MAINTENANCE AND ADJUSTMENT OF THE EV
56
For frozen screws, apply penetrating fluid as
described, the insert a screwdriver in the slot and
rap the top of the screwdriver with a hammer. This
loosens the rust so the screw can be removed in the
normal way. If the screw head is too damaged to
use this method, grip the head with locking pliers
and twist the screw out.
Avoid applying heat unless specifically
instructed. Heat may melt, warp or remove the
temper from parts.
Removing Broken Fasteners
If the head breaks off a screw or bolt, several methods are available for removing
the remaining portion. If a large portion of the remainder projects out, try gripping it with
locking pliers. If the projecting portion is too small, file it to fit a wrench of cut a slot in it
to fit a screwdriver (
Figure 37
)
If the head breaks off flush, use a screw extractor. To do this, center punch the
exact center of the remaining portion of the screw or bolt. Drill a small hole in the screw
and tap the extractor into the hole. Back the screw out with a wrench on the extractor
(
Figure 38
)
Repairing Damaged Threads
Occasionally, threads are stripped through
carelessness or impact damage. Often the threads
can be repaired by running a tap (for internal threads
on nuts) or die (for external threads on bolts) through
the threads (
Figure 39
). To clean or repair spark
plug threads, use a spark plug tap.
If an internal thread is damaged, it may be
necessary to install a Helical or some other type of
thread insert. 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 other. Remove the stud by turning the
lower nut
(Figure 41).
Summary of Contents for HS5DUTV-2
Page 25: ...GENERAL INFORMATION 25 IDENTIFICATION CODE Frame No...
Page 69: ...MAINTENANCE AND ADJUSTMENT OF THE EV 69 Periodic Service Schedule...
Page 108: ...MAINTENANCE AND ADJUSTMENT OF THE EV 108...
Page 130: ...MAINTENANCE AND ADJUSTMENT OF THE EV 130...
Page 137: ...ENGINE 137...
Page 146: ...ENGINE 146 No Part Name Remarks 1 Binding post 2 Output shaft 3 Socket connector 4 Bearing...
Page 148: ...ENGINE 148...
Page 151: ...ENGINE 151 No Part Name Qty Remarks 1 Charger 1 2 Battery Assy 1...
Page 164: ...CHASSIS 164 PANEL AND CARGO BED Front Panel...
Page 168: ...CHASSIS 168...
Page 175: ...CHASSIS 175...
Page 182: ...CHASSIS 182 28 Rear right side reflector 1 29 Washer 6 18 1 6 2...
Page 184: ...CHASSIS 184...
Page 192: ...CHASSIS 192 8 Dustproof cover1 2 9 Hex nut M14 1 25 2 10 Steering ball head components 2...
Page 200: ...CHASSIS 200 4 Check steering joint Crack distortion Replace BRAKE SYSTEM...
Page 206: ...CHASSIS 206 33 Hexagon Flange Bolt M12 1 25 2 34 Cylindrical Bush 12 5 22 55 2...
Page 208: ...CHASSIS 208...
Page 214: ...CHASSIS 214...
Page 218: ...CHASSIS 218...
Page 220: ...CHASSIS 220...
Page 222: ...CHASSIS 222...
Page 226: ...CHASSIS 226...
Page 227: ...CHASSIS 227 3 Install brake pad NOTE 4 Install brake pad holding bolts 17Nm 1 7 m kg 12 ft lb...
Page 228: ...CHASSIS 228...
Page 230: ...CHASSIS 230...
Page 239: ...CHASSIS 239...
Page 241: ...CHASSIS 241 TRANSMISSION SYSTEM...
Page 243: ...CHASSIS 243 Front Bridge...
Page 245: ...CHASSIS 245...
Page 247: ...CHASSIS 247...
Page 249: ...CHASSIS 249...
Page 251: ...CHASSIS 251...
Page 253: ...CHASSIS 253...
Page 255: ...CHASSIS 255 Front Transmission Axle Assy...
Page 257: ...ELECTRICAL COMPONENTS 257...
Page 260: ...ELECTRICAL COMPONENTS 260...
Page 264: ...ELECTRICAL COMPONENTS 264 C V Axle Rear Axle...
Page 266: ...ELECTRICAL COMPONENTS 266...
Page 268: ...ELECTRICAL COMPONENTS 268...
Page 270: ...ELECTRICAL COMPONENTS 270...
Page 272: ...ELECTRICAL COMPONENTS 272...
Page 274: ...ELECTRICAL COMPONENTS 274...
Page 277: ...ELECTRICAL COMPONENTS 277 Shift Operating System...
Page 281: ...ELECTRICAL COMPONENTS 281 Reverse mechanism parts...
Page 283: ...ELECTRICAL COMPONENTS 283 Reverse mechanism parts...
Page 285: ...ELECTRICAL COMPONENTS 285 SUSPENSION...
Page 294: ...ELECTRICAL COMPONENTS 294 Rear Suspension...
Page 302: ...ELECTRICAL COMPONENTS 302 Nut 45 Nm 4 5 m kg 32 ft lb...
Page 321: ...ELECTRICAL COMPONENTS 294 CHARGING SYSTEM CIRCUIT DIAGRAM see 337 page...
Page 325: ...ELECTRICAL COMPONENTS 298 TROUBLESHOOTING IF THE HEADLIGHT AND OR TAILLIGHT FAIL TO COME ON...
Page 330: ...ELECTRICAL COMPONENTS 303 SIGNALING SYSTEM CIRCUIT DIAGRAM see 337 page...
Page 336: ...FOREWORD 309...
Page 338: ...FOREWORD 311...
Page 340: ...FOREWORD 313...
Page 341: ...FOREWORD 314 7 If the four wheel drive indicator light fails to come on...
Page 345: ...FOREWORD 318 SCHECKING THE SWITCH...
Page 346: ...FOREWORD 319...
Page 347: ...FOREWORD 320...