMBLY SERVICE AND ASSEMBLY Pull out the diff...

Page 283: ...the differential pinion washer 1 and differential pinion 2 to the differential case fit the dif ferential pinion shaft 3 with its hole facing up Then insert the differential pinion 4 and differential...

Page 284: ...ball bearings 1 onto the front and back 6 UUVW854A Tap the clutch assembly into the case with a rubber hammer 7 UUVW855A Take out the snap ring 1 1 FRONT AXLE DISASSEMBLY SERVICE AND ASSEMBLY When ins...

Page 285: ...remove the washer 5 rubber spacer 6 upper mounting ball 7 and lower mounting ball 8 in order 2 FRONT AXLE DISASSEMBLY SERVICE AND ASSEMBLY UUVW857A Remove the spring seating plate 2 spring 3 spring se...

Page 286: ...ber assembly 3 4 UUVW863A Pull out the knuckle snap ring 13 and remove the bearing 14 5 UUVW864A Unscrew the ball joint bracket mounting screws and separate the bracket 15 and ball joint 16 6 FRONT AX...

Page 287: ...ONT AXLE STEERING HYDRAULIC ELECTRIC INDEX UUVW865A Assemble in the reverse order of disassembly 7 UUVW866A Place and install the front wheel shock absorber onto the knuckle Then tighten the mounting...

Page 288: ...LLER SHAFT FRONT UNIVERSAL JOINT REPLACEMENT UUVW867A Remove the propeller shaft mounting spring pin 1 on the front axle case side by tapping it 1 UUVW868A Pull the propeller shaft toward the transmis...

Page 289: ...FRONT DRIVE SHAFT LH 2 BOOT REPAIR KIT FRT O B W GREASE 3 BOOT REPAIR KIT FRT I B W GREASE 4 WINNOW BEARING HOLDER 5 OIL SEAL 30 40 8 6 BEARING BALL 7 O RING 8 FRONT DRIVE SHAFT RH 9 BOOT REPAIR KIT F...

Page 290: ...PIN STRAIGHT 14 BOLT UBS 15 SHAFT DIFFERENTIAL PINION 16 PIN STRAIGHT 17 PINION DIFFERENTIAL 18 WASHER DIFFERENTIAL SIDE 19 GEAR DIFF SIDE 20 SHIM 0 8 21 SHIM 1 0 22 SHIM 1 2 23 BALL BEARING 6010SH 2...

Page 291: ...RG SEAT UPR FR 10 FRICTION SPRING 11 BUMP STOPPER 12 SPRG SEAT LWR FR 13 KUNCKLE ASSY FR LH 14 BRACKET B JOINT 15 BOLL JOINT ASSY FR LWR 16 BOLT 17 HUB BEARING FR 18 SNAP RING 19 NIPPLE GREASE 20 BOLT...

Page 292: ...MEMO...

Page 293: ...agram 10 3 2 2 Structure in steering gearbox 10 4 2 3 Steering gearbox components 10 5 3 TROUBLESHOOTING 10 6 4 INSPECTION AND ADJUSTMENT 10 7 4 1 Tie rod length adjustment 10 7 4 2 Toe in adjustment...

Page 294: ...in Average turning torque 1 1 5 Nm 0 102 0 153 kgf m 0 735 1 102 lb ft Rotating ratio rack moving distance pinion shaft rotation 32 52 mm rev 1 28 in rev Steering wheel revolution factory spec 3 69 t...

Page 295: ...ering wheel 1 is turned the steering wheel shaft 2 that its splined part is engaged with the steering wheel rotates and this movement is transferred to the steering gear box 4 through the universal jo...

Page 296: ...C ELECTRIC INDEX STEERING SYSTEM STRUCTURE AND FUNCTION 2 2 STRUCTURE IN STEERING GEARBOX In the steering gearbox the pinion is engaged with the rack When the pinion rotates the rack moves to the side...

Page 297: ...E BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX STEERING SYSTEM STRUCTURE AND FUNCTION 2 3 STEERING GEARBOX COMPONENTS 1 2 3 4 5 6 8 9 10 7 UUVW903A COMPONENTS 1 PLUG 2 OIL SEAL 3 PINION SHAFT 4...

Page 298: ...e size inflation pressure or shape Worn or damaged tie rod end Improper toe in Adjust the inflation pressure or replace the tires Replace Adjust Excessive steering wheel reac tion Worn or damaged tie...

Page 299: ...g nut 1 turn the tie rod end to set its length correctly and tighten the mounting nut firmly 2 4 INSPECTION AND ADJUSTMENT 4 1 TIE ROD LENGTH ADJUSTMENT 4 2 TOE IN ADJUSTMENT Adjust the toe in so that...

Page 300: ...st ment in section Inspection and adjustment 1 UUVW904A UUVW906A Undo the band 1 and remove the rubber boot bel lows 2 2 UUVW907A Unfold the caulked part of the holder 1 and rotate the ball joint 2 to...

Page 301: ...ing sections of the gears and in the case sufficiently REMARK 5 2 STEERING COLUMN REMOVAL AND INSTALLATION UUVW914A Disconnect the connectors for the instrument cluster 1 power supply ignition switch...

Page 302: ...ing torque 48 0 55 9 Nm 4 9 5 7 kgf m 35 3 41 2 lb ft UUVW921A UUVW920A Unscrew the panel mounting screws 1 M8 8 EA to remove the panel Screws under hood 2 EA LH 2 EA RH side of body 1 EA LH 1 EA RH c...

Page 303: ...ering column assembly by tapping the steering shaft 1 downward Then unscrew the steer ing column mounting bolt 2 M8 1 EA with the 13 mm spanner to remove the steering column Install in the reverse ord...

Page 304: ...STEERING GEAR BOX ASSY 2 GEAR BOX STEERING 3 NUT 4 CLIP A 5 BOOT LH 6 CLIP B 7 CLIP C 8 BOOT RH 9 TIE ROD ASSY 10 BRKT STEERING UNIT 11 BOLT 12 BOLT 13 WASHER BOLT 14 BOLT 15 WASHER PLAIN 16 NUT CAST...

Page 305: ...sure 11 19 5 DISASSEMBLY SERVICE AND ASSEMBLY 11 20 5 1 Gear pump disassembly and assembly 11 20 5 1 1 Gear pump removal 11 20 5 1 2 Gear pump disassembly 11 20 5 2 Auxiliary hydraulic valve dumping v...

Page 306: ...ressure Rotating direction 22 5 min 5 94 u s gal min 10 cc rev 210 kgf cm2 20 58 MPa 2 986 psi Counterclockwise Dumping cylinder Single rod double acting type Cylinder outside diameter 50mm 1 968 in C...

Page 307: ...LE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX HYDRAULIC SYSTEM OPERATING PRINCIPLE 2 OPERATING PRINCIPLE 2 1 HYDRAULIC COMPONENT LAYOUT COMPONENTS 1 GEAR PUMP 2 OIL TANK 3 DUMPING VALVE 4 AUXI...

Page 308: ...3215 33601 CONNECTOR T4715 47071 OIL TANK HYD HOSE ASSY P U3215 31401 HOSE SIZE 3 8 HYD HOSE ASSY A U3215 31801 HOSE SIZE 1 4 HYD HOSE ASSY T U3215 31501 GEAR PUMP ASSY 10 cc rev U3215 33301 ELBOW T48...

Page 309: ...ingle Acting Valve Detent Floating Valve Front Block 5 0 2 Relief Valve 155 kgf cm Gear Pump 10cc rev Oil Tank 15 liter 22 5lpm Cargo Bed Lift Cylinder Single Rod Double Acting Cylinder ID 40mm Rod ID...

Page 310: ...the gear pump 1 pushes out the hydraulic oil the hy draulic oil flows to the front block under the dumping valve 3 Then it passes through the dumping valve and auxiliary hydraulic valve if equipped an...

Page 311: ...ve Front Block Gear Pump 10cc rev Oil Tank 15 liter 22 5lpm Cargo Bed Lift Cylinder Single Rod Double Acting Stroke 195mm Cylinder ID 40mm Rod ID 25mm 5 0 2 Relief Valve 155 kgf cm UUVWB03A CIRCUIT Rl...

Page 312: ...AKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 3 2 EXTERNAL HYDRAULIC OIL OPERATION HYDRAULIC OIL FLOW DIAGRAM 2 5 1 4 6 3 UUVWB10A 1 GEAR PUMP 2 OIL TANK 3 FRONT BLOCK ASSEMBLY 4 AUXILIARY HYDRAU...

Page 313: ...CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX CIRCUIT P T A B 0 1 0 1 5 0 2 Relief Valve 155 kgf cm UUVWB04A Rlo wdqn Jhdu sxps Dx loldu k gudxolf ydoyh Rlo wdqn Jhdu sxps Dx l...

Page 314: ...SSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 4 GEAR PUMP MOUNTING LOCATION AND STRUCTURE 1 REAR COVER 2 SEAL BLOCK 3 DRIVE GEAR SHAFT 4 DRIVEN GEAR 5 SEAL BLOCK 6 CASE...

Page 315: ...gine However the rotating speed is increased by the 29 gear 1 and 18 gear 2 to drive the hydraulic pump Engine 2800rpm Engine and gear pump speed ratio 1 0 805 2800 x 1 2 x 29 18 2255 rpm The hydrauli...

Page 316: ...ND STRUCTURE 1 TUBE 2 ROD 3 HEAD COVER 4 PISTON 5 SPRING WASHER 6 NUT 7 O RING 8 PISTON PACKING 9 WEAR RING The dumping cylinder is a double acting single rod cylinder Its rod outside diameter is 25mm...

Page 317: ...m The hydraulic line on the lifting side of the dumping cylinder is equipped with the orifice and check valve When the cylinder is extended lifting the check valve is opened to draw more oil into the...

Page 318: ...ANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 2 6 FRONT BLOCK DUMPING VALVE MOUNTING LOCATION ANDSTRUCTURE UUVWB46A 1 BODY 2 SPOOL 3 POPPET 4 SPRING 5 COVER FRONT BLO...

Page 319: ...2 0 1 1 0 3 UUVWB77A The dumping valve is a double acting type and has a detent floating function When the valve lever is operat ed to the cylinder extending direction the cargo bed is lifted Operati...

Page 320: ...STEERING HYDRAULIC ELECTRIC INDEX 2 7 AUXILIARY HYDRAULIC VALVE MOUNTING LOCATION AND STRUCTURE 1 BODY 2 PLUG 3 SPOOL ASSEMBLY 4 SPRING 5 BALL 6 DETENT BALL 7 MOUNTING NUT 8 DETENT HOUSING 9 ADJUSTING...

Page 321: ...return port which is distinct from the single acting valve in the tractor This means that this single acting valve can operate the hydraulic motor by the hydraulic oil from its outlet port while the...

Page 322: ...nt operating oil Replace Inspect or replace Inspect or replace Replace Add oil Impossible to retract dumping cylinder Faulty control valve or foreign material entered Inspect or clean replace Dumping...

Page 323: ...he hydraulic line REMARK Make sure that the quick coupler is firmly tightened CAUTION Place the selector shift lever in the neutral posi tion start the engine and speed up the engine to its maximum Mo...

Page 324: ...umping operation le ver and stop the engine 1 2 To prevent an injury by the falling cargo bed accidently set the support between the cargo bed and frame CAUTION Disconnect the hose on the hydraulic fl...

Page 325: ...the adapter 1 and unscrew the mounting bolts 3 M8 2 EA to remove the cover 4 and double acting valve 2 UUVWB17A Remove the rear cover 1 seal block 2 drive gear shaft 3 driven gear 4 seal block 5 and...

Page 326: ...semble in the reverse order of disassembly 4 UUVWB23A UUVWB22A Disconnect the dumping cable 1 from the adapter 2 and the dumping cylinder hoses 3 Then disconnect the hydraulic hose P A and hydraulic h...

Page 327: ...he adjusting nut 1 and remove the ad justing screw 3 with the detent ball 2 Count the number of threads of the adjusting screw protruded from the nut for later installation 1 UUVWB26A Unscrew the dete...

Page 328: ...Assemble in the reverse order of disassembly 5 UUVWB82A Unscrew the plug 1 and pull out the spool 2 4 During disassembly and assembly be careful not to damage the O ring If it is not intact replace w...

Page 329: ...down the detent housing 2 UUVWB31A Fit the tool into the hole of the lever 1 as shown in the figure to fix the spool in position Then tap the detent housing with a hammer to screw it to the valve bod...

Page 330: ...ter 2 detent housing mounting nut 3 internal spring 4 exter nal spring 5 detent ball 6 and balls 7 in order 2 UUVWB53A UUVWB54A Unscrew the plug 1 and pull out the spool 2 4 Pull out the lever fixing...

Page 331: ...The ball is in the floating detent status when seating it onto the section A of the adapter and installing it completely to place it to the section B REMARK UUVWB61A Insert the springs double 1 into...

Page 332: ...r is not returned but fixed to the lifted position detent position 7 UUVWB66A Install the adjusting screw 1 and lower the lever so that it can return Then secure it with the adjust ing nut 2 Tighten t...

Page 333: ...spring 2 tappet 3 and spool 4 in order 2 UUVWB57A Remove the spool by turning it with a flat bladed screwdriver 3 Adjust the relief valve pressure by unscrewing the adjusting nut 1 and turning the ad...

Page 334: ...the engine Place the support between the cargo bed and frame so that the cargo bed does not fall down ac cidentally 1 2 3 Remove the pin 1 from the dumping cylinder boss mounting bracket to separate...

Page 335: ...e nut to remove the nut 1 spring washer 2 piston assembly 3 head cover 4 and piston rod 5 in order 2 UUVWB73A When installing the head cover check the condition of the O ring 1 If it is not intact rep...

Page 336: ...G 26 NUT 27 BOLT 28 BOLT 29 FUEL CAMSHAFT COVER GASKET 30 BALL BEARING 31 RING SNAP 32 ELBOW 33 BLOCK ASSY FR 34 DETENT FLOATING VALVE 35 ADAPTOR CONTROL VALVE 36 ADAPTOR CONTROL VALVE 37 PIN SPRING 3...

Page 337: ...IC INDEX 6 2 U1310A AUXILIARY HYDRAULIC VALVE 1 6 5 14 12 10 4 3 2 8 7 7 9 4 11 11 13 UUVWB06A 1 DU SECTIONAL VALVE 2 ADAPTOR CONTROL VALVE 3 PIN SPRING 4 PIN SNAP 5 BOLT 6 NUT 7 COUPLER SELF SEALING...

Page 338: ...MEMO...

Page 339: ...splay unit 12 16 5 1 1 External wiring diagram for display unit 12 17 5 2 Cooling fan motor 12 18 5 3 Headlamp 12 20 5 4 Slow blow fuse 12 21 5 5 Glow plug 12 21 5 6 Engine stop solenoid 12 22 5 7 Par...

Page 340: ...t charged 12 57 7 2 3 Check the charge warning lamp for malfunction 12 58 7 2 4 When the system is not preheated manually 12 59 7 2 5 When the system is not preheated automatically 12 60 7 2 6 When hi...

Page 341: ...plug 12V 20A Resistance at room temperature 430 Micro switch for parking brake N O type Brake lamp switch N C type Safety start switch N C type Coolant temperature sensor For temp gauge approx 2 45k...

Page 342: ...Yellow Light Green Red Light Green White Black Blue Blue White Green White Red Black Blue Red Blue Black Red Blue The following figures are examples for colors according to the codes 2 CIRCUIT DIAGRAM...

Page 343: ...tion Fuse Single bulb Lamp Slow blow fuse Double bulb Motor Diode Zener diode Switch Normally Open Type Switch Normally Close Type LED Light Emitting Diode Compressor Photo Diode Ground Wire Ground Ch...

Page 344: ......

Page 345: ...099 080 081 2 0RY 0 85G 0 85Br 0 85W 0 5BrW 0 85G 0 85GW 0 85WR 047 001 001 001 001 050 055 STARTER SWITCH HORN FLASHER UNIT HEAD LAMP TAIL LAMP HORN HAZARD SWITCH LOW BEAM RELAY HIGH BEAM RELAY COMB...

Page 346: ...CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 3 LOCATION OF ELECTRICAL DEVICES ELECTRIC SYSTEM LOCATION OF ELECTRICAL DEVICES UUVWA01B UTV EZGO _12_ELECTRIC SYSTEM_S 8 8 UTV EZ...

Page 347: ...001 001 0 85RW BATTERY 007 007 SLOW BLOW FUSE 60A 5 0R 5 0R 5 0R 003 003 0 85RW 0 85RW 0 85RW 010 010 010 3 0R 3 0RW 075 075 075 075 075 075 3 0RW 3 0RW 2 0LR 2 0LR 2 0LR 0 85LR 018 018 020 014 014 0...

Page 348: ...5RW 0 5P 5 0R 3 0RW POWER GROUND ENG OIL SWITCH UUVWAA3A Power supplied to the combi meter flows through the charge warning lamp and diode on through to ground in the alternator to turn the charge war...

Page 349: ...or 15 seconds of preheating time At the same time the dis play unit also gives the power to glow indication lamp on the dash board for 8 seconds The preheating seconds and indication seconds can be sh...

Page 350: ...ti vated when the negative line of start signal is open by the neutral switch which is mounted on the gear shift lever The neutral switch is normally open and closed only when the gear shift lever is...

Page 351: ...ON and OFF operation of fan motor The fan motor can run even when the engine is stopped if the key is in ON po sition and the coolant is still hot To prevent engine failure the display unit keeps runn...

Page 352: ...send the signal to hour meter on the dash board to operate it Therefore the hour meter oper ates only when the generator runs properly As the engine oil pressure builds up more than 7 psi the engine o...

Page 353: ...from generator to the display unit drops below 13V However the turning signal lamps horn and flasher lamps if equipped can be operated while the key is in OFF position as the power line of those are...

Page 354: ...e preheat time can be less than 15 seconds on occasion while the post heating time is always 15 seconds 4 Preheat system protection If the voltage becomes over 16 V the preheat and post heating operat...

Page 355: ...9 Electronic pickup signal from ground speed 10 16 Hz output for hour meter 11 Coolant temperature sensor signal input 12 1 sec output for pull coil 13 Speed signal output 5 1 1 EXTERNAL WIRING DIAGR...

Page 356: ...ed Coolant temperature below 75 C 167 F FAN MOTOR TEST 1 Turn the ignition switch to the OFF position and disconnect the electric motor connector 2 Connect the terminal 1 to the positive battery ter m...

Page 357: ...cover mounting bolts 1 M6 2 EA using the 10 mm socket wrench to remove the cover assembly 2 UUVWA09A 2 Remove the clip 1 from the cooling fan side Then remove the cooling fan 2 by pulling it up UUVWA1...

Page 358: ...ing spring 2 UUVWA15A 3 Pull out the bulb Bulb specification 12 V 55 60 W Do not touch the glass of new bulb 3 Remove the bulb and fit a new one HEADLAMP BULB REPLACEMENT 1 Open the hood and disconnec...

Page 359: ...e is blown repeatedly it is probable that B line battery power has a short circuit to body 5 5 GLOW PLUG UUVWA19A The glow plug is installed in the engine cylinder head The glow plugs are used to warm...

Page 360: ...the ignition switch is in the HEAT position manual preheating condition 5 6 ENGINE STOP SOLENOID UUVWA20A The engine stop solenoid is installed on the engine gear case The resistance of the engine st...

Page 361: ...UVWA21A The parking brake switch is installed to the front of the parking brake lever on the left side from the driver s seat N O Normally open type It is normally open OFF but it is closed ON when co...

Page 362: ...is installed to prevent the engine from start ing when the shift lever is not in the neutral position N C Normal Closed Type It means that it is normally closed ON but it is open OFF when the contact...

Page 363: ...ange It is not recommended to measure the resistence of temperature sensor separately Measure the V DC on the display unit while the key is ON with the wire con nected Tester selector Tester s measuri...

Page 364: ...d the negative test lead to the pin No 6 of the display unit connector and measure the VDC with the ignition switch in the ON position 1 2 3 4 5 6 7 8 9 10 11 12 13 DISPLAY UNIT WIRE CONNECTOR B LG Th...

Page 365: ...float moves with the fuel level in the fuel tank changing resistance in the circuit of the fuel gauge Level Full 1 2 Empty Resistance 2 5 32 5 110 Tolerance 2 7 1 2 T46WBA3C Temp C 40 20 0 20 40 Resis...

Page 366: ...connector and disassemble the fuel sender to measure its resistance 5 12 ALTERNATOR UUVWA26A There are some components such as headlamp start motor engine stop solenoid and glow plugs which need a lo...

Page 367: ...verage curve for the cold and hot conditions is presented as guaranteed performance In general the alternator s pulley ratio is determined to maximize the alternator power in the rated speed of the en...

Page 368: ...proportional to the gear speed is sent to the display unit which then converts this to the voltage and operates the speedometer on the instrument cluster NO 1 0 5B NO 35 0 85YW UUVWA67A 1 COIL 2 CORE...

Page 369: ...wheel is turning while it shows 0V or 14V when the wheel is stopped The speed change can not be read by multi tester as the speedometer in the dash can read it according to the frequency Hz change RE...

Page 370: ...in ON position there will be continu ity between the AM ACC and M terminals re sistance 0 With the key in GL position there will be continuity between the AM M and G terminals resistance 0 With the ke...

Page 371: ...l lamp RH Horn 1 HEAD LAMP SWITCH When operating the switch to first position the head lamps low beam and tail lamps are turned on When operating the switch to 2nd position the head lamps high beam an...

Page 372: ...ONT AXLE STEERING HYDRAULIC ELECTRIC INDEX Br G B RY LW GW RW Or Y 10 9 8 7 5 4 3 2 1 U Ru Eu J UZ JZ E OZ 8 7 43 6 5 4 T46WB49D Lever operation Wiring color Term position Lever operation Wiring color...

Page 373: ...it A 12 volt battery and auxiliary light are needed to test the flasher unit Install the battery s positive cable to the terminal B of the flasher unit Install the light s positive lead to the termina...

Page 374: ...from the wiring Check the resistance and continuity within the resis tance range of a tester Numbers on the auxiliary relay terminals indicate cor responding coil and contact Capacity 12 V 70 A Termi...

Page 375: ...EERING HYDRAULIC ELECTRIC INDEX Tester selector Tester s measuring point Result Red lead Black lead Resistance Relay 85 Relay 86 Approx 84 6 Relay 30 Relay 87 No continuity When measuring the resistan...

Page 376: ...TIONS ELECTRIC SYSTEM ELECTRICAL COMPONENTS Don t leave the dash board upside down for long time Rear view UUVWA34A SYMBOL TURN L TURN R 4WD OIL 14V 1 4W 14V 1 4W 14V 1 4W 14V 1 4W 14V 1 4W 14V 1 4W 1...

Page 377: ...OLEX P No 35205 2010 1 10 11 20 TEMP U SPEED U TEMP GND HOUR U IGN 4WD OIL BRAKE CHARGE FUEL WARNING HI BEAM GLOW NEUTRAL FUEL U B GND TURN L TURN R ILL PIN 1 CONNECTOR No CIRCUIT NAME ILL 20 19 18 17...

Page 378: ...ON TOLERANCE UNIT KM H GAUGES AND INDICATORS Fuel gauge UUVWA37A UUVWA39A 40 40 2 SPEEDOMETER SIGNAL Hour meter also has similiar patern of signal as speedometer does Hour meter and speedometer signal...

Page 379: ...er selector Tester s measuring point Operation Result Red lead Black lead DC voltage Connector pin No 16 WR Connector pin No 13 B Operating turn signal lamp LH DC 12V Connector pin No 19 GW Connector...

Page 380: ...n No 7 Parking switch ON DC 12 5V See 12 39 page for pin location For the test procedure refer to the figure on page 12 40 This indicator indicates the operations of headlamp high beam When the high b...

Page 381: ...turn ing by the engine If this lamp comes on while driving the charging sys tem is malfunctioning Check the charging system im mediately Charge warning lamp Tester selector Tester s measuring point O...

Page 382: ...r the hood ELECTRIC SYSTEM ELECTRICAL COMPONENTS Tester selector Tester s measuring point Result Red lead Black lead Resistance Relay No 85 Relay No 86 Approx 86 5 87 0 15 C Relay No 30 Relay No 87a C...

Page 383: ...is relay supplies power to the high and low beams The twin relay work fog lamp is attached to the relay bracket under the hood This relay supplies power to the work lamps and fog lamps S76WBH9B S76WBH...

Page 384: ...and circuit Conditions Results 110 of rated current is applied The fuse is not blown 130 of rated current is applied The fuse is blown within 60 seconds 150 of rated current is applied The regular fu...

Page 385: ...sed N C Normally Closed type It is normally closed ON but it is open OFF when contact point is pressed The brake pedal presses the switch when the brake is not applied Tester selector Tester s measuri...

Page 386: ...0 Apr 2011 SAFETY FIRST GENERAL ENGINE CVT TRANSMISSION CHASSIS REAR AXLE BRAKE FRONT AXLE STEERING HYDRAULIC ELECTRIC INDEX 6 WIRING CONFIGURATION 6 1 WIRING DIAGRAM UUVWA54A ELECTRIC SYSTEM WIRING C...

Page 387: ...es for battery failure can be divided into the following three causes 1 Overly discharged The specific gravity of electrolyte is too low and the terminal voltage is not measurable Cause Self discharge...

Page 388: ...operation and be ready to follow proper inspection pro cedures using proper devices If necessary the inspector can shake wiring or electric parts gently while testing them Open circuit There is a dis...

Page 389: ...gh the ground connection seems to be clean there might be a thin corroded layer on the surface Perform the following steps for inspecting the ground connection Remove any ground bolt and clip Check if...

Page 390: ...ems The electric problems can be divided into the following 6 sections Vibration Damage by heat Freezing Moisture Electric load Starting in frozen or overheated condition Check the symptom by asking c...

Page 391: ...aperture of contact spring can be bent Properly folded Insulator not removed Missing harness Intermittent signal through insulator T46WB32A T46WB31B CONNECTOR CHECK Seal Seal Intermittent contact Pul...

Page 392: ...to electric load Perform the inspection while turning on all electric devices A C cigarette lighter radio head lamps etc ENGINE COLD OR HOT CONDITIONS An electric fault can occur when the engine is co...

Page 393: ...same to the battery voltage Check for corrosion Check connection of battery cable 3 Slow blow fuse Check fuse engagement Check main fuse for short circuit Rated capacity 60 A 4 Key switch Check for pr...

Page 394: ...stop solenoid 1 Check the solenoid unit Measure resistance on both ends of engine stop solenoid Between No 68 and ground Approx 0 4 Approx 32 A Between No 67 and ground Approx 13 8 Approx 0 77 A Click...

Page 395: ...new one with rated capacity UUVWA57B 2 Regulator operating power with the key switch ON Measure the voltage between No 68 RB of 2P connector and alternator body ground with the key switch ON Normal Ov...

Page 396: ...battery voltage approx 3 V when the key switch is in ON position 2 Check the fuse 5 headlamp UUVWA58B 2 Charge warning lamp bulb 1 Check if the bulb filament is blown visual check UUVWA59A 3 Fuse 1 C...

Page 397: ...ed closed circuit 2 Not connecting power to No 85 and 86 terminals No 87 and 30 terminals open S76WBI7B 2 Glow plug 1 Check if the resistance between the glow plug ring terminal and ground chassis is...

Page 398: ...nal and chassis should be approx imately same as the battery voltage 2 When voltage is not supplied Check proper connection of battery cable Check the corrosion Continue to the next step T46WBC0A 3 Sl...

Page 399: ...he output voltage between No 1 terminal and ground is 12 V for 8 seconds Preheat lamp No 2 Suhkhdw Odpsv Dowhuqdwru fkdujlqj vljqdo Vtart switch ST Pdqxdo suhkhdw vljqdo GND Idq prwru rxwsxw Suhkhdw u...

Page 400: ...use engagement Fuse for open circuit Fuse 5 15 A UUVWA60B 2 Combination switch Check the low beam for proper connection B1 T 1 connected Check the high beam for proper connection B1 T 2 connected Turn...

Page 401: ...ltmeter or oscilloscope for frequency reading UUVWA68A 3 Display unit Check if the voltage between No 6 and 9 terminals is 12 V Check the output of square wave 10Vp p between No 13 and 1 terminals usi...

Page 402: ...capacity 5 A UUVWA62B 2 Fuel sender Measure the resistance between two terminals of fuel sender con nector after disconnecting wiring and connector E point 110 F point 2 5 T46WBG5A 3 Fuel gauge on in...

Page 403: ...l Over 12 V Abnormal Below 10 V Measure the voltage between No 80 P of 2P connector and alternator body ground with the engine running Normal 14 0 V 14 7 V Abnormal Below 12 V S76WBH5B 3 Display unit...

Page 404: ...ERING HYDRAULIC ELECTRIC INDEX 8 EXPLODED VIEW FOR THE COMPONENTS 8 1 U500A LIGHT 1 HEADLIGHT BEZEL FR LH 2 HEADLIGHT BEZEL RR LH 3 HEADLIGHT LH 4 BULB 5 SCREW 6 HEADLIGHT BEZEL FR RH 7 HEADLIGHT BEZE...

Page 405: ...LIC ELECTRIC INDEX 8 2 U510A ELECTRICAL SYSTEM 1 1 INSTRUMENT CLUSTER ASSY 2 BULB 12V 3W 3 BULB 14V 3W 4 BULB 14V 1 4W 5 SCREW 6 COMBINATION SWITCH ASSY 7 SWITCH STARTER 8 SOCKET 9 COVER 10 PICK UP SE...

Page 406: ...USE 25A 7 NUT 8 BOLT FLANGE 9 RELAY 10 RELAY 5P 11 ACCESSORY RELAY ASSY 12 BOLT FLANGE 13 DISPLAY UNIT 14 RELAY BRACKET ASSY 15 BOLT FLANGE 16 NUT 17 WIRE HARNESS MAIN 18 FUSE 60A 19 DIODE 2P 20 WASHE...

Page 407: ...CHAPTER 13 INDEX...

Page 408: ...st for radiator 3 37 Caliper pad clearance and thickness 8 7 Camshaft and fuel camshaft 3 13 Camshaft 3 7 Cargo bed removal 6 6 Cautions for high pressure hoses 1 5 Cautions when handling the battery...

Page 409: ...9 20 Dimensions 2 5 Disassembled view 3 27 Disassembly service and assembly Rear axle 7 14 Disassembly service and assembly Steering 10 8 Disassembly service and assembly Hydraulic system 11 20 Disas...

Page 410: ...umping valve 11 14 Front block relief valve disassembly 11 29 Front differential case disassembly and assembly 9 19 Front differential case removal 9 17 Front wheel brake removal brake pad and disc re...

Page 411: ...ion of electrical devices 12 7 Lsd limited slip device 9 6 Lsd disassembly and assembly 9 22 Lubrication and replenishment 2 12 Lubrication system 3 16 Main bearing case assembly 3 75 Main relief valv...

Page 412: ...t and adhesive CVT 4 2 Sealant and adhesive Transmission 5 3 Sealant and adhesive Front axle 9 3 Seat and fender removal 6 7 Serial number 2 3 Service specifications 3 6 Shift cable length 5 12 Shift...

Page 413: ...ing Engine 3 32 Troubleshooting CVT 4 8 Troubleshooting Transmission 5 8 Troubleshooting Rear axle 7 8 Troubleshooting Brake 8 5 Troubleshooting Front axle 9 7 Turning torque of 8 bevel pinion shaft 9...

Page 414: ...MEMO...

Page 415: ......

Page 416: ...1451 Marvin Griffin Road Augusta GA 30906 800 241 5855 I Fax 706 796 4540 I www ezgo com e mail ezgo textron com I 2011 E Z GO Division of Textron Inc 4x4 4x4...

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