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Hisun Motors HS800UTV 2014, Maintenance Handbook

The Hisun Motors HS800UTV 2014 Maintenance Handbook is a comprehensive manual designed to assist users in the proper care and maintenance of their vehicle. Available for free download at manualshive.com, this user-friendly manual provides valuable information and step-by-step instructions to ensure optimal performance and longevity of your HS800UTV.

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                                      ENGINE MANAGEMENT SYSTEM                                                 

 

- 322 - 

4

．

Cleaning Procedure 

If there is cover on the bottom, it may be removed and cleaned using carburetor cleaner (3M 
make recommended). Once the throttle body cover is removed, spray the throttle-body cleaner 
inside the shipping air passage, and use the brushes to gently dislodge the dirt, gum and 
varnish that are present. Do not let the bye pass holes be blocked by dirt or foreign particles. 

 

5

．

Throttle Body Installation 

•

  Reverse the procedure for installation noting the following: 

•

  Adjust accelerator cable play 

•

  Check to ensure that all removed parts are back in place.Reinstall any necessary part which 

have not been reinstalled 

 

6

．

Precautions 

•

  Do not submerge TPS in any cleaning fluid.   

•

  Always open the throttle valve using the throttle cable or lever.     

•

  Do not hold the valve at opening position by inserting tools or any sticks into the bore. The 

valve may be warped and the bore may be scratched. This type of damage may keep the 
throttle from opening easily or fully closing. 

•

   

 

Engine Coolant Temperature Sensor 

1

．

Description and Working Principle   

This sensor is used in water cooled engines. It provides a resistance that varies as a function of 
temperature within prescribed tolerance limits.  The sensor has a negative temperature 
coefficient of resistance. This is a non-serviceable part. 

 

 

2

．

Installation Requirements 

•

  Dynamic Torque Requirement: The sensor shall be hand into the application and then 

driven by a driver with a maximum no load speed of 400 rpm or installed to the desired 
torque by a hand torque wrench (5/8” hex).    The recommended installation torque is:           
Minimum: 20 N·m 

Maximum: 25 N·m 

•

  Static Torque Requirement: The torque required to remove the sensor from the mating hole 

shall be within 200% of the installation torque mentioned above. 

 

3

．

Sample Cleaning 

•

  When necessary the samples may be cleaned in isopropyl alcohol for one minute with 

mating connectors in place and then air-dried 

 
 
 
 
 
 
 
 

Summary of Contents for HS800UTV 2014

Page 1: ...e read the handbook through and fully understand it otherwise any improper repairing and amounting would bring you problems and accident may occur in your use Proper use and maintenance can guarantee UTV being driven safely reduce its malfunction and help the vehicle remain its best performance The standards performances and specifications mentioned in interpretation are based on the sample in des...

Page 2: ...ely 4 Cleaning parts 5 Warning labels 5 SERIAL NUMBERS 6 FASTENERS 6 Torque specifications 6 Self locking fasteners 6 Washers 6 Cotter pins 7 Snap rings and E clips 7 SHOP SUPPLIES 8 Lubricants and Fluids 8 Engine oils 8 Greases 8 Brake fluid 9 Coolant 9 Cleaners Degreasers and solvents 9 Gasket sealant 9 Gasket remover 10 Thread locking compound 10 BASIC TOOLS 10 Screwdrivers 11 ...

Page 3: ...eeler gauge 17 Calipers 17 Micrometers 18 Adjustment 18 Care 19 Metric micrometer 19 Standard inch micrometer 20 Telescoping and small bore gauges 21 Dial Indicator 21 Compression gauge 22 Multimeter 22 Cltp on ammeter 22 Magneto puller 23 ELECTRICAL SYSTEM FUNDAMENTALS 23 Voltage 23 Resistance 23 Amperage 23 BASIC SERVICE METHODS 24 Removing frozen fasteners 25 Removing broken fasteners 25 Repair...

Page 4: ... engine 34 ENGINE WILL NOT START 34 Identifying the problem 34 Spark test 35 The starter cannot work repeatedly or can only work slowly 36 POOR ENGINE PERFORMANCE 36 The engine starts slowly or difficultly 36 Engine backfires cuts out or misfires during acceleration 37 The engine is not idling or cannot idle stably 37 Poor fuel mileage 37 Engine will not idle or idles roughly 38 Low engine power 3...

Page 5: ...4 HIGH OIL CONSUMPTION OR EXCESSIVE 44 Exhaust smoke 44 Low oil pressure 44 High oil pressure 44 No oil pressure 44 Oil level too low 45 Oil contamination 45 CYLINDER LEAK DOWN TEST 45 ELECTRICAL TESTING 47 Preliminary checks and precautions 47 Intermittent problems 48 Electrical component replacement 49 Test equipment 49 Ammeter 49 Self powered test light 50 Ohmmeter 50 Jumper wire 50 TEST PROCED...

Page 6: ...ing master cylinder 56 CHAPTER 2 SPECIFICATIONS HOW TO USE CONVERSION TABLE OF UNIT 57 How to use conversion table 57 Definition of unit 57 GEBERAR SPECIFICATIONS 58 ENGINE SPECIFICATIONS 61 CHASSIS SPECIFICATIONS 67 ELECTRICAL SPECIFICATIONS 69 TIGHTENING TORQUES 71 Engine tightening torques 71 Chassis tightening torques 74 GENERAL TIGHTENING TORQUE SPECIFICATIONS 76 LUBRICATION PIONTS AND LUBRIC...

Page 7: ...Cleaning the spark arrester 100 Adjusting the brake pedal 101 Checking the brake fluid level 102 Checking the front brake pads 103 Checking the rear brake pads 103 Checking the brake hoses and brake pipes 104 Bleeding the hydraulic brake system 104 Adjusting the select lever shift rod 106 Adjusting the brake light switch 106 Checking the final gear oil level 107 Changing the final gear oil 107 Che...

Page 8: ...light bulb 127 CHAPTER 4 ENGINE ENGINE NOTE 129 ENGINE REMOVAL 130 CYLINDER HEAD AND CYLINDER HEAD COVER 131 ROCKER ARMS AND CAMSHAFT 136 VALVES AND VALVE SPRINGS 139 CYLINDER AND PISTON 144 ENGINE LEFT CRANKCASE COVER A C MAGNETO 148 STARTER MOTOR AND OIL FILTER 152 PRIMARY AND SECONDARY SHEAVES 155 CRANKCASE COVER AND OIL PUMP 159 CRANKCASE AND MIDDLE DRIVEN SHAFT 163 OUTPUT SHAFT 168 GEARCASE S...

Page 9: ...OTREST ASSEMBLY 217 WHEEL AND TYRE PARTS 220 Front wheels 220 Rear wheels 221 TRANSMISSION SYSTEM 225 C V axle front axle 225 Front bridge 226 C V axle rear axle 232 Rear bridge reducer 233 Rear bridge 237 SHIFT OPERATING SYSTEM 238 SUSPENSION 242 Front swing arm 242 Front Suspension 244 Rear anti roll bar 250 Rear swing arm 251 COOLING SYSTEM 256 Water and oil radiator 256 Water pump 263 SEAT 270...

Page 10: ...ARTING SYSTEM 287 Circuit diagram 287 Troubleshooting 288 STARTER MOTOR 291 Checking the starter motor 292 Assembling the starter motor 293 CHARGING SYSTEM 293 Circuit diagram 293 Troubleshooting 294 LIGHTING SYSTEM 295 Circuit diagram 295 Troubleshooting 296 Checking the lighting system 297 SIGNALING SYSTEM 298 Circuit diagram 298 Troubleshooting 299 Checking the signal system 300 COOLING SYSTEM ...

Page 11: ...20 Engine coolant temperature sensor 322 Intake air pressure and temperature sensor 323 Oxygen sensor 323 Ignition coil 323 Fuel pump module 327 EMS FAULT DIAGNOSIS EME fault diagnosis 323 Fault code list 323 CHAPTER 8 TROUBLESHOOTING STARTING FAILURE HARD STARTING 335 Fuel system 335 Electrical system 335 Compression system 336 POOR IDLE SPEED PERFORMANCE 336 Poor idle speed performance 336 POOR ...

Page 12: ...339 LIGHTING SYSTEM 339 Head light is out of work 339 Bulb burnt out 340 Error display of meter 340 CHAPTER 9 HS800UTV WIRING DIAGRAM HS800UTV WIRING DIAGRAM 341 HS800UTV WIRING EFI DIAGRAM 342 IGNITION SYSTEM CIRCUIT DIAGRAM 343 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 344 CHARGING SYSTEM CIRCUIT DIAGRAM 345 LIGHTING SYSTEM CIRCUIT DIAGRAM 346 SIGNALING SYSTEM CIRCUIT DIAGRAM 347 COOLING SYSTEM C...

Page 13: ...the first time WARNINGS CAUTIONS AND NOTES The terms WARNING CAUTION and NOTE have specific meaning in this manual WARNING emphasizes areas where injury or even death could result from negligence Mechanical damage may also occur WARNINGS are to be taken seriously CAUTION emphasizes areas where equipment damage could result Disregarding a CAUTION could cause permanent mechanical damage though injur...

Page 14: ...4 Rear shock absorber assembly adjusting ring 15 V belt case 16 Passenger seat belt 17 right shoulder protection plate 18 Spark plug 19 Oil filter cartridge 20 Fuel tank cap 21 Passenger seat 22 rearview mirror 23 Coolant reservoir 24 Radiator cap 25 Steering wheel 26 Light switch 27 Main switch 28 On Command four wheel drive and differential lock switches 29 Multi function meter unit 30 Auxiliary...

Page 15: ...GENERAL INFORMATION 3 IDENTIFICATION CODE Frame No Frame No is carved on the right side of front main frame Engine No Engine NO Is carved on the right side of the engine Figure ...

Page 16: ...air and chemicals 11 Wear the correct clothing for the job Tie up or cover long hair so it does not get caught in moving equipment 12 Do not carry sharp tools in clothing pockets 13 Always have an approved fire extinguisher available Make sure it is rated for gasoline Class B and electrical Class C fires 14 Do not use compressed air to clean clothes the UTV or the work area Debris may be blown int...

Page 17: ...al cleaners and solvents are available for shop use Most are poisonous and extremely flammable To prevent chemical exposure vapor buildup fire and serious injury observe each product warning label and note the following 1 Read and observe the entire product label before using any chemical Always know what type of chemical is being used and whether it is poisonous and or flammable 2 Do not use more...

Page 18: ... various subassemblies are not installed and tightened correctly Fasteners that are improperly installed or work loose can cause extensive damage it is essential to use an accurate torque wrench as described in this chapter Self Locking Fasteners Several types of bolts Screws and nuts incorporate a system that creates interference between the two fasteners Interference is achieved in various ways ...

Page 19: ...secure parts within housing bores In some applications in addition to securing the component s snap rings of varying thicknesses also determine endplay These are usually called selective snap rings The two basic types of snap rings are machined and stamped snap rings Machined snap rings Figure 2 can be installed in either direction Because both faces have sharp edges Stamped snap rings Figure 3 ar...

Page 20: ...oil satisfies The classifications are MA high friction applications and MB low frication applications NOTE Refer to Engine Oil and Filter in Chapter Three for further information on API SAE classifications Always use an oil with a classification recommended by the manufacturer Using an oil with a different classification can cause engine damage Viscosity is an indication of the oil s thickness Thi...

Page 21: ... most common from of antifreeze Check the UTV Manufacturer s recommendations when selecting antifreeze Most require one specifically designed for aluminum engines There types of antifreeze have additives that inhibit corrosion Only mix antifreeze with distilled water Impurities in tap water may damage internal cooling system passages Cleaners Degreasers and Solvents Many chemicals are available to...

Page 22: ... carried out with basic hand tools and test equipment familiar to the home mechanic Always use the correct tools for the job Keep tools organized and clean Store them in a tool chest with related tools organized together Quality tools are essential The best are constructed of high strength alloy steel These tools are light easy to use and resistant to wear Their working surface is devoid of sharp ...

Page 23: ...ound on the driving faces or flutes of the screwdriver s tip figure 4 ACR Phillips II screwdrivers were designed as part of a manufacturing drive system to be used with ACR Phillips II screws but they work of tool companies offer ACR Phillips II screwdrivers in different Tip size and interchangeable bits to fit screwdriver bit holders NOTE Another way to prevent cam out and to increase the grip of...

Page 24: ...ontact the fastener at only two points which makes them more subject to slipping off the fastener Because one jaw is adjustable and may become loose this shortcoming is aggravated Make certain the solid jaw is the one transmitting the force Socket 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 dr...

Page 25: ...ble to remove stubborn fasteners without damaging them Impact drivers and interchangeable bits Figure 10 are available from most tool suppliers When using a socket with an impact driver Make sure the socket is designed for impact use Refer to Socket Wrenches Ratchets and handles in this section WARNING Do not use hand sockets with air or impact tools because they may shatter and cause injury Alway...

Page 26: ...cause of the size of the torque wrench head drive and socket If a torque adapter changes the effective lever length Figure 14 the torque reading on the wrench will not equal the actual torque applied to the fastener It is necessary to recalibrate the torque setting on the wrench to compensate for the change of lever length When using a torque adapter at a right angle to the drive head calibration ...

Page 27: ... are needed to cut wire and can be used to remove cotter pins Use needle nose pliers to hold or bend small objects Locking pliers Figure 16 sometimes called Vise Grips are used to hold objects very tightly They have many uses ranging 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 Ri...

Page 28: ... 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 accurate measurements is essential to determine which components require replacement or further service Each type of measuring instrument is designed to measure a dimension with a certain degree of accur...

Page 29: ...iquid crystal display LCD to show the measurement Properly maintain the measuring surfaces of the caliper There must not be any dirt or burrs between the tool and the object being measured Never force the caliper to close around an object Close the caliper around the highest point so it can be removed with a slight drag Some calipers require calibration Always refer to the manufacturer s instructi...

Page 30: ...djust care for and read the measurements of various types of outside micrometers For accurate results properly maintain the measuring surfaces of the micrometer There cannot be any dirt or burrs between the tool and the measured object Never force the micrometer to close around an object Close the micrometer around the highest point so it can be removed with a slight drag Adjustment Before using a...

Page 31: ...sure the spindle and anvil faces do not contact each other or another object If they do temperature changes and corrosion may damage the contact faces 3 Do not clean a micrometer with compressed air Dirt forced into the tool will cause wear 4 Lubricate micrometers with WD 40 to prevent corrosion Metric micrometer The standard metric micrometer Figure 24 is accurate to one one hundredth of a millim...

Page 32: ...eeve is marked in 0 025 in increments Every fourth sleeve mark is numbered 1 2 3 4 5 6 7 8 9 These numbers indicate 0 100 0 200 0 300 and so on The tapered end of the thimble has 25 lines marked around it Each mark equals 0 001 in One complete turn of the thimble will align its zero mark with the first mark on the sleeve or 0 025 in To read a standard inch micrometer perform the following steps an...

Page 33: ...to the limit within the bore Do not over tighten the gauge because there is no built in release Excessive tightening can damage the bore surface and damage the tool Remove the gauge and measure the outside dimension Figure 30 Small bore gauges are typically used to measure valve guides Dial Indicator A dial indicator Figure 31 is a gauge with a dial face and needle used to measure variations in di...

Page 34: ...ic test meter Results may vary if using a meter not recommended by the manufacturer Such requirements are noted when applicable Ohmmeter analog calibration Each time an analog ohmmeter is used or if the scale is changed the ohmmeter must be calibrated Digital ohmmeters do not require calibration 1 Make sure the meter battery is in good condition 2 Make sure the meter probes are in good condition 3...

Page 35: ...the opposite direction Alternator output is an example of AC voltage This voltage must be changed or rectified to direct current to operate in a battery powered system Resistance Resistance is the opposition to the flow of electricity within a circuit or component and is measured in ohms Resistance causes a reduction in available current and voltage Resistance is measured in an inactive circuit wi...

Page 36: ...n Do not rely on memory alone 5 Protect finished surfaces from physical damage or corrosion Keep gasoline and other chemicals off painted surfaces 6 Use penetrating oil on frozen or tight bolts Avoid using heat where possible Heat can warp melt or affect the temper of parts Heat also damages the finish of paint and plastics 7 When a part is a press fit or requires a special tool to remove the info...

Page 37: ... using self locking fasteners replace them with new ones Do not install standard fasteners in place of self locking ones 20 Use grease to hold small parts in place if they tend to fall out during assembly Do not apply grease to electrical or brake components Removing Frozen Fasteners If a fastener cannot be removed several methods may be used to loosen it First apply a penetrating fluid Apply it l...

Page 38: ...t Follow the manufacturer s instructions when installing their insert If it is necessary to drill and tap a hole refer to Table 8 for metric tap and drill sizes Stud Removal Installation A stud removal tool Figure 40 is available from most tool suppliers This tool makes the removal and installation of studs easier If one is not available thread two must onto the stud and tighten them against each ...

Page 39: ...care to prevent damaging it Bearing replacement procedures are included in the individual chapters where applicable however Use the following sections as a guideline NOTE Unless otherwise specified install bearings with the manufacturer s mark or number facing outward Removal While bearing are normally removed only when damaged there may be times when it is necessary to remove a bearing that is in...

Page 40: ... 47 Shows the correct way to use a driver and hammer to install a bearing 3 Step 1 describes how to install a bearing in a case half or over a shaft However when installing a bearing over a shaft and into the housing at the same time a tight fit is required for both outer and inner bearing races In this situation install a spacer underneath the driver tool so that pressure is applied evenly across...

Page 41: ...g to approximately 100 212 F in an oven or on a hot plate An easy way to check that it is the proper temperature is to place tiny drops of water on the housing if they sizzle and evaporate immediately the temperature is correct Heat only one housing at a time CAUTION Do not heat the housing with a propane or acetylene torch Never bring a flame into contact with the bearing or housing The direct he...

Page 42: ...eas of extreme temperature variations This deterioration can be minimized with careful preparation for storage A properly stored motorcycle is much easier to return to service Storage Area Selection When selecting a storage area consider the following 1 The storage area must be dry A heated area is best but not necessary It should be insulated to minimize extreme temperature variations 2 If the bu...

Page 43: ...eturning a UTV to service after storage depends on the length of non use and storage conditions In addition to performing the reverse of the procedure note the following 1 Remove the covers from the intake and exhaust openings 2 Service the air filter as described in Chapter Three 3 Inspect the cooling system Check the drain plug and hose connections for leaks 4 Refill the fuel tank Turn the fuel ...

Page 44: ...fications and service limits ENGINE PRINCIPLES AND OPERATING REQUIREMENTS An engine needs three basics to run properly Correct air fuel mixture Compression Engine runs A spark at the right time If one basic requirement is missing the engine will not run STARTING THE ENGINE When experiencing engine starting troubles it is easy to work out of sequence and forget basic starting procedures The followi...

Page 45: ...two oxygen sensors disturb each other the EFI system will appear mistake which results high temperature error Countermeasure If it is found that the temperature of muffler is too high please check whether the plug of oxygen sensor is in wrong position 5 Special fault The engine can t start normally after changing air filter or air throttle Reason The inner cleanness of old air filter and air throt...

Page 46: ...the engine fails to start after performing these checks refer to the troubleshooting procedures indicated in the steps If the engine starts but idles or runs roughly refer to Poor Engine Performance in this chapter 1 Refer to Starting the Engine in this chapter to make sure all starting procedures are correct 2 If the engine seems flooded refer to Starting The Engine in this chapter If the engine ...

Page 47: ...s like a spark plug with an adjustable gap between the center electrode and grounded base Because the voltage required to jump the spark tester gap is sufficiently larger than that of a normally gapped spark plug the test results are more accurate than with a spark plug Do not assume that because a spark jumped across a spark plug gap the ignition system is working correctly Perform this test on t...

Page 48: ...peak voltage checks described under Ignition System Testing 8 Reinstall the fuel tank The Starter Cannot Work Repeatedly Or Can Only Work Slowly Refer to Starting System Testing POOR ENGINE PERFORMANCE If the engine runs but performance is unsatisfactory refer to the following section that best describes the symptoms The Engine Starts Slowly Or Difficultly Check for the following 1 Incorrect choke...

Page 49: ...solate the damaged ignition system component Check the ignition timing as described NOTE The ignition timing is controlled by the ICM and cannot be adjusted However checking the ignition timing can be used to diagnose problems 6 Check the following engine components a Broken valve springs b Stuck or leaking valves c Worn or damaged camshaft lobes d Incorrect valve timing due to incorrect camshaft ...

Page 50: ...sh the UTV forward If the UTV is harder to push than normal Check for dragging brakes b Damaged or binding drive system c Damaged drive system and gear bearing 2 Test ride the UTV and accelerate quickly from first to second gear If the engine speed in creased according to throttle position Perform Step 3 If the engine speed did not increase Check CVT a Warped clutch plates discs b CVT spring 3 Tes...

Page 51: ...ldup in combustion chamber e Worn pistons and or cylinder bores Poor Idle or Low Speed Performance 1 Check for an incorrect pilot screw adjustment 2 Check for damaged or loose intake pipe and air filter housing hose clamps These conditions will cause an air leak 3 Perform the spark test in this chapter Note the following a If the spark is good Go to Step 4 b If the spark is weak Perform the Peak V...

Page 52: ...llowing examination Remove the spark plug see if there is fuel on the end of it Note the following a If there is no visible fuel on the end of the spark plug go to check whether the fuel valve oil injector or fuel hose is clogged b If the spark plug at the bottom of a fuel And the engine has spark Check for an excessive intake air leak or the possibility of contaminated or stale fuel NOTE If the U...

Page 53: ...perating temperature the water evaporates and exits the engine through the crankcase vent system However if the UTV is ridden for short trips or repeatedly started and stopped and allowed to cool off without the engine getting warm enough water will start to collect in the crankcase With each short run of the engine more water collects As this water mixes with the oil in the crankcase sludge is pr...

Page 54: ...gine 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 and under pressure Attempting to remove the items when the engine is hot can cause the coolant to spray violently from the radiator water pump or hose causing severe burns and injury 1 Low coolant level 2 Air in cooling system 3 Clogged radiator...

Page 55: ... a mechanic s stethoscope or a small section of hose held near your ear not directly on your ear with the other end close to the source of the noise to isolate the location Determining the exact cause of a noise can be difficult If this is the case consult with a professional mechanic to determine the cause Do not disassemble major components until all other possibilities have been eliminated Cons...

Page 56: ...sure of the engine High Oil Consumption or Excessive Exhaust Smoke 1 Worn valve guides 2 Worn valve guide seals 3 Worn or damaged piston rings 4 Incorrect piston ring installation Low Oil Pressure 1 Low oil level 2 Worn or damaged oil pump 3 Clogged oil strainer screen 4 Clogged oil filter 5 Internal oil leakage 6 Oil relief valve stuck open 7 Incorrect type of engine oil High Oil Pressure 1 The l...

Page 57: ...t at TDC on its compression stroke so that all the valves are closed When the combustion chamber is pressurized very little air should escape However the difficulty in performing a leak down test on a single cylinder engine especially on the engines described in this manual with low static engine compression is in preventing the piston from moving as the combustion chamber starts to pressurize Any...

Page 58: ...kcase cover Remove the hex socket from the primary drive gear 8 Perform the following to lock the transmission so the engine remains at TDC on its compression stroke when performing the leak down test WARNING Do not attempt to lock the engine by trying to use a tool to hold the Allen bolt on the end of the crankshaft Once the combustion chamber becomes pressurized any crankshaft movement can throw...

Page 59: ...ked cylinder head or cylinder liner e Air leaking through the oil filler hole indicates the rings are not sealing properly in the bore 11 If the cylinder leak down is 10 percent or higher further service is required 12 Disconnect the test equipment and install all the parts previously removed ELECTRICAL TESTING This section describes basic electrical testing and test equipment use Preliminary Chec...

Page 60: ...Vibration This is a common problem with loose or damaged electrical connectors a Perform a continuity test as described in the appropriate service procedure Or under Continuity Test in this section b Lightly pull or wiggle the connectors while repeating the test Do the same when checking the wiring harness and individual components especially where the wires enter a housing or connector c A change...

Page 61: ...ng a component that teats only slightly out of specification especially resistance A number of variables can affect test results dramatically These include the testing meter s internal circuitry ambient temperature and conditions under which the machine has been operated All instructions and specifications have been for accuracy however Successful test results depend to a great degree upon individ...

Page 62: ... test leads to the terminals or leads of the circuit or component to be tested If an analog meter id used is must be calibrated by touching the teat leads together and turning the set adjust knob until the meter needle reads zero When the leads are uncrossed the needle reads zero When the leads are uncrossed the needle should move to the other end of the scale indicating infinite resistance During...

Page 63: ... This would result in a direct short and will blow the fuse s Test Procedures Voltage test Unless otherwise specified Make all voltage tests with the electrical connectors still connected Insert the test leads into the backside of the connector and make sure the test lead touches the electrical wire or metal terminal within the connector housing If the test lead only touches the wire insulation Th...

Page 64: ...em where the battery is fully charged but the starter motor turns over slowly Voltage drop would be the difference in the voltage at the batter source and the voltage at the starter destination as the engine is being started current is flowing through the batter cables A corroded battery cable would cause a high voltage drop high resistance and slow engine cranking d Common sources of voltage drop...

Page 65: ...Remove the blown fuse 2 Connect the test light or voltmeter across the fuse terminals in the starter relay Turn the ignition switch ON and check for battery voltage 3 With the test light or voltmeter attached to the fuse terminals wiggle the wiring harness relating to the suspect circuit at various intervals Start next to the fuse terminal a work systematically away from the fuse terminal Watch th...

Page 66: ...ease in pad wear check the brake hoses lines and banjo bolts for leaks 3 Leak in the brake system 4 Contaminated brake fluid 5 Plugged brake fluid passages 6 Damaged brake lever or pedal assembly 7 Worn or damaged brake pads 8 Warped brake disc 9 Contaminated brake pads and disc WARNING A leaking fork seal can allow oil to contaminate the brake pads and disc 10 Worn or damaged master cylinder cups...

Page 67: ...rd check for the following possible causes 1 Clogged brake hydraulic system 2 Sticking caliper piston 3 Sticking master cylinder piston 4 Glazed or worn brake pads 5 Mismatched brake pads 6 Damaged front brake lever 7 Damaged rear brake pedal 8 Brake caliper not sliding correctly on slide pins 9 Worn or damaged brake caliper seals Brake Grabs 1 Damaged brake pad pin bolt Look for steps or cracks a...

Page 68: ...ose caliper body bolts 4 Loose banjo bolt 5 Damaged banjo bolt washers 6 Damaged banjo bolt threads in caliper body Leaking Master Cylinder 1 Damaged piston secondary seal 2 Damaged piston snap ring snap ring groove 3 Worn or damaged master cylinder bore 4 Loose banjo bolt washers 5 Damaged banjo bolt washers 6 Damaged banjo bolt threads in master cylinder body 7 Loose or damaged reservoir cap ...

Page 69: ...4 0 6214 3 281 1 094 0 3937 0 03937 mph mi ft yd in in Volume capacity cc cm3 cc cm3 lit liter lit liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Others kg mm kg cm2 Centigrade 55 997 14 2234 9 5 32 Ib in psi lb in2 Fahrenheit F 2 Definition of unit Unit Read Definition Measurement mm cm Millimetre Centimetre 1 mm 10 3 Meter 1 cm 10 2 Meter Length Length kg Kilogram 1 ...

Page 70: ... Bore stroke Compression ratio Starting system Lubrication system Liquid cooled 4 stroke Water cool V type twin cylinder 800cm3 91 61 5mm 3 58 2 42in 10 1 Electric starter Wet sump Engine oil Final gear oil Differential gear oil Engine oil Periodic oil change With oil filter replacement Total amount API service SE SF SG type or higher SAE80 API GL 4 Hypoid gear oil SAE80 API GL 5 Hypoid gear oil 1...

Page 71: ...peed automatic Sub transmission ratio Low High Reverse gear V belt Shaft drive V belt automatic Right hand operation 2 900 0 650 34 29 1 172 43 20 2 150 31 14 2 214 Chassis Frame type Camber angle Trail Toe in Steel tube frame 0 5 26 0mm 1 02 in 8 18 mm 0 31 0 70 in Tire Type Size Front Rear Pressure of front wheel Pressure of rear wheel Tubeless 25 8 12 25 10 12 140kpa 140kpa Brake Front brake Ty...

Page 72: ... 12 in 150mm 5 91 in Electrical Ignition system Generator system Battery type Battery capacity EFI A C magneto GSU1 9 or U1L 11 12 V 32 0Ah Headlight type Bulb wattage quantity Headlight Front Position Lamp Front direction indicator Rear direction indicator Rear position lamp Stop lamp Neutral Reverse Coolant temperature Parking brake Four wheel drive Differential gear lock S2 12V 35W 35W 2 12V 5W...

Page 73: ...3 mm 0 0012 in Cylinder Bore size Measuring point 91 016 91 030mm 3 544 3 584 in 50 mm 1 97 in Camshaft Drive method Cam dimensions Intake A B Exhaust A B Camshaft runout limit 31 95 32 11mm 1 258 1 264 in 25 95 26 05mm 1 022 1 026in 32 14 32 30mm 1 2654 1 2717in 25 95 26 05 1 2165 1 0256 ...

Page 74: ...0026in 0 15 0 20 mm 0 0059 0 0079 in Valve dimensions head diameter face width seat width margin thickness A head diameter IN EX B face width IN EX C seat width IN EX D margin thickness IN EX Stem outside diameter IN EX Guide inside diameter IN EX 26 9 27 1mm 1 0591 1 0669 in 30 9 31 1 mm 1 2165 1 2244in 2 25 mm 0 0900 in 2 26 mm 0 0890 in 0 9 1 1 mm 0 0354 0 0433 in 0 9 1 1 mm 0 0354 0 0433 in 0 ...

Page 75: ...0 08 mm 0 0031 in 0 10 mm 0 0039 in 0 01 mm 0 0004 in Valve spring Inner spring Free length IN EX Set length valve closed IN EX Compressed pressure installed IN EX Tilt limit IN EX Direction of winding top view IN EX 41 0mm 1 61 in 41 0mm 1 61in 31 0mm 1 22 in 31 0 mm 1 22 in 250 0 290 0N 25 51 29 59 kg 56 25 65 25 lb 250 0 290 0N 25 51 29 59 kg 56 25 65 25 lb Clockwise Clockwise 2 5 1 4 mm 2 5 0 ...

Page 76: ... in 4 0 mm 0 15 in 0 5mm 0 0394 in Intake side 20 002 20 008mm 0 7875 0 7877in 19 99 19 995 mm 0 7870 0 7872 in 0 15 mm 0 0059 in Piston rings Top ring Type Dimensions B T End gap installed Side clearance installed 2nd ring Type Dimensions B T End gap installed Side clearance Barrel 1 2 3 5 mm 0 0472 0 1378in 0 25 0 40 mm 0 0098 0 0157 in 0 04 0 08 mm 0 0016 0 0031 in Taper 1 5 3 9 mm 0 0591 0 153...

Page 77: ... 0276 in 0 06 0 15 mm 0 0024 0 0059 in Crankshaft Crank width A Runout limit C1 C2 Big end side clearance D Big end radial clearance E 90 523 90 577mm 3 5639 3 5660in 0 35 0 65 mm 0 0138 0 0256 in 0 010 0 025 mm 0 0004 0 0010 in 0 03 mm 0 0012 in 0 03 mm 0 0012 in 1 0 mm 0 0394 in Automatic centrifugal clutch Clutch engagement speed 1800r min ...

Page 78: ... cm2 9 2 psi at 1 500 r min Cylinder head Water pump Type Reduction ratio Single suction centrifugal pump 15 15 1 0 Shaft drive Middle gear backlash Final gear backlash Differential gear backlash 0 1 0 3 mm 0 004 0 012 in 0 1 0 3 mm 0 004 0 012 in 0 05 0 25 mm 0 002 0 010 in Cooling system Radiator core Width Height Thickness Radiator cap opening pressure Radiator capacity including all routes Coo...

Page 79: ... in 328 mm 12 91 in 273 2 mm 10 76 in 47 6 N mm 4 85 kg mm 266 55 lb in 108 8N mm 11 10kg mm 609 24 lb in 0 60 mm 0 2 36 in 60 81 mm 2 36 3 19in Front wheel Type Rim size Rim material Rim runout limit radial lateral Aluminum Alloy wheel 12 6 0 AT ST12 ZL101A 1 0 mm 0 04in 1 0 mm 0 04 in Rear wheel Type Rim size Rim material Rim runout limit radial lateral Aluminum Alloy wheel 12 8 0 AT ST12 ZL101A...

Page 80: ... diameter Brake fluid type Dual 200 3 5 mm 7 87 0 14 in 9 0 mm 0 35 in 9 0 mm 0 35 in 19 0mm 0 75in 25 0mm 0 98in DOT 4 Rear disc brake Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Dual 183 0 3 5 mm 7 20 0 14in 9 0 mm 0 35 in 9 0 mm 0 35 in 19 0mm 0 75in 25 0mm 0 98in DOT 4 ...

Page 81: ...istance 4 5 5 0 kΩ Oxygen sensor type 25325359 Charging system Nominal output Charging coil resistance color 14 V 23 A at 4 500 r min 0 32 0 43Ωat 20 68 F White White White Rectifier regulator Regulator type No load regulated voltage DC Capacity Withstand voltage Semi conductor Switch type 14 1 14 9 V 18 A 200 V Battery Specific gravity 1 32 Circuit breaker Type Lighting system fuse Ignition fuse ...

Page 82: ... Brush overall length Spring force Commutator diameter Mica undercut Starter relay Amperage rating Coil winding resistance Constant mesh type 0 8 kW 0 025 0 035 Ωat 20 C 68 F 12 5 mm 0 49 in 7 65 10 01 N 780 1 021 g 27 5 36 0 oz 28 mm 1 10 in 0 7 mm 0 03 in 180 A 4 18 4 62 at 20 C 68 F 5 mm 0 20 in 27 mm 1 06 in ...

Page 83: ... Oil pump assembly Oil cooler inlet pipe 1 oil cooler outlet pipe 1 Oil cooler inlet pipe 1 oil cooler outlet pipe 1 clamp Oil cooler inlet pipe 2 oil cooler outlet pipe 2 clamp Intake manifold Intake manifold screw clamp Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Union Bolt Union Bolt Union Bolt Union bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt M6 M9 M12 M8 M6 M32 ...

Page 84: ...2 10 1 0 7 2 Starter clutch Bolt M8 3 30 3 0 22 Clutch carrier assembly Nut M22 1 160 16 0 115 Stake Clutch housing assembly Bolt M6 9 10 1 0 7 2 Bearing retainer middle drive shaft Screw M8 4 29 2 9 21 Middle drive pinion gear Nut M22 1 145 14 5 105 Stake Middle drive shaft bearing housing Bolt M8 4 32 3 2 23 Middle driven pinion gear bearing Retainer Nut M60 1 110 11 0 80 Left hand threads Unive...

Page 85: ...iator bracket and frame Bolt M6 4 7 0 7 5 1 Fuel pump Bolt M6 2 7 0 7 5 1 Fuel tank Bolt M8 2 30 3 0 22 Muffler stay Bolt M6 2 11 1 1 8 0 Muffler and exhaust pipe Bolt M8 1 20 2 0 14 Muffler bracket and muffler Bolt M8 1 20 2 0 14 Muffler bracket and frame Bolt M8 2 20 2 0 14 Muffler damper and muffler Bolt M6 1 10 1 0 7 2 Muffler damper and frame Bolt M6 1 10 1 0 7 2 Exhaust pipe Nut M8 4 14 1 4 ...

Page 86: ... 13 1 3 9 4 Differential gear case cover and differential gear case M8 25 2 5 18 Rear driving axle gear case and frame M10 70 7 0 51 Rear driving axle gear case filler plug M20 23 2 3 17 Rear driving axle gear case drain plug M10 20 2 0 14 Ring gear bearing housing and final drive gear case M8 23 2 3 17 M10 40 4 0 29 Ring gear stopper nut M8 16 1 6 11 Bearing retainer and final gear pinion gear be...

Page 87: ...and constant velocity joint of half shaft M20 260 26 0 190 Stake Rear brake hose and frame M6 7 0 7 5 1 Brake pipe and brake master cylinder M10 19 1 9 13 Pedal holder assembly and frame M8 16 1 6 11 Brake master cylinder and pedal holder assembly M8 16 1 6 11 Secondary brake master cylinder kit stopper bolt M6 9 0 9 6 5 Brake rod locknut M8 17 1 7 12 Rear brake disc and brake disc Install seat M6...

Page 88: ...ghten multi fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter General tightening torques A nut B bolt Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 1...

Page 89: ...rtridge O ring Apply lithium soap based grease Starter idle gear shaft Apply molybdenum disulfide grease Starter wheel gear Apply engine oil Clutch housing assembly shaft end Apply lithium soap based grease Clutch carrier assembly Apply engine oil One way clutch bearing Apply molybdenum disulfide grease Middle driven shaft splines Apply molybdenum disulfide oil Drive axle driven sprocket high whee...

Page 90: ...int of front brake cable Light lithium base grease Front brake lever axle and rear brake lever axle Light lithium base grease Adjusting nut and pin of front brake cable Light lithium base grease Adjusting nut and pin of rear brake cable Light lithium base grease Rear brake pedal pivot and brake pedal axle hole Light lithium base grease Throttle rotating frame shaft and end section of throttle cabl...

Page 91: ...SPECIFICATIONS 79 HYDROGRAPHIC CHART Hydrographic chart Pressure ...

Page 92: ...SPECIFICATIONS 80 LUBRICATION OIL WAY LUBRICATION OIL WAY Pressure splashing oil ...

Page 93: ...SPECIFICATIONS 81 Engine gearbox lubrication oil path circuit Gearbox lubrication oil path circuit Pressure splashing oil ...

Page 94: ...lement clean Replace if necessary Every20 40hours More often in wet of dusty areas Front brake Check operation fluid leakage See NOTE page 8 Correct if necessary Rear brake Check operation Adjust if necessary Wheel Check balance damage Repair if necessary Front and rear suspension Check operation Correct if necessary Wheel bearing Check bearing assemblies for looseness damage Replace if necessary ...

Page 95: ...Engine oil filter cartridge Replace Final gear oil Differential gear oil Check oil level oil leakage Replace Lights and switches Check operation Adjust headlight beams NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassembling the master cylinder or caliper replace the brake fluid Normally check the brake fluid level and add fluid as required On the inner parts of the master cyl...

Page 96: ...ust the valve clearance when the piston is at the Top Dead Center TDC on the compression stroke Remove driver seat passenger seat console 1 Remove following parts spark plug cylinder cover Crankshaft position sensor Inspection hole cover bolt M6 x 10 cylinder 1 cylinder 2 2 Remove remove the bolts Crankshaft position sensor Inspection hole cover cylinder cover ...

Page 97: ...ke 0 08 0 12 mm 0 0031 0 0047 in Exhaust 0 12 0 16 mm 0 0047 0 0063 in 4 calibration adjusting tools A Spin the crank when the rotoflex s scale shows 1 it is cylinder 1 s timing spin the crank counter clockwise280 the rotoflex s scale shows 2 it is cylinder 2 s timing the valve clearance of cylinder 2 can be adjusted ...

Page 98: ... adjusting tool until the proper clearance is obtained in order to avoid adjuster rotating along fix the lock nut after finishing Measuring clear Measure the clearance of valve with gap gauge If the gap beyond the standard value repeat the above steps until the correct gap 6 Install all removed parts According to remove the reverse order for installation left front cover crankcase ignition sensor ...

Page 99: ... clearance by thickness gauge It is qualified if the pole clearance is between 0 8 to 0 9mm Otherwise it should be adjusted Wear damage Replace insulator Abnormal color Replace Normal color is a medium to light tan color 5 Clean the spark plug with a spark plug cleaner or wire brush 6 Install spark plug 17 5 Nm 1 75 m kgf 12 7 ft lbs Then hook up the spark plug cap NOTE Before installing a spark p...

Page 100: ...al starting mechanism name 5 Check Engine tachometer a worm up the engine at specified speed Engine speed 1 400 1 500 r min b Remove Ignition signal sensor c Visually check the stationary pointer to verify it is within the required firing range indicated on the flywheel Incorrect firing range Check the pulser coil assembly d Install the timing plug 6 Install Engine manual starting mechanism 7 Nm 0...

Page 101: ...E standard value standard compression pressure data 1200Kpa 12kg c 1000r min 5 read the highest data on the compression pressure meter Above the maximum pressure Check the cylinder head valve surfaces and piston crown for carbon deposits Below the minimum pressure Check the accumulation carbon in the firebox of the cylinder head and accumulation carbon on the piston head Refer to the table below C...

Page 102: ...m 20Nm 1 8 m kg 13 ft lb 5 Lower the cargo bed CHECKING THE ENGINE OIL LEVEL 1 Place the vehicle on a level surface 2 Remove driver seat passenger seat console Refer to SEATS in chapter 5 3 Check engine oil level Oil level should be between the maximum and minimum marks Oil level low Add oil to the proper level NOTE Do not screw the dipstick in when checking the oil level Recommended oil Follow th...

Page 103: ...face 1 Start the engine and let it warm up for several minutes 2 Stop the engine and place an oil pan under the engine 3 Remove driver seat passenger seat console 4 Remove dismount the following parts step by stem oil gauge oil draining blind nut crankcase oil draining bolt gear box bolt M6 x 20 oil filter oil filter cover sealing ring paper core oil filter 5 If you need to change the oil filter c...

Page 104: ...el when the vehicle is placed on flat ground Oil level of gearbox Periodic oil change The oil capacity after the engine is disassembled and reassembled 2L The oil should be put into the engine for after all the oil is drawn out 2L 8 Install engine oil filler plug 9 Worm up the engine for a few minutes and then stop the engine 10 Check engine for engine oil leaks refer to Chapter 4 check the level ...

Page 105: ...filter check hose air filter case cover air filter element NOTE Never operate the engine with the air filter element removed This will allow unfiltered air to enter causing rapid wear and possible engine damage Additionally operation without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating 2 Check air filter element air filter frame ...

Page 106: ...eze out the excess oil NOTE The element should be wet but not dripping 4 Install air filter element air filter case cover NOTE To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case console passenger seat driver seat CHECKING THE COOLANT LEVEL 1 Place the vehicle on a level surface 2 Remove front faceplate 3 Check start the engine warm it up ...

Page 107: ...reservoir cap Disconnect coolant reservoir hose Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 2 Drain coolant from the coolant reservoir 3 Connect coolant reservoir h...

Page 108: ...r a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped turn the radiator cap counterclockwise while pressing down on it and then remove it 6 Drain coolant 7 Disconnect coolant outlet hose water pump inlet hose 8 Drain coolant 9 Check copper washer coolant drain bolt Damage Repla...

Page 109: ...shes in your eyes thoroughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomiting and get immediate medical attention If coolant comes into contact with painted surfaces immediately wash them with water Do not mix different types of antifreeze Recommended antifreeze High qu...

Page 110: ...led water is not available 14 Install air bleed bolt 9 Nm 0 9 m kg 6 5 ft lb radiator cap Fill coolant reservoir Install coolant reservoir cap Start the engine warm it up for several minutes and then turn it off Check coolant level Refer to THE COOLANT in chapter 4 NOTE Before checking the coolant level wait a few minutes until the coolant has settled Close the hood Install driver seat Refer to SE...

Page 111: ...e Coolant temperature warning light checking method Turn the main switch ON Coolant temperature warning light does not come on Coolant temperature warning light come on Turn the main switch to START with the transmission in neutral position Coolant temperature warning light comes on momentarily Coolant temperature warning light does not come on Coolant temperature and electrical circuit are OK Go ...

Page 112: ... sheave and secondary sheave Install the V belt NOTE Install the V belt so that its arrow faces the direction shown in the illustration Remove the bolts 2 Install drive belt cover driver seat CLEANING THE SPARK ARRESTER 1 Clean Tap the tailpipe lightly with a soft face hammer or suitable tool then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and th...

Page 113: ...lpipe into the muffler and align the bolt holes Insert the bolt 1 and tighten it Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop the engine and allow the exhaust pipe to cool ADJUSTING THE BRAKE PEDAL 1 Check brake pedal free play a Out of specification adjust NOTE The end of...

Page 114: ...n checking the brake fluid level make sure that the top of the brake fluid reservoir top is horizontal 2 Lift the hood up 3 Check brake fluid level Fluid level is under MIN line Fill up NOTE Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designed quality brake fluid otherwise the rubber seals may deteriorate causing leakage an...

Page 115: ...pads Wear indicator groove a almost disappeared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 5 Brake pad wear limit a 1 5 mm 0 06 in 3 Operate the brake pedal 4 Install front wheels CHECKING THE REAR BRAKE PADS 1 Check brake pads Wear indicator groove a almost disappeared Replace the brake pads as a set Refer to FRONT AND REAR BRAKES in chapter 5 Brake pad wear limit a...

Page 116: ...pedal 4 Install driver seat BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake operation has been faulty A loss of braking performance may occur if the brake system is not properly bled 1 Bleed brake system a Add the proper brake fluid to the rese...

Page 117: ...ase the pedal i Repeat steps e to h until all the air bubbles have disappeared from the fluid j Tighten the bleed screw Front brake caliper bleed screw 6 Nm 0 6 m kg 4 3 ft lb Rear brake caliper bleed screw 5 Nm 0 5 m kg 3 6 ft lb NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have di...

Page 118: ...re the select lever is in NEUTRAL b Loosen both locknuts WARNING The select lever shift rod locknut select lever side has left handed threads To loosen the locknut turn it clockwise c Tighten the locknuts ADJUSTING THE BRAKE LIGHT SWITCH NOTE The brake light switch is operated by movement of the brake pedal The brake light switch is properly adjusted when the brake light comes on just before the b...

Page 119: ... 1 Place the vehicle on a level surface 2 Remove oil filler plug 3 Check oil level Oil level should be up to the brim of the hole Oil level low Add oil to the proper level Recommended oil SAE 80 API GL 4Hypoid gear oil WARNING Take care not allow foreign material to enter the final gear case 4 Install oil filler plug 23 Nm 2 3 m kg 17 ft lb CHANGING THE FINAL GEAR OIL 1 Place the vehicle on a leve...

Page 120: ...IL 1 Place the vehicle on a level surface 2 Remove oil filler plug 3 Check oil level Oil level should be up to the brim of hole Oil level low Add oil to proper level WARNING Take care not allow foreign material to enter the differential gear case 4 Install oil filler plug 23 Nm 2 3 m kg 17 ft lb CHANGING THE DIFFERENTIAL GEAR OIL 1 Place the vehicle on a level surface 2 Place a receptacle under th...

Page 121: ... oil is filled to the brim of the oil filler hole oil may start leaking from the differential gear case breather hose Therefore check the quantity of the oil not its level WARNING Take care not to allow foreign material to enter the differential gear case 7 Install oil filler plug 23 Nm 2 3 m kg 17 ft lb CHECKING THE CONSTANT VELOCITY JOINT DUST BOOTS 1 Check dust boots Damage Replace Refer to FRO...

Page 122: ...ace the sliding bearing Refer to secrtion Steering ststem of chapter 5 Check tie rod ends Ball pin unit of steering tension rod Rotate the steering bar leftward and or rightward Then roate from left to right lightly If the ball pin unit of steering tension rod have any vertical clearance replace it Refer to secrtion Steering ststem of chapter 5 Check Ball joints and or wheel bearings Move the whee...

Page 123: ...e beetween two marks d Rotate the front tires 180 until the marks are exactly opposite one another e Measure distance B between the marks f Calculate the toe in using the formula given below Toe in B A g If the toe in is incorrect adjust it 3 Adjust toe in WARNING Make sure that left right tension rods have turned the same turns Otherwise the UTV will still go UTV left and right even though Operat...

Page 124: ...to keep the length of the rods the same d Tighten the rod end locknut on each tie rod Locknut rod end 40 Nm 4 0 m kg 29 ft lb ADJUSTING THE FRONT AND REAR SHOCK ABSORBERS Option 1 WARNING Always adjust both shock absorber spring preload to the same setting Uneven adjustment can cause poor handling and loss of stability NOTE The spring preload of the shock absorbers can be adjusted to suit the oper...

Page 125: ...y Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a HSUN dealer for any service The spring preload rebound damping and compression damping forces of the front and rear shock absorber assemblies can be adjusted to suit the operating conditions NOTE Never turn an adjusting mechanism b...

Page 126: ...e locknut NOTE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque Rebound damping force Turn the rebound damping force adjusting screw in direction S to increase the rebound damping force and thereby harden the damping and in direction F to decrease the rebound damping force and thereby soften the damping Compression damping force Turn the compression ...

Page 127: ...ce the handling of vehicle s If other tire combinations are used they can adversely affect your vehicle s handling characteristics and are therefore not recommended Size Type Front 6PR 25 8 12 Rear 6PR 25 10 12 TIRE PRESSURE a Recommended tire pressure Front 140Kpa 20psi Rear 140KPa 20psi b Tyre pressure below the minimum specification could cause the tire to dislodge from the rim under severe rid...

Page 128: ...quipment If dust or the like is stuck to this gauge it will not provide the correct readings Therefore take two measurements of the tire s pressure and use the second reading WARNING Uneven or improper tire pressure may adversely affect the handling of this vehicle and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal i...

Page 129: ...ing a tire to allow it to seat itself properly on the rim CHECKING AND LUBRICATING THE CABLES WARNING A damaged cable sheath may cause corrosion and interfere with the cable movement An unsafe condition may result so replace a damaged cable as soon as possible 1 Check cable sheath Damage Replace cable operation Unsmooth operation Lubricate or replace NOTE Hold the cable end up and apply several dr...

Page 130: ...harging or handling batteries keep batteries and electrolyte out of reach of children Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury first aid in case of bodily contact External Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk followed with milk of magnesia beat...

Page 131: ...t possible to check the charge state of the battery by measuring the specific gravity of the electrolyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Lift the hood up battery case cover disconnect battery leads NOTE First disconnect the negative battery lead and then the positive battery lead Remove battery Check battery charge a ...

Page 132: ... not use a high rate battery charger since it forces a high amperage current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the vehicle If charging has to be done with the battery mounted on the v...

Page 133: ... explode As shown in the following illustration the open circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit voltage Charging method using a variable current voltage charger NOTE Leave the battery unused for more than 30 minutes before measuring its open circuit voltag...

Page 134: ...standard charging amperage after 5 minutes replace the battery Adjust the voltage to obtain the standard charging amperage Set the timer to the charging time determined by the open circuit voltage If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging ampe...

Page 135: ... than the standard charging amperage written on the battery Charge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the ba...

Page 136: ...y terminals Dirt Clean with a wire brush Loose connection Connect properly Lubricate battery terminals Install battery case cover Close the hood CHECKING THE FUSES NOTE Always turn off the main switch when checking or replacing a fuse Otherwise a short circuit may occur 1 Remove lift the hood up battery case cover 2 Check fuses a Connect the pocket tester to the fuse and check it for continuity NO...

Page 137: ...t rating Quantity Lighting system fuse 15 A 1 Ignition 10 A 1 Terminal Auxiliary DC jack 10 A 1 4WD Four wheel drive 5A 1 Signaling system fuse 10 A 1 Backup fuse 10 A 1 Reserve 15 A 1 Reserve 10 A 1 Reserve 5 A 1 WARNING Ever use a fuse with a rating other than that specified Never use other materials in place of a fuse An improper fuse may cause extensive damage to the electrical system a malfun...

Page 138: ...rning out Headlight beam lowered CHANGING THE HEADLIGHT BULB Remove Lift the hood up headlight bulb holder cover headlight bulb holder with bulb bulb NOTE Remove the defective bulb by unhooking the headlight bulb holder tabs WARNING Keep flammable products and your hands away from the bulb while it is on since it will be hot Do not touch the bulb until it cools down ...

Page 139: ...loth moistened with alcohol or lacquer thinner headlight bulb holder with bulb headlight bulb holder cover Close the hood CHANGING THE TAIL BRAKE LIGHT BULB 1 Remove Rear panel Tail brake light bulb holder with bulb Secure the new bulb with the tail brake light bulb holder tail brake light bulb holder with bulb bulb NOTE Turn the bulb holder counterclockwise and remove the defective bulb WARNING K...

Page 140: ...NOTE Avoid touching the glass part of the bulb Keep it free from oil otherwise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on the bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner tail brake light bulb holder with bulb bed panel ...

Page 141: ... specified torque Opposite order is for removing bolts and nuts 6 Make sure sealing bolt with the sealant must be replaced 7 Make sure to use new bearing when remove assembly set up by pressure 8 Determined axial and radial clearance of inner and outer bearing ring by touch new bear should be replaced if the clearance is too large or non rotating flexible 9 Bearing assembly directions bearing logo...

Page 142: ... the order listed 1 Dampers 1 2 Dampers joint intake manifold 1 3 Intake manifold 1 4 Temperature sensor 1 5 Cylinder head 2 6 Timing chain tensioner cap bolt 2 7 Pressure plate TMAP 1 8 Fuel Injector 2 9 Fuel Injector seat 2 10 Drain blind nut 1 11 Drain plug 1 For installation reverse the removal procedure ...

Page 143: ... head Remove the parts in the order listed 1 Thermostat cover 2 2 Thermostat 1 3 Cylinder water outlet connector 1 4 Washer 1 5 O ring 2 6 Cylinder head cover 2 7 Cylinder cover pad 2 8 Spark plug 2 9 Stud Bolt M8 45 stainless steel 4 10 Temperature sensor 1 11 Cylinder head 2 12 Timing chain tensioner cap bolt 2 ...

Page 144: ...ENGINE 132 No Part Name Qty Remarks 13 Timing chain tensioner gasket 2 14 Dowel pin 4 15 Timing chain guide exhaust side 2 For installation reverse the removal procedure ...

Page 145: ...er head as a set 3 Checking the tappet covers Cylinder head cover Cracks damage Replace Cylinder cover pad NOTE When installing new replacement washer and apply wheel bearing grease LS 4 Removing the screwdriver and slowly release the timing chain tensioner rod NOTE Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough movement rep...

Page 146: ...inder head bolts M9 1 6 38Nm bolts M6 7 10Nm NOTE Tighten the bolts in the proper sequence Follow the numerical order shown in the illustration Tighten the bolts in two stages timing chain guide exhaust side timing chain tensioner a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand b While pressing the timing chain tensioner rod wind it clockwise with a t...

Page 147: ... UP mark on the timing chain tensioner should face up Timing chain tensioner bolt 10 Nm d Remove the screwdriver make sure that the timing chain tensioner rod releases and tighten the cap bolt to the specified torque Timing chain tensioner cap bolt 7 Nm ...

Page 148: ... in the order listed camshaft Cylinder head cover 1 Rocker arm shaft 4 2 Wave washer 8 3 Rocker arm exhaust 2 4 Rocker arm intake 2 5 Valve adjuster 8 6 Locknut 8 7 Camshaft sprocket 2 8 Camshaft station plate 2 9 Camshaft Ⅱ 1 10 CamshaftⅠ 1 11 Cylinder head 2 For installation reverse the removal procedure ...

Page 149: ...diameter of the rocker arm holes Out of specification Replace Rocker arm inside diameter repairing limit value Φ12 05mm d Check the surface of the rocker arm shafts Worn pitting scratches Replace e Measure the external diameter of rocker arm shaft with micrometer Out of specification Replace Rocker arm shaft outside diameter repairing limit value Φ11 96mm f Calculate the clearance by subtracting t...

Page 150: ...e camshaft sprocket camshaft sprocket Wear damage Replace the camshaft sprocket and timing chain as a set a 1 4 of a tooth b Correct Timing chain Sprocket 4 Checking the decompression system decompression system Check while the camshaft sprocket is installed on the camshaft 2 INSTALL 1 Installing the rocker arms rocker arms rocker arm shafts NOTE After installation make sure that the thread hole o...

Page 151: ...ve springs Remove the parts in the order listed Cylinder head cover 1 Valve lock clip 16 2 Valve spring retainer 8 3 Intake valve spring 4 4 Exhaust valve spring 4 5 Intake valve 4 6 Exhaust valve 4 7 Valve stem seal 8 8 Valve spring seat 8 For installation reverse the removal procedure ...

Page 152: ...meter larger than the body of the stem Replace valve seats Pitting wear Reface the valve seat 2 MEASURE 1 Measure The valves surface width Repairing limit value 2 0mm stem to guide clearance Stem to guide clearance valve guide inside diameter valve stem diameter NOTE If the mating surface is coarse corrode or cannot contact with valve seat normally replace it Stem to guide clearance repairing limi...

Page 153: ...Press the valve through the valve guide and onto the valve seat to make a clear pattern c Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed Valve spring free length Valve spring squareness Out of specification Replace Valve spring free length Intake 41mm Exhaust 41mm Valve spring squareness Intake 1 60mm Exhaust 1 60mm compressed spring fo...

Page 154: ... to wide or narrow or cracked grind it to ensure impermeability 3 Lap valve face valve seat NOTE After reface the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped a If the pipe will be replaced grind the valve seat again CAUTION Do not let the compound enter the gap between the valve stem and the guide b Install the valve into the cylinder head c Tur...

Page 155: ...n h Measure the valve seat width again If the valve seat width is out of specification reface and relapse the valve seat 3 INSTALL 1 Apply molybdenum disulfide oil onto the valve stem and valve stem seal 2 Install valve spring seats valve stem seals valves valve springs valve spring retainers NOTE Install the valve springs with the larger pitch a facing upwards b Smaller pitch valve cotters NOTE I...

Page 156: ...nder and piston Remove the parts in the order listed Water pump outlet hose Cylinder head 1 Dowel pin 16 2 Cylinder head gasket 2 3 Cylinder 2 4 Cylinder gasket 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Piston ring set 2 For installation reverse the removal procedure ...

Page 157: ...groove is cracked and abraded 3 Checking the piston pin piston pin Blue discoloration grooves Replace then check the lubrication system 2 MEASURE At the top the middle and the bottom of the piston stroke NOTE Measure the bore diameter at directions of right angle intersection Repairing limit value Out of roundness 0 10mm Taper 0 10mm The external diameter 10mm above the bottom of the piston skirt ...

Page 158: ...suring the side clearance Side clearance Standard Limit Top ring 0 04 0 08mm 0 13mm 2nd ring 0 03 0 07mm 0 13mm piston pin to piston clearance a Measure the piston pin outside diameter b Measure the piston pin bore inside diameter Repairing limit value 0 08mm c Calculate the piston pin to piston clearance with the following formula Piston pin to piston clearance Piston pin bore inside diameter Pis...

Page 159: ...il onto the piston pin piston rings and piston Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase 2 Installing the cylinder cylinder O ring NOTE Install the cylinder with one hand while compressing the piston rings with the othe...

Page 160: ...the parts in the order listed Engine oil Water pump assembly 1 Left crankcase cover 1 2 Inspection port cover O ring 1 1 3 Crankcase location sensor O ring 1 1 4 Plug oil level gauge O ring 1 1 5 A C magneto clip 1 6 Stator assembly 1 7 Left crankcase cover gasket 1 8 Dowel pin 2 9 A C magneto rotor 1 10 Starter clutch 1 11 Starter wheel gear 1 ...

Page 161: ...ENGINE 149 No Part Name Qty Remarks 12 Starter idle gear 1 13 Starter idle gear shaft 1 For installation reverse the removal procedure ...

Page 162: ...t a Install the starter wheel gear onto the starter clutch and hold the starter clutch b Turn the starter wheel gear counterclockwise to check that the starter clutch and wheel gear engage If the starter clutch and wheel gear do not engage replace the starter clutch c Turn the starter wheel gear clockwise to check the starter wheel gear for smooth operation If operation is not smooth replace the s...

Page 163: ... C magneto rotor NOTE Before installing the rotor clean the outside of the crankshaft and the inside of the rotor After installing the rotor check that the rotor rotates smoothly If not reinstall the key and rotor dowel pins gasket New replacement ...

Page 164: ...lter Remove the parts in the order listed A C magneto rotor 1 Starter idle gear 1 2 Starter idle gear shaft 1 3 Relief valve spring steel ball 1 1 4 Chain plate 1 5 Timing chain guide first cylinder 1 6 Timing chain 1 7 Pump 1 8 Oil filter cover 1 9 O ring 1 10 Oil filter cartridge 1 11 Starter motor 1 ...

Page 165: ...ENGINE 153 No Part Name Qty Remarks 12 Oil pressure sensor 1 For installation reverse the removal procedure ...

Page 166: ...cking the relief valve spring Relief valve steel ball Relief valve spring Damage wear Replace the defective part s 4 Checking the oil filter cartridge Oil filter cartridge Damage Replace Contaminants Clean with engine oil 5 Checking the starter motor starter motor Damage wear Replace the defective part s 2 INSTALL Starter motor Oil filter cartridge Starter idle gear shaft Starter idle gear NOTE Ap...

Page 167: ...and secondary sheaves Remove the parts in the order listed Engine assembly 1 Drive belt cover 1 2 Rubber gasket 1 3 Clutch cove of plug 1 4 keeper 1 5 V belt 1 6 Secondary fixed sheave 1 7 Secondary sliding sheave 1 8 Compression spring 1 9 Guide Base Driven Gear 1 10 Driving Flyweight 1 ...

Page 168: ...ssion spring Spring seat 1 1 13 Spacer 1 14 Fixing Base One Way Bearing 1 15 Guide pin spring 1 1 16 Primary sliding sheave 1 17 Flange Bolt M6 25 1 18 Flange Bolt M6 22 8 19 Spring Washer φ6 9 20 Drive belt case 1 21 O ring 2 For assembly reverse the disassembly procedure ...

Page 169: ...econdary sheave spring free length a Out of specification Replace the secondary sheave spring 3 INSTALL 1 Assembling the primary sheave 1 Clean primary sliding sheave primary fixed sheave primary sliding sheave cam face NOTE Remove any excess grease 2 Install weights NOTE Apply grease 90g to the whole outer surface of the weights and install Apply grease to the inner surface of the collar Apply gr...

Page 170: ...l secondary sheave assembly V belt primary sheave assembly NOTE Tightening the bolts will push the secondary sliding sheave away causing the gap between the secondary fixed and sliding sheaves to widen Install the V belt so that its right faces the direction show in the illustration 2 Tighten primary sheave nut 70Nm secondary sheave nut 50Nm NOTE Use the sheave holder to hold the primary sheave Fi...

Page 171: ...oving the crankcase cover and oil pump Remove the parts in the order listed Crankcase separation 1 Crankshaft cover 1 2 Gasket 1 3 Dowel pin 2 4 Crankcase exhaust pipe 1 5 Crankcase block 1 6 Oil seal 1 7 Oil pump gasket 1 8 Oil pump 1 9 Outer rotor 1 10 Innter rotor 1 ...

Page 172: ...2 12 Oil pump housing 1 13 Oil pump gear 1 14 Water pump Ⅱ gear circlip 1 1 15 Shaft pin 1 1 16 Water pump Ⅰ gear washer 1 1 17 Oil pump middle gear 1 18 Shaft 1 19 Bearing 1 20 Fuel and air separator assy 1 21 V ring 1 22 Shaft 1 23 Valve piece plate 1 ...

Page 173: ...ENGINE 161 No Part Name Qty Remarks 24 Valve piece 1 25 Chain plate 1 26 Timing chain guide secondly cylinder 1 27 Timing chain 1 28 Right crankcase 1 For assembly reverse the disassembly procedure ...

Page 174: ... set timing chain guides Wear damage Replace 2 MEASURE 1 Measure the oil pump tip clearance a between the inner rotor and the out rotor side clearance b between the outer rotor and the pump housing body clearance c between the outer rotor and the pump housing Out of specification Replace the oil pump Tip clearance Limit 0 23 mm Side clearance Limit 0 25 mm Body clearance Limit 0 20 mm 3 INSTALL 1 ...

Page 175: ...kcase and middle drive shaft Remove the parts in the order listed Crankcase separation 1 Right crankcase 1 2 Crankcase gasket 1 3 Dowel pin 2 4 Crankshaft 1 5 Shaft 2 6 Connection rod cover rod bushing 2 4 7 Universal joint 1 8 Oil seal 1 9 Bearing retainer 2 10 Bearing seat dowel pin 2 ...

Page 176: ...ENGINE 164 No Part Name Qty Remarks 11 Bearing 1 12 Middle driven shaft 1 13 Bearing 1 14 O ring bearing 1 1 15 Left crankcase 1 For installation reverse the removal procedure ...

Page 177: ...case mating surfaces thoroughly 3 heck crankcase Cracks damage Replace oil delivery passages Clogged Blow out with compressed air 2 MEASURE 1 Measure the crankshaft crank width A Out of specification Replace the crankshaft Crank width 90 52 90 58 mm side clearance D Out of specification Replace the crankshaft Big end side clearance Limit 1 0 mm 0 0384 in runout b C Out of specification Replace the...

Page 178: ...Before installing and torque the crankcase holding bolts be sure to check whether the transmission is functioning properly by manually rotating the shift drum in both directions 4 Tighten crankcase bolts follow the proper tightening sequence NOTE Tighten the bolts in stages using a crises cross pattern 3 INSTALL 1 Installing the crankshaft crankshaft NOTE Hold the connecting rod at the Top Dead Ce...

Page 179: ... each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place a Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installed b Install the circlip into the groove of...

Page 180: ...the parts in the order listed Middle drive gear 1 Left gear case cover 1 2 Drive shaft coupling 1 3 Drive shaft spring bearing 1 1 4 Output shaft Y 1 1 5 Washer collar 1 1 6 Washer o ring 1 1 7 Universal Joint A φ22 1 1 8 Fuel seal 1 9 Collar o ring 1 1 10 Rear drive bearing seat 1 ...

Page 181: ...ENGINE 169 No Part Name Qty Remarks 11 Dowel pin 4 12 Gearcase 1 13 Washer φ10 φ32 5 1 14 Cross Joint φ22 1 15 Universal Joint B φ22 1 For installation reverse the removal procedure ...

Page 182: ...r to hold the middle driven gear c Attach the gear lash measurement tool and dial gauge a 6 7 mm 0 26 in d Measure the gear lash while rotating the output shaft Y 1 back and forth NOTE Measure the gear lash at 4 positions Rotate the middle driven gear 90 each time 3 INSTALL bearing retainer a Place a rag in the vise b Secure the bearing housing edge in the vise c Attach the bearing retainer wrench...

Page 183: ...n easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place a Press each bearing into the universal joint using a suitable socket NOTE The bearing must be inserted far enough into the universal joint so that the circlip can be installed e Install the circlip into the groove of each bearing drive shaft co...

Page 184: ... and gearcase Remove the parts in the order listed Gear case separation 1 Shift lever cover gasket 1 1 2 Shift lever 2 assembly 1 3 Shift lever 1 1 4 Oil pump o ring 1 5 5 Outer rotor 1 6 Inner rotor 1 7 Oil pump shaft pin 1 1 8 Connecting pipe1 2 1 1 9 Gear case exhaust nozzle 1 10 Dowel pin 1 ...

Page 185: ...ft drum stopper spring steel ball 1 1 14 Reverse switch washer 1 1 15 Gearshift indicator o ring 1 1 16 Spring seat circlip 1 1 17 Guide bar 1 18 Shift fork 1 long spring 1 1 19 Shift fork 2 short spring 1 1 20 Gea r case cover 1 21 Bracket clutch cover seat 1 For assembly reverse the disassembly procedure ...

Page 186: ...emove the parts in the order listed Gear case separation 1 Gear case cover 1 2 Inner hexangular screw M8 45 1 3 Inner hexangular screw M8 40 3 4 Spring washerφ8 4 5 Oil seal 32 47 7 1 6 Bush φ25 φ32 18 1 7 O ring 25 2 4 1 8 Flange bolt M6 45 1 9 Flange bolt M6 35 4 10 Bracket clutch cover seat 1 ...

Page 187: ...earing plate 1 13 Cross recessed countersunk head Screw 3 14 Main shaft 1 15 Pin φ2 18 1 16 Needle bearing 25 29 12 6 2 17 H Drive gear 1 18 Washer φ27 3φ2 2 3 19 L Drive gear 1 20 Bearing 6204 DU 1 21 Bearing 6403 1 22 Washer φ17 3 φ34 2 1 23 R Driven gear 1 ...

Page 188: ... 1 26 L Driven gear 1 27 Needle bearing 25 29 9 6 2 28 Counter shaft 1 29 Needle bearing AXK15 28 2 1 30 Washer φ15 3 φ32 1 5 1 31 Needle bearing NBI19 27 16 1 32 R Idle gear 1 33 R Idle gear shaft 1 34 Reverse gear shaft φ12 56 1 For assembly reverse the disassembly procedure ...

Page 189: ... guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar shift fork movement on the guide bar Unsmooth operation Replace the shift fork and the guide bar springs Cracks damage Replace 2 Checking the shift drum shift drum grooves Scratches wear damage Replace ...

Page 190: ...mp operation Unsmooth Repeat steps 1 and 2 or replace the defective parts 2 Measure 1 Measure the oil pump tip clearance a between the inner rotor and the out rotor side clearance b between the outer rotor and the pump housing body clearance c between the outer rotor and the pump housing Out of specification Replace the oil pump Tip clearance Limit 0 23 mm Side clearance Limit 0 25 mm Body clearan...

Page 191: ...t spring 2 Installing the shift levers shift lever 2 assembly 14Nm shift lever 1 NOTE When installing the shift lever 1 align the punch mark a on the shift lever 1 with the punch marks b on the shift lever 2 3 Assembling the oil pump inner rotor outer rotor oil pump shaft with the recommended lubricant ...

Page 192: ...brake clamp assembly parts deformed 1 Check whether disc plates abrasion exceeded limits 2 Check whether brake shoe of clamp abrasion exceeded limits or polluted by friction material such as oil 2 Brake performance degressive 3 Check whether the oil cup of brake fluid lack oil 1 Check whether brake plate deformed 3 Grinding noises emerged from front brake or brake plate become red during drive due...

Page 193: ...eck whether king pin ball joint damaged 3 Check whether front wheel and axle locknut loosen or damaged 4 Check whether front wheel hub inner spline and front wheel axle outer spline worn or loosen 3 Front wheel sway during drive 5 Check whether rubber cushion connected to front suspension rocker and frame damaged 1 Check whether rear axle bearing damaged 2 Check whether sliding bearing connected t...

Page 194: ...bber boot damaged or universal joint damaged 1 Check whether four wheel drive switch normal 2 Check whether power divider damaged 8 Fail to shift into four wheel drive or lock differential 3 Check whether differential mechanical conversion agency locked or damaged 1 Check whether the switch of rear axle differentinal lock on the dashboard is damaged 9 Rear axle differentional lock failure 2 Check ...

Page 195: ...ing the steering wheel 1 Socket hexagon screw M6 16 6 2 Steering wheel body 1 3 Hexagon flange nut M12 1 25 1 4 Nylon bush Φ11 Φ16 Φ23 11 2 5 Steering column 1 6 Hex flange step bolt M8 13 Φ12 12 2 7 Hexagon flange self lock nuts M8 2 8 Steering rod 1 9 Hexagon flange bolt M6 25 1 ...

Page 196: ...er steering column 1 12 Cross large plate head screw M6 16 6 13 Passenger handle bar assy 1 14 Handle bar grip 2 15 Locking knob handle bar 1 16 Steering drive axle 1 17 Hexagon flange bolt M8 30 2 18 Washer Φ8 Φ16 1 6 2 19 Driving gear 1 20 Hexagon flange bolt M10 1 25 35 4 ...

Page 197: ...late head screw M5 16 4 22 Hexagon flange nut M5 4 23 Screw M5 12 4 24 Clamp 2 25 Rubber dust cover 1 26 Clip Φ15 2 27 Ball joint steering mechanism 2 28 Hexagon nut M12 1 25 2 29 Collar pin 2 25 2 30 Steering wheel comp 1 31 Hexagon flange bolt M6 30 1 ...

Page 198: ...er for steering column 1 34 Handle sheath 1 35 Steering mechanism comp 1 36 Hexagon flange bolt M8 35 1 37 Hexagon flange self lock nuts M8 1 38 Bushing Φ6 Φ10 18 2 39 Spring washer 8 2 40 Dust sleeve 1 41 Down cover for steering wheel 1 42 Decoration cover for steering wheel 1 ...

Page 199: ... Up cover for steering wheel 1 45 Screw M8 16 2 46 Upper cover ignition lock 1 47 Ignition switch 1 48 Lower cover for ignition switch assy 1 49 Light switch assy 1 50 Spring washer Φ10 4 51 Washer Φ10 Φ20 2 4 52 Cross recessed plate head screw ST3 6 10 3 53 Washer Φ15 Φ28 2 1 ...

Page 200: ...ocky ledge reverse turning clearance crack break Replace loose play Adjust the steering wheel to rotate whether nimble do not have stagnation Adjust the torque of the steering wheel whether obviously increase Adjust NOTE The steering force cutting which exerts to transfers in steering wheel outflow boundary is smaller than 245N The reverse running clearance whether does surpass the limited stipula...

Page 201: ...roblems in the check it should be service immediately to ensure the normal work of the steering system DIASSEMBLING THE STEERING COLUMN PARTS Remove Front cover connection covers part steering wheel cover display board steering wheel a Takes down the parts of the front panel engine covers and the connection covers part and the display board and the steering wheel center covers b Take down the stee...

Page 202: ... if so instead the central axis 3 Check The spline in the two ends of the central axis whether have wear if dose instead the central axis 4 Check The steering shaft tube and welding line of the branch whether have crack and corrosion if it does instead the steering shaft tube DIASSEMBLING THE STEERING DRIVE AXLE 1 Loose the clamp one piece M8 25 flange bolt in the cross gimbal internal spline on t...

Page 203: ...adation Replace NOTE When replace the dust boots of the ball must enter 1 2 volume in lithium grease in to the dust boots 2 Check Ball joint steering mechanism turning rocky ledge Free play Replace the tie rod end Turns roughly Replace the tie rod end 3 Check tie rods Bends damage Replace 4 Check steering joint Crack distortion Replace ...

Page 204: ...erwise please adjust the screw to meet required travel distance 1 Inspect the brake pedal does maintain the certain counter tension When checks disk brake plate the saved liquid in the oil cup will pour automatically into the pressure pipe and the liquid level along with it to reduce the periodic inspection the disk brake plate liquid volume will be an important project 2 rear disk brake plate thi...

Page 205: ... components 1 Auxiliary bumper 1 2 Rear brake oil pipe 1 3 Clamp Ⅱ L 250 3 4 Rubber water pipe clip 1 5 Hexagon flange bolt M6 16 1 6 Hexagon flange bolt M6 30 2 7 Hexagon flange bolt M6 16 5 8 Oil pipe clip 5 9 Hexagon flange bolt M6 12 4 10 Oil pipe clip front disc brake 4 ...

Page 206: ... Qty Remarks 11 Disc brake parts 1 12 Front brake hose 1 13 Oil pipe clip 1 14 Corrugated pipe Φ10 Φ13 450 1 15 Corrugated pipe Φ10 Φ13 250 1 16 Corrugated pipe Φ10 Φ13 300 1 17 Rear right brake hose 1 18 Rear left brake hose 1 19 Rear T junction 1 ...

Page 207: ... Removing front brake caliper 1 Front brake disc 2 2 Hexagon step bolt M8 15 Φ15 5 8 3 Front brake disc 2 4 Front brake caliper 2 5 Brake caliper piston assembly 2 6 Brake caliper piston 4 7 Dust seal 4 8 Caliper piston seal 4 9 Bleed screw 2 10 Brake pad 2 ...

Page 208: ...CHASSIS 196 No Part Name Qty Remarks 11 Pad spring 2 12 Brake pad holding bolt 4 13 Hexagon flange bolt M10 1 25 22 8 ...

Page 209: ...f specification Check the wheel runout If wheel runout is within the limits replace the brake disc Brake disc maximum deflection 0 10 mm 0 004 in brake disc thickness wheel hub wheel tyre Out of specification Replace Brake disc minimum thickness 3 0 mm 0 12 in NOTE Apply the locking agent to the 30Nm bolt with screw down ...

Page 210: ...tall brake pads brake pad spring NOTE Always install new brake pads and brake pad spring as a set a Connect a suitable hose tightly to the brake caliper bleed nozzle Put the other end of this hose into an open container b Loosen the brake caliper bleed screw and using a finger push the caliper piston into the brake caliper c Tighten the brake caliper bleed screw Brake caliper bleed screw 6 Nm 0 6 ...

Page 211: ...assembly and reassembly may cause serious injury and even death Replace damaged brake caliper If only replace the brake caliper of one side please check carefully whether the braking force of right and left are balance and equal 1 Remove brake caliper pistons dust seals caliper piston seals a Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper bod...

Page 212: ...and distort 2 Check brake caliper pistons Scratches rust wear Replace the brake caliper assembly brake caliper cylinders Wear scratches Replace the brake caliper assembly brake caliper body Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air WARNING Replace the caliper piston seals and dust seals whenever the brake caliper is disassembled ...

Page 213: ...Brake Fluid Replace the caliper piston seals and dust seal whenever a brake caliper is disassembled 1 Install caliper piston seals dust seals 2 Install brake caliper pistons INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the front brake calipers 1 Install brake caliper assembly bolt flange 48Nm 4 8m kg 35 ft lb brake hose copper washers union bolt ...

Page 214: ...hose routing is essential to insure safe vehicle operation 2 Fill brake reservoir Must use DOT4 Brake Fluid NOTE Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately 3 Air bleed brake system 4 Check brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fluid to the proper level ...

Page 215: ...ks Removing rear brake caliper 1 Rear brake disc 2 2 Rear brake disc 2 3 Hexagon step bolt M8 15 Φ15 5 8 4 Rear brake caliper 2 5 Brake caliper piston assembly 2 6 Brake caliper piston 4 7 Dust seal 4 8 Caliper piston seal 4 9 Bleed screw 2 10 Brake pad 2 ...

Page 216: ...CHASSIS 204 No Part Name Qty Remarks 11 Pad spring 2 12 Brake pad holding bolt 4 13 Hexagon flange bolt M10 1 25 22 8 ...

Page 217: ...CHASSIS 205 The service method of the rear brake caliper is as the same as the front brake caliper please refer to the before mentioned to operate ...

Page 218: ...NG BRAKE CALIPER No Part Name Qty Remarks Removing parking brake caliper 1 Parking caliper assembly 1 2 Nut 6 3 Bolt 6 4 Parking disc 1 5 Bolt flange 2 6 Brake pad holding bolt 2 7 Brake caliper assembly 1 8 Brake pad 1 ...

Page 219: ...t Name Qty Remarks 9 Brake pad piston side 1 10 Insulator pad shim 2 2 11 Pad spring 1 12 Parking brake arm nut 1 13 Set bolt 1 14 Parking brake arm 1 15 Parking brake arm shaft 1 16 Spring 1 17 Parking brake case bolt 2 ...

Page 220: ...CHASSIS 208 No Part Name Qty Remarks 18 Parking brake case 1 19 Gasket 1 20 Bleed screw 1 21 Brake caliper bracket 1 22 Caliper piston seal 1 23 Dust seal 1 24 Brake caliper piston 1 ...

Page 221: ...eck parking disc Galling damage Replace 2 Measure parking disc deflection Out of specification Replace Parking disc maximum deflection 0 10 mm 0 004 in parking disc thickness Out of specification Replace Parking disc minimum thickness 4 5 mm 0 18 in ...

Page 222: ...04 in 3 Install brake pads pad spring NOTE Always install new brake pads new brake pad shims new insulators and a new brake pad spring as a set 4 Check brake fluid level minimum level mark Should the fluid level falls under the minimum mark please refill the box with the same type of fluid as was recommended by the manufacturer to ensure the fluid level is higher than the minimum mark Must use DOT...

Page 223: ...ck carefully whether the braking force of right and left are balance and equal 1 Remove brake caliper piston dust seal caliper piston seal a Turn the brake caliper piston counterclockwise to remove it b Remove the dust seal and caliper piston seal 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 Check ...

Page 224: ... cleaned and lubricated with new brake fluid only before installation Must use DOT4 Brake Fluid Replace the caliper piston seal and dust seal whenever a brake caliper is disassembled 1 Install caliper piston seal dust seal 2 Install brake caliper piston Turn the brake caliper piston clockwise until section ⓐ of the brake caliper piston is level with the surface of the brake caliper body NOTE Align...

Page 225: ...the parking brake arm shaft has multiple threads If the punch mark ⓐ on the parking brake arm shaft is not between the alignment marks ⓑ when the parking brake arm shaft is screwed in completely remove the parking brake arm shaft and screw it in from a different starting position b Turn the parking brake arm shaft approx imately 60 clockwise c Install the parking brake arm to the parking brake arm...

Page 226: ...RAKE CALIPER 1 Install brake caliper assembly brake caliper mounting bolts 40Nm 4 0m kg 29 ft lb brake hose copper washers union bolt 48Nm 4 8m kg 35 ft lb NOTE Tighten the union bolt while holding the brake hose as shown WARNING Proper brake hose routing is essential to insure safe vehicle operation 2 Fill brake reservoir Must use DOT4 Brake Fluid Note Brake fluid may damage painted surfaces or p...

Page 227: ...body Cracks damage Replace brake fluid delivery passage brake master cylinder body Blockage Blow out with compressed air 2 Check brake master cylinder kit Scratches wear damage Replace as a set 3 Check brake fluid reservoir brake fluid reservoir diaphragm Cracks damage Replace ASSEMBLING THE BRAKE MASTER CYLINDER WARNING All internal brake components should be cleaned and lubricated with new brake...

Page 228: ... 13 ft lb washer plate brake hose union bolt 27Nm 2 7 m kg 19 ft lb 3 Fill brake fluid reservoir Must use DOT4 Brake Fluid NOTE Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately 4 Air bleed brake system 5 Check brake fluid level Brake fluid level is under the LOWER level line Fill up ...

Page 229: ...ft front mud guard board 1 2 Cross big plate head screw M6 12 2 3 Screw thread clip M6 2 10 4 Right front mud guard board 1 5 Cross large plate head screw M6 16 2 6 Screw thread clip M6 2 4 7 Left footrest protector 1 8 Cross large plate head screw M6 16 7 9 Screw thread clip M6 2 4 ...

Page 230: ...te head screw M6 12 8 12 Screw thread clip M6 2 4 13 Axle cover 1 14 Cross large plate head screw M6 16 5 15 Dustproof plate brake pedal 1 16 Welding parking pedal 1 17 Spring D 1 18 Spring Φ3 Φ30 46 1 19 Rear brake pump bracket assy 1 20 Hexagon flange bolt M8 20 4 21 Washer Φ12 1 2 ...

Page 231: ...lerator pedal welding assy 1 25 Throttle cable 1 26 Washer Φ15 Φ22 1 5 4 27 Spring Φ2 Φ14 62 1 28 Expansion bolt plastic 5 29 Cross large plate head screw M6 16 3 30 Cross large plate head screw M6 16 1 31 Cross big plate head screw M6 12 4 32 Collar pin 2 32 1 33 Lamp switch rear break 1 ...

Page 232: ...emarks Removing the front wheel 1 Front wheel rim 2 2 Front tyre 2 3 Cycle valve 2 4 Nut M10 8 5 Wheel decoration cover Ⅳ 2 6 Cotter 3 2 50 2 7 Nut M22 1 5 2 8 Front hub 2 9 Bolt M10 30 4 WARNING Securely support the vehicle so There is no danger of it falling over ...

Page 233: ...moving the rear wheel 1 Rear wheel rim 2 2 Rear tyre 2 3 Cycle valve 2 4 Rear hub 2 5 Bolt M10 30 8 6 Nut M10 8 7 Wheel decoration cover Ⅳ 2 8 Nut M22 1 5 2 9 Cotter 3 2 50 2 WARNING Securely support the vehicle so There is no danger of it falling over ...

Page 234: ...Check wheel balance Out of balance Adjust Wheel runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in WARNING The profile depth falls below 3mm Please replace the tyre immediately tire wear limit a CHECKING THE WHEEL HUB 1 Check wheel hub Cracks damage Replace splines wheel hub Wear damage Replace nuts wheel hub loosen or distorted Replace or tighten ...

Page 235: ...t lb INSTALLING THE WHEEL TYRE 1 Install wheel NOTE The arrow mark on the tyre must point in the direction of rotation A of the wheel 2 Tighten wheel nuts WARNING Tapered wheel nuts are used for both the front and rear wheels Install each nut The angle of the conical bores is 60 ...

Page 236: ...nd profile depth Insufficient tyre pressure can result in not only intensified wearing of the tyre but also instability during the course of operating the vehicle such as hard turning Excessive tyre pressure can also reduce the friction force between the tyre and ground causing spinning or lose of control Therefore please ensure the tyre pressure strictly complies with figures shown in the chart a...

Page 237: ...oving the C V axle front axle L R 1 Circlip 2 2 Double off set assembly 4 3 Circlip 4 4 Ball bearing 4 5 Circlip 4 6 Hoop A dust P shed 4 7 Outer rubber dust P cover C 1610 2 8 Adjustable clamp 4 9 C V shaft assembly 2 10 Inner rubber dust P cover C 1605 2 11 C V axle front axle 2 ...

Page 238: ...ront differential case Ⅱ 1 3 Fuel drain screw plug 2 4 O ring gasket fuel injection Φ2 2 Φ16 4 2 5 Drive driven gears 1 6 Differential 1 7 Breather pipe 1 8 Clip Φ11 1 9 Dustproof rubber coverΦ19 Φ38 50 2 10 Front transmission shaft comp 1 11 Front differential assy 1 12 Universal jointⅠ 1 13 Circlip D0 19 2 ...

Page 239: ...ing transmission shaft 2 18 O ring gasket fuel injection Φ2 2 Φ16 4 1 19 Front transmission shaft 1 20 Speed sensor comp 1 21 Joint cross shaft 2 22 Connection fork Ⅱ 1 23 Connection fork Ⅰ 1 24 Transfer case assembly 1 25 Seal ring Φ3 1 Φ78 transfer 1 26 Bearing 6306 P5 1 27 Bearing Rna4910 1 28 Bearing 32008 2 P5 2 ...

Page 240: ...Part Name Qty Remarks 29 Differntial adjustment gasket 2 30 Hexagon flange bolt M8 25 8 31 Outer raceway 1 32 Washer 14 5 30 4 1 33 Hexagon flange self lock nuts M14 1 5 1 34 Hexagon flange bolt M8 30 4 35 Clip Φ72 1 ...

Page 241: ...int a Remove the circlips b Place the universal joint in a press c With a suitable diameter pipe ben eath the yoke press the bearing into the pipe as shown d Repeat the steps for the opposite bearing e remove the yoke NOTE It may be necessary to lightly tap the yoke with a punch ...

Page 242: ...ft movement is Smooth ceaseless If it is stagnation and obvious becoming less loosen replace it Disassembe the left and right transmission shaft cleaning and assemble it again NOTE 1 The dustproof rubber wrap on the ball cage is not allow to contact with the gas and diesel oil 2 The dustproof rubber wrap does not allow to be scratched a slight scratches can damage the dustproof rubber wrap very qu...

Page 243: ...earing into the universal joint using a suitable socket CAUTION Check each bearing The needles can easily fall out of their races Slide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of plate NOTE The The bearing must be inserted far enough into the universal joint so that the circlip can be installed e Install the circlips into the groov...

Page 244: ...2 2 Adjustable Clamp 4 3 Hoop A dust p shed 4 4 Inner rubber dust proof c 1513 front axle 2 5 Circlip 4 6 Double off set joint assembly 2 7 Double off set joint assembly 2 8 Circlip 4 9 Ball bearing 4 10 Joint shaft assembly 2 11 Outer rubber dust proof C 1605 front axle 2 12 C V Axle rear axle 2 ...

Page 245: ...ear bridge 1 Rear differential caseⅠ 1 2 Rear differential case Ⅱ 1 3 Oil seal Φ52 Φ35 7 2 4 Bearing 32008E 1 5 Rear differntial 1 6 Vent pipe rear differential 1 7 Steel wire clamp Φ11 1 8 Rear differential assy 1 9 Hexagon flange locked nut M14 1 5 1 10 Magnetic valve 1 ...

Page 246: ...earing seat 1 13 Metal Bushing 1 14 Fuel drain O type seal 1 15 Fuel drain screw plug 1 16 Welding combination of shift fork 1 17 U Type spring 1 18 Fix bracket 1 19 Returning spring 2 20 Sleeve of shift fork 1 21 Column pin of shift fork 1 22 Washer Φ12 Φ30 4 1 ...

Page 247: ...fuel injection 1 23 O ring gasket 1 24 Hexagon flange nut M10 1 25 2 25 Bearing 32206E 2 26 Adjust bushing Ⅱ 1 27 Gasket of adjust bushing 1 28 Adjust bushing Ⅰ 1 29 Oil fill plug 1 30 O Ring gasket fuel injection 1 31 Driving and driven gears 1 32 Rear adjustment gasketⅠ 3 ...

Page 248: ...te 1 35 Hexagon step zylinderschraube M6 14 Φ7 15 6 36 Middle brake assy 1 37 Hexagon flange bolt M10 1 25 30 2 38 Mount bracket rear disk brake plate 1 39 Differntial adjustment gasket 1 40 Adjustment gasket 2 41 O ring Φ2 5 Φ192 1 42 Hexagon flange bolt M8 25 8 43 Parking brake pad assy 1 ...

Page 249: ...is as the same as the front bridge parts please refer to the before mentioned to operate NOTE Apply lithium soap based grease to the bearing assembly and o ring and bearing and driven gear and oil seal and drive shaft coupling and final drive pinion gear bearing housing ...

Page 250: ...e shift operating system 1 Gear shifter assembly 1 2 Gear Shifting Support 1 3 Hexagon Flange bolt M8 12 3 4 Gearshift Rod Ⅰ 1 5 Hexagon flange bolt M6 16 1 6 Hexagon flange self lock nuts M6 1 7 Gearshift rod Ⅱ 1 8 Gearshift boot 1 9 Gearshift knob 1 10 Gear shifting support 1 ...

Page 251: ...s 11 Hexagon flange self lock nuts M6 1 12 Hexagon flange bolt M6 16 1 13 Gearshift arm assy Ⅱ 1 14 Hexagon flange nut M8 2 15 Gearshift arm assy Ⅰ 1 16 Gearshift assy 1 17 Rubber cover clamp 1 18 Plastic screw 1 19 Hexagon flange bolt M8 20 1 ...

Page 252: ...NOTE Before shifting you must stop the vehicle and take your foot off the accelerator pedal Otherwise the transmission may be damaged 1 Adjust Select lever shift rod a Make sure the select lever is in NEUTRAL b Loosen both in nuts c Adjust the shift rod length for smooth and correct shifting d Tighten the nuts Nut 23 Nm 2 3 m kg 17 ft lb ...

Page 253: ... Remove the gear shift mechanism and check whether the linking rod is cracked If so it should be changed 4 Check whether the bouncing spring of gear shift mechanism is intense enough 5 Check whether the gear is engaged correctly and whether there are tripstop or lack If these situation exists call for the maintanance staff to test and repair it 6 If the gear can not be engaged we can test it from ...

Page 254: ...oving the front swing arm 1 Front shock absorber 2 2 Hexagon flange nut M10 1 25 2 3 Hexagon flange bolt M10 1 25 55 2 4 Hexagon flange nut M10 1 25 2 5 Front anti roll bar 1 6 U type rubber bush Φ21 40 2 7 Press block rear anti roll bar 2 8 Hexagon flange bolt M8 22 4 ...

Page 255: ...CHASSIS 243 No Part Name Qty Remarks 9 Tie Rod front anti roll bar 2 10 Hexagon flange bolt M10 1 25 45 2 11 Hexagon flange nut M10 1 25 2 12 Hexagon flange bolt M10 1 25 102 2 13 Bush Φ10 Φ16 20 2 ...

Page 256: ...t front upper swing arm 1 2 Left front upper swing arm 1 3 Right Front Lower Swing Arm 1 4 Left front lower swing arm 1 5 Hexagon flange bolt M10 1 25 70 4 6 Dust cover B 16 7 Hexagon flange nut M10 1 25 4 8 Middle rubber tube swing arm 8 9 Elasticity block ring D 30 4 10 Universal joint A 4 ...

Page 257: ... Qty Remarks 11 Hexagon flange bolt M10 1 25 70 4 12 Hexagon flange nut M10 1 25 4 13 Hexagon nut M12 1 25 4 14 Collar pin 2 5 30 4 15 Protective board swing arm 2 16 Spring washer 12 4 17 Cross large plate head screw M6 16 4 ...

Page 258: ...shock absorber and maintain method whether it can returns to the position under the pressure and the torsional spring is rupture If it is rupture or nearly to rupture instead the shock absorber whether it leak oil if so instead the same spec shock absorber According to the different request if there is a oil cup on the rocker must check it whether complete and refuels 2 Install Mount fore L R damp...

Page 259: ...ut with cotter pin 4 pcs and make these tension rods bisection on feet CHECKING THE STABILIZER 1 Check bar stabilizer Bends cracks damage Replace CHECKING THE STEERING KNUCKLES 1 Check steering knuckles Damage pitting Replace CHECKING THE FRONT ARMS 1 Check front arms Bends damage Replace 2 Check Middle bushing Wear damage Replace 3 Check ball joints Damage pitting Replace the ball joint Free play...

Page 260: ...CK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Fatigue Replace the shock absorber assembly Move the spring up and down ...

Page 261: ...rm NOTE Lubricate the bolts with lithium soap based grease Be sure to position the bolts so that the bolt head faces inward Temporarily tighten the nuts b Install the front shock absorber Nut 45 Nm 4 5 m kg 32 ft lb c Install the front knuckle Nut 45 Nm 4 5 m kg 32 ft lb d Tighten the nuts Nut 45 Nm 4 5 m kg 32 ft lb AIRBAG SHOCK ABSORBER Refer to the previous 113 to 115 pages ...

Page 262: ... flange nut M12 1 25 4 4 Hexagon flange bolt M12 1 25 60 2 5 Rear anti roll bar 1 6 U type rubber bush Φ21 40 2 7 Press block rear anti roll bar 2 8 Hexagon flange bolt M8 22 4 9 Rear Anti roller lever assy 2 10 Hexagon flange bolt M10 1 25 45 4 11 Hexagon flange nut M10 1 25 4 12 Spring washer 8 4 13 Shock absorber adjusting wrench 1 14 Washer Φ8 Φ22 1 2 2 ...

Page 263: ...1 Rear right upper swing arm 1 2 Rear left upper swing arm 1 3 Rear right lower swing arm 1 4 Rear left lower swing arm 1 5 Cross big plate head screw M6 12 4 6 Protective board rear right lower swing arm 1 7 Hexagon flange bolt M10 1 25 195 2 8 Nylon bush Ⅲ 4 9 Bush Φ10 Φ15 175 2 ...

Page 264: ...y Remarks 10 Hexagon flange nut M10 1 25 2 11 Middle rubber tube swing arm 4 12 Hexagon flange Nut M10 1 25 4 13 Protective board rear left lower swing arm 1 14 Iron nipple 2 15 Hexagon flange bolt M10 1 25 70 4 16 Dust cover B 8 ...

Page 265: ...rant According to the front Suspension 3 The cotter pin on the head of the install axis which in the rear shock absorber whether is credible NOTE After disassemble the rear shock absorber check if there exists any distortion or crack on the frame connection hole and the rear shock absorber if so inform the special serviceman to inspect and service first or install the rear shock absorber on the fr...

Page 266: ...itting Replace CHECKING THE REAR ARMS 1 Check rear arms Bends damage Replace 2 Check Middle bushing Wear damage Replace CHECKING THE REAR SHOCK ABSORBER 1 Check shock absorber rod Bends damage Replace the shock absorber assembly shock absorber assembly Oil leaks Replace the shock absorber assembly spring Move the spring up and down Fatigue Replace the shock absorber assembly ...

Page 267: ...th lithium soap based grease Be sure to position the bolts so that the bolt head faces outward Temporarily tighten the nuts b Install the rear shock absorber Nut 45 Nm 4 5 m kg 32 ft lb c Install the ball joints Nut 30 Nm 3 0 m kg 22 ft lb d Install the new cotter pins e Tighten the nuts Nut 45 Nm 4 5 m kg 32 ft lb AIRBAG SHOCK ABSORBER Refer to the previous 113 to 115 pages ...

Page 268: ...s Removing the radiator 1 Screw hoop Φ12 20 12 2 Pressureproof rubber oil pipe A 860 1 3 Pressureproof rubber oil pipe A 1100 1 4 Oil cooling radiator assy 1 5 H shaped rubber washer 4 6 M type clip oil pipe 2 7 Front metal oil pipe 2 8 Pressureproof rubber oil pipe C 1280 1 ...

Page 269: ...er pipe R 1 11 Reaer water pipe L 1 12 Metal water pipe L 1 13 Metal water pipe R 1 14 Clip metal water pipe 5 15 Hexagon flange bolt M6 16 6 16 Front water pipe L 1 17 Front water pipe R 1 18 Expansion water tank rubber pipeⅡ 1 19 Clip Φ10 1 20 Cap standby water bottle 1 ...

Page 270: ...6 Φ9 Φ22 6 5 2 23 Hexagon flange Bolt M6 16 2 24 Expansion water tank rubber pipe Φ5 Φ9 540 30 1 25 Clip Φ9 2 26 Water pipe 1 27 Rear metal water pipe R 1 28 Water inlet assy 1 29 Hexagon flange bolt M6 12 2 30 Cooler water tank 1 31 Water tank assy 1 32 Water tank fan assy 2 ...

Page 271: ...CHASSIS 259 No Part Name Qty Remarks 33 Water pipe G 1 34 Pressure proof rubber oil pipe A 540 2 35 Front metal oil pipe Ⅱ 2 36 Water temperature sensor 1 37 Hexagon flange bolt M6 16 4 ...

Page 272: ...the tightness of Bolt clip If loosen please have the hoop tightened immediately 4 Check radiator fan Damage Replace Malfunction Check and repair 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 107 9 137 3 KPa 1 079 1 373 kg cm2 15 35 19 53 psi a Install the radiator cap tester and adapter onto the radiator cap b Apply the ...

Page 273: ... fluid loose the exhaust nut on the pipe the water level will get lower at this time Supply the refrigerating fluid until the water level stop to change then screw the exhaust nut cover the water tank lid The water tank inspection is finished 2 Check cooling system Leaks Repair or replace any faulty part ...

Page 274: ... 1 Check oil cooler Obstruction Clean Apply compressed air to the rear of the oil cooler Damage Repair or replace the oil cooler NOTE Straighten any flattened fins with a thin flathead screwdriver 2 Check oil pipes Cracks damage Replace ...

Page 275: ...ng the water pump 1 Clip 3 2 Water pipe 1 3 O ring Φ27 2 5 1 4 Water outlet connector cylinder 1 5 Save temperature 1 6 Bolt M6 50 2 7 Bolt M6 12 2 8 Washer Φ6 Φ10 1 2 9 Bolt M6 25 2 10 Thermostat cover 1 11 Washer Φ20 5 Φ30 1 1 12 Gasket 1 13 Water pipe 1 ...

Page 276: ... Remarks Removing the water pump 1 water pump housing cover 1 2 Water pump assembly 1 3 Bolt M6 40 3 4 Washer Φ6 Φ10 1 1 5 Bolt M6 65 1 6 Secondary gear water pump 1 7 Transmission shaft water pump 1 8 Pin Φ4 21 1 9 Circlip Φ10 1 ...

Page 277: ... Name Qty Remarks 10 Bearing 1 11 Oil seal Φ15 Φ10 5 1 12 Gasket water pump cover 1 13 O ring Φ34 2 5 1 14 Water pump housing 1 15 Boot band 1 16 Overflow pipe 1 17 Gasket water pump cover 1 18 Water pump seal assembly 1 ...

Page 278: ...CHASSIS 266 No Part Name Qty Remarks 19 Impeller 1 20 Cover water pump 1 21 Clip 1 22 Water pipe 1 ...

Page 279: ... Remove water pump seal Water pump housing NOTE Tap out the water pump seal from the inside of the water pump housing 3 Remove bearing oil seal water pump housing NOTE Tap out the bearing and oil seal from the outside of the water pump housing Apply lithium soap based grease to the oil seal and apply engine oil to the bearing ...

Page 280: ...e NOTE Apply lithium soap based grease to the o ring 2 Check water pump seal oil seal water pipe Cracks damage wear Replace bearing Rough movement Replace NOTE Apply lithium soap based grease to the oil seal and apply engine oil to the bearing 3 Measure impeller shaft tilt Straightedge Impeller Out of specification Replace Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 281: ...ump seal into the water pump housing mechanical seal installer and water pump seal installer water pump seal installer NOTE Never lubricate the water pump seal surface with oil or grease Install the water pump seal with the special tools 3 Install rubber damper rubber damper holder NOTE Before installing the rubber damper apply tap water or coolant onto its outer surface Make sure that the rubber ...

Page 282: ...the seat 1 Safety belt assy 1 2 Back rest 2 3 Seat cushion 2 4 Seat connection assy 2 5 Socket hexagon screw M8 25 10 6 Washer Φ8 Φ16 1 6 10 7 Washer Φ8 Φ28 3 16 8 Slide rail R 2 9 Slide rail L 2 10 Socket hexagon screw M8 25 8 11 Seat mounting board 2 ...

Page 283: ... Hexagon flange bolt M10 1 25 22 2 16 Combined connecting rod guide 1 17 Shock absorbtion rubber Ⅱ 2 18 Rubber insulation R 2 19 Hexagon flange step bolt M10 1 25 20 Φ14 5 2 20 Gasket Φ10 5 Φ19 5 2 21 Hexagon flange nut M10 1 25 2 22 Hexagon flange nut M10 1 25 2 23 Hexagon flange bolt M10 1 25 22 2 24 Hexagon flange nut M10 1 25 2 ...

Page 284: ... 272 No Part Name Qty Remarks 25 Hexagon flange step bolt 2 26 Seat Belt buckle R 1 27 Rubber insulation L 1 28 Wire stop plunger for safty belt 2 29 Rubber plug Φ19 Φ25 10 10 30 Hexagon flange nut M10 1 25 2 ...

Page 285: ...n is the reverse of removal CAUTION These components should be greased with butter before assembly The surface of components can not be cracked Moving Seat Forward And Backward Driver seat handle Passenger seat handle The seat can be moved forward and backward to fit the height of different drivers Pull up the handle then you can move the seat forward and backward ...

Page 286: ...flange bolt M8 25 2 3 Flanging collar Φ8 Φ10 Φ20 7 3 4 T Style rubber ring Ⅳ 3 5 Lid for fuel tank 1 6 Rubber pipe Φ7 Φ11 1400 1 7 Plug for fuel outlet 1 8 Binder plate for fuel tank 1 9 Hook fuel tank 1 10 Hexagon flange self lock nuts M8 2 11 Fuel tank support 1 12 Hexagon flange bolt M8 45 2 ...

Page 287: ...assy 1 15 Fuel pipe Φ8 Φ14 250 3 16 Fuel tank cap 1 17 Triplet joint fuel pipe 1 18 Clamp 8 19 High voltage fuel filter 1 20 Fuel pump plate 1 21 Hexagon flange nut M6 6 22 Seal gasket for fuel pump 1 23 Shock absorbtion rubber Φ15 6 4 24 Plug fuel inlet 1 25 Foam sleeve ⅡΦ10 250 2 26 Clip Φ16 1 ...

Page 288: ...SSIS 276 No Part Name Qty Remarks 27 Hexagon flange bolt M8 25 2 28 Hexagon flange bolt M8 45 1 29 Fuel pipe Φ8 Φ14 500 1 30 Clip Φ11 1 31 O seal Ⅰ 1 32 Fuel fairwater 1 33 Fuel pump connection wire assy 1 ...

Page 289: ...CHASSIS 277 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise ...

Page 290: ...eck whether crankshaft speedmeter magneto ignition signal normal 7 Check whether oil pump damaged 8 Check whether air filter plugged 3 Fail to electric start 9 Check whether oil circuit smooth 1 Check whether speedmeter damaged 2 Check whether meter damaged 4 Abnormal speed indication between meter and mileage 3 Check whether speedmeter surface polluted by iron scrap 1 Check whether neutral switch...

Page 291: ... ELECTRICALCOMPONENTS 1 Thermo switch 2 2 Radiator fan 3 Brake light switch 4 Thermo switch 1 5 Ignition coil 1 6 Gear position switch 7 Reverse switch 8 Speed sensor 9 Ignition coil 2 10 stator assembly 11 Windlass 12 Windlass controller ...

Page 292: ...COMPONENTS 280 1 Relay assy 2 ECU unit 3 Battery 4 Starter relay 5 DC socket 6 Speedmeter 7 On Command four wheel drive switch and differential gear lock switch 8 Light switch 9 Main switch 10 Rectifier regulator ...

Page 293: ...e when testing the 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 This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates the terminals with continuity The example chart shows t...

Page 294: ...heck for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled 1 Fuse 2 Brake light switch 3 Main switch 4 On Command four wheel drive switch and differential gear lock switch 5 Light switch 6 Parking brake switch 7 Reverse switch ...

Page 295: ...bulb bulb socket or both WARNING Since the bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down CAUTION Be sure to hold the socket firmly when removing the bulb Never pull the lead otherwise it may be pulled out of the terminal in the coupler Avoid touching the glass part of the bulb to keep it free from oil otherwise the transparency of the gl...

Page 296: ...CORRECT 3 Spark plug Check the spark plug condition Check the spark plug type Check the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 3 7 Main switch 8 Pickup coil resistance 9 Rotor rotation direction detection coil resistance 10 Wiring connection the entire ignition system NOTE 1 Cushion 2 Front frame 3 Front fender Check and repaire with following special tools NO CONTINUITY Replac...

Page 297: ...lug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap Check that the spark plug cap has the specified resistance Spark plug cap resistance 10 kΩ at 20 C 68 F MEETS SPECIFICATION 6 Ignition coil resistance Disconnect the ignition coil connector from the wire harness Connect the pocket tester Ω 1 to the ignition coil Tester lead Orange lead terminal Tester...

Page 298: ...N 7 Main switch Refer to CHECKING THE SWITCH CORRECT 8 Pickup coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil terminal Tester lead White Blue terminal Tester lead Green terminal Check the pickup coil for the specified resistance Pickup coil resistance 459 561 Ω at 20 C 68 F White Red White Green MEETS SPECIFICATION OUT OF ...

Page 299: ...Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM CORRECT Replace the ECU unit ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM See 344 page POOR CONNECTION Properly connect the ignition system ...

Page 300: ... of the starter motor 6 Gear position switch 7 Brake light switch 8 Diode 1 9 Wiring connection the entire starting system NOTE Remove the following part s before troubleshooting 1 Console 2 Front frame 3 Front fender Use the following special tool s for troubleshooting NO CONTINUITY INCORRECT WARNING A wire that is used as a jumper lead must have the equivalent capacity or more as that of the bat...

Page 301: ...o CHECKING THE SWITCH CORRECT 6 Gear position switch Refer to CHECKING THE SWITCH CORRECT 7 Brake light switch Refer to CHECKING THE SWITCH CORRECT 8 Diode 1 Remove the diode from the coupler Connect the pocket tester Ω 1 to the diode terminals as shown Check the diode for continuity as follows NO CONTINUITY Replace the starter relay INCORRECT Replace the main switch INCORRECT Replace the gear pos...

Page 302: ...ad Yellow Blue terminal Tester lead Blue White terminal Tester lead Yellow Blue terminal NO Continuity CORRECT 9 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM NOTE When you switch the tester s positive and negative probes the readings in the left chart will be reversed INCORRECT Replace the diode 1 POOR CONNECTION Properly connect the starting syste...

Page 303: ... Starter motor O ring 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure Disassembling the starter motor Bracket 1 Washer kit Bracket 2 Shims Brush seat 1 brush seat 2 Armature coil 1 Yoke 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ASSEMBLING THE STARTER MOTOR ...

Page 304: ...tor 3 Measure mica undercut b Out of specification Scrape the mica using a hacksaw blade NOTE Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator 4 Check armature coil insulation continuity Defects Replace the starter motor a Connect the pocket tester for the continuity check and insulation check b Measure the armature resistances c If the ...

Page 305: ...DIAGRAM See 345 page ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE Align the projection a on the brush seat 1 with the slot b on the yoke 2 Install yoke brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets ...

Page 306: ...20 V to the battery Tester lead Battery terminal Tester lead Battery terminal Start the engine and accelerate to about 1 000 r min Charging voltage 14 V at 1 450 r min NOTE Use a fully charged battery OUT OF SPECIFICATION 4 Charging coil resistance 5 Wiring connections the entire charging system NOTE Remove some parts before maintenance 1 Cushion Repair with following special toolings NO CONTINUIT...

Page 307: ...rminal Tester lead White terminal Measure the charging coil resistance Charging coil resistance 0 32 0 43 Ω at 20 C 68 F MEETS SPECIFICATION 5 Wiring connections Check the connections of the entire charging system Refer to CIRCUIT DIAGRAM CORRECT Replace the rectifier regulator LIGHTING SYSTEM CIRCUIT DIAGRAM See 346 page OUT OF SPECIFICATION Replace the pickup coil stator assembly POOR CONNECTION...

Page 308: ...the entire lighting system Refer to CIRCUIT DIAGRAM CORRECT Check the condition of each of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM 4 Light switch 5 Wiring connections the entire lighting system NOTE Remove the following part s before troubleshooting 1 Console 2 Front luggage carrir 3 Front covering parts Use special tool s for troubleshooting NO CONTINUITY Replace the ...

Page 309: ...erminal or Yellow terminal Tester lead Black terminal A When the light switch is on B When the light switch is on Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Green and Yellow leads on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket A B OUT OF SPECIFICATION The wiring circuit from the...

Page 310: ...ad Blue lead terminal Tester lead Black lead terminal Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Blue lead on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty SIGNALING SYSTEM CIRCUIT DIAGRAM See 347 page NO CONTINUITY Replace the bulb and or bulb socket OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket...

Page 311: ...signal system Refer to CIRCUIT DIAGRAM CORRECT Check the condition of each of the signal system s circuits Refer to CHECKING THE SIGNAL SYSTEM 3 Main switch 4 Wiring connections the entire signal system NOTE Remove the following part s before troubleshooting 1 Console 2 Front frame 3 Front pedal Use special tool s for troubleshooting NO CONTINUITY Replace the fuse s INCORRECT Clean the battery ter...

Page 312: ...DC 20 V to the bulb socket connector Tester lead Yellow terminal Tester lead Black terminal Turn the main switch to ON Turn the light switch to or Check the voltage 12 V of the Yellow lead on the bulb socket connector MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the brake light switch OUT OF SPECIFICATION The wiring circuit ...

Page 313: ...the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Sky blue terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the gear position switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket c...

Page 314: ...Connect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Blue Red terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the parking brake switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb ...

Page 315: ...onnect the pocket tester DC 20 V to the indicator light assembly 2 coupler Tester lead Brown terminal Tester lead Green Blue terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION Replace the ECU unit NO CONTINUITY Replace the bulb and or bulb socket NO CONTINUITY Replace the Reverse switch OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket conn...

Page 316: ...ect the pocket tester Ω 1 to the thermo switch 1 Immerse the thermo switch 1 in coolant Check the thermo switch 1 for continuity While heating the coolant use a thermometer to record the temperatures A The thermo switch 1 circuit is open and the coolant temperature warning light is off B The thermo switch 1 circuit is closed and the coolant temperature warning light is on Test step Coolant tempera...

Page 317: ...hould it be dropped it must be replaced GOOD CONDITION 3 Voltage Connect the pocket tester DC 20 V to the indicator light assembly 1 coupler Tester lead Brown terminal Tester lead White Blue terminal Turn the main switch to ON Check the voltage 12 V BAD CONDITION Replace the thermo switch 1 OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair i...

Page 318: ...r Ω 1 and the battery 12 V to the differential gear lock indicator light relay terminals Check the differential gear lock indicator light relay for continuity as follows Tester lead Brown Red terminal Tester lead Brown Black Terminal Continuity Battery terminal Brown Red terminal Battery terminal Brown Black Terminal Tester lead Black Terminal Tester lead Black Red terminal No continuity CONTINUIT...

Page 319: ...he indicator light assembly 1 coupler Tester lead Brown terminal Tester lead White Black terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty NO CONTINUITY Replace the gear motor OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it ...

Page 320: ...ester Ω 1 and the battery 12 V to the four wheel drive indicator light relay terminals Check the four wheel drive indicator light relay for continuity as follows Tester lead Blue Black terminal Tester lead Black Terminal Continuity Battery terminal Blue Black terminal Battery terminal Black Terminal Tester lead White Black terminal Tester lead Black terminal No continuity CONTINUITY NO CONTINUITY ...

Page 321: ...ssembly 1 coupler Tester lead Brown terminal Tester lead Black Red terminal Turn the main switch to ON Check the voltage 12 V MEETS SPECIFICATION This circuit is not faulty COOLING SYSTEM CIRCUIT DIAGRAM See 348 page NO CONTINUITY Replace the gear motor OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty repair it ...

Page 322: ...G THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C 68 F CORRECT 3 Main switch Refer to CHECKING THE SWITCH CORRECT 5 Thermo switch 3 6 Wiring connection the entire cooling system NOTE Remove the following part s before troubleshooting 1 Console 2 Front frame 3 Front pedal Use special tool s for troubleshooting NO CONTINUITY Replace the fuse INCORRECT Clean the battery terminals...

Page 323: ... to the thermo switch 3 Immerse the thermo switch 3 in coolant Check the thermo switch 3 for continuity While heating the coolant use a thermometer to record the temperatures A The thermo switch 3 circuit is closed B The thermo switch 3 circuit is open Test step Coolant temperature Continuity 1 Less than 75 3 C 167 5 4 F No 2 More than 75 3 C 167 5 4 F Yes 3 More than 68 C 154 4 F Yes 4 Less than ...

Page 324: ...ped it must be replaced Thermo switch 3 28 Nm 2 8 m kg 20 ft lb GOOD CONDITION 6 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM CORRECT This circuit is not faulty 2WD 4WD SELECTING SYSTEM CIRCUIT DIAGRAM See 349 page BAD CONDITION Replace the thermo switch 3 POOR CONNECTION Properly connect the cooling system ...

Page 325: ...please check the fuse 2 Check if the rear differential is working a Check the sound When the switch is turned on the magneto valve will make s sound TA to show that it is working and the rear wheel won t be able to rotatable at the same direction b If no sound is made check if the controller of magnetic valve has a output of 12V electricity and check if the magnetic valve has a input of 12V electr...

Page 326: ... engine speed load and temperature and 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 Of EMS 1 Electronic Control Unit 2 Multec 3 5 Injectors 3 Throttle Body Assembly with stepper motor 4 Engine Coolant Temperature Sensor 5 Intake Air Pressure and Temperature Sensor 6 Oxygen Sensor 7...

Page 327: ...ions of the engine through the system sensors It also provides the necessary computation adaptability and output control in order to minimize the tailpipe emissions and fuel consumption while optimizing vehicle drivability for all operating conditions The ECU also provides diagnosis when system malfunctions occur Legend Dotted line indicates inputs Solid line indicates outputs ...

Page 328: ...a torque of 3 9Nm 10 The mounting surface should also be flat to avoid subjecting the base plate to unnecessary force and warping the PCB 4 Maintenance service and Repair ECU is a non serviceable part Once there are problems it s important to first determine if the problem is caused by software calibration If it is caused by software calibration please refer to software calibration reflashing proc...

Page 329: ...damage injectors or seal rings DO NOT Apply excessive side loads to electrical connectors May cause loss of electrical continuity DO NOT Use any dropped unit Internal damage may have occurred DONOT Store injectors rails or subassemblies including engines on which the injectors have been installed in an unprotected environment External contamination can damage the injector electrically and or mecha...

Page 330: ...r re installation process Lubrication Apply a light coating of lubricant to the lower injector seal ring ISO 10 light mineral oil or equivalent is recommended The preferred technique is to apply the lubricant to the sockets the injectors are being installed into rather than directly to the seal ring itself This will help minimize the possibility of injector contamination Avoid applying lubricant o...

Page 331: ...mproper spray orientation 4 Replacement Techniques WARNING The injector and all associated hardware may be extremely hot Shut off ignition Disconnect negative battery cable to avoid possible fuel discharge if an 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 332: ...e the fuel pressure in the system and disconnect the fuel connection at the injector Plug the fuel feed line Injector cleaner with the specific ratio of the cleaner and gasoline to be mixed in the Injector cleaning tank Connect the injector cleaning tank to injector in the vehicle Pressurize the injector cleaning tank to system pressure Start and idle the engine for 15 20 minutes Disconnect the in...

Page 333: ...on which can prevent proper operation DO clean the by pass passage after removing bottom cover To ensure good idle stability DO NOT Use any dropped or impacted unit Internal damage may have occurred or emissions settings may have been upset DO NOT Store units without protective caps in place Contamination may impair correct operation DO NOT Ship or store near saltwater without protection Corrosion...

Page 334: ...he bore The valve may be warped and the bore may be scratched This type of damage may keep the throttle from opening easily or fully closing Engine Coolant Temperature Sensor 1 Description and Working Principle This sensor is used in water cooled engines It provides a resistance that varies as a function of temperature within prescribed tolerance limits The sensor has a negative temperature coeffi...

Page 335: ... small engine It is the feedback element for engine closed loop control 2 Installation Requirements Mounting Angle with Level 10 degree Tightening Torque Requirement 40 60 Nm Ignition Coil 1 Description and Working Principle This coil provides energy to the spark plug in the combustion chamber The coil itself doesn t have a driver The high voltage tower of the coil is connected to the spark plug u...

Page 336: ...sprayed materials to be sprayed onto the electrical connectors Insulating type sprays can create a high resistance or open connection And a conductive type spray can create an electrical short condition DO NOT Support the ignition system by the wiring harness or plug wire These leads are not designed to support the weight of the ignition system It can create a poor electrical connection Or become ...

Page 337: ...kouts when testing the ignition system Connector and or component damage may occur DO Insure the appropriate seals are included in the connector system Liquid intrusion into the terminal connection area might occur causing an electrical intermittent or short condition In the event of severe terminal corrosion an open condition might occur DO Operate with gasoline based internal combustion engines ...

Page 338: ... plugs follow the following steps 1 Grasp the spark plug boot and gently 2 rotate 90 and then pull the spark plug boot and cable away from the spark plug 3 Before removing spark plug brush or air blast dirt away from the well areas 4 Use correct size deep socket wrench to loosen each spark plug one or two turns To remove spark plugs from Aluminum heads allow the engine to cool The heat of the engi...

Page 339: ... spark plug gasket seat is clean then thread the gasket to fit flush against the gasket seat Tapered seat plugs do not require gaskets 3 Screw the spark plugs finger tight into the cylinder head Then use a torque wrench to tighten spark plugs following manufacturer s recommendation Torque is different for various plug type cylinder head material If the thread is damage it prevents a good heat tran...

Page 340: ...isconnecting fuel line will cause dangerous spout of fuel Before loosening disconnecting fuel lines please follow the Fuel Pressure Relief Procedure described in this section Small amount of fuel may drip after the fuel lines are disconnected In order to reduce the risk of personal injury cover the pipe hose ends with suitable blind with no rust or contamination After servicing make sure that the ...

Page 341: ...upler Drain the fuel in fuel tank thru fuel filler with help of hand pump siphon Collect the fuel in approved container for contamination and safety Disconnect the fuel hoses from fuel module by using standard tools Remove the fuel tank from vehicle Place the fuel tank with bottom up condition Care to be taken not to cause any scratches damages on fuel tank Open the fuel module mounting bolts Take...

Page 342: ...odule Apply gradual pull force on retainer to avoid any personal injury due to spring action of retainer Take out the pressure regulator assembly from module Do not hit damage on the regulator dome and crimping portion Lubricate the O rings in new pressure regulator assembly with recommended lubrication oils as mentioned in Table no 3 Lubrication oil is applied only for ease of regulator assembly ...

Page 343: ...n fuel lines In this state check to see that there are no fuel leakage from any part of fuel system Fuel Tank Hoses Hose Joints etc 8 Handling DOs and DONTs FUEL MODULE HANDLING ACTION REASON DO NOT Drop Fuel Module on Floor Could cause internal damage to Fuel Pump DO NOT Run Fuel Pump Dry without fuel at pump inlet strainer ensure atleast 3 litres of gasoline is present in the fuel tank Caused in...

Page 344: ...for wiring harness in vibrations DO Use only standard gasoline for operating vehicle module Fuel Module is intended to run in standard gasoline Adulterated fuel can cause fuel module premature failures which are not covered under warranty DO Change the fuel filter at recommended intervals Clogged fuel filter will cause restriction in fuel flow and can cause flow reduction DO Use fuel filters suppl...

Page 345: ...M_CoolantShortHigh 0122 TPS Circuit Low Voltage or Open KsDGDM_TPS_ShortLow Throttle Position Sensor TPS 0123 TPS Circuit High Voltage KsDGDM_TPS_ShortHigh 0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow Oxygen Sensor 0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 0031 O2S Heater Circuit High Voltage KsDGDM_O2_HeaterShortHigh Oxygen Sensor Heater 0032 O2S Heater Circuit Low Voltage KsDG...

Page 346: ..._O2_2_ShortHigh 0038 O2S Heater 2 Circuit High Voltage KsDGDM_O2_HeaterShortHigh Oxygen Sensor Heater 2 0037 O2S Heater 2 Circuit Low Voltage KsDGDM_O2_HeaterShortLow Vehicle Speed Sensor 0500 VSS No Signal KsDGDM_VSS_NoSignal Park Neutral Switch Diag 0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 0445 CCP short to high KsDGDM_CCP_CircuitShortHigh CCP 0444 CCP short to low open KsDGDM_CCP...

Page 347: ...t Gasoline filter Block up ELECTRICAL SYSTEM Spark plug 1 Improper plug gap 2 Worn electrodes 3 Wire between terminals broken 4 Wrong Spark plug heat value 5 Faulty spark plug cap 6 High voltage wires strapped on frame cause shortage of high pressure ignition energy EFI system 1 Broken ECU 2 Clogged nozzle or the rupture the line from nozzle to ECU 3 Damage of engine speed signal sensor 4 Rupture ...

Page 348: ...piston Valve camshaft and crankshaft 1 Improperly sealed valve 2 Improperly contacted valve and valve seat 3 Improper valve timing 4 Broken valve spring 5 Seized camshaft Crankcase and crankshaft 1 Improperly seated crankcase 2 Seized crankshaft Valve train 1 Improperly adjusted valve clearance 2 Improperly adjusted valve timing POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE EFI system 1 ...

Page 349: ...the plugs of fuel injector or oxygen sensor plug in wrong cylinder the fuel trim will happen mistakes After a thin combustion muffler will appear abnormal high temperature and then burn down the covering parts Air filter Clogged air filter element Muffler Clogged muffler Set out The reverse signal error trigger FAULTY GEAR SHIFTING SHIFT LEVER DOES NOT MOVE Shift drum shift forks 1 Groove jammed w...

Page 350: ... 3 Inferior oil quality Brake Brake drag Cooling system 1 Low coolant level 2 Clogged or damaged radiator 3 Damaged or faulty water pump 4 Faulty fan motor 5 Faulty thermo switch Oil cooling system Clogged or damaged oil cooler FAULTY BRAKE POOR BRAKING EFFECT Disc brake 1 Worn brake pads 2 Worn disc 3 Air in brake fluid 4 Leaking brake fluid 5 Faulty master cylinder kit cup 6 Faulty caliper kit s...

Page 351: ...r worn or loosen direction linkage ball stud Tires 1 Uneven tire pressures on both sides 2 Incorrect tire pressure 3 Uneven tire wear Rim 1 Deformed wheel 2 Loose bearing 3 Bent or loose wheel axle Frame 1 Bent 2 Damaged frame Suspension 1 Over worn or loosen main knuckle ball stud 2 Bent rocker 3 Broken shock absorber 4 Broken buffer rubber of rocker shaft LIGHTING SYSTEM HEAD LIGHT IS OUT OF WOR...

Page 352: ...attery 3 Faulty rectifier regulator 4 Improperly grounded 5 Faulty main and or lights switch 6 Bulb life expired ERROR DISPLAY OF METER Wrong Speed 1 Then sensor on rear axle is damaged or polluted by iron powder 2 The connection between sensor to meter is wrong 3 Broken meter ...

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